harbison walker 2005 refractory handbook

$: Harbison Walker 2005 Refractory Handbook$
HARBISON-WALKER

Handbook of

Refractory Practice

2005

© 2005 Harbison-Walker Refractories Co.

Harbison-Walker Refractories Company400 Fairway Drive

Moon Township, PA 15108

© 2005 Harbison-Walker Refractories Company. All Rights Reserved.



Phone: (412) 375-6600 Fax: (412) 375-6783

www.hwr.com

2005Harbison-Walker

Handbook ofRefractory Practice

DISCLAIMER: The information presented in this book is for general education-al use only. It does not contain recommendations for any particular refractoryfor any particular use. It is not intended as, and should not be taken as, a war-ranty of any kind, including but not limited to a warranty of fitness.

WARNING: Some materials which are present in refractory products are harm-ful. One such group is classified as substances known to cause cancer tohumans. Other substances may be classified as probably or possibly carcino-genic. These materials include minerals used in or formed during the manufac-ture of these products. The primary threat presented by many of these materi-als comes from inhaling respirable dust. The use of proper respiratory equip-ment, as well as other personal protective equipment is mandatory whererequired by applicable law. Please refer to the applicable Material Safety DataSheet for such product.

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Handbook ofRefractory Practice

Table of Contents

Section 1 Introduction I

Section 2 Classes of Refractories CR

Section 3 Properties of Refractories PR

Section 4 Using Refractories UR

Section 5 Monolithic and Ceramic Fiber Products MP

Section 6 Brick Products BP

Section 7 Installation References IR

Section 8 Appendix A

Section 9 Literature L

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Introduction

History of Harbison-Walker 1

Technical Research Capabilities 3

Broad-Based Expertise 4

SECTION 1

Harbison-Walker I - 1

INTRODUCTION

Out of the FireThe history of high heat manufacturing and refractory technologybegan with the discovery of fire. Nature provided the first refractories,crucibles of rock where metals were softened and shaped into primi-tive tools. Modern refractories are customized, high-temperatureceramics designed to withstand the destructive and extreme serviceconditions needed to manufacture metals, glass, cement, chemicals,petroleum and other essentials of contemporary life.

The History ofHarbison-WalkerThe refractories company knownas Harbison-Walker opened onMarch 7, 1865, as the Star FireBrick Company. The firm wasfounded by J.K. Lemon, a Pitts-burgh entrepreneur who hoped tobuild a fortune on America’sgrowing demand for refractorybrick following the Civil War.

In 1866, Lemon hired SamuelPollock Harbison as a part-timebookkeeper. Within four years,the ambitious accountant hadacquired enough stock andrefractory expertise to be namedGeneral Manager of Star FireBrick. In 1875, Harbison teamedwith another stockholder, HayWalker, to purchase the under-achieving company, and renamedit Harbison-Walker.

Almost immediately, Harbisonand Walker realized a majoropportunity to grow their busi-ness and its reputation. Throughan on-going relationship withThomas Carnegie, the fledgingcompany landed a contract fromKloman, Carnegie, and Companyto build the Lucy Furnace, thelargest blast furnace ever de-signed.

The company garnered acco-lades for the superior perfor-mance of the Lucy Furnace andbegan to expand rapidly, pushedin large measure by the explosivegrowth of the steel industry. In1910, a 10-company mergercreated Harbison-WalkerRefractories Company, a 33-plant operation that was thelargest of its kind in the world.Harbison-Walker also thrived onits vertical structure, exertingcontrol over every stage of itsproduction process, throughmining and raw materialsmanagement to manufacturing,transportation and distribution.

In the decades that followed,Harbison-Walker established andfortified its position of industryleadership by building newfacilities and acquiring relatedorganizations.

• In 1916, Harbison-Walkerorganized the NorthwestMagnesite Company nearChewelah, WA. This gavethe company a secure domes-tic source of magnesite, amaterial of choice for indus-trial furnaces in short supplyduring World War I.

• In 1927, Harbison-Walkeracquired majority ownershipof Northwest Magnesite, andfollowing World War II,commissioned the companyto build and operate a sea-water magnesite facility atCape May, NJ.

• In 1945, the company pur-chased Canadian RefractoriesLimited, makers ofMAGNECON, an outstand-ing refractory for rotarycement kilns.

• In the 1950’s, Harbison-Walker built a high-qualitymagnesite facility atLudington, Michigan. Thiskeyed the development ofseveral industry standardproducts, including direct-bonded magnesite-chromebrick, pitch-bonded andpitch-impregnated magnesiteproducts, and magnesite-carbon refractories.

• In 1954, Harbison-Walkerbecame the first U.S. com-pany to produce refractoriesfor the basic oxygen furnace.

I - 2 Harbison-Walker

• In 1962, the company discov-ered massive deposits of highpurity bauxitic kaolins atEufaula, AL. This permitted thecompany’s Bessemer andFairfield, Alabama, plants tomanufacture significantlyimproved high-alumina brickthat became a refractory ofchoice for much of the refrac-tory consuming industries.

• In 1967, Harbison-Walkerwas purchased by DresserIndustries, prompting anaccelerated diversificationinto non-steel related indus-tries.

• In 1994, the company be-came a part of Global Indus-trial Technologies, a majormanufacturer of technologi-cally advanced industrialproducts. This developmentenabled Harbison-Walker tostrengthen its presence inseveral key markets throughalliances with other GlobalIndustrial Technologiescompanies. They includedRefractories Mexicanos(REFMEX) and RefractoriosChileanos (RESCA), two ofLatin America’s leadingrefractory producers; andMagnesitwerk Aken, aGerman refractory maker.

• In 1998, Harbison-Walkeracquired A.P. Green Industries,Inc. With 22 plants in sixcountries, A.P. Green, a majorrefractory producer in its ownright, expanded considerablythe global resources atHarbison-Walker’s disposal.

• In 2000, RHI AG, an Aus-trian company with manyholdings in the global refrac-tories industry, completed itsacquisition of Global Indus-trial Technologies, Inc., theparent company of Harbison-Walker. RHI AG subse-quently combined NorthAmerican RefractoriesCompany (NARCO) andHarbison-Walker, at the timenaming the resulting organi-zation RHI RefractoriesAmerica.

Today, the U.S. and exportoperations have been reorganizedand operate independently underthe name ANH Refractories.Because of the strong reputationsthat Harbison-Walker andNARCO established over theirlong histories, the companieshave retained their names and arecontinuing to be the refractorysuppliers of choice in theirrespective market places.Harbison-Walker continues toprovide outstanding refractorymaterials to meet the needs of theindustrial markets, while NARCOserves the needs of the steelindustry.

Harbison-Walker TodayFollowing World War II and thesubsequent proliferation of techno-logical advances, Harbison-Walkerrecognized the need for additionalresearch capacity. In 1958, thecompany opened Garber ResearchCenter, now known as the Techni-cal Center West Mifflin. The newfacility vastly enhanced Harbison-Walker’s ability to test productsunder simulated service condi-tions and to conduct “post-mortem” analyses of used refrac-tory samples.

Today, the Technical CenterWest Mifflin, ranks among theworld’s largest and most well-equipped refractory researchfacilities. A staff of outstandingphysicists, chemists, metallur-gists and engineers work closelywith Harbison-Walker customersto develop new products and tosolve process or productionproblems.

In the mid-1990s, Harbison-Walker completed a multi-million-dollar investment in theTechnical Center West Mifflinaimed at providing thecompany’s engineers and scien-tists with the very latest testingand analytical equipment. Thiscommitment, made at a timewhen many refractory companieswere diminishing their internalresearch capability, aggressivelypositioned Harbison-Walker forthe new century of refractoryindustry leadership.

Harbison-Walker I - 3

The capabilities and equipment atthe Technical Center West Mifflinhave been further enhanced by itsadditional staff and equipmentacquired through its acquisition ofA.P. Green and merger withNARCO.

Application FocusedTechnical Marketing andSales SupportHarbison-Walker has adopted amarketing structure that enablesit to function more like a networkof smaller, industry-focusedcompanies. Throughout each ofits markets, Harbison-Walkeremploys application focusedtechnical marketing support,each with specific training in aparticular industry or series ofrelated industries. Individualmarket segments include glass,industrial metals, mineralsprocessing and environmental,energy and chemicals markets. Over the long term, this struc-ture is specifically designed topromote innovation through acontinuous dialogue betweenHarbison-Walker and the indi-vidual industries the companyserves. On a daily basis, thisstructure allows Harbison-Walkerto respond more quickly tocustomer requests and to serve asa reliable and ever present prob-lem-solving partner. Over the years, this studied,individualized approach tocustomer service has yielded anunending stream of innovativerefractory products and applica-tion strategies for the entire rangeof heat-processing industries.

Broad Based ExpertiseHarbison-Walker’s sales andtechnical support staff consists ofchemical, ceramic, metallurgical,industrial and mechanical engineers.With strong technical educationsand practical knowledge of theindustries they serve, these individu-als are highly skilled at working withcustomers to identify and selectrefractories that can extend servicelife and improve process efficien-cies. Typical consultations explorespecific operating conditions in acustomer’s furnace and whythose conditions suggest theimplementation of one refractorytype over another in a particularfurnace zone. This process canbe further aided through interac-tive CAD systems that allowscustomers to select and previewrefractory linings and configura-tions. Another valuable serviceHarbison-Walker offers is perfor-mance assessments. This pro-cess is usually aimed at identify-ing causes for deterioratingrefractory performance resultingfrom changing operating condi-tions within a customer’s plant.Most often, diagnoses are basedon post-mortem analyses of usedrefractories to determine themodes of refractory wear. Test results may point to theadaptation of existing refracto-ries, applying refractories in newcombinations, the selection ofdifferent refractory brands or thecustom design of new refracto-ries to better meet the alteredservice conditions.

Helping customers understand andimplement a proper refractorymanagement strategy is the first stepin an on-going relationship betweenHarbison-Walker and the refractoryuser. Sales and technical represen-tatives are often on-site for refrac-tory installation and furnace start-up. Follow-up technical supportcan include orientation and trainingprograms, troubleshooting, andservice and performance assess-ments.

Quality ControlHarbison-Walker’s qualitycontrol programs encompassevery facet of the organization,from the acquisition of rawmaterials to the packaging andshipment of the finished mate-rial.

The company operates anaggressive program of mineralland acquisition, permitting it tocontrol a significant percentageof the raw materials it consumes.This program also helps ensurethe uniform quality of rawmaterials while insulating thecompany from fluctuating sup-plies of key refractory minerals.Imported minerals, such aschrome ore, also are examinedand tested for quality byHarbison-Walker engineers. At the processing stage, manu-facturing sites are dedicated to asingle product or single class ofproducts. This enablesHarbison-Walker to maintain ahigh degree of chemical purity,resulting in uniform products,free of contaminants and capableof tight dimensional tolerances.

I - 4 Harbison-Walker

In addition, each plant maintains alaboratory and a staff of qualitycontrol engineers to measureproduct characteristics againststated specifications.

The company also operates acentralized Quality ControlDepartment in West Mifflin, PA.,which is responsible for monitor-ing quality standards for allHarbison-Walker brands.

Industry DialogueHarbison-Walker encourages acontinuous dialogue among itsindustry “partners” by communi-cating continuously with contrac-tor/installers and solicitingregular customer input andfeedback about all aspects ofrefractory performance.

Every year, the companybrings together its engineers andselect installers to disseminate

technical information in an educa-tional forum. This presents oppor-tunities for installers to discuss theirgoals and expectations of refractoryperformance, as well as plant safetyrequirements.

In turn, Harbison-Walkerengineers offer refractory productupdates, and a comprehensivereview of installation and con-struction techniques. Thismutual information exchangeleaves participants more pre-pared to work cooperativelythroughout the year

As the refractory industrycontinues to evolve and expand,Harbison-Walker pledges tomaintain this dialogue, seekingways to better ways to containthe heat of industrial progress.

Classes of Refractories

Basic Refractories CR-1

High-Alumina Refractories CR-7

Fireclay Refractories CR-10

Silica Refractories CR-12

Special Purpose Refractories CR-14

Mortar Materials CR-17

Monolithic Refractories CR-19

SECTION 2

Harbison-Walker CR - 1

The broad variety of pyroprocessing applications across industry demandsgreat diversity in the supply of refractory materials. In fact, many of thesematerials have been developed specifically to meet the service conditions of aparticular process. The characteristic properties of each refractory class are afunction of both their raw materials base and the methods used to manufacturethe refractory products. Primarily, refractories are classified as basic, high-alumina, silica,fireclay and insulating. There are also classes of “special refractories”which include silicon carbide, graphite, zircon, zirconia, fused cast andseveral others. Most refractory materials are supplied as preformedshapes. However, they also are manufactured in the form of specialpurpose clays, bonding mortars, and monolithics, such as hydraulicsetting castables, plastic refractories, ramming mixes and gunning mixes.A variety of processed refractory grains and powders are also availablefor certain applications. This section reviews primary refractory classifications, their typicalproperties and most common applications, as well as several speciallydesigned refractories.

CLASSES OF REFRACTORIES

CR - 2 Harbison-Walker

OverviewBasic refractories were so named because they exhibit resistance to corrosivereactions with chemically basic slags, dusts and fumes at elevatedtemperatures. While this is still a useful definition, some classes of basicrefractories have been developed that exhibit excellent resistance to ratheracidic slags. Some types of direct bonded chrome-magnesite brick, such asthose used in primary copper applications, fall into this latter category.

Broadly speaking, basic refractories generally fall into one of fivecompositional areas:

1.Products based on deadburned magnesite or magnesia.2.Products based on deadburned magnesite or magnesia in combination

with chrome-containing materials such as chrome ore.3.Deadburned magnesite or magnesia in combination with spinel.4.Deadburned magnesite or magnesia in combination with carbon.5.Dolomitic products.One of the more important types of magnesite brick are those that have low

boron oxide contents and dicalcium silicate bonds. These chemical featuresgive the brick excellent refractoriness, hot strength and resistance to load atelevated temperatures. Another category of magnesite brick contains a higherboron oxide content to improve hydration resistance.

Basic refractories containing chrome continue to be an important group ofmaterials due to their excellent slag resistance, superior spalling resistance,good hot strengths and other features. Historically, silicates in thegroundmass or matrix formed the bond between the chrome ore and periclasein the brick. However, the advent of high purity raw materials incombination with high firing temperatures made it possible to produce“direct bonded” brick, where a ceramic bond between the chrome ore andpericlase particles exists. These direct bonded brick exhibit superior slagresistance and strengths at elevated temperatures.

Magnesite-spinel brick have increased in importance due to a desire toreplace chrome-containing refractories because of environmental concerns.Brick made with spinel and magnesite have better spalling resistance andlower coefficients of thermal expansion than brick made solely withdeadburned magnesite. These features minimize the chance of the brickcracking during service.

Basic brick containing carbon include pitch impregnated burned magnesitebrick with carbon contents up to 2.5%, pitch bonded magnesite brickcontaining about 5% carbon and magnesite-carbon brick which contain up to30% carbon. Development of the more corrosion resistant magnesite-carbonbrick has resulted in decreased consumption of pitch impregnated and pitchbonded magnesite brick. In addition, in many instances the magnesite-carbonbrick have replaced magnesite-chrome brick in applications such as electricarc furnaces. It is anticipated that magnesite-carbon brick will continue togrow in importance as new products are developed and additional uses forthese products are found.

Dolomitic products are an important class of refractories that are used forexample in rotary cement kilns and AOD’s. Dolomite brick offer a goodbalance between low cost and good refractoriness for certain uses. They alsooffer good metallurgical characteristics for certain “clean steel” applications.

RAW MATERIALSThe principal raw materials used in theproduction of basic refractories aredead-burned and fused magnesites,dead-burned dolomite, chrome ore,spinel and carbon. In recent years, thetrend has shifted to developing highlyengineered basic refractories. This hasresulted from attempts to address therapidly evolving needs of themetallurgical and mineral processingindustries that use basic refractories.One result of this effort has been thedevelopment of technology to addressspecific wear mechanisms by employingspecial additives in the refractorycomposition. These additives generallyconstitute less than 6% of the total mix,although levels at 3% and below areprobably the most common.

Examples of these special additivesinclude zirconia, which is sometimesused to improve the spalling resistanceof burned basic refractories. As carbonhas become an important constituent inthe formulation of composite magnesite-carbon refractories, metallic additives,such as powdered aluminum,magnesium or silicon have been used toimprove hot strength and oxidationresistance. Small boron carbide (B

4C)

additions also can improve the oxidationresistance of certain magnesite-carboncompositions. These compositions areused in special applications such asbottom blowing elements of basicoxygen furnaces.

MAGNESITE BRICKBrick made with dead-burned magnesiteare an important category of basicrefractories. Magnesite brick arecharacterized by good resistance tobasic slags as well as low vulnerabilityto attack by iron oxide and alkalies.They are widely employed inapplications such as glass tank checkers,subhearth brick for electric arc furnaces,and sometimes as backup linings inbasic oxygen furnaces. They are oftenimpregnated with pitch in the latterapplication. Magnesite compositionsare also widely used to control the flowof liquid steel in continuous castingsystems, either as the slide gaterefractory or as a nozzle.

BASIC REFRACTORIES


Various grades of dead-burnedmagnesite are available for theproduction of magnesite brick. Theyrange from natural dead-burnedmaterials, with MgO contents of 90% orless, to high purity synthetic magnesitescontaining 96% MgO or greater.

A large amount of work has beendone to produce highly refractorymagnesites. Since magnesia itself hasan extremely high melting point, i.e.,5070°F (2800°C), the ultimaterefractoriness of a magnesite brick isoften determined by the amount andtype of impurity within the grain. Inpractice, the refractoriness of a dead-burned magnesite is improved bylowering the amount of impurities,adjusting the chemistry of the impuritiesor both.

There are many types of magnesiterefractories, both burned andchemically-bonded. For simplification,they can be divided into two categorieson the basis of chemistry. The firstcategory consists of brick made withlow boron magnesites, generally lessthan 0.02% boron oxide, that have lime-to-silica ratios of two to one or greater.Often, the lime-to-silica ratio of thesebrick is intentionally adjusted to a molarratio of two to one to create a dicalciumsilicate bond that gives the brick highhot strength. Brick with lime-to-silicaratios greater than two to one are oftenof higher purity than the dicalciumsilicate-bonded brick. This greaterchemical purity makes them moredesirable for certain applications.

The second category of magnesitebrick generally has lime-to-silica ratiosbetween zero and one, on a molar basis.These brick may contain relatively highboron oxide contents (greater than 0.1%B

2O

3) in order to impart good hydration

resistance. Sometimes, for economicreasons, these brick are made with lowerpurity natural dead burned magnesiteswith magnesia contents of 95% or less.At other times, the brick are made withvery pure magnesites with MgOcontents greater than 98% for betterrefractoriness.

MAGNESITE-CHROME ANDCHROME-MAGNESITE BRICKA major advance in the technology ofbasic refractories occurred during theearly 1930’s, when importantdiscoveries were made regardingcombinations of chrome ore and dead-burned magnesite.

Chrome ores are often represented bythe generic formula RO•R

2O

3, where the

RO constituent consists of MgO andFeO, and the R

2O

3 constituent consists

of Al2O

3, Fe

2O

3 and Cr

2O

3. It should be

recognized that most of the iron contentof raw chrome ores is present as part ofthe RO constituent. Chrome ores alsocontain siliceous impurities asinterstitial gangue minerals. These aregenerally olivine, orthopyroxene, calcicplagioclase, chlorites, serpentine andtalc.

If raw chrome ore were fired in theabsence of dead-burned magnesite, theFeO that is present would oxidizereadily to Fe

2O

3. This would result in an

imbalance between the RO and R2O

3, as

the RO decreases and the R2O

3

increases. Two solid phases wouldappear: (1) a spinel consisting mainly ofMgO•R

2O

3 and (2) a solid solution of

the excess R2O

3 constituents

(Fe2O

3,Cr

2O

3 and Al

2O

3). Frequently,

the solid solution is easily visible underthe microscope as needle-like inclus-ions.

When a chrome ore is heated withadded magnesia, as in a chrome-magnesite or magnesite-chrome brick,MgO enters the chrome spinel to replacethe FeO as it oxidizes to Fe

2O

3. The

MgO also combines with the newlyformed Fe

2O

3 to maintain the spinel

structure. The new spinel will haveessentially the formula MgO•R

2O

3.

The reaction of chrome ore with deadburned magnesite increases therefractoriness of the spinel minerals,since spinels formed by MgO withCr

2O

3, Al

2O

3 and Fe

2O

3 have higher

melting points than the correspondingspinels formed by FeO. In addition, theadded magnesia also reacts with theaccessory silicate minerals of lowmelting points present in thegroundmass of the ore, and converts

them to the highly refractory mineralforsterite, 2MgO•SiO

3. These reactions

explain why magnesite-chrome andchrome-magnesite refractories havebetter hot strength and high temperatureload resistance than refractories madefrom 100% chrome ore.

Direct-BondedMagnesite-Chrome BrickWhile the reactions between chrome oreand magnesite outline the fundamentalchemistry of magnesite-chrome brick, asignificant advance in the quality ofthese products occurred in the late1950’s and early 1960’s with theintroduction of “direct-bonded” brick.Prior to that time, most magnesite-chrome brick were silicate-bonded.Silicate-bonded brick have a thin film ofsilicate minerals that surrounds andbonds together the magnesite andchrome ore particles. The term direct-bonded describes the direct attachmentof the magnesia to the chrome orewithout intervening films of silicate.Direct-bonding was made possible bycombining high purity chrome ores andmagnesites, and firing them atextremely high temperatures. Highstrength at elevated temperatures is oneof the single most important propertiesof direct-bonded brick. They also havebetter slag resistance and betterresistance to “peel spalling” thansilicate-bonded brick.

Direct-bonded magnesite-chromebrick are available with various ratios ofmagnesite-to-chrome ore. The balanceof properties of the brick is a function ofthe magnesite-to-chrome ore ratio. Forexample, a direct bonded brickcontaining 60% magnesia wouldgenerally be regarded as having betterspalling resistance than one containing80% magnesia, although the latter mightbe considered a better choice in a high-alkali environment. This changingbalance of properties as a function ofthe ratio of magnesite-to-chrome oremakes it possible to choose productsbest suited for an individual application.

BASIC REFRACTORIES


Chrome-Magnesite BrickBurned chrome-magnesite brick may beof either the direct-bonded or silicate-bonded variety. The direct-bondedbrands are used under more severeservice conditions.

Chemically-Bonded Magnesite-Chrome and Chrome-MagnesiteBrickSome magnesite-chrome brick arechemically-bonded rather than burned.These chemically-bonded brick do nothave the high temperature strength, loadresistance or slag resistance of burnedcompositions. They are widely used,usually as lower cost compositions tobalance out wear profiles in variousapplications.

Chemically bonded magnesite-chrome brick are sometimes used withsteel casing. In service, the steeloxidizes and forms a tight bond betweenthe brick. The technique of steel casinghas accounted for improved service lifein many applications.

FUSED MAGNESITE-CHROMEGRAIN BRICKProducts have been developed thatcontain fused magnesite-chrome grainto offer improved slag resistance. Fusedgrain is made by melting deadburnedmagnesite and chrome ore in an electricarc furnace. The melted material is thenpoured from the furnace into ingots andallowed to cool. The resulting ingotsare crushed and graded into grain forbrickmaking. Brick made from thisgrain, are called “rebonded fusedmagnesite-chrome brick”.

Fused magnesite-chrome grain hasextremely low porosity and ischemically inert. In addition, brickmade from this grain have a tendency toshrink on burning rather than expand, asis characteristic of many direct-bondedmagnesite-chrome brick. As a result ofthese features, the rebonded fusedmagnesite-chrome brick have lowerporosity and superior slag resistance ascompared to direct-bonded magnesite-chrome brick.

This type of brick is used in AOD’s,degassers and sometimes in the moresevere areas of nonferrous applications.

The fused grain brick used in NorthAmerica typically contain 60%magnesia. Some compositions contain acombination of fused and unfusedmaterials for better spalling resistance,to lower cost, or to achieve a balance ofproperties that is appropriate to theparticular application in which they will beused.

COBURNED MAGNESITE-CHROME GRAIN BRICKSome magnesite-chrome brick are madefrom coburned magnesite-chrome grain,often referred to merely as coburnedgrain. Coburned grain is made bycombining fine magnesia and chromeore and dead-burning in, for example, arotary cement kiln. The resulting grainis dense and exhibits a direct-bondedcharacter. Like brick made with fusedmagnesite-chrome grain, brick madewith coburned grain shrink in burningand thus can have lower porosity thancertain classes of direct-bondedmagnesite-chrome brick. Brick madewith coburned grain find wide variety ofuses, such as in vacuum degassers insteelmaking and in certain nonferrousindustries, such as primary copper andnickel production.

MAGNESITE-SPINEL BRICKMagnesite-spinel brick have been morebroadly used in recent years. The term“spinel” as used in describing this typeof brick refers to the mineralMgO•AI

2O

3. In discussing magnesite-

chrome brick and chrome ores, the term“spinel” is often used to refer to thefamily of minerals that crystallize in thecubic system and have the generalformula RO•R

2O

3, where RO may be

MgO, and FeO and R2O

3 may be Fe

2O

3,

Al2O

3 and Cr

2O

3. While usage of the

term “spinel” in this broader sense isaccepted practice, the mineral spinel hasthe chemical formula MgO•Al

2O

3. It

has become accepted usage to use theterm magnesite-spinel brick to refer tothe products containing MgO•Al

2O

3.

A family of magnesite-spinel brick hasbeen developed by combining theconstituent raw materials in variousways. Some magnesite-spinel brick aremade by adding fine alumina tocompositions composed mainly ofmagnesia. On firing, the fine aluminareacts with the fine magnesia in thematrix of the brick to form an in situspinel bond. An alternative is to addspinel grain to a composition containingmagnesia.

One of the principal benefits ofcombining spinel and magnesia is thatthe resulting compositions have betterspalling resistance than brick madesolely with dead burned magnesite.This feature results in the avoidance orinhibition of peel spalling caused bytemperature cycling and infiltration ofconstituents from the serviceenvironment. Spinel additions alsolower the thermal expansion coefficientsof magnesite compositions. This canreduce thermal stresses that couldcontribute to cracking in certainenvironments.

A desire to use chrome-free basicbrick for environmental reasons hasincreased the importance of magnesite-spinel brick. Trivalent chromium (Cr+3)present in magnesite-chrome brick canbe converted to the hexavalent state(Cr+6) by reaction with alkalies, alkalineearth constituents and other compoundsthat are present in some serviceenvironments. These factors have led tobroad use of magnesite-spinel brick inrotary cement kilns. They haveexcellent spalling resistance, goodthermal expansion characteristics andhave been shown to provide excellentservice results in many rotary kilns.

CARBON-CONTAININGBASIC BRICKThe idea of adding carbon to amagnesite refractory originally stemmedfrom the observation that carbon is noteasily wetted by slag. Thus, one of theprincipal functions of carbon is toprevent liquid slag from entering thebrick and causing disruption. Until themid 1970’s brick based on carbon incombination with magnesite were

BASIC REFRACTORIES


mainly used in basic oxygen steelmakingfurnaces; but since that time they havebeen more broadly utilized in electric arcfurnaces and steel ladle applications.

Carbon-containing basic brick can becategorized as follows:

1. Pitch-impregnated, burnedmagnesite brick containing about2.5% carbon;

2. Pitch-bonded magnesite brickcontaining about 5% carbon;

3. Magnesite-carbon brick containing8% to 30% carbon (in this class,carbon contents ranging from 10%to 20% are most common).

While all brick in these categoriescontain both magnesite and carbon, theterm “magnesite-carbon brick” astypically used in the United States refersto brick with carbon contents greaterthan 8%.

Pitch-impregnated and pitch-bondedmagnesite brick can be thought of asproducts containing just enough carbonto fill their pore structures. Inmagnesite-carbon brick, however, thecarbon addition is too large to beconsidered merely a pore filler. Thesebrick are considered compositerefractories in which the carbon phasehas a major influence on brickproperties.

Burned Pitch-ImpregnatedMagnesite BrickOne category of burned pitch-impregnated magnesite brick is madewith a dicalcium silicate bond.Dicalcium silicate has an extremely highmelting point of about 3870°F (2130°C).Use of this bond in combination withtight chemical control of other oxidesgives these brick excellent hot strengthand an absence of fluxes at temperaturescommonly found in metallurgicalprocesses.

The carbon derived from theimpregnating pitch when the brick isheated in service prevents slagconstituents from chemically alteringthe dicalcium silicate bond, preserving

the hot strength and high refractoriness.The carbon also prevents thephenomenon of peel spalling, where thehot face of a brick cracks and falls awaydue to slag penetration in combinationwith temperature cycling.

Dicalcium silicate bonded burnedmagnesite brick that have beenimpregnated with pitch are used in anumber of applications. In basic oxygenfurnaces, this type of brick is sometimesused in charge pads, where its highstrength enables it to resist cracking anddisruption caused by the impact of steelscrap and liquid metal being added tothe furnace. These brick are also widelyused as a tank lining material, i.e. as abackup lining behind the main workinglining of a basic oxygen furnace. Theyare also used in subhearths of electricarc furnaces.

Not all pitch impregnated burnedmagnesite brick are dicalcium silicatebonded, however. One important classof brick that deserves mention has a lowlime to silica ratio and a high boronoxide content. These chemical featurescause the brick to have relatively lowhot strength, but at the same time, resultin very good hydration resistance. Thus,brick such as this are the products ofchoice where it is judged that there ispotential for hydration to occur.

Pitch-Bonded Magnesite BrickPitch-bonded magnesite brick are usedin various applications, but mainly inbasic oxygen furnaces and steel ladles.These products have excellent thermalshock resistance and high temperaturestrength, and good slag resistance.

Pitch-bonded magnesite brick werethe principal working lining materialsfor basic oxygen furnaces for manyyears. Although in severe serviceenvironments they have been replacedto a large extent by more erosionresistant graphite-containing magnesite-carbon brick, they continue to play animportant role in, for example, lowerwear areas of basic oxygen furnaces.

Magnesite-Carbon BrickThe high carbon contents of magnesite-carbon brick are generally achieved byadding flake graphite. The highoxidation resistance of flake graphitecontributes to the reduced erosion ratesof these brick. In addition, the flakegraphite results in very high thermalconductivities compared to mostrefractories. These high thermalconductivities are a factor in theexcellent spalling resistance ofmagnesite-carbon brick. By reducingthe temperature gradient through abrick, the high thermal conductivitiesreduces the thermal stresses within thebrick. High thermal conductivity alsoresults in faster cooling of a magnesite-carbon brick between heats and thusreduces potential for oxidation.

In recent years, product developmentefforts have been directed towardsproducing magnesite-carbon brick withgood slag resistance and hightemperature stability. High temperaturestability refers to the ability of the brickto resist internal oxidation-reductionreactions that can reduce hot strengthand adversely affect the physicalintegrity of the brick at elevatedtemperatures (i.e. the oxides in the brickare reduced by the carbon). A highdegree of slag resistance and good hightemperature stability have been found tobe advantageous in the hotter and morecorrosive service environments.

The high temperature stability ofmagnesite-carbon brick has beenachieved by utilization of high puritygraphites and magnesites. Since flakegraphite is a natural, mined material,there are impurities associated with it.These may be minerals such as quartz,muscovites, pyrite, iron oxides andfeldspars. Although much purification isaccomplished through flotationprocesses, most flake graphites containa limited amount of these impurities.These mineral impurities are oftenreferred to as graphite “ash”. Some ofthe ash constituents, especially the silicaand iron oxide, are easily reduced bycarbon and thus will result in a loss ofcarbon from the brick and a reduction inhot strength at elevated temperatures.

BASIC REFRACTORIES


Magnesia can also be reduced by carbonat high temperatures. For best hightemperature stability, high puritymagnesites are used. Magnesites withvery low boron oxide contents areespecially desirable.

The service environments in whichthese carbon-containing basic brick areused are very diverse due to processchanges in the steelmaking industry anddue to broader use of the products. Agreat deal of work has been done todevelop special additives to improve theperformance of carbon-containing brickin these applications. These additivesinclude powdered metals such asaluminum, magnesium and silicon. Onereason for adding these metals is toimprove oxidation resistance. Themetals consume oxygen that wouldotherwise oxidize carbon. Thealuminum and silicon also cause thepore structure of a magnesite-carbonbrick to become finer after the brick isheated. It is believed that the poresbecome finer due to formation ofaluminum carbide (AI

4C

3) and silicon

carbide (SiC) by reaction between themetals and the carbon in the brick. Thefiner pores result in decreasedpermeability of the brick and inhibitoxidation by making it more difficult foroxygen to enter the brick structure.

Another reason for adding metals isto improve the hot strength ofmagnesite-carbon brick. It has beensuggested that the improvement in hotstrength is due to the formation ofcarbide “bridges” within the matrix ofthe magnesite-carbon brick.(1) Anotherway that metals may improve hotstrength is simply by protecting thecarbon bond in these brick fromoxidation.

Silicon has been employed as anadditive to inhibit the hydration ofaluminum carbide that is formed inaluminum-containing magnesite-carbonbrick. Aluminum carbide can react withatmospheric humidity or any othersource of water to form an expansivereaction product that can disrupt thebrick. This is illustrated by thefollowing equation:

Al4C

3 + 12H

2O • CH

4 + 4Al(OH)

3

This reaction represents a potentialproblem for applications withintermittent operations such as somesteel ladles or electric arc furnaces.Adding silicon to an aluminum-containing brick greatly extends thetime before which hydration will occur.

Boron-containing compounds such asboron carbide (B

4C) are used to improve

oxidation resistance in certain criticalapplications such as tuyere elements inbottom blown basic oxygen furnaces. Inaddition, magnesite-carbon brick aresometimes impregnated with pitch inorder to improve oxidation resistance aswell as to promote brick to brickbonding in service.

DOLOMITE BRICKDolomite brick are available in burnedand carbon-bonded compositions. Thecarbon-bonded varieties include bothpitch and resin-bonded versions. Someof the carbon-bonded products containflake graphite and are somewhatanalogous to magnesite-carbon brick.Dolomite brick are widely applied inapplications as diverse as argon-oxygendecarburization vessels (AOD’s), rotarycement kilns and steel ladles.

(1) A. Watanabe et.al., “Effects of MetallicElements Addition on the Properties of Magnesia-Carbon Bricks”, Preprint of The First InternationalConference on Refractories, Tokyo, Japan, Nov.1984, pp 125-134.

BASIC REFRACTORIES


OverviewThe term high-alumina brick refers to refractory brick having analumina (AI

2O

3) content of 47.5% or higher. This descriptive title

distinguishes them from brick made predominantly of clay or otheraluminosilicates which have an alumina content below 47.5%.

High-alumina brick are classified by their alumina contentaccording to the following ASTM convention. The 50%, 60%, 70%and 80% alumina classes contain their respective alumina contentswith an allowable range of plus or minus 2.5% from the respectivenominal values. The 85% and 90% alumina classes differ in that theirallowable range is plus or minus 2% from nominal. The final class,99% alumina, has a minimum alumina content rather than a range, andthis value is 97%.

There are several other special classes of high-alumina productsworth noting:

• Mullite brick - predominantly contains the mineral phasemullite (3Al

2O

3•2SiO

2) which, on a weight basis, is 71.8%

Al2O

3 and 28.2% SiO

2.

• Chemically-bonded brick - usually phosphate-bonded brick inthe 75% to 85% Al

2O

3 range. An aluminum orthophosphate

(AlPO4) bond can be formed at relatively low temperatures.

• Alumina-chrome brick - typically formed from very highpurity, high-alumina materials and chromic oxide (Cr

2O

3). At

high temperatures, alumina and chromia form a solidsolution which is highly refractory.

• Alumina-carbon brick - high-alumina brick (usually bonded bya resin) containing a carbonaceous ingredient such asgraphite.

temperature in service. Both Fe2O

3

and TiO2 will react with Al

2O

3 and

SiO2, to form lower melting phases.

Therefore, within any class of high-alumina brick, the raw materials andtheir associated impurities impact onthe quality of the product andperformance in service.

In addition to the melting behaviorof brick, several other properties areaffected by composition.

Slag ResistanceHigh-alumina brick are resistant toacid slags, that is, those high in silica.Basic components in slag, such asMgO, CaO, FeO, Fe

2O

3 and MnO

2

react with high-alumina brick,particularly brick high in silica. AsAl

2O

3 content increases, slag

resistance generally improves.

Creep or Load ResistanceThis property is most affected bymelting point and, therefore, is likelyto be directly related to Al

2O

3

content. Impurities, such as alkalies,lime, etc., have a significant effect oncreep resistance. Mullite crystaldevelopment is also particularlyeffective in providing load resistance.

DensityAlumina has a specific gravity of3.96 and silica, in its various forms,ranges in specific gravity from 2.26to 2.65. In refractories formulatedfrom both alumina and silica, bulkdensity increases with aluminacontent.

Other physical, chemical andthermal properties will be discussedwithin the following sectionsconcerning high-alumina brick.

TYPES OF HIGH-ALUMINABRICK

50% Alumina ClassAs previously mentioned, a brickclassified as a 50% alumina producthas an alumina content of 47.5% to52.5%. Chemically, such brick arenot greatly different from superduty

HIGH ALUMINA REFRACTORIES

CHEMISTRY AND PHASEMINERALOGYFor alumina-silica brick, refractorinessis generally a function of aluminacontent. The refractoriness of 50%alumina brick is greater than fireclaybrick and progressively improves asalumina content increases up to 99+%.This relationship is best described bythe Al

2O

3-SiO

2 phase diagram. The

primary mineral phases present in firedhigh-alumina brick are mullite andcorundum which have melting points of3362°F (1850°C) and 3722°F (2050°),respectively. However, since phaseequilibrium is seldom reached,particularly in the fired refractory, theAl

2O

3-SiO

2 diagram cannot be strictly

applied. For example, a 70% aluminaproduct might contain a combination ofa bauxite aggregate of about 90%alumina, with various clay mineralscontaining less than 45% Al

2O

3. When

fired, the brick could contain a range ofphases which includes corundum(alumina), mullite, free-silica and glass.

In addition to Al2O

3-SiO

2 content, the

presence of certain impurities is criticalin determining refractoriness. Mostnaturally occurring minerals containamounts of alkalies (Na

2O, K

2O and

Li2O), iron oxide (Fe

2O

3) and titania

(TiO2). Alkalies can be particularly

harmful since they ultimately react withsilica to form a low melting glass whenthe brick are fired or reach high


fireclay brick which can contain up to44% alumina. Brick within the 50%alumina class are often upgradedversions of fireclay brick with theaddition of a high-alumina aggregate.Compositions of this class are designedprimarily for ladles. These 50% aluminaclass brick have low porosity andexpand upon reheating to 2910°F(1600°C) - desirable features for ladleapplications since they minimize jointsbetween brick, giving a near monolithiclining at service temperature. Thesebrick are also characterized by lowthermal expansion and good resistanceto spalling. Many high-temperatureindustries use them as backup brick.

50% alumina products based on highpurity bauxitic kaolin, and otheringredients in the matrix, provideexceptional load-bearing ability, alkaliresistance and low porosity. Thesequalities make such brick an excellentchoice for preheater towers andcalcining zones of rotary kilns.

60% Alumina ClassThe 60% alumina class is a large,popular class of products. These brickare used in the steel industry, as well asrotary kilns. Brick in this class aremade from a variety of raw materials.

Some are produced from calcinedbauxitic kaolin and high purity clay toprovide low levels of impurities. As aresult of firing to high temperature,these brick have low porosity, excellenthot strength and creep resistance, andgood volume stability at hightemperatures.

70% Alumina ClassThis is the most frequently used high-alumina product class because of itsexcellent and cost-effectiveperformance in multiple environments.Applications include the steel-industryand cement and lime rotary kilns.

Most brick in this class are based oncalcined bauxite and fireclay. Brick areusually fired to fairly low temperaturesto prevent excessive expansion inburning which causes problems in finalbrick sizing. Expansion is caused byreaction of the siliceous ingredients with

bauxite to form mullite. The bricktypically undergo large amounts ofsecondary expansion when heated. Thisis advantageous in reducing the size ofjoints between brick and providing atight vessel structure, e.g., a rotary kiln.

A higher cost and higher qualityalternative to producing a 70% aluminabrick is represented by brands based onhigh purity calcined bauxitic kaolin.These brick have superior hightemperature strength and refractorinessand significantly lower porosity thantypical products based on calcinedbauxite. Due to their morehomogeneous structure, they showsomewhat less expansion on reheatingthan bauxite-based products.

80% Alumina ClassThese products are based primarily oncalcined bauxite with additions ofvarious amounts of other fine aluminasand clay materials. They are usuallyfired at relatively low temperatures tomaintain consistent brick sizing. Mostbrick in this class have about 20%porosity, good strength and thermalshock resistance. Because they arerelatively inexpensive, perform well andare resistant to most slag conditionspresent in steel ladles, they are usedextensively in steel ladle applications.

90% and 99% Alumina ClassesThese brick contain tabular alumina asthe base grain and may include variousfine materials such as calcined alumina,clay and fine silica. As these brickgenerally have low impurity levels,alumina and silica typically make up99% of the chemical composition.Usually, the only mineral phases presentare corundum and mullite. Propertiessuch as high hot strength, creep and slagresistance benefit from this purity level.

ALUMINA-CHROME BRICKAlumina-chrome brick consist ofcombinations of the two oxides fired todevelop a solid-solution bond. A widerange of products are availabledepending upon Cr

2O

3 content. These

include a 90% Al2O

3-10% Cr

2O

3 product

based on high purity sintered alumina

and pure chromic oxide. The solid-solution developed in firing results inbrick with exceptional cold strength, hotstrength and load-bearing ability. Inaddition, the solid-solution bondbetween alumina and chromic oxide isinert to a wide variety of slags.

Brick with higher Cr2O

3 content are

also available. Based on a special fusedgrain high in chromic oxide, theseproducts are selected for the mostextreme cases of high temperature andcorrosiveness.

MULLITE BRICKIn brick of this special category, themineral phase mullite predominates.The alumina content varies from about70% to 78% and the brick can contain amajor portion of either sintered grain orfused mullite grain. These brick aretypically fired to high temperature tomaximize mullite crystal development.

PHOSPHATE-BONDED BRICKPhosphate-bonded brick can beproduced from a variety of high-aluminacalcines, but typically they are madefrom bauxite. A P

2O

5 addition, such as

phosphoric acid or various forms ofsoluble phosphates, reacts with availablealumina in the mix. After the pressingoperation, brick are cured attemperatures between 600°F and 1000°F(320°C and 540°C) which sets a chemicalbond of aluminum phosphate. They mayeven be fired at higher temperatures todevelop a combination chemical andceramic bond. Phosphate-bonded brickare characterized by low porosity andpermeability and very high strength atintermediate temperatures between1500°F (815°C) and 2000°F (1090°C).

Phosphate-bonded brick are widelyused in the mineral processingindustries, particularly in applicationssuch as nose rings and discharge endsof rotary kilns where excellent abrasionresistance is required.



ALUMINA-CARBON BRICKIn this class, brick are bonded by specialthermosetting resins that yield acarbonaceous bond upon pyrolysis. Awide variety of compositions arepossible based on the various high-alumina aggregates now available.Graphite is the most commoncarbonaceous material, although siliconcarbide is used, as well.



OVERVIEWRefractory fireclay consists essentially of hydrated aluminum silicates withminor proportions of other minerals. As defined by the American Societyfor Testing Materials (ASTM), there are five standard classes of fireclaybrick: superduty, high-duty, medium-duty, low-duty and semi-silica. Theseclasses cover the range from approximately 18% to 44% alumina, and fromabout 50% to 80% silica.

A blend of clays is commonly used in the manufacture of high-dutyand superduty fireclay brick. Flint clays and high-grade kaolin imparthigh refractoriness; calcined clays control the drying and firingshrinkages; plastic clays facilitate forming and impart bondingstrength. The character and quality of the brick to be made determinesthe relative proportions of clays used in a blend.

Superduty fireclay brick have good strength and volume stability at hightemperatures and an alumina content of 40% to 44%. Some superdutybrick have superior resistance to cracking or spalling when subjected torapid changes of temperature. There are several possible modifications inthe superduty fireclay class, including brick fired at temperatures severalhundred degrees higher than the usual product. High firing enhances the hightemperature strength of the brick, stabilizes their volume and mineralcomposition, increases their resistance to fluxing, and renders thempractically inert to disintegration by carbon deposition in atmospherescontaining carbon monoxide gas.

High-duty fireclay brick are used in large quantities and for a wide rangeof applications. Because of their greater resistance to thermal shock, high-duty fireclay brick can often be used with better economy than medium-dutybrick for the linings of furnaces operated at moderate temperatures overlong periods of time but subject to frequent shutdowns.

Medium-duty brick are appropriate in applications where they areexposed to conditions of moderate severity. Medium-duty brick,within their serviceable temperature ranges, can withstand abrasionbetter than many brick of the high-duty class.

Low-duty fireclay brick find application as backing for brick withhigher refractoriness, and for other service where relatively moderatetemperatures prevail.

Semi-silica fireclay brick contain 18% to 25% alumina and 72% to80% silica, with a low content of alkalies and other impurities. Withnotable resistance to shrinkage, they also have excellent load-bearingstrength and volume stability at relatively high temperatures.

FIRECLAY MATERIALSRefractory fire clays consist essentiallyof hydrated aluminum silicates withminor proportions of other minerals. Thegeneral formula for these aluminumsilicates is Al

2O

3•2SiO

2•2H

2O,

corresponding to 39.5% alumina (AI2O

3),

46.5% silica (SiO2) and 14% water (H

2O).

Kaolinite is the most common member ofthis group. At high temperatures, thecombined water is driven off, and theresidue theoretically consists of 45.9%alumina and 54.1% silica. However, eventhe purest clays contain small amountsof other constituents, such ascompounds of iron, calcium, magnesium,titanium, sodium, potassium, lithium andusually some free silica.

Of greatest importance as refractoriesare flint and semi-flint clays, plastic andsemi-plastic clays, and kaolins.

Flint clay, also known as “hard clay”,derives its name from its extremehardness. It is the principal componentof most superduty and high-dutyfireclay brick made in the United States.Most flint clays break with aconchoidal, or shell-like, fracture. Theirplasticities and drying shrinkages, afterthey have been ground and mixed withwater, are very low; their firingshrinkages are moderate. The best claysof this type are low in impurities andhave a Pyrometric Cone Equivalent(PCE) of Cone 33 to 34-35. Deposits offlint and semi-flint clays occur in ratherlimited areas of Pennsylvania,Maryland, Kentucky, Ohio, Missouri,Colorado and several other states.

Plastic and semi-plastic refractoryclays, often called “soft clays” or “bondclays”, vary considerably inrefractoriness, plasticity and bondingstrength. Drying and firing shrinkagesare usually fairly high. The PCE of claysof this type ranges from Cone 29 toCone 33, for the most refractoryvarieties, and from Cone 26 to Cone 29for many clays of high plasticity andexcellent bonding power. Substantialdeposits of plastic and semi-plasticrefractory clays are found inPennsylvania, Ohio, Kentucky,

FIRECLAY REFRACTORIES


Missouri, Mississippi, Alabama andvarious other states.

Kaolins consist essentially of themineral kaolinite. They usually aremoderately plastic and have extremelyhigh drying and firing shrinkages.Siliceous kaolins shrink less and bauxitickaolins shrink more than kaolins whichconsist almost wholly of kaolinite.Refractory kaolins generally have a PCEof Cone 33 to 35; less pure varieties witha PCE of Cone 29 to 32 are common.Among the largest deposits of refractorykaolin are those which occur in Georgiaand Alabama.

Most commercial deposits of flint andplastic refractory clay occur insedimentary strata in association withcoal beds. Usually, individualoccurrences are relatively small and ofirregular form. In the north-centralOzark region of Missouri, bodies ofrefractory clay occur in the form ofisolated sink-hole deposits. The kaolindeposits of Georgia and Alabama occurin the form of lenslike bodies.

BRICK CLASSIFICATIONS

SuperdutyThe outstanding properties of superdutyfireclay brick are refractoriness, aluminacontent of 40% to 44%, strength, andvolume stability at high temperatures.Many superduty brick have goodresistance to cracking or spalling whensubjected to rapid changes oftemperature. Their refractoriness, interms of their PCE values, may not beless than 33. In the class of superdutyfireclay refractories are severalmodifications, including brick which arefired at temperatures several hundreddegrees higher than the usual product.The high firing temperature enhancesthe high-temperature strength of thebrick, stabilizes their volume andmineral composition, increases theirresistance to fluxing and renders thempractically inert to disintegration bycarbon deposition in atmospherescontaining carbon monoxide gas.

High-DutyThe PCE value of high-duty fireclaybrick may not be less than 311/2, andordinarily varies from 311/2 to 321/2 -33.

Medium-Duty and Low-DutyFireclay brick of the medium-duty classhave PCE values of 29 to 31. The PCEvalues of low-duty fireclay brick coverthe range from 15 to 27-29.

FIRECLAY BRICK MANUFACTUREMost fireclay brick are made fromblends of two or more clays. Somebrick, especially those of the low-dutyclass, are made of a single clay. Themixes for superduty and high-duty brickcommonly contain raw flint and bondclays, with or without calcined clay. Inmaking brick of kaolin and various otherclays, a large proportion of the mix isprecalcined to control firing shrinkageand stabilize the volume and mineralcomposition of the product.

In making fireclay brick, the particlesof ground clay must include a range ofgraded sizes, each in proper proportion.The clays are typically ground in a “drypan,” which is a rotating, pan-shapedgrinding mill having slotted openings inthe bottom. The batches are screened tothe desired sizes and thoroughly mixedwith a small but closely controlledamount of water. The moistened batchis then fed to a mechanically orhydraulically operated press in whichthe brick are formed under pressure.

In a modification of the power-pressprocess, certain physical properties areenhanced by the application of a highvacuum during the forming of the brick.Brick made in this way typically have amore homogeneous texture and areharder, stronger, less porous and moredense than those made without vacuum.As a consequence, they are moreresistant to impregnation and corrosionby slags and to penetration by gases.

The extrusion process is sometimesused for making special shapes. Inmaking extruded brick, clays are groundin a dry pan, mixed wet or dry in amixer, brought to the proper consistencyin a pug mill, and extruded through thedie of an auger machine in the form of a

stiff column. The air is removed from theclay before extrusion by a deairingsystem within the auger machinechamber. The column is cut into brickby means of wires. The brick are thentypically repressed to give them sharpcorners and edges and smooth surfaces.Many intricate special shapes are formedin vertical piercing-and-forming presses,in which blanks from the extrusionmachine are completely reshaped.

Brick formed by any of the processesdescribed above are dried in tunnel orhumidity driers. The temperature offiring depends upon the maturingtemperatures of the clays, and oftenupon the service for which the brick areintended. In firing the brick, severalnecessary ends are accomplished: freeand combined water are driven off; ironand sulfur compounds and organicmatter are oxidized, and the gasesformed are eliminated; mineraltransformations and changes in volumeare affected; and finally, the particles ofclay are ceramically-bonded togetherinto mechanically strong brick.

FIRECLAY REFRACTORIES


OverviewSilica refractories are well adapted to high temperature service because oftheir high refractoriness, high mechanical strength and rigidity attemperatures almost up to their melting points, as well as their ability to resistthe action of dusts, fumes and acid slags.

The American Society for Testing Materials (ASTM) divides silicabrick into Type A and Type B based on the brick’s flux factor. Fluxfactor is determined by adding the alumina content and twice the totalalkali content. The Type A class includes silica brick with a flux factorof .50 or below; Type B includes all silica brick with a flux factorabove .50.

Both classes require that brick meet the following criteria: Al2O

3 less

than 1.5%; TiO2 less than 0.2%; Fe

2O

3, less than 2.5%; CaO less than

4%; and average modulus of rupture strengths not less than 500 psi.This system for classifying silica brick was preceded by a less exact

system which still is referenced today. Under the earlier system, non-insulating silica brick were either of conventional or superduty quality.Insulating silica brick were classified only as superduty. Brickclassified as superduty silica brick could not contain more than a totalof 0.5% alumina, titania and alkalies.

EFFECTS OF ALUMINASAND ALKALIESAfter firing, silica brick contain a smallproportion of silicates in the body that isotherwise crystalline silica. Upon beingreheated to high temperatures, thesesilicates melt and form a small amountof liquid. As the temperature rises, theliquid increases because the silica alsomelts, at first slowly and then morerapidly, especially above 2900°F(1600°C). When relatively small amountsof silicate liquid are present, the solidcrystalline portion of the brick forms arigid skeleton, with liquid merely presentbetween the solid particles, and the brickas a whole retains its rigidity even underload. When larger amounts of liquiddevelop at higher temperatures, thebond weakens and the brick may lose itsrigidity.

When silica brick contain the usual2% to 3.5% of lime, the percentage ofliquid formed at high temperaturesincreases almost in direct proportion tothe total amount of alumina, titania and

alkalies present. The temperature offailure under load decreasescorrespondingly. Individually, theseoxides and alkalies vary appreciably intheir effects on temperature of failure,but their total concentration is thesignificant factor. When the sum ofalumina, titania and alkalies is less than0.5%, the temperature of failure under aload of 25 pounds per square inch is50°F (28°C) to 90°F (50°C) higher, thanfor brick containing a total of 1% ofthese oxides. For this reason, brickclassified as superduty must contain nomore than a total of 0.5% alumina,titania and alkalies.

CHARACTERISTIC PROPERTIESAmong the important properties of silicabrick are their relatively high meltingtemperatures, i.e., approximately 3080°F(1695°C) to 3110°F (1710°C); their abilityto withstand pressure of 25 to 50 poundsper square inch at temperatures within50°F (28°C) to 100°F (56°C) of theirultimate melting points; high resistanceto acid slags; constancy of volume attemperatures above 1200°F (650°C); andvirtual freedom from thermal spallingabove 1200°F (650°C). At hightemperatures, the thermal conductivityof most silica brick is somewhat higherthan that of fireclay brick.

At temperatures below 1200°F (650°C),silica brick have less resistance tothermal shock. They are readily attackedby basic slags and iron oxide at hightemperatures in a reducing atmosphere.

SILICA REFRACTORIES

MANUFACTURE OF SILICAREFRACTORIESThe raw material used in the manufactureof silica refractories consists essentiallyof quartz in finely crystalline form havingthe proper characteristics for conversionto the high temperature crystalmodifications of silica. To assure thehighest commercial quality in therefractory product, the mineral must bewashed to remove natural impurities.

After being formed, the brick must befired at a temperature high enough toconvert the quartz into forms of silicathat are stable at high temperatures. Inthe firing and cooling process,refractories must pass through severalcritical temperature ranges;consequently, it is necessary to maintaina carefully planned time-temperatureschedule during the firing process. Aproper schedule assures the productionof strong, well-bonded brick whichattain their normal permanent expansionof 12% to 15% by volume.


SILICA BRICK PRODUCTSCertain superduty silica brick have beendeveloped to meet the demand for asilica refractory that would permithigher furnace temperatures, give longerlife and reduce maintenance costs.These brick contain no more than 35%alumina plus alkalies and titania.Superduty silica brick are used withexcellent results in the superstructuresof glass-tank furnaces.

For many years, conventional qualitysilica brick have been regarded as thestandard. The properties responsible forthe excellent service record of this brickare rigidity under load at hightemperatures, high resistance to spallingabove 1200°F (650°C), high mechanicalstrength, resistance to abrasion,resistance to corrosion by acid slags anduniformity of size. Improved versions ofconventional quality silica brick areavailable having better resistance tohigh temperature thermal shock.

A lightweight silica brick with a bulkdensity of 65 to 70 pounds per cubicfoot (1,041 to 1,121 kg/m3) is suitablefor use up to 3000°F (1650°C). At a meantemperature of 1200°F (650°C), itsinsulating value is excellent.Lightweight silica brick are used largelyfor the insulation of silica brickconstructions, especially the crowns ofglass-tanks. They are also ideal for theconstruction of tunnel kiln crowns, andtheir properties are conducive to archeshaving a wide span.

SILICA REFRACTORIES


OverviewMaterials that surpass commonly used refractories in one or more of theiressential properties are often required for industrial purposes. Carbon andgraphite, silicon carbide, zircon, zirconia, fused cast, fused silica andinsulating brick are some of the refractories with extraordinary properties forspecial applications.

shapes, such as stopper rods andsleeves. Clay-graphite shapes have beenreplaced, for the most part, by alumina-graphite shapes which provide longerservice life.

SILICON CARBIDESilicon carbide, a major component inthis special refractory class, is producedby reacting silica sand and coke attemperatures above 3600°F (2000°C). Thecenter of the reacted mass is the areahaving the highest purity, with the puritylevel decreasing towards the outer zonesof the mass. By selectively cropping asilicon carbide ingot, a producer can sellvarious grades of silicon carbide grainsranging from 90% SiC content to 98%SiC. Silicon carbide by itself is extremelyinert. Under normal atmosphericconditions, it will not selfbond, even athighly elevated temperatures. Variousschemes have been developed to bondsilicon carbide using clay, silica, metallicpowders and molten silicon.

Clay bonded SiC refractories are madeby adding crude clay to silicon carbidegrain and firing the shape to sufficienttemperature to vitrify the clay andproduce a glassy bond. These shapesare used with success in hot, abrasion-prone applications with temperaturesunder 2600°F (1427°C). Their usefulnessis limited by the refractoriness of theclay bond.

Higher strength bonds can beachieved by bonding silicon carbidewith a nitride phase or by self-bondingsilicon carbide grains with secondary insitu formed silicon carbide. Nitridebonds are typically formed by addingfine silicon powder to SiC, forming ashape and heating the shape in anitrogen atmosphere to above 2200°F(1205°C). Gaseous nitrogen reacts withthe dispersed silicon phase and formssilicon nitride crystals which readily

bond to the surface of the silicon carbideaggregate. To produce a siliconoxynitride bond, an oxygen source(typically silica) is added to the startingmaterials. To form a sialon bond,alumina is typically added to the startingmixture. The various nitride phases allpossess non-wetting properties,relatively low thermal expansion andhigh strength. The selection of anappropriate nitride bond is dependentupon the degree of oxidation in theservice environment. Generally, thesialon bond possesses the highest degreeof oxidation resistance. Nitride-bondedSiC-shapes are typically used inaluminum melting and refiningapplications, as well as in the bosh andlower in wall of blast furnaces.

Self-bonded SiC refractories are madeby first forming a shape usingconventional ceramic binders and thenfiring the shape at very hightemperatures 3622°F to 4082°F (2000°Cto 2250°C) in an atmosphere of siliconvapors. Fine carbon placed in thestarting materials reacts with the siliconvapors to form a silicon carbidesecondary phase. Such shapes have a“recrystallized” appearance and arereadily distinguishable. Self-bonded SiCis typically used in heating elements andstructural supports.

ZIRCONZircon is a silicate of zirconium havinga composition of about 67% zirconiaand 33% silica. Zircon refractories aremade by blending beneficiated zirconsands, milled zircon sands and aplasticizer or temporary binder, forminga desired shape, and firing to anelevated temperature. The firingtemperature of zircon is limited totemperatures beneath 2732°F to 3000°F(1500° to 1650°C), because within thistemperature range zircon dis-sociates.The actual temperature at which zircondissociates into zirconia and silica isinfluenced by mineralizers, such asalkalies and fluorides. Brick consistingessentially of zircon are typically madeby a forming process called impactpressing, originally developed byHarbison-Walker. This process uses a

SPECIAL PURPOSE REFRACTORIES

CARBON AND GRAPHITEThis type of refractory is essentiallycomposed of the element carbon. Its useis limited to applications which are eitherstrongly reducing or where the oxygencontent of the atmosphere at a givenoperating temperature is low enough toprevent appreciable combustion ofcarbon. Starting materials for theproduction of carbon refractories aretypically the amorphous carbons, e.g.,metallurgical coke, petroleum coke, heattreated coal tar pitches and the like.

Naturally occurring flake graphite orartificial graphites are sometimesblended with amorphous carbons toachieve a desired thermal conductivity.These materials are combined with highcarbon yielding resins or pitch andformed into blocks and slabs. Suchshapes are well suited to places wherehigh heat transfer is required, such asareas using watercooled panels.Historically, carbon blocks have beenused to line the hearth and bosh of blastfurnaces. Carbon blocks have also beenused to line the hearth and sidewalls ofaluminum reduction pots. Electrodesand anodes used in numerous industrialapplications also are typically madefrom carbon.

Carbon is a desirable element forrefractory use because it is not wettedby most molten metals and slags; it hasexcellent thermal shock resistance; andits strength increases when it becomesheated. Because of its susceptibility tooxidation, however, this refractoryshould be used under reducingconditions; or efforts should be made tominimize reaction with gaseous oxygenby adding oxidation inhibitors to theshape, such as boron carbide, finemetals (Al, Si, Mg), or by coating theshape with a protective glaze. Metalmelting crucibles made of clay-graphitehave been used for a considerablenumber of years as have clay-graphite


rapid series of air hammer impacts tocompress the mix into simple shapes,such as rectangles. Other, more intricateshapes are made by air ramming orvibration casting. The main advantagesof zircon refractories are their relativechemical inertness against acidic slagsand their good thermal shock resistance.

ZIRCONIAZirconia (ZrO

2) is usually obtained

through a chemical process involvingzircon or by fusing zircon with coke inan electric furnace. Zirconia has heldpromise as an ideal refractory materialfor many decades. It has long beenknown to have excellent chemicalinertness. It has an extremely highmelting point of 4856°F (2680°C). Wide-spread use of zirconia has been limited,however, because of two majordrawbacks, its high cost and itstendency to change crystal form uponheating.

Zirconia can occur in threepolymorphs; monoclinic, tetragonal, andcubic. The typical room temperaturephase is monoclinic which is stable toabout 2120°F to 2174°F (1160°C to1190°C) upon heating. Heating throughthe monoclinic-tetragonal transitioncauses a volume contraction; coolingthrough the transition causes a volumeexpansion. The phase change transitionthrough cooling is instantaneous andresults in spontaneous failure of thezirconia crystal. This failure isexpressed in the cracking and/ordisintegration of the refractory shape.

The fundamental cracking problemcan be overcome using either of twocontrasting approaches. One is to millmonoclinic zirconia to a fine size (lessthan one micron) and disperse it withina refractory body so that destructivemicro-cracking is avoided. In fact, thedispersed phase works as a stressabsorber as energy is absorbed byzirconia to convert from one phase toanother. In this way, the dispersedphase is said to produce a “toughening”effect.

The other approach is to stabilize thecubic structure with lime, magnesia oryttria by heating zirconia with one ofthese oxides within the temperature

range 2750°F to 3100°F (1500°C to1700°C). The cubic form of zirconia hasa uniform thermal expansion, whereasthermal expansion of the otherpolymorphs reflect volume changeswhich occur upon heating. Adisadvantage of stabilized zirconia isits tendency to thermally age. That is,the stabilizer tends to migrate out ofthe structure when the material isexposed to long term temperatureswithin the 1472°F to 2552°F (800°C to1400°C) range.

Due to its high cost, zirconiarefractories are only used in criticalapplications, such as metering nozzlesused in continuous casting and insertsin the bore area of slide gates. In theseapplications, control of the borediameter during casting is vital. Somezirconia is used to make crucibles forrefining special alloys where purity ofthe molten metal is of concern. Themain use of zirconia in the refractoriesindustry, however, is as an additive toincrease the thermal shock or slagresistance of the refractory.

FUSED SILICA REFRACTORIESFused silica is produced by electricallyheating quartzite (SiO

2) with a purity of

at least 98% silica in a fusion furnace.In this process, the crystalline nature ofthe silica is transformed into anamorphous structure by rapidquenching from a molten condition.Because of the extremely low thermalexpansion of fused (amorphous) silica,this material has excellent thermalshock resistance. Fused silica also hasexcellent corrosion resistance in acidicmedia, such as strong acids. Fusedsilica powders are used in theelectronics industry as resin extendersdue to their excellent electricalinsulating property. Fused silica filledresins are used to encapsulateelectronic components to protect themfrom the environment.

Fused silica grains are classified intovarious sizes and formulated into a slipmix for casting into plaster molds.Using this technique, many intricate,complex shapes can be made. Theseshapes are used as coke oven doors,shroud tubes, glass-tank refractories,

nonferrous troughs and spouts, and aslinings for chemical reactors. Fusedsilica shapes can be used in constanttemperatures up to 3000°F (1650°C) andcyclical temperatures up to 2000°F(1094°C). Beyond about 2000°F (1094°C)amorphous silica devitrifies intocristobalite which undergoes a volumeexpansion when heated, displaying asignificantly higher thermal expansionthan fused silica. Because of theseproperties, devitrified fused silica is notconsidered volume or thermally stablewhen heated to elevated temperatures.

FUSED CAST REFRACTORIESAs the name implies, this classificationof refractories is formed by meltingrefractory compounds in a fusionfurnace and casting the liquid melt intoa simple shape, such as a block. Specialattention must be paid to the coolingrate of the melt to prevent cracking ofthe shape and localized defects, such asshrinkage cavities.

The advantage of using fused castrefractories to contain molten metal orslag is their lack of interconnectedporosity, a feature inherent to sinteredrefractories. The absence of openporosity enables this type of refractoryto resist corrosion and infiltration ofcorrosive agents. The maindisadvantage of fused cast refractoriesis their great sensitivity to thermalfluctuations. The sudden temperaturechanges which occur in manyapplications are simply too rapid toprevent cracking or shattering of fusedcast refractories.

Fused cast refractories are typicallysold in the following compositions:alumina, alumina-zirconia-silica,alumina-silica, magnesite-chrome,zircon and spinel.Fused cast alumina is primarily used is inrefining and superstructure areas ofglass tanks. The predominant type offused cast is alumina-zirconia-silica. It isused in melting and superstructureareas. Fused cast magnesite -chromerefractories are generally composed of50% to 60% dead-burned magnesite and40% to 50% chrome ore. They offerexcellent resistance to fluid corrosivebasic slags; however, their relatively



high cost and the development ofsuitable alternative refractories at lowercost has limited their wide-spread usage.

INSULATING BRICKInsulating brick are made from a varietyof oxides, most commonly fireclay orsilica. The desirable features of thesebrick are their light weight and lowthermal conductivity, which usuallyresults from a high degree of porosity.The high porosity of the brick is createdduring manufacturing by adding a fineorganic material to the mix, such assawdust. During firing, the organicaddition burns out, creating internalporosity. Another way to accomplishhigh porosity involves the addition of afoaming agent to slip. Using thisapproach, insulating brick can be castinstead of dry pressed. Additions oflightweight aggregates like diatomite,haydite, etc., is another approach.Because of their high porosity,insulating brick inherently have lowerthermal conductivity and lower heatcapacity than other refractory materials.

