Download - Brick Lining Installation
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B r i c k
l i n i n g i
n s t a l l a t i o n
JULY 2007 / Version 2
Brick lining installationgolden rules
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Foreword
These Golden Rules for Brick Lining should be guidelines for thepersonnel in charge of kiln rebricking in the plants.
• This booklet contains the most important rules and should therefore be
handed out to all involved persons before starting the lining.• It deals only with the most common dry lining method, but other
methods (mainly mortar) are important in special cases.
• It is a good idea to discuss the content with the persons involved to
ensure it is fully understood.• As it only contains the most important rules and does not cover specific
situations, it cannot replace necessary training, especially for safety!
• Information given is not sufficient for the person responsible for
Refractory in the plant. He will need to study the related procedures ofthe Cement Portal’s Refractory Domain carefully.(connect to: http://webcementportal.lafarge.com)
We hope that this booklet will make your work more successful.
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Content
1 –
Safety gear2 – Safety equipment
3 – Reference lines are drawn axially & radially
4 –
General rule: Lining patterns are staggered5 – Mixed ratio is adjusted
6 – Mortar is used to correct deformed shell / welding
7 –
Key bricks are not in one line8 – Shims are not installed close to key bricks
9 – Rings are closed using hydraulic jack
10 – Bricks are cut with a brick cutting machine
11 –
Cut bricks are always in between full bricks
12 – Closing of the last ring is done properly
13 – Cardboard spacers are placed adequately
14 –
Additional guidelines
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Safety gear
Longsleeved
For all personnel
Overalls
Hard hatSafety shoesGlovesSafety glasses
Dust maskEar protections
Polyester
Non-skidAbrasion resistant
Remark: Follow the detailed safety procedures published on the Cement Portal’sRefractory domain:
How to ensure safety for brick demolition & brick lining worksHow to ensure safety for brick cutting
How to ensure safety for castable mixing
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PolycarbonateScratch resistant
Heavy duty
rubber apron
For cutting bricksFace shield
Apron
1
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Safety equipment
Equipped with compressedair reservoir (5l) + non-return valveAlarm if pressure < 4.5 bars
Using a brick rig is the only safe kilnbricking method
If you have to pass through the coating, asafe way is to use Tunnel cages
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Inside the kiln, all electrical
equipment used must be class II(double insulation) supplied bysafety transformers situated outsidethe kiln
Compressed airhosepipes andcouplings
are in goodcondition
2
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Axial
Reference lines are drawn axially &radially
2nd point
1st point
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Radial
3
Base lines
Parallel
Welding
Parallel
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General rule: Lining patterns are staggered
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Use a rubberhammer for brickinstallation
Ensure the kiln shell surfaceis clean and smooth
4
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Mixing ratio is adjusted
Right
Wrong
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No brick upside downCheck hot face marking
5
Wrong Right
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Mortar is used to correct deformed shell /welding
Right
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Wrong
6
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Key bricks are not in one line
Right
Key bricks
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Key bricksface to face
Key bricks side to side
Wrong
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Shims are not installed close to key bricks
Shims
Maximum of 2 to 3 shims per ring
Shim thickness = 2 mm max.
2 shims
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Use shim driver
8
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Rings are closed using hydraulic jack
Pressure to be applied = ½ brick cold
crushing strengthTypical CCS ranges are 50 to 70 N/mm2
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Example: ANKRAL-ZECold crushing strength = 70 N/mm2
Pressure to be applied = 350 bars or 5000 PSI
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Conversion factor:1 N/mm2 = 10 bars = 145 PSI
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Bricks are cut with brick cutting machine
Do not cutin this
direction
Mandatorydirection
of cut
Minimum brickcutting length is
respected.
Dry cut for basicbricks
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nMinimum cut
2/3 of original length
200 mm300 mm
140 mm200 mm
Minimum cutBrick originallength
10
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Cut bricks are always in between fullbricks
Cutbricks
Oldbricks
Full bricks
It is recommendedto have 300 mmlong bricks
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nCut
bricks
Full bricks
Retaining ring
11
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Closing of the last ring is done properly
Tight lining must be ensured for the last ring, too.
Hammer
Mortar, liquidenoughClosure brick
Piece of
wood
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Instead of mortar, additional
metal shims can be used
Shims
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Cardboard spacers are placed adequately
To allow expansion
No cardboardAlumina
1 cardboard of 1 mmbetween each ring
Dolomite
1 cardboard of 2 mmbetween each ring
Magnesia
Cardboard spacersBricks type Remark:
These are general rules.
Follow exactly theinstructions given by therefractory suppliers.
Never remove thecardboards from theoriginal bricks!
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Nosering
No cardboard
spacers Retaining ring
13
Remark:For installation of the retaining ring, see details in the “How to install & line
a retaining ring” procedure in the Cement Portal’s Refractory domain.
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Additional guidelines
Don’t change thequality under the tiresor the girth-gear
On deformed areasbricks should be laidwith mortar
Don’t hesitate to discuss with yourTC Refractory Expert if you have any doubt!
Mortar
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Notes
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Notes
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Notes
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B r i
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n
Direction des Performances Cimentières (DPC)
95, rue du Montmurier - BP 7038291 St-Quentin-Fallavier Cedex - France
Tel. + 33 4 74 82 16 16