ASTM classifies fireclay and high-alumina insulating refractories in thefollowing sequence: 16, 20, 23, 26, 28,30 and 33. These numbers multipliedby 100 represent the nominal servicetemperature in degrees Fahrenheit towhich the refractory can be exposed inservice. Products numbered from 16 to26 are made from a fireclay base andproducts numbered from 28 to 33 aremade from a high-alumina base.Typically, insulating refractories are usedas backup materials, but they can also beused as working linings of furnaceswhere abrasion and wear by aggressiveslag and molten metal are not a concern.Where they can be used, insulatingmaterials offer several distinctadvantages:

• Savings in fuel cost due todecreased heat losses throughthe furnace lining and less heatloss to the refractory.

• Faster heat-up of the liningdue to the insulating effect andlower heat capacity of theinsulating refractory.

• Thinner furnace wallconstruction to obtain adesired thermal profile.

• Less furnace weight due to thelower weight of the insulatingrefractory.

A variety of insulating brick provide arange of thermal efficiencies andstrengths. By composition and propertycharacteristics, lightweight insulatingsilica brick are similar to conventionalsilica brick with the exception of densityand porosity. They have a maximumservice limit of 3000°F (1650°C) and areused in the crowns of glass furnaces andtunnel kilns. Insulating brick based onfireclay aggregate are also available witha combination of high strength and lowthermal conductivity. These brick offer amaximum service limit in the range of2100°F to 2300°F (1150°C to 1261°C).They are primarily used in rotary cementkilns and glass tanks.

For even higher temperature andcorrosive applications, lightweight,insulating 90% and 99% alumina brickand alumina-chrome bricks are alsomade.



OverviewMasonry built of refractory brick consists of many relatively small units laidtogether to conform to a prescribed plan or design. The strength of themasonry depends upon the strength of the individual brick, the manner inwhich they are laid together and the nature of the mortar material used in thejoints. The purpose of the mortar is to fill the joints and bond the individualbrick together. It should protect the joints from attack by slag and otherfluxes and provide resistance to infiltration by cold air and to the outwardflow of gases.

Mortar material should be selected as carefully as the brick with which itis to be used. Users of refractories recognize that poorly made joints, orjoints filled with improper material, may greatly shorten the life of arefractory structure.

or trowelling consistency. With excellentworkability and water retention over arange of consistencies, a mortar can beused for dipped or trowelled joints, as asurface coating for walls, or forpatching. The mortar should not shrinkexcessively upon drying or heating, norshould it overfire and become vesicularat the maximum service temperature.The thermal expansion of the mortarshould be approximately the same asthat of the brick with which it is used;otherwise, temperature changes willaffect the bond between brick andmortar and cause surface coatings tocrack or peel. If strong joints areneeded, the mortar material must beaffected sufficiently by the heat todevelop a strong ceramic bond.However, the refractoriness of themortar must be high enough to resistmelting or flowing from joints at hightemperatures.

In some cases, there must beadequate chemical reaction betweenbrick and mortar to develop a strongbond between them, but in no caseshould the chemical reaction besufficient to damage the brick. In manytypes of service, it is essential that jointmaterial be highly resistant to chemicalattack by the furnace charge, slag, dust,volatized fluxes or gases; and for certainuses it is important that the mortarmaterial should not discolor norotherwise contaminate the materialbeing processed in the furnace. Mortars

which do not develop a strong bond areoften desirable for use in laying brickwalls which are alternately subjected tosoaking heat and cooling cycles.

TYPES OF MORTARS

Fireclay MortarsAir-setting mortars containing a mixtureof high fired, fireclay and high-aluminacalcines and smooth working plasticclays are recommended for use in layinghigh-alumina brick in the 50% to 70%range, as well as insulating brick.Mortars of this kind meet ASTMspecification C 178-47 superduty classmortar and are available in a wet or dryform.

Other air-setting mortars are availablewith high refractoriness, excellentintermediate temperature strength andsmooth working properties.

High-Alumina MortarsHeat-setting mortars with very highrefractoriness, volume stability, andresistance to attack by molten metal orslag are used in laying high-alumina andsuperduty fireclay brick in variousapplications, especially those whereresistance to ferrous slags is required.These mortars can be dipped ortrowelled.

High-alumina air-setting mortars areused in applications up to 3200°F(1760°C). They have high refractorinessand excellent resistance to attack bycorrosive slags.

Phosphate-bonded mortars with highrefractoriness and exceptionally smoothworking properties are used for layinghigh-alumina brick in a variety ofapplications.

Heat-setting mortars based on highpurity tabular alumina calcines areavailable for use up to 3400°F (1871°C).These mortars have exceptional stabilityand load-bearing ability at hightemperatures and are highly resistant tocorrosion by volatile alkalies and slagsin all types of furnaces. They aretypically used for laying brick in the 90%alumina class.

Phosphate-bonded alumina-chromemortars generate high bond strengths

MORTAR MATERIALS

MORTAR CLASSESRefractory mortar materials are dividedinto two classes: heat-setting mortarsand air-setting mortars.Most heat-setting mortars requirerelatively high temperatures to develop aceramic set, in contrast with air-settingmortars which take a rigid set merelyupon drying. Phosphate-bondedmortars develop a chemical bond atlower temperatures. Temperatures inexcess of 700°F (370°C) are necessary topermit formation of more stablephosphate bonds which are lesssusceptible to rehydration in highmoisture conditions. Included in each ofthese groups are materials of variouscompositions for use in specificapplications.

Mortar materials and their methods ofpreparation have been developed forparticular combinations of propertieseach bonding mortar should possess.Among the factors included areworkability, plasticity, water retention,fineness of grind, drying and firingshrinkages, chemical composition,refractoriness, cold and hot bondingstrengths, vitrification temperature andresistance to chemical attack.

The conditions which a bondingmortar must meet in service are oftenextremely exacting and require acarefully adjusted balance of properties.For economy and convenience in laying,a mortar should have good workingproperties when mixed to either dipping


and show excellent resistance tocorrosion by ferrous and nonferrousmetals. Mortars of this kind arerecommended for use when layingalumina-chrome brick, brush coatingover refractory walls, or otherapplications where strong bonded jointsand resistance to slag or metalpenetration are desired.

Basic MortarsDry, air-setting mortars with a chromeore base have excellent resistance to awide range of corrosive slags and fumesin chemical applications. They are usedfor laying basic brick of all types, butcan be used as a neutral layer betweenbasic and acid brick.

Mortar brands are also availablewhich contain high quantities ofpenetration and corrosion inhibitors.These materials have exceptionally highresistance to corrosive slags and areused for laying all types of basic brick,as well as some high-aluminacompositions where slag attack andcorrosion are especially damaging.

Mortars based on high puritymagnesite are also available and oftenused for refractories with high MgOcontent. These are usually dry and maybe used with other types of basic brick.

MORTAR MATERIALS


OverviewMonolithic or monolith-forming refractories are special mixes or blends ofdry granular or cohesive plastic materials used to form virtually joint-freelinings. They represent a wide range of mineral compositions and varygreatly in their physical and chemical properties. Some are relatively low inrefractoriness, while others approach high purity brick compositions in theirability to withstand severe environments.

Ramming mixes consist essentially ofground refractory aggregates, with asemi-plastic bonding matrix which can bepurchased ready-to-use or prepared byadding water in the mixer at theconstruction site. Ramming mixes areplaced with pneumatic hammers in 1-11/2inch layers. They supply a denser,stronger refractory body than plastics,but need some sort of form to restrainthem when rammed.

Gunning mixes consist of gradedrefractory aggregate and a bondingcompound, and may contain plasticizingagents to increase their stickiness whenpneumatically placed onto a furnacewall. Typically, gunning mixes aresupplied dry. To use, they arepredamped in a batch mixer, thencontinuously fed into a gun. Water isadded to the mix at the nozzle to reachthe proper consistency.

Castables consist of graded dryrefractory aggregates combined with asuitable hydraulic-activated bondingagent. Castables are furnished dry andform a strong cold set upon mixing withwater. They are usually poured or castin much the same manner as ordinaryconcrete, but are sometimes vibrated,trowelled, rammed or tamped into place,or applied with air placement guns.They form strong monolithic linings,possessing combinations of propertiesthat make them ideal for manyapplications.

In more recent years, new installationtechnologies have been developed forrefractories that parallel that of Portlandcement. New equipment and improvedrefractory materials have led to newinstallation techniques like self levelingcastables and pumping and wet sprayingof refractory mixes. Pumping low cementand ultra-low cement castables in a

variety of applications is now anaccepted installation practice. Wetspraying is different than gunning sincethis is a wet castable pneumaticallyapplied with a set activator added at thenozzle. In gunning, dry material isconveyed to the nozzle and water addedat the nozzle creating the wet mixture as itis applied to the wall. The great upsurgein the use of these installationtechniques is sufficient evidence of itsutility and effectiveness and itsacceptance by all segments of the pyro-processing industries as an importantmethods for the placement of refractoryconcretes.

The discussion above suggests themanner in which each class ofmonolithic refractory is most commonlyinstalled. However, not infrequently,material of one group may be installedby a technique more common to anothergroup. Specially designed plastics aresometimes gunned, as are manycastables and ramming mixes. Gunningmixes are often cast or trowelled.Typically, however, the best propertiesare achieved when monolithic materialsare installed in their intended manner.

When air-setting or hydraulicactivated monolithic refractories areused, the entire thickness of a liningbecomes hard and strong at atmospherictemperatures. The strength can besomewhat lower through theintermediate temperature range, butincreases at higher temperatures withthe development of a ceramic bond.

Heat-setting monolithic refractorieshave very low cold strength and dependon relatively high temperatures todevelop a ceramic bond. In the case ofa furnace wall having the usualtemperature drop across its thickness,the temperature in the cooler part isusually not enough to develop a ceramicbond. However, with the use of asuitable insulating material as backup,the temperature of the lining can be highenough to develop a ceramic bondthroughout its entire thickness.

When monolithic linings are used asthe primary furnace lining, they areusually held in place with either ceramic

MONOLITHIC REFRACTORIES

ADVANTAGES OF MONOLITHICREFRACTORIESMonolithic refractories are used toadvantage over brick construction invarious types of furnaces. Their usepromotes quick installation, avoidingdelays for the manufacture of specialbrick shapes. Using monolithicsfrequently eliminates difficult bricklayingtasks, which may be accompanied byweakness in construction. They are ofmajor importance in the maintenance offurnaces because substantial repairs canbe made with a minimum loss of timeand, in some cases, even duringoperations. Under certain conditions,monolithic linings of the same chemicalcomposition as firebrick provide betterinsulation, lower permeability andimproved resistance to the spallingeffects of thermal shock.

Monolithic refractories are packagedin suitable containers for convenience inhandling and shipping. With little or nopreparation, they can be applied to formmonolithic or joint-free furnace liningsin new construction, or to repair existingrefractory masonry.

TYPES OF MONOLITHICREFRACTORIESCommon usage divides monolithicrefractories into the following groups:

• Plastic Refractories

• Ramming Mixes

• Gunning Mixes• Castables

Plastic refractories are mixtures ofrefractory aggregates and cohesiveclays, prepared in stiff plastic conditionat the proper consistency for usewithout further preparation. They aregenerally rammed into place withpneumatic hammers, but may also bepounded into place with a mallet.


or high temperature steel anchors. Eachmethod of anchoring has advantages,depending upon furnace conditions andinstallation technique.

Plastic RefractoriesPlastic refractories are used to formrefractory monolithic linings in variouskinds of furnaces, and are especiallyadaptable for making quick, economicalemergency repairs. They are easilyrammed to any shape or contour.

The high refractoriness, the range ofcompositions, and the ease with whichthey can be rammed into place makeplastics suitable for many importantapplications. Plastic refractories areoften highly resistant to destructivespalling.

Plastics can include all the fireclay,clay-graphite, high-alumina, high-alumina graphite and chrome typesadapted for many different operatingconditions. They are typically packagedin strong, easy to handle, moisture proofcartons. Special gunning versions arealso available and are shipped ingranulated form in moisture resistantpallet packages. These are prepared atthe proper consistency, ready to use.

Types of Plastic RefractoriesHeat-setting superduty fireclay plasticsform a solid monolithic surface highlyresistant to thermal shock and manyacid slags. They have excellentworkability and very low shrinkage,making them the ideal choice for rotarykiln hoods, incinerators and othergeneral superduty plastic requirements.Cold setting versions of superdutyfireclay plastics are available with manyof the same features.

Superduty heat-setting plastics withgraphite exhibit excellent resistance towetting and corrosion by molten metaland slags. This type of composition istypically used in metal applications.

Plastics in the 50% alumina classtypically serve as upgrades to superdutyplastics. They are resistant to spallingdue to thermal shock and many types ofacid slags.

Heat-setting 60% alumina classplastics offer higher refractoriness oversuperduty plastics, with increased

strength and volume stabilitythroughout their temperature range.Application areas include cement kilncoolers and bull noses.

Air-setting high-alumina plastics inthe 80% alumina class are primarilyused where improved refractoriness over60% alumina plastics is desired. Theyoffer good resistance to fluxing oxidesand slags up to their maximum servicetemperature.

Phosphate-bonded high-aluminaplastics ranging in alumina contentsfrom 70% to 90% are widely used inmany applications as primary liningmaterials and for patching existingrefractory linings. These productstypically have high density andstrengths, combined with excellentvolume stability throughout theirtemperature range. Plastics rangingfrom 70% to 85% alumina content areoften used in applications whereresistance to slags and metal wash arerequired. The excellent abrasionresistance of 85% alumina plastics makethem suitable for use in high abrasionconditions in petrochemicalapplications. Additional uses includeboth ferrous and nonferrous metalapplications, where slag and metalpenetration are wear mechanisms.Plastics in the 90% alumina class arebased on high purity aluminas. Theseproducts typically have high strengths athigh temperatures and are often used inthe foundry and steelmaking process.

Phosphate-bonded alumina-chromeplastics have very high strength at hightemperatures. These compositions,based on high purity alumina aggregatesand chromic oxide, form an alumina-chrome solid solution bond at hightemperatures which has extremely goodresistance to high iron oxide slags of anacid to neutral nature and to attack bycoal slag.

Other phosphate-bonded alumina-chrome plastics with lower aluminacontents have been developed forspecific service conditions. Theseinclude mullite based alumina-chromeplastics which have outstanding slagresistance to acid to neutral slags. Thepresence of mullite grain allows forearlier reaction, making this type of

plastic refractory ideal for slaggingapplications between 2500°F (1370°C)and 2900°F (1593°C).

Silicon-carbide based phosphate-bonded plastics with an aluminumphosphate bond are also available.These have high conductivity and highabrasion resistance as well as non-wetting properties to many acid slagsand nonferrous metals.

Castable RefractoriesCastables are generally referred to asrefractory concretes. They are availablein a wide variety of base materials andtypically consist of a refractoryaggregate, special purpose additives anda cement binder. The bonding systemsused are often used to classify the typesof castables into four categories:conventional, low cement, ultra-lowcement and lime-free castables.

Conventional castables have acement-bonded matrix where, typically,a calcium-aluminate type of cement fillsin the spaces between aggregates. Thiskind of castable is the most versatile forplacement purposes in that normally itcan be poured, vibrated, rammed orgunned into place while maintaining itsdesigned properties.

Low cement castables are materialswith lime contents of roughly between1% to 3%. High densities and strengthare achieved by careful particle packingand the use of additives to reduce thewater needed to cast.

Ultra-low cement castables containfrom 0.2% to 0.8% lime. Like lowcement castables, they consist of sizedparticles to achieve maximum particlepacking. Because of the low cementcontent, these mixes are not usually asstrong in the low to intermediatetemperature range as other types ofcastables; but they tend to have higherhot strength and refractorinesscompared to chemically similar mixeswith conventional or low cement bonds.

Lime-free castables have beendeveloped with bonding systemscontaining no cement. These castableshave desirable properties for use incertain chemical applications and wherethe highest possible hot strength andhigh temperature load resistance is



required, such as metallurgicaloperations and other high temperaturefurnace applications. Some of thesematerials can approach the properties ofpressed and fired brick.

Fireclay CastablesMixtures of high fired fireclay with arefractory cement binder are designed toimpart high initial strength and maintaingood intermediate temperature strength.At high temperatures, a strong ceramicbond forms, providing good strengththroughout their working temperaturerange. These castables are used in manyapplications, including boiler furnaceash pits, piers, hoppers, annealingfurnace tops, tunnel kiln car bottoms,flues, stacks, linings for chain sectionsin rotary kilns and subbottoms ofvarious types of furnaces.

Use of higher purity aggregates andhigher purity cements can createcastables with additional refractoriness.Primary uses for these castables includerotary cement and lime kilns in sectionsother than the burning zone.

Other types of fireclay castablesinclude high purity conventional typesdeveloped for high strength andabrasion resistance. These are excellentall-purpose castables for applications upto 2800°F (1538°C). In the petrochemicaland mineral processing industries,fireclay castables designed for extremeabrasion applications in the intermediatetemperature range, have been developed.They have outstanding intermediatestrength and abrasion resistance.

Low cement fireclay castables areused where high strength andrefractoriness are needed. The lowerlime content and porosity compared toconventional fireclay castables makethem ideal for many applications.

High-Alumina CastablesHigh-alumina castables typically consistof accurately sized high-aluminaaggregates with low iron refractorycements. This mixture provides goodall-purpose castables with servicetemperature limits of 3000°F (1650°C).

Upgraded high-alumina conventionalcastables based on low alkali, high

purity alumina-silica aggregate andsuper purity cements offer better hightemperature strengths and more totalrefractoriness than castables made fromlower purity cements. These productshave a wide range of uses up to 3100°F(1705°C).

High purity alumina-bondedconventional castables with super highpurity cement typically have extremelyhigh refractoriness and chemicalresistance up to 3300°F (1816°C). Thesetypes are extremely low in silica content,making them quite effective where silicacould react with furnace constituents.This form of castable is used in manysevere abrasion and chemicallycorrosive applications.

Low cement high-alumina castableswith excellent intermediate to hightemperature properties are anotheralternative in this category. Whenproperly vibrated into place, theyprovide high density, strength andexcellent abrasion resistance. Thelower lime content provides goodchemical resistance to furnaceatmospheres that can attack lime.Alumina contents of 60% to 70% aretypical of many low cement castablesand are used for applications up to3100°F (1705°C), such as kiln floors,doors, cartops, cement kiln coolers, andprecast shapes.

High-alumina castables also include85% alumina low cement castables foruse up to 3200°F (1760°C). They arechemically similar to 85% phos-bondedplastics, but can develop greaterintermediate strengths. Their usesinclude rotary kiln lifters and coolercurbs.

Low cement castables based on highpurity aluminas with alumina contentsfrom 90% to 98% are also used.Because of their high purity and verylow silica content, they have outstandinghot strength at elevated temperaturesand are excellent for metal contactareas.

Ultra-low cement castables in the 70%alumina category exhibit excellent hightemperature strength and thermal shockresistance.

Bauxite-based, 85% alumina ultra-lowcement castables offer excellent hotstrength and thermal shock resistance.

Silica CastablesSilica-based castables include thosemade with vitreous silica as the rawmaterial with extremely low thermalexpansion, giving them excellentresistance to cracking under repeatedthermal cycling to 2000°F (1093°C).Their maximum service temperature is2400°F (1316°C) under continuousservice conditions. Primary applicationsare coke oven doors, zinc inductionfurnaces, glass forming dies andaluminum transfer ladles.

Other silica-based castables includehigh strength castables containing afortified matrix and silica aggregate.This type of composition hassubstantially lower density and thermalconductivity than fireclay extra strengthcastables with comparable strengths andabrasion resistance. This combinationof properties allows it to be used as asingle component lining where a densecastable with a lightweight castablebackup would otherwise be used.

Ultra-low cement silica basedcastables with chemistry, refractoriness,density and porosity equivalent to highquality fired silica brick are alsoproduced.

Basic Refractory CastablesThis class of castables includes chromeore base products with hydraulic cementbinders. These compositions haveoutstanding strength and abrasionresistance and resist chemical attack andthermal spalling. Typical uses includepatching for rotary kiln linings.

Basic castables also come in the formof chrome-magnesite mixes withchemical air-setting bonds. They canbe cast, rammed or gunned and havemany uses. Other high strength, air-setting magnesite castables havebonding systems which can give themextremely high hot strength.



Refractory Gunning MixesIn some industrial furnaces, turnaroundtime and installation costs are the majorfactors when choosing a refractorylining. In other cases, repairs need to bemade with little or no downtime. In bothcircumstances, pneumatic convey-ing ofmaterial, or gunning, is often the methodof choice. Dense, homogeneousmonolithic linings can be gunnedwithout the use of forms and with amarked savings in time.

Gun mixes include siliceous, fireclay,high-alumina, dead-burned magnesiteand chrome types. Many castables,ramming mixes and specially designedplastics can also be applied successfullywith pneumatic guns. Acid gun mixesare normally predamped and fedthrough a continuous dual chamber orrotary gun. Magnesite and hot gunmixes are not predamped and are placedin a batch pressure gun. Gun mixesshould wet up well, have as wide awater range as possible, and provideexcellent coverage in a variety ofapplications.

Fireclay Gunning MixesFireclay gunning mixes include multi-purpose hard-fired fireclay and standardcalcium-aluminate cement compositionsespecially formulated for easyinstallation and low rebounds. Thesemixes are used in boilers, incinerators,process heaters, stacks, breechings and avariety of other medium service areas.

There are also fireclay gunning mixeswith high purity calcium-aluminatebonding systems, designed for moresevere service conditions experienced inincinerators. Other versions aredesigned for high alkali applicationssuch as in cement kiln preheaters; or toprovide excellent CO and loaddeformation resistance, for use in steelmaking.

High-Alumina Gunning MixesThese are high purity alumina mixeswhich provide exceptional refractori-ness, volume stability and a servicetemperature up to 3000°F (1650°C). Gunmixes which combine high fired aluminaaggregate with a high strength, highpurity calcium-aluminate binder have

excellent strength and chemical puritywhich allow them to withstand severeenvironments with a maximum servicetemperature of 3300°F (1820°C). Primaryapplication areas are primarily chemical.

There are also gunning mixesdeveloped specifically for hot gunningmaintenance. These are based on high-alumina content aggregates, providing a3000°F (1650°C) service temperaturelimit. They typically have good slag andcorrosion resistance.

Silica and Silicon CarbideGunning MixesA gun mix based on vitreous silica and aspecial combination of calcined fireclayand high purity calcium-aluminatecement binder gives excellent strengthand abrasion resistance coupled withoutstanding thermal shock resistanceand low thermal conductivity.

Silicon carbide-based gunning mixesare designed for preheater buildups andcooler bull noses. They are available ina variety of silicon carbide levels andhave a high purity calcium-aluminatecement bond. The cement bond has theadvantage of forming a roomtemperature set and a water insolublebond at low temperatures.

Basic Refractory Gunning MixesA series of gun mixes are available forhot electric furnace maintenance. Theserange in magnesia content from 60% to95% and are available with or without aphosphate bond. Gunning mixes of thiskind are designed to provide an evenfeed in a batch gun, wet up well andstick to a hot furnace wall.

Refractory Ramming MixesRefractory ramming mixes consist ofrefractory aggregates and a semi-plasticbonding phase. When properlyinstalled, ramming mixes offer a way ofplacing a cementless monolithic liningat high density and relatively lowporosity.

A well balanced selection of rammingmaterials includes compositions withbase materials of silica, high-alumina,corundum, mullite, dead-burnedmagnesite, chrome ore, zircon andothers. These materials are particularly

suited for forming dense monolithic,lining construction and numerous othermonolithic constructions. Rammingmixes are typically supplied in both wetand dry forms, depending on the bindersystem.

High-Alumina Ramming MixesAlumina-silicon carbide ramming mixesare designed for non-ferrous industries.

High purity ramming mixes based onmullite grain are also used insteelmaking, burner blocks, ports andsimilar applications.

Ramming mixtures of 80% plusalumina content have excellentresistance to shrinkage and thermalspalling at high temperatures.

Other air-setting high-alumina mixesemploy stabilized, chemically refinedhigh purity aluminas. These haveexcellent resistance to thermal spallingat high temperatures and remarkablevolume stability up to their temperaturelimit.

Phosphate-bonded, alumina-chromeramming mixes can offer exceptionallyhigh purity. They typically feature veryhigh strength at high temperatures andextremely good resistance to acid toneutral slags, including coal ash slags.

Alumina-graphite ramming mixes aredesigned for the steelmaking industry.Their combination of high-aluminaaggregate and slag inhibitors gives themexcellent slag resistance to acid toslightly basic slags.

Basic Refractory Ramming MixesDry ramming mixes based on highpurity magnesite and a sintering aidhave been designed for steelmaking.Magnesite ramming mixtures ofexceptional purity and stability are usedprimarily as lining materials forcoreless-type induction furnaces meltingferrous alloys. Magnesite-chrome fusedgrain ramming mixes exist whichprovide exceptional density andstrength. The bond of this compositionprovides adequate strength at lowtemperatures until direct-bonding occursat higher temperatures.


Properties of Refractories

Physical Properties Room Temperature PR-2

Physical Properties Elevated Temperature PR-4

Changes in Dimension PR-5

Creep and Thermal Expansion PR-7

Heat Transmission PR-9

Spalling PR-11

Slag Reactions PR-12

Mineral Composition PR-13

SECTION 3

Harbison-Walker PR - 1

PROPERTIES OF REFRACTORIES

An understanding of the important properties of refractories isfundamental to the development, improvement, quality control andselection of refractory linings for high temperature processes.

While properties of refractories alone cannot be used to predict liningperformance, comparisons among properties of refractories are often usedas screening tools by refractory engineers and users to select and upgraderefractory linings. The systematic selection process starts with a carefulevaluation of furnace operating conditions and performance demands, i.e.,the degree to which refractories must contain corrosive processatmospheres, metals and slags and provide thermal protection andmechanical stability to safeguard the furnace. Matching refractory liningrequirements to service demands typically proceeds with a review of the hotphysical and chemical properties of the lining materials under consideration.

Evaluation of refractory properties is also vital to the manufacture ofsuperior refractory products. Quality control and manufacturingengineers use property determinations throughout the manufacturingprocess to assure that products meet defined standards for the brand.

Post-mortem analyses of the properties of refractories taken from serviceare useful in improving both refractory and furnace operating performance.Comparison of properties of used refractories against original propertiesoften helps to identify wear mechanisms and actual operating conditions,including operational upsets.

Refractory properties are equally important to the work of refractoryresearch engineers who use them as product design criteria in thedevelopment of new and improved refractories.

This section discusses important room temperature and hotproperties of refractories, the methods used in their determination andtheir relationship to service conditions.

PR - 2 Harbison-Walker


PHYSICAL PROPERTIES —ROOM TEMPERATURE

Chemical CompositionChemical composition serves as a basisfor classification of refractories and as aguide to their chemical properties andrefractories. Another important applica-tion of chemical analysis, as related torefractories, is in the control of qualityof both raw materials and finishedproducts. Minor components oncethought to be unimportant are nowrecognized as controlling factors in theperformance of many refractories.Among the applications of chemicalanalysis to control of quality are: thedetermination of iron oxide and alkalicontents of some clays; the aluminacontent of bauxites; the alumina andalkali content of silica refractories; thechromic oxide content and accessoryoxide levels in chrome ores; the carboncontent of graphite; and the boron oxidelevel in magnesites.

The chemical composition of arefractory material may not be the mostimportant selection criterion, as brick ofalmost identical chemical compositionmay differ widely in their behavior underthe same furnace conditions. Chemicalanalysis of a refractory alone does notpermit evaluation of such properties asvolume stability at high temperatures orability to withstand stresses, slagging orspalling.

In any given class of refractory brick,the various brands commerciallyavailable differ considerably in chemicalcomposition. Table 3.1 shows typicalchemical analyses for common industrialrefractories. Relatively few consist ofmore than 90% of any single componentand some, particularly in the basiccategory, are rather complex chemically.

Of the three types shown in Table 3.1a(fireclay, high-alumina, silica), alkaliesconstitute the most serious impurity oraccessory and, generally, the less thebetter. However, other oxides, such asTiO

2, Fe

2O

3, CaO, and MgO, should also

be low to obtain best performancecharacteristics. The lime (CaO) contentof silica brick is an exception. It isdeliberately added during manufacture

and actually improves service perfor-mance.

For the basic refractories listed inTable 3.1b, MgO, Cr

2O

3, and Al

2O

3 are

considered the primary refractorycomponents, with SiO

2, Fe

2O

3 and CaO

the accessory oxides. However, basicrefractories often have a spinel mineralstructure which is tolerant of consider-able iron content, thus explaining manyof the high totals in the “others” column.

The special refractory brick listed inTable 3.1c are essentially single-component systems. Zircon is naturally-occurring zirconium silicate and isrefractory in that form. Silicon carbidewill contain a small amount of SiO

2 as a

result of oxidation during manufacture.Alumina-carbon and magnesia-

carbon brick are special refractories notshown in Table 3.1c.

Bulk Density (ASTM C134)The bulk density is a measure of theratio of the weight of a refractory to thevolume it occupies. Bulk density isusually expressed in pounds per cubicfoot (pcf) or kilograms per cubic meter(kg/m3). The density of refractories is anindirect measurement of their heatcapacity or ability to store heat. This isparticularly important in applicationssuch as regenerator installations.

Apparent Porosity (ASTM C830)The apparent porosity, sometimesreferred to as open porosity, is a measureof the open or interconnected pores in arefractory. The porosity of a refractoryhas an effect upon its ability to resistpenetration by metals, slags and fluxesand, in general, the higher the porosity,the greater the insulating effect of therefractory. In contrast to apparentporosity, true porosity represents asample’s total porosity, both open andclosed pores. Closed porosity refers toporosity within the coarser grains, whichcannot be readily determined. Hence,true porosity may be difficult to mea-sure.

PROPERTIES OFREFRACTORIESImportant properties of refractorieswhich can be determined most readilyare chemical composition, bulk density,apparent porosity, apparent specificgravity and strength at ambient tempera-tures. These properties are often amongthose which are used as controls in themanufacturing and quality controlprocess. The chemical compositionserves as a basis for classification ofrefractories. The density, porosity andstrengths of fired products are influ-enced by many factors. Among these aretype and quality of the raw materials, thesize and “fit” of the particles, moisturecontent at the time of pressing, pressure ofpressing, temperature and duration of firing,kiln atmosphere and the rate of cooling.

The mechanical strength of refractorybrick is governed largely by the ground-mass material between the larger grains.At ambient temperatures, the compres-sive strength is typically much higherthan the tensile strength. For example, afireclay or 50% alumina product maycontain glassy material in the bondingphase. This glassy material is difficult tocompress but may be broken quitereadily in tension. A product’s roomtemperature strength is an importantindicator of its ability to withstandabrasion and impact in low temperatureapplications and to withstand handlingand shipping. Other important propertiesdetermined at ambient temperatures areporosity, permeability and pore sizedistribution.

The strength of brick at ambienttemperatures may provide little or noindication of their strength at furnaceoperating temperatures. For example, afireclay or 50% alumina material thathas good strength at ambient tempera-tures will typically exhibit significantlyreduced strength at elevated tempera-tures where the glassy phase maybecome quite soft or even fluid.

Important properties determined atelevated temperatures are hot modulusof rupture, hot crushing strength, creepbehavior, refractoriness under load,spalling resistance, dimensional changesand thermal conductivity.



Abrasion Resistance(ASTM C704)In many types of service, refractories aresubjected to impact by heavy pieces ofmaterial charged into the furnace;abrasion by metallic or nonmetallicsolids; or direct impingement byabrasive dusts and high velocity gases.For greatest resistance to these actions,brick should be mechanically strong andwell-bonded. The strongest brickgenerally show the highest resistance toabrasion. As compared with otherproperties, the modulus of rupture orcrushing test offers the best indication ofresistance to abrasion.

The abrasion test determines theresistance of a material to erosion whenimpacted by fine silicon carbide at roomtemperature. This test is particularlyappropriate to applications in whichparticulate laden gas streams impinge onrefractories, or where charge materialcontacts refractory surfaces at lowertemperatures.

Cold Crushing Strength andModulus of Rupture of RefractoryBrick and Shapes (ASTM C133)Strength is one of the most widely usedparameters for evaluating refractories.Strength can be measured at roomtemperature or at any temperature forwhich suitable test equipment exists.Room temperature (cold) strengthmeasurements cannot be used directly topredict service performance, but doprovide a good tool for evaluating thedegree of bond formation duringproduction. Room temperature testingalso indicates the ability of brick towithstand handling and shipping withoutdamage and to withstand abrasion andimpact in relatively low-temperatureapplications.

Strength testing at elevated tempera-tures is valuable in assessing the abilityof a material to survive stresses causedby restrained thermal expansion, thermalshock and mechanical loading. Impactand abrasion resistance depend onmaterial strength, as well. It is alsocommon to use high temperaturestrength numbers to predict resistance toerosion and corrosion by metals and

slags, although other properties, such asmineral composition and porosity, maybe of equal or greater importance.

Two types of strength tests arecommon. The modulus of rupture(MOR) test measures the flexural(transverse) breaking strength and thecrushing strength test measures thecompressive strength. Both tests have aversion for cold (ambient) temperaturesand high (service) temperatures. Thecold crushing strength (CCS) and coldmodulus of rupture tests are describedby ASTM Method C133. In the coldcrushing strength test, a sample 41/2” x41/2” x 21/2” or 3” is loaded at a standard

rate using a suitable mechanical testingmachine (see Figure 3.1). The load isapplied vertically to the 41/2” x 41/2” faceof the sample until failure. The crushingstrength is calculated by dividing themaximum load supported by the sampleover the surface area of the face whichreceives the load.The equation for calculating is:

S = W/Awhere:

S = cold crushingstrength, psi (N/mm2)

W = maximum load, lbf (N)A = cross-sectional area,

in2 (mm2)

Table 3.1 Chemical Analysis of Common Industrial Refractories

3.1a Refractory Brick of the Alumina-Silica Types

Alumina Silica Alkalies Others(Al2O3) (SiO2) (Na2O, K2O, (TiO2, Fe2O3,

Types of brick Li2O) CaO, MgO)

Fireclay

Superduty 41.9% 53.2% 1.2% 3.7%

High-duty 41.0 51.6 2.0 5.3

Low-duty 30.0 62.0 3.7 4.3

High-Alumina

60% class 58.0 38.0 0.1 3.9

70% class 69.2 26.2 0.2 4.4

85% class 86.5 8.9 0.1 4.5

90% class 88.5 11.0 0.2 0.3

Corundum class 99.2 0.4 0.2 0.2

Silica

Conventional 0.5 95.9 0.1 3.4

Superduty 0.2 96.5 0.04 3.4

3.1b Basic Brick

Magnesia Chromia Alumina OthersTypes of brick (MgO) (Cr2O3) (Al2O3) (SiO2, Fe2O3)

Magnesite, fired 98.2% – 0.2% 1.6%

Magnesite-chrome, fired 55.7 4.1% 3.3 36.9

Magnesite-chrome, unfired 72.1 8.8 9.7 9.5

Chrome, fired 18.4 30.4 32.1 19.1

Chrome-magnesite, fired 36.1 24.8 22.3 16.8

Chrome-magnesite, unburned 31.5 26.6 23.4 18.5

3.1c Special Refractory Brick

OthersSilica Zirconia Carbide (Al2O3, TiO2,

Types of brick (SiO2) (ZrO2) (SiC) Fe2O3)

Zircon 32.3% 66.0% – 1.7%

Silicon carbide 5.6 – 90.8% 3.6



The setup for the cold modulus ofrupture test is shown in Figure 3.2. Thetest specimen, again a standard nine-inchstraight, is placed on two bearingcylinders with the top and bottom (9” x41/2”) faces oriented horizontally. Thespecimen is broken at mid-span inflexure at a standard loading rate. Themodulus of rupture is calculated usingthe following equation:

MOR = 3PL/2bd2

where:MOR = modulus of rupture,

psi (N/mm2) P = load at rupture, lbf (N) L = span between supports,

in (mm)

b = breadth or width ofsample, in (mm)

d = depth or thickness ofsample, in (mm)

Strength values vary widely amongclasses of refractories and even amongrefractories of the same classification.Typical values for a number of refracto-ries are given in Table 3.2. Variableswhich significantly affect cold strengthof refractories are bond chemistry, firingtemperature, porosity, and the strengthand sizing of the aggregate.

PHYSICAL PROPERTIES —ELEVATED TEMPERATUREThe most significant properties ofrefractories are those which enable themto withstand the conditions to whichthey are exposed in service at elevatedtemperatures. These conditions may beclassified broadly as thermal, mechani-cal, chemical and various combinationsof the three.

Refractories must be sufficientlyrefractory to withstand the maximumtemperatures to which they will beexposed in service. Frequently, theymust be resistant to the stress effects ofrapid temperature change within criticaltemperature intervals. They may berequired to withstand varying loads,abrasive action and penetration andcorrosion by solids, liquids and gases.

High temperature properties ofrefractories which are relevant to serviceconditions include the following:

• Refractoriness• Melting behavior• Mechanical strength and load

bearing capacity• Changes in dimensions

when heated• Resistance to abrasion,

mechanical erosion and impactof solids

• Resistance to corrosion anderosion at high temperatures bysolids, liquids, fumes and gases

• Resistance to spalling• Thermal conductivity

Thermal EffectsThe one condition obviously common toall furnace operations is high tempera-ture. A closely related combination ofother thermal effects results from hightemperatures and from the rate oftemperature change. Heat energy flowsinto the refractory structure when thefurnace is heated and a temperaturedifferential develops between the insideand outside surfaces. Part of the heatenergy is stored in the refractorystructure and part flows through thewalls and other parts of the furnacestructure and is lost to the outside airthrough radiation and convection.

Figure 3.1 Cold Crushing Strength Test

Figure 3.2 Modulus of Rupture Test



When refractories are hot their lineardimensions and volumes are greater thanwhen they are cold due to “reversiblethermal expansion.” With some refracto-ries, additional volume change, usuallynot reversible, results from mineralinversions and transformations andsometimes from other causes.

Within a single brick in a furnace wallor arch, there is commonly a tempera-ture drop of many hundreds of degreesbetween the hot face and the cold end.Consequently, differences in the amountof thermal expansion in various sectionsof the brick will cause internal stressesto develop within the brick. In a refrac-tory structure, pressure inherent in thefurnace construction, such as archstresses, generally will be increased bythermal expansion of the brickwork.Unequal volume changes resulting fromrapid fluctuations in temperature maycause the development of higher stresseswithin the refractories than they arecapable of withstanding.

Reactions Between RefractoriesWhen no single kind of refractorymaterial is adequate to meet the variousconditions prevailing in different parts ofa furnace, two or more different kinds ofrefractories may be employed in theconstruction. However, refractories ofdissimilar chemical compositions mayreact chemically with each other if incontact at high temperatures. Furnacefumes, dust, and slags can acceleratethese reactions.

In the high temperature portions of afurnace, it is good practice to separatereactive refractories by an intermediatecourse of refractory brick which will notreact with either at the temperature ofoperation, or by a joint of non-reactivebonding mortar.

Pyrometric Cone Equivalent(ASTM C24)A standard method of evaluating thehigh temperature softening behavior ofalumina-silica and fireclay compositions

is the determination of their PyrometricCone Equivalent, abbreviated PCE(ASTM C24).

A ground sample of the material to betested is molded into the form of testcones and mounted in a ceramic plaquewith a series of standard pyrometriccones having known high temperaturesoftening values. The plaque is heated ata fixed rate until the test cones softenand bend. The number of the standardcone whose tip touches the plaque at thesame time as the tip of the test cone isreported as the PCE value of the testcone.

The PCE does not indicate a definitemelting point or fusion point because thetest is not a measurement, but merely acomparison of the thermal behavior ofthe sample to that of standard cones. Thetest is used in evaluating the refractoryquality of clays and the softeningtemperature of slags, as well as in themanufacture and quality control offireclay products. PCE values ofalumina-silica refractories are given inTable 3.3.

CHANGES IN DIMENSION

Permanent Reheat Change(ASTM C113)

This is also referred to asPermanentLinear Change or PLC. In the firing ofrefractory brick, permanent changes indimensions generally occur, altering theindividual brick from the mold size to thefired size. It is desirable that the changesbe completed in the firing step to preventexpansion or shrinkage later in service.However, changes in dimensions andvolume require time as well astemperature for completion. As firingproceeds, the rate of dimensional changegradually diminishes. Yet, it is rarelyfeasible to attain complete expansion orcontraction during the firing process.Therefore, in service, if the furnacetemperature is high enough andmaintained for a sufficient period of time,there can be an additional change indimensions, generally slight, butpermanent. Excessive dimensionalchanges in service are objectionable dueto their potentially harmful effect on thestability of the furnace. A reheat test

Table 3.2 Physical Properties of Refractory Brick

Cold crushing Modulus ofDensity, Apparent strength, rupture,

Types of brick lb/ft3 porosity lb/in2 lb/in2

Fireclay

Superduty 144-148 11-14% 1,800-3,000 700-1,000

High-duty 132-136 15-19 4,000-6,000 1,500-2,200

Low-duty 130-136 10-25 2,000-6,000 1,800-2,500

High-Alumina

60% class 156-160 12-16 7,000-10,000 2,300-3,300

70% class 157-161 15-19 6,000-9,000 1,700-2,400

85% class 176-181 18-22 8,000-13,000 1,600-2,400

90% class 181-185 14-18 9,000-14,000 2,500-3,000

Corundum class 185-190 18-22 7,000-10,000 2,500-3,500

Silica (superduty) 111-115 20-24 4,000-6,000 600-1,000

Basic

Magnesite, fired 177-181 15.5-19 5,000-8,000 2,600-3,400

Magnesite-chrome, fired 175-179 17-22 4,000-7,000 600-800

Magnesite-chrome,

unburned 185-191 – 3,000-5,000 800-1,500

Chrome, fired 195-200 15-19 5,000-8,000 2,500-3,400

Chrome-magnesite, fired 189-194 19-22 3,500-4,500 1,900-2,300

Chrome-magnesite,

unburned 200-205 – 4,000-6,000 800-1,500

Magnesite-carbon 170-192 9-13 – 1,000-2,500

Dolomite 165-192 5-20 1,500-3,500 500-2,500

Fused cast

magnesite-chrome 205-245 1-15 900-1,400 6,000-8,000

Silicon carbide 160-166 13-17 9,000-12,000 3,000-5,000

Zircon 225-232 19.5-23.5 7,000-11,000 2,300-3,300



gravity provides an adequate measure ofthe amount of permanent or residualexpansion.

In the reheat test at 2910°F (1600°C),most basic brick will show a slight linearshrinkage, varying from a few tenths of apercent or less for some types of brick,up to 2.5% for others. High fired chrome-magnesite brick usually have little or noshrinkage in the reheat test at 2910°F(1600°C) and a shrinkage of only sometenths of a percent at 3000°F (1650°C).

Linear Thermal ExpansionIn common with essentially all otherstructural materials, refractories willexpand when heated and contract whencooled. Knowledge of the thermalexpansion behavior of refractorymaterials is often crucial in designingfurnace linings. If the lining is con-strained by the furnace structure,destructive forces may result as thelining expands during furnace heat-up.In such cases, the lining must bedesigned to allow some free expansion.The amount of expansion allowance,however, must not be so much as tocause lining instability. An understand-ing of thermal expansion characteristicsis also important in assessing the thermalshock resistance of a material. Thermalshock occurs when severe temperaturegradients in a material cause internalstresses due to differential thermalexpansion.

The measurement of the linearthermal expansion of a refractory isusually made by determining the changein length of a bar-shaped specimenheated uniformly at a constant rate. Themovement of the sample may be detectedby connecting an electrical transducer,located above the furnace, with the topof the specimen by means of a sapphirerod. A device of this type is known as adilatometer.

Thermal Expansion ofFired RefractoriesIf no changes of a permanent natureoccur during heating, fired refractoriesreturn to their original dimensions whencooled. This characteristic is known as“reversible thermal expansion.” Typically,

determines the amount of permanentchange in dimensions of refractory brickwhich may occur at high temperatures.This permanent reheat or linear changeis in addition to the reversible linearthermal expansion that all refractoriesexhibit when they are heated or cooled.

High temperature reheat tests may beused to reveal (1) whether a refractorycomposition of a given quality has beenfired long enough; or (2) at a highenough temperature; or (3) if not fired,whether it is made of volume stablematerials; and (4) whether a compositionhas adequate refractoriness and volumestability. The tests may be used in theseways to estimate refractoriness. Theresults should be interpreted withcaution, however, as the amount ofshrinkage or expansion depends not onlyon the refractory’s characteristics, butalso on the temperature and time ofheating during the test. The results of ashort term reheat test may not be asufficient basis for predicting the longterm volume changes which a refractorymay undergo in service.

In the standard ASTM reheat test,Method C113, brick are placed in a

furnace, gradually heated to a predeter-mined temperature and maintained at thattemperature for five hours. After cooling,measurements are made to determinechanges in linear dimensions andvolume.

Reheat Changeof Fired RefractoriesIn the reheat test at 2550°F (1400°C),high-duty fireclay brick generally show aslight (up to 1.5%) linear contraction. At2910°F (1600°C), superduty fireclay brickusually shrink 0.0% to 1.0% in length.Some fireclay brick expand slightly in thereheat test, however, the expansion doesnot occur if the brick are in compression.

For high-alumina brick of the 50% to80% alumina classes, the temperature ofthe reheat is usually 2910°F (1600°C).Some brick show a linear shrinkage of asmuch as 2.0% to 2.5%; others, anexpansion up to 3.5% or more. For brickof the 90% alumina class, corundumbrick, and mullite brick, the temperatureof the test may be 3140°F (1725°C) andthe linear change is usually within therange of minus 0.5% to plus 1.5%.

The reheat test is not usually appliedto silica brick, as the apparent specific

Table 3.3 Typical Pyrometric Cone Equivalents of Refractory Brick

MinimumPCE Typical

Types of brick ASTM C24 PCE

Fireclay

Superduty 33 33 to 34

High-Duty 31.5 31.5 to 33

Medium-Duty 29 29 to 31

Low-Duty 15 15 to 27

Semi-Silica – 27 to 31

High-Alumina

50% Alumina Class 34 35

60% Alumina Class 35 36 to 37

70% Alumina Class 36 37 to 38

80% Alumina Class 37 39

90% Alumina Class – 40-41

Mullite Class* – 38

Corundum Class* – 42 Minus

* Estimated and shown for convenience. It is generally impractical to obtain thePCE values of high-alumina brick above the 50% or 60% alumina class.

In reporting PCE values, the word “to” is used between two standard cone numbers toindicate that different lots of the given material have a range of softening from the lower tothe higher value. A dash (-) between two standard cone numbers does not indicate a range,but shows that the material has a position as to softening approximately midway betweenthe two pyrometric cone values.



refractories that are heated to tempera-tures below their firing temperature showthis behavior. The linear thermal expan-sion characteristics of a number of firedrefractories are given in Figures 3.3 and3.4. The expansions of different brands ineach class of refractory differ somewhatamong themselves, and the data there-fore represent mean values. Magnesiteand forsterite brick have relatively highrates of thermal expansion; fireclay,silicon-carbide, zircon brick, and mostinsulating firebrick have relatively lowrates. The thermal expansions of otherrefractories have intermediate values. Formost fired refractories, thermal expansionincreases at a fairly uniform rate over theworking range of temperature. Notableexceptions are silica brick which undergo

the greater part of their expansion below800°F (about 425°C).

Thermal Expansion ofUnfired RefractoriesIn general, the thermal expansionbehaviors of unfired refractories are morecomplex than those of their fired counter-parts. During initial heating, dramaticexpansions or contractions may occur inan unfired material as a result of changesin bonding structure, changes inminerology, and sintering effects.

The thermal expansion characteristicsof a number of cement-bonded refracto-ries during initial heat-up are shown inFigure 3.5. These materials show shrink-age over the temperature range 400°F to600°F (205°C to 315°C) which is associ-

ated with thermal decomposition of thecement. The amount of shrinkage isdetermined by the quality and amount ofcement. At temperatures above 1800°F to2000°F (980°C to 1090°C), additionalshrinkage occurs as a result of sintering.The underlying thermal expansion isdetermined by the characteristics of theaggregate. The shrinkages which takeplace during initial heat-up to 2600°F(1430°C) are permanent in nature andcommonly are on the order of 0.2% to1.5%.

The thermal expansion curves forinitial heat-up of several phosphate-bonded plastics and clay-bonded plasticsare shown in Figure 3.6. Typically, thesematerials show linear behavior belowabout 1900°F (1040°C). At about 1900°F(1040°C), however, mineralogical changesamong the clay constituents result indensification and the materials contract.Permanent shrinkages of 0.2% to 0.6%are common after initial heating to 2600°F(1430°C).

CREEP AND THERMALEXPANSION UNDER LOAD

Changes in DimensionsUnder LoadIn service, refractory materials mustsupport a load which, at its minimum, isequal to the weight of the lining abovethe reference point. The pressure whichis exerted depends on the height of thelining and the density of the material.Therefore, for applications in which theentire lining component is at hightemperatures, it is important to under-stand the load-bearing capabilities ofcandidate materials. Examples of suchapplications include blast furnace stovesand carbon bake furnaces in which therefractories are heated relativelyuniformly to high temperatures.

The standard laboratory tests forrefractories include one for the determi-nation of the behavior of brick under loadat high temperatures. In this test, two 9-inch straight brick are set on end in afurnace of specified design and a verticalload of 25 lb/in2 is applied. In the stan-dard procedure, (ASTM C16), thetemperature is gradually raised in

0.20

00

1/16

1/8

3/16

1/4

0

0 100 200 300 400 500 600 700 800 900 1100 1300 1500

200 400 600 800 1200 1600 2000 2400 2800

LINE

AR E

XPAN

SION

– P

ER C

ENT

LINE

AR E

XPAN

SION

– IN

CHES

PER

FOO

T

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

TEMPERATURE – DEGREES FAHRENHEIT

TEMPERATURE – DEGREES CENTIGRADE

CONVENTIONAL SILICAMAGNESITE (92% MgO)

FORSTERITE

99% ALUMINA

80% TO 90% ALUMINA

60% TO 70% ALUMINA

SILICON CARBIDE

FIGURE 3.3 Approximate Reversible Thermal Expansion of Brick

FIGURE 3.4 Approximate Reversible Thermal Expansion of Brick

0.20

00

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0 100 200 300 400 500 600 700 800 900 1100 1300 1500

200 400 600 800 1200 1600 2000 2400 2800

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ER C

ENT

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TEMPERATURE – DEGREES FAHRENHEIT

TEMPERATURE – DEGREES CENTIGRADE

HIGH-DUTY AND SUPERDUTY FIRECLAY

SUPERDUTY SILICA

ZIRCON

CHROME

SEMI-SILICA FIRECLAY

SUPERDUTY SILICA (NOT PATCH)



This reflects a marked difference in theway the latter types behave under thecombined forces of heat and mechanicalstress. They typically maintain theirintegrity until a particular temperature isreached, after which failure occursabruptly rather then showing gradualsubsidence over time as with fireclayand high-alumina brick. Test proceduresare different for those brick which aresimply heated on a rising curve untilfailure occurs.

Load testing provides very significantdata relative to maximum servicetemperatures in the field. More recently,the preferred test is the ASTM methodfor measuring the thermal expansion andcreep of refractories under load (ASTMC832). Commonly referred to as a“creep test,” the test is more sophisti-cated than the conventional ASTM loadtest. Rather than measuring the subsid-ence of a sample after testing, it providesa continuous monitoring of this sample’sdimensional changes during the test.

The properties measured during thistest are known as thermal expansionunder load (TEUL) for the heatingportion of the test, and “creep” duringthe hold portion. In the standard proce-dure, ASTM method C832, a constantvertical load, usually 25 psi, is appliedto the 11/2” x 11/2” faces of a specimenmeasuring 11/2” x 11/2” x 41/2”. Afterheating to the prescribed temperature ata constant rate, the sample reaches apoint of peak expansion, called themaximum dilation point; the temperatureand expansion at this point characterizethe thermal expansion under load. Thetemperature of the sample is then heldfor 50 hours or longer, and the creepbehavior is characterized by the amountof subsidence which occurs between the20th and 50th hours.

Like most structural materials,refractories show creep behavior whenexposed to high temperatures. Mostrefractories show two characteristicstages of creep. In the first stage, calledprimary creep, the rate of subsidencedeclines gradually with time. In thesecondary stage, called steady state, therate of subsidence is constant. At veryhigh temperatures, steady state creep issometimes followed by a tertiary creep

accordance with a definitely prescribedschedule. For fireclay and high-aluminabrick, the maximum temperature is heldfor 1½ hours, after which the furnace isallowed to cool by radiation to 1830°F(1000°C) or lower before the load isremoved.

The amount of subsidence is reportedas percentage of the original length. Thenormal temperature of the hold for high-duty fireclay brick is 2460°F (1350°C); forsuperduty fireclay brick, 2640°F (1450°C).However, recent improvements in thehigh-temperature strength of certaintypes of high-duty fireclay brick,

especially checker brick, have led to theirbeing tested at 2,640°F. For most classesof high-alumina brick the top temperatureof testing is 2640°F (1450°C); for those ofthe 90% alumina class and mullite andcorundum brick it is 2900°F (1595°C) and3200°F (1760°C).

Results of such testing on fireclay andhigh-alumina brick are shown in theupper portion of Table 3.4.

The lower portion of Table 3.4 showresults for silica, basic, and silicon-carbide brick. It will be seen that testresults are reported as “withstands loadto” rather “subsidence after heating to.”

FIGURE 3.5 Thermal Expansion of Various Refractory Castables

FIGURE 3.6 Thermal Expansion of Various Refractory Plastics

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TEMPERATURE F

-1 16/

0

1 16/

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FIRECLAYCASTABLE

90% ALUMINACASTABLE

LOW CEMENTFIRECLAYCASTABLE

LIN

EA

R E

XPA

NS

ION

-PE

RC

EN

T

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0

1 16/

90% ALUMINA PLASTIC

70% MULLITE PLASTIC

SUPERDUTYFIRECLAYPLASTIC



region where the rate of subsidenceaccelerates and leads to catastrophicfailure or creep rupture. Primary creep isgenerally short in duration, whilesecondary creep can occur over a longterm. Therefore, secondary creep usuallyprovides a more meaningful comparisonof refractories. Secondary creep is theparameter determined by the methoddescribed above. The creep behavior at2600°F (1430°C) of a series of fired high-alumina refractories is illustrated byFigure 3.7. It is obvious that the creepbehaviors of brick cannot be predictedbased only on their chemistry. Importantvariables which affect creep behavior arechemistry of the bonding phase andfiring temperature. Formation of lowviscosity glassy phases results in poorcreep behavior, whereas well-formedcrystalline bond phases give good creepbehavior. Aggregate sizing and porosityalso affect creep behavior with larger

aggregate and lower porosity givingbetter creep resistance.

HEAT TRANSMISSION

Thermal ConductivityWhen a furnace is heated, thermalenergy flows into the refractory struc-ture, causing a temperature difference todevelop between inside and outsidesurfaces of walls and roofs. Part of thisthermal energy is stored in the refractorystructure and its foundation, and partflows through the walls, roofs, andhearths, and is lost to the outside air byradiation and convection. The amount ofheat which escapes in this manner isoften of considerable importance in theeconomy of the process. In estimatingthe quantities of heat flowing throughthe parts of a furnace, use is made of acoefficent known as the thermal conduc-tivity, or K-value, of each material

involved in the construction. The thermalconductivity value differs not only fordifferent materials, but usually also forthe same material at different tempera-tures. The thermal conductivity isreported at the mean temperature of thetest brick. Measured thermalconductivites of various refractories aregiven in Table 3.5.

Major factors which affect the thermalconductivity of a refractory material arethe mineral composition, the amount ofamorphous material (glass or liquid)which it contains, its porosity and itstemperature. For materials which havesimilar mineralogical compositions, theproportion of pore space is questionablythe most important factor affecting theamount of heat which will flow throughit at a given temperature. Within thetemperature range seen in most applica-tions, thermal conductivity decreaseswith increasing porosity.

At ambient temperatures, the thermalconductivity of glass is considerablylower than that of crystalline material ofthe same composition. With risingtemperatures, the conductivity of glassestends to increase, while that of crystallinematerial tends to decrease. However, inrefractory bodies consisting of crystalaggregates with limited amount of glass,the temperature effects are difficult topredict. The conductivity of a refractoryin service at high temperature is oftenchanged somewhat, either by an increasein the amount of glass or liquid itcontains, or by devitrification of anyglass it may contain.

High thermal conductivity is desirablefor refractories used in constructionsrequiring efficent transfer of heatthrough brickwork, as in retorts, muffles,byproduct coke oven walls andrecuperators. In most types of vessels,however, low thermal conductivity isdesirable for heat conservation, but isusually less important than other proper-ties of the refractories.

Heat FlowThe rate of heat flow in refractoryconstructions can be calculated onlyapproximately for several reasons:

TABLE 3.4 Typical Results of Load Test as Indicated by 25 lb/in2 Load Testing

Type of brick Results of load testing

FireclaySuperduty 1.0-3.0% subsidence after heating at 2640°FHigh-duty Withstands load to <2640°FLow-duty Withstands load to <2640°F

High-Alumina60% Class 0.1-0.5% subsidence after heating at 2640°F70% Class 0.4-1.0% subsidence after heating at 2640°F85% Class 0.2-0.8% subsidence after heating at 2640°F90% Class 0.0-0.4% subsidence after heating at 3200°FCorundum Class 0.1-1.0% subsidence after heating at 2900°F

Silica (superduty) Withstands load to 3060°F

BasicMagnesite, fired Withstands load to 3200°FMagnesite-Chrome,

fired Withstands load to 2700°FMagnesite-Chrome,

unburned Withstands load to 2950°FChrome, fired Withstands load to 2800°FChrome-Magnesite,

fired Withstands load to 3020°FChrome-Magnesite,

unburned Withstands load to 3020°F

Silicon Carbide Withstands load to 2800°F

Zircon 0.1-0.8% subsidence after heating at 2900°F

Conversion Factor: °C = (°F - 32)/1.8



LINE

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UBSI

DENC

E–PE

R CE

NT

TIME (Hrs.)

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-9

-8

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-1

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1

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60% Alumina–Low Alkali

85% Alumina

50% Alumina

70% Alumina

FIGURE 3.7 Creep measurement of various high-alumina refractoriesunder 25 psi load at 2600°F for 0-100 hrs. Note the excellentcreep resistance of 60% alumina low alkali brick.

• The accuracy of the methods usedto measure thermal conductivityis unconfirmed.

• The temperatures of the hotterand cooler faces of the refractorywall or roof are rarely knownwith exactness.

• The conductivity of a refratorymay be altered in service bymineral changes in the refractory,by vitrification of the refractory,or by absorption of slags, metalsor other materials.

• The thickness of a furnace liningmay not remain constant duringoperation. The lining may becomethinner because of wear andtransmit more heat; or it maybecome thicker and transmit lessheat because of the formation of asolid coating (as in rotary cementkilns).

• The rate of heat flow is influencedby the pressure of the furnacegases and by the permeabilityof the refractory. A positivepressure tends to force hot gasesout through the walls, while anegative pressure tends to drawcold air from the surroundingsinto the furnace.

• The rate of heat flow may beinfluenced by the thickness ofthe joints and gaps betweenlining components and by thecharacter of the bonding mortar,if used.

Other important factors which affectthe amount of heat flowing throughrefractory linings include the emissivityof the refractory or metal shell; the kindof gases within the furnace; and theexternal convection currents.

Effects of GasesIn refractory structures built of insulat-ing firebrick or other very porousrefractories, the type of furnace atmo-sphere can have a very appreciable effecton heat loss through the refractory walls.This is especially true of atmosphereswith a high content of hydrogen.

Most protective atmospheres, includ-ing dissociated ammonia, exothermic

Table 3.5 K-Values for Refractory Brick atVarious Mean Temperatures, Btu • in/ft3 • hr • °F

Mean Temperature, °F

Types of brick 600 1200 1500 1800 2200 2600

FireclaySuperduty 9.8 9.9 10.2 10.5 11.4 12.8

High-duty 8.1 8.3 8.5 8.7 9.2 10.0

High-Alumina60% Class 13.0 12.9 13.1 13.3 14.1 15.7

70% Class 15.6 14.4 14.4 14.3 14.6 14.9

85% Cclass 18.4 16.2 16.9 17.5 19.6 22.9

90% Class 21.9 18.5 17.6 17.6 17.9 18.8

Corundum Class 34.6 22.6 20.7 18.7 17.9 18.3

Silica (superduty) 9.0 10.1 11.0 11.8 13.5 16.1

BasicMagnesite, fired 73.2 43.9 36.1 31.7 30.5 32.3

Magnesite-Chrome, fired 17.9 15.2 14.7 14.2 14.7 16.2

Magnesite-Chrome, unburned 18.4 17.2 15.7 14.5 14.7 16.0

Chrome, fired 15.2 15.0 15.1 14.5 13.3 12.9

Chrome-Magnesite, fired 11.8 12.3 12.4 12.5 12.5 13.6

Magnesite-Carbon 150.0 115.0 106.0 100.0 95.0 90.0

Silicon Carbide 121.2 112.0 107.5 103.0 97.0 94.6

Zircon 22.4 16.5 16.6 16.6 16.8 17.9

LIN

EA

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UB

SID

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%



gases, and endothermic gases, containappreciable percentages of hydrogen.The conductivity of the hydrogen mustbe taken into consideration in calculatingthe heat losses through the refractorywalls of controlled atmosphere, heat-treating furnaces.

The thermal conductivity of hydrogenis approximately seven times as great asthat of air. Consequently, the presence ofhydrogen gas in the pores of a porousrefractory product increases the rate ofheat flow through the refractory. With anatmosphere of 100 percent hydrogen, theheat flow through an insulating firebrickor other refractory with similar porositywould be two to two and one-half timesas great as in an atmosphere of air. Atlower concentrations of hydrogen, theincrease will be less and the relationshipis almost directly proportional to thepercentage of hydrogen present.

As compared with the conductivity ofair, that of nitrogen is 100 percent,carbon dioxide about 59 percent, andcarbon monoxide about 97 percent.

SPALLINGSpalling is the loss of fragments or spallsfrom the face of a refractory brick orstructure through cracking and rupture.In various types of furnace operation,service conditions necessarily expose thebrickwork to spalling influences. Theresistance of refractory brick to spallingis enhanced by the addition of spallinhibitors, proper design of the brickshapes, optimum sizing of grains, properchoice of grains and close manufacturingcontrol. For a given refractory, spallingcan also be minimized by proper design,construction, and operation of thefurnace.

Spalling of refractory bodies can bedivided into three general types: thermal,mechanical and structural.

Thermal SpallingThis type of spalling is caused bystresses resulting from unequal rates ofexpansion or contraction betweendifferent parts of the brick and is usuallyassociated with rapid changes intemperature. Brick with the greatestresistance to thermal spalling are those

having the lowest average rate of thermalexpansion, high tensile strength and atexture conducive to flexibility and reliefof stress. These compositions also donot show a high rate of thermal expan-sion through narrow temperature ranges.Other factors being equal, temperaturegradients and stresses which causespalling are least destructive in brickhaving the highest thermal conductivi-ties. A refractory of a given mineralcomposition will usually have maximumresistance to spalling when the ratio ofstrength to the modulus of elasticity is amaximum.

The spalling characteristics of fireclaybrick are generally dependent upon theamount of free silica present in the clays,the composition of the glassy bond andthe size and “fit” of the particles. Theamount and character of the glass arefixed by the quantity and kind ofaccessory minerals in the clays and bythe time and temperature of firing.Within the temperature range at whichthe glass is rigid, a high glass content isconducive to spalling. However, attemperatures high enough to cause theglassy bond to become somewhatviscous, fireclay brick can be highlyresistant to spalling.

Relatively porous, light-duty fireclaybrick are usually more resistant tospalling than denser, hard-burned brick.Superduty fireclay brick of the spallresistant variety, while dense and hardburned, have high resistance to spallingand retain this resistance upon exposureto high temperatures.

Some high-alumina brick also haveexcellent resistance to spalling. In manycases, brick are designed to generate asystem of stress-relieving microcracks toenhance their spalling resistance. Withother conditions being equal, higherdensity, lower porosity compositionstend to have poorer spall resistance thanaverage density, average porositycompositions.

Most silica brick are sensitive to rapidtemperature changes at low temperaturesdue to the abrupt volume changesassociated with the crystalline inversionof the mineral cristobalite. However, silicabrick may be heated or cooled quite

rapidly as long as they remain above theinversion temperature of about 1200°F(650°C).

Burned basic brick, in general, do nothave as high a resistance to thermalspalling as fireclay and high-aluminabrick. However, with proper choice ofraw materials, basic brick with improvedthermal shock resistance can be manu-factured.

Mechanical SpallingThe spalling of refractory brick causedby stresses resulting from impact orpressure is known as mechanicalspalling. Shattering or spalling ofbrickwork may result from such influ-ences as the rapid drying of wet brick-work, inadequate provision for thermalexpansion, or pinching of hot ends ofbrick, especially in furnace arches. Brickwhich are strongest and toughest atoperating temperatures have the greatestresistance to mechanical spalling.

“Pinch spalling” is often observed insprung brick arches because the hot endsof the brick expand more than the coldends. This condition is aggravated byrapid heating because the furnacestructure cannot rapidly adjust to theexpansion forces. The differentialexpansion may cause a concentration ofarch stresses upon relatively smallbearing surfaces at the inner ends of thebrick. Insulation decreases the tempera-ture gradient through a roof arch andtends to somewhat reduce pinch spalling.

Structural SpallingStructural spalling of a refractory unit iscaused by stresses resulting fromdifferential changes in the structure ofthe unit. The word “structural”, as usedin this context, does not refer to thefurnace or the furnace lining assembly,but to the texture or structure of theindividual brick units in the lining.

Contributing to structural spalling arechanges which occur in service to thetexture and composition of the hotterportions of the brick through the actionof heat, the absorption of slags or fluxesand their reactions with the refractory.These alterations may result in zones inthe brick which differ in mineral content



and chemical and physical propertiesfrom the unaltered portions of the brick.Following the development of a zonedstructure, hot ends of the brick may spallor fall off for various reasons, includingdifferences in thermal expansion orcontraction between adjacent zones,increased sensitivity to rapid temperaturechanges or the presence of shrinkage orexpansion cracks.

Monolithic refractories, not havingbeen fired prior to installation, are moreresistant to thermal spalling than aretheir fired-brick counterparts, at leastuntil they have become vitrified orslagged in service.

Being lower in strength than firedbrick, however, monolithic refractoriesmay be more subject to mechanicalspalling.

Spalling TestsSeveral tests are commonly used todetermine the relative resistance ofrefractory compositions to spalling. Themost common are the panel spalling test,the prism spalling test and the loss ofstrength test.

SLAG REACTIONSSlag attack refers to chemical reactionsand solutions which corrode the surfaceof a refractory lining in service andreactions which can take place betweenthe molten slag, refractory and fluxingagents which have been absorbed.Erosion of the refractory often followscorrosion. An example is the washingaway of refractory grains after the bondbetween grains has been dissolved byfluxing agents in the slag.

The composition of industrial slags, ofthe refractories which they contact inservice, and of the reaction productsderived from them are exceedinglycomplex. The most advantageousselection of refractories frequently isgoverned by the chemical nature offluxing agents present in the furnace.Alkaline materials are highly basic; mostmetallurgical slags and metallic oxides arebasic; and fluxes high in silica are acidic.To determine whether a particular slag is

acidic or basic, the ratio of lime-to-silicain the slag is commonly examined. As ageneral rule, if the CaO/SiO

2 ratio (or CaO

+ MgO/SiO2 + Al

2O

3 ratio) is greater than

1, the slag is usually considered to bebasic. If the ratio is less than 1, the slag isconsidered to be acidic.

Fireclay, high-alumina or silica brick aregenerally used where the corrosive agentis acidic. High-alumina refractories maybe preferred if the flux is only slightlybasic. For highly basic slags, magnesia,chrome or a blend of these two materialstypically give the best service. Excep-tions to these general principles arebased on operating and reaction tempera-tures, reaction rates and formation ofprotective glazes and coatings on therefractory surfaces.

Slag TestsIn many industrial applications, therefractory is in contact with a slag ormetal during service. A chemicalreaction often results between therefractory and the slag or metal. Somereaction products can be extremelydetrimental to brick service life whileother reactions result in little or nochange in service life. In order todetermine the relative resistance of arefractory to the slag or metal present inan industrial application, various slagtests have been developed. Among themost common are the cup slag test, dripslag test, gradient slag test, rotary slagtest, dip and spin tests and aluminumboat test. The slag used in the tests maybe the actual material provided by thecustomer or a synthetic material pre-pared to be chemically similar to the slagor metal chemistry typical of thecustomer’s operation.



MINERAL COMPOSITIONMinerals and Glasses

At room temperature, all refractoryproducts which have been molded intobrick and later given a ceramic bond byfiring, consist of crystalline mineralparticles bonded by glass or by smallercrystalline mineral particles. Theycontain a significant volume of smallpores. When such a brick is againheated to high temperatures, as inservice, a liquid phase develops, largelyfrom the groundmass materials, inproportions which depend upon thecomposition of the refractory and uponthe temperature. The physical proper-ties of a refractory at any given tem-perature are fixed by the amount andcharacter of the minerals, glass, andliquid of which it is composed.

A mineral may be defined as anatural inorganic substance which iseither definite in chemical compositionand physical properties, or which variesin these respects within fixed limits. Amineral usually has a definite crystal-line structure, although a few compara-tively common minerals are amorphousin nature. Opal is an example of such amineral.

A mineral having a true or congruentmelting point when heated will passcompletely from the crystalline condi-tion to the liquid state at a definitetemperature. When cooled slowly, theliquid formed will solidify or freeze atthe same definite temperature, and willagain assume the crystalline form.With rapid cooling, the liquid maysolidify with an amorphous formingglass.

A mineral is said to have an incongru-ent melting point when it does notchange from a completely solid to acompletely liquid condition at a definitetemperature, but dissociates, forming adifferent solid crystalline phase and aliquid phase. When the temperaturerises above the temperature of dissocia-tion, the solid material dissolvesgradually in the liquid. As an example,the mineral clino-enstatite (MgO•SiO2)melts incongruently at 2835oF (1557oC)to form a mixture of forsterite(2MgO•SiO2) and liquid.

A glass differs from a crystallinematerial in several respects. Its chemicalcomposition may vary continuouslyover rather wide limits, it lacks crystal-line structure, and it has no specificmelting point. When a glass is progres-sively heated, the change from theapparently solid state to the fluid stateis gradual and continuous. When amolten glass is cooled, the change fromthe fluid state to the apparently solidstate is likewise gradual and continuous.Theoretically, at least, a glass is not asolid at all, but is an under cooled liquidwhich has stiffened as it cooled, untilthe viscosity has become so great thatthe body conforms to the generallyaccepted concept of a “solid.”

A glass will change into the crystal-line condition or “devitrify” if kept fora sufficient time within a criticaltemperature range. Some melts crystal-lize even with very rapid cooling.Others must be maintained at a criticaltemperature for a considerable length oftime before any crystals are formed.Alkali-silicate melts high in silica areextremely viscous and do not crystallizereadily upon cooling. This immunity todevitrification is an essential attributeto commercial glass compositions.

The Ceramic Bond of BrickOne of the most important purposes

for which brick are fired is to give thempermanent mechanical strength, bycausing adjacent particles to adhere.The bond developed by the heattreatment is known as a “ceramicbond.”

Unfired or “green” brick consist ofmixtures of particles of refractorymaterial which usually vary from coarsethrough intermediate to very fine sizes.The coarser particles in some caseshave a diameter of ¼ inch or more. Thefines, which may be regarded as theparticles which will pass a 200-meshscreen, often amount to as much as 30percent of the total. After having beenfired, the borders of the larger particlesare usually distinct; the fines generallyform a more or less vitrified ground-mass, which bonds together theparticles of larger size. The character

and continuity of this groundmass, andits degree of adherence to the particles,have very important effects upon thephysical properties of the fired refrac-tory brick.

The strength of the ceramic bond isdependent upon the character of thebrick mix as well as upon the time andtemperature of firing. In many cases,the constituents of a refractory whichoccur in only small amounts (the socalled impurities) play an importantrole in the development of the bond.With some types of refractories smallamounts of reactive materials areintentially added; the bond is formed bychemical reaction of the material addedwith a portion of the refractory. In themanufacture of silica brick for example,about 1.8 to 3.5 percent of lime isadded for bonding.

During the firing of refractory brick,mineral dissociation or transformationoccurs; such minerals as kaolinite ordiaspore dissociate, and quartz istransformed wholly or in part into otherforms of silica. Crystal growth andchemical reactions may occur also inthe solid state, resulting in the forma-tion of a strong ceramic bond betweenparticles in contact. This type ofbonding is common in basic brickcompositions. However, solid-statereactions are believed to have lessinfluence upon the bonding of silica-alumina brick than does the formationof a liquid phase. In the case of brickmolded wholly or in part from calcinedor dead-burned materials, some of thechanges described above in thisparagraph may have already occurred inthe original heat treatment.

In the firing of refractory brick, asmall amount of liquid can be expectedto form in the groundmass at a tempera-ture some hundreds of degrees belowthat at which complete fusion wouldoccur. With rise in temperature, thisliquid takes other materials present intosolution and thereby increases in amount.The liquid becomes a medium suitablefor the transport of material which itdissolves, and for the formation andgrowth of crystals, especially at interfacesbetween liquid and solid particles.



Upon cooling, the liquid formed athigh temperatures may become a rigidglass, or it may become partly or whollycrystalline. The relative proportions ofglass and crystalline material in thebonding groundmass will depend uponits composition, and upon the rate ofcooling. Rapid cooling favors theformation of glass; slow cooling, theformation of crystals.

The brick mass is bonded togetherand given strength by the adhesivepower of the glass, by adherence ofparticles, and by interlacing of crystals.Elongated crystals, like those of mullite,may tend to interlace; crystals having anearly equidimensional habit, likepericlase(MgO), obviously cannotinterlace.

A brick containing a large amount ofglass will usually have high strength inthe cold condition; but if the glass is oflow viscosity at furnace operatingtemperatures, the brick may deformreadily under pressure. For a brick towithstand pressure at high temperatureswithout deformation, its content ofglass must be low, or the viscosity ofthe glass must be high, or both; ingeneral, the brick should have beenfired under conditions which arefavorable to the growth of crystals.

Certain types of refractories havetheir load carrying capabilities at hightemperatures materially increased byincorporation in the brick mixes offinely ground materials which affectchanges in the body. The addedmaterial may function in one of severalways; it may react chemically with theglass and transform it into highlyrefractory crystalline material; it maymake the glass more viscous at furnaceoperating temperatures; it may cause oraccelerate solid-state reactions; or itmay cause improvement merely byreducing the proportion of the glass. Achange which reduces the amount ofglass or liquid in the refractory wouldusually be more beneficial in servicethan a change which makes the glassmore viscous.

Equilibrium DiagramsMelting of mixtures of two or more

minerals or oxides takes place over arange of temperatures. The tempera-tures at which melting is completedepend upon both the relative amountsof the materials present and theircompositions. The melting behavior ofsuch mixtures and the nature of theequilibria between the solids and theliquids formed by melting have engagedthe attention of many investigators.Since the early years of the twentiethcentury, many papers on the subjecthave appeared in scientific literature.Those published by the staff of theGeophysical Laboratory of the CarnegieInstitution and by the College ofMineral Industries of The PennsylvaniaState University, have contributed muchfundamental information to the ceramicindustries.

The data are presented mainly in theform of drawings known as phaseequilibrium diagrams. A compilation ofthese diagrams, called “Phase Diagramsfor Ceramists,” was published in 1956under the auspices of the AmericanCeramic Society, Incorporated (ASC); asupplement, “Phase Diagrams forCeramists, Part II,” was published in1959. The first volume contains asection of general material on phasediagrams, including an explanation ofthe phase rule, an interpretation ofdiagrams, experimental methods, aglossary of terms, and a selectedbibliography. In 1960, the AmericanCeramic Society published ten large-scale equilibrium diagrams of importantternary systems. Expanded volumeswere published by the ACS in 1964,1969, 1975, 1981, 1983, and 1987.

Alumina-Silica SystemThe equilibrium diagram for mix-

tures of alumina and silica, publishedby Bowen and Greig in 1924, for thefirst time gave a clear picture of theequilibrium conditions in alumina-silicacompositions.

Aramaki and Roy revised thealumina-silica diagram on the basis ofstandard quenching experiments, inwhich the specimens were heated insealed platinum-rhodium containers to

prevent losses due to exposure to thefurnace atmosphere. Their results areshown in Fig 1. The new diagram is inclose agreement with the older one upto 55 percent alumina, and thusconclusions based upon the earlierdiagram for silica and fireclay composi-tions are not materially altered by thislater work. However, revisions of amajor nature have been made in thehigh-alumina side of the diagram.

Significant features of the newdiagram are the following:

(1) The earlier conclusion isconfirmed that mullite of thecomposition 3Al2O3• 2SiO2 (71.8percent Al2O3, 28.2 percent SiO2)is in equilibrium with silica up toabout 2903oF (1595oC). Themullite which occurs in fireclayrefractories therefore has themolecular alumina: silica ratio of 3:2.

(2) The composition of mullite inequilibrium with siliceousalumina-silica liquids was foundto change a little with risingtemperatures above 2903oF(1595oC), becoming slightlymore aluminous. The aluminacontent of the mullite at 3345oF(1840oC) is apparently about72.1 percent.

(3) Mullite does not melt incongru-ently as formerly believed, buthas a true melting point of about3362oF (1850oC). At thistemperature, however, it containsapproximately 73.0 percentalumina, instead of the theoreti-cal 71.8 percent.

(4) There is a eutectic betweencorundum and mullite at 3344oF(1840oC) with 77.4 percentalumina.

(5) In compositions containing morethan 71.8 percent alumina,mullite forms solid solutionswith corundum. Accordingly,solid solution mullites containingas much as 78 percent aluminacan be prepared. Those contain-ing more than about 74.2 percentalumina are believed to be“metastable,” that is, they havelimited stability.



The new alumina-silica diagram isused in the following paragraphs toillustrate the application of phasediagrams in determining the behavior ofrefractories at high temperatures.When conditions are favorable for thevolatization of silica, such as thepresence of a reducing atmosphere, or atemperature of about 3270oF(1800oC)or above, caution must be exercised inthe precise application of the phase ruledata to predict or interpret reactions incompositions containing more thanabout 55 percent alumina.

It cannot be emphasized too stronglythat all phase diagrams apply strictlyonly (1) to completely pure materials,and (2) to conditions of completeequilibrium. Practically the firstcondition is never met by commerciallyfired refractory materials, and thesecond condition is seldom if everattained in furnace practice. Moreover,phase diagrams give no informationconcerning rates of reaction, or theviscosity of the liquid phases, both ofwhich have considerable effect on theproperties of refractories at hightemperatures. Consequently, thetheoretical considerations outlined hereneed to be amplified by other data, for acomplete understanding of the meltingbehavior of refractory clays and otheralumina-silica materials.

Detailed Description: The tempera-tures of complete melting of all possiblemixtures of pure silica and purealumina, under conditions of completeequilibrium, are represented in Figure 1by the heavy curved line (the “liquidus”line), which extends across the width ofthe diagram. The melting point of thepure silica is 3133oF (1723oC). Withincreasing amounts of alumina, up to5.5 percent, complete melting occurs atsuccessively lower temperatures,reaching a minimum of about 2903oF(1595oC), at a composition of 5.5percent alumina and 94.5 percent silica,and then the melting temperature risesas the alumina content exceeds 5.5percent. Such a composition of lowestmelting point is known as a “eutecticcomposition,” and the temperature at

which it melts is known as a “eutectictemperature.”

Consider any homogenous composi-tion of alumina and silica with less than5.5 percent alumina (Al2O3). Toachieve homogeneity in a reasonabletime, it is necessary to start with finelydivided and uniformly mixed particles,and to heat them until the mullite-forming reaction is complete, prefer-ably at a temperature just below that atwhich a liquid could begin to form(2903oF or 1595oC). As the temperatureof the material is further increased, theentire mass will remain solid until thetemperature of 2903oF (1595oC) isreached. At this temperature a portionof the batch will melt, forming anexceedingly viscous liquid of theeutectic composition (5.5 percentAl2O3, 94.5 percent SiO2). All of thealumina will enter into the formation ofthis liquid, and if equilibrium condi-tions have been obtained, any excesssilica above the eutectic ratio willremain in the solid form as cristobalite.With further temperature rise above2903oF (1595oC) the amount of solidsilica will decrease. The amount of liquidwill increase through solution of thesolid, until the entire mass has melted.

The temperature at which completemelting occurs for any specific mixture isindicated by the heavy curved liquidusline.

Any composition of alumina andsilica which contains more than 5.5percent and less than 71.8 percentalumina, will melt in part at the eutectictemperature 2903oF (1595oC). Theinitial liquid phase will have the samecomposition as the eutectic (5.5 percentalumina, 94.5 percent silica), and theunmelted solid will consist of crystalsof the mineral mullite. Mullite formedunder these conditions has the chemicalformula 3Al2O3•2SiO2, corresponding to71.8 percent alumina, 28.2 percentsilica. When the temperature risesabove 2903oF (1595oC) the liquid takesmullite into solution. The amount ofliquid thereby increases and its compo-sition changes, becoming richer inalumina, until the temperature reachesthe heavy curved line for the particularcomposition being heated, whencomplete melting occurs. The tempera-ture of complete melting is almostconstant from 60 to about 77 percentalumina.

The mullite composition in equilibriumwith siliceous liquid changes with the

Melting Point of Silica (Cristobalite) 1723°C, 3133°FMelting Point of Alumina (Corundum) 2050°C, 3722°F

100 90 80 70 60 50 40 30 20 10 0

WEIGHT PERCENT SiO2

0 10 20 30 40 50 60 70 80 90 100

WEIGHT PERCENT Al O2 3

3800

3600

3400

32003133

3000

2800

2600

2400

CR

ISTO

BA

LIT

E P

LUS

LIQ

UID

— 2000

— 1900

— 1800

— 1700

— 1600

— 1500

— 1400

2050

LIQUID

MULLITE SOLID SOLUTIONPLUS LIQUID

MULLITE PLUS LIQUID

CRISTOBALITE PLUS MULLITE

TRIDYMITE PLUS MULLITE

MULLITE SOLIDSOLUTION

CORUNDUM PLUSMULLITE SOLID

SOLUTION

3362°F3344°F

2903°F

2678°F

71.8

% A

lO28

.2%

SiO

23

2

3Al O

• 2S

iO(M

ULL

ITE

)2

32

CORUNDUMPLUS LIQUID

5.5% Al O94.5% SiO

2 3

2DE

GR

EE

S F

AH

RE

NH

EIT

DE

GR

EE

S C

EN

TIG

RA

DE

Figure 1 Equilibrium Diagram of the System Alumina-Silica (Al2O

3•SiO

2)



temperature, becoming somewhat morealuminous at the higher temperatures.However, the difference is so slight thatthe line at the right-hand side of the fieldof “mullite plus liquid” in Figure 1appears to be vertical, up to about3345oF (1840oC), and therefore appearsto represent a constant alumina-silicaratio.

Mullite has a true or congruentmelting point of 3362oF (1850oC).However the mullite which melts at thistemperature has an alumina content ofabout 73.0 percent, instead of thetheoretical 71.8 percent.

As shown in Figure 1, there is aeutectic between mullite and corundum,similar to that between silica andmullite previously described. Theeutectic temperature for the mullite-corundum range is 3344oF (1840oC),and the eutectic contains 77.4 percentalumina by weight. Thus any alumina-silica composition containing more than71.8 percent alumina will show the firstliquid development at 3344oF (1840oC).If the composition contains more than71.8 percent alumina, but less than 77.4percent, the solid phase in equilibriumwith the liquid will be mullite; if thecomposition contains more that 77.4per cent alumina, the solid phase iscorundum. Again, as the temperaturerises above 3344oF (1840oC), the solidphase (mullite or corundum) willdissolve in the liquid until completemelting occurs.

Under equilibrium conditions,mullite can take excess alumina intosolid solution in the crystal, up to 74.2percent total alumina. In fact, mullitescontaining up to 78 percent alumina areeasily prepared and commonly found infusion-cast mullite; however it isbelieved that the mullites richest inalumina are metastable. X-ray diffrac-tion spacings of various solid-solutionmullites vary with heat treatmentalmost as much as they vary withchemical composition; hence they arenot reliable indices of composition.Index of refraction measurements ontrue glasses containing up to 77 percentalumina were also used to locate theliquidus line in Figure 1.

The diagram (Figure 1) shows thatthere is no solid solution of silica inmullite under equilibrium conditions.This has been confirmed by the authorsin another report.

Relative Amounts of Components: Bya simple calculation, based upon the so-called “lever principle,” the amount ofeach component present at equilibriumcan be determined for any compositionand any temperature. Consider, forexample, a composition of 40 percentalumina, 60 percent silica. At alltemperatures included in Figure 1below 2678oF (1470oC), tridymite andmullite coexist in equilibrium and arethe only minerals present. Equilibriumpercentages are determined thus:

71.8-40.0% Tridymite = ( 71.8-0.0 )100 = 44.3%

40.0- 0.0% Mullite = ( 71.8-0.0) 100 = 55.7%

At 2678oF (1470oC) the tridymitechanges to cristobalite. With furtherheating, no other changes occur untilthe eutectic temperature of 2903oF(1595oC) is reached. At that point allthe cristobalite melts, with some of themullite, forming a liquid with thecomposition 5.5 percent alumina, 94.5percent silica. At the eutectic tempera-ture, the relative amounts of thecomponents as calculated are 48.0percent liquid, 52.0 percent mullite.

With further rise in temperatureabove 2903oF (1595oC) progressivesolution of the mullite in the liquidoccurs. The composition of the meltchanges, as indicated by the curvedliquidus line shown in Figure 1. All ofthe mullite is dissolved at about 3265oF(1796oC) and the material is thencompletely melted.

Upon cooling, the mass wouldundergo the same changes as describedabove, in reverse order. Between3265oF (1796oC) and 2903oF (1595oC)mullite would crystallize from theliquid, and at the eutectic temperature,2903oF (1595oC), the entire mass wouldsolidify abruptly, becoming a mixture ofcrystals of cristobalite and mullite.

The Sillimanite Minerals: Theminerals sillimanite, kyanite, andandalusite all have the theoreticalcomposition Al2O3•SiO2, correspondingto 62.9 percent alumina, 37.1 percentsilica. Dissociation of these mineralscan be affected by a heat treatment at asufficiently high temperature and for along enough time to provide thenecessary energy to alter their crystalstructure. By such heat treatment, anyof the sillimanite minerals can beconverted into a mixture consisting ofabout 88 percent mullite and 12 percentfree silica.

Sillimanite begins to dissociate intomullite and free silica at about 2785oF(1530oC), kyanite at 2415oF (1325oC),and andalusite at 2460oF (1350oC).

Mineral Changes During theHeating of Fireclay

In the commercial burning of fireclaybrick, the mineral changes which occurdo not follow as simple a pattern as thatdescribed on the preceding page. Themain reasons are that the ground claymixtures are not homogeneous either asto mineral composition or as to particlesize, and firing temperatures are notheld long enough to attain equilibrium.The mineral compositions may varyover a wide range and the grains mayvary all the way from pieces ¼ inch ormore in diameter to particles muchsmaller than one-thousandth of an inchin diameter.

Clays are composed essentially ofone or more of a group of mineralsclassified as “clay minerals.” Typically,these are hydrous aluminum silicates.Refractory clays consist mainly of theclay mineral kaolinite, which has theapproximate compositionAl2O3•2SiO2•2H2O, corresponding to39.5 percent alumina (Al2O3), 46.5percent silica (SiO2), and 14 percentwater (H2O). Pure kaolinite has aP.C.E. value of Cone 35, correspondingto a softening temperature of about3245oF (1785oC).

The clays of greatest importance in therefractories industry are refractory flintand semi flint clays, refractory plastic andsemi-plastic clays, and refractory kaolin.



Even clays of highest quality containsignificant amounts of constituentsother than the alumina-silica mineralkaolinite. Many clays contain substan-tial amounts of illite, a form of micawhich has more combined water andless potash than is found in muscovite(3Al2O3•6SiO2•K2O•2H2O). Thehydrous mica in clays is somewhatvariable in composition, but apparentlyaverages about 6 percent in potash(K2O). In many refractory clays theaccessory mineral present in largestamount is quartz (SiO2); in others it isdiaspore (Al2O3•H2O). Nearly allrefractory clays contain minor amountsof titania-bearing minerals. Othercommon accessory minerals arechlorite, montmorillonite, pyrite (FeS2),feldspars, and micaceous minerals otherthan illite. Siderite (FeCO3) occurs insome deepmine clays, limonite (hy-drated iron oxide) in clays which occurnear the surface.

The changes which take place inheating a fireclay have been the subjectof extensive investigation for a greatmany years. Some of the changes nowbelieved to take place on heating afireclay composed mainly of kaoliniteare outlined in the following para-graphs.

Upon being heated, kaolinite losesmost of its combined water (dehy-drates) at about 750o to 980oF (400o to525oC) depending on the particle size,with the formation of a semi-crystallinecompound metakaolin, 2Al2O3•4SiO2.This reaction is endothermic.

When metakaolin is heated to about1700oF (925oC) an exothermic reactiontakes place, in which some of the silicamigrates out of the metakaolin, leavingbehind a cubic spinel type phaseapproximately 2Al2O3•3SiO2 in compo-sition. The silica set free may beamorphous; at least, it is so poorlycrystallized that it cannot be identifiedas crystalline material by X-raydiffraction.

At about 1920o to 2010oF (1050o to1100oC) the spinel-type phase begins tobreak down and to discard more silica.A phase resembling mullite and ofuncertain composition forms, probably

containing more silica than the composi-tion 3Al2O3•2SiO2. The discarded silicaappears as cristobalite, giving a well-defined X-ray diffraction pattern. Heatis evolved in this temperature range.

Above 2190oF (1200oC) cristobaliteand mullite continue to develop. Themullite formed at 2550oF (1400oC) orabove is believed to have the composi-tion 3Al2O3•2SiO2 with no excess silica.Thus the alumina –silica ratio variesfrom 1:2 in the original kaolinite and inmetakaolin, through 2:3 in the spineltype phase, to 3:2 in the final mullite.

Up to this point little has been saidregarding the effects of the accessoryminerals at high temperatures. Quartzwhich is present as an accessorymineral begins to change to cristobaliteat about 2280oF (1250oC). If the quartzcrystals are large the central portionsmay remain as residual quartz in bodieswhich have been heated to a tempera-ture as high as 2700oF (1480oC). Someof the oxides present in the accessoryminerals lower the temperature atwhich liquid begins to form andincrease the amount of liquid at anygiven temperature. The alkalies sodaand potash are especially potent in thisrespect, reacting to form a highlyviscous liquid at temperatures severalhundred degrees below the temperatureat which liquid would begin to form ifthe body consisted wholly of aluminaand silica.

In clays which are otherwise pure, avery small amount of potash is suffi-cient to lower the temperature of initialliquid formation to 1805oF (985oC). Inthe alkali-alumina-silica liquid, acces-sory minerals containing lime, magne-sia, and iron oxide dissolve wholly or inpart, as do both amorphous andcrystalline silica and at very hightemperatures even mullite. Over a widerange of temperatures above 1805oF,the liquid is so viscous that it behavesessentially as if it were a solid. How-ever, the viscosity gradually decreasesas the temperature becomes higher.The temperature of complete meltingdepends upon the alumina-silica ratio,and upon the compositions andamounts of the accessory minerals.

In a single ground clay, most of thelarger particles have nearly the samecomposition as the finer sizes, whichform the groundmass of fired productsmade from the clay. However, there isprobably some concentration ofaccessory minerals in the groundmass.For this reason, and because of itsgreater fineness, the groundmassdevelops more liquid than the largerparticles during firing of fireclay brick.

When fireclay brick are at the firingtemperature, they consist of mullite andcristobalite crystals and a viscousliquid. On cooling, some additionalcristobalite and mullite may separatefrom the liquid. However, much of theliquid cools to a rigid glass, whichbonds the mass together and gives itstrength. Additional strength isimparted by the interlacing and adher-ence of crystals. Mullite is especiallyeffective as a ceramic bond, as it formsinterlacing needle-like crystals.

Mineral Composition of Fireclayand High-Alumina Brick

Burned fireclay refractories arecomposed largely of mullite and freesilica (cristobalite, quartz, and rarelytridymite). The crystals are mainlysubmicroscopic in size, but are identifi-able by means of their X-ray diffractionpatterns. Glass also is present inamounts depending upon the composi-tion of the material, the time andtemperature of firing, and the rate ofcooling. Super duty fireclay brickusually contain less glass than do brickof the high-duty class. In any fireclaybrick, the impurities tend to be concen-trated in the glass.

In fireclay brick exposed to hightemperatures, the mullite crystalsincrease in size. In photomicrographsof super duty fireclay brick reheated to2910oF (1600oC), the presence ofmullite crystals is clearly indicated.

High-alumina brick contain mulliteand usually corundum, some free silica(generally cristobalite with occasionalquartz), and glass in amounts varyingwith the alumina content of the brick.The mineral constitution is alsoinfluenced by the raw materials from



which the brick were made, the mineralplacement with respect to grains and thematrix, the proportion of accessoryoxides, and the firing treatment.

If complete equilibrium could beattained during the firing process, anypure alumina-silica refractory with lessthan 71.8 percent alumina wouldcontain no crystalline material otherthan mullite and free silica. One withmore than 71.8 percent alumina wouldcontain only mullite, with a smallamount of alumina dissolved in it, orthe mullite solid solution and corun-dum. However, in brick made whollyor in part from bauxite or diaspore clay,corundum may be present even incompositions with less than 71.8percent alumina, and free silica may bepresent even in compositions with morethan 71.8 percent alumina. Underfavorable conditions the developmentof mullite during firing proceeds to anadvanced degree, yet it does notproceed to completion. The mulliteformed at the surfaces of the grains ofbauxite or diaspore appears to act as aprotective film, retarding or preventingfurther reaction between the corundumon the interior of the grains and the freesilica formed from the fireclay betweenthe grains.

A similar condition exists when fusedalumina (artificial corundum) is addedto or is bonded by fire clay in themanufacture of high alumina brick.When the refractory is fired, a protec-tive film of mullite forms at thesurfaces of the grains of corundum bycombining with free silica released byrecrystallization of the fire clay. Theinterior of the corundum grains isunaltered by the firing treatment.

The Minerals in Silica RefractoriesStability relations of the silica miner-als: The three common crystal modifi-cations of silica are quartz, tridymite,and cristobalite. The form generallyfound in nature is quartz. This mineralmay be converted to tridymite orcristobalite by appropriate heat treat-ment. The formation of tridymiteappears always to require the presenceof a liquid, which may be formed byreaction of silica with a suitable fluxing

an abrupt volume increase of approxi-mately 0.9 percent on heating, and acorresponding shrinkage on cooling.However, the total reversible expansionwhich occurs between 600oF (316oC) and1100oF (593oC) is about 3.2 percent.When heated or cooled rapidly throughthe inversion point quartz has a strongtendency to crack.

The low-high inversion ofcristobalite occurs at about 428o-513oF(220o-267oC) on heating; the reversechange on cooling takes place at about480o-392oF (249o-200oC). However, thetemperature is somewhat variable, anddepends both on the material fromwhich the cristobalite was formed andthe temperature of formation.Cristobalite, when heated or cooledthrough the inversion range, has avolume change of about 2.8 percent.Refractory brick or other bodiesconsisting largely of this mineral tendto crack or spall if heated or cooledrapidly through the inversion range.

Two well-crystallized tridymitesoccur at ambient temperature, desig-nated as tridymite-M (for metastable)

agent. Cristobalite is formedin the absence of liquid.Quartz is the stable form ofsilica below 1598oF (870oC);tridymite is the stable formfrom 1598oF (870oC) to2678oF (1470oC); andcristobalite is the stable formabove 2678oF (1470oC).However, at ambient tempera-ture and pressure, there is noperceptible tendency forcristobalite or tridymite tochange to quartz.

In the absence of a liquidphase, quartz does notchange to trydimite, evenwithin the temperature rangeat which tridymite is thestable form. At about 2280oF(1250oC) quartz begins tochange slowly to cristobalite;the rate of transformationincreases rapidly as the temperaturerises. At 2900oF (1593oC) transfor-mation is complete in approximatelyone hour.

In the presence of an appropriateliquid, cristobalite changes to tridymiteat temperatures between 2280oF(1250oC) and 2678oF (1470oC). Thechange is very slow at 2280oF (1250oC)and is not rapid even at 2630oF (about1445oC).

The specific gravity at roomtemperature of quartz is 2.65; that ofcristobalite, 2.32; that of tridymite 2.26.Hence the transformation of quartz tocristobalite causes a volume increase of14.3 percent; of quartz to tridymite, avolume increase of 17.2 percent.

Each of the three crystal forms ofsilica has high-temperature and low-temperature modifications. These areknown as high-quartz and low-quartz;high cristobalite and low-cristobalite;and upper high-tridymite, lower high-tridymite, and low-tridymite. A changetakes place rapidly from a low tempera-ture to a high temperature form onheating, and from a high to low form oncooling.

The change from low-quartz to high-quartz or the reverse, which occurs atabout 1063oF (573oC), is accompanied by

100 90 80 70 60

TRIDYMITE AND LIQUID “B”

3200

3100

3000

2900

2800

2700

2600

LIQUID “A” AND “B”

CRISTOBALITEAND LIQUID “B”

3133 CaO+SiO2

CaO+SiO2

FeO+SiO2

FeO+SiO2

3090°

3106°

PERCENT OF SILICA (SiO )2

TE

MP

ER

ATU

RE

-DE

GR

EE

S F

AH

RE

NH

EIT

Figure 2 Partial Equilibrium Diagram of the BinarySystems Lime-Silica and Ferrous Oxide-Silica(CaO•SiO

2 and FeO•SiO

2)



and tridymite-S (for stable). Tridymite-M passes through reversible inversionpoints at 235o and 306oF; (113o, and152oC) tridymite-S at 147o, 235o, and280oF (64o,113o, and 138oC). The totalvolume changes through the inversionpoints are small, probably not exceeding0.35 percent. So far as is known, nocracking occurs when tridymite isheated or cooled rapidly through theinversion points.Equilibrium Diagrams and SilicaRefractories: Highly siliceous mixturesof silica with certain other oxides havea constant temperature of completemelting over a wide range of composi-tion. Within this range the mixturesform two immiscible liquids uponmelting, instead of the usual singleliquid. The two liquids do not blend,but preserve their separate identitites,like mixtures of oil and water. Highlysiliceous mixtures of silica with lime orwith ferrous oxide exhibit this type ofmelting behavior, as shown in Figure 2.

The addition of up to 1 percent limeto silica results in a progressivelowering of the temperature of com-plete melting from 3133oF (1723oC) to3106oF (1708oC). Further additions oflime, however, do not result in addi-tional lowering of the melting tempera-ture, but the formation of a secondliquid containing 27.5 percent lime andhaving the same melting point 3106oF(1708oC). Thus the addition of 2.5percent lime to silica would result in theformation of only (2.5/27.5) x 100, orabout 9 percent liquid at temperaturesjust below 3106oF (1708oC). Similarly, allmixtures of silica and ferrous oxide,containing from 1 percent to 40 percentferrous oxide, under equilibriumconditions melt completely at 3090oF(1699oC).

The equilibrium diagrams of silicawith alumina, with titania, and with thealkalies do not show the “ImmiscibilityPlateau” effect. Instead, a single liquidresults from melting, and the tempera-ture of complete melting drops rapidlywith even small additions of any one ofthese oxides. Moreover, in lime-silicaor ferrous oxide-silica mixtures, a small

percentage of alumina or alkaliesdestroy the immiscibility.

The effect of the “ImmiscibilityPlateau” upon the melting temperaturecan be seen by comparison of Figures 2& 3. At 2920oF (1605oC), a mixture of5.5 percent lime with 94.5 percent silicaunder equilibrium conditions willconsist of 82 percent solid material with18 percent liquid, while at the sametemperature a mixture of 5.5 percentalumina, soda, or potash with silica willbe completely melted.

The Mineral Changes WhichOccur Upon Firing Silica Brick

The raw material used in the manu-facture of silica refractories is a rockconsisting almost wholly of quartz. In

that used for making brickof conventional quality thesum of the alumina, titania,and alkalies is usually about0.5 to 1.2 percent and theferric oxide content about0.3 to 1.0 percent. The rawmaterial used in themanufacture of superdutysilica refractories containsabout 99.0 percent silica,with a total of 0.15 to 0.4percent alumina, titiania,and alkalies. In the manu-facturing process, 1.8 to 3.5percent of lime is added forbonding.

During the firing, mostof the quartz changes withaccompanying expansioninto other forms of silica.The lime combines withsilica and the impurities ofthe rock to form a liquidwhich solidifies largely to aglass on cooling. Under

some conditions, the mineralpseudowollastonite (CaO•SiO2) isformed also.

The coarse grains in a silica brickusually contain 99+ percent silica, oftenbeing well in excess of 99.5 percentSiO2. Hence the fine grained ground-mass, about 25 percent of the totalweight of the brick, contains almost allthe lime and iron oxide, as well as muchof the alumina, titania, and alkalies.Thus the lime content of the ground-mass is of the order of 8 to 10 percent,a significant factor in the developmentof the liquid phase during firing. In thesystem CaO-Al2O3-FeO-SiO2, liquid canform at a temperature as low as about2048oF (1120oC). Small amounts ofalkalies may depress this temperature

EUTECTIC MIXTURE31% K O 69%SiO

MELTING POINT 1358°F2 2

EUTECTIC MIXTURE26% Na O 74%SiO

MELTING POINT 1460°F2 2

K O2

Na O2

TiO

2

TiO2

AlO

23

Al O2 3

Na O2

K O2

2822

2903

0 2 4 6 8 10 12 14

PERCENT OF IMPURITY

PERCENT OF SILICA

ME

LTIN

GT

EM

PE

RAT

UR

E-D

EG

RE

ES

FA

HR

EN

HE

IT

3200

3150

3100

2950

2900

2850

2800

3050

3000

2750

100 98 96 94 92 90 88 86

3133

Table IMINERAL COMPOSITION OF SILICA BRICK

PercentApparently

Pseudo- Noncrystalline Type Tridymite Cristobalite Quartz wollastonite Material *

Superduty 33-61 27-49 <1.3+ <2.5+ 9-17

Superduty- 35-38 33-35 2.3+ 1.3+ 20-30

Spall Resistant

Conventional 40-54 28-41 <1 <1.5+ 5-24

* By difference; believed to consist of “disordered” silica and 5 to 15 percent glass < = less than

Figure 3 Effect of Certain Impurities Upon Melting

Behavior of Silica



still further. Besides its effect onbonding strength, the liquid has amarked influence on the rate at whichthe mineral transformations occur.

In the firing of silica brick, conver-sion of quartz to cristobalite begins atabout 2280oF (1250oC). The rate oftransformation is slow at this tempera-ture, but increases as the temperaturerises. Small grains in the groundmassare converted first, together with thesurfaces of the larger grains. Thetransformation progresses into theinteriors of the larger grains gradually,and ultimately the only quartz remain-ing, if any, is that in the interior of thelargest grains.

During the firing, the liquids formedin the groundmass begin to affect thecristobalite, converting it to tridymite,the stable form of silica at the firingtemperature of about 2625oF (1440oC).In a silica brick after firing, the largergrains are likely to consist predomi-nately of cristobalite, with thin rims oftridymite at their surfaces, and with anyremaining unconverted quartz in thecenters of the largest grains. Most ofthe tridymite is in the groundmass, withthe glass from which it crystallized.

The permanent linear expansion ofsilica brick during firing, due to thetransformation of quartz to cristobaliteand tridymite, is about 4.2 percent.

Silica brick, as now manufactured,consist mainly of tridymite andcristobalite, with some glass, residualquartz, and often small quantities of afinely crystalline mineral, which hasbeen identified as pseudowollastonite(CaO•SiO2). The amounts of thesephases which occur in silica brick areshown in Table I.

Silica brick ordinarily are light incolor with a yellowish cast, but oftenare mottled or splotched in irregularbrownish patterns. Such coloration isdue to subtle changes in the ground-mass, accompanying devitrification.These odd colorings, which are of nopractical significance, are most likely toappear in brick of the highest purity, orin those containing more than aboutthree times as much lime as alumina.As the alumina content increases, the

color generally becomes less pro-nounced.

The Mineral Composition ofMagnesite RefractoriesMagnesite Materials: The raw materi-als used in the manufacture of refracto-ries consisting essentially of the basicoxide magnesia (MgO) are (1) chemi-cally precipitated magnesium hydrox-ide, (2) the mineral magnesite, which isnaturally occurring magnesium carbon-ate, and to a minor extent (3) themineral brucite, naturally occurringmagnesium hydroxide. Chemicallyprecipitated magnesium hydroxide,prepared by causing slaked lime orslaked calcined dolomite to react withmagnesium-bearing brine, containssmall amounts of accessory mineralsderived from the limestone or dolomite,and from the brine. The natural mineralmagnesite contains small amounts ofaccessory minerals, such as dolomite,serpentine, talc, chalcedony, and quartz.Iron carbonate, in solid solution with

the magnesium carbonate, is present inmany magnesites.

Raw magnesia-containing materialsare “dead-burned” in rotary or shaftkilns to prepare them for use. Thedead-burning consists of a high-temperature heat treatment whichdrives off chemically combined waterand/or carbon dioxide, and converts theremaining product into dense grains orlumps resistant to atmospheric moistureand carbon dioxide. In dead-burning,additions such as iron oxide, alumina,silica, or lime may be made to obtaindesired compositions.

The temperature of dead-burningvaries from about 2800oF to 3350oF(1540oC to 1845oC), depending uponthe type and purity of the product. Inthe process of dead-burning, magnesiahydroxide dissociates to form magnesiaand water vapor; magnesium carbonatedissociates to form magnesia andcarbon dioxide gas. The water vaporand the carbon dioxide escape with thekiln gases. The dead-burned product,

Figure 4 Composition Triangles in the Lime-Magnesia-Silica (CaO•MgO•SiO2) System

3CaO SiO2•

2MgO SiO2•

CaO :SiO = 2.8 :12

CaO :SiO = 1.865 :1

2

3CaO • MgOSiO

2

•

CaOMgO

SiO2

•

•

CaO :SiO = 1.4 :12

CaO :SiO= 0.93 :1

2

A

2CaO SiO2•

10

30

40

20

50

60

70

80

90

MgO20 1030

40506080 7090CaO

SiO2

70

90

80

60

50

40

30

20

10

PE

RC

EN

TO

FS

ILIC

A

PERCENT OF LIME

PE

RC

EN

TO

FM

AGN

ES

IA



which is known commercially as “dead-burned magnesia” consists mainly ofaggregates of periclase crystals, with afine-grained crystalline groundmassusually composed of silicates ofmagnesium and to a minor extent ofcalcium.

The color of dead-burned magnesialow in iron oxide varies from white tobuff or tan. Dead-burned magnesiawhich contains several percent of ironoxide is generally chocolate-brown incolor, and microscopic examinationshows that the periclase crystals usuallycontain dark moss-like inclusions.These have been identified asmagnesioferrite (MgO•Fe2O3).

The most desirable amounts of theaccessory constituents, and theirrelative proportions, depend upon thepurposes for which the product is to beused. Dead-burned magnesia used infurnace hearths in general has a highercontent of accessory constituents thanthat used for making brick. Thecompositions of most of the commercialdead-burned magnesias used in theUnited States lie within the rangesshown in Table II. In recent years, ultrahigh purity dead-burned magnesiacontaining 99 percent MgO have gainedwide spread use.

The exact mineral composition ofmagnesia grains cannot be calculatedaccurately from the chemical composi-tion, because adequate data regardingthe six component system MgO-CaO-Al2O3-FeO-Fe2O3-SiO2 are not avail-able, and because equilibrium condi-tions are not entirely reached in thebrief period of exposure to hightemperatures during dead-burning.However, the major components can beidentified by painstaking research withX-ray diffraction.The CaO-MgO-SiO2 System: Consider-ation of the three component system

CaO-MgO-SiO2 serves as an excellentstarting point in studying the mineralcomposition of magnesia refractories.The composition triangles in this systemare shown in Figure 4, which is ex-plained as follows: Any point within thelarge equilateral triangle of Figure 4represents a definite composition,consisting solely of CaO, MgO, andSiO2. For example, the point “A”represents a composition of 35.9percent CaO, 25.6 percent MgO, and38.5 percent SiO2, which corresponds tothe composition of the mineralmonticellite.

The large equilateral triangle isdivided by heavy lines into triangles ofunequal size. These are known as“composition triangles.” Each of thethree apexes of any compositiontriangle represents the chemicalcomposition of a specific mineral. Aline connecting any two apexesrepresents all compositions in which thetwo minerals indicated may coexist inequilibrium. The area within a trianglerepresents all compositions in which thethree minerals indicated by the apexes

may coexist in equilibrium.The particular minerals to be found in

any stable blend of lime, magnesia, andsilica may be predicted from the trianglewithin which the composition lies.Under equilibrium conditions, the bodywould consist of the three mineralsrepresented by the apexes of thetriangle, in relative amounts fixed by thedistances from the point representingthe composition, to the individualapexes.

That part of the CaO-MgO-SiO2

system in which the magnesia is presentin great excess, and in which thereforepericlase (MgO) is invariabley acomponent, is of particular interest inconnection with magnesia refractories.In Figure 4 the composition triangles ofthis part of the system appear as fulllines. The calcium and magnesiumsilicates which may coexist in equilib-rium with periclase are indicated. Forany given composition, the particularsilicates which may be present, andtheir relative proportions, are fixed bythe lime-silica ratio.

In that part of the three componentsystem CaO-MgO-SiO2 in whichmagnesia (MgO) is present in greatexcess, and in which the lime-silicaratio is less that 1.86 to 1 by weight(less than 2 to 1 on a molecular basis),either one or two magnesium-bearingsilicate minerals will invariable bepresent at room temperatures, as shown

Table IITYPICAL COMPOSITIONS OF DEAD-BURNED MAGNESITE

For Furnace Bottoms For Making Brick

Magnesia (MgO) 83-98% 88-98%Lime (CaO) 1.0-6.0 1.0-3.5Silica (SiO

2) 0.5-8.0 0.5-6.0

Alumina (Al2O

3) 0.3-1.5 0.3-1.5

Ferric Oxide (Fe2O

3) 0.3-3.0 0.3-6.5

Table IIIMINERALS IN THE CaO-MgO-SiO

2 SYSTEM WHICH COEXIST IN

EQUILIBRIUM WITH PERICALSE

Molecules of CaO Parts By Weight Compatible Components Case to 1 Molecule of SiO

2of CaO

to 1 part of SiO2

Minerals Compositions

1 Under 1 Less than 0.93 parts Forsterite 2MgO•SiO2

(Less CaO than SiO2) Monticellite CaO•MgO•SiO2

2 1 0.93 parts Monticellite CaO• MgO•SiO2

3 1-1 ½ 0.93 – 1.40 parts Monticellite CaO• MgO• SiO2

(More CaO than SiO2) Merwinite 3CaO•MgO•2SiO2

4 1 ½ 1.40 parts Merwinite 3CaO•MgO•2SiO2

5 1 ½-2 1.40 – 1.86 parts Merwinite 3CaO•MgO•2SiO2

Dicalcium Silicate 2CaO•SiO2

6 2 1.86 parts Dicalcium Silicate 2CaO•SiO2

7 2-3 1.86 – 2.80 parts Dicalcium Silicate 2CaO•SiO2

Tricalcium Silicate 3CaO•SiO2

8 3 2.80 parts Tricalcium Silicate 3CaO•SiO2

9 Over 3 Over 2.80 parts Tricalcium Silicate 3CaO•SiO2

Lime CaO



in Table III. If the lime-silica ratio of thehigh magnesia compositions is 1.86 orhigher, no magnesium-bearing silicateswill be present.

The lime-silica ratio has an importantbearing upon the melting behavior oflime-magnesia-silica compositions.Any combination of lime, magnesia,and silica alone, in which periclase is acomponent, and in which the amount oflime by weight is less than 1.86 timesthe amount of silica, will develop aliquid phase at 2867oF (1575oC), andmay develop liquid at a temperature aslow as 2714oF (1490oC). If completelyhomogenous mixtures could beobtained, no combination of theseoxides, in which the amount of lime isequal to or more than 1.86 times theamount of silica, would form liquidbelow 3254oF (1790oC). However,lower lime-silica ratios, in areas of evenmicroscopic size, would permit smallquantities of liquid to form at tempera-tures lower than 3254oF (1790oC), andwould cause some coalescing togetherof particles, even though diffusion athigher temperatures should cause theliquid to disappear.The Accessory Minerals in MagnesiaRefractories: Incomplete data areavailable concerning the complex six-component system CaO-MgO-SiO2-Al2O3-FeO-Fe2O3, the system applicableto refractories which consist essentially

of magnesia. However, the moreimportant relationships are fairly wellunderstood. In such mineral composi-tions, consisting mainly of periclase, ifthe amount of lime is less than 0.93 timesthe amount of silica, the mineralsforsterite and monticellite will form athigh temperatures in the groundmass.If the amount of lime is between 0.93and 1.40 times the amount of silica,monticellite and merwinite will form;

and if it is between 1.40 and 1.86 timesthe amount of silica, merwinite anddicalcium silicate will form. In all thesecompositions, any ferrous oxide presentdissolves in the magnesia; alumina andferric oxide combine with the magnesia,forming the spinel minerals MgO•Al2O3

and MgO•Fe2O3.If the amount of lime equals or

exceeds 1.86 times the amount of silica,in the six-component system, themineral relationships are much morecomplex, and the lime-silica ratio doesnot suffice to determine what mineralsare present. The lime reacts with silicato form dicalcium or tricalcium silicate,and with alumina and ferric oxide toform calcium aluminates and calciumferrites. Many attempts have beenmade to formulate rules whereby themineral compositions at room tempera-tures can be calculated from thechemical analyses, but often thecalculated compositions are not insatisfactory agreement with the resultsof microscopic and X-ray determina-tions.

Forsterite is a common bondingconstituent of magnesia refractories oflow lime content. It is highly refractoryand has no undesirable mineral inver-sions; it is little affected by the pres-

5070

5500

5000

4500

4000

3500

3000

2500

2000 010 20 30 40 50 60 70 80 90 100

LIQUID

MAGNESIO WÜSTITE

FeO MgOWEIGHT PERCENT

TE

MP

ER

ATU

RE

- D

EG

RE

ES

FA

HR

EN

HE

IT

Figure 5 Equilibrium Diagram of the system FeO•MgO

Table IVMELTING POINTS OF COMPOUNDS WHICH MAY BE PRESENT

IN MAGNESITE REFRACTORIESoF oC

Lime CaO ~4660 ~2570Pericalse MgO ~5070 ~2800Spinel MgO•Al

2O

3~3875 ~2135

Dicalcium Silicate 2CaO•SiO2

~3865 ~2130Forsterite 2MgO•SiO

2~3450 ~1900

Tricalcium Silicate 3CaO•SiO2

Stable only from 3452oF (1900oC) to 2880oF(1250oC). At and above 3452oF (1900oC) itdissociates into 2CaO•SiO

2 and CaO; below

2280oF (1250oC) it tends to dissociate into2CaO•SiO

2 and CaO.

Dicalcium Ferrite 2CaO•Fe2O

3Melts incongruently at 2617oF(1436oC) formingCaO and liquid.

Magnesioferrite MgO•Fe2O

3Dissociates slightly; begins to melt at 3115oF (1713oC).

Monticellite CaO•MgO•SiO2

Melts incongruently at 2709oF (1487oC) to formMgO and liquid; melting complete at approximately3000oF (1650oC).

Merwinite 3CaO•MgO2•SiO

2Melts incongruently at 2871oF (1577oC) to form2CaO•SiO

2, MgO and liquid

~ = Approximately



ence of moderate amounts of ferricoxide, but reacts with lime to form theminerals monticellite and merwinite.

Monticellite and merwinite melt atrelatively low temperatures, and in minoramounts may have some value in thedevelopment of the ceramic bond ofmagnesia brick. Dead-burned magnesiacompositions having a lime:silica ratiofavorable to the development of anundesirable amount of monticellite ormerwinite can be corrected by theaddition of sufficient lime so that therewill be 1.86 times as much lime assilica, by weight. When this is done,magnesia is displaced from the silicates,and the lime and silica combine to formthe compound dicalcium silicate(2CaO•SiO2).

Dicalcium silicate (2CaO•SiO2) ishighly refractory. It does not react withmagnesia (MgO), and it is stable in thepresence of moderate amounts of ferricoxide (Fe2O3). At one time, it wasregarded as an undesirable componentof basic refractories, because of itstendency to turn completely into duston cooling; this affect results from amineral inversion at about 1340oF(725oC) which is accompanied by anabrupt volume increase of 10 percent.However, means have been found toprevent the dusting of dicalcium silicateby adding small amounts of stabilizingminerals to the raw magnesia ormagnesium hydroxide, before deadburning. These added materials inhibitthe inversion of the silicate on cooling.

The lime compounds tricalciumsilicate (3CaO•SiO2) and dicalciumferrite (2CaO•Fe2O3), which may occurin magnesia refractories having highlime-silica ratio, are compatible with

dicalcium silicate but do not coexist inequilibrium with monticellite,merwinite, or forsterite. Tricalciumsilicate is unstable below about 2280oF(1249oC) and tends to dissociate intodicalcium silicate and free lime.Dicalcium ferrite is unstable above2617oF (1436oC), and decomposes intofree lime and a liquid high in ironoxide. It has been suggested that whenthis occurs the iron oxide may leave theliquid and combine with magnesia toform the mineral magnesioferrite(MgO•Fe2O3); and that, if the materialis cooled rapidly, the dicalcium ferritemight not re-form. Under theseconditions, free lime would be presentin the dead-burned magnesite aftercooling.

In basic refractories, the state ofoxidation of the iron changes with thetemperature, and with changes in theoxygen pressure of the furnace atmo-sphere. When heated in air, free ferricoxide loses oxygen at 2530oF (1368oC)and changes to the spinel mineralmagnetite (FeO•Fe2O3). If the furnaceatmosphere is strongly reducing, ironoxide will be in the form of FeO; ifstrongly oxidizing, it will be ferricoxide (Fe2O3).

An important property of magnesiumoxide is its ability to absorb greatamounts of iron oxide-either ferrous orferric-without undue decrease inrefractoriness. This property ofmagnesia, together with its very highmelting temperature, is responsible, inlarge measure, for its value as arefractory. It accounts for the fact thatrefractories high in magnesia can beused advantageously in the presence ofiron oxides, in either an oxidizing or a

reducing atmosphere, and also, forsome of the particular advantages ofsteel-encased basic brick.

The equilibrium diagram for theMgO•FeO system is shown in Figure 5,if the incongruent melting of FeO isneglected. Magnesium oxide (MgO)and ferrous oxide (FeO) form acontinuous series of solid solutionswhich decrease in refractoriness withincreasing proportions of ferrous oxide.However, even with more than 50percent FeO, the refractoriness is stillhigh.

Magnesium oxide reacts with ferricoxide (Fe2O3) to form magnesioferrite,which begins to melt only at 3115oF(1713oC), notwithstanding the fact thatit contains 80 percent Fe2O3. With lessthan 70 percent Fe2O3, the temperatureof incipient melting is even higher than3115oF (1713oC).

At ordinary temperatures, iron oxidein dead burned magnesia or in magnesiabrick may be present within thepericlase grains as MgO•FeO solidsolution, or as inclusions of magnesio-ferrite (MgO•Fe2O3) particles. If thelime-silica ratio by weight exceeds1.86, iron oxide may be present also inthe groundmass in combination withlime and alumina as brownmillerite(4CaO•Al2O3•Fe2O3), in combinationwith lime as dicalcium ferrite(CaO•Fe2O3), or in solid solution withsilicates.

While magnesioferrite is completelysoluble in periclase at high tempera-tures, it separates out upon cooling,unless cooled very rapidly. Thisaccounts for the presence of the darkcolored inclusions in periclase crystalsfrequently observed in microscopicexamination.

Very dense grains of magnesia oftenare greenish in their interiors, whichwere cooled out of contact with air, andchocolate-brown at their surfaces,which were exposed to air duringcooling. In the greenish centers thepericlase crystals probably containferrous oxide in solid solution; in thebrown surface portions the periclasecrystals contain inclusions ofmagnesioferrite particles. Porous

Table VMELTING POINTS OF SOME CaO-MgO-SiO2

EUTECTICS

Melting Points of EutecticsEutectics Between These Compounds oF oC

MgO and CaO ~ 4172 ~2300MgO, CaO and 3CaO•SiO

2~3360 ~1850

MgO, 3CaO•SiO2 and 2CaO•SiO

2~3255 ~1790

MgO and 2CaO•SiO2

~3270 ~1800MgO, 2CaO•SiO

2 and 3CaO•MgO•2SiO

22867 1575

MgO, 3CaO•MgO•2SiO2 and CaO•MgO•SiO

22714 1490

MgO, CaO•MgO•SiO2 and 2MgO•SiO

22736 1502

MgO and 2MgO•SiO2

~3380 ~1860

~ = Approximately



grains are less likely to have greencenters than dense grains.

Dead-burned magnesia sometimescontain somewhat more free lime thanwould be anticipated from theirCaO:SiO2 ratio. The free lime has nodisadvantage from the standpoint ofmelting, but it is very active chemicallyand slakes upon exposure to the air.

Chrome RefractoriesOres: Chrome ores in general consist ofmassive or granular aggregates ofchromite crystals, with minor amountsof silicates in the matrix. Refractorychrome ores may be regarded asnaturally occurring mixtures of twocomponents: (1) the essential compo-nent, a highly refractory chrome-containing spinel; (2) accessorycomponents, consisting mainly ofmagnesium silicates in the form ofinterstitial material and veinlets. Thesesilicates are often of complex andwidely varying compositions.Chrome Spinel: The spinel minerals allhave the general formula RO•R2O3 andall crystallize in the cubic system. Inthe spinels of chrome ores, the ROconsists of FeO and MgO (ferrousoxide and magnesia), and the R2O3 ofCr2O3, Al2O3, and Fe2O3 (thesesquioxides of chromium, aluminum,and iron). The proportion of Fe2O3 isrelatively small.

An important property of the spinelminerals is their habit of forming solidsolutions, or isomorphous mixtures,with each other. The various spinelminerals are soluble in each other overa very wide range of compositions.Their tendency to form mixed crystalsis so great that some of the spinelminerals are not known to occur pure innature. For example, chromite of theformula FeO•Cr2O3 is known only inmeteorites; all other natural chromitesare believed to be isomorphous mix-tures.

The composition of a chrome spinel(excluding all accessory minerals) maybe stated in terms of molecular ratios ofRO and R2O3. For example, theaverage molecular composition of thespinel in chromite of one of the larger

deposits in the Camaguey district ofCuba is approximately the following:___________________________________________________________________________

RO R2O3___________________________________________________________________________

MgO 75% Cr2O3 40%FeO 25% Al2O3 55%

_____ Fe2O3 5%100% 100%

___________________________________________________________________________This composition may be expressed

more simply by the formulam75f25•(c40a55f5), in which m=MgO, c=Cr2O3, a= Al2O3, f outside the parenthe-sis =FeO, f within the parenthesis =Fe2O3. The subscripts representmolecular percentages.

Typical molecular compositions ofcertain other chrome spinels, asreported by J. R. Rait and others, maybe represented by the followingformulas:___________________________________________________________________________

Cuban (Moa Bay) m72f28 (c47a50f3)Rhodesian m66f34 (c73a21f6)Philippine m73f27 (c42a55f3)Transvaal, brown m47f53 (c62a28f10)Turkish Refractory Grade m71f29 (c42a55f3) Metallurgical Grade m74f26 (c77a19f4)

___________________________________________________________________________

There is evidence which indicatesthat the crystals of balanced spinel in agiven specimen of chrome ore may notall be of identical composition. There-fore, the molecular formula of a chromespinel, calculated from its chemicalcomposition, is merely an averagevalue, and does not necessarily applystrictly to each individual spinel crystal.

Frequently, the compositions ofchrome ore are reported in terms of

individual spinels, as if the ore con-tained a series of spinels existing sideby side. However, the preponderanceof evidence is that the individual spinelminerals have no identity as such in thespinel solid solution of chromite.Accessory Minerals: The accessoryminerals which occur most abundantlyin chrome ores are serpentine(3MgO•2SiO2•2H2O) and chlorite, acomplex hydrated silicate of magne-sium, iron, and aluminum. Thecomposition of clinochlore, one of themembers of this group is5(Mg,Fe)O•Al2O3•4H2O. Otheraccessory minerals include the follow-ing:_________________________________________________________________________

Olivine 2(Mg,Fe)O•SiO2

Talc 3MgO•4SiO2•2H2OPyroxene

Diopside CaO•MgO•2SiO2

Enstatite MgO•SiO2

Bronzite (Mg,Fe)O•SiO2

Hypersthene (Fe,Mg)O•SiO2

FeldsparAnorthite CaO•Al2O3•2SiO2

___________________________________________________________________________

The amount of accessory minerals incommercial chrome ores varies from 5percent to 25 percent. Most of theaccessory minerals have relatively lowmelting points, well below 3000oF or1650oC. The heat-resisting qualities ofchrome ore depend largely upon thecharacter and the amount of thesilicates which the ore contains.Analyses and Melting Points: Typicalanalyses of chrome ores are given inTable VI. The ores used for refractories

Table VITYPICAL ANALYSIS OF CHROME ORES

Source of Ore Cr2O3 Al2O3 FeO MgO CaO SiO2

Pakistani Chrome Ore 54.4 10.4 15.4 6.6 0.2 2.8Phillipine Chrome Ore

Gov’t Stockpile 33.7 26.5 14.9 17.4 0.6 5.3+ 10 mesh 32.4 16.6 0.4 5.2Fine Lump Ore 32.0 27.5 14.4 19.4 0.5 6.0

Transvaal Chrome OreGov’t Stockpile 44.7 12.8 26.6 10.2 0.3 4.3ERS Grade 44.3 15.9 26.1 11.6 0.2 0.8MN46 44.2 15.9 28.2 9.8 0.3 0.9-48 mesh 45.0 15.4 28.5 9.2 0.4 1.3

Tiegaghi Chrome Ore 55.3 10.2 15.3 15.7 0.2 3.2Marico Chrome Ore 48.4 16.3 22.3 11.6 0.2 0.8



usually fall within the ranges of 30 to 50percent chromic oxide (Cr2O3), 14 to 20percent ferrous oxide (FeO), 14 to 20percent magnesia (MgO), 12 to 25percent alumina (Al2O3), 3 to 6 percentsilica (SiO2) and less than 1 percentlime(CaO). The Philippine chromeores are noted for their high content ofalumina. To an increasing extent, oresare being used which contain as muchas 26 percent ferrous oxide and as littleas 8 percent magnesia and 10 percentalumina.

As might be expected from itsconstitution, a chrome ore does nothave a true melting point, but rather amelting range. The melting behavior ofa particular chrome ore depends notonly on the composition and refractori-ness of its major component chromespinel, but also on the amount, compo-sition, and melting points of thesilicates present, and on the furnaceatmosphere, whether oxidizing orreducing.

From Table IV, showing the meltingpoints of the individual spinel minerals,it may be inferred that the mostrefractory chromites are those highestin magnesia and chromic oxide.

In most chrome ores of refractorygrade, melting of the silicate impuritiesbegins at temperatures as low as 2300oF(1260oC). As the temperature rises,some solution of the spinels in theliquid occurs, but melting of thesespinels is not complete until a muchhigher temperature is reached-possiblyas high as 3900oF (2150oC).

Mineral Changes During Firing ofChrome OreThe thorough investigations of Rigby,Lovell, and Green and others, concern-ing the behavior of various chrome oresand synthetic spinels on firing, appearto have established the following facts:

(1) Chrome spinels in general arebalanced, containing equalmolecular percentages of RO andR2O3 constituents.

(2) Most of the iron content ofchrome ores is present as part ofthe RO constituent.

(3) The FeO in the spinel of mostchrome ores is readily oxidizedinto Fe2O3when the ores, or brickcontaining them, are fired in anoxidizing atmosphere. Thisresults in an unbalance betweenRO and R2O3, as the RO de-creases and the R2O3 increases.Two solid phases appear: (a) aspinel consisting mainly ofMgO•R2O3 and (b) a solidsolution of the excess R2O3

constituents (Fe2O3, Cr2O3, andAl2O3). Frequently the solidsolution is easily visible underthe microscope as needle likeinclusions.

(4) Chrome spinels of relatively highalumina content appear to have alesser tendency to oxidize in airat temperatures up to 2640oF(1449oC) than those in chromicoxide.

(5) Raw chrome ores, in which mostof the iron is present as FeO, areapparently affected relativelylittle by heating in a reducingatmosphere. However, in achrome ore which has been fired,the iron is present largely asFe2O3 in an R2O3 solid solution,and is readily reduced by heatingin a reducing atmosphere. Inextreme cases, it may be reducedto metallic iron.

(6) In a chrome ore which hasbecome oxidized on firing,reduction of the Fe2O3 in theR2O3 solid solution is usuallyaccompanied by expansion andan increase in porosity, andsometimes by cracking. Theexpansion and cracking areobserved only when the oxidizedore is exposed to reducing gases.Repeated oxidation and reduc-tion may cause an ore to becomefriable. Chrome ores high inalumina show much less ten-dency to become friable.

(7) When a chrome ore is heatedwith added magnesia, as in achrome-magnesite or magnesite-chrome brick, MgO enters thechrome spinel to replace the

FeO, as it oxidizes to Fe2O3, andalso combines with the newlyformed Fe2O3 to maintain thespinel structures. The new spinelwill have essentially the formulaMgO•R2O3.

(8) During oxidation, in the presenceof excess magnesia, part of theFe2O3 may leave the spinelcrystal as MgO enters, react withMgO, and form a border ofMgO•Fe2O3 surrounding thechrome spinel crystal.

(9) While Fe2O3 in the simple spinelMgO•Fe2O3 is easily reduced, itis much more stable in the spinelMgO•R2O3, when the R2O3

consists of Al2O3 and Cr2O3, aswell as Fe2O3. Thus, an oxidiz-ing heat treatment of a chromeore in the presence of excessMgO to stabilize the spinelrenders it less likely to becomefriable when exposed to alternat-ing oxidizing and reducingconditions.

(10)The stabilization of the chromespinel by oxidation of FeO andabsorption of MgO may beaccompanied by a volumeexpansion of about 5 to 10percent, depending on theamount of FeO oxidized. Thiseffect may be partially offset byshrinkage of the silicates presentas accessory minerals.

(11) The stabilization of the chromespinel by MgO increases therefractoriness of the spinelgrains, since spinels formed byMgO with Cr2O3, Al2O3, andFe2O3 have higher melting pointsthan the corresponding spinelsformed by FeO.

(12)The added magnesia also reactswith the accessory magnesiumsilicate minerals of low meltingpoint present in the groundmassof the ore, and converts them tothe highly refractory mineralforsterite, 2MgO•SiO2. How-ever, the amount of magnesiaabsorbed by the spinel isprobably much greater than thatwhich enters into the formation



of forsterite in the matrix.(13) The volume expansion of

stabilization with MgO maycause the edges of the spinelgrains to shatter, and may alsoweaken the natural bond betweengrains. In addition the increasein refractoriness of the silicategroundmass, resulting from theaddition of MgO, may decreasethe bonding strength. Thereforea fired chrome magnesite brickwill normally not be as strong atroom temperature as a brickconsisting only of chrome ore,but is usually stronger at hightemperature.

Composite Chrome-MagnesiaRefractoriesIn the early 1930’s, important discover-ies were made concerning combinationsof chrome ore and dead-burnedmagnesia. Most of the silicates inchrome ores have relatively low meltingpoints. It was learned that if finelyground dead-burned magnesia wereadded to chrome refractories, thesilicates would be largely converted,during firing, to the refractory mineralforsterite (2MgO•SiO2), which has amelting point of 3450oF (1900oC).Later, it was discovered that theaddition of the magnesia resulted alsoin stabilization of the chrome spinel.These discoveries provided greatimpetus to the use of chrome-contain-ing refractories, since the improvementsled to the production of brick of greaterutility.

Today, a large proportion of all thebasic refractories used commerciallyconsist essentially of blends of dead-burned magnesia and chrome ore invarious proportions and in numerousmodifications. There are two maingroups: (1) chrome-magnesia brick, inwhich chrome ore predominates, andusually constitutes all the larger grains,while the dead-burned magnesia isconfined to the fine-grained ground-mass; and (2) magnesia-chrome brick,in which dead-burned magnesia, themain component, consists of a completerange of sizes, while the chrome ore is

coarsely ground. However, there arevarious other modifications of the sizingof the particles.

In the manufacture of chrome-magnesia refractories, considerablymore magnesia is customarily addedthan is required for reaction with thesilicates. Part of the excess magnesiaenters the chrome-spinel grains tomaintain the RO: R2O3 balance whenthe FeO of the spinel is oxidized at hightemperatures to Fe2O3; and part of themagnesia remains in the brick as freepericlase.

The mineral relationships in the six-component system CaO•MgO•SiO2•Al2O3•FeO•Fe2O3 have been describedon preceding pages. The relationshipsin the broader system containing Cr2O3

also are similar. With the ratio of limeto silica of 1.86 or less, the phasescontaining lime and magnesia are thesame as those shown in Table III, andthe sesquioxides Cr2O3, Al2O3, andFe2O3 are combined with FeO and MgOto form spinel solids solutions.Chrome-magnesia brick usually have alime-silica ratio less than 0.93 byweight, and consist of spinel solidsolutions, periclase, forsterite, andmonticellite. At high temperatures,periclase absorbs iron oxides from thespinel grains to form solid solutions ofMgO with FeO and MgO•Fe2O3.

With CaO:SiO2 ratios greater than1.86 by weight, compounds of CaOwith sesquioxides will occur. Thiscondition rarely if ever exists incommercial chrome-magnesia composi-tions as manufactured, but may occur inservice as the result of exposure tobasic slags.

While the addition of magnesia tochrome refractories increases theirrefractoriness, and has an importanteffect on their high-temperaturemineralogy, the addition of chrome oreto refractories consisting mainly ofdead-burned magnesia serves a differ-ent purpose. The addition of coarsechrome ore imparts improved spallingresistance to brick consisting mainly ofdead-burned magnesia, apparently byproviding stress relief in an otherwiserelatively rigid structure. Usually,

magnesia-chrome brick are chemicallybonded and encased in steel sheets.They are also made with internal steelplates.

The mineral changes occurring inmagnesia-chrome refractories in serviceare similar to those which occur inmagnesia and chrome refractories. Anyforsterite (2MgO•SiO2) or monticellite(CaO•MgO•SiO2) present in therefractory may react with basic slags toproduce secondary periclase (MgO),merwinite (3CaO•MgO•2SiO2), andoccasionally dicalcium silicate(2CaO•SiO2). The ferrous oxide (FeO)in the chrome ore oxides to ferric oxide(Fe2O3) and is replaced in the spinelstructure by magnesia. The ferric oxideproduced reacts with additionalmagnesia to form magnesioferrite(MgO•Fe2O3). The steel plates oxidizealso, and the oxide formed diffuses intothe magnesia adjacent to the plates toform additional magnesioferrite.Chrome grains adjacent to the oxidizedsteel plates frequently show growth ofmagnetite (FeO•Fe2O3) ormagnesioferrite (MgO•Fe2O3) on thesurface of the chrome spinel crystals.

Forsterite RefractoriesForsterite is a magnesium silicate

with the theoretical formula2MgO•SiO2, corresponding to 57.3percent magnesia (MgO) and 42.7percent silica (SiO2). Its melting point is3450oF (1900oC). Forsterite almostalways occurs in homogenous combina-tion with fayalite (2FeO•SiO2). Theseries of mixed crystals consisting offorsterite and fayalite is called “olivine”or “chrysolite,” while the rock consist-ing of Mg-Fe olivine, with minoramounts of accessory minerals, isknown as “dunite.” Commonly the ironcontent of magnesium olivines used forthe production of refractories corre-sponds to about 15 percent of fayalite.

The accessory minerals occurring inthe olivine used for making forsteritebrick are largely serpentine and talc.Serpentine has the composition3MgO•2SiO2•2H2O, and contains equalamounts of magnesia and silica byweight. The composition of talc is



3MgO•4SiO2•2H2O, corresponding toonly half as much magnesia as silica byweight. Upon heating, both theseminerals develop large amounts of liquidat relatively low temperatures. At 2838oF(1559oC) pure serpentine would form60.5 percent forsterite and 39.5 percentof a siliceous liquid; at 2811oF (1544oC)pure talc would become 4.4 percentcristobalite and 95.6 percent liquid. Ineither case, the presence of thesenatural impurities in olivine lowers thetemperature at which liquid forms.

The development of a considerableamount of liquid in a refractory body isnot of itself a serious matter. Forexample, Fireclay brick contains largeproportions of liquid at temperatureswithin their working range. Yet theliquid is so very viscous that there canbe no drainage from the pores. How-ever, brick containing magnesiumsilicate melts behave quite differently.Birch and Harvey found that a brickmade of Mg-Fe olivine relatively high inaccessory minerals, when heated to2640oF (1450oC) developed a melt ofsuch high fluidity that liquid drainedfreely from the pores. They also foundthat this drainage could be prevented bythe addition of sufficient magnesia toconvert the magnesium silicatesserpentine and talc into forsterite uponfiring, and to combine with the ironoxide present to form magnesioferrite(MgO•Fe2O3).

Forsterite brick are fired productsconsisting essentially of olivine withadded magnesia. During the firingunder oxidizing conditions, importantchanges take place in the forsteritefayalite solid solution of the olivine.The forsterite is stable, and persists assuch in the finished brick. The ferrousoxide (FeO) of the fayalite oxidizes toform ferric oxide (Fe2O3), and the silicaof the fayalite is liberated. The ferricoxide then combines with a part of theadded magnesia to form magnesioferrite(MgO•Fe2O3). The silica liberated by thedecomposition of the fayalite unites withpart of the added magnesia to formsecondary forsterite.

A comparable transformation occursin the accessory silicate minerals. Anyserpentine present in fissures or in thegroundmass decomposes upon firing toform secondary forsterite and silica.The latter forms additional amounts ofsecondary forsterite by reacting with aportion of the added magnesia.

An important modification of burnedforsterite brick is made by the additionof alumina which during the firingreacts with free magnesia and ironoxide from the olivine to form a solid-solution spinel. This stabilized spinel ishighly resistant to growth resultingfrom cyclic oxidation and reduction.

Using Refractories

Selection of Refractories UR-1

Ordering Refractories UR-3

Thermal Expansion UR-4

Thermal Conductivity UR-6

Heat Flow Calculations UR-7

Installing Castables UR-9

Installing Gun Mixes UR-13

Installing Rammed and Gun Plastics UR-15

Installing Ramming Mixes UR-17

Furnace Refractory Lining and Construction UR-19

Arch Construction UR-22

SECTION 4

WARNING: Some materials which are present in refractoryproducts are harmful. One such group is classified assubstances known to cause cancer to humans. Othersubstances may be classified as probably or possiblycarcinogenic. These materials include minerals used in orformed during the manufacture of these products. The primarythreat presented by many of these materials comes frominhaling respirable dust. The use of proper respiratoryequipment, as well as other personal protective equipment ismandatory where required by applicable law. Please refer tothe applicable Material Safety Data Sheet for such product .

Harbison-Walker UR - 1

Using RefractoriesJust as the design and construction of masonry and concretestructure must meet exacting load-bearing and curing demands,so must refractory materials stand up to the demands of hightemperature and otherwise destructive environments. Slag, moltenmetal, abrasive raw materials, corrosive gases or any combination ofthese elements can contact and threaten the integrity of refractories.A substantial investment in products intended to handle theseconditions can be lost through inadequate design and carelessconstruction of refractory structures.

This section addresses problems inherent to refractory design andconstruction and describes workable solutions to many of them.Discussions involve thermal expansion of refractories, thermalconductivity, heat transfer and the installation of monolithicrefractories including anchoring and the construction of refractoryfurnace linings and arches. Calculations are also provided for avariety of arch and ring combinations.

A comprehensive treatment of refractory design and constructionissues is beyond the scope of this section. If your specific refractorylining problem is not addressed in the following pages, pleasecontact your Harbison-Walker representative for assistance.

USING REFRACTORIES

UR - 2 Harbison-Walker

OPERATING FACTORS• Function of the furnace

• Nature of material being processed

• Rate and continuity of operation

• Range and rapidity of temperaturechanges

• Chemical attack by metals,slags, ash, etc.

• Fluidity of molten metal or slag

• Velocity of furnace gases

• Abrasion from contained solids orgases

• Impact from charging

• Erosion by molten furnace contents

• Impinging flames or hot spots

FURNACE DESIGN AND

CONSTRUCTION• Type of furnace

• Design and dimensions of wallsand arches

• Loads imposed on the lining

• Conditions of heating (one ormore sides)

• Amount of insulation

• Air- or water-cooling

• Type of refractory construction(brick or monoliths)

• Methods of bonding or support

• Provision for thermal expansion

• Mechanics of any movingfurnace parts

SELECTION OF REFRACTORIES

Optimum use of refractories is achieved by careful study offurnace design and evaluation of operating conditions prior toselection of refractory products which meet the design andoperating requirements.

From the multiple factors listed below, it may appear that thechoice of most suitable material would be exceedingly difficult.Sometimes this is true.However, there are usually data on hand from previous experienceunder similar conditions. Moreover, the best refractory selectionoften depends on a few requirements so important that otherfactors play a minor role. In some cases, refractoriness, i.e.,maximum service temperature, alone will be the deciding factor,and in others high refractoriness will have to be coupled withresistance to thermal shock. Under other circumstances, resistanceto metals, slags, or disintegration by reducing gases may be thegoverning factors. Sometimes high insulating value is desirable,but in other situations high thermal conductivity may be needed.When selecting refractories, the following major factors must beidentified.

REFRACTORY-RELATED

FACTORS• Properties at room temperature –

Workmanship and physical strength

Density, porosity, permeability

Chemical and mineral composition

Uniformity

Size and design

• Properties at high temperatures –

Refractoriness or maximum servicetemperature

Reversible thermal expansion

Resistance to thermal shock

Resistance to chemical attack

Resistance to mechanical impact or stress

Resistance to abrasion or erosion

Permeability to gases or liquids

Volume stability (bloating or shrinkage)

Resistance to gases and fumes

Thermal conductivity

Heat capacity

Electrical resistance

• Economic factors

Delivered cost

Cost of installation (brick vs. monoliths)

Special shapes or forming required

Service life


ORDERINGREFRACTORIESRefractory technology is becomingincreasingly specialized, year after year,so that it is often necessary to thor-oughly understand an application areabefore making refractory selections.Harbison-Walker Marketing Representa-tives have been trained to do this workand are ready as an accommodation todiscuss your application with you. H-Woffices are listed in phone books inmajor cities throughout the UnitedStates.

In most cases, careful specification ofyour requirements and operation willhelp Harbison-Walker fill your ordercorrectly and without delay. When youorder various shapes and sizes, it is notnecessary to send drawings, but providea complete description and correctdimensions for the shapes that you need.If you order circle brick or other shapesdesigned to fit a circular lining, provideboth the inside and outside diameter ofthe lining.

Orders for brick should includeenough mortar material of the right kindto lay the brick. Information required tospecify the number, shape and size ofbrick as well as the quantity of mortarappears in the following tables and in theBrick Sizes and Shapes Section of theHandbook.

Approximate Pounds of Mortar per 1000 9-Inch Brick(9 X 41/2 X 21/2 Inch)*

Brick Laid withBrick Laid Dipped or Thinly

Mortar Materials Dry and Grouted Trowelled Joints

Heat-Setting MortarsSATANITE® 250 - 300 350 - 450

Air Setting MortarsHARWACO BOND® 250 - 300 350 - 450

‘SAIRSET® 250 - 300 350 - 450

H-W® PERIBONDTM 300 - 400 500 - 600

‘SAIRBOND® 250 - 300 350 - 450

* This is for 9-inch straights. Normally, for larger sizes the quantities required are reduced in porportion to the decrease in surface area covered by the mortar per 1000 9-inch equivalent.

NOTE: Minimum figures are used ordinarily for estimating.

OVERAGE

Quantity QuantitySpecified Overage Specified Overage

1-100 10% 5,000 - 10,000 2%100-1,000 7% Over 10,000 1%1,000-5,000 3%

*Not less than one shape. If in sets, one complete set.

Number of Refractory Straights Required PerSquare Foot ofWall or Floor

Wall or Floor 9 X 41/2 X 3 InchThickness, Inches Brick

3 3.641/2 5.3

6 7.271/2 8.9

9 10.7131/2 21.4

18 21.4

27 32.1

Number of brickper cubic foot 14.2

Special ShapesOn initial orders for special shapes, senda drawing of the shape and the assemblyinto which it fits. The assembly drawingwill help Harbison-Walker engineersevaluate the design and verify that thecombination of refractories and designproduces the best results. On subsequentorders the Harbison-Walker drawingnumber or your drawing and shapenumber will ensure that the order isproperly filled. Refer to the previousorder by number and date.

When filling orders for special shapes,Harbison-Walker makes a slightly largernumber of shapes than specified to coverpossible breakage in firing. In somecases, all of the extra pieces will comefrom the kilns in perfect condition.

ORDERING REFRACTORIES

Then, Harbison-Walker will ship alimited quantity of extra pieces inaccordance with the following table,unless special instructions are entered onthe order. This standard procedure alsohelps avoid shortages resulting frombreakage during transit and handling.

Standard PackagingStandard packaging for monolithicrefractories are 55 lb. sacks, pails,cartons, 2,000 lb., 3,000 lb., and 4,000 lb.bulk bags. Non standard palletizing forbrick or monoliths and non standardpackaging options including exportpalletizing are available for additionalcharges.


OverviewLike virtually every construction material, refractories expand orcontract at high temperatures. Thus, thermal expansion must beconsidered in the design of most refractory structures. Walls must beallowed to expand freely upward, and joints must permit the horizontalexpansion required by the refractories.

Further, expansion allowances must be determined with reasonableaccuracy. Too little will cause pinch spalling; too much may weakenthe wall or roof unnecessarily. How much expansion allowance tocalculate depends largely on the refractory material; and how expan-sion will occur depends on several factors, including the type ofrefractory.

thermal expansion for certain refractorybrick classes shown in thermal expan-sion graphs are available from yourHarbison-Walker Marketing representa-tive. Thermal expansion data can befound in the Harbison-WalkerHEATransferTM 2003 program found onour webpage at www.hwr.com.

The thermal expansion data repre-sents average values. Brands evenwithin a class, will differ somewhatamong themselves. Generally, fireclay,silicon carbide, zircon brick and mostinsulating firebrick have relatively lowrates of expansion. Basic brick showrelatively high rates of thermal expan-sion while other refractories fallbetween the two.

EXPANSION ALLOWANCESBrick RefractoriesMethods of making allowance forthermal expansion in refractory brickdiffer considerably, depending on walldimensions, insulation, the mortar usedand operating conditions, as well as thetype of refractories involved.

Adequate provision for expansionbecomes especially important in high orlong walls where total thermal expan-sion may be substantial. The thicknessand insulation of a wall determine thetemperature drop between hot and coldface, and, thus, the amount of thermalexpansion at both faces.

When construction calls for a heat-setting mortar, vertical expansion jointscan be staggered to tighten construc-tion. However, where brick are laidwith an air-setting mortar, expansionjoints must be lined up vertically fromcourse to course. Brick required tomove with respect to each other as therefractory expands should not be laidwith air-setting mortar.

In fireclay boiler settings with walls15 feet or more in length, furnacebuilders customarily stagger verticalexpansion joints 4 to 6 feet apart. If thewalls are low, expansion joints may fallsomewhat farther apart than in othertypes of construction. For example,tunnel kiln construction usually callsfor expansion joints 10 to 15 feet apartin the high temperature section and 15to 20 feet apart in the low temperaturesection.

In silica brick walls, vertical expan-sion joints typically are placed toextend from bottom to top, spaced 10 to16 feet apart.

Basic brick-magnesite and chrome-are laid in a number of ways to allowfor expansion. Some furnace builderslay the brick dry with sufficient space ateach vertical joint, or at about 18-inchor wider intervals. Basic brick also canbe laid dry with a heavy paper orcardboard filler in each vertical joint.

THERMAL EXPANSION TYPESRefractory thermal expansion occurs intwo forms. “Permanent” thermalexpansion takes place as the result ofmineralogical changes within therefractory brick when they remain athigh temperatures for long periods oftime. “Reversible” thermal expansionoccurs as the brick expand and shrinkwhen the temperature rises and fallsduring operation.

Results of reheat testing, shown withother properties of each brand, indicatethe amount of permanent linearexpansion to be expected.

The table below lists approximateexpansion values for refractory brick inhigh temperature service. Reversible

THERMAL EXPANSION

Thermal Expansion of Refractory Brick in High Temperature Service

Approximate ExpansionPer foot, Per meter,

Type of Brick inches cm

FireclaySuper DutyHigh-Duty 3/32 0.76Low-Duty

High-Alumina60%Class70%Class 3/32 0.7685%Class90% Class 1/8 1.04Corundum Class 5/32 1.30

Silica 5/32 1.30Basic

Magnesite, fired 1/4 2.08Magnesite-chrome, fired 1/4 2.08

Magnesite-chrome, unburned 3/16 1.55Chrome, fired 1/8 1.04Chrome-magnesite, fired 1/8 1.04Chrome-magnesite, unburned 5/32 1.30

Silicon Carbide 3/32 0.76Zircon 3/32 0.76

}}

Click here to go to Harbison-Walker HEATransferTM 2003program or go towww.hwr.com

http://www.hwr.com/heat

http://www.hwr.com/heat


Castable RefractoriesIn any consideration of thermalexpansion, castable refractories differconsiderably from brick. Castables arenot fired before installation. Only afterprolonged exposure to heat do theyassume the reversible expansion andcontraction characteristics found in firedceramic bodies.

During initial heat-up, castables showthe results of complex forces at work:

• The fired aggregate expandsaccording to its chemical composi-tion;

• The cement phase shrinks as itloses the water of hydration; and

• The body itself expands or con-tracts as it sinters and mineralogi-cal reactions occur.

Most background material concern-ing thermal expansion of refractories isbased on brick, and that knowledge isdifficult to transfer to castables. But, inthe field, there are two practical rules ofthumb:

• Fireclay castables do not normallyrequire an expansion allowance;and

• Certain dense, highly refractorycastables have substantial revers-ible thermal expansion up to2000oF (993oC) or more.Castables of this type may requirean expansion allowance in massiveinstallations.

THERMAL EXPANSION

Construction joints are suggested formost castable installations except forthose which will be used in metalcontact. Construction joints controlshrinkage and cracks that can form ondrying.

Expansion joints in refractorycastables are typically designed in thesame manner as construction jointsrequired to control shrinkage. How-ever, some types of compressiblematerial should be incorporated in theexpansion joint. The figure belowillustrates typical configurations forjoint construction.

If you have specific questions aboutthermal expansion in refractories,please call your Harbison-WalkerMarketing Representative.

Typical Joint Construction

Thin Single Component Thick Single ComponentLining – 5” or Less Lining – 5” or More

Double Lining Double LiningHot Face or Backup – 5” or Less Hot Face or Backup – 5” or More

When construction joints are required, anchors should remain halfway between them. Anchor tinesshould be 2 to 3 inches from the joint. If joint position is not fixed in the drawing, always cut or formthe joint midway between anchors. No anchors should be located at any joint. Expansion jointconstruction is the same, except that the joint is thicker to permit insertion of the requiredexpansion material.


OverviewIn selecting refractory lining configurations for high temperaturevessels, it is often necessary to calculate the heat flow and temperatureprofile of the refractory lining. Heat flow rates are important inassessing the economics of furnace operation. Temperature profilesare important in choosing combinations of materials which preventoverheating of refractories and support structures, such as the shelland anchors, and in determining the solidification and condensation offurnace process components in the lining. Thermal conductivity datafor many of our products are available on our HEATransferTM 2003 pro-gram which can be access on our website at www.hwr.com. A user nameand password is required to secure this data and perform on-line heatflow calculations. With certain limitations, steady-state heat flow rates andtemperature profiles in walls and roofs can be calculated with sufficientaccuracy for most engineering purposes.

equal to the rate of heat flow out of thelining. In conventional furnaces, heatenters the inside surface of the lining,passes through the lining via conduc-tion, and escapes to the surroundings atthe outside surface via radiation andconvection. Therefore, the steady statecondition for flow through a flat wall orroof may be expressed mathematicallyas:

QL = Q

S

where QL is the heat flux in the lining,

and QS is the heat flux at the outside

surface.The heat flux in the lining may be

determined using the following expres-sion:

QL = (T

i-T

o)/ R

T

whereQ

L = heat flux in the wall,

BTU/ft2-hr(W/m2)T

i = temperature of inside

surface, °F (°C)T

o = temperature of

outside surface, °F (°C)R

T = total thermal resistance of

wall, ft2-hr-oF/BTU(m2-K/W)

The total thermal resistance of thewall is calculated by summing theindividual thermal resistances of allrefractory components and the furnaceshell:

nΣ R

T = L

j/K

j

j=1

wheren = number of componentsL

j = thickness of

component j, in. (m)K

j = thermal conductivity of

component j,BTU-in/ft2-hr-°F(W/m-K)

For example, a wall consisting of tworefractory components and a shellwould have a thermal resistance givenby:

RT = (L

1/K

1)+(L

2/K

2)+(L

3/K

3)

The inside and outside surfaces arecommonly called the hot and cold facesof the furnace wall. The hot facetemperature is usually assumed to beequal to the gas temperature within thefurnace. Actually, the hot face tem-perature is somewhat cooler, but thedifference is typically too small towarrant the complex calculation.

The heat flux at the cold face, Qs, is

determined by two mechanisms,radiation and convection. The portionwhich is lost by radiation may bequantified by using the followingequation:

Qr = Fg(T

o4 - T

a4)

whereQ

r = heat loss by radiation, BTU/

ft2-hr (W/m2)

F = 1.74 x 10-9 BTU/ft2-hr-°R4

(5.67 x 10-8 W/m2-K4)

g = total emissivity of outsidesurface, dimensionless

To = temperature of outside

surface, °F (K)

Ta = temperature of surrounding

air, °F (K)

ONE DIMENSIONAL STEADYSTATE FLOWFor most furnace designs, it is usuallyacceptable to assume that all heatentering the hot face of the lining flowsin one direction, perpendicular to itssurface. In order for this assumption tobe valid, the lining must be of uniformthickness and the lining materials mustbe uniform in all directions parallelwith the hot face. Examples of areas ofa vessel in which one-dimensional flowcannot be assumed are corners andregions of transition between materialzones. In the case of a wall zonedvertically, some heat may flow betweenzones, upward or downward, dependingon relative conductivity. In the case ofa corner, heat flows along differentpaths having different lengths; these arecommonly referred to as edge effects.In areas which are well removed fromedge effects, one-dimensional flow maybe assumed.

A widely used method for calculatingone-dimensional steady state heat flowis presented in A.S.T.M. Proposal P142,“Proposed Procedure for CalculatingHeat Losses Through Furnace Walls.”This method uses an interactiveapproach which, for practical reasons,typically requires use of a computer.

When a furnace lining is understeady state (or equilibrium) conditions,the rate of heat flow into the lining is

THERMAL CONDUCTIVITY


The convection mechanism may beeither natural or forced. Naturalconvection occurs when no forced airmotion occurs. In this case, the motionof the air at the outside surface iscaused by differences in density (hot airrises), and the proper equation is:

Qnc

= 0.53C(1/Tavg

)0.18(To-T

a)1.27

whereQ

nc = heat loss by natural

convection, BTU/ft2-hrC = 1.39 for a vertical wall or

1.79 for a crownT

avg = average of outside surface

and surrounding airtemperatures, °R

To = outside surface

temperature, °RT

a = surrounding air

temperature, °R

Forced convection occurs whenforced air moves across the outsidesurface, e.g., wind and fan-blown air.The appropriate equation here is:

Qfc = (1 + 0.225V)(T

o-T

a)

whereQ

fc = heat loss by forced convec-

tion, BTU/ft2-hrV = air speed, ft/secT

o = outside surface temperature,

oFT

a = surrounding air temperature,

oFThe convection equations were

determined empirically and apply onlyfor the units given; heat flux values inmetric units can be obtained bymultiplying Q

nc or Q

fc in BTU/ft2-hr by

3.153 to convert to units of W/m2. Itmust be realized that only one convec-tion equation is applicable to a givencondition.

To find the steady state solution, aset of conditions, including hot facetemperature (T

i), surrounding air

temperature (Ta), and total emissivity of

the outside surface (g), must be given.If forced convection is in effect, the airspeed (V) must also be known. Theapproach is to determine the tempera-ture of the outside surface whichsatisfies the heat balance criterion:

QL = Q

r + Q

nc

orQ

L = Q

r + Q

fc

After the correct outside surfacetemperature is determined, the interfacetemperature between any two liningcomponents may be calculated inaccordance with the following relation:

n

Tn = T

i –Q

L E R

j

j=1

j=1

For the first interface (closest to theinside surface):

T1 = T

i -Q

LR

1

For the second interface:T

2 =T

i-Q

L (R

1 + R

2)

And so on.

Example 1: Estimate the steady stateheat flux and interface temperatures ina furnace wall consisting of 6“ of 60%alumina brick (UFALA®), 2 ½ “ of 2300°F(1260°C) insulating firebrick, and a ¼“steel shell. The inside surface tempera-ture is 2700°F (1482°C), and the sur-rounding air temperature is 70°F (21°C).There is no forced air motion. The totalemissivity of the shell is 0.9.

The first table on the following pageshows the sequence of computercalculations searching for heat balance(i.e., heat in equals heat out). For eachiteration, the thermal resistance value ofeach component was re-evaluated basedon the newly chosen value of theoutside surface (cold face) temperature,since thermal conductivity changes withtemperature. A cold face temperature of402°F (206°C) resulted in heat balancewith a heat flux of 1099 BTU/ hr-ft2 (3465W/m2).

If the material used for a liningcomponent has a thermal conductivitycurve which does not approximate astraight line over the range of thegradient through it, the componentshould be subdivided. Each subcompo-nent is given its own thermal conductiv-ity characteristic which should be moreaccurate, since its temperature gradientis smaller. Subdivision is usually notnecessary, but with the use of a com-puter, it is a good practice sincecalculation time is typically of noconcern.

Example 2: A 6-inch layer of tabularalumina castable has been chosen as aworking lining of a furnace wall. Theengineer must determine the maximumamount of 2200°F (1204°C) lightweightcastable which can be safely used forthe insulating layer. The design criteriaare:

1. Hot face temperature: 2500oF(1370°C)

2. Outside air temperature: 100°F(38°C)

3. No forced air at outside surface4. Emissivity of shell: 0.85

The thickness of the insulatingcomponent was varied from 2 to 5inches in ½ inches increments. Thetemperature at the first interface, theshell temperature, and the heat flux foreach lining thickness are shown in thesecond table on the following page.The 4-inch thickness gave an interfacetemperature of 2196°F (1202°C); this wasessentially equal to the maximum servicetemperature of the lightweight castable,but it is common practice to allow a100°F (38°C) safety factor. Therefore, a2½ to 3inch thickness would be chosen.

Example 3: The shell of the furnacewall described in Example 1 is coatedwith aluminum paint (emissivity =0.30). The computer solution indicatedthat the heat flux would decrease from1099 to 1055 BTU/ft2-hr (3465 to 3326 W/m2) and the shell temperature wouldincrease from 402°F to 547°F (206°C to286°C). By decreasing the emissivity ofthe shell, less heat would be radiated tothe surroundings; and since more heatwould be retained (stored), the shelltemperature would increase.



Heat Balance Calculations

To(oF) R

T(ft2-hr-oF/BTU) Q

L(BTU/ft2-hr) Q

R(BTU/ft2-hr) Q

NC(BTU/ft2-hr)

70 2.062 1275 0 0 170 2.235 1132 123 81 270 2.173 1118 321 193 370 2.137 1090 620 319 470 2.100 1062 1048 453 460 2.064 1085 998 440 450 2.071 1087 950 426 440 2.074 1090 904 412 430 2.078 1093 859 399 420 2.081 1095 816 385 410 2.085 1098 774 372 400 2.089 1101 733 358 401 2.092 1099 737 660 402 2.091 1099 741 361

Determinants of Insulation Thickness

Insulation Interface Shell Heat FluxThickness (in) Temperature (oF) Temperature (oF) (BTU/ft2-hr)

2 1980 460 13102 ½ 2050 428 1130

3 2110 403 9923 ½ 2160 382 886

4 2200 364 8024 ½ 2230 348 732

5 2250 334 674

Example 4: The shell of the furnace wall described in Example 1 is cooled using

forced air; the air speed is constant at10 ft/ sec (3.05m/sec). Here, theconvection mechanism is forced. Thesolution predicts that the heat fluxwould increase from 1099 to 1128 BTU/ft2-hr and the shell temperature woulddecrease from 402oF to 297oF. Theforced air flow would draw heat awayfrom the outside surface at a faster rate;and since less heat would be retained,the shell temperature would decrease.

In Examples 1 through 4, it is assumedthat the walls are flat. Many vesselshave a cylindrical geometry which may

require special treatment because theinside surface area may be significantlyless than the outside surface area. Inthe case of a cylindrical vessel which isheated at the inside surface, heat flowsradially outward, and even under steadystate conditions, the heat flux decreasesas the distance from the inside surfaceincreases.

For this case (Ti > T

o), the equation

for steady state heat flux at the outsidesurface caused by conduction is:

nQ

L = (T

i-T

o)/r

o E (L

j/K

j)(ln (r

jo/r

ji)

j=1

whereQ

L = heat flux at outside surface,

BTU/ft2-hr (W/m2)T

i = temperature of inside

surface, oF (K)T

o = temperature of outside

surface, oF (K)r

o = radius of outside surface,

in (m)r

jo = outside radius of jth

component, in (m)r

ji = inside radius of jth

component, in (m)K

j = thermal conductivity of jth

component, BTU-in/ft2-hr-oF(W/m-K)

lj = thickness of jthcomponent, in (m)

n = number of componentsThe effect of wall curvature is

indicated in the following example:

Example 5: The table below gives theshell temperatures and heat fluxes ofcylindrical walls having different insidediameters but identical linings. Eachwall is heated at the inside surface to2000oF (1093oC) and consists of 6inches of fused silica castable and a ¼inch steel shell. Notice that as theinside diameter grows, the valuesapproach those for a flat wall of thesame construction.

In the sample calculations, valueshaving as many as four significantdigits were used to precisely illustratevarious effects. Realistically, however,no more than three significant digits areappropriate.

Effect of Wall Diameter on Heat Flow

Inside Diameter (ft) Shell Temperature (oF) Heat Flux (BTU/hr-oF)

0.5 435 1240 1.0 471 1450 2.0 500 1630 4.0 519 1760 8.0 531 1850 16.0 538 1900 ∞* 545 1950

* flat wall



OverviewCastables are defined as the large group of refractory concretescontaining a hydraulic setting binder. They are shipped dry anddevelop strength when tempered with water. These instructions coverthe basic principles of castable installations with specific reference tomixing, consistency, placement, forms and curing. Individual productdata sheets and package instructions provide information relevant toeach product.

Conventional CastablesFor mechanical mixing a clean paddle-type mixer is recommended. Addpotable water to material and mixthoroughly to desired castingconsistency. Water contents are listed onproduct data sheets. Dense castablesshould never be mixed for less than 2 to3 minutes. Lightweight castables shouldbe mixed for 2 to 3 minutes. To avoidbreaking down the lightweight aggregatein the mix, do not over mix (i.e., past thepoint where proper casting consistencyis reached). Excessive mixing willgenerate heat, speed up setting time,reduce strength and break down theaggregate.

Castable refractories tend to stiffensomewhat after leaving the mixer.Judgment on whether the mix hasreached proper consistency should bemade at the point of placement.

The “ball-in-hand” test for castinstallations provides a useful guide toproper consistency. Tossed 6 to 12inches, a ball of properly mixed castableshould adapt to the shape of the handwhen it is caught. The ball should notflow through the fingers or break apart.Breaking may indicate insufficient waterin the mix.

Castables should be poured intoforms immediately after they are mixed,particularly when being installed underhigh temperature and/or humidityconditions. In no case should the timebetween mixing and casting exceed 30minutes. Castables containing highpurity calcium-aluminate cementsshould be placed within 15 minutes.

MIXINGAll castable refractories should bemechanically mixed in a paddle mixerof 4 to 12 cubic foot capacity. Thesemixers assure a rapid, thorough mix,discharge the full batch and virtuallyclean themselves from batch to batch.

The mixer must be clean. Somesubstances found in dirty mixerscombine with the cement in castablesand can cause flash setting or otherwiselower the ultimate strength of thecastable. The water used in mixingcastable refractories must be fit to drink.In cold weather, warm water can beused to raise the temperature of the mixto between 60°F and 80°F (16°C and27°C); however, it should never exceed100°F (38°C). In hot weather, the wateror castable should be cooled so that thetemperature does not exceed 80°F(27°C) at the mixer.

To begin a mix, pour one-half tothree-quarters of the total amount ofwater required for a batch into the mixerwith the paddles turning. Add the drycastable in units of full bags.Segregation of castable componentsmay occasionally occur duringtransportation. If a partial bag is to beused, the contents should be carefullydry mixed beforehand. Add the balanceof water required to bring the mix tocasting consistency in small incrementsafter the castable in the mixer comes toa uniform color. Do not use more thanthe recommended amount of water.Decreased castable strength results fromexcess moisture.

Specific mixing instructions followfor Harbison-Walker’s wide range ofcastables.

EXPRESS® Free FlowingCastablesEXPRESS® castables are available inconventional and ultra-low cementformulations. They can be installedusing a wide variety of pouring orpumping systems and require novibration to fill the mold or surroundanchors. EXPRESS® castables allowquick installation into the most intricatelining cavities and molds withoutforming air pockets.

This ball shows too much water in the mix.

A paddle mixer is used for castables.

This ball is too dry for casting.

A properly mixed ball shows the impressionof fingers when tossed 6 to 12 inches in theair and caught.

INSTALLING CASTABLES


This mix is right for vibration casting.

There is not enough water in this batch.

This contains too much water for vibration.

VERSAFLOW® Castables andULTRA-GREEN® Ultra-LowCement CastablesFor mixing EXPRESS® andVERSAFLOW® castables, paddle orturbine mixers are recommended toobtain effective distribution of the lowwater additions for these products.Tempering water should be addedconservatively and mixing continued fora minimum of five minutes. The longermixing time will help distribute the lowwater additions. At one time, only mixan amount that can be cast within 30minutes. Specific water contents arepublished on the castable bag and shouldbe followed. At proper consistency, ahandful of material should begin to leveland consolidate when shaken vigorouslyback and forth. For pump castinstallations with EXPRESS® andVERSAFLOW® castables, a wet “ball-in-hand” consistency is desired. Mixingoften is done in large paddle mixers,continuous mixes and transit trucks.

Guidelines for placing ULTRA-GREEN® ultra-low cement castables aresimilar to those for VERSAFLOW®.Water contents for these products arecritical in order to obtain maximumphysical properties. These materialsshould be placed immediately aftermixing, with extreme care in placementand vibration.

INSTALLATIONTo prevent premature loss of moisturefrom the mix, forms or molds used forcasting refractories must be thoroughlyoiled or greased. The ultimate strengthof the refractory will be reduced bypremature loss of water required forhydration of the cement. Casting shouldbe carried out quickly enough to assurethat the exposed surface of the castabledoes not dry out.

All high strength castables should bevibrated into place, especially coarseaggregate mixes. An immersion vibratorshould be drawn slowly up through thecastable so it does not leave holes orchannels behind. The mix is too stiff ifthe vibrator leaves holes (seeaccompanying photographs). Extended

vibration will segregate components andweaken the castable.

For VERSAFLOW® castables andULTRA-GREEN® ultra-low cementcastables form vibration is the preferredinstallation method. This can beaccomplished with a clamp-on or bolt-on style vibrator. Steel forms arepreferable to wood forms, which tend todampen vibration. When used, woodforming should be treated to preventabsorption of water from the mix and ifthe castable is placed against existingmasonry, the masonry must also bewaterproofed beforehand. Immersionvibration must be used with care toprevent holes being left whenwithdrawing the vibrator from thecastable. Extended vibration willsegregate the components and weakenthe castable.

Generally speaking, constructionjoints will coincide with the expansionjoints shown on the drawings of theinstallation. Whenever possible, analternate bay system should be used inconstruction. This permits initialshrinkage to take place prior toinstallation of the adjacent section, andreduces total linear shrinkage within thelining.

Pumping InstallationsMost conventional castables are nottypically installed using pump castingmethods due to segregation of mixes athigh water contents.

EXPRESS® and VERSAFLOW®

castables can be installed using pumpcasting methods.

For large installations where pumpingthe castable is the desired method ofplacement, tempering water contents inthe upper end of the recommended rangewill be necessary. Large multiple paddlemixers or Redi-Mix trucks have beenused for this type of installation.

IMPORTANT SAFETYNOTESAll persons performing castableinstallations should wear protectivelong-sleeved clothing, gloves and plasticsafety helmets, as well as close-fitting

safety goggles. A respirator mask shouldbe worn over the mouth and nose toprotect the respiratory tract from dust.

CURINGUpon mixing with water, an exothermichydration reaction takes place with thecalcium aluminate cement. Mixing andcasting should always take place inambient temperatures between 60°F and80°F (16°C and 27°C). This is becausethe heat released from the exothermicreaction tends to increase the materialtemperature into the temperature rangefor optimum development of strength.



this takes longer in very cold weather.Curing at low temperatures alsoincreases the risk of steam spallingduring initial heat-up.

STORAGETo obtain maximum storage life forcastable and gun mix refractories, thematerial must be kept completely dry.Castables and gun mixes should bestored away from weather elements,preferably indoors. If stored outside, thebags must be protected from rain ordripping water. If bags are protected byplastic sheeting, be sure there issufficient ventilation under the plasticsheet to prevent water from condensingon the bags. Do not set bags on dampground or concrete, and avoid storing inareas of high humidity.

All Harbison-Walker castables andgun mixes have a finite shelf life. Anycastable or gun mix will eventuallybecome unsuitable for use, even undergood storage conditions. Typically,storage life for conventional castablesand gun mixes is one year from date ofmanufacture. Harbison-Walker castablesare stamped with a code date whenmanufactured to aid in determining theage of the material. This also aids inrotating inventory to use the oldest codedated materials first. New products andlow cement castables may have shortershelf lives. Consult Harbison-Walker forthe current shelf life of these materials.

HEAT-UPSee Heat-Up information on page UR-14

The heat released during thehydration reaction may partially dry outthe refractory surface. Loss of waterfrom the surface before the cement isfully hydrated promotes dusting whenthe furnace is heated. The preferred andcommon method to prevent surfacemoisture loss is to spray a generouscoating of resin-based concrete curingcompound onto the surface. The curingcompound will form an impermeablemembrane or vapor barrier duringcuring, but will burn off at relatively lowtemperatures.

After the initial 24-hour air cure andunder ideal conditions, the refractorymay be air dried indefinitely before heatis applied.

Curing TemperaturesLess Than 70°F (21°C)As with all chemical reactions, thecement hydration reaction is time-temperature dependent. The lower theatmospheric temperatures, the slower thehydration reaction therefore, increasedcuring time is required.

In cold weather, i.e., less than 50°F(10°C), the cement-containing monolithshould be mixed and installed within thetemperature range of 50°F to 80°F (10°Cto 27°C). The temperature in the areawhere the castable is being installedshould also fall within this range. Spaceheaters can be used to accomplish this.Temporary exterior shell insulation canbe used to retain heat on the steel shellgenerated by the heat of hydration.

If the unit is to be idle for longperiods in very cold weather, the liningshould be heated to at least 250°F to300°F (121°C to 149°C). Thistemperature range is sufficient to driveoff excess casting water and prevent icecrystal formation within the refractory.In long periods of cold weather,releasing steam into the unit is an idealway to heat the lining.

Refractory damage will occur if thecement freezes before it has developedfull strength. Seventy to eighty percentof the cement’s strength should bedeveloped after the 24-hour cure, but



PredampeningProper predampening is required tocontrol hose flow and limit rebounds anddust at the point of application. Fordense gunning mixes, pre-dampeningwith 4% to 6% by weight of water in apaddle or similar mixer is typical.Lightweight and medium-weightgunning mixes could require 10% to15% or more by weight of water.Material consistency should allow ahandful of the gun mix to be squeezedinto a column which, when tapped,breaks into pieces. For KAST-O-LITE®

Gun Mixes pre-dampening to highmoisture levels is the key to successfulinstallation. Refer to specific productdata sheets for recommended levels.

Air Pressures and MaterialFeedHarbison-Walker gun mixes require highair pressures and high material feed ratesfor optimum installation. A 600 CFM,100 psi air compressor is suggested forsingle gun operation. Largercompressors are recommended whenseveral guns are used concurrently.

High air pressures and material feedrates speed the gun mix through thenozzle water ring. This tends to widenthe water range because the morematerial that passes the water ring pergiven amount of time the less sensitivethe material is to slight changes in theamount of water added. High pressuresalso help reduce laminations within therefractory mass.

Equipment PreparationsPrior to start-up, check to insure that thehoses are laid with no loops to preventplugging. The water ring and nozzleliner must be clean and in goodcondition. There should be plenty of airfor sufficient material flow and at least80 psi water via a 3/4-inch diameterhose. If one of these variables is belowpar it can adversely affect the flowemerging from the gun and ruin thequality of the job. Water booster pumpscan help achieve up to 150 psi waterpressure and should be used with H-Wgun mixes.

Controlling the FlowWhen gunning starts, the nozzleoperator and gun operator areteammates. Together, by means of handsignals or radio, they control air andwater pressures and material feed ratesso that proper flow occurs and thecorrect consistency of material emergesfrom the nozzle.

OverviewHarbison-Walker Gun Mixes are specifically designed to provide the highestquality gunned linings at the lowest possible installed cost. The installationprocedures review the steps to control predampening, air pressure, materialfeed, nozzle water and flow technique. Following the installation steps asoutlined is most important to assure the quality of Harbison-Walker’s GunMixes.

INSTALLING GUN MIXES

Nozzle Water ControlThe appearance of the gunned refractorysurface is the best indicator of thecorrect water/mix ratio. The amount ofwater should be controlled so that agunned surface has a wet, silky sheenand the coarse aggregate makes craterson the surface upon impact. A sandy,gritty surface indicates too little water isbeing used. Slumping, ripples or awashboard effect on the surfaceindicates too much water is being used.

Harbison-Walker’s Gunning Mixeswere designed to have a wider waterrange and therefore less sensitivity to theamount of water added. Gunningmaterials have optimum adhesion in the“sticky” material condition. In Figure 1,it is clear that the water adjustmentrange is much wider for optimumadhesive quality. Water control is not ascritical and product slumping anddusting is minimized. With old style gunmixes (castables shot through a gun), theproper sticky consistency range is verynarrow.

Figure 1

Old-StyleGun Mixes H-W Gun Mixes Water Addition

Wide WaterAdjustment Range

Castable

Sticky

Damp

Dusty

Mat

eria

l Con

sist

ency


Aiming the NozzleOnce proper flow is achieved, the nozzleoperator should direct the stream ofmaterial at the base of the wall andproceed to build upward. The nozzleshould be kept perpendicular to andabout three to four feet from the surfaceof the work. Material is deposited as thenozzle is moved rhythmically in a seriesof oval loops six to nine inches high and18 to 24 inches wide. See Illustration 1.

Be careful that rebounds fall orbounce clear of the target and are notentrapped. Entrapment of rebounds bythe fresh stream from the nozzle can leadto laminations or spots of low density inthe lining.

Installing Medium-weight andLightweight Gunning MixesA quality medium-weight or lightweightinstallation depends at least as much onthe gunning technique as on thecharacteristics of the gun mix. Withtraditional techniques, higher thanspecified densities and relatively highrebounds are expected. High predampand high gun pressure reverse the rules,reducing rebounds and significantlylowering the density of the installation.At the same time, these techniques canalso increase production rates.

Harbison-Walker recommends the useof high predampening and high pressurematerial feed rates. Maintain the nozzle-to-surface distance of three to four feet.Following these procedures willsignificantly cut rebounds, lam-inationsand density, as well as material, laborand installation costs, while increasingthe insulating value of the lining.

HEAT-UPSee Heat-Up information on page UR-14

Illustration 1Direct nozzle spray to form loops.

General GunningPreparationsMost of the water is added at the nozzleduring placement. Typically, most gunmixes should be predampened beforegunning. This makes flow through thenozzle easier and traps cement thatmight dust off at the nozzle.

During actual gunning, the nozzleshould be pointed at an angle 90 degreesto the surface, and work should begin atthe lowest point of the installation.Corners should be shot first in order toprevent trapping rebounds. Limit thework to an area which can be kept moist.

Gunning to repair existing liningsprovides somewhat better adhesion thancasting, especially for irregular patches.Anchors should be welded on the shellin the appropriate anchor patternspacing. The edges should be square andthe patch area clean. For better adhesion,the existing refractory should be wettedimmediately before placement.Following standard procedures, the newmaterial can be gunned into place.

INSTALLING GUN MIXES


DRYING AND HEAT UP OF CASTABLES AND GUN MIXES

HEAT-UP

After curing for a minimum of 24 hours,castable and gun mix linings mustnormally undergo a controlled heat-upschedule to remove the moisture. This isespecially true for those containing highstrength, high purity binders.

Heat will remove the free water assteam at around 212°F (100°C), whilethe water of hydration will be driven offbetween 400°F (204°C) and 1200°F(649°C). With increasing temperature,sintering takes place between the cementand the refractory aggregate in the1,600°F to 2500°F (871°C to 1371°C)range (depending on the aggregate andbinder).

Initial firing rates typically raise thetemperature at about 50°F (28°C) perhour. For high strength, high puritycement binders, the rate is 30°F (17°C)per hour. Normally, holds areincorporated at 250°F (121°C), 500°F(260°C) and 1000°F (538°C). The timeperiod for the temperature hold is

dependent on refractory thickness.Thicker linings contain a larger volumeof material and thus, a larger volume ofwater. Steam dissipation should beslower for thicker linings to preventsteam spalling. As a rule of thumb todetermine the time period, use one hourper inch of thickness for dense linings.The hold period helps dissipate steamand allows heat to penetrate the lining(this avoids a steep thermal gradientwith increasing temperature). Steepthermal gradients can cause stresseswithin the lining and spalling. If, at anypoint during the heat-up, steaming isnoticed, the temperature should be helduntil steaming subsides. Direct flameimpingement on the refractory should beavoided.

Because each installation is unique,no one dry-out schedule can be advisedto fit all uses. Consult your installationrepresentative for specific guidance.

CAUTION:

IF PROPER PROCEDURES FOR PREPARATION, APPLICATION AND HEAT-UP OFCASTABLES ARE NOT OBSERVED SPALLING DURING HEAT-UP MAY OCCUR.SEE INSTRUCTIONS ON PRODUCT PACKAGE.

THE TEMPERATURES REFERRED TO IN SCHEDULES ARE THE TEMPERATURES OF THEHOT GASES IN CONTACT WITH THE CASTABLE OR GUN MIX AND NOT THE LINING IT-SELF. THERMOCOUPLES MAY BE PLACED ½” AWAY FROM THE LINING SURFACE FORAN ACCURATE MEASURE OF TEMPERATURE DURING HEAT-UP.

IF AT ANY TIME DURING THE HEAT-UP OR HOLD TIME, STEAMING OF THE LINING ISOBSERVED, THE HOLD PERIOD SHOULD BE MAINTAINED UNTIL STEAMING SUBSIDES.INCREASED HEATING DURING STEAMING CAN RESULT IN SIGNIFICANT STEAM PRES-SURE BUILD UP AND POSSIBLE STEAM SPALLING.

PROPER VENTILATION AND AIR CIRCULATION WITHIN THE FURNACE MUST BE PRO-VIDED FOR THE REMOVAL OF STEAM AND EXHAUST GASES. FLAME IMPINGEMENT ONTHE REFRACTORY MUST BE AVOIDED. THIS WILL CAUSE LOCALIZED OVERHEATINGAND POSSIBLE SPALLING.

For the proper schedulefor specific products, usethis link to the Mixing andUse section of our website. www.hwr.com

http://www.hwr.com/ourproducts/mixing.asp


INSTALLING RAMMED AND GUNNED PLASTICS

OverviewH-W manufactures plastics for both rammed and gunnedinstallations. Here are some basic guidelines for the properinstallation of each.

massive installations, it may be desirableto cut “construction joints” in therefractory hot face. These joints shouldbe scored approximately2 inches deep on 36-inch centers,horizontally and vertically betweenanchors. After scoring the joints with atrowel, they should be patted shut sothat only a thin line remains on thesurface of the hot face.

Roof Finishing. Overhead installationof plastics, particularly phosphate-bondedtypes, requires special attention.Generally, they require support forms toprevent slumping during installation.After ramming, these forms need to beprogressively removed and replacedwith expanded metal since the ignitionof wood forms during heat-up can causespalling of the refractory surface. As anintermediate step, the plastic adjacent toanchors should be lightly rammed upand around the anchors to give a tighterseal. This technique is called peening.

Venting

Immediately after finishing is complete,pierce the finished plastic with a 1/8 or3/16-inch diameter rod to provide escapevents for steam which develops duringheat-up. These steam vents should beinstalled on 8 or 12-inch centers andshould penetrate to about two-thirds ofthe refractory lining thickness.

For special conditions such as verythick walls, please contact Harbison-Walker's Technical Support Group inPittsburgh, Pennsylvania for installationguidelines.

RAMMED PLASTICSProcedure

A pneumatic ramming tool witha minimum 21/2 – 3-inch convex alumi-num head is strongly recommended forpositive knitting of plastic refractoryslabs. When ramming plastics, the bestknitting is accomplished by breaking theslabs into smaller pieces. The directionof the rammer should always be parallelto the hot face of the material and vesselwalls, roof or floor. The entire massshould be rammed thoroughly two orthree times to secure its integrity. Thebest anchor system to use with rammedplastics are ceramic anchors. Whenseating anchors into the plastic, tapthem into the mass with a leather malletto be certain that they set properly andthat there are no voids around them.When ramming around burner ports orrefractory anchors, slabs of plastic mustbe broken up to facilitate installationin these tight areas.

As installation progresses, theramming force should be directed intothe main refractory mass in a mannerthat forces the plastic to seal against theanchors or ports. A lining thicknessoverage of 1/8 – 1/4-inch of plastic shouldbe installed, so that when forms arestripped and the surface of the hot faceis finished, the refractory mass willretain its full specified thickness. Whenramming next to forms, ram the 3-incharea adjacent to the form one extra timeto minimize laminations.

Peening. Plastic adjacent to anchors shouldbe lightly rammed up and around theanchors to give a tighter seal.

Wall Finishing. After ramming iscompleted, the hot face of the plasticmust be trimmed (or shaved) back to theface of the refractory anchors, using atrowel or trimming spade. Care shouldbe taken not to peel the plastic awayfrom the anchor. Shave toward theanchor to press the plastic tight againstthe anchor. If forms were needed, onlystrip as much as can be finished in ashort time, e.g., two or three hours. Thiswill save material and make a betterinstallation.

During trimming, special care must betaken not to smooth the exposed surfaceof the refractory hot face; a coarsesurface is necessary for uniform drying.To minimize and control cracking on all



Patching with Plastics

Refractory plastics provide a simple wayto repair almost any worn brick, castable,or plastic refractory structure. Strong,phosphate-bonded plastics are espe-cially suited for repairs. To make alasting repair patch, chip back the wornrefractory area until a sound,unpenetrated and unaltered surface isexposed. Loose particles must beremoved and, for best results, the voidshould have steeply angled sides toprovide a grip for the repair patch. Inany but the smallest patches, it isadvisable to cut away the worn refrac-tory in a V-shape toward the cold face.This helps tie in the patch with therefractory mass. When using phosphate-bonded plastics, a thin coatof PHOXBOND® high-alumina phos-phate-bonded mortar shouldbe applied to the entire void afterthe surface is prepared. Trim off anyexcess plastic in the patch so that itssurface is flush with the hot face.Roughen the surface of the patchto facilitate moisture removal. The patchwill develop a phosphate bond atapproximately 500°F (260°C) duringheat-up and will become extremelystrong and resistant to penetration anderosion.

Gunning Advantages

GREENGUN® Plastic Gunning Tech-nology was developed in 1986 inresponse to refractory contractors whowere looking for a more efficient andfaster method to install plastic refrac-tory. The best anchor system to usewith gunned plastics are ceramicanchors. The installation time ofGREENGUN® can be as much as 50%less than the installation time of airrammed plastic. Today, H-W’sGREENGUN® Plastics are widelyaccepted throughout the refractorymarket place.

Installation

Equipment. The key to a successfulinstallation is the GREENGUN® BSMGun, Model GL 404-50, with a 15pocket feed wheel.

Other required key hardwareincludes:• 13/8" ID, high pressure, BSM

material hose, which is availablein 33' lengths.

• a 440 volt, 3 phase, electric powersource required to operate theBSM Gun.

• a 750 CFM air compressor neededto transport the gunned materialthrough the hoses.Common job tools needed for

installation are a fork lift, two wayradios, shovels, trimming tools, face

shields and hard hats, plus extra wearpads and drive belts.

Harbison-Walker is the exclusivedistributor for the BSM Gun in theUnited States and the gun is available torent or purchase.

Procedure. The typical crew size on anyGREENGUN® project is 4 to 6 people.The crew includes: one BSM Gunoperator, one nozzle man, two materialhandlers, and for larger jobs, twotrimmers and rebound reclaimers.

The installation process is verysimple. The GREENGUN® bulkcontainers are placed above the BSMGun. Next, the GREENGUN® carton iscut into a “V” shaped opening. Then thematerial is raked into the feed hopper ofthe BSM Gun. The GREENGUN®

material falls into the feed wheelpockets. Air pressure transfers thematerial into the hose and is then appliedto the refractory surface.

GREENGUN® Plastics gunningrebound can be recycled. For estimatingpurposes, typical rebound rates withGREENGUN® are 15-20%.

Here you can see the BSM Gun,the “V” Shaped opening in thebulk carton, and the GREENGUN®

plastic being raked into the hopper.

GUNNED PLASTICS



PACKAGINGHarbison-Walker packages rammedplastic refractories in 55-lb (25 kg) or100-lb (44 kg) cartons. The refractorymass is divided into four to six slabs, ormore, depending on product or cus-tomer preference. Plastics are made tospecified workability and moisturelevels. Harbison-Walker will manufac-ture to individual customer requirementsas needed. This can be important whenthick walls, overhead installation, orimmediate installation is anticipated.Please discuss your special workabilityneeds with your H-W representative.Plastic is sealed in polyethylene tominimize moisture loss and preserve theplastic's workability.

Gunned plastics are packaged in 1500,2500, and 3000-lb. bulk containers.Storage

HEAT-UP

It is necessary to begin heat-up as soonas possible after completion of thestructure. If this cannot be done, allrefractory surfaces should be coveredwith a resin-based curing compound toslow drying and reduce shrinkagecracks. The use of a colored curingcompound is helpful when performing avisual inspection of surface coverage.Shrinkage cracks should be resprayedwith curing compound to keep themfrom getting larger, although theynormally close during heat-up. Ifdesired, cracks can be sealed with aslurry of PHOXBOND® mortar. (Do notuse an air-setting mortar.) Removeforms; do not permit wood forms to burnout. If forms cannot be removed, thenexpanded metal forms are often a betterchoice because they allow the heat topenetrate the plastic better.

Schedule I:

Heat-Setting and Air-Setting Plastics1. From ambient temperature, heat to

500°F (260°C) at the hot face of thelining at a rate not exceeding 50°F(10°C) per hour.

2. Hold at 500°F (260°C) for one hourper inch plastic thickness.

3. Heat to 1000°F (538°C) at a rate of50°F–75°F (10°C–24°C) per hour.

4. Hold at 1000°F (538°C) for onehour per inch plastic thickness.

5. Heat to operating temperature ata rate not exceeding 100°F (38°C)per hour.

6. Hold for steaming (see note).

PLUS® DESIGNATIONPlastics that include the word PLUS® inthe product name contain non-metallicfiber additions to facilitate moistureremoval during the dry-out. Theseplastics have passed a very severespalling test indicating that underspecific conditions they can be heatedmore quickly. For specific heat-uprequirements, contact your Harbison-Walker Sales Representative.

Note: If steaming of the lining is evident at anytime during heat-up, hold the temperature untilsteaming subsides.

STORAGEEven though Harbison-Walker plasticrefractories are carefully packaged toretain moisture, dry-out is possible ifplastics are stored too long, especiallyin warm places. Unopened packages ofplastic materials should be stored incool, shaded areas under roof and awayfrom sources of heat. The optimumtemperature for storage of plasticsis 55-60°F (13-16°C) . If plastics must bestored outdoors, the packages shouldbe covered with a tarpaulin or similarcovering. In hot outdoor areas, the tarpor covering should be raised to providean 8–12 inch space for air circulation. Inwinter, plastics should be preventedfrom freezing. As a rule of thumb, useplastics as soon after receipt as possible,on a first-in, first-out basis. Check allplastic carefully before use. Duringinstallation, unwrap only as muchplastic as is immediately needed. Pre-opened plastic may lose moisture andworkability, resulting in improperknitting of slabs and a less thansatisfactory installation.

WINTERIZINGFor heat-set and air-set plastics,Harbison-Walker offers a winterizedversion. This lowers the freezing pointto below 15°F (-9°C) and permitsstorage of the products at lowertemperatures. The winterizing processhas no effect on refractory properties.Phosphate-bonded plastics already havea similar freezing point and do notrequire winterizing. All plastic materi-als, even those winterized, should bekept above freezing before installationand, equally important, after installationuntil heat-up.

Schedule II:

Phosphate-Bonded Plastics

1. From ambient temperature, heat at arate not exceeding 50°F (10°C) perhour to 250°F (121°C) at the hot faceof the lining.


3. Heat to 500°F (260°C) at a rate of50°F (10°C) per hour.


5. Heat to 1000°F (538°C) at a rate of50°F–75°F (10°C–24°C) per hour.


7. Heat to operating temperature ata rate not exceeding 100°F (38°C)per hour.

8. Hold for steaming (see note).


OverviewRigid forms are required when ramming vertical walls, roofs, or arches and care mustbe taken to prevent deflection of the forms during the ramming operation. Ram at themost acute angle possible to the hot face.

RAMMINGAn anvil-type or reciprocating airrammer having a metal ramming headshould be used to install Harbison-Walker ramming mixes. Metal rammingheads are of various shapes and sizes.The type of installation involveddetermines which is appropriate.Serrated ramming heads have been usedfor some installations.

Continuous feeding of the mix duringramming is preferable to batch feeding.When batch feeding the material, thesmooth surface formed by the rammershould be roughened with a small trowelor small rake to eliminate laminationsand provide a continuous bond frombatch to batch. Score each layer toapproximately ¼-inch depth to assureknitting of the subsequent layer. Theblows of the rammer should be directedin such a manner that lamination planesare not parallel to the hot face of theramming mix.

Proper installation of Harbison-Walker ramming mixes will provide adense, lamination-free structure. A good

INSTALLING RAMMING MIXES

indication that the material has beenrammed sufficiently, is when the rammerhead leaves noticeable tracks in the topface of the layer. The surface shouldthen be scored and additional materialrammed. The installation should befinished in one continuous operation, ifpossible. If it is necessary to interruptthe ramming operation for more thanone hour, cover the unfinished area witha damp cloth so that the face will remainmoist and new material will bond to itproperly.

HEAT-UPBring temperature up slowly, at a rate ofno more than 75oF (40oC) per hour andhold at 500oF (260oC) for at least onehour for every inch of thickness.Temperatures then can be increased at arate of no more than 100oF (55oC) perhour until operating temperatures arereached.

Installing ramming mix in top cap of coreless induction furnace.


OverviewSound furnace refractory lining and construction — whether carried out byexperienced masonry specialists working on a high production furnace or a contractorbuilding a municipal incinerator — begins with a few fundamental ideas required toproduce satisfactory performance.

FURNACE REFRACTORY LINING & CONSTRUCTION

FOUNDATIONThe foundation must function at thetemperature produced by the furnace.For many industrial furnaces, contrac-tors build foundations of concrete,consisting of a crushed stone aggregate,sand and binder of hydrated Portlandcement. Under normal conditions,Portland cement concrete has beensafely used for furnace foundations upto 700°F (371°C). When the tempera-ture reaches 900°F (483°C), dehydrationof the cement reaches a point where theconcrete retains little mechanicalstrength.

Ordinary aggregates include quartzpebbles, silica gravel, crushed silicarock and/or crushed limestone. Anaggregate of silica rock in any form willexpand sufficiently at temperatures upto 1000°F (538°C) to set up stresses inthe concrete and weaken the foundation.Limestone or dolomite rock in anaggregate will calcine at somewhathigher temperatures and weakenconsiderably. For temperatures above700°F (371°C), good practice points tothe choice of a castable refractory forthe foundation. Calcined fireclay, insizes up to 1 inch, can be substituted forconventional aggregate. Its thermalexpansion is low, and it will not shrinkat the highest temperature to whichconcrete can be subjected.

High temperature furnace operationalso calls for ventilation in the lowercourses of brickwork or the upper partof the foundation. Good furnace designoften requires placement of the furnaceon plates, girders or low brick piers, sothat air circulates under the vessel.Sometimes, cross flues are formed in thetop of the concrete foundation. Atothers, pipes, 3 inches in diameter orlarger, are embedded in the foundation.

Building furnaces is a specializedbranch of masonry, best placed in the

hands of bricklayers experienced infurnace construction. Walls, arches andother furnace details should be de-signed and constructed to assurestructural stability. Otherwise, a returnon your refractory investment may notbe realized.

WALL CONSTRUCTIONCourses of brick laid in a wall so thatthe lengths parallel the face of the wallare called stretchers. Brick with lengthsrunning at right angles to the face areheaders. In soldier courses, the brickstand on end, and in row-lock courses,they lie on one edge (See illustration, UR -20).

Header courses tend to spall less thanstretchers at the hot face of a furnacewall because they expose a smaller areato high temperature. However, stretchercourses expose fewer joints thanheaders, and this provides an advantagein applications where joints tend towear more rapidly than brick.

Bonding, or tightening constructionthrough combinations of headers andstretchers and off-setting vertical joints,strengthens and stabilizes furnacewalls. The type of bond selected for anyparticular furnace will depend upon thedesign of the furnace, thickness of thewalls, the need for gas-tight construc-tion, severity of operating conditionsand the need for easy maintenance.

In any case, the wall should bebonded so that loads will be transferredto the cooler part of the wall when theinner, hotter portion loses its ability tocarry them. Walls must be designed tocarry structural loads at high tempera-tures.

Stretcher walls — one brickthick — usually have the least struc-tural stability, but they are sometimes

used in smaller furnaces and in furnaceswhere heat must pass through the walls.Double tongue and groove brick providestability for thin walls.

Alternate header and stretcher coursesprobably provide the most commonarrangement for standard industrialfurnaces. Large 9-inch brick breakjoints, start ends of walls and turncorners.

Courses consisting mostly of headersare often used advantageously in 9 and13½-inch walls subject to high tempera-tures, heavy loads and slag attack. Thisconstruction is usually preferred forbasic brick walls. The bond providesstability and easy replacement, but mostexpansion joints pass entirely through 9-inch walls.

Courses consisting mainly or entirelyof headers on the inner face and mainlystretchers on the cold face are some-times considered desirable whenspalling conditions are severe. Three orfour stretcher courses to one headerprovide a wall to which a 4½-inch skinwall can be tied for repairs. However, itshould not be used where stretchercourses may fall into the furnace.

In composite wall constructionconsisting of two or more kinds of brickin inner and outer courses, the coursesare sometimes tied together. Usually, themore refractory brick go into theinterlocking courses.

However, when brick have markeddifferences in rates of thermal expan-sion, the backup courses should not betied to the inner courses. This isespecially true when the temperaturegradient through the wall makes asignificant difference in total expansion.

The number of refractory straightsrequired to build a simple wall can bedetermined from the chart on UR - 21.Multiply brick per square foot from theappropriate row, depending on wallthickness, by the area of the wall toprovide the brick count. For walls not ofsimple rectangular shapes, determine thevolume in cubic feet from the appropri-ate formula on this page and multiply bythe number of brick per cubic foot.

Wall thickness must bear somerelation to height and unsupported


Wall 9 inches thick

Wall 13½ inches thick


Wall 18 inches thick


Wall 18 inches thick



Alternate header andstretcher courses


Three header courses toone stretcher course onexposed or hot face


Three stretcher courses to oneheader course on exposed or hot face

Only header course on hot face

Mainly stretcher course on cold face

Only header course on hot face

Alternate header andstretcher course on cold face

Five header courses to onestretcher course on hot face

Only stretcher course on cold face

Back-up bricknot tied to inner courses

BONDING OF WALLS BUILT WITH RECTANGULAR BRICK



length. In unsupported straight walls, a4½-inch thickness will carry heights upto 3 feet; 9 inches will carry heights of 3to 8 feet; 13½ inches, 8 to 12 feet; and 18inches, walls higher than 12 feet.

Walls with unsupported length morethan one and one half times their heightsshould be somewhat thicker, and thermalspalling conditions may indicate addi-tional thickness. Walls of cylindricalfurnaces and stacks, with adequatebacking, may be somewhat thinner for agiven height than straight walls.

Cylindrical walls, arches and domesare built with brick tapered to turncircles. Arch brick slope from edge toedge so that the length of the brickparallels the furnace wall like a stretcher,while the wedge tapers from end to endso that it faces into the furnace like aheader. A 9 x 4½ x 2½-inch arch brickmakes a 4½-inch lining, while the samewedge shape makes a 9-inch lining. Inbasic brick, key brick shapes may alsotaper along the edges. Combinations ofthese shapes taper in two dimensions toturn domes.

JOINT CONSIDERATIONSIn many cases, brick sizes and shapes orthe type of bond will be chosen tominimize the number of joints in thelining. Monoliths — not withoutconstruction or thermal expansion joints– present the fewest joints and opportuni-ties for penetration by metal, slag orfurnace gases.

Ramming mixes or castable refractorymaterials are often used to fill placeswhere brick would be cut to fit. Forexample, ramming mixes or dry refrac-tory materials can be used to protect thetoe of the skewback (See discussion ofArch Construction, UR - 22). On manyinstallations, the irregular space betweenelectric furnace roof brick and electrodeports is filled with ramming mix orcastable refractories.

The thickness of joints betweenrefractory brick depends on the brick, themortar, the need for preventing gasleakage or slag penetration, and the

requirements for thermal expansion.When there is no need for an especiallystrong bond, the brick are laid withoutmortar. In some cases, the fusion thattakes place on the hot face will providethe bond required. Generally, however,the use of mortar is desirable to levelcourses and to provide smooth beddingfor the brick.

Brickwork laid with heat-settingmortars should have thin joints, eitherdipped or poured. The brick should berubbed or tapped into place to produce asmuch brick-to-brick contact as possible.Joints made with an air-setting mortargenerally can be somewhat thicker, butsuch joints should be completely filled.

In furnace construction, properallowance must be made for thermalexpansion. Usually, vertical expansionallowances permit walls to move freelyupward and horizontal expansionallowances appear at joints in the brick.The subject is covered in some detail inthe discussion of thermal expansionwhich begins on UR-4.

HEARTHSThe construction of furnace hearthspresents special problems. Some furnacebottoms must withstand impact andabrasion from a charge of scrap metal.Liquid pressure may tend to float brick.Many hearths must resist penetration bymetal or slag accompanied by corrosionor erosion.

Furnace hearths, in many cases, arebuilt of refractory brick, usually seatedon a monolithic refractory bed. Othershave sub-bottoms built of brick withworking hearths composed of monolithicrefractories, such as dead-burnedmagnesite or a ramming mix.

Construction details, as well as therefractories themselves, depend onapplications. Even different furnaceswithin the same application area mayperform more efficiently with a differentrefractory design.

Sophisticated applications for refracto-ries call for specialists in refractoriesdesign. A number of engineering firms

specialize in high temperature processdesign, and many contractor/installerorganizations concentrate on refractoryconstruction.

Harbison-Walker maintains closecontact with these organizations, lendingits engineering skills and applicationsknow-how to the search for solutions toany problem involving the use ofrefractories.

Number of Refractory StraightsRequired Per Square Foot of Wall

or FloorThickness, 9 x 4½ x 3” Brick

Inches3 3.6

4½ 5.36 7.2

7½ 8.99 10.712 14.2

13½ 16.018 21.427 32.1

Rammed plastic refractories used forarch construction minimize thenumber of joints.



ARCH CONSTRUCTION

OverviewArches form the roofs of most furnaces, combustion chambers andflues. Providing the standard solution to the problem of spanning thehigh temperature process with refractories. In some application, archesspan wall openings, and sometimes they carry the weight of walls orcheckerwork. Most arches are built of brick, but monolithic materialsare gaining popularity throughout the industry.

TYPES OF ARCHES

Sprung ArchesIn a true arch, the design of the wholedetermines the shape of each block orstructural unit. Theoretically, each jointis a small piece of the radius of the circleof which the arch is a segment. Each endof the arch rests on a skewback. Thearch becomes self-supporting after all ofthe pieces go into place, but it must besupported until the final, center shapesthe keys go into place. When it iscomplete, the arch springs from thesloping faces of the skewback shapes.The skewbacks cut off the arc of thecircle on the outside radii of the arc.

The sprung arch exerts a downwardvertical force and an outward horizontalforce on the skewbacks, essentially adistribution of its weight. The verticalforce may be carried by steel beams orby the furnace walls or a combination ofwalls and steel buttresses. Thehorizontal thrust of a roof arch travelsthrough the skewbacks to a steelsupporting system known as the bindingwhich is composed of beams and tierods. The tie rods, usually above thefurnace, link one side of the furnace tothe other, and balance opposing forces,one against the other.

In traditional furnace design, thebinding consists of:1. Horizontal buttress beams

running lengthwise to the furnacein contact with the skewbackswhere possible;

2. Vertical beams, or backstays,spaced at intervals along theconcrete; and

3. Horizontal tie rods, I-beams, orchannels extending across thefurnace above the roof to connectthe upper ends of oppositebuckstays.

Ring ArchesIn ring arches, each course of brickforms a separate ring running across theroof and the joints are continuous acrossthe roof. Ring arches require somewhatless labor for initial construction. Coldrepairs are easier to make and they offerbetter resistance to spalling. However,ring arches require support at the end ofthe furnace to forestall outwarddisplacement.

In bonded construction, all joints arebroken and the rings help bond oneanother in a stronger construction.Bonded roofs are better adapted for hotrepairs but they demand more skill ofthe brick masons and more uniformity inthe brick.

Sometimes, furnace designersstrengthen ring arch roofs by using alonger brick in every third or fourthring. This construction creates ribsacross the roof, which remain strongwhen the thinner parts of the roof wearaway. The strength of the ribs also helpswhen roofs must be patched.

Suspended ArchesIn suspended arches, a steel super-structure helps carry the weight of theroof, otherwise distributed through the

arch to the walls and binding.Suspended arches are often used withdense, heavy basic brick. Harbison-Walker has basic brick brands to providea method for attaching the brick to anoverhead steel superstructure.

In suspended construction,refractories carry smaller loads andtherefore, suffer less deformation at hightemperatures than they otherwise might.Using suspended construction, it is alsoeasier to make allowance for thermalexpansion to avoid thermal stresses andpinch spalling.

Monolithic ArchesMonolithic arches–cast over forms muchlike those required for brick arches–havereplaced brick in some applications.Skews may be eliminated in monolithicarches, but design considerations remainthe same as those for brick arches. Amonolithic arch provides all of theadvantages monolithic construction,including reduced cost and downtime.

ARCH GEOMETRYArch geometry determines all designcharacteristics. From the viewpoint ofarch design, the outside and inside arcs,or surfaces of the roof, are segments ofconcentric circles separated by thethickness of the roof. The skewbackslope cuts the arc, and its angular valueequals half the included central angle ofthe arch. The rise of the arch measuresthe distance from the inner chord - equalto the span and cutting the inside arc tothe center of the roof at midspan.

Hypothetical position of thurst in a simple sprung arch, when the bricks are in full contact at joints.

2

H

-F

F-H

-F

F

T

h

r

2S

W2

W2

CENTER OF GRAVITYLINE OF THRUST

CENTER OF PRESSURE


ARCH CONSTRUCTION

Ribbed arch roof

Ring arch roof

Bonded arch roof

Typical castableconstructionfor sprung arch


ARCH CONSTRUCTION

When span, thickness and rise areestablished, all other dimensions can becalculated using the formulas in thissection.

The stability of any arch will dependon its rise, thickness and weight, as wellas the thermal properties of therefractories. Hot strength and thermalexpansion are particularly important.Good arch design must take these factorsinto consideration.

Rise is normally expressed in inchesper foot of span, or in terms of thecentral angle. They are directly related.It should be easy to visualize a larger

for higher values. Silica roofs made withbrick that maintain dimensional stabilityand hot strength almost to their meltingpoint, normally rise from one to twoinches per foot.

High-alumina refractories used in archconstruction call for at least 1.608 inchper rise per foot of span. Basicrefractories need 21/4 to three inches ofrise in sprung arches. Insulatingfirebrick, which give up hot strength inexchange for low thermal conductivity,call for two to three inches of rise perfoot of span.

For many applications, a 1.608 inchrise, about 15/8-inch, is a logical standardin that it meets normal requirements forstrength and stability. The 60° centralangle equals one sixth of a circle and thespan equals the inside radius, so thenumber of brick required to build theroof is easy to calculate.

The reaction of refractory brick tofurnace operation, i.e., heat-up,establishes the practical limit for roofrise. Operation and thermal expansiontend to push the brick upward, openingjoints at the top and pinching brick at thebottom. Brick that soften at operatingtemperatures may become permanentlydeformed, shortening the radius of thearc and increasing the rise.

As the arch rises on heat-up, the lineof thrust, the line of force along whichthe arch distributes the vertical andhorizontal elements of its weight, shiftsdownward. As the line of thrustapproaches a horizontal position in thearch, the horizontal force approaches itsmaximum value.

In some furnaces allowance forthermal expansion of the brick will limitupward movement of the arch. Steelcasings can provide an allowance forexpansion. Paperboard placed betweenbrick will burn out and make room forexpansion. In some cases, horizontal tierods arc spring loaded or manuallyadjusted to permit thermal expansion ofthe refractories.

Without adequate provision forthermal expansion, the relationshipbetween arch thickness and rise* of thecold arch must be such that the line ofthrust does not drop out of the arch

angle including a higher rise and ashorter radius. On the other hand, theflatter roof with a smaller rise indicates asmaller included central angle and alonger radius.

Experiences suggests that a simpleroof arch should rise not less than onenor more than three inches per foot ofspan. For any particular furnace, the riseselected should depend on operatingconditions, chiefly temperature, thermalcycling and the refractories used. Typically, stable fireclay arches risefrom 11/2 to three inches per foot of span.High temperatures and soaking heat call

SpecialSkew

Approx.Line ofThrust

Ground Brick andMortar Mixture

Header Course

StandardSkew


Ground Brick andMortar Mixture

Header Course

Special skewbackA recommened construction

Built-up skewbackA recommened construction

StandardSkew



ButtressAngle

Top ofSkewback

Bulk Insulation

BuckstayButtress Block Skewback No. 60-9

Built-up skewbackA construction to be avoided.

A 60° skewback withbuttress block.

Special skewbackA construction occasionaly used

Arch with skewbackssupported outside of walls

Special Skew Special Shapes

Note: A stretcher course should never be used immediately below the skewback.


ARCH CONSTRUCTION

when it is heated. If it does, the arch willnot be stable.

The line of thrust in a cold archshould lie within the middle third of thebrick. Generally, selecting the propercombination of brick shapes and doing aprofessional job to assure face-to-facecontact between brick will keep thethrust where it belongs.

In practical construction problems, thevertical and horizontal components aremore important than the resultant force.The walls, with or without steel supports,must carry the vertical force, and thehorizontal binding, including buckstaysand tie rods, must contain the horizontalforce.

* Assuming that the absolute lower limitfor the rise of the line of thrust is 1/4 inch(1/48) per foot of span, the rise (h) mustexceed thickness (T) times the of thecosine of the central angle (0)plus 1/48

span (S). This implies that T should notexceed:

h-1/48S

Cosine 0/2

For a more complete discussion of archstresses see: J. Spotts Mcdowell, “Sprung-ArchRoots for High Temperature furnaces,” Blast

Furnace and Steel Plant, September 1939.

ARCH CONSTRUCTIONCALCULATIONSThe brick count for many sizes can becalculated from the tables of brickcombinations for rings, since simplesprung arches are segments of circles.

Calculation of arch parameters, thearch numbers, is sometimes lengthy, butnot difficult, especially when carried outwith a pocket calculator. Equationsrequired to produce the necessary valuesare included in this section.

Suppose that a furnace design calls foran arch with a 12 foot span, 131/2 inchesthick built of NARMAG® 60DB brandbrick, on a furnace 20 feet long.NARMAG® 60DB basic brick, requiresa minimum rise of 21/4 inches per foot ofspan.

The table of Arch Constants belowprovides data to develop the requireddesign values. For a 21/4 inch rise,multiply the span by 0.76042 todetermine the inside radius, in this case,9.125 or 9 feet, 11/2 inches. That meansthe arch is a segment of a circle with an18 foot, three inch inside diameter, twicethe inside radius.

The table also indicates that thecentral angle for this arch will be 82°13.4’, equal to 2,284 ten thousandths of acircle.

Skewbacknot flush witharch at top

Skewbackflush witharch at top

On page IR - 45 the tables of brickcombinations for rings for 13½ inchlinings show that an 18 foot, 3 inch ringcan be built with:

82 pieces, No. 2 Wedge and176 pieces, No. 1 Wedge

If this design calls for 2,284 tenthousandths of a ring, then:

0.2284 x 82 = 18.73 or 19 pieces,No. 2 Wedge

0.2284 x 176 = 40.2 or 41 pieces,No. 1 Wedge

If the design specifies 13½ x 6 x 3 inchshapes, then two rings will cover arunning foot on the 20 foot roof, and 40rings will roof the furnace. Thus, thedesign calls for 40 times 19, a total of 760pieces, No. 2 Wedge, and 40 times 41, atotal of 1,640 pieces, No. 1 Wedge.

Arch Constants for Given Rises per Foot of Span

Rise Central Angle 0 Difference SkewbackInches Inside Inside Between

Per Foot Radius Degress Part of Arc Outside & H V Fof Span (r) Circle (aa) Inside Arc

(d) (Aa - aa)

(1) (2) (3) (4) (5) (6) (7) (8) (9)

1 1.54167S 37° 50.9’ 0.10514 1.01840S 0.66059T 0.32432T 0.94595T 0.34286Q11/4 1.25208S 47° 4.4’ 0.13076 1.02868S 0.82157T 0.39933T 0.91681T 0.43557Q11/2 1.06250S 56° 8.7’ 0.15596 1.04117S 0.97992T 0.47059T 0.88235T 0.53333Q

1.608 1.00000S 60° 0.0’ 0.16667 1.04720S 1.04720T 0.50000T 0.86603T 0.57735Q13/4 0.93006S 65° 2.5’ 0.18067 1.05579S 1.13519T 0.53760T 0.84320T 0.63757Q2 0.83333S 73° 44.4’ 0.20483 1.07251S 1.28701T 0.60000T 0.80000T 0.75000Q

21/4 0.76042S 82° 13.4’ 0.22840 1.09125S 1.43507T 0.65753T 0.75342T 0.87273Q2.302 0.74742S 83° 58.5’ 0.23326 1.09544S 1.46563T 0.66896T 0.74329T 0.90000Q21/2 0.70417S 90° 28.8’ 0.25133 1.11200S 1.57918T 0.71006T 0.70414T 1.00840Q23/4 0.66004S 98° 29.7’ 0.27360 1.13464S 1.71906T 0.75753T 0.65280T 1.160444Q3 0.62500S 106° 15.6’ 0.29517 1.15912S 1.85459T 0.80000T 0.60000T 1.333334Q

NOTE: The factors in the above tables are the following functions of 0: Column 2, 1/2 cosecant 1/2 0; column 4, Ø divided by360°; column 5; 1/2 cosecant 1/2 0


ARCH CONSTRUCTION

SKEWBACK DESIGNSkewbacks may be built-upcombinations of rectangular brick sizes,as previously illustrated, or one-piecespecial skews designed to fit the arch.Built-up skews satisfy the requirementsof narrow spans, four feet or less, butthe one-piece skewback generallyprovides greater strength and bettersupport at the buttress.

The slope of the skewback must bedesigned to match the central angle ofthe arch, determined by the rise andspan. When the skewback is carried on achannel or angle, the line of thrustshould pass through, or slightly above,the corner of the supporting steel.

Skewback dimensions can bedetermined from the table of ArchConstants below. From the exampleabove, a 2¼ inch rise produces a centralangle of 82° 13.4'. The slope equals halfthe central angle, amounting to 41° 6.6'in this example. Other dimensions canbe calculated from constants in the sametable.

The V dimension is 0.75342 times thethickness of an arch with a 2¼ inch rise.In this example above, 0.75342 times13.5 equals approximately 10.17 inches.Other skewback dimensions can bedetermined in the same way.

The amount of stress in a furnace canbe only approximated because of thefollowing variables: (1) the exact position

Maximum Values on the following page. Consider the NARMAG® 60DB brickarch design described earlier in this

chapter. Its design parameters are:

Span (S) = 12 ft

Thickness (T)= 1.125 ft

Inside Radius (r) = 9.125 ftDensity of

NARMAG® 60DB (D) = 192 lb/ft3

Rise (h) = 2.25 inches per foot of

span=12 x 2.25 = 27 inches=2.25 ft

Outside radius (R+T) = 10.25 ft

Central Angle (0) = 82°13.4' The following calculations are basedon the assumption that the line of thrustpasses from the center of arch thicknessat midspan to the center of archthickness at the skewbacks.

As shown in the table below, theweight of the arch equals 1.17 DST. Thatis, for this arch, 1.17 times 192 times 12times 1.125 equals 3032.64 pounds perfoot of arch length. Since W/2 equals1516.32, the vertical force that the wallsand buttresses must carry amounts to1516.32 pounds per foot of arch length.

From the same table, the horizontalthrust of cold arch with a 2¼ inch riseper foot of span equals 0.64 time itsweight (W). For the arch underconsideration, 0.64 times 3032.64 equals1940.89 pounds per foot of arch length.

Constants for Calculation of Stresses in Unheated Arches

Forces Per Foot of Arch LengthRise inInches H F

Per Foot Central W Horizonal Resultant Thrust atof Span Angle (0) Weight Thrust Skewback

1 37° 50.9’ 1.05 DST 1.49 W 1.57 W11/4 47° 4.4’ 1.07 DST 1.18 W 1.28 W11/2 56° 8.7’ 1.09 DST 0.98 W 1.10 W

1.608 60° 0.0’ 1.10 DST 0.91 W 1.04 W13/4 65° 2.5’ 1.11 DST 0.83 W 0.97 W2 73° 44.4’ 1.14 DST 0.72 W 0.88 W

21/4 82° 13.4’ 1.17 DST 0.64 W 0.81 W2.302 83° 58.5’ 1.17 DST 0.62 W 0.80 W21/2 90° 28.8’ 1.19 DST 0.57 W 0.76 W23/4 98° 29.7’ 1.22 DST 0.51 W 0.71 W3 106° 15.6’ 1.25 DST 0.46 W 0.68 W

D= Density of brick in pounds per cubic foot. S=Span in feet. T=Thickness of arch in feet. W=Weight of brick per foot of arch length. Theconstants given in this table are based on the assumption that the line of thrust passes from the center of the arch thickness at the point ofmidspan, to the center of arch thickness at the skewbacks.

of the line of thrust, even when thearch is cold, is not known, (2)workmanship in construction of thearch may be less than perfect, (3) theposition of the line of thrust willchange when the furnace is heated, (4)tie rods can stretch and the furnacecan settle, changing arch parameters,and (5) arch stresses can be increasedby the weight of material adhering to,or absorbed by the bricks. The forceacting against the skewbacks dependsprimarily on the span, rise andthickness of the arch, the weight of thebrick, and conditions in the furnace.Vertical force equals one half theweight of the arch per running foot.

The horizontal force depends on theweight of the arch and on the span andrise.

The resultant thrust (F) acting at theskewback equals the square root of thesum of the squares of horizontal (H)and vertical (W) forces, that is:

F= H2+(W/2)2

However, the stresses of a coldarch, in which all adjoining brick are infull contact, can be approximatelydetermined from the table below. Thelimiting value which the horizontalthrust approaches in a heated arch,Hmax, can be calculated approximatelyfrom the constants in the table of


ARCH CONSTRUCTION

The resultant force, also determined fromthe table above, is 0.81 times 3032.64equals 2546.44 pounds per foot of archlength.

Maximum values approached byhorizontal thrust can be determined fromthe factors listed in the table. These dataindicate that the maximum valueapproached by horizontal thrust for aheated arch free to rise can bedetermined by multiplying the cold archhorizontal thrust by a factor dependenton the ratio of thickness to span. In theexample considered earlier, thicknessequals 9% of span, that is, 1.125/12equals 0.09. For a 2¼ inch rise,maximum thrust approaches 1.84H, or1.84 times 1940.89 equals 3571.24pounds per foot of arch length. Thisvalue is an approximation, but it lieswell within the requirements of practicalfurnace design.

The safety factor used in furnacebinding design is ordinarily higher thanthat used in conventional steel structuraldesign because the furnace binding maybecome overheated. For ordinarystructural steel bindings, many furnacedesigners limit tensile stress to 12,000pounds per square inch.

COMPLEX REFRACTORYDESIGN PROBLEMSCustomers who design or buildrefractory structures often tap Harbison-Walker resources, e.g., engineering skillsand advanced refractories technology,for solutions to complex problemsinvolving refractory applications.Harbison- Walker engineers havedeveloped computer programs, whichare used with customers, that canproduce complex arch or dome designparameters in a few minutes, oftensaving many man-hours of calculation.For assistance with your difficult designproblems, please call your Harbison-Walker representative.

Initial Heat-Up ConsiderationsIn most cases, a new furnace should beheated slowly with enough aircirculating over the walls to removemoisture. Steam trapped in the pores ofbrick or mortar may damage thebrickwork. Good practice permits afurnace to dry out thoroughly at atemperature not over 250°F(121°C) for 24hours or longer, depending on the size ofthe vessel and the refractories in use.

Maximum Value Approached by Horizonal Thrust in Heated Arch Free to Rise

Hmax Per Foot of Arch LengthInches Thickness of Arch in Precent of Span

Per Foot Centralof Span Angle (O) 4% 5% 6% 7% 8% 9% 10%

1 37° 50.9’ 1.88 H* 2.41 H 3.29 H 5.0 H ** ** **

11/4 47° 4.4’ 1.61 H 1.86 H 2.29 H 2.80 H 3.73 H 5.34 H **

11/2 56° 8.7’ 1.47 H 1.63 H 1.94 H 2.14 H 2.55 H 3.06 H 3.88 H

1.608 60° 0.0’ 1.43 H 1.59 H 1.79 H 1.98 H 2.31 H 2.75 H 3.30 H

13/4 65° 2.5’ 1.39 H 1.52 H 1.67 H 1.93 H 2.17 H 2.41 H 2.77 H

2 73° 44.4’ 1.33 H 1.43 H 1.56 H 1.69 H 1.86 H 2.04 H 2.22 H

21/4 82°13.4’ 1.29 H 1.38 H 1.47 H 1.58 H 1.70 H 1.84 H 2.00 H

2.302 83° 58.5’ 1.28 H 1.37 H 1.46 H 1.57 H 1.69 H 1.81 H 1.95 H

21/2 90° 28.8’ 1.26 H 1.33 H 1.42 H 1.51 H 1.60 H 1.72 H 1.82 H

23/4 98° 29.7’ 1.24 H 1.29 H 1.37 H 1.45 H 1.53 H 1.63 H 1.73 H

3 106° 15.6’ 1.22 H 1.26 H 1.33 H 1.41 H 1.48 H 1.57 H 1.63 H

* H = Horizonal thrust, as determined from the previous table.** Stress excessive.

Temperatures above 400°F to 600°F(205°C to 316°C) should be avoided untilall steaming ceases.

Furnace builders and refractoryconsumers should understand therequirements of the brands that line theirfurnaces. Careful drying of linings builtof magnesia and some of its compoundsis especially important. Water vapor orsteam under pressure can causehydration of the magnesia.

Flame impingement on brickworkduring heat-up can cause rapid, localizedexpansion with consequent spalling.Silica and basic brick, especially, tend tospall when subjected to excessivelyrapid changes in temperature.

In low temperature furnaces, it is oftengood practice to heat the refractories to ahigher temperature than that required foroperation for a short period of time. Thispreliminary heat-up develops theceramic bond in mortared joints andincreases their mechanical strength.


ARCH CONSTRUCTION

Arch Formulas

1. r = S2/8h + h/2

2. R = r+T

3. h = r - r2-(S/2)2

4. Sine ½ 0 = S/2r

5. Tan ¼ 0 = 2h/S

6. Tan ¼ 0 = d/6

7. Part of circle = 0/360°

8. H = T Sine ½0

9. d = 6 Tan ¼0

10. aa = 6.2832r (0/360°)

11. Aa= 6.2832R (6/360°)

12. V=T Cos½0

13. P=QTan ½0

Arch Symbols

The following symbols and variablesare used in the arch formulas:aa = Length of inside arc

Aa = Length of outside arc

R = Outside radius of archr = Inside radius of arch

S = Span of arch

d = Rise in inches per foot of spanh = Total rise of arch

T = Thickness of arch

0 = Central Angle (Theta)H, V, P, Q = Skewback dimensionsindicated in the Arch Constants table.

REFRACTORYCONSTRUCTIONCALCULATIONS

Calculations to determine thedimensions or numerical characteristicsof refractory structures are not difficult.Generally, they involve three steps: (1)pick out the formula that produces thedimension or other number that youneed; (2) substitute the numbers in yourproblem that fit the letter-variables inthe formula; and (3) perform thearithmetic operations required by theformula. Remember, once the span andrise of an arch are decided, all otherdimensions follow.

To use these formulas, all the algebrayou need to know is that parentheses tellyou to perform the arithmetic operationinside before carrying out the otheroperations.

All you have to know abouttrigonometry is that each sine, cosine ortangent is a particular numberassociated with one particular angle,and that an arcsine, arccosine orarctangent is a particular angleassociated with a particular number.That allows you to go from number toangle, or from angle to number, or backand forth, depending on therequirements of the problem. Sines,cosines or tangents are found in tables oftrigonometric functions or in pocketcalculators.

ArchesMany pocket calculators will makecalculation of arch parameters, i.e.numerical characteristics such asdimensions, quick and easy. Sine, cosineand tangent values are literally at yourfingertips on many models. Solutions toarch problems involve nothing morethan substituting numbers into theformulas and pushing buttons on thecalculator. For example in the designpreviously specified:

Sine ½0 =S/2r = 12 (2 x 9.125)= 0.6575

Arcsine 0.6575 = 41.11°= ½ The Central Angle

The Central Angle = 82.22° = 82° 13'

The problem is no more difficult withpaper, pencil and a table oftrigonometric functions, but themultiplication, division and reference tothe table take more time.

Skewbackflush witharch to top

Skewbacknot flush witharch to top


ARCH CONSTRUCTION

RingsThe number of brick of two sizes to forma ring can be calculated from formulaslisted below. When one brick, E, is astraight, and the other, F, is a radial, useFormulas 1-a, 1-b and 1-c. When bothbrick, E and F, are radial with outsidechord dimensions and inside chorddimensions unequal, use Formulas 2-a,2-b, and 2-c. When both brick, E and F.are radial and the inside and outsidechord dimensions of E differ from thoseof F, use Formulas 3-a, 3-b and 3-c for asingle combination, and 4-a, 4-b, and 4-cfor a series of combinations.

Ring Formulas Ring Symbols

E = Either a straight brick or a radialbrick used with a companion brickF; when brick E is radial it turns alarger diameter than brick F.

F = A radial brick, used with acompanion brick E which may beeither straight or radial; in thelatter case, brick F turns a smallerdiameter than brick E.

T = Radial dimension common to bothbrick E and F.

De = Outside diameter of ring formed by

brick E.

Df = Outside diameter of ring formed by

brick F.

Dg = A given outside diameter larger than

Df, if brick E is radial D

g must lie

between De and D

f.

dg = A given inside diameter.

Ce= Outside chord dimension of

brick E.

Cf = Outside chord dimension of

brick F.c

e= Inside chord dimension of

brick E.

cf= Inside chord dimension of brick F.

Ne=Number of pieces of brick E, when

used in combination with brick F, toform a ring having a given outsidediameter D

g.

Nf=Number of pieces of brick F, when

used in combination with brick E, toform a ring having a given out sidediameter D

g.

Nt=Total number of pieces of brick E and

F used in combination to form a ringhaving a given outside diameter D

g.

Nx=Number of pieces of brick E required

to form a complete ring having anoutside diameter D

e.

Ny=Number of pieces of brick F required

to form a complete ring having anoutside diameter D

f.

Outside Cord Dimensions Outside Cord Dimensions

RingCalculations

Inside Chord DimensionsCombination of a Straight Brick (E)

and a Radial Brick (F)to Form a Ring

Inside Chord DimensionsCombination of Two Radial Brick

(E and F) to Form a Ring. Brick ETurns a Large Diameter than Brick F

(1-a) N =f2 TC-c

�f f

(2-a) N = =t

�DC

g

e

�DC

g

f

(3-a) N c +NC = De e f f g�

(4-a) N = (D -D)e g fN

D -Dx

e f

(1-b) N =e

�D -NCCg f f

e

(2-b) N =e

�D -Ncc -c

g f f

e f

(3-b) N c +Nc = de e f f g�

(4-b) N = (D -D )f e gN

D -Dy

e f

(1-c) N = N +Nt e f

(2-c) N = N-Nf t e

(3-c) N = N +Nt e f

(4-c) N = N +Nt e f

Monolithic and

Ceramic Fiber Products

Mortar Materials MP-1

Plastic Refractories MP-4

Gunning Mixes MP-8

Castable Refractories MP-11

Ramming Refractories MP-20

Ceramic Fiber Products MP-22

Data Sheets* www.hwr.com

SECTION 5

*In order to provide current data to the users on this handbook, we havechosen to use an on-line link to our website, www.hwr.com. If you are notable to access the website, please contact your local sales representative tosecure the required data sheets.


Click here forTechnical Data Sheetsor go to www.hwr.com

Harbison-Walker MP - 1

OverviewSince masonry built of refractory brick consists of many relatively small units, thestrength of the masonry depends on the strength of the individual brick, the manner inwhich they are laid together, and the nature of the mortar materials used in the joints.Mortar fills the joints, bonds individual brick together, and protects the joints from attackby slag and other fluxes. Mortar material should be selected as carefully as the brick withwhich it is to be used, and it must be chosen for compatibility with the composition of thebrick.

A bonding mortar often must meet extremely exacting conditions while in service,which may require an adjusted balance of properties. A mortar should have goodworking properties for both economy and convenience in laying when mixed to eitherdipping or trowelling consistency.

Mortar should not shrink excessively upon drying or heating, nor should it overfire andbecome vesicular at the maximum service temperature.

Thermal expansion of the mortar should be approximately the same as that of thebrick with which it is used; otherwise, temperature changes will affect the bond betweenbrick and cause surface coatings to crack or peel.

In some applications, strong joints are desired. Consequently, brick and mortar shoulddevelop a strong bond. Refractoriness must be sufficiently high so that mortar will notmelt or flow from the joints at high temperatures. However, for laying brick walls that aresubjected alternately to soaking heat and cooling cycles, mortars that do not develop astrong bond are often desirable.

Refractory mortar materials are generally divided into two classes: heat-setting mor-tars and air-setting mortars.

Heat-setting mortars develop a ceramic set with a strong bond only at furnace tem-peratures. These mortars provide flexibility in expansion and contraction as furnacetemperature rises and falls. Heat-setting mortars may also compensate for the highthermal expansion of certain brick, and for differences in thermal expansion betweenbrick of different types used in the same furnace. Available in various compositions,heat-setting mortars are supplied for laying refractory brick in applications where full orsolid joints with minimum shrinkage are especially desirable; or where a very strongbond through the entire wall thickness is not an essential requirement.

Air-setting mortars take a rigid set when dried. Prepared from suitable refractorymaterials by proper selection and combination, chemical binders impart air-settingproperties, and maintain the strength of the bond up to the temperature at which theceramic bond takes effect. Air-setting mortars form mechanically strong joints with highresistance to abrasion and erosion. The wall is bonded throughout, from the hot to thecold surface.

The following product descriptions of Harbison-Walaker’s mortar materials refracto-ries are categorized by their classification. This listing represents the major brandssupplied for a wide variety of furnaces and applications.

MORTAR MATERIALS


MP - 2 Harbison-Walker

BASIC MORTARS

THERMOLITH®

An air-setting, high temperaturebonding material with a chrome orebase, THERMOLITH® possessesexcellent resistance to corrosive slagsand fumes through a wide range oftemperatures. It is used to lay basicbrick of all types or as a neutral layerbetween brick of any type.

FIRECLAY MORTARS

HARWACO BOND®

Shipped wet or dry, HARWACOBOND® refractory mortar consists ofhigh fired, high-alumina calcines andsmooth working plastic clays. Itcombines high refractoriness, volumestability, and smooth trowellingqualities.

’SAIRSET®

A wet, high strength, air-setting, hightemperature mortar. This mortar isformulated for trowelled joint, but canbe thinned for dipping by adding water.

’SAIRBOND®

A dry, air-setting version of ’SAIRSET®,for use at temperatures up to 3000°F.’SAIRBOND® has excellent trowellingcharacteristics.

PHOSPHATE-BONDED HIGH-ALUMINA MORTARS

PHOXBOND®

This phosphate-bonded, wet mortarprovides high bonding strength andexcellent resistance to corrosion anderosion. PHOXBOND® refractorymortar can be sprayed or brush coatedover refractory walls to reduce perme-ability without peeling. PHOXBOND®

mortar should not be thinned unlessabsolutely necessary, and then verycautiously. Rolling the drums prior toopening will help bring the mortar toworking consistency. Heating to aminimum of 500°F (260°C) is necessaryto develop full strength.

GREENSET® -85-PA wet, phosphate bonded, highalumina mortar, with smooth workingcharacteristics, and good resistance toslag attack.

GREENSET®-94-PA wet, 94% alumina, phosphate-bonded mortar with excellent refractori-ness. GREENSET®-94-P has excellentresistance to aluminum reaction,smooth working characteristics, andresistance to slag attack. It is especiallyeffective in laying extra high-aluminabrick and as a coating in a variety ofapplications.

HIGH-ALUMINA MORTARS

CORALITE® BONDA dry high-alumina based air-settingmortar. Develops high strength andhas excellent working properties.CORALITE® BOND his high refractori-ness and excellent resistance to attackby corrosive slags

No. 36 REFRACTORY CEMENT®

No. 36 REFRACTORY CEMENT® is awet, air-setting, high temperaturecement with good bonding strengthand refractoriness. It can be used forall types of high-alumina brick whereextra bond strength is needed in thejoints for structural stability.

HIGH-ALUMINA MORTARS Con’t

KORUNDAL® BONDHigh-Alumina air-setting mortar basedon high purity alumina aggregate. It issuitable for use at temperatures up to3200°F (1760°C).

KORUNDAL® MORTARA heat-setting mortar with extremelyhigh refractoriness, KORUNDAL®

MORTAR provides excellent service attemperatures up to 3400°F (1873°C). Italso has exceptional stability and load-bearing ability at high temperaturesand is very resistant to corrosion byvolatile alkalies and slags in all typesof furnaces.

TUFLINE® MORTARA dry, high purity 95% alumina mortar.TUFLINE® MORTAR has very goodtrowelling characteristics. It isintended for use with TUFLINE® 95DM and TUFLINE® 98 DM inapplications requiring materials withvery low silica contents.

GREENPATCH 421An air setting high-alumina patchingplaster. It is used primarily forrepairing fiber lined furnaces.

GREFPATCH® 85 & WETA phosphate-bonded, 84% aluminapatching plaster. GREFPATCH® 85 canbe applied by trowelling or handpacking of areas that have spalled oreroded. Formulated to minimizeshrinkage. A WET version, temperedto a higher workability is also available.

MORTAR MATERIALS




ALUMINA-CHROME MORTARS

AUREX® BONDA 75% chromic oxide containing,phosphated bonded mortar . AUREX®

BOND is used in highly corrosiveapplications such as slagging gasifiers.

RUBY® MORTARPhosphate-bonded mortar with 10%chromic oxide. High bond strength;excellent resistance to corrosion bynon-ferrous and ferrous metals.

RUBY® BONDA unique air set alumina-chrome mortarwith excellent corrosion resistance andhigh temperature strength

SILICA MORTARS

FUSIL® MORTARA high purity, air-setting fused silicamortar. Available dry with a separateliquid component. For varying consis-tency, a special liquid thinner isavailable.

MORTAR MATERIALS




OverviewPlastic refractories are mixtures of refractory materials prepared instiff, extruded condition for application without mixing. They aregenerally rammed into place with pneumatic hammers, but they canalso be pounded with a mallet, gunned or vibrated into place. Plasticrefractories are especially adaptable for making quick, economical,emergency repairs and are easily installed to any shape or contour,eliminating the need to cut special shapes.

The ease with which plastic refractory materials can be installed qualifiesthem for many applications. Typically, these include soaking pits, boilers,forging furnaces, annealing ovens, aluminum furnaces, cupolas, incinerators,ladles, bake ovens, and many other industrial applications. In the group of plastic refractories, those that are “air-setting” take afirm set as they dry out at ambient temperatures. “Heat-setting” refractoriesremain relatively soft, as most clay-bonded materials do until heated. Afterheating, both types take the strong ceramic set typical of refractories.

Harbison-Walker’s ramming plastic refractories are precut into slabs foreasy use, and packaged in 55 or 100 pound cartons for shipping. Gunningplastics are granulated to accommodate charging the BSM gun, and pack-aged in 3000 pound boxes. Vibratable plastics are packaged in 55 poundsacks for easy handling on the job site. Each of these types of plasticrefractories is enclosed in polyethylene prior to packaging to preserve itsmoisture content.

For shipment during cold weather, Harbison-Walker “winterizes” its non-phosphate bonded plastic refractories. Winterizing the mix suppresses thefreezing point a few degrees and permits storage of the refractory at lowertemperatures, but has no effect on refractory properties.

The following product descriptions of Harbison-Walker’s plastic refrac-tories are categorized by their classification. This listing represents the majorbrands supplied for a wide variety of furnaces and applications.

PLASTIC REFRACTORIES

FIRECLAY PLASTICS (Air-Set)

SUPER HYBOND® PLUSAn air-setting, super-duty fireclayplastic. Its special bonding systemprovides additional strength at lowertemperatures. It has excellent adhesionproperties and low shrinkage.

FIRECLAY PLASTICS (Heat-Set)

SUPER GA 50% alumina, heat-set plastic. Itexhibits excellent resistance to thermalshock from rapid heating or coolingfurnace conditions. It is very volumestable at high furnace operatingconditions.

HIGH-ALUMINA PLASTICS (Air-Set)

SUPER HYBOND® 60 PLUSAn air-set, 60% alumina plastic basedon high purity bauxite. It exhibitsincreased strength and volume stabilitythroughout its temperature range.Exceptional purity provides maximumresistance to slag attack and outstand-ing ability to withstand load at operat-ing temperatures. Also developsmoderate strength upon drying.

SUPER HYBOND® 80An air-setting, 80% alumina, plasticrefractory. SUPER HYBOND® 80remains refractory at high tempera-tures. It offers excellent resistance tofluxing oxides and slags and goodvolume stability up to its maximumservice temperature, 3200°F (1761°C).




HIGH-ALUMINA PLASTICS(Phosphate Bonded)

GREENPAK 50-P PLUSA 50% alumina, phosphate bondedplastic based on high purity bauxitickaolin. It exhibits higher strengths towithstand mechanical abuse and hasbetter alkali resistance than conven-tional, heat-setting plastics.

H-W® BULL RAM PLASTICA highly workable and cohesive 70%alumina/mullite phosphate bondedplastic. H-W® BULL RAM PLASTICis used in a wide range of applications,including incinerators, boilers, heattreating furnaces, ferrous and non-ferrous metals furnaces, and rotary kilnfiring hoods.

NARMUL® P PLASTICA 70% alumina, mullite plastic. It hashigh purity for outstanding corrosionresistance. NARMUL® P PLASTICalso has high density and good hotstrength.

NARPHOS™ 85P PLASTICAn 85% alumina, phosphate-bonded,plastic, NARPHOSTM 85P PLASTICprovides high strength and densitycombined with excellent volumestability throughout its entire tempera-ture range. It displays non-wettingcharacteristics to provide outstandingresistance to erosion from slag andmetal wash. This product is used whereexcellent resistance to temperatures,slag, thermal shock, and abrasion isrequired.

NARPHOS™ 85 TPAn 85% alumina, phosphate-bonded,trowelling plastic. It has excellentphysical properties, and workabilitycharacteristics. NARPHOS 85 TP isideal for patching and veneering thinlinings.

CORAL PLASTIC® (28-82)An 85% alumina, phosphate-bonded,plastic. CORAL PLASTIC® (28-82)provides high strength and densitycombined with excellent volumestability throughout its entire tempera-ture range. It displays non-wettingcharacteristics to provide outstandingresistance to erosion from slag andmetal wash. This product is usedwhere excellent resistance to tempera-tures, slag, thermal shock, and abrasionis required.

GREENPAK 85-P PLUSGREENPAK 85-P PLUS is a highalumina, phosphate bonded plastic withexcellent strength, outstanding slagresistance, good workability, andvolume stability at high temperatures.It demonstrates good resistance toalkali attack.

GREENPAK 85-MP PLUSThis is an economical version ofGREENPAK 85-P PLUS. It isphosphate-bonded and shows im-proved strength at intermediateoperating temperature.

GREENPAK 85-PF PLUSA fine grind, 85% alumina, phosphatebonded plastic refractory. It featureshigh refractoriness, excellent workabil-ity, high strength, slag resistance andlow shrinkage. It was developed foruse as a patching material in areas ofsevere abrasion and erosion. Typicalapplications include induction fur-naces, spouts, tundish and foundryladles, troughs and tap-out areas,cyclones, and catalyst lines.

KORUNDAL® PLASTICA phosphate-bonded, tabular aluminabased plastic with exceptional refracto-riness. It is used in applications wherehigh strength at high temperature isneeded.

GREENPAK 90-P PLUSGREENPAK 90-P PLUS is an extrahigh alumina, phosphate bondedplastic. It exhibits high density andexcellent strength.

ALUMINA-CHROME PLASTICS

RUBY® PLASTIC AMCAn economical, high strength, phos-phate-bonded, corrosion resistantalumina-chrome plastic. Its highchromic oxide content gives it out-standing resistance to acid and neutralslags. The presence of mullite grainallows for earlier sintering, making itideal for slagging applications between2500°F (1371°C) and 2900°F (1593°C).Applications include foundry troughs,ladles, induction furnaces and pulp millrecovery boilers.

RUBY® PLASTIC SA phosphate-bonded, high-aluminachromic oxide containing plasticformulated to optimize slag erosionresistance and iron oxide penetrationresistance while retaining high hotstrengths and low open porosity.RUBY PLASTIC S has extremelygood resistance to high iron oxide slagsof an acid to neutral nature and toattack by coal slag. Typical usesinclude iron and steel troughs, dams,impact areas, spouts, and tap holes,industrial incinerators, boiler bottoms,and lower side walls in slagging areasover tubes.

RUBY® PLASTICA phosphate-bonded, alumina-chromeplastic with very high strength at hightemperatures. At high temperatures,RUBY PLASTIC forms an alumina-chrome solid solution bond which hasextremely good resistance to high ironoxide slags of an acid to neutral natureand to attack by coal slag. Applicationsinclude dams, impact areas, industrialincinerators, boiler bottoms, andslagging areas over tubes.





ALUMINA-CHROME PLASTICScon’t

RUBY® PLASTIC 20High strength, phosphate-bondedalumina-chrome plastic with 20%chromic oxide content. With highstrength at elevated temperatures, thisplastic has enhanced resistance to ironoxide and coal slag, beyond standardphosphate-bonded plastics.

SHAMROCK® 885 PLASTICA phosphate-bonded, alumina-chromerefractory plastic. Its 30% chromicoxide content, and very high densityprovide outstanding corrosion resis-tance. Typical applications includepatching glass contact and stack areasof wool insulation furnaces, andextreme-service areas in wet-slag, coal-fired boilers.

AUREX 65 PLASTICA phosphate-bonded, chrome-aluminaplastic refractory. AUREX 65 PLAS-TIC utilizes a fused chrome-aluminagrain to achieve the maximum possibleresistance to highly corrosive slags.Applications include coal gasifiers andchemical incinerators.

GUNNING PLASTICS

GREENGUNTM

70-P PLUSA high alumina, phosphate bondedplastic gunning mix with high strength,low porosity, and good abrasion andalkali resistance. Typical applicationsare incinerator linings, cement plantfiring hoods and fluid bed combustorcyclones.

GREENGUNTM

80An 80% alumina, air-setting gunningplastic. It exhibits excellent resistanceto thermal shock from rapid heating orcooling furnace conditions. It is veryvolume stable under high temperatureconditions. Typical applications arerotary kiln feed and discharge hoods,combustion chambers, boilers, forgefurnace sidewalls and roofs, hightemperature dryers, reheat furnacesoak zones, and brass reverberatoryfurnace upper sidewalls.

GREENGUNTM

85-P PLUSA high density, phosphate bonded, highalumina gunning plastic that exhibitsexcellent thermal shock resistance,high strength, and excellent abrasionresistance. It is an excellent choice forboth hot and cold repairs.

GREENGUNTM

ECLIPSE® 73-P

PLUSA phosphate bonded gunning plasticcontaining approximately 73% siliconcarbide. It is specially formulated togun on studded tubes in cycloneboilers, on water-wall tubes in waste-to-energy units, and on other heatrecovery units.

GREENGUNTM

JADE PLUSAn alumina-chrome, phosphatebonded, gunning plastic. With its highpurity alumina and chromic oxide, ithas extremely high refractoriness andresistance to acidic and slightly basicslags. It is used in many applicationsincluding reheat furnaces, waste heatboilers, incinerators, and recoveryboilers.

SILICON CARBIDE PLASTICS

ECLIPSE® 60-P ADTECH®A phosphate-bonded silicon carbideplastic that forms an aluminumphosphate bond. It has high conductiv-ity and abrasion resistance as well asnon-wetting properties to many acidslags and nonferrous metals. Principalapplications include municipal incin-erators, fluid-beds, boiler tube protec-tion and high abrasion.

ECLIPSE® 70-P ADTECH®A phosphate-bonded 70% siliconcarbide plastic. It is especiallyformulated for ramming on studdedtubes in cyclone boilers, on water-walltubes in waste-to-energy units, andother heat recovery units.

ECLIPSE® 80-P ADTECH®A phosphate-bonded 80% siliconcarbide plastic. Its high silicon carbidecontent provides high thermal conduc-tivity and outstanding strength andabrasion resistance.

HARBIDE PLASTIC 70 ALA high purity silicon carbide, phos-phate bonded refractory plasticcontaining a penetration inhibitor forimproved aluminum resistance. Itshows excellent strengths, goodthermal shock resistance, excellentpenetration resistance and goodabrasion resistance.

VIBRATABLE PLASTICS

GREFVIBE 700A phosphate-bonded, 70% aluminaplastic refractory. GREFVIBE 700 hasbeen developed so that it can bequickly vibrated into place behind steelforms. With this characteristic and thelow temperature bonding at 700-1200°F(370-650°C), GREFVIBE 700 is speciallysuited for lining iron foundry and steelfoundry ladles which must be linedquickly with minimum labor cost.

GREFVIBE 850A high alumina, phosphate bondedvibratable plastic which features veryfast installation and turn-around time.GREFVIBE 850 has high refractori-ness, high density and is resistant toferrous and non-ferrous metal penetra-tion, corrosive slags and abrasion.

TASIL® 570 LM VIBRATABLEA 70% alumina, air/heat set vibratableplastic. It is phosphate free, pre-densified and ready to install. It isused in iron and steel ladles, tundishes,troughs, runners, arc furnaces, channelfurnace upper cases and special shapes.





SiC & CARBON CONTAININGPLASTICS

SUPER NARCARB PLASTICBased on fused alumina with SiC andoxidation inhibitors. This yields verylow porosity for enhanced corrosionresistance to cupola slags. SUPERNARCARB PLASTIC is intended forextended cupola campaigns and themost severe service conditions. Itoffers the highest level of carboncontaining, non-wetting components,and a more environmentally friendlybond system than the phenolic resinbonded materials.

NARCARB ZP PLASTICThis phenolic resin bonded plasticprovides high strengths at iron produc-ing temperatures. It contains SiC withoxidation inhibitors. NARCARB ZPprovides excellent performance inextended cupola campaigns undersevere conditions.

SUPER GRAPHPAK-85This air-setting, SiC and graphitecontaining, oxidation resistant plasticcontains no pitch or resins. As a result,it does not give off polluting emissions.This plastic possesses good resistanceto hot metal and slag erosion andrepresents an economical alternative toNARCARB ZP and SUPERNARCARB in less severe conditions.

GRAPHPAK-45 & PLUSA super-duty fireclay plastic refractorycontaining graphite. It exhibits betterresistance to molten iron or iron slagpenetration than conventional super-duty plastics.

GRAPHPAK-85 & PLUSA high alumina plastic containinggraphite. It exhibits good resistance tomolten iron or iron slag penetration. Itis ideally suited for high temperaturemolten iron up to 2850°F (1566°C) metaltemperature.





OverviewGunning mixes are granular refractory mixtures designed for applica-tion with air-placement guns. A variety of air guns are used to spraythe mixes at high velocity and pressure to form homogeneous, compactlinings, essentially free from lamination and cracks.

Gunning mixes are either air-setting or heat-setting and some allowrepairs to refractory furnace linings without greatly reducing the furnacetemperature. Lightweight gunning mixes normally are used for insulation,while denser mixes are used in the more severe applications. Some compo-sitions combine relatively low heat losses with good strength.

Although gunning requires more skill than pouring castables, it can placea higher volume of material in less time than any other method. Gunning alsomakes it possible to line horizontal, vertical, overhead or irregular structureswithout forms.

The properties of Harbison-Walker’s gunning mixes vary considerablyand, thus, encompass a wide range of applications. The mixes perform verywell in both original linings and maintenance applications within a servicetemperature range of 1600°F (872°C) to 3300°F (1817°C). In manyapplications, they represent the most economical choice for a refractorylining.

The following product descriptions of Harbison-Walker’s gunning mixesare categorized by their classification. This listing represents the majorbrands supplied for a wide variety of furnaces and applications.

GUNNING MIXES

FIRECLAY GUNNING MIXES

GREENCAST® 12 GR PLUSA high strength castable for withstand-ing severe abrasion at temperatures upto 1200°F. It is CO resistant anddisplays excellent gunning characteris-tics.

NARCO® GUNCRETEA high strength, fireclay gun mix thatdisplays excellent gunning characteris-tics.

NARCO® GUNCRETE ARAbrasion resistant version of NARCO®

GUNCRETE..TUFSHOT® LI/OT ADTECH®

An extra strength, low iron fireclaygunning mix characterized by very lowrebounds. Used in boilers, incinera-tors, process heaters, stacks, breech-ings and other medium service areas.

KS-4® GR PLUSA specially formulated fireclaygunning mix with good strength andcorrosion and abrasion resistance. Ithas low rebound and good settingcharacteristics. Good for thinnerlinings in large areas.

GREFCOTE® 50 PLUSGREFCOTE® 50 PLUS is a 50% alumina,cold or hot gunning mix for mainte-nance of refractory linings. It displaysgood adhesion to walls that are hot orcold. It can be gunned to thickness tomaintain the original contour of therefractory lining. Typical applicationsare: hot gunning of iron torpedo ladlelips, aluminum furnace upper sidewalland roof areas, soaking pit linings andreheat furnace sidewalls.

CONVENTIONAL HIGH- ALUMINAGUN MIXES

LO-ABRADE® GR PLUSA fireclay based, dense abrasionresistant gunning mix. It exhibitsexceptional resistance to abrasion,erosion, high-energy impact, andtemperature.

GREENCAST® 94 GR PLUSA high strength, 94% alumina, highpurity gun mix with good abrasionresistance. Excellent strength andchemical purity allow it to withstandsevere environments with a maximumservice temperature of 3400°F

(1820°C).

NARCOGUN® LC-95NARCOGUN® LC-95 is a highalumina, low cement, low moisture gunmix. This product shows excellentgunning characteristics with belowaverage rebound loss.

KRUZITE® GR PLUSKRUZITE® GR PLUS is a 70%alumina, dense, 3200°F (1760°C)maximum service temperature gunningcastable. It exhibits excellent strengthsand high densities.




LOW CEMENT FIRECLAYGUNNING MIXES

VERSAGUN® BF A high strength, low cement gun mixbased on a high-fired, low-iron, fireclayaggregate. Used in applicationsrequiring resistance to abrasion andreducing environments.

VERSAGUN® PHVERSAGUN® PH is a high strength,low cement gun mix based on selectedsuperduty fireclays and a lower cementcontent. It has excellent abrasionresistance and high refractoriness to2800°F (1538°C).

LOW CEMENT HIGH- ALUMINAGUNNING MIXES

VERSAGUN® 50 ADTECH® A high strength gun mix based on high-fired fireclay aggregate and a reducedcontent of high purity cement. Used inapplications requiring high strength andabrasion resistance.

VERSAGUN® 60 ADTECH®

A 60% alumina low cement gunningmix based on hard fired calcinedkaolins and a reduced lime content.VERSAGUN® 60 ADTECH® featuresexcellent strengths, very good abrasionresistance, and improved refractoriness.

MIZZOU® GR® PLUS60% alumina gunning castable.MIZZOU® GR® PLUS is a 3000°F(1650°C) gunning refractory with lowiron content, good slag resistance, andexcellent volume stability. Developedespecially for gun placement to allowquick installations and/or repairs withminimum downtime.

VERSAGUN® 60Z ADTECH®

A 60% alumina low cement gunningmix based on Alabama bauxitic calcinesand with the addition of zircon.Excellent abrasion resistance, hotstrength and thermal shock resistance.

VERSAGUN® 70 ADTECH®

A 70% alumina, low cement gunningmix having a reduced lime content,based on hard fired calcined kaolins.It has excellent strengths, very goodabrasion resistance, improved refracto-riness & hot strengths.

VERSAGUN® 70/AL A 70% alumina, low cement gun mix,containing an aluminum penetrationinhibitor that installs with conventionalgunning equipment. Excellentphysical properties in the 1500°F(816°C) range and permits fast andeffective repairs to metal line areas.

NARCOGUN® BSC-DSNARCOGUN® BSC-DS is a bauxitebased trough mix that is totally dustsuppressed to eliminate any dusting atthe nozzle or gun. This is a SiCcontaining material.

DENSE MAGNESITE GUN MIXES

MAGSHOT®

MAGSHOT® is a magnesite basedgunning refractory. It is based on adicalcium silicate natural magnesitethat has good resistance to moltensmelt and soda. This unique formula-tion does not require lengthy cure timeor slow heat-up schedules.

MAGNAMIX 85GMAGNAMIX 85G is a basic gun mixof the 85% MgO class. Primary use inrepairing and maintaining electricfurnace linings in the small to mediumsized foundries.

SPECIAL PURPOSEGUNNING MIXES

VERSAGUN® THERMAX®

ADTECHTM

A high strength, vitreous silica gun mixwith reduced cement content. It has aspecial fortified matrix to provideexcellent strength and abrasionresistance, along with unmatchedthermal shock resistance.

NARCOGUN® SiC 80 ARA strong, low cement, silicon carbidegunning mix. The reduced cementcontent yields improved abrasionresistance.

INSULATING GUNNING MIXES

KAST-O-LITE® 22 G PLUS(Formerly CASTABLE INSULATION #22 GR)

An insulating gun mix designed for amaximum service temperature of 2200°F(1205°C).

KAST-O-LITE® 26 LI G PLUS(Formerly H-W® LT WT GUN MIX 26)

A low iron, medium density gun mixdesigned for a maximum servicetemperature of 2600°F (1427°C).

KAST-O-LITE® 30 LI G PLUSA low iron, gun mix designed for amaximun service temperatures of 3000°F(1650°C).

GREENLITE 45 L GRA 2500°F insulating gunning mix withhigh strength and low density.

HPVTM GUN MIXA high strength, lightweight, insulatinggunning mix with exceptionally highstrength and abrasion resistance.

GUNNING MIXES




SPRAY MIXES

PNEUCRETE® BF ADTECH®

PNEUCRETE® BF ADTECH® is a superduty fireclay based low cement spraymix for use in abrasion environmentsand carbon monoxide environments. Ithas the unique property that whencombined with an activator at thenozzle it can be applied by standardshotcreting methods. PNECRETE® BFADTECH® can be used for blastfurnace repairs, minerals processing,and other applications requiring highstrength, low cement compositions.

PNEUCRETE® 45 ADTECH ®

PNEUCRETE® 45 ADTECH® is afireclay based low cement spray mixfor use in abrasion environments. Ithas the unique property that whencombined with an activator at thenozzle it can be applied by standardshotcreting methods. PNEUCRETE®

45 ADTECH® can be used for mineralsprocessing, chemical industry applica-tions, and incineration and aluminumfurnace backup linings.

PNEUCRETE® THERMAX®

Unique vitreous silica based lowcement spray mix. Nearly dust freeinstallation with minimal rebounds. Ithas the unique property that whencombined with an activator at thenozzle it can be applied by standardshotcreting methods. Lower densitythan conventional extra strengthcastables, outstanding thermal shockresistance in cycling applications, lowcoefficient of thermal expansion andgood abrasion resistance.

PNEULITE® SPRAY 22PNEULITE® SPRAY 22 ADTECH® is auniquely formulated refractory specifi-cally for spray application that lowersdust and permits virtually no rebounds.Used primarily to replace conventionalgunning mixes as insulation forpetroleum heaters or as insulationbackup lining in two component liningsfor many applications.

PNEULITE® SPRAY 26 ADTECH®

PNEULITE® SPRAY 26 is a uniquelyformulated refractory specifically forspray application that lowers dust andpermits virtually no rebounds. Usedprimarily to replace conventionalgunning mixes applied in FCCUregenerating vessels, naphtha reform-ers and other process furnaces requir-ing semi-insulating, one spray linings.

PNEUCRETE® 55/AR ADTECH®

A 55% alumina low cement spray mixfor use in high alkali and abrasionenvironments. Features nearly dustfree installation with minimal re-bounds. It has the unique property thatwhen combined with an activator at thenozzle it can be applied by standardshotcreting methods.

PNEUCRETE® 60 ADTECH®

A 60% alumina, low-cement spray mixfor use in a wide variety of applica-tions. Nearly dust free installation withminimal rebounds. It has the uniqueproperty that when combined with anactivator at the nozzle it can be appliedby standard shotcreting methods.PNEUCRETE® 60 ADTECH® can beused in cement and lime plant mainte-nance and other applications requiringhigh strength, low cement composi-tions.

.

Gunning Mixes




CASTABLE REFRACTORIES

OverviewOften called refractory concretes, castable refractories are furnisheddry to be mixed with water before installation. Usually cast or vibratedin the same manner as ordinary concrete, castables can also be in-stalled by trowelling, pneumatic gunning or occasionally ramming.

The growing use of castables stems directly from their economic andhandling advantages. Castables reduce installation costs, go into placequickly and easily, and mixing, conveying and placement can bemechanized. They also save time formerly spent cutting brick to fitand eliminate inventories of special shapes.

Along with ease of installation, castables offer several performanceadvantages. They are less permeable, partly because of the nature ofthe hydraulic bond and partly because cast walls, roofs and floorshave fewer joints. Thus, castables often provide the best lining forvessels or chambers at other than atmospheric pressures. Manycastable refractories have good resistance to impact and mechanicalabuse; and most castables offer good volume stability within thespecified temperature range.

The service capability of any refractory is determined by its majoringredients – fireclay, alumina, silica or basic materials such as mag-nesite and chrome ore. Properties of the binders, i.e., hydraulic ce-ments that give castables an air-set, are designed to match those of therefractory base materials. They include standard calcium-aluminatecements, low iron oxide cements, high purity cements, and highstrength, high purity cements. Some special castables use sodiumsilicate or portland cement binders.

The following product descriptions of Harbison-Walker’s castablerefractories are categorized by their classification. This listing repre-sents the major brands supplied for a wide variety of furnaces andapplications.




CONVENTIONAL FIRECLAYCASTABLES

MC-25® PLUSA high strength, coarse aggregatecastable for temperatures to 2250°F.MC-25® possesses two-to-three timesthe strength of regular dense castables,has excellent resistance to thermalshock, and withstands heavy loads andmechanical abuse.

KS-4® PLUSA dense, strong general purposecastable refractory for use at tempera-tures up to 2550°F. It combines highstrength with abrasion resistance.

KS-4TA more plastic material than mostrefractory castables. It is preferred foruse as a plastering material to repairboiler baffles. It is recommended foruse in relatively thin sections. It canalso be used for overhead gunningrepairs where thickness is required.

KS-4V PLUSA general purpose castable for use totemperatures to 2600°F. KS-4Vfeatures good resistance to abrasion, alow iron content, and minimal shrink-age, even when used in large patches.

EXPRESS®-27 PLUSEXPRESS®-27 PLUS is a 2700oF,dense, free-flowing refractory castablethat can also be vibration cast usingreduced water levels to providevibrated product with propertiessuperior to those attained at selfflowing consistency. Its densitytogether with very good abrasionresistance makes it an ideal hot facelining material.

EXPRESS® 27 C PLUSA coarse, fireclay based, conventionalcement castable for use where highstrength and high impact resistance arerequired up to 2700°F (1482°C). Itfeatures improved impact resistanceover conventional extra-strengthcastables or fireclay plastics. It is easyto install by pumping, vibcasting andconventional casting techniques.EXPRESS® 27 C PLUS can also beinstalled at a self leveling consistency.

HARCAST® ES ADTECHA very high strength, super-dutycastable with high purity binder.Excellent for applications up to 2800°F.

HYDROCRETE®

A 2200°F maximum service tempera-ture, dense, general purpose castable.It easily conforms to irregular furnaceshells to increase the speed of installa-tion versus conventional brick linings.Its moderate density allows for reducedenergy loss through the refractorylining.

SUPER KAST-SET® PLUSA 2800°F general purpose castable. Ithas good permanent volume character-istics and high strength to producestable linings for long service.

CONVENTIONAL HIGH-ALUMINACASTABLES

LO-ABRADE® PLUSA 2600°F castable with excellentresistance to abrasion and erosion. Itslow iron content makes it particularlygood for use in specialized atmospherefurnaces. It is recommended for usewhere abrasion is encountered.

MIZZOU CASTABLE® PLUSA high strength 60% alumina castable,with excellent resistance to slagpenetration and spalling. It is used formany applications such as combustionchambers, low temperature incinera-tors, air heaters, boilers, burner blocks,aluminum furnace upper sidewalls androof regions, forge furnaces, and ironfoundry ladles.

EXPRESS®-30 PLUSA 3000°F (1647°C), dense free flowingrefractory castable. It can either becast or pumped. Its density togetherwith very good abrasion resistancemakes it an ideal hot face liningmaterial. If reduced water content isused, cast vibrated properties aresuperior to free-flowing properties.EXPRESS® 30 QS is a quick settingversion, designed for quick turnaround.It is ideal for precast shapes.

KRUZITE® CASTABLE PLUSA general purpose 3200°F castable,displaying high refractoriness andmoderate strength. Applicationsinclude foundry ladles, burner blocks,high temperature boilers, and inductionfurnace covers.

GREENCAST®-94 & PLUSA high strength, high purity calciumaluminate bonded 94% aluminacastable with extremely high refracto-riness. Used in conditions requiringhigh abrasion and chemical resistance.

NARCOCAST® LM95 GA high purity, conventional cementcastable employing a low moisturedesign. NARCOCAST® LM95 G hasextremely high strength at tempera-tures up to 3000°F. It has excellentresistance to molten metal erosion,abrasion and mechanical abuse. It hassignificantly higher density and lowerporosity than conventional castables.Due to its fine grained design,NARCOCAST® LM95 G is especiallywell suited as a grout material. Alsoideal for thin walled castings requiringimproved properties.

SPECIAL HIGH ALUMINACASTABLE ADTECHSHAC is a high purity, extra highalumina, hydraulic setting castable theforms a dense, high strength mono-lithic lining. It has excellent abrasionand erosion resistance. SHAC alsopossesses good volume stability and isresistant to carbon monoxide disinte-gration.




CONVENTIONAL HIGH-ALUMINACASTABLES con’t.

TAYCOR® 414-FH HYDROCASTHigh purity, fine grained, extra-highalumina, conventional cement castable.High refractoriness, strength and grainsizing make TAYCOR® 414-FHHYDROCAST especially well suitedfor thin walled castings. Excellentchoice for coil grouting in corelessinduction furnaces melting steel alloys.

GREENCAST® 97 PLUSGREENCAST® 97 PLUS is a 97%alumina dense castable for tempera-tures up to 3400°F (1870°C). It isbased on very high purity ingredients,low in silica, iron oxide, and alkalies.

LOW CEMENT FIRECLAY

VERSAFLOW® 45 PLUSA fireclay based low cement castable,with versatile installation capability.This product features good strengths.An excellent utility castable for use inhigh abrasion areas.

VERSAFLOW® 45C ADTECH®

A coarse aggregate, fireclay based lowcement castable. Its coarse aggregateimproves thermal shock, abrasion andimpact resistance.

ULTRA LOW CEMENT FIRECLAY

ULTRA-GREEN 45A 45% alumina, ultra-low cement,vibratable castable. Features excellentstrength, outstanding hot load bearingability, superior corrosion resistance,low porosity and high density. Can beused as original linings, to repairexisting linings, and as pre-cast shapes,non-ferrous furnaces and ladles,cement kilns, coolers and rings, boilersand in the chemical processingindustry.

ULTRA-EXPRESS 45A 50% alumina, flint-based, dense, self-flowing, ultra-low cement castable. Ithas the unique property that vibrationis not required to remove air voids. Thisversatile product can be either cast orpumped.

LOW CEMENT HIGH-ALUMINACASTABLES

KALAKAST AR® ADTECH®

A 60% alumina casting mix.KALAKAST AR® ADTECH® hasexceptional resistance to alkali attack.Other benefits include better abrasionresistance than 60% alumina firedbrick, castables, and phosphate-bondedplastics after curing. High hotstrengths at elevated temperatures.Designed to replace brick and plasticwhere joints are undesirable.

VERSAFLOW® 60 PLUSA 60% alumina low cement castablebased on bauxite calcines, which hasversatile installation capability - fromvib-casting to pump casting. Thisproduct has excellent abrasion resis-tance, high hot strengths at 2500°F. Anexcellent all purpose castable forapplications such as incinerator chargezones, burners, and rotary kilns.

VERSAFLOW® 55/AR ADTECH®

A unique castable refractory of 60%alumina class with exceptional resis-tance to alkali attack and abrasion.Typical applications include incinera-tors and aluminum furnace uppersidewalls and roofs.

VERSAFLOW® 55/AR C ADTECH®

A 55% alumina, low cement, coarsegrain castable based on bauxiticcalcines. Specifically designed forimpact and abrasion resistance in highalkali environments. Typical usesinclude incinerators and aluminumfurnace roofs.

VERSAFLOW® 57AA 60% alumina, andalusite based, self-flowing castable with excellent thermalshock and alkali resistance. Thisversatile product can be cast orpumped.

NARCON 65 CASTABLEA low moisture mullite castable for useto 3200°F (1760°C). The low cementcontent provides extremely highstrengths to withstand the erosiveeffects of hot dust laden gases. Itshomogeneity of structure makesNARCON 65 much less susceptible tothermal shock damage than conven-tional castables.

NARCON 70 CASTABLEA low moisture mullite castable for useto 3250°F (1788°C). The low cementcontent provides extremely highstrengths to withstand the erosiveeffects of hot dust laden gases. Itshomogeneity of structure and coarsegrain sizing makes NARCON 70 muchless susceptible to thermal shockdamage than conventional castables.

VERSAFLOW® 70 ADTECH®

A 70 % Alumina low cement castablebased on Alabama bauxitic calcineswhich can be installed in several ways,from vibcast consistency to pumpcasting techniques. It features excel-lent abrasion resistance, high hotstrengths at 2500°F (1371°C), and highrefractoriness.

VERSAFLOW® 70 C ADTECH®

A 70% alumina, coarse grain castablewith high strength, high refractorinessand excellent abrasion and impactresistance. Typical uses includefoundry ladles, rotary kiln nose ringsand lifters, incinerator charge zones,and precast tundish furniture.




LOW CEMENT HIGH-ALUMINACASTABLES con’t.

VERSAFLOW® 70/CU ADTECH®

A 70% alumina low cement castablecontaining a special penetrationinhibitor for increased resistance tometal penetration. It can be vibcast,poured, or pumped and is suited forservice temperatures up to 2850°F(1566°C). Designed specifically forcopper and iron foundry applications.


VERSAFLOW® 80 C ADTECH is acoarse, 80% alumina low cementcastable based on calcined bauxite,which can be pumped or vibration cast.It has excellent impact resistance andoutstanding thermal shock resistance.

FASKAST 80An 80% alumina, low cement castablewith a high purity mullite matrix. Ithas a relatively fast set time and goodhot strengths and outstanding flow.Ideal for field casting in areas such asladle lip rings.

GREFCON® 85GREFCON® 85 is a high-alumina lowcement, low moisture castable charac-terized by its high density, low poros-ity, and high hot strength. GREFCON®

85 can be installed by ramming,vibration cast, hand casting, orpumping by varying the amount ofwater.

D-CAST 85 TM CASTABLEAn 85% alumina low cement castablewith a higher purity matrix than othercastables in this class. High densityand low porosity result in increasedslag resistance. Typical applicationsinclude kiln car tops; kiln nose rings,foundry ladles, coke calcining andalumina kiln burning zones. D-CAST85 TM uses special gas formingtechnology to create gas channels foreasier drying.

D-CAST 85 TM-CC CASTABLEAn equivalent product compared withD-CAST 85 TM in regards to baseaggregate and matrix additions.However, D-CAST 85 TM-CCCASTABLE does not employ the gaschannel technology but relies on anorganic fiber addition to aid in drying.The ‘CC’ is designed for customcasting applications where a morecontrolled dry out can be conducted.

D-CAST 85 HS CASTABLEThis specially designed low-cement,high alumina castable offers highdensity and high hot strengths. Basedon a higher purity aggregate and matrixsystem than the other D-CASTcastables, D-CAST 85 HS CASTABLEexhibits excellent slag corrosion andmetal penetration resistance resultingin longer campaign life and easiercleaning of ladles, troughs, andrunners.

TAYCOR® 414-C HYDROCASTThis is a coarse grained 96% aluminacastable with intermediate cementcontent. This coarse grained structureprovides for very good thermal shockresistance.

GREFCON® 98GREFCON® 98 is a volume stable 98%alumina, low cement, low-moisturecastable, characterized by its highdensity, low porosity, high hot and coldstrengths, and excellent abrasionresistance.

GREFCON® 98 SPAn extra-high alumina, high purity, lowmoisture castable that contains spineladditions for slag penetration resis-tance and excellent high temperaturestrength.

GREFCON® 98 TA tabular alumina based castable withhigh purity and high refractoriness.This product has exceptional strengthand abrasion resistance, and is an idealchoice for many metal-contact areas.

ULTRA LOW CEMENT HIGH-ALUMINA

ULTRA-GREEN 57AULTRA-GREEN 57A is a 57%alumina, andalusite based, ultra lowcement castable with outstandingthermal shock resistance in applica-tions having extreme cyclic tempera-ture conditions. ULTRA-GREEN 57Aalso features high hot strength, lowporosity, and high density superior orequal to fired brick of similar composi-tion.ULTRA-GREEN 60 & PLUSULTRA-GREEN 60 is a 60% aluminalow cement castable characterized byits high density, low porosity and highhot strength. ULTRA-GREEN 60 isdesigned for placement by ramming,vibration cast, hand casting, orpumping by varying the amount ofwater.

ULTRA-GREEN 70 ADTECH®

ULTRA-GREEN 70 is a 70% alumina,ultra-low cement, vibratable castable.Features excellent strength, outstand-ing hot load bearing ability, superiorcorrosion resistance, and low porosity-high density.

ULTRA-EXPRESS 70 ADTECH®

A dense, free-flowing, ultra-lowcement refractory castable. It has theunique property that vibration is notrequired to remove air voids. It can beeither cast or pumped. Its densitytogether with very good abrasionresistance makes it an ideal hot facelining material.

ULTRA-GREEN 80An 80% alumina, ultra-low cementcastable with high hot strength forresistance to hot load, abrasion and hotmetal erosion. Typical applications arecyclones, burners, and nose rings.

ULTRA EXPRESS 80ULTRA EXPRESS 80 is an 80%alumina, dense self-flowing, ultra lowcement castable. It has the uniqueproperty that vibration is not requiredto remove air voids. It can either becast or pumped.




ULTRA LOW CEMENT HIGH-ALUMINA con’t.

ULTRA-GREEN SRULTRA-GREEN SR is a tabularalumina based, 86% alumina, ultra-lowcement, vibrating castable. Thisproduct displays high hot strength forresistance to hot load deformation andhot abrasion. Maximum operatingtemperature is 3400°F (1870°C). Itsaddition of andalusite gives it thermalshock resistance superior to conven-tional ultra-low cement tabular aluminacastables.

HP-CAST ULTRALow moisture, low-cement, spinelforming 96% alumina castable. With a3400°F service temperature andoutstanding hot strengths this castableis ideally suited for steel contact andprecast shapes.

HP-CAST 93SLow moisture, low-cement, spinelcontaining 94% alumina castable.Excellent hot strengths and thermalshock resistance. Its spinel additionand outstanding hot properties com-bine to provide improved slag andmetal erosion resistance in ladle impactpads and other precast shape.

HP-CAST 94MA-CCoarse grained, low cement castablebased on high purity alumina aggre-gates. HP-CAST 94MA-C containspreformed magnesia-alumina spinel foroptimum slag resistance. Coarse graintechnology provides excellent thermalshock resistance. High density, lowporosity and high hot strengths helpresist metal and slag attack at steelprocessing temperatures.

HP-CAST MAXIMALow moisture, low-cement 92%alumina castable with patented bond.Contains both preformed and in-situspinel additions for optimum slagresistance. Ideally suited for impactpads, well blocks and other high wearareas.

HP-CAST 93Z3A high purity, thermal shock resistant,ultra low cement castable. It has highhot strength, low hot load deformation,and low porosity. Typical applicationsinclude ammonia plant secondaryreformers and transfer lines, carbonblack reactors, nozzles, burner blocksand channel induction furnace linings.

CEMENT - FREE HIGH-ALUMINACASTABLES

NOVACON® 65 ADTECH®

A 65% alumina, lime free monolithwith excellent creep resistance.Relative to conventional castables, thismonolith has superior hot strengths athigh temperatures, in addition toreduced dry-out time. This monolithprovides resistance to alkali andchloride attack. It has problem -solving capabilities in numerousapplications.

NOVACON® 85An 85% alumina, lime free monolithwith exceptional refractoriness loadresistance, and superior hot strengthsbetween 2000 and 2700°F compared toconventional castables. The lime freebinder allows for reduced dry-out time,in addition to resistance to chlorineenvironments. For use in hearths,incinerators, and precast shapes.

NOVACON® 95A 95% alumina, lime free monolithwith exceptional refractoriness andpurity. This product has excellent hotstrengths at high temperatures andgood chemical resistance. It hasproblem solving capabilities for precast shapes and burner blocks.

NOVACON® SA 97% silica cement-free monolithbased on vitreous silica aggregate withoutstanding thermal shock resistance.This product has high hot strength andvolume stability, as well as excellentresistance to alkali and chlorine attack.

FASTDRY 8 CASTABLEThis is a high alumina, cement freecastable with an alumina rich spinelmatrix. It offers good resistance tosteel and iron slags. The cement freeformulation provides exceptionalstrength at high temperatures andallows the dry out to begin sooner thanfor cement containing castables.

CHEMICALLY BONDEDCASTABLES

EXCELERATE™ ABR PLUSEXCELERATE ABR PLUS is aphosphate bonded, chemical settingcastable that can be rammed, vib-cast,hand packed, or gunned hot and cold.It develops a quick set and can beheated within 4 hours of installation tominimize furnace downtime. Thiscastable displays outstanding strengthsand abrasion resistance.

VITREOUS/FUSED SILICACASTABLES

ATM-2000A high purity, fused silica castable. Itfeatures volume stability, thermalshock resistance, and low thermalconductivity. ATM-2000 is designedfor easy placement in inaccessibleplaces and for shapes that are difficultto manufacture by conventionalmethods.

DESCON® S97 ADTECH®

A vitreous silica based casting mixwith outstanding thermal shockresistance. DESCON® S97 ADTECH®

features chemistry, refractoriness,density, and porosity equivalent to highquality fired silica brick, and is idealfor hot repair work and manufacture oflarge and/or complicated shapes.Typical uses include glass tanks, cokeoven maintenance, hot patching ofglass tank crown and burner blocks.




VITREOUS/FUSED SILICACASTABLES con’t.

FUSIL® CASTABLE 820IA fine grained, fused silica castableutilizing a high purity, hydraulic settingcement binder. FUSIL® CASTABLE820 I has exceptional volume stability,thermal shock resistance, low thermalconductivity, and light weight.

HPV ESX CASTABLEA high purity, fused silica castable. Ithas volume stability which leads tooutstanding thermal shock resistance.HPV ESX is an excellent choice forburner blocks and other thermallycyclical applications.

VISIL® ES CASTABLE ADTECH®

A refractory castable employing ablended mixture of carefully sizedvitreous silica aggregate and hydraulicbinder. It features extremely lowthermal expansion resulting in excel-lent resistance to cracking due tothermal shock. Easily installed bycasting, trowelling or air placementgun. Primary applications includefurnaces in which severe cyclingconditions exist and maximum tempera-ture does not exceed 2000°F (1093°C).

VERSAFLOW® THERMAX® PLUSA unique, extra-strength, low cementvitreous silica castable with a highpurity binder and reinforced matrix. Itslow density and thermal conductivityalong with high strength and abrasionresistance allow it to be used as asingle component lining where a densecastable, lightweight castable combina-tion may be used.

VERSAFLOW® THERMAX® ALADTECH®

A vitreous silica based low-cementcastable with an aluminum penetrationinhibitor. VERSAFLOW®

THERMAX® AL ADTECH® offersexceptional thermal shock and abrasionresistance, as well as volume stability.

EXPRESS® THERMAX® ADTECH®

A unique low cement refractorycontaining a fortified matrix andunique vitreous silica aggregate.Ideally suited for installation in severalways-from vibcast consistency to pumpcasting techniques. This refractory isself leveling when tempered at the highend of the recommended water range.This product has excellent abrasionresistance.

ZIRCON CASTABLES

NARCON ZRALA 60% zirconia castable with excellentcorundum resistance. Zoning alumi-num furnace belly bands withNARCON ZRAL has proven to be verysuccessful in furnaces prone tocorundum formation.

THOR AZSP ADTECH®

A pumpable, low-moisture fusedzirconia-mullite castable with a siliconcarbide addition. The zircon is tied upwith the mullite and will not reduce. Ithas exceptional resistance to alkalis,chlorides and sulfates. It has excellentabrasion high refractoriness.

ALUMINA-CHROME CASTABLES

FUSECRETE® CFUSECRETE® C is a high aluminacastable refractory characterized byhigh cold compressive strength,erosion resistance and containing 3%chromic oxide for resistance to slagerosion.

FUSECRETE® C10A high alumina castable refractory withhigh chromic oxide content forresistance to corrosion by ferrous andnon-ferrous slags.

FUSECRETE® C6FUSECRETE® C6 is a high aluminacastable refractory that has highchromic oxide content for resistance tocorrosion by ferrous and non-ferrousslags.

AUREX® 70 CASTABLEA chrome-alumina castable based onAUREX® and NOVACON® technology.It has excellent corrosion resistanceand contains a spall inhibitor forimproved resistance to thermal shock.

DENSE MAGNESITE CASTABLES

GR-FG® CASTABLEA chemically bonded basic castablethat employs fused magnesium-chromate spinel aggregate that pro-vides excellent resistance to slagpenetration in both ferrous and non-ferrous applications. GR-FG®

CASTABLE has the ability to beapplied by both casting and pneumaticgunning techniques.

HARCHROME® CASTABLEA chrome ore base castable refractoryusing a standard calcium aluminatehydraulic binder. It features outstand-ing strength and abrasion resistance. Italso has high resistance to chemicalattack and thermal spalling.HARCHROME® CASTABLE can beinstalled by casting, gunning, orramming.

H-W® CHROMEPAK®

A chrome magnesite mix with a silicatebond. H-W CHROMEPAK is a strong,volume stable refractory and can becast or gunned.

NARMAG® FG CASTABLEFused grain, Magnesia-Chromecastable with excellent resistance toerosion by basic slags. NARMAG® FGCASTABLE has high density and lowpermeability to help prevent penetra-tion by molten metals, slags and gases.

NOVUS® CASTABLEA magnesia chrome spinel castable,which does not contain a calciumaluminate binder. It features outstand-ing resistance to chemical attack byfluxes and slags due to purity of rawmaterials. Typical uses include AODhoods or covers, steel or ductile ironladle linings, lance sections, collectornozzles, and copper applications.




DENSE MAGNESITE CASTABLEScont.

MAGSHOT® CASTABLEMAGSHOT® CASTABLE is based ona dicalcium silicate natural magnesitethat has good resistance to moltensmelt and soda. This unique formula-tion does not require lengthy cure timeor slow heat up schedules. It offersexcellent casting characteristics.

NARMAG® 95LS CASTABLEA 96% magnesia castable with highdensity and strength. It is intended forbasic steel and iron operations.

DENSE SILICON CARBIDE

THOR 30 ADTECH®

A low cement, 30% silicon carbidecontaining castable that can beinstalled by vibration casting, shotgun-ning, or shotcreting. A reduced cementcontent with a special additive packagehelps improve alkali resistance.

THOR 60 ADTECH®

A low cement, 60% silicon carbidecontaining castable that can beinstalled by vibration casting, shotgun-ning, or shotcreting. A reduced cementcontent with a special additive packagehelps improve alkali resistance.

THOR 60 ABR ADTECH®

A 60% silicon carbide castable withvery high strength and abrasionresistance. Used primarily in thealuminum industry, it is a provenproblem solver in hearths, ramps andsills.

SILICON CARBIDE CONTAININGCASTABLES

D-CAST XZR-OR and XZR-OR-CCCASTABLEA low cement, high alumina, siliconcarbide containing castable. Resistantto abrasion by hot flowing moltenmetals. D-CAST XZR-OR hasexcellent thermal shock resistance,high density, low hot load deformation,and excellent oxidation resistance.Typical applications include copperand brass furnace linings and launders,cupola front slaggers and holders, andfoundry ladles and slag runners. To aidin drying, the ‘CC’ version contains anorganic fiber addition while thestandard version employs gas formingtechnology. Can be applied usingSHOTKAST technology.

D-CAST TRC-SRA low cement, high alumina, siliconcarbide and carbon containing castabledeveloped for optimum slag resistance.The combination and sizing of thesilicon carbide and carbon additionsmake D-CAST TRC-SR extremelyresistant to hot flowing molten metalsand slags. Outstanding hot propertiesand low permeability also make thecomposition resistant to corrosive anddust laden gases. Typical applicationsinclude cupola wells, troughs and slagrunners. Can be applied usingSHOTKAST technology.

D-CAST TRC-OR and TRC-OR-CCCASTABLEA low cement, high alumina, siliconcarbide and carbon containing castabledeveloped for improved oxidationresistance. An anti-oxidant addition isprovided to protect the silicon carbideand carbon additions from oxidation.D-CAST TRC-OR features goodthermal shock resistance, low porosityand permeability, and volume stabilityfor negligible sintering cracks duringservice. These properties combine toprovide resistance to abrasion by hotflowing molten metals and slags and tolimit corrosion and penetration ofliquid metals, slags, and gases. To aidin drying, the ‘CC’ version contains anorganic fiber addition while thestandard version employs gas formingtechnology. Can be applied usingSHOTKAST technology.

D-CAST TRC-OR PLUSA low cement, high alumina, siliconcarbide and carbon containing castable.Contains the same oxidation resistanttechnology as D-CAST TRC-OR. ThePLUS designation is a separateaddition for improved slag resistance.Low porosity and permeabilitycombined with the non-wetting andPLUS additions make D-CAST TRC-OR PLUS the most slag resistant D-CAST TRC material. Typical applica-tions include cupola wells and tapholesand casthouse applications inironmaking. Can be applied usingSHOTKAST technology.




INSULATING CASTABLES

KAST-O-LITE® 16 PLUSA 1600°F insulating castable withoutstanding low density and very lowthermal conductivity that can beapplied by casting or gunning.

KAST-O-LITE® 19L PLUSA 1900°F (1037°C) maximum servicetemperature insulating castable. Itexhibits greater crushing strengths thantraditional mineral wool block insula-tion and can conform to irregular shellconfigurations. It is used ideally as aback-up lining behind hot face liningsto reduce shell temperatures.

KAST-O-LITE® 20 PLUSA 2000°F (1095°C) insulating castableusable in direct contact with hot gasesunder continuous or intermittentoperation without loss of thermalefficiency.

KAST-O-LITE® 20 LI ADTECH®

A low iron insulating castable with amaximum service temperature of2000°F (1093°C).

KAST-O-LITE® 22 PLUSA lightweight castable for temperaturesto 2200°F (1205°C). It features lowthermal conductivity and good strengthfor such a lightweight material.

KAST-O-LITE® 23LI PLUSKAST-O-LITE® 23LI PLUS is a2300°F (1260°C) maximum servicetemperature insulating castable. Itcontains low iron to resist detrimentalreducing furnace conditions. Typicalapplications are: flues, stacks, breech-ings, controlled atmosphere furnaces,petroleum transfer and riser back-uplinings, catalytic reformer liningsbehind stainless steel shroud and wasteheat boilers.

KAST-O-LITE® 23 ES ADTECH®

An intermediate strength insulatingcastable with a maximum servicetemperature of 2300°F (1260°C).

KAST-O-LITE® 50-25A 2500°F (1370°C) insulating castablewith good strength and low thermalconductivity. KAST-O-LITE 50-25can be installed by pouring, pumping,or gunning.

KAST-O-LITE® 26 LI PLUSA low iron insulating castable with amaximum service temperature of2600°F (1427°C).

MC-28L PLUSA 2800°F insulating castable combin-ing the features of an extra strengthcastable in a lightweight, insulatingmaterial. It has high strength, lowshrinkage, and low iron.

KAST-O-LITE® 30 LI PLUSA lightweight insulating castable withhigh purity cement and a maximumservice temperature of 3000°F(1649°C).

KAST-O-LITE® 97L PLUSA 3300°F (1815°C) maximum servicetemperature insulating castable. Itcontains bubble alumina for highstrength and moderate density. It has avery low silica content to resistdetrimental hydrogen atmospheres.Typical applications are secondaryammonia reformer back-up linings,carbon black reactor back up linings,very high temperature back-up linings,waste heat boiler tube sheets, andcontrolled atmosphere furnace linings.

GREENLITE 75-28 PLUSA lightweight, super-duty, hydraulicsetting castable with high strength.GREENLITE 75-28 is rated to 2800°F.

GREENLITE EXPRESS 24 PLUSA 2400°F, self-flowing, insulatingrefractory castable. It has the uniqueproperty that vibration is not requiredto remove air voids. It can be conven-tionally cast, or pumped using aPutzmeister pneumatic pump.

GREENLITE CASTABLE 22 PLUSGREENLITE CASTABLE 22 PLUS isa 2200°F (1203°C) maximum servicetemperature insulating castable thatcan be cast or gunned. It has moderatedensity, good strengths, and a lowpermanent linear change after heatingto 1500°F (816°C).

GREENLITE-45-L PLUSA 2500°F insulating castable, withhigh strength and low density.GREENLITE-45-L can be pumpedusing a Putzmeister pneumaticpump.

HPV™ CASTABLEA high strength, lightweight, insulatingcastable with exceptionally highstrength and abrasion resistance.

ALUMINUM RESISTANTCASTABLES

GREENLITE-45-L ALThis lightweight castable has a veryhigh strength to weight ratio. It isideally suited for insulating Aluminumsub-hearths and crucibles.

HYDROCRETE® ALAn aluminum resistant version of thestandard HYDROCRETE®. It has highstrength and a moderate density.HYDROCRETE® AL is an attractive,economical choice for aluminumfurnace sub-hearths.

H-W® ES CASTABLE C ALAn industry standard for aluminumfurnace safety linings, H-W® ESCASTABLE C AL is a coarse aggre-gate castable with excellent impact andthermal shock resistance.

VERSAFLOW® 45/AL ADTECH®

A 45% alumina, pumpable, low-cement castable with improvedstrength versus conventional castables.




ALUMINUM RESISTANTCASTABLES con’t.

GREENKLEEN 60 PLUSIs a 60% alumina, low cement castablecontaining andalusite. GREENKLEEN60 PLUS displays outstanding abrasionresistance, thermal shock resistance,and resistance to aluminum penetra-tion. It can be vibration cast orpumped as required. GREENKLEEN60 PLUS contains special additiveswhich enable it to be fired morequickly than regular castables. It isnon-wetting in contact with aluminum,and slag resistant in waste-to-energyboilers.

VERSAFLOW® 65/AL PLUSA 65% alumina, low cement castablewith high strength and versatileinstallation characteristics.

VERSAFLOW®

65/AL C ADTECH®

A 65% alumina, aluminum resistant,coarse grain castable. For use in highwear areas in aluminum contact suchas ramps, sill and cruce bottoms. Itscoarse aggregate improves its thermalshock and impact resistance.

NARCOTUFFTM SUPER ALWith a minor zircon addition,NARCOTUFF SUPER AL is anexcellent choice for the lower sidewallor bellyband in an aluminum furnacewith slight corundum growth.

ARMORKAST™ 65ALA very high purity low cementcastable. Its unique bonding matrixprovides exceptionally high strengthand ultimate corrosion resistance.

ARMORKAST™ 70 ALAn economical, low cement, 70%alumina, aluminum resistant castable.It has good strength and resistance tomolten aluminum alloys.

ULTRA-EXPRESS 70 ALAn ultra-low cement, 70% aluminacastable designed with enhanced flow,and self-leveling characteristics.ULTRA-EXPRESS 70 AL is verystrong and is ideal for pumping overlong distances and for casting intointricate form patterns.

ARMORKAST™ 80AL ADTECH®

This high purity, pumpable, 80%alumina castable is built for corrosionresistance. It has exceptional strengthand aluminum resistance.ARMORKASTTM 80AL is designed forthe most severe aluminum contactapplications.

ALSTOP GREFCON® 80 AAn industry standard for more than 15years, ALSTOP GREFCON® 80A is ahigh strength, high corrosion resis-tance, 80% alumina low cementcastable.

ARMORKAST™ XPUR/ALADTECH®

This tabular alumina based castable isalso silica-free, and is designed combatcorundum formation. It shows veryhigh strength and excellent aluminumresistance.

HP-CASTTM 96ALA high purity, tabular alumina based,aluminum resistant castable. It hashigh hot strength and very low poros-ity. It is well suited for melting andholding furnaces where pure metalchemistry is of extreme importance.

HIGH TOUGHNESS CASTABLES

2-TOUGH® HP ADTECH®

The combination of a coarse tabularalumina aggregate and a fine tabularalumina matrix gives this high puritymix outstanding corrosion resistance.2-TOUGH® HP ADTECH® has set arecord in the impact test, survivingalmost 70 impacts!! This uniqueproduct has solved severe wearproblems in several steel applicationsincluding well blocks, ladle bottomsand electric furnace deltas.

2-TOUGH® FA ADTECH®

Exceptionally high strength and impactresistance characterize this product.Its fused alumina coarse aggregate hasa higher density than tabular alumina,resulting in significantly lower porositythan traditional 90% alumina castables.Typical uses for 2-TOUGH® FAADTECH® include ladle bottoms,aluminum furnace jambs and lintels,and rotary kiln lifters.

2-TOUGH® AL ADTECH®

2-TOUGH® AL ADTECH® is specifi-cally designed for use in aluminumcontact. It is essentially silica free, andcontains an aluminum penetrationinhibitor. This makes it very resistantto aluminum corrosion. Typical usedinclude precast hearths, ramps, andsills, belly bands, troughs, and cruces.



OverviewRamming mixes typically consist of ground refractory grog materialsin a wide range of chemical composition, carefully graded as torelative proportions of different particle sizes, with minor amounts ofother materials added to make the mixes workable and self-bonding. Most ramming mixes are supplied dry, but some are shipped in ready-to-use, wet form. Dry mixes are prepared for use by adding water andmixing. Some ramming mixes can be applied successfully with air-place-ment guns. Others, known as dry-vibratibles, are specifically designed tovibrated into place.

Once rammed, gunned or vibrated into place, dried and heated, rammingmixes form dense, strong monolithic structures. Ramming mixes are par-ticularly suitable for forming dense monolithic hearths.

The following product descriptions of Harbison-Walker’s ramming mixesare categorized by their classification. This listing represents the majorbrands supplied for a wide variety of furnaces and applications.

RAMMING MIXES

HIGH-ALUMINA RAMMING MIXES

BRIKRAM® 57 RBA phosphate-bonded, high aluminaramming mix with high hot strengthand excellent resistance to deformationunder load.

HARMIX® ALAn air-setting, high purity aluminaramming mix with excellent strengthsat all temperatures within its use range.Resists spalling and has remarkablelinear and volume stability up to itstemperature limit. HARMIX AL isideally suited for inductor blocks.

NARPHOS 55R (FINE) RAMAn economical, phosphate bonded,high-alumina ramming mix. It has highstrength and excellent installationcharacteristics.

NARPHOS 85R RAMAn 85% alumina class, phosphate-bonded, ramming mix, NARPHOS 85RRAM provides high strength anddensity combined with excellentvolume stability throughout its entiretemperature range. It displays non-wetting characteristics to provideoutstanding resistance to erosion fromslag and metal wash. This product isused where excellent resistance totemperatures, slag, thermal shock, andabrasion is required.

NARPHOS 90R RAMNARPHOS 90 R RAM is a high purity,extra high alumina, phosphate bondedramming mix. It exhibits high densityand excellent strength.

RAMAL® 80A high alumina air-setting rammingmixture furnished in wet form, readyfor use. It features excellent resistanceto shrinkage and thermal spalling athigh temperatures. Typical usesinclude burner rings, electric furnaceroofs, and ladle linings for ferrous andnonferrous industries

TAYCOR® 245-D RAM MIXA dry ramming mix based on highpurity sintered alumina. In-situ spinelformation provides improved slag andmetal resistance and volume stability atelevated temperatures.

ALUMINA-CHROMERAMMING MIXES

RUBY® RAMMING MIXA phosphate-bonded, high purityalumina-chrome ramming mix withexceptional intermediate and hightemperature strengths. Resists attackby acid and neutral slags and isespecially suited for use where therefractory is exposed to coal ash andcoal slag.

MAGNESITE & MAG-CHROMERAMMING MIXES

GREFMAG® 95RA high quality, magnesia based,chemically bonded ramming mixavailable in the dry form. When mixedwith water, GREFMAG® 95R developsgood plastic workability so it can berammed to the highest density. Typicalapplications include the workinglinings of coreless induction furnaces,bottoms and working linings of ElectricArc furnaces, and steel ladles.

HARMIX FE®

A high purity magnesite ramming mixwith exceptional stability for use incoreless induction furnaces meltingsteel and alloys.

H-W® C MIXA high purity, chemically bondedramming mix for electric furnacehearths, subhearths and other levelingpurposes in process vessels.

MAGNAMIX® 95A versatile, high purity periclase mixwhich can be installed by ramming,gunning, or vibration casting. For newconstruction of electric furnace hearthsand maintenance of electric furnaceand BOF tapholes.

GR-FG RAMMING MIXAn organic bonded, magnesite-chrome,fused grain ramming mix. It featuresexceptionally high density and strengthand volume stability throughouttemperature range.




MAGNESITE & MAG-CHROMERAMMING MIXES con’t.

OXIMIX®

A carbon containing magnesia ram-ming mix for increased resistance topenetration by ferrous metals.

SiC & CARBON CONTAININGPLASTICS & RAMMING MIXES

RAMAL 85 GThis is a fused grain containing, highalumina wet ramming mix with a highamount of graphite. The high purityaggregate and graphite additioncombine to provide resistance to slagand metal erosion. RAMAL 85 G isespecially well suited for cupolabottoms, troughs, and runners.

SUPER NARCARB RAMBased on fused alumina with SiC andoxidation inhibitors. This yields verylow porosity for enhanced corrosionresistance to cupola slags. SUPERNARCARB RAM is intended forextended cupola campaigns and themost severe service conditions. Itoffers the highest level of carboncontaining, non-wetting components,and a more environmentally friendlybond system than the phenolic resinbonded materials.

NARCARBTM XZR RAMThis is a phenolic resin-bondedramming mix with the second highestamount of non-wetting components.This mix offers high density, lowporosity and high hot strengths.NARCARBTM XZR RAM providesexcellent performance in maintenancesituations or as the original lining inCupola bottoms and troughs.

NARCARBTM XZR-HS RAMThis phenolic resin-bonded rammingmix is a high strength, oxidationresistant upgrade to NARCARBTM XZRRAM. The improved properties,combined with its high amount of non-wetting components, make this mixextremely resistante to metal erosionand slag attack. This mix is ideallysuited for cupola taphole applications.

GREFITE RGREFITE R is a damp fireclay based,high quality graphitic ramming mixpossessing good resistance to slag andmolten iron. It has non-wettingcharacteristics that permit easyremoval of skulls which results incleaner linings and metal. Typical usesinclude cupola breasts, wells, andrunners, gray and malleable iron ladles,blast furnace troughs and runners.

HARMIX CU®

A mullite bonded, high alumina basedramming mix with a penetration andcorrosion inhibitor. It offers excellentdimensional stability and has acombination of physical and chemicalproperties particularly adapted to resistwetting, penetration and corrosion bymolten copper and copper alloys.Typical uses include linings for copperinduction furnaces. It is also suitablefor some high carbon steels.

DRY VIBRATABLES

NARCOVIBE 82A FINEA bauxite-based, dry vibratable for useas a fill material between brick workingand backup linings of steel ladles. Thismaterial will not sinter in serviceproviding for easier lining removalduring ladle tearouts.

NARCOVIBE SAn alumina-magnesia spinel dryvibratable refractory designed for thecoreless induction melting of steelalloys. Based on sintered alumina andhigh purity magnesia, its high bondstrength and high purity raw materialsprovide extreme resistance to theerosion created by high temperaturesand corrosive alloys. Designed forsmaller furnaces with installations ofless than 5-inches of sidewall thick-ness.

NARCOVIBE SDAn alumina-magnesia spinel dryvibratable refractory designed for thecoreless induction melting of steelalloys. Based on sintered alumina andhigh purity magnesia, it is engineeredfor deeper sintering and higher strengthdevelopment to protect against liningfracture during the charging procedure.Designed for larger furnaces withinstallations of greater than 5-inches ofsidewall thickness.

NARCOVIBE XLAn alumina-magnesia spinel dryvibratable refractory designed for thecoreless induction melting of steelalloys. Based on sintered alumina andhigh purity magnesia, it is engineeredto provide intermediate sintering forlarge or small size furnaces. Containsa spinel addition for improved corro-sion resistance.

NARCOVIBE TOP CAPAn alumina-magnesia spinel dryvibratable refractory designed for topcap of coreless induction furnacesmelting steel alloys. Designed for deepsintering at 1000°F or greater toprotect against damage from chargingthe furnace. Engineered to sinter andbond with the hot face lining.

RAMMING MIXES




OverviewINSWOOL® Ceramic Fibers are a family of products that are manufacturedfrom alumina-silica materials into several product forms. Those products aremade from spun fibers that provide low thermal conductivity, low heat storage,excellent thermal shock resistance, high temperature stability, lightweight andexcellent sound absorption.

The INSWOOL® Ceramic Fiber Product line has a wide temperature rangefor applications from 1500° F to 3000° F. These products also offer excellentchemical stability and resistance to chemical attack from most corrosive agents.The exceptions are phosphoric acid, hydrofluoric acid and strong alkalies.

INSWOOL® Ceramic Fibers come in various product forms which include:

• Blankets• Modules• Bulk• Board

CERAMIC FIBER PRODUCTS

INSBOARD®

INSBOARD is a vacuum formedceramic fiber board with excellentinsulating characteristics, as well asthermal stability. It can be used as ahot face or back up insulation material.Applications include petro-chemical,ceramics, steel, aluminum, wasteincineration, and the glass industry.INSBOARD is available in 2300,2600, and 3000 degree board.

INSBOARD® HDINSBOARD HD is a high density,vacuum formed ceramic fiber boardwith excellent insulating characteristicsand increased mechanical strength. Itis often used as a hot face insulation inhigh velocity applications.Applications include petro-chemical,steel, glass, ceramics, aluminum, andwaste incineration. INSBOARD isavailable in 2300, 2600, 2800, and3000 degree board.

INSBOARD® 2300 LWINSBOARD 2300 LW is a lightweightvacuum formed ceramic fiber boardwith excellent insulatingcharacteristics, thermal stability, andmachinability where special shapedboards are required. Its lightweightenables easy cutting and machining inthe field. Applications include areaswhere high quality back up insulationis required.

INSWOOL® Ropes and BraidsH-W provides a family of ropes andbraids for industrial use intemperatures up to 2300°F (1260°C).Typical applications for these productsinclude gasketing, packing and sealingin and around high-temperature heatingequipment. Produced from ceramicfibers, these products exhibit excellentchemical stability, resisting attack frommost corrosive agents. Exceptions arehydrofluoric and phosphoric acids andconcentrated alkalies. These fiberropes and braids also resist oxidationand reduction. If wet by water orsteam, thermal properties arecompletely restored upon drying. Nowater of hydration is present.

• Paper• Moldable and Pumpable• Rope and Braids

http://www.hwr.com/




INSWOOL® CG BLANKETINSWOOL CG is an alumina silicablanket used in applications up to2000°F. It is a high quality product thatcan be used as back up insulation formost furnace applications.

INSWOOL® HP BLANKETINSWOOL HP BLANKET is a low iron,high purity ceramic fiber blanketdeveloped especially for use in highlyreducing atmospheres. It islightweight, flexible and suitable foroperating temperatures to 2400°F.INSWOOL HP BLANKET retains asoft fibrous structure right up to itsmaximum usage temperature, and eventhe most extreme temperature changeswill not affect its ability to insulate andstay in place. INSWOOL HPBLANKET was developed to meet thedemand for a high temperature, flexibleblanket insulation with a low ironcontent of less than 1%. INSWOOLHP BLANKET has excellent strength,both hot and cold. It remains in placeon the furnace anchors even at hightemperatures and can resist damageeven when subjected to normalmistreatment in shipment and handling.

INSWOOL® HP BULKINSWOOL HP BULK is a low iron, highpurity alumina-silica bulk ceramic fiberwhich can be used at temperatures to2400°F. INSWOOL HP BULKdemonstrates excellent hightemperature resistance, thermalstability and resistance to vibration, aswell as outstanding low thermalconductivity and low heat storage. It isresistant to attack under reducingatmospheres. It is attacked by acidsand concentrated alkalis. The thermaland physical properties of INSWOOLHP BULK are completely restoredupon drying if it becomes wet by water,steam, or oil.

INSWOOL® HP MODULESINSWOOL HP MODULES are a familyof 12" x 12" modules up to 12" thick.Special shapes are available uponrequest. These modules will resisttemperatures up to 2400°F (1315°C) for

intermittent use and up to 2250°F

(1230°C) for continuous use.INSWOOL HP MODULES will reduceenergy losses through the lining moreeffectively than insulating firebrick,and insulating castables. Typicalapplications include oil heaters,annealing furnaces, reformer sidewallsand end walls, and homogenizingfurnaces. DO NOT use for linings incontact with molten metal, abrasive,alkali laden, and high positive pressureconditions.

INSWOOL® HTZ BLANKETINSWOOL HTZ BLANKET is a 2700°Frelated alumina-silica-zirconia ceramicfiber blanket. It displays very lowthermal conductivity, excellent thermalshock resistance, low heat storage, andgood sound absorption. Typicalapplications are glass furnace crowninsulation, expansion joint seals,furnace doors and shields.

INSWOOL® HTZ BULKINSWOOL HTZ BULK is an alumina-silica-zirconia bulk ceramic spun fiberwhich can be used at temperatures to2700°F. INSWOOL HTZ BULKdemonstrates excellent hightemperature resistance, thermalstability and resistance to vibration, aswell as outstanding low thermalconductivity and low heat storage. It isresistant to attack under reducingatmospheres. It is attacked by acidsand concentrated alkalis. The thermaland physical properties of INSWOOLHTZ BULK are completely restoredupon drying if it becomes wet by water,steam, or oil.

INSWOOL® HTZ MODULESINSWOOL HTZ MODULES are afamily of 12" x 12" modules up to 12"thick. Special shapes are availableupon request. These modules willresist temperatures up to 2700°F

(1480°C) for intermittent use and up to

2450°F (1345°C) for continuous use.INSWOOL HTZ MODULES willreduce energy losses through the liningmore effectively than insulatingfirebrick, and insulating castables.Typical applications include oilheaters, annealing furnaces, reformersidewalls and end walls, andhomogenizing furnaces. DO NOT usefor linings in contact with moltenmetal, abrasive, alkali laden, and highpositive pressure conditions.

INSWOOL® UTILITY BLANKETINSWOOL UTILITY BLANKET is aKaolin based ceramic fiber blanket. Itis lightweight, flexible and suitable foroperating temperatures to 2300°F. Ithas relatively low shot content andexcellent conductivity. INSWOOLUTILITY BLANKET exhibits moderatetensile strength and handlingcharacteristics.





INSWOOL® MOLDABLEINSWOOL MOLDABLE is a 2300°Fceramic fiber, putty-like consistencymaterial, used for linings up to threeinches thick, to pack large voids, oreven fill thin cracks.It can be troweled or hand packed intoplace. INSWOOL MOLDABLE islight weight, with very low thermalconductivity, and therefore a goodinsulator, yet it develops a strong hotface surface to withstand physicalabuse and high air velocities ascompared to conventional ceramicfiber products. It is also used as a hightemperature gasket material, and as ageneral purpose patching product. Itsability to compress makes INSWOOLMOLDABLE an excellent material forexpansion joints and for fillingcontraction cracks. It is also an idealmaterial to fill ceramic cuplockanchors for ceramic fiber blanketlinings, and can be used in contact withmolten aluminum. INSWOOLMOLDABLE has excellent thermalshock resistance, and can be dried orput into service immediately with nopre-heat required, with the exception ofdirect molten metal contact.

INSWOOL® PUMPABLEINSWOOL PUMPABLE is a 2300°Fceramic fiber, putty like consistencymaterial, especially formulated forpumping with special equipment. It isusually used for pumping behindexisting hot face linings for insulatingpurposes, however it can be used to fillsmall voids and thin cracks.INSWOOL PUMPABLE is a lightweight material with very low thermalconductivity, and therefore a goodinsulator. It dries to a firm, board-likeconsistency, for good sturdy integrity.Its ability to compress makes it idealfor expansion joints, and for fillingcontraction cracks. In addition it is

used in contact with molten metal.Although normally used as a back upmaterial, as mentioned above, whenused as a hot face material, theINSWOOL PUMPABLE has excellentthermal shock resistance, and can bedried or put into service immediatelywith no pre-heat required, with theexception of direct molten metalcontact.

INSWOOL® PAPERINSWOOL PAPER is a lightweight,refractory material processed fromalumina-silica ceramic fibers formed ina flexible sheet. It is recommended forcontinuous use at temperatures to2300°F. INSWOOL PAPER is clean andefficient, containing no unfiberizedshot. It is especially noted for havingexceptional low thermal conductivityand good handling strength. Its highlyuniform structure assures equal thermalconductivity throughout and its clean,smooth surface makes it ideal as agasket, seal and spacer material.

INSWOOL® UTILITY PAPERINSWOOL UTILITY PAPER is alightweight, refractory materialprocessed from alumina-silica ceramicfibers formed into a flexible sheet. It isrecommended for continuous use attemperatures to 2300°F. INSWOOLUTILTITY PAPER is a commercialgrade of ceramic paper. It is especiallynoted for having exceptional lowthermal conductivity and goodhandling strength. Its highly uniformstructure assures equal thermalconductivity throughout and its clean,smooth surface makes it ideal as agasket, seal, and spacer material.

INSBLOK-19INSBLOK-19 is a 1900°F maximumservice temperature lightweight mineralwool block insulation. INSBLOK-19exhibits very low thermal conductivity,good moisture resistance, easyhandling, and easy cutting. Its organicbinder gives INSBLOK-19 excellentcold strength but will dissipate above475°F. INSBLOK-19 meets the ASTMC612 Class 5 specification. Its principalapplication is as a backup lining tolower furnace shell temperatures.

INSFORM PREFIRED MODULEINSFORM PREFIRED MODULE is avacuum formed, pre-fired ceramic fibermodule. INSFORM’s module shell is apre-fired vacuum formed five sidedbox. This box or shell, open at theback, is manufactured from a widerange of ceramic fiber mixes designedto withstand specified serviceconditions. Normal box size is 18" x12", but special sizes as required areavailable. Thickness range from 4" to12".

INSFORM ADHESIVE GRADE 2INSFORM ADHESIVE GRADE 2 is afinely ground alumino-silicate and inertbinder based compound. Excellentchemical resistance and resistance towetting by most non-ferrous metals.Excellent thermal shock resistance,thermal reflectance and dielectricstrength properties. When exposed totemperatures above 1562°F (850°C) itundergoes an increase in strength dueto formation of the ceramic bond.



Brick Products

Basic Refractories BP-1

High-Alumina Refractories BP-3

Fireclay Refractories BP-6

Insulating Refractories BP-7

Special Purpose Refractories BP-9

Data Sheets* www.hwr.com

SECTION 6

*In order to provide current data to the users on this handbook, we havechosen to use an on-line link to our website, www.hwr.com. If you are notable to access the website, please contact your local sales representative tosecure the required data sheets.


Harbison-Walker BP - 1


OverviewBasic refractories are those based on magnesite (MgO). The termbasic refractory refers to refractory materials composed primarily ofbasic (non-acidic) oxides. At high temperatures, basic refractories arehighly resistant to the corrosive action of chemically basic slags, solidor liquid oxides, dusts, and fumes. Consequently, they are the refrac-tory materials of choice when one or more of these conditions arepresent. As the technology of basic refractories has advanced, theapplication for these products has broadened to include non-basicconditions, e.g., furnaces in the copper industry where siliceous(acidic) slags are present. Development of new and improved basicrefractories continues at a rapid pace driven by equally rapid techno-logical changes occurring in the industries they serve. The following product descriptions of Harbison-Walker’s basic brickrefractories are categorized by their classification. This listing repre-sents the major brands supplied for a wide variety of furnaces andapplications.

BURNED MAGNESITEBRICK

SUPER NARMAG® BOutstanding hot strength and goodresistance to alkali attack are featuresof SUPER NARMAG® B a 98%magnesia refractory brick. SUPERNARMAGr B brand brick provideunusual resistance to oxidation-reduction reactions as well as slagattack.

NOKROME 87 LKNOKROME 87 LK has very lowthermal conductivity and lends itself toapplications to reduce shell tempera-ture. It is standard product for applica-tions in upper and lower transitionzones of cement kilns under normaloperations.

NOKROME 92 LKNOKROME 92 LK has goodcoatability characteristics and performswell in all zones of kilns under normaloperations. Its coatability makes it agood performer in the burning zone.

DIRECT-BONDEDMAGNESITE-CHROMEBRICK

SUPER NARMAG® FGThis is a burned 100% fused MG-Crgrain brick with chrome enhancement.This yields extremely low porosity,very high density, and excellentstrength. SUPER NARMAG® FG isintended for the most basic iron andsteel containing conditions with regardsto slag corrosiveness and temperature.

NARMAG® FGThis is a burned 100% fused Mg-Crgrain brick. This yields excellentporosity, density, and strength.NARMAG® FG is intended for extremebasic iron and steel containing condi-tions.

SUPER NARMAG® 142This is a burned 20% fused Mg-Crgrain brick. It offers very goodporosity, density, and strength. Thisproduct is for normal basic iron andsteel containing conditions.

NARMAG® 142High-fired, direct bonded, magnesite-chrome brick based on high puritymagnesite and chrome ore.NARMAG® 142 features excellent hotstrength and good corrosion resistanceat steel-melting temperatures.

NARMAG® 60 DBHigh-fired, direct-bonded basic brick ofapproximately 60% magnesia content,NARMAG® 60 DB features excellenthot strength and good corrosion andspalling resistance elevated tempera-tures. NARMAG® 60 DB brick aremade from high purity periclase andbeneficiated chrome ore.

SUPER NARMAG® 145High fired, direct-bonded, magnesite-chrome brick based on high puritymagnesite and chrome ore with 50%fused grain. SUPER NARMAG® 145offers improved resistance to slag andload at high temperatures as well ashigher hot strength.

TOMAHAWK®

High-fired, rebonded, magnesite-chrome brick based on high purityfused magnesia-chrome spinel grain.TOMAHAWK® also has secondarydirect-bonding for improved thermalshock resistance.

BASIC BRICK


BP - 2 Harbison-Walker


MAGNESITE-SPINELBRICK

ANKRAL R17This is a burnt magnesia aluminatespinel brick. It has great resistanceagainst alkali and sulphur attack, aswell as a great mechanical flexibility.

MAGNEL® RSThis magnesia aluminate spinel-containing refractory is based on highpurity magnesite with a reinforcedspinel bond for higher hot strength. Ithas low thermal expansion and thermalconductivity for a basic brick, as wellas excellent spalling resistance.

MAGNEL® N/XT A combination of high purity syntheticmagnesite and fused spinel giveMAGNEL® N/XT its excellent physicalproperties.

MAGNEL® RSV A combination of high purity syntheticmagnesite, fused spinel and a matrix ofreinforced spinel gives MAGNEL®

RSV its excellent physical properties ata cost effective price. The moderateamount of spinel yields a product thathas excellent ressitance to clinkerliquids while maintaining lowerthermal conductivity and thermalexpansion than similar products of thesame class. MAGNEL® RSV can beused in all basic zones, but is bestsuited for lower transition and burningzone areas.

MAGNEL® HFMAGNEL® HF is composed ofcrystalline magnesia with a bond ofmagnesium-aluminate spinel. It offersimproved spalling resistance and goodhot strength. This brick is typicallyused for vacuum induction furnacemelting.

MAGNESITE-CARBONBRICK

COMANCHE®

An alumina-magnesia-carbon brickdesigned for steel ladle barrels andbottoms. COMANCHE® undergoes agradual permanent expansion at the hotface during service. Ladles lined withCOMANCHE®® will maintain tightbrick joints throughout the entire ladlecampaign without the need for mortar.

EAFEAF series magnesite carbon refracto-ries are high density, premium carbonbonded refractory brick based on highpurity magnesite. This broad productoffering makes it possible to designzoned refractory linings. Specializedproducts contain high purity graphites,metal antioxidants and fused refractorygrains.e brick are designed to havegood slag resistance and retain hightemperature stability, i.e. the ability ofthe brick to resist internal oxidation-reduction reactions that can reduce hotstrength and otherwise adversely affectthe physical integrity of the brick athigh temperature.

BASIC BRICK




OverviewHigh-alumina brick belong to the alumina-silica group containing more than47.5% alumina. These multi-purpose refractories are available with aluminacontents of up to 99+% and are useful for service extending to about3300°F (1817°C). Their refractoriness is generally in proportion to theiralumina content.

Often chosen for their resistance to spalling, impact, abrasion, orload, high-alumina brick’s broadest appeal lies in its high refractorinessand excellent corrosion resistance to acid and neutral slags at hightemperatures.

Harbison-Walker manufactures high-alumina brick of all classes,including mullite, corundum and alumina-chrome brick. The productline covers a wide range in refractoriness and other properties, andmeets the requirements of a great variety of service conditions in manydifferent types of furnaces.

Harbison-Walker’s continually improving manufacturing techniques,coupled with the company’s use of high purity domestic raw materials,has led to the manufacture of high-alumina refractories unequaled ineconomic service life.

The following product descriptions of Harbison-Walker’s high-alumina refractories are categorized by their classification. This listingrepresents the major brands supplied for a wide variety of incineratorand industrial furnace applications.

BURNED HIGH ALUMINABRICK

50% ALUMINA CLASS

KALA®

High purity, 50% alumina refractorywith low porosity and exceptionalresistance to alkali attack and creepunder sustained loads. Primaryapplications include carbon bakingflues, glass tank regenerators riderarches, blast furnace stoves andincinerators.

KALA® SRA 50% alumina refractory with an-dalusite to enhance load and thermalshock resistance. KALA SR providesimproved service in applications wheretemperature swings are common

60% AND 65% ALUMINA CLASS

UFALA®

This product manufactured from highpurity bauxitic kaolin displays lowporosity, very good hot strength, andsuperior resistance to thermal shockand alkali attack. Major applications arein checker settings of blast furnacestoves, along with incinerators androtary kilns.

UFALA® XCRAn upgraded version of UFALA® CR,this high-alumina brick is based on highpurity bauxitic kaolins and andalusite.UFALA® XCR offers improved loadresistance and thermal shock resistanceover conventional 60% aluminaproducts.

ARCO® 60 A 60% alumina firebrickexhibiting good properties forcontinuous temperatures up to 2650oF(1450oC).

UFALA® UCRThis brick is the premium qualitymember of the UFALA® family ofandalusite containing refractories.Ultimate creep resistance and excellentthermal shock resistance make UFALA®

UCR an ideal choice for applicationsinvolving high loading and temperaturecycling.

NIKETM 60 ARThis 60% alumina brick, with an-dalusite, shows good strength andexcellent resistance to alkali attack.

RESISTAL SM 60CAn andalusite containing, low porosity60% alumina brick with a phosphoruspentoxide addition to yield increasedthermal shock resistance and alkaliresistance.

RESISTAL® S 65 W AAn andalusite containing chemicallybonded 65% alumina brick with veryhigh strength and alkali resistance.

HIGH-ALUMINA BRICK




70% ALUMINA CLASS

KRUZITE® 70A dense, low-porosity 70% aluminabrick with excellent spalling resistance,hot load strength and the ability towithstand attack by corrosive slagsand metals. Successful applicationsinclude cement kilns, electric furnaceroofs, soaking pits, ladles, incinerators,reheat furnaces and many ferrous andnon-ferrous melting furnaces.


VALORTM P70A 70% alumina phosphate containingburned alumina brick.

ALTEX® 75BA 75% alumina, burned, phosphatebonded brick that exhibits low porosity

and high hot strengths.


GREENAL-80-PAn 80% alumina, mullite bonded,burned brick containing phosphate.Excellent alkali rating from 2200°F to2500°F. Good thermal shock resistance.

ALADIN® 80Based on calcined bauxites, ALADIN®

80 has good strength, reheat expansionand thermal shock resistance alongwith lower porosity than any otherbrick in this class. Resistant to mostslag conditions in steel ladles,ALADIN 80 is an economicalrefractory.

DV-38DV-38 is an extra high strength, lowapparent porosity, high alumina,burned phosphate-bonded brickfeaturing excellent alkali resistance.Withstands the penetration of fluidslags, metals, and fluxes. DV-38 is anexcellent choice for abrasiveenvironments at low temperatures.

GREENAL-80An 80% alumina burned brickcontaining premium bauxite. Thisbauxite results in less vitrification attemperatures in excess of 3000oF(1650oC)

ALADIN® 85This brick features high density andhigher strengths than most 80%alumina brick. Based on calcinedbauxite with very low alkali levels,ALADIN® 85 offers improved perfor-mance potential over other conven-tional products typically used for steelladle applications.

90% - 99% ALUMINA CLASS

KORUNDAL XD®

High purity ingredients and a highpurity mullite bond make KORUNDALXD a premium refractory brick, capableof handling very difficult applications.It has been the acknowledged standardfor 90% alumina brick since the mid-1960’s. These brick carry a substantialload at temperatures above 3000°F(1650°C), and also offer excellentresistance to penetration and corrosionby molten slags and other fluxes. It hasserved successfully in many applica-tions, such as slagging rotary kilns,where it resists corrosion and penetra-tion by slag and in constructions whereheavy loads and high temperaturesprevail.

KORUNDAL XD® DMThis is a mullite-bonded high puritycorundum refractory with DensifiedMatrix (DM). Characterized by lowporosity, high hot strength, and goodresistance to acid slags. KORUNDALXD DM has provided longer campaignlife in channel induction furnaces forthe foundry industry.

GREENAL-90A mullite bonded, 90% alumina brickcontaining phosphorous pentoxideadditions. It exhibits excellent alkali,slag, and abrasion resistance.

TUFLINE® 90A dense 90% alumina refractory withhigh hot strength, exceptional thermalshock resistance and low porosity.

TUFLINE® 90 DMA 90% alumina refractory with aDensified Matrix (DM) and mullite bondcharacterized by exceptional slagresistance and resistance to thermalshock.

TUFLINE® 95 DMHigh purity corundum bonded extrahigh-alumina brick with DensifiedMatrix (DM). Features are highstrength, low porosity and improvedrefractoriness. TUFLINE® 95 DM hasexcellent thermal shock resistance.

TUFLINE® 98 DMA 98% high purity corundum bondedbrick with the lowest porosity and silicacontent in its class, along with signifi-cant thermal shock resistance.

H-W® CORUNDUM DMA high-alumina brick product consist-ing of high purity corundum. It is usedin applications where the high meltingpoint, i.e., about 3700°F (2040°C) andstability and inertness of alumina arerequired.

ALADIN® 90 A 90% alumina brick with high densityand hot strengths.

HIGH-ALUMINA BRICK




PHOSPHATE BONDED HIGHALUMINA BRICK

ALTEX® 75BThis 75% alumina, phosphate bonded,burned brick has high strength and lowporosity. It is well suited for use inalkali environments needing resistanceto mechanical abuse.

CORAL® BPFeaturing low porosity, high strengthand volume stability at high tempera-tures, these burned, phosphate-bondedbrick provide good resistance towetting, penetration and reaction bymolten metals.

BURNED ALUMINA-CHROMEBRICK

RESISTAL® KR 85 CThis 85% alumina, 5% chromic oxide,chemically bonded brick has very highstrength. The chromic oxide additionprovides enhanced resistance tocorrosive incinerator slags.

RUBY® SRThis is a solid solution bonded,alumina-chromic-oxide brick, designedfor extremely high temperature service,where it provides extraordinaryresistance to chemical attack, corrosionand thermal shock. Typicalapplications include slag pools ofrotary incinerators. Also available incustom brick shapes as RUBY® SR/C.

RUBY®

A solid-solution bonded, alumina-chromic oxide brick designed forextremely high temperature servicewhere it provides extraordinaryresistance to chemical attack, corrosionand severe slag attack. Typicalapplications include the slag lines ofinduction furnaces and carbon blackreactors.

RUBY® DMAn alumina-chrome refractory with adensified matrix and a solid-solutionbond.

BURNED CHROME-ALUMINABRICK

AUREX® 20 SRA high purity, corundum-basedrefractory with 20% chromic oxide andsolid-solution bond. This brick hasexceptional resistance to thermalspalling.

AUREX® 30 SRA high purity, fused grain refractorycontaining 30% chromic oxide andsolid-solution bond with good spallresistance.

AUREX® 75This very dense, high purity, fusedgrain refractory contains 75% chromic-oxide with a solid solution bond Alsoavailable in custom brick shapes asAUREX® 75/C.

.AUREX® 75SR An upgraded versionof AUREX® 75 with improvedresistance to thermal spalling. Alsoavailable in custom brick shapes asAUREX 75SR/C.

AUREX® 90 An extremely dense,fused-grain refractory containing 90%chromic oxide. This brick featuresoutstanding resistance to iron-silicaslags and excellent stability at veryhigh temperatures.

.

HIGH-ALUMINA BRICK




OverviewThe five standard classes of fireclay brick are super-duty, high-duty, semi-silica, medium-duty, and low-duty. Fireclay brick in these classes coverthe approximate range of about 18% to 44% alumina, and from 50% to80% silica. High-duty and super-duty fireclay brick are commonly made of a blendof clays. Flint clays and high-grade kaolins impart high refractoriness;plastic clays facilitate forming and impart bonding strength; calcined clayscontrol drying and firing shrinkages. The relative proportions of theseused in a blend depend upon the character and quality of the ware to bemade. Some fireclay brick, especially those of the medium and low-dutyclass, are made of a single clay. The following product descriptions of Harbison-Walker’s fireclayrefractories are categorized by their classification. This listing representsthe major brands supplied to a wide variety of applications.

HIGH-DUTY FIRECLAY

EMPIRE® SAn economical, dry-pressed, high-dutyfireclay brick meeting ASTM regulartype classification. It is suitable forboilers, dense brick back-up linings, airheaters, and other areas encounteringmoderate operating temperatures. Notsuggested for abrasive conditions.

SUPER-DUTY FIRECLAY

ALAMO®

An economical, dry-pressed, super-duty fireclay brick. It is intended forgeneral service conditions. ALAMO®

is available in 9” x 4½” x 3”and 2½”sizes.

CLIPPER® DPA dry pressed super-duty brick withgood strength, low shrinkage, and goodresistance to thermal shock. Typicalapplications included air heaters,combustion chambers, flue and ductlinings, furnace stacks, rotary kilns andgraphitizing furnaces.

FIRECLAY BRICK

KX-99®-BFA high fired dry pressed, coarse grain,super-duty brick with low porosity,high strength, good alkali resistance,and good resistance to carbon monox-ide disintegration.

KX-99®

Is a high fired, super-duty, dry pressedfirebrick that exhibits low porosity,high strength, good alkali resistance,and resistance to carbon monoxidedisintegration. Typical applicationsinclude glass tank lower checkers,boilers, stacks, charcoal furnaces, zincgalvanizing pots, and cyclones.




OverviewInsulating refractory brick are lightweight, porous materials with much lowerdensity, thermal conductivity, and heat storage capacity than other refractories.The American Society for Testing Materials (ASTM) classifies insulatingfireclay brick (IFB) into groups 16, 20, 23, 26, and 28. The group number,multiplied by 100 represents the nominal maximum temperature to which therefractory can be exposed in service at the hot face. IFB’s with temperaturerating of 3000oF are also available. Typically a 150 to 200oF safety factor isused in selecting the appropriate brick. Special insulating refractories offeringsignificantly higher strength than standard IFB’s are also available. These canbe used in applications requiring load bearing ability. Another type of insulatingbrick are those based on high purity hollow sphere alumina. These productscan be used in high temperature ceramic kiln application and some high corro-sive applications as either hot face or back up lining materials. Harbison-Walker also manufacturers a full range of insulating castable,gunning mixes, and ceramic fiber products to provide additional insulating liningoptions. These materials are covered in other sections. The following product descriptions of Harbison-Walker insulating refractorybrick are categorized by their classification.

INSULATING BRICK

INSULATING ALUMINA-CHROMEREFRACTORIES

RUBY® LWA unique lightweight alumina-chromebrick intended for very severe servicein both hot face and back up applica-tions.

INSULATING HIGH-ALUMINAREFRACTORIES

TUFLINE® LWThis 99% alumina, corundum-bondedinsulating brick is intended for serviceconditions involving hydrogen andfluorine containing atmospheres.

GREENLITE® HSThis is a 2600oF rated, high strengthinsulating brick that is used back up intwo layer paper kiln burning zones andas full thickness liners in intermediatezone. It is available in RKB as well asstandard sizes. GREENLITE

® HS is

appropriate for other applicationsrequiring higher strength than standardinsulating firebrick.

INSULATING FIRECLAYREFRACTORIES

LOTHERM® RK

This brick is the original high strength,semi-insulating brick for rotary kilnservice. It offers slightly higherrefractoriness than GREENLITE® HS.

GREENLITE® 27

This is a 2700oF rated, high strengthinsulating brick. It offers lower densityand better insulating value than the HSversion listed above. It is not sug-gested for rotary kiln service.

G-Series Insulating FirebrickHarbison-Walker’s low iron insulatingfirebrick are available at five servicetemperature ratings between 2000oF and3000oF. They offer excellent insulatingvalue along with traditional chemicaland physical properties.




OverviewMaterials that surpass commonly used refractories in one or more of theiressential properties are often required in industrial processes. Chemical-resistant brick and tile, silicon carbide, and zircon refractories are examples ofproducts with extraordinary properties for special applications.

The following product descriptions of Harbison-Walker’s special purposerefractories are categorized by their classification. This listing represents themajor brands supplied for a wide variety of furnaces and applications.

VIB-TECH SHAPES

Harbison-Walker manufacturesVIB-TECH shapes for applicationrequiring high-performance, complexshapes. They are thixotropic cast,ceramic bonded, high-fired shapes thatprovide the unique characteristics ofseveral of our premium brick brands.They are designated by the /C suffix.These brands includeKORUNDAL® XD/C, TUFLINE® 90DM/C, TUFLINE® 98 DM/C, TUFLINE®

DM/C AL, H-W® CORUNDUM DM/C,RUBY® SR /C, and AUREX® 75 /C. Inaddition to these alumina and alumina-chrome products, we also manufacturevitreous silica, VISIL /C® , and siliconcarbide, HARBIDE® /C, shapes.


ZIRCON REFRACTORIES

This family of brick, mortars, andpatching mixes, designated by the TZBname, have been the standard of theindustry for many years. They aresuited for applications involvingsiliceous fluxes including glass.

VITREOUS SILICA

VISIL® is a vitreous silica brick thatprovides exceptional resistance tothermal cycling at temperatures below2000oF. It also offer excellent resistanceto many acidic slags and chemicals.

SILICON CARBIDE

HARBIDE® is a clay bonded silicon

carbide brick that offers excellentresistance to abrasion and high thermalconductivity.


Installation References

Brick, Sizes, Shapes IR-1

EAF Door Jambs/Blast Furnace IR-6

Blast Furnace Keys IR-7

Electric Furnace Roof Shapes IR-8

Semi-Universal Ladle Brick IR-10

Skewback Shapes IR-11

Combination Linings for Rotary KIlns IR-16

ISO and VDZ Combination Linings IR-20

Ring Combinations IR-25

Arch Combinations IR-52

Anchoring Refractories IR-63

SECTION 7

Wherever furnace construction and operating conditions permit, refractory

linings are typically constructed with brick of standard sizes and shapes.

Standard materials cost less than larger, more intricate shapes and

frequently are more serviceable. They are also more accessible, in that they

are likely to be routinely stocked by the manufacturer.

The most widely used standard size for all types of refractory brick

is 9 x 41/2 by 3 inches. Most brands offer larger sizes, as well. Special

shapes, such as skewback brick, are important in the construction of

numerous kinds of furnaces having sprung arches.

This section provides a comprehensive listing of standard brick sizes

and shapes for a variety of furnace applications, as well as ring and

arch combinations for standard size refractory brick. Additional sections

address special shapes such as semi-universal ladle brick, brick counts for

rotary kilns and rotary kiln brick shapes, including ISO, VDZ and CR

two-shape systems for combination linings. Together, offer refractory users

a ready reference of information governing furnace refractory lining and

construction.

If you require a special shape which is not included in this booklet,

please contact your Harbison-Walker representative. Harbison-Walker

manufactures special shapes based on customer designs showing

shape details and assembly in the furnace lining.

Harbison-Walker IR - 1

BRICK SIZES AND SHAPES

9 Inch Straight9 X 41/2 X 3

4 1/2"

9"3"

Small 9 Inch Straight9 X 31/2 X 3

3 1/2"

3"9"

9 Inch Soap9 X 21/4 X 3

2 1/4"

3"9"

9 – 2 Inch Split9 X 41/2 X 2

4 1/2"

9"2"

9 Inch Split9 X 41/2 X 11/2

4 1/2"

9"

1 1/2"

9 Inch No. 1-X Wedge9 X 41/2 X (3 – 27/8)

4 1/2"

9"

2 7/8"

3"

9 Inch No. 1 Wedge9 X 41/2 X (3 – 23/4)

4 1/2"

9"

2 3/4"

3"

9 Inch No. 2 Wedge9 X 41/2 X (3 – 21/2)

4 1/2"

9"

2 1/2"

3"

9 Inch No. 3 Wedge9 X 41/2 X (3 – 2)

4 1/2"

9"

2"

3"

OVERVIEWRefractory brick are classified on the basis of their form as Rectangular

Shapes or Special Shapes.

Rectangular Sizes are brick of relatively simple design, with certain

definite shapes, that are marketed in sufficient amounts to permit quanti-

ty production. Rectangular sizes are preferred wherever furnace con-

struction and operating conditions permit. These brick cost less than

longer and more intricate shapes.

Special Shapes are refractory brick of special design of either sim-

ple or intricate form. Some special shapes may be considered as mod-

ifications of rectangular tile having the same overall dimensions.

For initial orders of special shapes, drawings showing complete

details of the shapes, as well as their assembly in the furnace, should

be included. The drawing and shape numbers should be provided on

all subsequent orders.

Nine-Inch Sizes ( 9 X 41/2 X 3 )

IR - 2 Harbison-Walker



Nine-Inch Sizes ( 9 X 41/2 X 3 )

9 Inch No. 1 Arch9 X 41/2 X (3 – 23/4)

4 1/2"

9"

2 3/4"

3"

9 Inch No. 3 Arch9 X 41/2 X (3 – 2)

4 1/2"

9"

2"

3"

9 Inch No. 1 Key9 X (41/2 – 4) X 3

4 1/2"

4"

3"

9"

9 Inch No. 2 Key9 X (41/2 – 31/2) X 3

4 1/2"

3 1/2"

3"

9"

9 Inch No. 3 Key9 X (41/2 – 3) X 3

4 1/2"

3"

3"

9"

9 Inch No. 4 Key9 X (41/2 – 21/4) X 3

4 1/2"

2 1/4 "

3"

9"

9 Inch Edge Skew9 X (41/2 – 11/2) X 3

9"3"

4 1/2"

1 1/2"

9 Inch – 60° End Skew(9 – 71/4) X 41/2 X 3

3"

9"

7 1/4"

4 1/2"

9 Inch No. 2 Arch9 X 41/2 X (3 – 21/2)

4 1/2"

9"

2 1/2"

3"

9 Inch – 48° Side Skew9 X (41/2 – 113/16) X 3

4 1/2"

3"

1 13/16"

9"

9 Inch – 60° Side Skew9 X (41/2 – 23/4) X 3

4 1/2"

3"

2 3/4"

9"

9 Inch Jamb9 X 41/2 X 3

3"

4 1/2"

9"

9 Inch Featheredge9 X 41/2 X (3 – 1/8)

4 1/2"

3"

1/8"

9"

9 Inch Neck9 X 41/2 X (3 – 5/8)

4 1/2"

3"

5/8"

9"

9 Inch – 48° End Skew(9 – 65/16) X 41/2 X 3

3"

9"

6 5/16"

4 1/2"



12 x 9 x 3 No. 1 ArchNo. 2 ArchNo. 3 Arch

StraightNo. 1-X WedgeNo. 1 WedgeNo. 2 WedgeNo. 3 Wedge

12 x 9 x (3-23/4)12 x 9 x (3-21/2)12 x 9 x (3-2)

12 x 9 x 312 x 9 x (3-27/8)12 x 9 x (3-23/4)12 x 9 x (3-21/2)12 x 9 x (3-2)

3.072.932.67

3.203.133.072.932.67

12 x 41/2 x 3

12 x 6 x 3

12 x 63/4 x 3

StraightNo. 1 ArchNo. 2 ArchNo. 3 Arch

No. 1-X WedgeNo. 1 WedgeNo. 2 WedgeNo. 3 Wedge



No. 1 KeyNo. 2 KeyNo. 3 Key


12 x 41/2 x 312 x 41/2 x (3-23/4)12 x 41/2 x (3-21/2)12 x 41/2 x (3-2)

12 x 41/2 x (3-27/8)12 x 41/2 x (3-23/4)12 x 41/2 x (3-21/2)12 x 41/2 x (3-2)

12 x 6 x 312 x 6 x (3-23/4)12 x 6 x (3-21/2)12 x 6 x (3-2)

12 x 6 x (3-27/8)12 x 6 x (3-23/4)12 x 6 x (3-21/2)12 x 6 x (3-2)

12 x (6-51/2) x 312 x (6-5) x 312 x (6-3) x 3

12 x 63/4 x 312 x 63/4 x (3-27/8)12 x 63/4 x (3-23/4)12 x 63/4 x (3-21/2)12 x 63/4 x (3-2)

1.601.531.471.33

1.571.531.471.33

2.132.041.961.78

2.092.041.961.78

2.041.961.87

2.402.352.302.202.00

Sizes

9 x 6 x 3

9 x 63/4 x 3

9 x 9 x 3

Name






Dimensions (In.)

9 x 6 x 39 x 6 x (3-23/4)9 x 6 x (3-21/2)9 x 6 x (3-2)

9 x 6 x (3-27/8)9 x 6 x (3-23/4)9 x 6 x (3-21/2)9 x 6 x (3-2)

9 x (6-53/8) x 39 x (6-413/16) x 39 x (6-3) x 3

9 x 63/4 x 39 x 63/4 x (3-27/8)9 x 63/4 x (3-23/4)9 x 63/4 x (3-21/2)9 x 63/4 x (3-2)

9 x 9 x 39 x 9 x (3-27/8)9 x 9 x (3-23/4)9 x 9 x (3-21/2)9 x 9 x (3-2)

Equivalent

1.601.531.471.33

1.571.531.471.33

1.521.441.20

1.801.761.721.651.50

2.402.352.302.202.00

Sizes

9 x 41/2 x 21/2

9 x 31/2 x 21/2

9 x 21/4 x 21/2

9 x 41/2 x 21/2

9 x 41/2 x 21/2

9 x 41/2 x 21/2

9 x 41/2 x 39 x 31/2 x 39 x 21/4 x 39 x 41/2 x 11/2

9 x 41/2 x 3

9 x 41/2 x 3

9 x 6Flat Back

Name

StraightSoap2" SplitSplit

No. 1-X WedgeNo. 1 WedgeNo. 2 WedgeNo. 1 ArchNo. 2 ArchNo. 3 ArchNo. 1 KeyNo. 2 KeyNo. 3 KeyNo. 4 Key

48° End Skew60° End Skew48° Side Skew60° Side SkewEdge SkewFeatheredgeNeckJamb

StraightSm. StraightSoapSplit

No. 1 ArchNo. 2 ArchNo. 3 ArchNo. 4 Arch


No. 1 KeyNo. 2 KeyNo. 3 KeyNo. 4 Key

48° End Skew60° End Skew48° Side Skew60° Side SkewEdge SkewFeatheredgeNeckJamb

StraightSplitNo. 1 ArchNo. 2 Arch

Dimensions (In.)

9 x 41/2 x 21/2

9 x 21/4 x 21/2

9 x 41/2 x 21/2

9 x 41/2 x 11/4

9 x 41/2 x (21/2-21/4)9 x 41/2 x (21/2-17/8)9 x 41/2 x (21/2-11/2)9 x 41/2 x (21/2-21/8)9 x 41/2 x (21/2-13/4)9 x 41/2 x (21/2-1)9 x (41/2-4) x 21/2

9 x (41/2-31/2) x 21/2

9 x (41/2-3) x 21/2

9 x (41/2-21/4) x 21/2

(9-63/4) x 41/2 x 21/2

(9-79/16) x 41/2 x 21/2

9 x (41/2-21/4) x 21/2

9 x (41/2-31/16) x 21/2

9 x (41/2-11/2) x 21/2

9 x 41/2 x (21/2-1/8)9 x 41/2 x (21/2-5/8)9 x 41/2 x 21/2

9 x 41/2 x 39 x 31/2 x 39 x 21/4 x 39 x 41/2 x 11/2

9 x 41/2 x (3-23/4)9 x 41/2 x (3-21/2)9 x 41/2 x (3-2)9 x 41/2 x (3-1)

9 x 41/2 x (3-27/8)9 x 41/2 x (3-23/4)9 x 41/2 x (3-21/2)9 x 41/2 x (3-2)

9 x (41/2-4) x 39 x (41/2-31/2) x 39 x (41/2-3) x 39 x (41/2-21/4) x 3

(9-65/16) x 41/2 x 3(9-71/4) x 41/2 x 39 x (41/2-113/16) x 39 x (41/2-23/4) x 39 x (41/2-11/2) x 39 x 41/2 x (3-1/8)9 x 41/2 x (3-5/8)9 x 41/2 x 3

9 x 6 x 21/2

9 x 6 x 11/4

9 x 6 x (31/2-21/2)9 x 6 x (31/2-2)

Equivalent

1.000.500.800.50

0.950.880.800.930.850.700.940.890.830.75

0.880.920.750.840.670.530.630.89

1.200.930.600.60

1.151.101.000.80

1.171.151.101.00

1.131.071.000.90

1.021.080.840.970.800.630.731.07

1.330.671.601.47


High-Alumina, Basic and Silica BrickTYPICAL STRAIGHT, ARCH, WEDGE AND KEY BRICK

Straight Arch Wedge Key

15 x 9 x 3 StraightNo. 1-X WedgeNo. 1 WedgeNo. 2 WedgeNo. 3 Wedge

15 x 9 x 315 x 9 x (3-27/8)15 x 9 x (3-23/4)15 x 9 x (3-21/2)15 x 9 x (3-2)

4.003.923.833.673.33

131/2 x 63/4 x 3

131/2 x 9 x 3

15 x 41/2 x 3

15 x 6 x 3








131/2 x 63/4 x 3131/2 x 63/4 x (3-27/8)131/2 x 63/4 x (3-23/4)131/2 x 63/4 x (3-21/2)131/2 x 63/4 x (3-2)

131/2 x 9 x 3131/2 x 9 x (3-23/4)131/2 x 9 x (3-21/2)131/2 x 9 x (3-2)

131/2 x 9 x (3-27/8)131/2 x 9 x (3-23/4)131/2 x 9 x (3-21/2)131/2 x 9 x (3-2)

15 x 41/2 x 315 x 41/2 x (3-23/4)15 x 41/2 x (3-21/2)15 x 41/2 x (3-2)

15 x 41/2 x (3-27/8)15 x 41/2 x (3-23/4)15 x 41/2 x (3-21/2)15 x 41/2 x (3-2)

15 x 6 x 315 x 6 x (3-27/8)15 x 6 x (3-23/4)15 x 6 x (3-21/2)15 x 6 x (3-2)

15 x (6-5) x 315 x (6-43/8) x 315 x (6-3) x 3

2.702.642.592.472.25

3.603.453.303.00

3.523.453.303.00

2.001.921.831.67

1.961.921.831.67

2.672.612.562.442.22

2.562.312.00

Sizes

131/2 x 41/2 x 3

131/2 x 6 x 3

Dimensions (In.)

131/2 x 41/2 x 3131/2 x 41/2 x (3-23/4)131/2 x 41/2 x (3-21/2)131/2 x 41/2 x (3-2)

131/2 x (41/2-4) x 3131/2 x (41/2-31/2) x 3131/2 x (41/2-3) x 3131/2 x (41/2-21/4) x 3

131/2 x 6 x 3131/2 x 6 x (3-23/4)131/2 x 6 x (3-21/2)131/2 x 6 x (3-2)

131/2 x 6 x (3-27/8)131/2 x 6 x (3-23/4)131/2 x 6 x (3-21/2)131/2 x 6 x (3-2)

131/2 x (6-5) x 3131/2 x (6-43/8) x 3131/2 x (6-3) x 3

Name


No. 1 KeyNo. 2 KeyNo. 3 KeyNo. 4 Key




Equivalent

1.801.721.651.50

1.701.601.501.35

2.402.302.202.00

2.352.302.202.00

2.202.071.80

18 x 41/2 x 3

18 x 6 x 3

18 x 9 x 3

21 x 6 x 3

21 x 9 x 3

Misc. Straights






StraightStraightStraightStraightStraightStraightStraightStraight

18 x 41/2 x 318 x 41/2 x (3-27/8)18 x 41/2 x (3-23/4)18 x 41/2 x (3-21/2)18 x 41/2 x (3-2)

18 x 6 x 318 x 6 x (3-27/8)18 x 6 x (3-23/4)18 x 6 x (3-21/2)18 x 6 x (3-2)

18 x 9 x 318 x 9 x (3-27/8)18 x 9 x (3-23/4)18 x 9 x (3-21/2)18 x 9 x (3-2)

21 x 6 x 321 x 6 x (3-27/8)21 x 6 x (3-23/4)21 x 6 x (3-21/2)21 x 6 x (3-2)

21 x 9 x 321 x 9 x (3-27/8)21 x 9 x (3-23/4)21 x 9 x (3-21/2)21 x 9 x (3-2)

9 x 6 x 29 x 7 x 29 x 71/2 x 2101/2 x 41/2 x 3101/2 x 41/2 x 41/2

131/2 x 41/2 x 41/2

18 x 63/4 x 318 x 9 x 41/2

2.402.352.302.202.00

3.203.133.072.932.67

4.804.704.604.404.00

3.733.653.583.423.11

5.605.485.375.134.67

1.071.241.331.392.102.703.607.20

Sizes Dimensions (In.)Name Equivalent



METALKASE DOOR JAMB BRICK

B

A D

C

9"

4 1/2"

3"

Nine-Inch Sizes(9 X 4 1/2 X 3)

Name A B C D(In) (In) (In) (In)

DJ-1-3 9 4 1/2 11/2 3

DJ-2-3 9 6 3/4 3 3/4 3

DJ-3-3 9 9 6 3

BS-115-3 13 1/2 6 3/4 2 3/4 3

BS-116-3 13 1/2 9 5 3

DJ-18-1-3 18 6 3/4 2 3/4 3

DJ-18-2-3 18 9 5 3

BLAST-FURNACE BOTTOM BLOCKS(18 X 9 X 4 1/2 Inches)Number per course for blocks laid on end

High-Alumina Circle Brick

Diameter ofNo. of

Diameter ofNo. ofHearth Jacket

BlocksHearth Jacket

Blocks(Ft In) (Ft In)

17 6 897 27 6 217618 0 947 28 0 225518 6 999 28 6 233519 0 1053 29 0 241719 6 1108 29 6 2500

20 0 1164 30 0 258420 6 1222 30 6 266921 0 1281 31 0 275621 6 1342 31 6 284522 0 1403 32 0 2935

22 6 1467 32 6 302623 0 1531 33 0 311923 6 1598 33 6 321324 0 1665 34 0 330824 6 1734 34 6 3405

25 0 1804 35 0 350325 6 1876 35 6 360326 0 1949 36 0 370426 6 2023 36 6 380627 0 2099 37 0 3909

* The first two numbers of theCircle Number indicate the inside and outside diameters,respectively, of the ring producedby each shape. For example, 24 - 33 - 3 Circle Brick will produce a ring with a 24-inchinside diameter and 33-inch outside diameter for a 41/2

inch lining.

Circle Brick NumberNumber* Chord Per(3 Inch) (Inch) Ring

24 - 33 - 3 6 17/32 12

36 - 45 - 3 7 3/16 16

48 - 57 - 3 7 19/32 20

60 - 69 - 3 7 13/16 24

72 - 81 - 3 8 29

84 - 93 - 3 8 1/8 33

96 - 105 - 3 8 7/32 37

108 - 117 - 3 8 5/16 41

120 - 129 - 3 8 3/8 45


EAF DOOR JAMBS/ BLAST FURNACE


BLAST FURNACE KEYS

6"

5 11/16"

3"

13 1/2"

13 1/2-Inch – X-1

6"

5 11/16"

3"

13 1/2"

13 1/2-Inch – X-2

5 29/32"

5 11/16"

3"

9"

9-Inch – X-1

5 29/32"

9"

9-Inch – X-2

5 11/16"

3"

SHAPES FOR ALL-KEY BLAST FURNACE LININGS

NOTE: Blast Furnace keys X-1 and X-2 are also regulary manufactured in 6, 101/2 and 15-inch lengths. The brick com-binations for rings (see Brick Combinations for All-Key Linings table) are applicable for X-1 and X-2 keys of alllengths.

BRICK COMBINATIONS FOR ALL-KEY LININGS

Diameter Inside Number Required Per RingBrickwork(Ft In) X-2 X-1 Total

13 3 98 — 9813 6 96 3 9913 9 95 6 10114 0 95 8 10314 6 93 13 106

15 0 91 18 10915 6 89 23 11216 0 87 28 11516 6 85 33 118

17 0 84 37 12117 6 82 42 12418 0 80 48 12818 6 79 52 131

19 0 77 57 13419 6 75 62 13720 0 73 67 14020 6 71 72 143

21 0 70 76 14621 6 68 82 15022 0 66 87 15322 6 65 91 156

23 0 63 96 15923 6 61 101 16224 0 59 106 16524 6 57 111 168

25 0 56 116 17225 6 54 121 17526 0 52 126 17826 6 51 130 181

Diameter Inside Number Required Per RingBrickwork(Ft In) X-2 X-1 Total

27 0 49 135 t8427 6 47 140 18728 0 45 145 19028 6 44 150 194

29 0 42 155 19729 6 40 160 20030 0 38 165 20330 6 37 169 206

31 0 35 174 20931 6 33 179 21232 0 32 184 21632 6 30 189 219

33 0 28 194 22233 6 26 199 22534 0 24 204 22834 6 23 208 231

35 0 21 213 23435 6 19 219 23836 0 18 223 24136 6 16 228 244

37 0 14 233 24737 6 12 238 25038 0 10 243 25338 6 9 247 256

39 0 7 253 26039 6 5 258 26340 0 4 262 26640 6 2 267 26941 0 — 272 272

ELECTRIC FURNACE ROOF-SHAPES9 X 41/2 X 3-Inch Arch-Key-Wedge Shapes

Spherical Radius Range H-W Shape Designations

6’6” to 7’9” HW-2721-BHW-2721-S

7’9” to 9’6”HW-2746-BHW-2746-A

9’6” to 12’6”HW-2745-BHW-2745-A

12’6” to 16’0”HW-2592-BHW-2592-A

16’0” to 22’4”HW-2704-BHW-2704-A

Annular rings are laid from the

combinations for your specific roof

design. Consideration must be

given to the best design to provide

cost-effective service life. The two-

shape, triple taper brick uses two

bricks that conform to the roof contour.

Bricklaying is simplified using only

two shapes, in that inventory levels

may be reduced and faster installation is

possible.

The chart below displays two-shape

electric furnace roof brick combina-

tions for 9-inch roof thicknesses. By

combining both shapes, all annular

rings for a given diameter can be cal-

culated. The center of the range indi-

cates the ideal spherical radius for the

given system. Shape identification is

done by a notching system at the cold

end of the brick shape, as illustrated on

p. IR-9. The two-shape system is also

available in 131/2-inch sizes for larger

electric furnace roofs.

Providing your Harbison-Walker

representatives with the dimensions of

your electric furnace roof or a current

drawing of your roof enables them to

produce an accurate ring count and

assembly detail.

OVERVIEW

Electric furnace roofs may be constructed using many different shapes

and combinations. The combination of standard size key-arch and

key-wedge shapes with standard shapes design, and the two-shape

(arch-key-wedge) brick design are the most common in electric fur-

nace roof construction.


ELECTRIC FURNACE ROOF SHAPES


ELECTRIC FURNACE ROOF SHAPES

A

B

B

B

B B

BA

A

A

A

A

A

A

A

A

“A” and “B” Arch-Key-Wedge Brick

Two-Shape Electric FurnaceRoof ConstructionTwo-Shape (arch-key-wedge) roof brick designs are available in a variety of 9-inch sizes to fit EAF roof contours and spherical radii.

In all four series, the width of the brick,

equivalent to the thickness of the lin-

ing, is positioned in the rectangular

frame . For example, a 5-inch

thick lining in a ladle about 120 inches

in diameter would require an SU 5-45

series brick. SULB’s are also available

in two additional thicknesses — 4-inch

and 100 mm. A universal starter set that

suits all series and wall thicknesses up

to 7 inches is available. The 12-piece

UL-7-SS12 set is illustrated below. A

regular 18-piece starter set for 9-inch

thick walls is also available.

The number of SULB shapes

required for a lining can be calculated by

multiplying the average diameter of the

ladle by 3.1416, then dividing by 8.25

(length of brick) to find the number per

ring. The height in inches of the ladle

wall divided by 3 equals the number of

rings. The number of pieces per ring

times the number of rings equals the

total number of SULB shapes required.

For a ladle with an average

diameter of 120 inches (outside

diameter of SULB lining) and a height of

96 inches, the calculations follow:

OVERVIEW

Harbison-Walker manufactures Semi-Universal Ladle Brick (SULB) in

fireclay, high-alumina and basic refractories in four series of brick to

line sidewalls of iron and steel teeming ladles of various diameters

and configurations. All series can be produced in widths to construct

linings 3 to 9 inches thick. A SULB lining usually includes a tilt back

course to lay the rings square against the sloping sides of a ladle and

one or more starter sets to start the upward spiral. For guidance in

selecting the proper series for any ladle, the following chart identifies

1

2

3

4

56

78

9 10 11 12

Series Ladle Diameter (Inch)

SU - - 20 45 to 70

SU - - 30 70 to 100

SU - - 45 100 to 140

SU - - 60 140 and Up

AName Size

SU 4-20 6.983

SU 4-30 7.414

SU 4-45 7.690

SU 4-60 7.831

3.1416 x 120

8.25= 46 pieces per ring

96

3= 32 rings

46 x 32 = 1472 SULB brick per lining

Half brick to bond course

Regular Semi-Universal (to close the first course-cut the ends square of two bricks)

One tilt back course (to close ring-cut the ends square of two bricks)

8.250"

A3"

4"

(All series for a 4-inch thick wall)


SEMI-UNIVERSAL LADLE BRICK (SULB)


SKEWBACK SHAPES

9"

9" 4 1/2 "

1 13/16 "

4 1/2 "

9 "

4 1/2"

29/32"9"

4 1/2"

4 1/2"

9"

4 3/4 "

4 3/4 "

9 1/2"11/16"

2 1/8"

4 1/2"

4 1/2 "

2 1/4 "

4 1/2"

19/32"

12"

4 1/2"12"

1 19/32"

6"

4 1/2"

3 19/32"

9"

9"

13/16"

7 1/2"

2 1/4"

9"9"

9"

13 1/2"

6 3/4"

13 1/2"

1 13/18"

4 1/2"

9"

9"

17/32"

4 1/2"

4 1/2"

For Arch 4 1/2 Inches ThickRise 1 1/2 Inches Per Foot of SpanCentral Angle 56° 8.7’

Skewback Consists of 1–9 Inch – 2 Inch Split1–9 Inch Featheredge

Shape 56-9For Arch 9 Inches ThickRise 1 1/2 Inches Per Foot of SpanCentral Angle 56° 8.7’

Shape No. 60-40 1/2for Arch 4 1/2 Inches Thick

Rise 1.608 (119/32) InchesPer Foot of Span

Shape No. 60-9for Arch 9 Inches Thick

Shape No. 60-12for Arch 12

Shape No. 60-13 1/2for Arch 13 1/2 Inches Thick

Shape 74-4 1/2For Arch 4 1/2 Inches ThickRise 2 Inches Per Foot of SpanCentral Angle 73° 44.4’

Shape 74-9For Arch 9 Inches ThickRise 2 Inches Per Foot of SpanCentral Angle 73° 44.4’

For Arch 4 1/2 Inches ThickRise 2.302(2 5/16) Inches Per Foot of Span, Central Angle 83° 58.5’

Skewback Consists of 2–9 Inch – 48° End Skew1–9 Inch – 48° Side Skew1–9 Inch Soap

For Arch 9 Inches ThickRise 2.302 (2 5/16) Inches Per Foot of Span, Central Angle 83° 58.5’Skewback Consists of 2 – 9 Inch – 48° End Skew2 – 9 Inch – 48° Side Skew1 – 9 Inch Soap

NINE-INCH SIZES ADDITIONAL SIZES FOR ARCHES WITH60° CENTRAL ANGLE

8 1/4 " 4 1/2 "

3 3/4 "

9"

17/32 "

8 1/4 " 4 1/2 "

5 "

9"

17/32 "

13 1/2"

12 3/8"

1 13/16"

4 1/2"

5 5/8"

13 1/2"

12 11/16"

1 13/16"

4 1/2"

3"2 15/16"

2 1/2"1 1/4"

2 1/2"2 1/4"

9"

8 1/4"

17/32"

4 1/2"

12"

1 19/32"

11 1/4" 4 1/2"

SKEWBACK BRICK WITH CUTOUTS FOR STEELANGLE AND CHANNEL SUPPORTING FRAMEWORK

For Arches with 60° Central AngleRise 1.608 (1 19/32) Inches Per Foot of Span

Shape No. 60-9-A Shape No. 60-9-CFor Arch 9 Inches Thick For Arch 9 Inches Thick

Shape No. 60-12-A Shape No. 60-12-CFor Arch 12 Inches Thick For Arch 12 Inches Thick

Shape No. 60-13 1/2-A Shape No. 60-13 1/2-CFor Arch 13 1/2 Inches Thick For Arch 13 1/2 Inches Thick

STEEL ANGLEMaximum Dimensions

ShorterLeg ThicknessSkewback(in) (in)

60-9-A 4 3/4

60-12-A 6 1

60-13 1/2-A 8 11/8

STEEL CHANNELMaximum Dimensions

Channel Flange WebSize Width ThicknessSkewback(in) (in) (in)

60-9-C 12 3 13/32 3/4

60-12-C 12 3 13/32 3/4

60-13 1/2-C 15 3 13/16 13/16

Note:Brick Combinations required for arch construction are detailed in the tablesstarting on pages IR - 52. Thesetables are useful for estimating thequantities of brick required for theconstruction of arches.


SKEWBACK SHAPES


BRICK COUNTS FOR ROTARY KILNS

HIGH-ALUMINA BRICK

ROTARY KILN BLOCKS Arch-Type (9 x 6 x 31/2)

The numbers in the RKB column indi-

cate the inside and outside diameters,

respectively, of the ring produced by the

shape. For example, RKB 162-A-174 will

produce a ring with a 162-inch inside

diameter and 174-inch outside diameter.

Ins. Dia. RKB Inside Number Kiln Shell Number Chord (In.) Per Ring

3’-6” 30-A-42 2 1/2 374’-0” 36-A-48 2 5/8 424’-6” 42-A-54 2 23/32 475’-0” 48-A-600 2 13/16 525’-6” 54-A-66 2 7/8 58

6’-0” 60-A-72 2 29/32 636’-6” 66-A-78 2 31/32 687’-0” 72-A-84 3 747’-6” 78-A-90 3 1/32 79

8’-0” 84-A-96 3 1/16 848’-6” 90-A-102 3 3/32 899’-0” 96-A-108 3 1/8 959’-6” 102-A-114 3 1/8 100

10’-0” 108-A-120 3 5/32 10510’-6” 114-A-126 3 5/32 11111’-0” 120-A-132 3 3/16 11611’-3” 123-A-135 3 3/16 11911’-6” 126-A-138 3 3/16 121

12’-0” 132-A-144 3 7/32 12612’-6” 138-A-150 3 7/32 13213’-0” 144-A-156 3 7/32 13713’-6” 150-A-162 3 1/4 142

14’-0” 156-A-168 3 1/4 14814’-6” 162-A-174 3 1/4 15315’-0” 168-A-180 3 9/32 15815’-6” 174-A-186 3 9/32 164

16’-0” 180-A-192 3 9/32 16916’-6” 186-A-198 3 9/32 17417’-0” 192-A-204 3 9/32 17917’-6” 198-A-210 3 5/16 185

18’-0” 204-A-216 3 5/16 190

To facilitate the keying of arch-type rotary kiln blocks, keying bricks of two-thirds thickness,RKA-2/3, and of three-quarters thickness, RKA-3/4, are made. Two of each keying brick shouldbe ordered for each ring.

* All brick quantities per ring have been calculated from theoretical diameter turned by the brick to which a steel plate (1.5 mm thickness) has been attached.

HIGH-ALUMINA BRICK

ROTARY KILN BLOCKS Nine-Inch Size (9 x 9 x 4)

The numbers in the RKB column indi-


respectively, of the ring produced by the

shape. For example, 48-66 RKB will

produce a ring with a 48-inch inside

diameter and 66-inch outside diameter

for a 9-inch lining.


5’-6” 48-66 6 17/32 236’-0” 54-72 6 3/4 266’-6” 60-78 6 17/16 287’-0” 66-84 7 1/16 307’-6” 72-90 7 3/16 32

8’-0” 78-96 7 5/16 348’-6” 84-102 7 13/32 369’-0” 90-108 7 1/2 389’-6” 96-114 7 19/32 40

10’-0” 102-120 7 21/32 4210’-6” 108-126 7 23/32 4411’-0” 114-132 7 25/32 4611’-3” 117-135 7 13/16 4811’-6” 120-138 7 13/16 49

12’-0” 126-144 7 7/8 5112’-6” 132-150 7 29/32 5313’-0” 138-156 7 31/32 5513’-6” 144-162 8 57

14’-0” 150-168 8 1/32 5914’-6” 156-174 8 1/16 6115’-0” 162-180 8 3/32 6315’-6” 168-186 8 1/8 65

16’-0” 174-192 8 5/32 6716’-6” 180-198 8 3/16 7017’-0” 186-204 8 7/32 7217’-6” 192-210 8 7/32 74

18’-0” 198-216 8 1/4 7618’-6” 204-222 8 9/32 7819’-0” 210-228 8 9/32 8019’-6” 216-234 8 5/16 82

20’-0” 222-240 8 5/16 8420’-6” 228-246 8 11/32 8621’-0” 234-252 8 11/32 8821’-6” 240-258 8 3/8 90





HIGH-ALUMINA BRICK

ROTARY KILN BLOCKS Six-Inch Size (9 x 6 x 4)

The numbers under the RKB column indi-


respectively, of the ring produced by

each shape. For example, 144-156 RKB

will produce a ring with a 144-inch

inside diameter and 156-inch outside

diameter for a 6-inch lining.


3’-6” 30-42 6 7/16 154’-0” 36-48 6 3/4 174’-6” 42-54 7 195’-0” 48-60 7 3/16 215’-6” 54-66 7 3/8 23

6’-0” 60-72 7 1/2 266’-6” 66-78 7 5/8 287’-0” 72-84 7 23/32 307’-6” 78-90 7 13/16 32

8’-0” 84-96 7 7/8 348’-6” 90-102 7 15/16 369’-0” 96-108 8 389’-6” 102-114 8 1/16 40

10’-0” 108-120 8 3/32 4210’-6” 114-126 8 5/32 4411’-0” 120-132 8 3/16 4611’-3” 123-135 8 3/16 4811’-6” 126-138 8 7/32 49

12’-0” 132-144 8 1/4 5112’-6” 138-150 8 9/32 5313’-0” 144-156 8 5/16 5513’-6” 150-162 8 11/32 57

14’-0” 156-168 8 11/32 5914’-6” 162-174 8 3/8 6115’-0” 168-180 8 13/32 6315’-6” 174-186 8 13/32 65

16’-0” 180-192 8 7/16 6716’-6” 186-198 8 15/32 7017’-0” 192-204 8 15/32 7217’-6” 198-210 8 1/2 74

18’-0” 204-216 8 1/2 7618’-6” 210-222 8 1/2 7819’-0” 216-228 8 17/32 8019’-6” 222-234 8 17/32 82

20’-0” 228-240 8 9/16 8420’-6” 234-246 8 9/16 86 21’-0” 240-252 8 9/16 88


KA AND KW BLOCKS FORROTARY KILNS

Harbison-Walker developed the KA

and KW system to simplify and

eliminate problems associated with the

linings of rotary kilns. KA and KW

blocks are 9 x 6 x 4-inch kiln liners

made in the arch or wedge shape for

high-alumina brick. Each shape is fur-

nished in four sizes, two of which will

line any kiln (see chart below).

In addition, two thirds and three

quarter splits are designed to work with

all KA and KW linings to eliminate the

need for cutting keys.

Using the proper combination of KA

and KW blocks also can reduce shim-

ming, thereby producing a tighter lining

with less chance of dropout or spiral-

ing. Because these shapes fit kilns of

many sizes, operators with kilns of dif-

ferent sizes can reduce their in-plant

inventories.

Kiln Diameter Combinations

6 to 8 feet 8 to 13 feet 13 to 21 feet

Linings 6 inches thick KA-3, KA-2 KA-2, KA-l KA-l, KA-lX

Linings 9 inches thick KW-3, KW-2 KW-2, KW-l KW-l, KW-lX

6"

9"9"9"

6" 6" 6"

KA-2 KA-3 KA-1X

KW-1 KW-2 KW-3 KW-1X

9"

KA-1 6"

9"

COMBINATION LININGS FOR ROTARY KILNS



Number of KA Blocks Required for Kilns

504438322519136

————————————

————————————

————————————

——————————————————

715243241505867

767268646056524844403633

2824211713951

————

————————————

——————————————————

————————

—6

13192532384451576369

76828894

100107113119118114111107

10410097939086827976726965

625854514744403733302623191512852

————————

————————————

————————5

111723

283540465258647075828793

99105111117123128135140146152158164170176182188193199

5759626466697173

7678818385889092959799

102

104106109111113116118120123125128130

132135137139142144146149151154156158

161163165168170172175177179182184187189191194196198201

675951433426188

————————————

————————————

————————————

——————————————————

1020324355677890

1029691868075706459544844

38322823181271

————

————————————

——————————————————

————————

—8

18263443515968768492

102110118126134143151159157152148143

139133130124120115110106102969287

8378726863595449444035312520161173

————————

————————————

————————7

152331

3747536270778593

100110116124

132140148156164

171180187195203211219227235243251257265

7779838689939698

102104109112114118121123127130132136

140142146149 152155158160164167171174

176180183186190192195199202206208211

215218220224227230234236239243246250252255259262264268

55556666

777788889999

101010101111111112121212

131313131414141415151515

161616161717171718181818191919192020

03690369

036903690369

036903690369

036903690369

036903690369036903

66667777

88889999

10101010

111111111212121213131313

141414141515151516161616

171717171818181819191919202020202121

03690369

036903690369

036903690369

036903690369

036903690369036903

InsideLining

Number Required Per RingInsideShell

DiametersNumber Required Per Linear Ft

KA-3 KA-2 KA-1 KA-1X Total KA-3 KA-2 KA-1 KA-1X TotalFt In Ft In

NOTE: When using KA - 1x shape, order two pieces each ring KW - 2/3 x and KW - 3/4 x to facilitate keying.


445555

666677778888

9999

1010101011111111

121212121313131314141414

151515151616161617171717

690369

036903690369

036903690369

036903690369

036903690369

666677

7788889999

1010

101011111111121212121313

131314141414151515151616

161617171717181818181919

504438322519

136

——————————

————————————

————————————

————————————

71524324150

586776726864605652484440

36332824211713951

——

————————————

————————————

——————

———6

1319253238445157

636976828894

100107113119117112

10810398948984797570656056

51464237322823181494

—

——————

————————————

——————————6

13

202734414855636976849198

105112119126133140147154161168175182

575962646669

717376788183858890929597

99102104106109111113116118120123125

128130132135137139142144146149151154

156158161163165168170172175177179182

036903

690369036903

690369036903

690369036903

690369036903

1008876645038

2612——————————

————————————

————————————

————————————

1430486482

100

116134152144136128120112104968880

7266564842342618102

——

————————————

————————————

——————

———12263850647688

102114

126138152164176188200214226238234224

216206196188178168158150140130120112

1029284746456463628188

—

——————

————————————

——————————1226

4054688296

110126138152168182196

210224238252266280294308322336350364

114118124128132138

142146152156162166170176180184190194

198204208212218222226232236240246250

256260264270274278284288292298302308

312316322326330336340344350354358364

Number of KW Blocks Required for Kilns

InsideLining

Number Required Per RingInsideShell

DiametersNumber Required Per Linear Ft

KW-3 KW-2 KW-1 KW-1X Total KW-3 KW-2 KW-1 KW-1X TotalFt In Ft In

NOTE: When using KA - 1x shape, order two pieces each ring KW - 2/3 x and KW - 3/4 x to facilitate keying.




CR COMBINATIONLININGS

CR (Combination Ring) rotary kilnbrick are designed to line kilns from8 to 24 feet in diameter for a 9-inchlining thickness. The appropriatecombinations of the two kiln linersare calculated for the best fit for thegiven diameter.

Kiln Diameter

Feet Meters CR-89 CR-249

9’-10” 3.00 72 33

10’- 0” 3.04 71 3510’- 2” 3.10 71 3710’- 6” 3.20 69 4310’-10” 3.30 67 48

11’- 0” 3.36 67 5011’- 2” 3.40 66 5311’- 6” 3.50 64 5811’-10” 3.60 63 63

12’- 0” 3.66 61 6612’- 2” 3.70 61 6612’- 6” 3.80 59 7412’-10” 3.90 57 79

13’- 0” 3.96 57 8113’- 1” 4.00 56 8313’- 5” 4.10 54 8913’- 6” 4.12 54 9013’- 9” 4.20 53 94

14’- 0” 4.26 51 9914’- 1” 4.30 51 9914’- 3” 4.34 50 10214’- 5” 4.40 50 10314’- 6” 4.42 49 10514’- 9” 4.50 48 109

15’- 0” 4.58 47 11215’- 1” 4.60 46 11415’- 5” 4.70 45 11915’- 6” 4.72 44 12115’- 9” 4.80 43 124

16’- 0” 4.88 42 12816’- 1” 4.90 41 13016’- 5” 5.00 40 13416’- 6” 5.02 39 13616’- 9” 5.10 38 140

17’- 0” 5.18 37 14317’- 1” 5.20 36 14517’- 5” 5.30 35 15017’- 6” 5.34 34 15217’- 9” 5.40 33 155

18’- 0” 5.48 32 15918’- 1” 5.50 32 16018’- 4” 5.60 30 16518’- 6” 5.64 29 16718’- 8” 5.70 29 169

19’- 0” 5.80 27 175

To facilitate the keying of wedge-type rotary kiln blocks, keying bricks of two-thirds thickness,RKW-2/3, and of three-quarters thickness, RKW-3/4, are made. Two of each keying brick shouldbe ordered for each ring.

Combination Linings – CR Series

CR Series Dimensions (Inches)

SHAPE A B L H

CR-89 31/2 213/16 6 9

CR-249 31/2 39/32 6 9


ISO and VDZCombination LiningsStandard practice in many NorthAmerican minerals processing plantsis to use one brick of a size manufac-tured to fit a specific rotary kiln diam-eter. On the other hand, internationalpractice is to use combination linings.Within practical limits, any rotary kilncan be lined with an appropriate com-bination of two kiln liners, one of whichfits a kiln of larger diameter and theother a kiln of smaller diameter.

As good engineering practice,Harbison-Walker suggests brick blend-ing ratios between 3:1 and 1:3 for thetwo-shapes. This helps to minimize thesmall amount of stepping which canoccur, allowing for a better fit.The principal advantages ofcombination linings are:

• In plants which have several kilnsizes, the number of kiln linershapes can be reduced, since twoshapes in appropriate combintionswill fit many kilns.

• Liner to liner contact is maintained,while following minor deformationsin kiln shells. This results in a tightlining and minimizes the need forcorrecting shims.

The charts for combination liningson the following pages provide severalliner options – ISO (International Stan-dards Organization) metric linings, andVDZ (Verein Deutscher Zementwerke)combination linings.

EXAMPLE: Designation 320 ISOThe first digit (3) denotes tapered brick which turn a circle of 3.0 meters diameter outsidebrickwork.

The last two digits (20) denote a lining thickness of 200 mm.Using ISO series combination lining charts, combinations are made using outside

diameter brickwork dimensions. A chart showing a 2M, 6M brick combination is fortapered brick which turn a diameter between 2.0 meters to 6.0 meters, in any liningthickness from 160 mm to 250 mm.

ISO Series - Dimensions (mm)

L - running LENGTH 198

H - lining THICKNESS 160180200220250

A - BACK Chord (cold face) 103

B - INSIDE Chord (hot face) VARIABLE

ISO AND VDZ COMBINATION LININGS


B

A

H

L

C

International System

Schematic diagram showing criticaldimensions of ISO and VDZ shapes

B

A

H

L

C

B

A

L

H

ISO brick outside chord (A)dimension is constant at

103mm (4.05”)

VDZ brick mean chord (C)dimension is constant at

71.5mm (2.81”)

INTERNATIONAL SYSTEM

ISO VDZ

BACK CHORD (A) 103 VARIABLE

INSIDE CHORD (B) VARIABLE VARIABLE

MIDDLE CHORD (C) VARIABLE 71.5

LENGTH (L) 198 198

HEIGHT (H) 160 160180 180200 200220 220

250 250

BASIC LINING X

NON-BASIC LINING X



B

A

H

L

ISO SHAPESSHAPE No. DIMENSIONS VOL. TAPER

A B H L dm3

216 103 86160

2.99 17

716 103 98.3 3.19 4.7

218 103 84180

3.33 19

718 103 97.7 3.58 5.3

320 103 89200 198 3.80 21

820 103 97.8 3.98 5.2

222 103 80 3.99 23

322 103 88220

4.16 15

622 103 95.5 4.33 11.5

822 103 97.3 4.36 5.7

ISO Shapes

MIXING RATIO FOR ISO SHAPESALUMINA LINING

JOINT THICKNESS - 0mmDRY LAYED

THICK = 198 mm

KILN 6.30" 7.09" 7.87" 8.66" 8.66" 8.66"DIAMETER 160mm 180mm 200mm 220mm 220mm 220mm

216 716 218 718 320 820 322 622 322 822 222 622SHAPE No: 06085 05807 06088 05808 06091 06093 05810 06095 05810 06096 06552 06095

6'-6" 60 17'-0" 57 8 58 8 58 77'-6" 55 14 56 14 56 148'-0" 54 21 54 21 53 218'-6" 52 28 52 27 51 289'-0" 50 34 50 34 49 359'-6" 48 40 49 40 47 42

10'-0" 46 47 47 46 88 5 92 2 92 1 44 4910'-6" 45 53 45 53 85 13 87 11 89 9 42 5611'-0" 43 60 43 59 83 20 82 20 86 16 40 6311'-6" 41 66 41 66 80 27 78 30 83 24 38 7012'-0" 39 73 40 72 77 35 73 39 80 31 35 7612'-6" 38 79 38 79 74 42 68 48 78 39 33 8313'-0" 36 85 36 85 72 50 64 57 75 46 31 9013'-6" 34 92 34 92 69 57 59 67 72 54 29 9714'-0" 32 98 32 98 66 64 54 76 69 61 26 10414'-6" 30 105 31 104 63 72 50 85 66 69 24 11115'-0" 29 111 29 111 61 79 45 95 63 76 22 11815'-6" 27 118 27 117 58 87 40 104 61 84 20 12516'-0" 25 124 25 124 55 94 36 113 58 91 17 13216'-6" 23 130 23 130 52 101 31 123 55 99 15 13917'-0" 22 137 22 137 50 109 26 132 52 106 13 14517'-6" 47 116 49 114 11 15218'-0" 44 124 46 121 8 15918'-6" 41 131 43 129 6 16619'-0" 39 138 41 136 4 173

P-160 P-180 P-200 P-220 P-250KEY BRICKS P-161 P-181 P-201 P-221 P-251

P-162 P-182 P-202 P-222



MIXING RATIO FOR VDZ SHAPESBASIC LINING

JOINT THICKNESS - 0mmDRY LAYED

THICK = 198 mm + 1mm (cardboard) = 199mm

KILN 6.30" 7.09" 7.87" 8.66" 8.66"DIAMETER 160mm 180mm 200mm 220mm 220mm

B-216 B-716 B-218 B-618 B-220 B-620 B-322 B-622 B-222 B-622

SHAPE No: 02474 05807 02476 02478 02479 02481 16484 06080 06078 060806'-6" 77 4

7'-0" 75 127'-6" 73 21 84 9

8'-0" 71 30 80 208'-6" 69 38 75 31 92 14

9'-0" 67 47 71 42 87 259'-6" 65 56 67 53 83 35 100 18

10'-0" 63 65 63 63 79 46 95 2910'-6" 61 73 59 74 75 57 91 40

11'-0" 59 82 54 85 71 68 87 5111'-6" 57 91 50 96 67 79 83 62

12'-0" 55 99 46 107 62 90 126 26 79 7312'-6" 53 108 42 118 58 101 119 39 74 84

13'-0" 51 117 38 129 54 112 112 52 70 9513'-6" 49 125 34 140 50 123 106 66 66 105

14'-0" 47 134 29 151 46 133 99 79 62 11614'-6" 45 143 25 161 41 144 92 93 58 127

15'-0" 43 152 21 172 37 155 85 106 53 13815'-6" 41 160 17 183 33 166 79 119 49 149

16'-0" 39 169 13 194 29 177 72 133 45 16016'-6" 25 188 65 146 41 171

17'-0" 20 199 59 160 37 18217'-6" 52 173 33 192

18'-0" 45 186 28 20318'-6" 39 200

19'-0" 32 213

P-160 P-180 P-200 P-220 P-250KEY BRICKS P-161 P-181 P-201 P-221 P-251

P-162 P-182 P-202 P-222

B

A

H

L

VDZ SHAPES

SHAPE No. DIMENSIONS VOL. TAPER

A B H L dm3

B-216 78 65160

2.27 13

B-416 75 68 2.27 7

B-218 78 65180

2.55 13

B-418 75 68 2.55 7

B-220 78 65200

1982.83 13

B-620 74 69 2.83 5

B-222 78 65 3.11 13

B-322 76.5 66.5 220 3.11 10

B-622 74 69 3.11 5

VDZ Shapes



RECOMMENDED LINING THICKNESS

ROTARY KILN DIAMETER *RECOMMENDED BRICK THICK

<3.6M (12’-0”) I.D. 160 mm

Up to 4M (13’-6”) I.D. 180 mm

Up to 4.5M (16’-6”) I.D. 200 mm

Up to 5.8M (19’-0”) I.D. 220 mm

Over 5.8M (19’-0”) I.D. 250mm

*Recommendations are based on kiln diameter only,not taking operating data into consideration.

RECOMMENDED LINING THICKNESS

Harbison-Walker IR- 25

BRICK COMBINATIONS REQUIRED FOR RINGSThe tables on the following pages are useful in estimating the quantities

of brick required for the construction of circular linings, roofs and

arches. These tables give the combinations of brick sizes required

for rings of given diameters.

In calculating the tables, no allowance was made for mortar or

expansion joints or for size deviations of the brick. Fractional parts

equal to or greater than one tenth of a brick were counted as an entire

brick. For these reasons, the brick combinations shown may lay up to

diameters which differ slightly from the theoretical diameters. The num-

ber of brick required for a ring, as given in the tables, may be slightly

in excess of the number actually required.

In laying a ring course of brick, it is often necessary to cut one or

two pieces, and in some instances several pieces, to complete the ring.

For brick combinations required for rings not shown in the

following tables, or to calculate the ring combinations for brick of

two different sizes, refer to the formulas found on page UR - 29

which covers ring calculations.

RING COMBINATIONS

Diam. Inside Number Required per Ring

Brickwork No.3 No.2 No.1Ft. In. Arch Arch Arch Straight Total

0 6 19 — — — 190 7 18 3 — — 210 8 17 5 — — 220 9 15 8 — — 230 10 14 10 — — 240 11 13 13 — — 261 0 12 15 — — 271 1 10 18 — — 281 2 9 20 — — 291 3 8 23 — — 311 4 7 25 — — 321 5 5 28 — — 331 6 4 30 — — 341 7 3 33 — — 361 8 2 35 — — 371 9 — 38 — — 381 10 — 36 3 — 391 11 — 36 5 — 412 0 — 34 8 — 422 1 — 33 10 — 432 2 — 31 13 — 442 3 — 31 15 — 462 4 — 29 18 — 472 5 — 28 20 — 482 6 — 26 23 — 492 7 — 26 25 — 512 8 — 24 28 — 522 9 — 23 30 — 532 10 — 21 33 — 542 11 — 20 36 — 563 0 — 19 38 — 573 1 — 18 40 — 583 2 — 16 43 — 593 3 — 15 46 — 613 4 — 14 48 — 623 5 — 13 50 — 633 6 — 11 53 — 643 7 — 10 56 — 663 8 — 9 58 — 673 9 — 8 60 — 683 10 — 7 63 — 703 11 — 5 66 — 714 0 — 4 68 — 724 1 — 3 70 — 734 2 — 2 73 — 754 3 — — 76 — 764 4 — — 76 1 774 6 — — 76 4 804 8 — — 76 6 824 10 — — 76 9 855 0 — — 76 11 875 2 — — 76 14 905 4 — — 76 16 925 6 — — 76 19 955 8 — — 76 21 975 10 — — 76 24 100

Diam. Inside Number Required per RingBrickwork No.3 No.2 No.1Ft. In. Arch Arch Arch Straight Total

6 0 — — 76 26 1026 2 — — 76 29 1056 4 — — 76 31 1076 6 — — 76 34 1106 8 — — 76 36 1126 10 — — 76 39 1157 0 — — 76 41 1177 2 — — 76 44 1207 4 — — 76 46 1227 6 — — 76 49 1257 8 — — 76 51 1277 10 — — 76 54 1308 0 — — 76 56 1328 2 — — 76 59 1358 4 — — 76 61 1378 6 — — 76 64 1408 8 — — 76 66 1428 10 — — 76 69 1459 0 — — 76 71 1479 2 — — 76 74 1509 4 — — 76 76 1529 6 — — 76 79 1559 8 — — 76 81 1579 10 — — 76 84 160

10 0 — — 76 87 16310 2 — — 76 89 16510 4 — — 76 92 16810 6 — — 76 94 17010 8 — — 76 97 17310 10 — — 76 99 17511 0 — — 76 102 17811 2 — — 76 104 18011 4 — — 76 107 18311 6 — — 76 109 18511 8 — — 76 112 18811 10 — — 76 114 19012 0 — — 76 117 19312 2 — — 76 119 19512 4 — — 76 122 19812 6 — — 76 124 20012 8 — — 76 127 20312 10 — — 76 129 20513 0 — — 76 132 20813 2 — — 76 134 21013 4 — — 76 137 21313 6 — — 76 139 21513 8 — — 76 142 21813 10 — — 76 144 22014 0 — — 76 147 22314 2 — — 76 149 22514 4 — — 76 152 22814 6 — — 76 154 23014 8 — — 76 157 23314 10 — — 76 159 23515 0 — — 76 162 238

41/2 Inch Lining - 21/2 Inch Arch Brick9 x 41/2 x 21/2 or 131/2 x 41/2 x 21/2 Inch

41/2 Inch Lining - 21/2 Inch Arch Brick9 x 41/2 x 21/2 or 131/2 x 41/2 x 21/2 Inch

RING COMBINATIONS



Brickwork No.2 No.1 No.1-XFt. In. Wedge Wedge Wedge Straight Total

2 3 57 — — — 572 4 55 3 — — 582 5 52 7 — — 592 6 51 10 — — 612 7 48 14 — — 622 8 46 17 — — 632 9 44 20 — — 642 10 42 24 — — 662 11 40 27 — — 673 0 38 30 — — 683 1 36 34 — — 703 2 34 37 — — 713 3 32 40 — — 723 4 29 44 — — 733 5 28 47 — — 753 6 25 51 — — 763 7 23 54 — — 773 8 21 57 — — 783 9 19 61 — — 803 10 17 64 — — 813 11 15 67 — — 824 0 13 70 — — 834 1 11 74 — — 854 2 9 77 — — 864 3 6 81 — — 874 4 4 84 — — 884 5 2 88 — — 904 6 — 91 — — 914 7 — 90 2 — 924 8 — 89 4 — 934 9 — 88 7 — 954 10 — 87 9 — 964 11 — 86 11 — 975 0 — 85 13 — 985 1 — 85 15 — 1005 2 — 84 17 — 1015 3 — 83 19 — 1025 4 — 82 21 — 1035 5 — 82 23 — 1055 6 — 81 25 — 1065 7 — 80 27 — 1075 8 — 79 29 — 1085 9 — 78 32 — 1105 10 — 77 34 — 1115 11 — 76 36 — 1126 0 — 75 38 — 1136 1 — 75 40 — 1156 2 — 74 42 — 1166 3 — 73 44 — 1176 4 — 72 47 — 1196 5 — 72 48 — 1206 6 — 71 50 — 1216 7 — 70 52 — 1226 8 — 69 55 — 1246 9 — 68 57 — 1256 10 — 67 59 — 126

9 Inch Lining - 21/2 Inch Wedge Brick9 x 41/2 x 21/2, 9 x 63/4 x 21/2 or 9 x 9 x 21/2 Inch


Brickwork No.2 No.1 No.1-XFt. In. Wedge Wedge Wedge Straight Total

7 0 — 66 63 — 1297 1 — 65 65 — 1307 2 — 64 67 — 1317 3 — 63 69 — 1327 4 — 62 72 — 1347 5 — 61 74 — 1357 6 — 60 76 — 1367 7 — 59 78 — 1377 8 — 59 80 — 1397 9 — 58 82 — 1407 10 — 57 84 — 1417 11 — 56 86 — 1428 0 — 56 88 — 1448 1 — 55 90 — 1458 2 — 54 92 — 1468 3 — 53 94 — 1478 4 — 52 97 — 1498 5 — 51 99 — 1508 6 — 50 101 — 1518 7 — 49 103 — 1528 8 — 49 105 — 1548 9 — 48 107 — 1558 10 — 47 109 — 1568 11 — 46 111 — 1579 0 — 46 113 — 1599 1 — 45 115 — 1609 2 — 44 117 — 1619 3 — 43 120 — 1639 4 — 42 122 — 1649 5 — 41 124 — 1659 6 — 40 126 — 1669 7 — 40 128 — 1689 8 — 39 130 — 1699 9 — 38 132 — 1709 10 — 37 134 — 1719 11 — 36 137 — 173

10 0 — 35 139 — 17410 1 — 35 140 — 17510 2 — 34 142 — 17610 3 — 33 145 — 17810 4 — 32 147 — 17910 5 — 31 149 — 18010 6 — 30 151 — 18110 7 — 30 153 — 18310 8 — 29 155 — 18410 9 — 28 157 — 18510 10 — 27 159 — 18610 11 — 26 162 — 18811 0 — 25 164 — 18911 1 — 24 166 — 19011 2 — 23 168 — 19111 3 — 23 170 — 19311 4 — 22 172 — 19411 5 — 21 174 — 195


RING COMBINATIONS



Brickwork No.2 No.1 No.1-XFt. In. Wedge Wedge Wedge Straight Total11 6 — 20 176 — 19611 7 — 20 178 — 19811 8 — 19 180 — 19911 9 — 18 182 — 20011 10 — 17 184 — 20111 11 — 16 187 — 20312 0 — 15 189 — 20412 1 — 14 191 — 20512 2 — 13 193 — 20612 3 — 13 195 — 20812 4 — 12 197 — 20912 5 — 11 199 — 21012 6 — 10 202 — 21212 7 — 10 203 — 21312 8 — 9 205 — 21412 9 — 8 207 — 21512 10 — 7 210 — 21712 11 — 6 212 — 21813 0 — 5 214 — 21913 1 — 4 216 — 22013 2 — 4 218 — 22213 3 — 3 220 — 22313 4 — 2 222 — 22413 5 — 1 224 — 22513 6 — — 227 — 22713 7 — — 227 1 22813 8 — — 227 2 22913 9 — — 227 3 23013 10 — — 227 5 23213 11 — — 227 6 23314 0 — — 227 7 23414 6 — — 227 15 24215 0 — — 227 22 24915 6 — — 227 30 25716 0 — — 227 37 26416 6 — — 227 45 27217 0 — — 227 52 27917 6 — — 227 60 28718 0 — — 227 67 29418 6 — — 227 75 30219 0 — — 227 83 31019 6 — — 227 90 317



Brickwork No.2 No.1 No.1-XFt. In. Wedge Wedge Wedge Straight Total20 0 — — 227 98 32520 6 — — 227 105 33221 0 — — 227 113 34021 6 — — 227 120 34722 0 — — 227 128 35522 6 — — 227 135 36223 0 — — 227 143 37023 6 — — 227 150 37724 0 — — 227 158 38524 6 — — 227 165 39225 0 — — 227 173 40025 6 — — 227 181 40826 0 — — 227 188 41526 6 — — 227 196 42327 0 — — 227 203 43027 6 — — 227 211 43828 0 — — 227 218 44528 6 — — 227 226 45329 0 — — 227 233 46029 6 — — 227 241 46830 0 — — 227 248 47530 6 — — 227 256 48331 0 — — 227 263 49031 6 — — 227 271 49832 0 — — 227 279 50632 6 — — 227 286 51333 0 — — 227 294 52133 6 — — 227 301 52834 0 — — 227 309 53634 6 — — 227 316 54335 0 — — 227 324 55135 6 — — 227 331 55836 0 — — 227 339 56636 6 — — 227 346 57337 0 — — 227 354 58137 6 — — 227 362 58938 0 — — 227 369 59638 6 — — 227 377 60439 0 — — 227 384 61139 6 — — 227 392 61940 0 — — 227 399 62640 6 — — 227 407 63441 0 — — 227 414 64141 6 — — 227 422 64942 0 — — 227 429 65642 6 — — 227 437 66443 0 — — 227 444 67143 6 — — 227 452 67944 0 — — 227 460 68744 6 — — 227 467 69445 0 — — 227 475 702


RING COMBINATIONS


41/2 Inch Lining — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch

00000000

111111111111

222222222222

333333333333

444444

151413121110

87

654431

——————

————————————

————————————

——————

—13579

1214

161820222427292826252423

222120191817161514131210

1098765321

———

——————

————————

———————

2579

11

131517192123252729313336

384042444648515355575655

545251504948

————————

————————————

————————————

——————————

24

69

11131517

————————

————————————

————————————

————————————

——————

1515161718192021

222324262728293031323334

353637383940414243444546

484950515253545556575859

606162636465

Number Required Per Ring

456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

012345

1/2

No. 2Arch

No. 1Arch

No. 3Arch

No. 4Arch TotalStraight

Diam. InsideBrickwork

Ft In

41/2 Inch Lining — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch — Continued

444444

555555555555

666666666666

777777777777

88888

9101112131415

6789

1011

0123456789

1011

0123456789

1011

0123456789

1011

01236

0000000

——————

————————————

————————————

————————————

—————

———————

——————

————————————

————————————

————————————

—————

———————

474645444342

414039383736353433323129

282726252423222120191817

16151413121110

97654

321

——

———————

192123262830

323436384042444648505255

575961636567707274767880

828486889092949699

101103105

107109111113113

113113113113113113113

——————

————————————

————————————

————————————

————

4

10223548607385

666768707172

737475767778798081828384

858687888990929394959697

9899

100101102103104105106107108109

110111112113117

123135148161173186198


No. 2Arch

No. 1Arch

No. 3Arch



Ft In

RING COMBINATIONS


41/2 Inch Lining — 3 Inch Circle Brick9 x 41/2 x 3 Inch

24-33-3Circle

36-45-3Circle

48-57-3Circle

60-69-3Circle

72-81-3Circle

Total

222222222222

333333333333

444444444444

555555555555

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

121110

987654321

————————————

————————————

————————————

—1345789

11121315

1614131211

9875432

————————————

————————————

————————————

—24579

101214151718

20191715141210

97542

————————————

————————————

————————————

—2468

10121416182022

2422201816141210

8642

————————————

————————————

————————————

—358

1012151719222426

121213131314141415151516

161617171818181919192020

202121212222222323232424

242525262626272727282828

Number Required Per RingDiam. InsideBrickwork

Ft In

41/2 Inch Lining — 3 Inch Circle Brick9 x 41/2 x 3 Inch — Continued

666666666666

777777777777

888888888888

999999999999

10

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

0

2926242219161412

9753

————————————

————————————

————————————

—

—358

1114171922252730

333027252219161411

853

————————————

————————————

—

————————————

—379

1216192125283134

373431282422181512

973

————————————

—

————————————

————————————

—37

101417212428313438

41383431282420171410

74

—

————————————

————————————

————————————

—48

111519232730343841

45

292929303030313131323233

333334343435353536363637

373738383839393940404141

414242424343434444444545

45


96-105-3Circle

108-117-3Circle

120-129-3Circle

84-93-3Circle

72-81-3Circle Total


Ft In

RING COMBINATIONS


6 Inch Lining — 3 Inch Arch Brick12 x 6 x 3 or 131/2 x 6 x 3 Inch

222222222222

333333333333

444444444444

555555555555

66666666

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

01234567

383736353432313029292827

262423222120191817161514

131211

987765421

————————————

————————

—2468

11131517192123

252830323436384042444648

505254575961636567697274

767574727170696867666564

6362616059585756

————————————

————————————

————————————

—2479

11131517192123

2527293234363840

————————————

————————————

————————————

————————————

————————

383940414243444546484950

515253545556575859606162

636465666768707172737475

767778798081828384858687

8889909293949596


No. 1Arch

No. 2Arch



Ft In

6 Inch Lining — 3 Inch Arch Brick12 x 6 x 3 or 131/2 x 6 x 3 Inch — Continued

6666

777777777777

888888888888

999999999999

101010101010101010101010

11121314

89

1011

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

0000

————

————————————

————————————

————————————

————————————

————

55545352

514948474645444342414039

383736353433323130292726

252423222120191817161514

13121110

98754321

————

42444648

505355575961636567697173

757880828486889092949799

101103105107109111113115117119122124

126128130132134136138141143145147149

151151151151

————

————————————

————————————

————————————

————————————

—132538

979899

100

101102103104105106107108109110111112

113115116117118119120121122123124125

126127128129130131132133134135137138

139140141142143144145146147148149150

151164176189


No. 1Arch

No. 2Arch



Ft In

RING COMBINATIONS


6 Inch Lining — Rotary Kiln or Cupola Blocks9 x 6 x 4 Inch

444444

555555

555555

666666

666666

777777

777777

888888

6789

1011

012345

6789

1011

012345

6789

1011

012345

6789

1011

012345

54-6623201511 8 4

60-7226211713 9 4

66-7828231814 9 5

72-843025201510 5

78-903226211611 6

84-963428231711 6

90-1023630241812 6

96-1083831251913 7

60-72— 4 9131721

66-78— 5 9141823

72-84— 510152024

78-90— 510162126

84-96— 612172228

90-102— 612182430

96-108— 613192532

102-114— 714202633

232424242525

262626272727

282828292929

303030313131

323233333334

343435353536

363637373738

383839393940

NOTE: In orders, the complete names of the blocks desired should be given, as for example “54-66 RKB” or “60-72 Cupola.”


Total


Ft In

6 Inch Lining — Rotary Kiln or Cupola Blocks9 x 6 x 4 Inch — Continued

888888

999999

999999

101010

101010

101010101010

111111111111

6789

1011

012345

6789

1011

012

345

6789

1011

012345

102-1144034272014 7

108-1204235282114 7

114-1264437292215 7

120-132463115

123-135483216

126-1384940322416 8

132-1445142342517 8

108-120— 714212835

114-126— 815223037

120-132— 816233139

123-135—1632

126-138—1632

132-144— 917263442

138-150— 917273544

404141414242

424343434444

444545454646

464747

484848

494949505050

515151525252



Total


Ft In

RING COMBINATIONS



111111111111

121212121212

121212121212

131313131313

131313131313

141414141414

6789

1011

012345

6789

1011

012345

6789

1011

012345

138-1505344352618 9

144-1565545372718 9

150-162574738281910

156-168594939292010

162-174615141302110

168-180635342312111

144-156— 918283646

150-162—1019293848

156-168—1020303949

162-174—1021314051

168-180—1021324253

174-186—1122334454

535353545455

555556565657

575758585859

595960606061

616162626363

636464646565



TotalFt In


141414141414

151515151515

151515151515

161616161616

161616161616

17

6789

1011

012345

6789

1011

012345

6789

1011

0

174-186655443322211

180-192675645332311

186-198705846352312

192-204726048362412

198-210746149372512

204-21676

180-192—1223344556

186-198—1223354658

192-204—1224364859

198-210—1224374961

204-216—1325385063

210-222—

656666666767

676868686969

707070717171

727272737373

747474757575

76



TotalFt In

RING COMBINATIONS


6 Inch Lining — Rotary Kiln Blocks9 x 6 x 4 Inch Arch Type —Two Shape System

55556666

777788889999

101010101111111112121212

131313131414141415151515

16161616171717171818

03690369

036903690369

036903690369

036903690369

0369036903

66667777

88889999

10101010

111111111212121213131313

141414141515151516161616

17171717181818181919

50443832251913

6

————————————

————————————

————————————

——————————

715243241505867

767268646056524844403633

2824211713

951

————

————————————

——————————

————————

—6

13192532384451576369

76828894

100107113119118114111107

104100

97939086827976726965

62585451474440373330

————————

————————————

————————

5111723

283540465258647075828793

99105111117123128135140146152

5759626466697173

7678818385889092959799

102

104106109111113116118120123125128130

132135137139142144146149151154156158

161163165168170172175177179182

03690369

036903690369

036903690369

036903690369

0369036903

NOTE: For each ring, order two (2) pieces each KA-2/3 and KA-3/4 to facilitate keying. For additional information, see discussion of KA and KW Blocks for Rotary Kilns.


KW-1

KW-1X

TotalKW-2

KW-3

InsideLining

Ft In

InsideShell

Ft In

9 Inch Lining — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch

333333333333

444444444444

555555555555

666666666666

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

575655545251504948474645

444342414039383736353433

323129282726252423222120

19181716151413121110

97

—2469

11131517192123

262830323436384042444648

505255575961636567707274

767880828486889092949699

————————————

————————————

————————————

————————————

————————————

————————————

————————————

————————————

575859606162636465666768

707172737475767778798081

828384858687888990929394

9596979899

100101102103104105106

NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting Nos. 1, 2 and 3 arch brick for the corresponding wedge brick.


No. 1

WedgeNo. 2

WedgeNo. 3

Wedge TotalStraightFt In

RING COMBINATIONS


9 Inch Lining — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.

777777777777

888888888888

999999999999

101010101010101010101010

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

654321

——————

————————————

————————————

————————————

101103105107109111113112111110109108

107106105104103102101100

99979695

949392919089888786858483

828180797877767473727170

———————

3579

11

131517192123252729323436

384042444749515355575961

636567697173757880828486

————————————

————————————

————————————

————————————

107108109110111112113115116117118119

120121122123124125126127128129130131

132133134135137138139140141142143144

145146147148149150151152153154155156



No. 1

WedgeNo. 2

WedgeNo. 3



111111111111111111111111

121212121212121212121212

131313131313131313131313

141414141414141414141414

151515151515

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

012345

————————————

————————————

————————————

————————————

——————

696967666564636261605958

575655545251504948474745

444342414039383736353433

323029282726252523222120

191817161514

889093959799

101103105107109111

113115117119122124126128130132134137

139141143145147149151153155157159161

163166168170172174176178181183185187

189191193195197199

————————————

————————————

————————————

————————————

——————

157159160161162163164165166167168169

170171172173174175176177178179181182

183184185186187188189190191192193194

195196197198199200201203204205206207

208209210211212213



No. 1

WedgeNo. 2

WedgeNo. 3


RING COMBINATIONS



151515151515

16161616161616171718181919

2020212122222323242425252626272728282929

3030313132323333343435353636

6789

1011

0123456060606

06060606060606060606

06060606060606

——————

—————————————

————————————————————

——————————————

13121110

87

654331

———————

————————————————————

——————————————

201203205207210212

214216218220222225227227227227227227227

227227227227227227227227227227227227227227227227227227227227

227227227227227227227227227227227227227227

——————

———————

61218253137

445056626975818894

100106113119125132138144150157163

169176182188194201207213220226232238245251

214215216217218219

220221222223225226227233239245252258264

271277283289296302308315321327333340346352359365371377384390

396403409415421

428434440447453459465472478



No. 1

WedgeNo. 2

WedgeNo. 3


9 Inch Lining — 3 Inch Key Brick9 x 41/2 x 3 Inch

111

222222

333333

444444

5555555

666666

777777

888888

999999

101010

68

10

02468

10

02468

10

02468

10

023468

10

02468

10

02468

10

02468

10

02468

10

024

262320

171412

963

——————

——————

———————

——————

——————

——————

——————

———

—48

131721252934

383532292724

2118151310

7

41

—————

——————

——————

——————

——————

———

——————————

—49

131721

253034384246

51555756555352

504948464543

424139383635

343231292827

252422212018

171514

——————————

——————

——————

———

247

10

131618212427

303235384144

464952555860

636669727477

808386

——————————

——————

——————

———————

——————

——————

——————

——————

———

262728

303133343537

383941424445

464849515253

55565758596062

636566676970

727374767779

808183848687

889091939495

9798

100



No. 2Key

No. 1Key

No. 3Key

No. 4Key

TotalStraightFt In

RING COMBINATIONS


9 Inch Lining — 3 Inch Key Brick9 x 41/2 x 3 Inch — Continued

101010

111111111111

121213131414

151516161717

181819192020

212122222323

242425252626

272728282929

303031313232

33333435

68

10

02468

10

060606

060606

060606

060606

060606

060606

060606

0600

——————————

——————

——————

—————————————

——————

——————

——————

————

——————————

——————

——————

—————————————

——————

——————

——————

————

131110

976432

——————

——————

—————————————

——————

——————

——————

————

889194

96100102105108110

113113113113113113

113113113113113113

113113113113113113

113113113113113113

113113113113113113

113113113113113113

113113113113113113

113113113113

——————————

—59

131721

263034384247

515559636872

768084889397

101105109114118122

126130135139143147

151155160164168172

176181185193

101102104

105107108109111112

113118122126130134

139143147151155160

164168172176181185

189193197201206210

214218222227231235

239243248252256260

264268273277281285

289294298306



No. 2Key

No. 1Key

No. 3Key

No. 4Key TotalStraightFt In

9 Inch Lining — 3 Inch Key Brick9 x 6 x 3 Inch

111

222222

333333

444444

555555

666666

777777

888888

999999

68

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

191818

171615151414

1312121110

9

987765

543221

——————

——————

——————

——————

—23

579

111314

161819212325

262830313335

363840424345

484746454443

414039383736

343332313028

272625242322

———

——————

——————

——————

——————

—2468

10

131517192123

262830323437

394143464850

———

——————

——————

——————

——————

——————

——————

——————

——————

192021

222324262728

293031323334

353637383940

414243444546

484950515253

545556575859

606162636465

666768707172

*NOTE: For brickwork of inside diameters less than 6 feet, involving the use of 9 x 6 inch No. 3 Keys which have a very sharp taper, a better bricklaying fit can be obtained by the use of the 9 x 41/2 inch Key-brick combinations.


No. 1Key

No. 2Key


RING COMBINATIONS


9 Inch Lining — 3 Inch Key Brick9 x 6 x 3 Inch — Continued

101010101010

111111111111

121212121212

131314141515

161617171818

192021222324

252627282930

313233343536

3738394041

02468

10

02468

10

02468

10

060606

060606

000000

000000

000000

00000

——————

——————

——————

——————

——————

——————

——————

——————

—————

211918171615

13121110

98

65432

—

——————

——————

——————

——————

——————

—————

525557596163

666870727476

798183858790

919191919191

919191919191

919191919191

919191919191

919191919191

9191919191

——————

——————

——————

—47

101316

192226293235

384451576370

76828895

101107

114120126132139145

151158164170176

737475767778

798081828384

858687888990

919598

101104107

110113117120123126

129135142148154161

167173179186192198

205211217223230236

242249255261267


No. 1Key

No. 2Key

No. 3Key

TotalStraightFt In

9 Inch Lining — Rotary Kiln Blocks9 x 9 x 4 Inch

555555

555555

666666

666666

777777

777777

012345

6789

1011

012345

6789

1011

012345

6789

1011

60-7828231814 9 5

66-843025201510 5

72-903226211611 6

78-963428231711 6—

82-1023630241812 6—

90-1083831251913 7

66-84— 510152024

72-90— 510162126

78-96— 612172228

84-102— 612182430

90-108— 613192532

96-114— 714202633

282828292929

303030313131

323233333334

343435353536

363637373738

383839393940

NOTE: In orders, the complete names of the blocks should be given, as for example “60-78 RKB.”


TotalFt In

RING COMBINATIONS


9 Inch Lining — Rotary Kiln Blocks9 x 9 x 4 Inch — Continued

888888

888888

999999

999

999

101010

012345

6789

1011

012345

678

91011

012

96-1144034272014 7

102-1204235282114 7

108-1264437292215 7

114-132463115

117-135483216

120-138493216

102-120— 714212835

108-126— 815223037

114-132— 816233139

117-135—1632

120-138—1632

123-141—1713

404141414242

424343434444

444545454646

464747

484848

494949



TotalFt In


101010

101010101010

111111111111

111111111111

121212121212

121212121212

131313131313

345

6789

1011

012345

6789

1011

012345

6789

1011

012345

123-141503316

126-1445142342517 8

132-1505344352618 9

138-1565545372718 9

144-162574738281910

150-168594939292010

156-174615141302110

126-144—1734

132-150— 917273544

138-156— 918283646

144-162—1019293848

150-168—1020303949

156-174—1021314051

162-180—1021324253

505050

515151525252

535353545455

555556565657

575758585859

595960606061

616162626363



TotalFt In

RING COMBINATIONS



131313131313

141414141414

141414141414

151515151515

151515151515

161616161616

161616161616

6789

1011

012345

6789

1011

012345

6789

1011

012345

6789

1011

162-180635342312111—

168-186655443322211—

174-192675645332311

180-198705846352312

186-204726048362412

192-210746149372512

198-216766350382513

168-186—1122334454

174-192—1223344556

180-198—1223354658

186-204—1224364859

192-210—1224374961

198-216—1325385063

204-222—1326395265

636464646565

656666666767

676868686969

707070717171

727272737373

747474757575

767676777778



TotalFt In


171717171717

171717171717

181818181818

181818181818

191919191919

191919191919

20—

012345

6789

1011

012345

6789

1011

012345

6789

1011

0

204-222786552392613

210-228806653402714

216-234826855412714

222-240847056422814

228-246867257432914

234-252887459443015

240-25890

210-228—1327405367

216-234—1428415468

222-240—1428425670

228-246—1529435872

234-252—1530445974

240-258—1530456075

——

787879797980

808081818182

828283838384

848585858686

868787878888

888989899090

90



TotalFt In

RING COMBINATIONS


9 Inch Lining — Rotary Kiln Blocks9 x 6 x 4 Inch Wedge Type —Two Shape System

445555

666677778888

9999

1010101011111111

121212121313131314141414

151515151616161617171717

690369

036903690369

036903690369

036903690369

036903690369

666677

7788889999

1010

101011111111121212121313

131314141414151515151616

161617171717181818181919

504438322519

136

——————————

————————————

————————————

————————————

71524324150

586776726864605652484440

36332824211713

951

——

————————————

————————————

——————

———

61319253238445157

636976828894

100107113119117112

108103

98948984797570656056

514642373228231814

94

—

——————

————————————

——————————

613

202734414855636976849198

105112119126133140147154161168175182

575962646669

717376788183858890929597

99102104106109111113116118120123125

128130132135137139142144146149151154

156158161163165168170172175177179182

036903

690369036903

690369036903

690369036903

690369036903

NOTE: For each ring, order two (2) pieces each KW-2/3 and KW-3/4 to facilitate keying. For additional information, see discussion of KA and KW blocks for Rotary Kilns.


KW-1

KW-1X

TotalKW-2

KW-3

InsideLining

Ft In

InsideShell

Ft In

12 Inch Lining — 3 Inch Wedge Brick12 x 41/2 x 3, 12 x 6 x 3 or 12 x 9 x 3 Inch

4444

5555

6666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

76726966

63605754

51474441

38353229

25221916

1310

73

————

————

————

————

————

————

—7

1319

25323844

50576369

75828894

101107113119

126132138145

151148144142

139135132129

126122120117

113110107104

101989591

88858279

————

————

————

————

————

————

—6

1319

25323844

50576369

76828894

100107113120

126132138144

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

76798285

88929598

101104107110

113117120123

126129132135

139142145148

151154157161

164167170173

176179183186

189192195198

201205208211

214217220223



No. 1Wedge

No. 1-XWedge Straight

No. 2Wedge

No. 3Wedge TotalFt In

RING COMBINATIONS


12 Inch Lining — 3 Inch Wedge Brick12 x 41/2 x 3, 12 x 6 x 3 or 12 x 9 x 3 Inch–Cont’d.

16161616

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

————

————

————

————

————

————

————

————

————

————

————

————

76736966

63605754

51474441

38353229

25221916

1310

73

————

————

————

————

————

————

151157164170

176182188195

201208214220

226232239245

252258264270

276283289296

302299295292

289286283280

277273270267

264261258255

251248245242

239236233229

————

————

————

————

————

————

—6

1319

26323844

50576370

76828894

101107114120

126132138145

————

————

————

————

————

————

————

————

————

————

————

————

227230233236

239242245249

252255258261

264267271274

277280283286

289293296299

302305308311

315318321324

327330333337

340343346349

352355359362

365368371374



No. 1Wedge


No. 2Wedge



28282828

29292929

30303030

31313131

32323232

33333333

34343434

35353535

36363636

37373737

38383838

39393939

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

226223220217

214211207204

202198195192

189185182180

176173170167

163160158154

151148145141

138135132129

126123119116

113110107104

101979491

88858279

151158164170

176182189195

201208214220

226233239245

252258264270

277283289296

302308314321

327333340346

352358365371

377384390396

402409415421

428434440446

————

————

————

————

————

————

————

————

————

————

————

————

377381384387

390393396399

403406409412

415418421425

428431434437

440443447450

453456459462

465468472475

478481484487

490494497500

503506509512

516519522525



No. 1Wedge


No. 2Wedge


RING COMBINATIONS



40404040

41414141

42424242

43434343

44444444

45454545

46464646

47474747

48484848

49495050

51515252

53535454

0369

0369

0369

0369

0369

0369

0369

0369

0369

0606

0606

0606

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

76726966

63605754

50474441

38353228

25221916

1310

63

————

————

————

————

————

————

452459465472

478484490496

503509516522

528534540547

553560566572

578584591597

604604604604

604604604604

604604604604

604604604604

604604604604

604604604604

————

————

————

————

————

————

—369

12151822

25283134

37445056

62697581

8894

100106

528531534538

541544547550

553556560563

566569572575

578582585588

591594597600

604607610613

616619622626

629632635638

641648654660

666673679685

692698704710



No. 1Wedge


No. 2Wedge


12 Inch Lining — 3 Inch Key Brick12 x 6 x 3 Inch

101010101010

111111111111

121212121212

131313131313

141414141414

151515151515

161616161616

171717171717

181818181818

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

767574727170

696867666564

636261605958

575655545352

514948474645

444342414039

383736353433

323130292726

252423222120

—2479

11

131517192123

252729323436

384042444648

505355575961

636567697173

757880828486

889092949799

101103105107109111

——————

——————

——————

——————

——————

——————

——————

——————

——————

767778798081

828384858687

888990929394

9596979899

100

101102103104105106

107108109110111112

113115116117118119

120121122123124125

126127128129130131

Number Required Per RingDiam. InsideBrickwork No. 1

KeyNo.2Key TotalStraightFt In

RING COMBINATIONS


12 Inch Lining — 3 Inch Key Brick12 x 6 x 3 Inch — Continued

191919191919

202020202020

212121212121

222222222323

242425252626

272728282929

303031313232

333334343535

363637373838

02468

10

02468

10

02468

10

024606

060606

060606

060606

060606

060606

191817161514

13121110

98

754321

——————

——————

——————

——————

——————

——————

113115117119122124

126128130132134136

138141143145147149

151151151151151151

151151151151151151

151151151151151151

151151151151151151

151151151151151151

151151151151151151

——————

——————

——————

—1236

10

131619222528

323538414447

505457606366

697276798285

88919498

101104

132133134135137138

139140141142143144

145146147148149150

151152153154157161

164167170173176179

183186189192195198

201205208211214217

220223227230233236

239242245249252255


KeyNo. 2Key

TotalStraightFt In

131/2 Inch Lining — 3 Inch Wedge Brick131/2 x 41/2 x 3, 131/2 x 6 x 3 or 131/2 x 9 x 3 Inch

44

5555

6666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

69

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

8582

79767369

66636057

54514744

41383532

29252219

161310

7

3———

————

————

————

————

—6

13192532

38445056

63697682

8894

100107

113120126132

138144151157

164170167163

160157154151

148145141138

135132129126

123119116113

——

————

————

————

————

————

————

——

613

19263238

44505763

70768288

94101107114

——

————

————

————

————

————

————

————

————

————

————

————

——

————

————

————

————

————

————

————

————

————

————

————

8588

929598

101

104107110113

117120123126

129132135139

142145148151

154157161164

167170173176

179183186189

192195198201

205208211214

217220223227



No. 1Wedge


No. 2Wedge

No. 3Wedge

TotalFt In

RING COMBINATIONS


131/2 Inch Lining — 3 Inch Wedge Brick131/2 x 41/2 x 3, 131/2 x 6 x 3 or 131/2 x 9 x 3 Inch – Continued

16161616

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

————

————

————

————

————

————

————

————

————

————

————

————

110107104101

97949288

85827975

72706663

60575350

48444138

35312826

22191613

964

—

————

————

————

120126132138

145151157164

170176182189

195201208214

220226233239

245252258264

270277283289

296302308314

321327333340

336333330327

324321318314

311308305302

————

————

————

————

————

————

————

————

————

7131925

31384451

57636975

————

————

————

————

————

————

————

————

————

————

————

————

230233236239

242245249252

255258261264

267271274277

280283286289

293296299302

305308311315

318321324327

330333337340

343346349352

355359362365

368371374377



No. 1 Wedge

No. 1-X Wedge

Straight

No. 2 Wedge

No. 3 Wedge TotalFt In

28282828

29292929

30303030

31313131

32323232

33333333

34343434

35353535

36363636

37373737

38383838

39393939

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

————

————

————

————

————

————

————

————

————

————

————

————

299296292289

286283280277

274270267264

261258255252

248245242239

236233230227

223220217214

210208205201

198195192188

186183179176

173170166164

161157154151

828895

101

107113119126

132139145151

157163170176

183189195201

207214220226

233239245251

258264270277

283289295302

308314321327

333339346352

358365371377

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

381384387390

393396399403

406409412415

418421425428

431434437440

443447450453

456459462465

468472475478

481484487490

494497500503

506509512516

519522525528




No. 1Wedge


No. 2Wedge


RING COMBINATIONS


40404040

41414141

42424242

43434343

44444444

45454545

46464646

47474747

48484848

49494949

50505050

51515151

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

148144142139

135132129126

122120117113

110107104101

98959188

85827976

73696663

60575451

47444138

35322925

22191613

1073

—

383390396402

409415421427

434440446453

459465471477

484490497503

509515521528

534541547553

559565572578

585591597603

609616622629

635641647653

660666673679

————

————

————

————

————

————

————

————

————

————

————

————

531534538541

544547550553

556560563566

569572575578

582585588591

594597600604

607610613616

619622626629

632635638641

644648651654

657660663666

670673676679




No. 1Wedge

No. 1-XWedge

Straight

No. 2Wedge


131/2 Inch Lining — 3 Inch Key Brick131/2 x 6 x 3 Inch

22222

333333

444444

555555

666666

777777

888888

999999

101010101010

3468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

2928262524

232120191817

1614131211

9

876432

——————

——————

——————

——————

——————

—1468

101315182022

242729313336

384042454749

525149484644

434140383635

333130282624

232119181614

1311

9865

—————

——————

——————

——————

—257

1013

161921242729

323537404346

485154565962

646770737678

—————

——————

——————

——————

——————

——————

——————

——————

——————

2929303132

333435373839

404142434445

464748495051

525354555657

596061626364

656667686970

717273747576

777879818283

*NOTE: For brickwork of inside diameters less than 6 feet, involving the use of 131/2 x 6 inch No. 3 Keys which have a very sharp taper, appreciable cutting may be necessary in some cases to secure the best bricklaying fit.


No. 1Key

No. 2Key


RING COMBINATIONS


131/2 Inch Lining — 3 Inch Key Brick131/2 x 6 x 3 Inch — Continued

11111111

121213131414

151516161717

181819192020

212122222323

242425252626

272728282929

3030313132

33343536

37383940

0236

060606

060606

060606

060606

060606

060606

06060

0000

0000

————

——————

——————

——————

——————

——————

——————

—————

————

————

31

——

——————

——————

——————

——————

——————

——————

—————

————

————

81848585

858585858585

858585858585

858585858585

858585858585

858585858585

858585858585

8585858585

85858585

85858585

———

2

58

11141821

242730333639

434649525558

616568717477

808387909396

99102105109112115

118121124127131

137143149156

162168175181

84858587

90939699

103106

109112115118121124

128131134137140143

146150153156159162

165168172175178181

184187190194197200

203206209212216

222228234241

247253260266


No. 1Key

No. 2Key


15 Inch Lining — 3 Inch Wedge Brick15 x 6 x 3 or 15 x 9 x 3 Inch

55555

6666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

01369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

9594918885

82797573

69666360

57535147

44413835

31292522

191613

9

73

——

————

————

————

————

—27

1319

25313844

51576369

75828895

101107113119

126132139145

151157163170

176183189186

182179176173

170167164160

157154151148

145142138135

—————

————

————

————

————

————

————

———

6

13192532

38445057

63697682

8894

101107

959698

101104

107110113117

120123126129

132135139142

145148151154

157161164167

170173176179

183186189192

195198201205

208211214217

220223227230

233236239242

Number Required Per RingDiam. InsideBrickwork No.2

WedgeNo.1

WedgeNo. 3

Wedge TotalFt In

RING COMBINATIONS


15 Inch Lining — 3 Inch Wedge Brick15 x 6 x 3 or 15 x 9 x 3 Inch — Continued

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

132129126123

120116113110

107104101

98

94918885

82797672

69666360

57545047

44413835

32282522

19161310

63

——

————

113120126132

138145151157

164170176182

189195201208

214220226233

239245252258

264270277283

289296302308

314321327333

340346352358

365371377374

371368365361

————

————

————

————

————

————

————

————

————

————

———

7

13192532

245249252255

258261264267

271274277280

283286289293

296299302305

308311315318

321324327330

333337340343

346349352355

359362365368

371374377381

384387390393


WedgeNo. 1-XWedge



No. 1-XWedge

No. 1Wedge

29292929

30303030

31313131

32323232

33333333

34343434

35353535

36363636

37373737

38383838

39393939

40404040

41414141

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

358355352349

346343339336

333330327324

321317314311

308305302299

295292289286

283280277273

270267264261

258255252248

245242239236

233230226223

220217214211

208204201198

38445157

63697682

8895

101107

113120126132

139145151157

164170176182

189195201208

214220226233

239245251258

264270277283

289295302308

314321327333

339346352358

396399403406

409412415418

421425428431

434437440443

447450453456

459462465468

472475478481

484487490494

497500503506

509512516519

522525528531

534538541544

547550553556


TotalFt In

RING COMBINATIONS



42424242

43434343

44444444

45454545

46464646

47474747

48484848

49494949

50505050

51515252

53535454

55555656

57575858

0369

0369

0369

0369

0369

0369

0369

0369

0369

0606

0606

0606

0606

195192189186

182179176173

170167164160

157154151148

145142138135

132129126123

120116113110

107104101

98

94918885

82766963

57504438

32251913

6———

365371377383

390396402409

415421427434

440446453459

465471478484

490497503509

515522528534

541547553559

566572578585

591603616629

641654666679

691704717729

742754754754

————

————

————

————

————

————

————

————

————

————

————

————

——

713

560563566569

572575578582

585588591594

597600604607

610613616619

622626629632

635638641644

648651654657

660663666670

673679685692

698704710717

723729736742

748754761767

Number Required Per RingDiam. InsideBrickwork No. 1-X

WedgeNo. 1


18 Inch Lining — 3 Inch Wedge Brick18 x 6 x 3 or 18 x 9 x 3 Inch

666666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

17171717

012369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

113112111110107104

101979491

88858279

76726966

63605754

50474441

38353228

25221916

1310

63

————

————

————

—357

1319

25323844

51576369

75828895

101107113119

126132139145

151157163170

176183189195

201207214220

227223220217

214211207205

201198195192

——————

————

————

————

————

————

————

————

————

—7

1319

25313844

51576369

113115116117120123

126129132135

139142145148

151154157161

164167170173

176179183186

189192195198

201205208211

214217220223

227230233236

239242245249

252255258261


WedgeNo. 1

WedgeNo. 3

Wedge TotalFt In

RING COMBINATIONS



18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

29292929

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

189185183179

176173170167

163161157154

151148145141

139135132129

126123119117

113110107104

101979591

88858279

75736966

63605753

51474441

75828895

101107113119

126132139145

151157163170

176183189195

201207214220

227233239245

251258264271

277283289295

302308315321

327333339346

352359365371

————

————

————

————

————

————

————

————

————

————

————

————

264267271274

277280283286

289293296299

302305308311

315318321324

327330333337

340343346349

352355359362

365368371374

377381384387

390393396399

403406409412


WedgeNo. 1-XWedge



30303030

31313131

32323232

33333333

34343434

35353535

36363636

37373737

38383838

39393939

40404040

41414141

42424242

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

38353129

26221916

13974

————

————

————

————

————

————

————

————

————

————

377383390396

402409415421

427434440446

453449446443

440437434431

427424421418

415412409406

402399396393

390387384380

377374371368

365362358355

352349346343

340336333330

————

————

————

—7

1319

25313844

51576369

75828894

101107113119

126132138145

151157163170

176182189195

201207214220

226233239245

415418421425

428431434437

440443447450

453456459462

465468472475

478481484487

490494497500

503506509512

516519522525

528531534538

541544547550

553556560563

566569572575


WedgeNo. 1-XWedge


RING COMBINATIONS


BRICK COMBINATIONS REQUIRED FOR ARCHESThe following tables are useful in estimating the quantities of brick

required for the construction of arches. These tables give the combina-

tions of brick sizes required for arches of given spans and rises.

In calculating the tables, no allowance was made for mortar or

expansion joints or for size deviations of the brick. Fractional parts

equal to or greater than one tenth of a brick were counted as an entire

brick. For these reasons, the number of brick required for an arch, as

given in the tables, may be slightly in excess of the number actually

required.

In laying an arch course of brick, it is often necessary to cut one or

two pieces, and in some instances several pieces, to complete the course.

For the brick combinations required for arches not included in the

following tables, or to determine the dimensions or other numerical

characteristics of arches, refer to the arch formulas found on page

UR - 28, which detail arch calculations.

ARCH COMBINATIONS


41/2 Inch Arch Thickness — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

111111111111

222222222222

333333333333

44444

5566

0123456789

1011

0123456789

1011

0123456789

1011

01236

0606

119/32

1 3/4 1 7/8 2 2 5/32

2 9/32

213/32

217/32

211/16

213/16

215/16

3 3/32

3 7/32

311/32

315/32

3 5/8 3 3/4 3 7/8 4 1/32

4 5/32

4 9/32

4 7/16

4 9/16

411/16

413/16

431/32

5 3/32

5 7/32

511/32

5 1/2 5 5/8 5 3/4 529/32

6 1/32

6 5/32

6 9/32

6 7/16

6 9/16

611/16

627/32

7 1/4

8 1/32

827/32

921/32

10 7/16

111111111111

222222222222

333333333333

44444

5566

0123456789

1011

0123456789

1011

0123456789

1011

01236

0606

44333222111—

————————————

————————————

—————

————

234456678899

998887776665

554443322211

1————

————

———————————

1

123345567789

101011121213141515161717

1819191919

19191919

————————————

————————————

————————————

———

12

468

10

6777888999

1010

101111111212121313131414

151515161616171717181818

1919192021

23252729

SpanFt In

RiseFt In

InsideRadius

Ft In

Number Required Per Course

No. 3 No. 2 No. 1 Arch Arch Arch Straight Total

41/2 Inch Arch Thickness — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch2 Inch Rise Per Foot of Span

11

111111111111

222222222222

333333

4444444

5566

0123456789

1011

0123456789

1011

02468

10

02468

1011

0606

2 2 5/32

211/32

2 1/2 221/32

227/32

3 3 5/32

311/32

3 1/2 321/32

327/32

4 4 5/32

411/32

4 1/2 421/32

427/32

5 5 5/32

511/32

5 1/2 521/32

527/32

6 611/32

621/32

7 711/32

721/32

8 811/32

821/32

9 911/32

921/32

927/32

1011 0 1

111111111

111112222222

222233

3333344

4455

101027/32

1121/32

0 1/2 111/32

2 5/32

3 327/32

421/32

5 1/2 611/32

7 5/32

8 827/32

921/32

10 1/21111/32

0 5/32

1 127/32

221/32

3 1/2 411/32

5 5/32

6 721/32

911/32

11 021/32

211/32

4 521/32

711/32

91021/32

011/32

1 5/32

2 7 0 5

655544432222

111—————————

——————

———————

————

122344567889

1010111211111110101099

887665

433211

—

————

————————————

————12234456

78

10111214

15171820212223

23232323

————————————

————————————

——————

———————

1357

777888999

101011

111112121213131314141415

151617171819

19202122222323

24262830

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 3 No. 2 No. 1 Arch Arch Arch

Straight Total

ARCH COMBINATIONS


41/2 Inch Arch Thickness — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch2.302 Inch (2 5/16 Inch) Rise Per Foot of Span

111111111111

22222222

333333

444444

555555

66

0123456789

1011

0123468

10

02468

10

02468

10

02468

10

06

1111

11

2 5/16

2 1/2 211/16

2 7/8 3 1/16

3 1/4 315/32

321/32

327/32

4 1/32

4 7/32

413/32

419/32

425/32

5 5 3/16

5 3/8 5 3/4 6 1/8 617/32

629/32

7 9/32

711/16

8 1/16

8 7/16

813/16

9 7/32

919/32

931/32

10 3/810 3/411 1/8

11 1/21129/32

0 9/32

021/32

1 1/16

1 7/16

113/16

231/32

1111111

11111112

222222

233333

333444

44

831/32

923/32

1015/32

11 7/32

1131/32

023/32

115/32

2 3/16

215/16

311/16

4 7/16

5 3/16

515/16

611/16

7 7/16

8 3/16

815/16

10 7/16

1129/32

113/32

229/32

413/32

529/32

713/32

8 7/810 3/8

11 7/8 1 3/8 2 7/8 4 3/8 527/32

711/32

827/32

1011/32

1127/32

111/32

213/16

4 5/16

513/16

10 5/16

766655544333

22211———

——————

——————

——————

——

—12234466788

910101112141312

111010

987

766543

321

———

——

————————————

——————

13

5679

1112

131516171921

222325272727

2727

————————————

————————

——————

——————

—————

1

24

7788899

1010101111

1112121213141415

161617181919

202122222324

252526272728

2931

SpanFt In

RiseFt In

InsideRadius

Ft In



41/2 Inch Arch Thickness — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch11/2 Inch Rise Per Foot of Span

111111111111

222222222222

333333333333

4444

5555

66

0123456789

1011

0123456789

1011

0123456789

1011

0369

0369

06

1 1/21 5/81 3/41 7/82 2 1/82 1/42 3/82 1/22 5/82 3/42 7/8

3 3 1/83 1/43 3/83 1/23 5/83 3/43 7/84 4 1/84 1/44 3/8

4 1/24 5/84 3/44 7/85 5 1/85 1/45 3/85 1/25 5/85 3/45 7/8

6 6 3/86 3/47 1/8

7 1/27 7/88 1/48 5/8

9 9 3/4

111111111112

222222222233

333333333344

4445

5556

66

0 3/4 113/16

2 7/8 315/16

5 6 1/16

7 1/8 8 3/16

9 1/410 5/16

11 3/8 0 7/16

1 1/2 2 9/16

3 5/8 411/16

5 3/4 6 3/16

7 7/8 815/16

1011 1/16

0 1/8 1 3/16

2 1/4 3 5/16

4 3/8 5 7/16

6 1/2 7 9/16

8 5/8 911/16

10 3/41113/16

0 7/8 115/16

3 6 3/16

9 3/8 0 9/16

3 3/4 615/16

10 1/8 1 5/16

4 1/210 7/8

333222111

———

————————————

————————————

————

————

——

334556778998

887776665554

443332221

———

————

————

——

——————————

12

23445667889

10

101112121314141516171818

18181818

18181818

1818

————————————

————————————

————————————

1234

5678

911

6677788899

1010

101111111212121313131414

141515151616161717171818

19202122

23242526

2729

SpanFt In

RiseFt In

InsideRadius

Ft In



ARCH COMBINATIONS


9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch11/2 Inch Rise Per Foot of Span

111111

222222222222

333333333333

444444444444

555555

6789

1011

0123456789

1011

0123456789

1011

0123456789

1011

012345

2 1/4 2 3/8 2 1/2 2 5/8 2 3/4 2 7/8

3 3 1/8 3 1/4 3 3/8 3 1/2 3 5/8 3 3/4 3 7/8 4 4 1/8 4 1/4 4 3/8

4 1/2 4 5/8 4 3/4 4 7/8 5 5 1/8 5 1/4 5 3/8 5 1/2 5 5/8 5 3/4 5 7/8

6 6 1/8 6 1/4 6 3/8 6 1/2 6 5/8 6 3/4 6 7/8 7 7 1/8 7 1/4 7 3/8

7 1/2 7 5/8 7 3/4 7 7/8 8 8 1/8

111112

222222222233

333333333344

444444444555

555555

7 1/8 8 3/16

9 1/410 5/16

11 3/8 0 7/16

1 1/2 2 9/16

3 5/8 411/16

5 3/4 613/16

7 7/8 815/16

10 11 1/16

0 1/8 1 3/16

2 1/4 3 5/16

4 3/8 5 7/16

6 1/2 7 9/16

8 5/8 911/16

10 3/41113/16

0 7/8 115/16

3 4 1/16

5 1/8 6 3/16

7 1/4 8 5/16

9 3/810 7/16

11 1/2 0 9/16

1 5/8 211/16

3 3/4 413/16

5 7/8 615/16

8 9 1/16

988877

766655544433

322111

——————

————————————

——————

122344

5667889

1010111212

131415161617181817171616

161515151414141313131212

121211111110

——————

————————————

————————

2234

45667889

10101112

121314141516

101010111111

121212131313141414151515

161617171718181819191920

202021212122222223232324

242525252626

NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No. 1, 2, and 3 arch brick for the corresponding wedge brick.

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 3 No. 2 No. 1 Wedge Wedge Wedge

NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No. 1 and 2 arch brick for the corresponding wedge brick.

9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.11/2 Inch Rise Per Foot of Span

555555

666666666666

777777777777

8899

1010

111112121313

141415

6789

1011

0123456789

1011

0123456789

1011

060606

060606

060

111111

111111

111

8 1/4 8 3/8 8 1/2 8 5/8 8 3/4 8 7/8

9 9 1/8 9 1/4 9 3/8 9 1/2 9 5/8 9 3/4 9 7/810 10 1/810 1/410 3/8

10 1/210 5/810 3/410 7/811 11 1/811 1/411 3/811 1/211 5/811 3/411 7/8

0 0 3/4 1 1/2 2 1/4 3 3 3/4

4 1/2 5 1/4 6 6 3/4 7 1/2 8 1/4

9 9 3/410 1/2

556666

666666667777

777777788888

899

101011

111212131314

141515

10 1/811 3/16

0 1/4 1 5/16

2 3/8 3 7/16

4 1/2 5 9/16

6 5/8 711/16

8 3/4 913/16

10 7/81115/16

1 2 1/16

3 1/8 4 3/16

5 1/4 6 5/16

7 3/8 8 7/16

9 1/210 9/16

11 5/8 011/16

1 3/4 213/16

3 7/8 415/16

6 0 3/8 6 3/4 1 1/8 7 1/2 1 7/8

8 1/4 2 5/8 9 3 3/8 9 3/4 4 1/8

10 1/2 4 7/811 1/4

1099888

777666555444

333322211

———

——————

——————

———

161818192020

212222232424252626272828

293030313232333434363636

363636363636

363636363636

363636

——————

————————————

————————————

13579

11

131517192124

262830

262727272828

282929293030303131313232

323333343434353535363636

373941434547

495153555760

626466

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 2 No. 1 Wedge Wedge Total Straight Total

ARCH COMBINATIONS


9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch1.608 Inch (119/32 Inch)Rise Per Foot of Span(60o Center Angle)

111111

222222222222

333333333333

444444444444

555555

6789

1011

0123456789

1011

0123456789

1011

0123456789

1011

012345

2 13/32

2 17/32

2 11/16

2 13/16

2 15/16

3 3/32

3 7/32 3 11/32

3 15/32

3 5/8 3 3/4 3 7/8 3 1/32

3 5/32

4 9/32 4 7/16

4 9/16

4 11/16

4 13/16

4 31/32

5 3/32

5 7/32

5 11/32

5 1/2 5 5/8 5 3/4 5 29/32

6 1/8 6 5/32

6 9/32

6 7/16

6 9/16

6 11/16

6 27/32

6 31/32

7 3/32

7 1/4 7 3/8 7 1/2 7 5/8 7 25/32

7 29/32

8 1/32

8 3/16

8 5/16

8 7/16

8 9/16 8 23/32

111112

222222222233

333333333343

444444444555

555555

6 7 8 91011

0 1 2 3 4 5 6 7 8 910 11

0 1 2 3 4 5 6 7 8 91011

0 1 2 3 4 5 6 7 8 910 11

0 1 2 3 4 5

1099988

877766555444

333222111

———

————————————

——————

—12234

45667899

10111112

131314151616171818191918

181817171716161615151514

141413131212

——————

————————————

——————————

12

23445667889

10

101112131414

101011111112

121213131314141415151516

161617171818181919192020

202121212222222323232424

242525262626


SpanFt In

RiseFt In

InsideRadius

Ft In




9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.1.608 Inch (119/32 Inch)Rise Per Foot of Span(60o Center Angle)

555555

666666666666

777777777777

88888

99

10101111

121213131414

15

6789

1011

0123456789

1011

0123456789

1011

01236

060606

060606

0

111111

11111

111111

111111

2

8 27/32

8 31/32

9 1/8 9 1/4 9 3/8 9 1/2

9 21/32

9 25/32

9 29/32

10 1/16

10 3/16

10 5/16

10 7/16

10 19/32

10 23/32

10 27/32

1111 1/8

11 1/411 3/811 17/32

11 21/32

11 25/32

11 15/16

0 1/16

0 3/16

0 5/16

0 15/32

0 19/32

0 23/32

0 7/8 1 1 1/8 1 1/4 1 21/32

2 15/32

3 9/16

4 1/16 4 7/8 5 11/16

6 1/2

7 9/32

8 3/32

8 29/32

9 11/16

10 1/211 5/16

0 1/8

556666

666666667777

777777777777

88888

99

10101111

121213131414

15

6 7 8 9 10 11

0 1 2 3 4 5 6 7 8 9 10 11

0 1 2 3 4 5 6 7 8 9 10 11

0 1 2 3 6 0 6 0 6 0 6

0 6 0 6 0 6

0

121111111010

1099988877766

655444333222

111

——

——————

——————

—

151616171818

192020212222232424252627

272829303031323233343435

3636373838

383838383838

383838383838

38

——————

————————————

————————————

————

1

357

101214

161820222426

28

272727282828

292929303030313131323233

333334343435353536363637

3737383839

414345485052

545658606264

66

SpanFt In

RiseFt In

InsideRadius

Ft In



ARCH COMBINATIONS


9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch2 Inch Rise Per Foot of Span


11

222222222222

333333333333

444444444444

555555555555

1011

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

321/32

327/32

4 4 5/32

411/32

4 1/2 421/32

427/32

5 5 5/32

511/32

5 1/2 521/32

527/32

6 6 5/32

611/32

6 1/2 621/32

627/32

7 7 5/32

711/32

7 1/2 721/32

727/32

8 8 5/32

811/32

8 1/2 821/32

827/32

9 9 5/32

911/32

9 1/2 921/32

927/32

1010 5/32

1011/32

10 1/21021/32

1027/32

1111 5/32

1111/32

11 1/21121/32

1127/32

11

111112222222

222222223333

333333333344

444444444444

611/32

7 5/32

8 827/32

921/32

10 1/21111/32

0 5/32

1 127/32

221/32

3 1/2 411/32

5 5/32

6 627/32

721/32

8 1/2 911/32

10 5/32

111127/32

021/32

1 1/2 211/32

3 5/32

4 427/32

521/32

6 1/2 711/32

8 5/32

9 927/32

1021/32

11 1/2 011/32

1 5/32

2 227/32

321/32

4 1/2 511/32

6 5/32

7 727/32

821/32

9 1/21011/32

11 5/32

1211

11101010

99988877

766555444333

222111

——————

————————————

—1

23445667889

10

101112131414151616171818

192020212222242323222221

212120202019191919181817

——

————————————

————————————

———————

11334

55677899

10111113

1212

131314141415151516161617

171718181919192020202121

212222222323242424252525

262626272727282829292930

SpanFt In

RiseFt In

InsideRadius

Ft In



9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.2 Inch Rise Per Foot of Span


666666666666

777777777777

888888888888

999999

10101112131415

0123456789

1011

0123456789

1011

0123456789

1011

02468

10

0600000

111111111111

111111111111

111111111111

111111

1112222

0 0 5/32

011/32

0 1/2 021/32

027/32

1 1 5/32

111/32

1 1/2 121/32

127/32

2 2 5/32

211/32

2 1/2 221/32

227/32

3 3 5/32

311/32

3 1/2 321/32

327/32

4 4 5/32

411/32

4 1/2 421/32

427/32

5 5 5/32

511/32

5 1/2 521/32

527/32

6 611/32

621/32

7 711/32

721/32

8 910 0 2 4 6

555555555555

555666666666

666667777777

777788

889

10101112

0 027/32

121/32

2 1/2 311/32

4 5/32

5 527/32

621/32

7 1/2 811/32

9 5/32

10 1027/32

1121/32

0 1/2 111/32

2 5/32

3 327/32

421/32

5 1/2 611/32

7 5/32

8 827/32

921/32

10 1/21111/32

0 5/32

1 127/32

221/32

3 1/2 411/32

5 5/32

6 721/32

911/32

11 021/32

211/32

4 9 2 010 8 6

171616161515151514141413

13121211111110101010

99

988776665555

44321

—

———————

131415151617171819192021

212323242525262727282929

303131333334353536373738

394041434546

47474747474747

————————————

————————————

————————————

——————

—249

131722

303031313132323333333434

343535353636363737383838

393939404040414141424243

434444454646

47495156606469

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 2 No. 1 Wedge WedgeTotal Straight Total

ARCH COMBINATIONS


9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch2.302 Inch (2 5/16 Inch) Rise Per Foot of Span

NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No. 1, 2 and 3 arch brick for the corresponding wedge brick.

222222222222

333333333333

444444444444

555555555555

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

111111111

419/32

425/32

5 5 3/16

5 3/8 5 9/16

5 3/4 515/16

6 1/8 611/32

617/32

623/32

629/32

7 3/32

7 9/32

715/32

711/16

7 7/8 8 1/16

8 1/4 8 7/16

8 5/8 813/16

9 1/32

9 7/32

913/32

919/32

925/32

931/32

10 5/32

10 3/810 9/16

10 3/41015/16

11 1/811 5/16

11 1/21123/32

1129/32

0 3/32

0 9/32

015/32

021/32

027/32

1 1/16

1 1/4 1 7/16

1 5/8

111111111222

222222222222

233333333333

333334444444

515/16

611/16

7 7/16

8 3/16

815/16

911/16

10 7/16

11 5/32

1129/32

021/32

113/32

2 5/32

229/32

321/32

413/32

5 5/32

529/32

621/32

713/32

8 1/8 8 7/8 9 5/810 3/811 1/8

11 7/8 0 5/8 1 3/8 2 1/8 2 7/8 3 5/8 4 3/8 5 3/32

527/32

619/32

711/32

8 3/32

827/32

919/32

1011/32

11 3/32

1127/32

019/32

111/32

2 1/16

213/16

3 9/16

4 5/16

5 1/16

141313121211111110101010

998877766665

44433332221

—

————————————

—11334556778

99

11111213131415151617

181919202121222323242526

272626262525252424232323

————————————

————————————

————————————

—11234456778

141414151515161616171718

181819191920202021212222

222323232424252525262626

272727282829292930303031

SpanFt In

RiseFt In

InsideRadius

Ft In



9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.2.302 Inch (2 5/16 Inch) Rise Per Foot of Span


666666666666

777777777777

888888

999999

101010101010

111112131415

0123456789

1011

0123456789

1011

02468

10

02468

10

02468

10

060000

111111111111

111111111111

111111

111111

111222

222222

113/16

2 2 3/16

2 3/8 219/32

225/32

231/32

3 5/32

311/32

317/32

323/32

315/16

4 1/8 4 5/16

4 1/2 411/16

4 7/8 5 1/16

5 9/32

515/32

521/32

527/32

6 1/32

6 7/32

613/32

613/16

7 3/16

7 9/16

731/32

811/32

823/32

9 3/32

9 1/2 9 7/810 1/410 5/8

11 1/32

1113/32

1125/32

0 3/16

0 9/16

015/16

1 5/16

215/32

3 5/8 515/16

8 1/41017/32

444444444555

555555555555

566666

666777

777778

8889

1011

513/16

6 9/16

7 5/16

8 1/16

813/16

9 9/16

10 5/16

11 1/32

1125/32

017/32

1 9/32

2 1/32

225/32

317/32

4 9/32

5 1/32

525/32

617/32

7 9/32

8 1/32

8 3/4 9 1/210 1/411

11 3/4 1 1/4 2 3/4 4 1/4 523/32

7 7/32

823/32

10 7/32

1123/32

1 7/32

211/16

4 3/16

511/16

7 3/16

811/16

10 3/16

1121/32

1 5/32

221/32

7 5/32

11 5/8 819/32

5 9/16

217/32

222222212120202019191918

181817171616161515151414

141312111110

988766

543321

——————

99

10111213131415151617

171819202121222323242525

262829313234

353738394142

444547485051

535353535353

————————————

————————————

——————

——————

——————

—249

1318

313132323333333434343535

353636373737383838393939

404141424344

444546464748

494950515252

535557626671

SpanFt In

RiseFt In

InsideRadius

Ft In



ARCH COMBINATIONS


12 Inch Arch Thickness — 3 Inch Wedge Brick12 x 41/2 x 3,12 x 6 x 3 or 12 x 9 x 3 Inch1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

6666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

11

1111

1111

1111

1111

1111

1111

1111

2222

921/32

10 1/16

10 7/16

1027/32

11 1/41121/32

0 1/16

015/32

0 7/8 1 1/4 121/32

2 1/16

215/32

2 7/8 3 9/32

311/16

4 1/16

415/32

4 7/8 5 9/32

511/16

6 3/32

6 1/2 6 7/8

7 9/32

711/16

8 3/32

8 1/2

829/32

9 5/16

911/16

10 3/32

10 1/21029/32

11 5/16

1123/32

0 1/8 017/32

029/32

1 5/16

6666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

21201918

17161514

13121110

8765

4431

————

————

————

————

————

9111315

17192123

25272931

34363840

42444649

51504847

46454443

42414039

38373635

34323231

————

————

————

————

————

—257

9111315

17192123

25272931

33363840

30313233

34353637

38394041

42434445

46484950

51525354

55565758

59606162

63646566

67687071

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 2 No. 1 No. 1-X Wedge Wedge Wedge

12 Inch Arch Thickness — 3 Inch Wedge Brick12 x 41/2 x 3,12 x 6 x 3 or 12 x 9 x 3 Inch–Cont’d.1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

16161616

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

2222

2222

2222

2222

2222

2222

2233

3333

3333

3333

123/32

2 1/8 217/32

215/16

311/32

323/32

4 1/8 417/32

415/16

511/32

5 3/4 6 5/32

617/32

615/16

711/32

7 3/4

8 5/32

8 9/16

831/32

911/32

9 3/410 5/32

10 9/16

1031/32

11 3/81125/32

0 3/16

0 9/16

031/32

1 3/8 125/32

2 3/16

219/32

3 3 3/8 325/32

4 3/16

419/32

5 513/32

16161616

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

30292827

25242322

21201918

17161514

13121010

9876

5321

————

————

————

42444648

51535557

59616365

67697173

75778082

84868890

92959799

101101101101

101101101101

101101101101

————

————

————

————

————

————

————

—123

4567

89

1011

72737475

76777879

80818283

84858687

88899092

93949596

979899

100

101102103104

105106107108

109110111112

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 1 No. 1-X Wedge Wedge Total Straight Total

ARCH COMBINATIONS


131/2 Inch Arch Thickness — 3 Inch Wedge Brick131/2 x 41/2 x 3, 131/2 x 6 x 3 or 131/2 x 9 x 3 Inch1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

6666

7777

8888

9999

10101010

11111111

1212121212

13131313

14141414

15151515

16161616

0369

0369

0369

0369

0369

0369

03

4 1/269

0369

0369

0369

0369

11

1111

1111

1111

1111

11111

1111

1111

2222

2222

921/32

10 1/16

10 7/16

1027/32

11 1/41121/32

0 1/16

015/32

0 7/8 1 1/4 121/32

2 1/16

215/32

2 7/8 3 9/32

311/16

4 1/16

415/32

4 7/8 5 9/32

511/16

6 3/32

6 1/2 6 7/8

7 9/32

711/16

7 29/32

8 3/32

8 1/2

829/32

9 5/16

911/16

10 3/32

10 1/21029/32

11 5/16

1123/32

0 1/8 017/32

029/32

1 5/16

123/32

2 1/8 217/32

2 15/16

6666

7777

8888

9999

10101010

11111111

1212121212

13131313

14141414

15151515

16161616

0369

0369

0369

0369

0369

0369

03

4 1/269

0369

0369

0369

0369

27262524

22212120

19181716

14131211

10987

6543

21

———

————

————

————

————

3579

12141618

20222426

29313335

37394143

45474951

5355575655

54535251

50494847

46454443

41403938

————

————

————

————

————

————

———

14

68

1012

14161820

22242628

31333537

30313233

34353738

39404142

43444546

47484950

51525354

5556575759

60616263

64656667

68697071

72737475

SpanFt In

RiseFt In

InsideRadius

Ft In



17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252626

27272828

29293030

0369

0369

0369

0369

0369

0369

0369

0369

0606

0606

0606

2222

2222

2222

2222

2222

2233

3333

3333

3333

3333

3344

311/32

323/32

4 1/8 417/32

415/16

511/32

5 3/4 6 5/32

617/32

615/16

711/32

7 3/4

8 5/32

8 9/16

831/32

911/32

9 3/410 5/32

10 9/16

1031/32

11 3/81125/32

0 3/16

0 9/16

031/32

1 3/8 125/32

2 3/16

219/32

3 3 3/8 325/32

4 3/16

5 513/16

619/32

713/32

8 7/32

9 913/16

10 5/811 7/16

0 7/32

1 1/32

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252626

27272828

29293030

0369

0369

0369

0369

0369

0369

0369

0369

0606

0606

0606

37363534

33323130

29282726

25242322

21191817

16151413

121210

9

8765

42

——

————

————

39414345

48505254

56586062

64666870

72757779

81838587

89919496

98100102104

106110113113

113113113113

113113113113

————

————

————

————

————

————

————

————

——

13

579

11

14161820

76777879

81828384

85868788

89909192

93949596

979899

100

101103104105

106107108109

110112114116

118120122124

127129131133

131/2 Inch Arch Thickness — 3 Inch Wedge Brick131/2 x 41/2 x 3, 131/2 x 6 x 3 or 131/2 x 9 x 3 Inch – Continued1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 1 No. 1-X Wedge Wedge

Total Straight Total

ARCH COMBINATIONS


15 Inch Arch Thickness — 3 Inch Wedge Brick15 x 6 x 3 or 15 x 9 x 3 Inch1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

17171717

369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

11

1111

1111

1111

1111

1111

1111

1111

2222

2222

2222

10 1/16

10 7/16

1027/32

11 1/41121/32

0 1/16

015/32

0 7/8 1 1/4 121/32

2 1/16

215/32

2 7/8 3 9/32

311/16

4 1/16

415/32

4 7/8 5 9/32

511/16

6 3/32

6 1/2 6 7/8

7 9/32

711/16

8 3/32

8 1/2

829/32

9 5/16

911/16

10 3/32

10 1/21029/32

11 5/16

1123/32

0 1/8 017/32

029/32

1 5/16

123/32

2 1/8 217/32

215/16

311/32

323/32

4 1/8 417/32

666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

17171717

369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

323130

28272625

24232221

20191817

16151413

121110

9

8754

321

—

————

————

————

————

—24

79

1113

15171921

23252729

32343638

40424446

48505355

57596163

62616059

58575655

54535251

49484746

———

————

————

————

————

————

————

————

2468

10131517

19212325

28303234

323334

35363738

39404142

43444546

48495051

52535455

56575859

60616263

64656667

68707172

73747576

77787980

SpanFt In

RiseFt In

InsideRadius

Ft In



15 Inch Arch Thickness — 3 Inch Wedge Brick15 x 6 x 3 or 15 x 9 x 3 Inch — Continued1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

29293031

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0600

2222

2222

2222

2222

2233

3333

3333

3333

3333

3333

3333

3344

415/16

511/32

5 3/4 6 5/32

617/32

615/16

711/32

7 3/4

8 5/32

8 9/16

831/32

911/32

9 3/410 5/32

10 9/16

1031/32

11 3/81125/32

0 3/16

0 9/16

031/32

1 3/8 125/32

2 3/16

219/32

3 3 3/8 325/32

4 3/16

419/32

5 513/32

513/16

6 3/16

619/32

7

713/32

713/16

8 7/32

8 5/8

9 913/32

913/16

10 7/32

10 5/811 7/16

0 7/32

127/32

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

29293031

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0600

45444342

41403938

37363534

33323130

29282625

24232221

20191817

16151413

121110

9

8764

321

—

————

36384042

44464850

52545759

61636567

69717476

78808284

86889092

949698

100

103105107109

111113115118

120122124126

126126126126

————

————

————

————

————

————

————

————

————

————

————

1359

81828384

85868788

89909293

94959697

9899

100101

102103104105

106107108109

110111112113

115116117118

119120121122

123124125126

127129131135

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 1 No. 1-X Wedge Wedge Total Straight Total

ARCH COMBINATIONS


18 Inch Arch Thickness — 3 Inch Wedge Brick18 x 6 x 3 or 18 x 9 x 3 Inch1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

17171717

18181818

19191919

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

1111

1111

1111

1111

1111

1111

1111

2222

2222

2222

2222

2222

0 7/8 1 1/4 121/32

2 1/16

215/32

2 7/8 3 9/32

311/16

4 1/16

415/32

4 7/8 5 9/32

511/16

6 3/32

6 1/2 6 7/8

7 9/32

711/16

8 3/32

8 1/2

829/32

9 5/16

911/16

10 3/32

10 1/21029/32

11 5/16

1123/32

0 1/8 017/32

029/32

1 5/16

123/32

2 1/8 217/32

215/16

311/32

323/32

4 1/8 417/32

415/16

511/32

5 3/4 6 5/32

617/32

615/16

711/32

7 3/4

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

17171717

18181818

19191919

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

36353432

31302929

28272524

23222120

19181716

15141312

11987

7654

21

——

————

————

————

468

11

13151719

21232628

30323436

38404244

46485052

54575961

63656769

72747675

74727170

69686766

65646362

————

————

————

————

————

————

————

————

———

2

479

11

13151719

21232527

40414243

44454648

49505152

53545556

57585960

61626364

65666768

70717273

74757677

78798081

82838485

86878889

SpanFt In

RiseFt In

InsideRadius

Ft In



18 Inch Arch Thickness — 3 Inch Wedge Brick18 x 6 x 3 or 18 x 9 x 3 Inch — Continued1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

29292929

30303030

31313131

32

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0

2222

2222

2233

3333

3333

3333

3333

3333

3333

3333

4444

4444

4

8 5/32

8 9/16

831/32

911/32

9 3/410 5/32

10 9/16

1031/32

11 3/81125/32

0 3/16

0 9/16

031/32

1 3/8 125/32

2 3/16

219/32

3 3 3/8 325/32

4 3/16

419/32

5 513/32

513/16

6 3/16

619/32

7

713/32

713/16

8 7/32

8 5/8

9 913/32

913/16

10 7/32

10 5/811 1/32

11 7/16

1113/16

0 7/32

0 5/8 1 1/32

1 7/16

127/32

2 1/4 221/32

3 1/32

3 7/16

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

29292929

30303030

31313131

32

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0

————

————

————

————

————

————

————

————

————

————

————

————

—

61605958

57565554

53525049

48474645

44434241

40393837

36353433

32313029

27262524

23222120

19181716

15141312

11

29323436

38404244

46485153

55575961

63656769

71737578

80828486

88909294

9799

101103

105107109111

113115117119

122124126128

130

90929394

95969798

99100101102

103104105106

107108109110

111112113115

116117118119

120121122123

124125126127

128129130131

132133134135

137138139140

141

SpanFt In

RiseFt In

InsideRadius

Ft In



Total Total

ARCH COMBINATIONS



INTRODUCTIONSince castable and plastic refractorieswere introduced, there has been aconstant search for improved methods ofholding these extremely useful productsin place under varying service conditions.At first, monoliths were typically used forthe temporary repair of small areas ofdamaged brickwork. Over the years,however, monolithic refractorytechnology has expanded far beyondsimple patchwork. Today, entireinstallations are lined with castables,plastics, and anchoring has emerged as atechnology of its own. As a recognized leader in refractorytechnology, Harbison-Walker hascompiled the following information as anoverview of this complex and importantsubject. Since refractory installationsvary, however, and each operation issubject to unique service conditions, thismaterial is provided only as a guideline. This section provides a partial listing ofHarbison-Walker’s anchor products.Please contact your Harbison-WalkerMarketing Representative if you needadditional information.

OverviewThis information is presented as a general guide to selection andinstallation of Harbison-Walker anchors and anchoring systems.Please contact your Harbison-Walker Marketing Representative at anytime for more specific information on the use of ceramic and metallicanchors in your application.

ANCHORING REFRACTORIES

SELECTION GUIDELINESThe primary function of any anchoringsystem is to retain the refractory mass inplace. In order to perform thisrequirement successfully, anchoringsystems must be selected and installed tomatch the service conditions under whichthe process vessels will operate.Installation parameters will differaccording to a number of variablesincluding:

• Type of refractory being installed

• Lining thickness and number of liningcomponents

• Method of refractory installation(gunning, ramming, casting, orshotcreting)

• Process vessel geometry

• Maximum and continuous vesseloperating temperatures

• Vibration and/or severity of vesseloperation

• Structural stability of vessel shell,bindings or support structure

• Exterior insulation

• Operating atmosphere or process

• Whether or not portions of existinglining remain or brick lining exist

IR 64 - Harbison-Walker

Wire AnchorsMany anchoring systems for castable andgunned linings utilize the V-type alloywire anchors they provide adequatesupport and holding power for therefractory, which also offers economythrough simple installation.

Wire anchors are used for most anchorapplications where the servicetemperatures do need exceed2000°F(1904°C). Metallic componentsshould be based on the temperatures ofthe lining and should be installed in wayswhich will allow heat dissipation byconduction and/or circulation.

Harbison-Walker supplies wire anchorsfor a broad range of monolithic anchoringsituations. Harbison-Walker wire anchorscome in mild steel, 304, 309 or 310stainless steels. The wire anchorspresented represent the most commonlyused types. Other available optionsinclude color coding anchor by metaltype, using color plastic tips, stampingmetal type and supply in specialpackaging upon request. Harbison-Walker also supplies custom madeanchors to meet special requirements.

Anchor SpacingDistance between anchors should beconsidered carefully. Edges, roofs, nose,and areas where vibration, mechanicalmovement or gravity impose loads on thelining, require more anchors. Standardspacing for various areas is suggested inthe table below and indicated in theaccompanying illustration. Anchorsshould be welded in a square pattern,rotating the anchor tines 90° fromneighboring anchors.

Anchor WeldingWire anchors require at least a half inch ofweld fillet on both sides. Tack welding isnot enough for wire anchors. Heavier rodanchors also may require more fillet weldon both sides of the leg. Welds can be tested by striking half ofthem with a hammer. A ringing soundindicates a good weld. A dull thudindicates a potential failure. Then bendflat one of every 100 anchors to insureweld does not fail. If the test shows poorwelds, check all the anchors and replacethose that fail.

Anchor LengthLength of wire anchors should be 0.8times the thickness of the lining.This figure is generally rounded up to the nearest half-inch. For example,a 6-inch lining times 0.8 equals 4.8 or 5inches of anchor length.

Estimating Anchor QuantitiesTo determine the total number of anchorsrequired, multiply the anchors per squarefoot by the total number of square feet inthe lining. Anchor quantities based ontypical anchor centers are shown in thetable.

Estimating Anchor Quantities

Anchor Spacing Anchors/Sq Ft6 x 6 48 x 8 2.39 x 9 1.89 x 12 1.33

10 x 10 1.4412 x 12 112 x 18 0.67

Typical Spacing Pattern

The majority of wire anchor installation liningsare 9 inches thick or less. The inset illustrationdetails the installation of a 4A wire anchor. Themetal washer allows the anchor tines to bespread to retain the block insulation.

Wire Anchor Dimensions

Anchor Available Lengths,(in)*

1A 2 to 72A 3 to 93A 5 to 154A 5 to 111L 1 to 72L 1 to 7

* Lengths vary in ½-inch increments

WIRE ANCHORS

Wire and Rod Anchor Spacing

Locations Lining AnchorThickness Centers

(in.) (in.)Walls, 2-4 6

Cylinders, 4-6 9Slopes 6-13½ 12

Overhead, 2-4 6Roofs, 4-7 9

Bullnoses 7-9 12Floors 2-5 9

5-9 159+ 24

¼” AWAYFROM BEND

¾”

1”¼”1¼”

316

”

NOTE: KEEP WELD ¼” AWAYFROM VERTICAL BEND


Wire Anchors1A – This ¼ inch diameter anchor is designed foreconomical use with linings 5 inches or less. Itmay also be used with lightweight materials whereloads are not high.2A – This ¼ inch diameter anchor can be used forthicker linings where additional holding power isneeded. An anchor configuration designed forholding power and a foot designed for added weldstrength give the 2A the versatility needed for usewith high density materials. A anchors can be usedin high density linings 7 inches thick or less andfor lightweight linings.3A – This 5/16-inch diameter anchor is a largerversion of the 2A. Also incorporating a foot foradded weld strength, the 3A handles thick denselinings up to 9 inches, heavy overhead loads andareas subject to movement or vibration..3A-3/8 – This 3/8 inch 3A anchor is designed fordense thick linings from 6 to 16 inches thick,heavy overhead loads areas subject to movementand vibration. The foot provides additional weldstrength.1L & 2L Clips – These metal clips are used withthe 3A and 2A anchors respectively, for installing2 component linings. 1L clips have a 5/16-inchnotch for use with the 3A anchor. 2L clips have a1/4- inch notch for incorporating the 2A anchors.In the 2 component lining application, the clippermits the first component to be installed beforethe 3A or 2A anchors are attached and the hot facelining is installed.4A – This ¼ inch diameter anchor is intended foruse with monolithic linings with backup insulation.A washer is furnished with the anchor whichpermits the anchor tines to be spread after theinsulation is in place. The 4A is typically used inlinings with a total thickness of 4 to 12 inches.5A & 6A – These ¼ inch and 5/16 inch anchorsare typically used for light duty monolithic linings.In lengths from 3 to 10 inches, they are typicallyused for anchoring in door framings, corners,pockets and small voids.7A – The “Christmas Tree” anchor, available inheights from 13 to 40 inches are typically used inspecific applications where massive installationsof refractories occur. Examples include rotary kilndams and lifters.KL – This 3/8 inch diameter anchor is for use inrotary kiln linings 4 ½ to 9 inches thick. The platesupplied with the anchor is welded to the shell.The tack weld between the plate and the anchorcan break during operation and thus allow limitedmovement between lining and shell. Expansionand contraction in the lining is assured while thelining is retained in place.

1A 2A & 3A

4A1L & 2L CLIPSFOR 2A & 3A ANCHORS

7A 3R

5A & 6A

KL

Grades of Steel Required for High Temperature Service

Type of Steel Color CodeMaximum Temp of

Metallic Components °FCarbon Steel Blue 1000

304 SS No Color 1600309 SS Red 1650310 SS Yellow 1700

WIRE ANCHORS


KL ANCHORS

TOTALLINING

THICKNESS KL-5 ½" 4 ½"

6" 5"7" 5 ½"

7 ½" 6"8" 6 ½"

8 ½" 7"9" 7"

9 ½" 7 ½"10" 8"

10 ½" 8 ½"11" 9"12" 9"

12 ½" 10"13 ½" 10 ½"

STANDARD WIRE ANCHORS

TOTALLINING

THICKNESS 5A- 6A-3 ½" 3" 3"

4" 3 ½" 3 ½"4 1/2" 4" 4"

5" 4" 4" 5 ½" 4 ½" 4 ½"

6" 5" 5"6 ½" 5 ½" 5 ½"

7" 6" 6"7 ½" 6" 6"

8" 6 ½" 6 ½"8 ½" 7" 7"

9" 7 ½" 7"9 ½" 8" 8"10" 8" 8"

10 ½" 8 ½" 8 ½"11" 9" 9"

11 ½" 9" 9"12" 10" 10"

12 ½" 10" 10"

SUGGESTED USE FOR 4A ANCHOR

TOTAL TOTAL LENGTH OF UNBENT ANCHOR WITH

LINING 1" 1 ½ “ 2” 2 ½ “ 3” 3 ½" 4"THICKNESS Block Block Block Block Block Block Block

4" 4" 4"4 ½" 4" 4" 4" 5" 4 ½" 4 ½" 4 ½" 4 ½"

5 ½" 5" 5" 5" 4 ½" 4 ½" 6" 5 ½" 5 ½" 5" 5" 5"

6 ½" 6" 6" 5 ½" 5 1½" 5 ½" 5 ½"7" 6 1/2" 6" 6" 6" 6" 6"

7 ½" 7" 7" 6 ½" 6 ½" 6 ½" 6 ½" 6 ½"8" 7" 7" 7" 7" 7" 7" 7"

8 ½" 7 ½" 7 ½" 7 ½" 7 ½" 7 ½" 7 ½" 7 ½"9" 8" 8" 8" 8" 8" 8" 8"

9 ½" 8 ½" 8 ½" 8 ½" 8 ½" 8 ½" 8 ½" 8 ½"10" 9" 9" 9" 8 ½" 8 ½" 8 ½" 8 ½"

10 ½" 9 ½" 9 ½" 9 " 9" 9" 9" 9"11" 10" 10" 10" 9 ½" 9 ½" 9 ½" 9 ½"

11 ½" 10 ½" 10 ½" 10 ½" 10" 10" 10" 10"12" 11" 11" 11" 10 ½" 10 ½" 10 ½" 10 ½"

12 ½" 11 ½" 11 ½" 11 ½" 11" 11" 11" 11"13" 11 ½" 11 ½" 11 ½" 11 ½" 11 ½" 11 ½" 11 ½"

13 ½" 12" 12" 12" 12" 12" 12" 12"

WIRE ANCHORS

STANDARD WIRE ANCHORS

TOTALLINING

THICKNESS 1A- 2A- 3A- 3A-3/8- 7A-2" 1 ½"

2 ½" 2"3" 2 ½"

3 ½" 3"4" 3"

4 ½" 3 ½" 3 ½" 5" 4" 4"

5 ½" 4½" 6" 5" 5"

6 ½" 5" 5"7" 5 ½" 5 ½"

7 ½" 6" 6"8" 6 ½" 6 ½"

8 ½" 7" 7"9" 7” 7"

9 ½" 7½" 7½"10" 8" 8"

10 ½" 8½"11" 9"

11 ½" 9"12" 9½"

12 ½" 10"13" 10 ½"

13½" 11"14" 11"

14½" 11½"15" 12"

15½" 12½" 13"16" 13"

>16"- 48" >13"- 40"


WIRE ANCHORS

1-L CLIPS

Anchor Dim A Dim B

1-L-1 1 1 11/16

1-L-1 1/2 1 1/2 2 3/16

1-L-2 2 2 11/16

1-L-2 1/2 2 1/2 3 3/16

1-L-3 3 3 11/16

1-L-3 1/2 3 1/2 4 3/16

1-L-4 4 4 11/16

1-L-4 1/2 4 1/2 5 3/16

1-L-5 5 5 11/16

1-L-5 1/2 5 1/2 6 3/16

1-L-6 6 6 11/16

1-L-6 1/2 6 1/2 7 3/16

1-L-7 7 7 11/16

1-L-7 1/2 7 1/2 8 3/16

7/8”

Dim

“A”

Dim

“B”

7/8

Dim

C

Dim

D

2A Anchor and 2-L Clip ArrangementFor 2 Component Cast Lining

3A Anchor and 1-L Clip ArrangementFor 2 Component Cast Lining

1-L CLIP 2-L CLIP

Hot Face

3-AAnchor

1-LAnchor Clip

½” FormBoard

/ ” StdWasher8 Ø7

½”

15½

”Max

.5½

”Min

.

7” Max.1” Min.

Wor

king

Lini

ng

BackupLining

Casing LR

2-L CLIPS

Anchor Dim C Dim D

2-L-1 1 1 5/8

2-L-1 1/2 1 1/2 2 1/8

2-L-2 2 2 5/8

2-L-2 1/2 2 1/2 3 1/8

2-L-3 3 3 5/8

2-L-3 1/2 3 1/2 4 1/8

2-L-4 4 4 5/8

2-L-4 1/2 4 1/2 5 1/8

2-L-5 5 5 5/8

2-L-5 1/2 5 1/2 6 1/8

2-L-6 6 6 5/8

2-L-6 1/2 6 1/2 7 1/8

2-L-7 7 7 5/8

Hot Face

2-AAnchor

2-LAnchor Clip

½” FormBoard

/ ” StdWasher8 Ø7

½”

9½”M

ax.

3½”M

in.

6 ½” Max.1” Min.

Wor

king

Lini

ng

BackupLining

Casing LR


WIRE ANCHORS

Dim

A

Dim

A

Dim

C

1-R-T Clip

1-R Clip

1-R CLIPShape No. Dim D

1-R-1 1.00

1-R-1.5 1.50

1-R-2 2.00

1-R-2.5 2.50

1-R-3 3.00

1-R-3.5 3.50

1-R-4 4.00

1-R-4.5 4.50

1-R-5 5.00

1-R-5.5 5.50

1-R-6 6.00

1-R-6.5 6.50

1-R-7 7.00

1-R-7.5 7.50

1-R-T CLIP

Shape No. Dim A Dim C

1-R-T-3 3.00 2.00

1-R-T-3.5 3.50 2.50

1-R-T-4 4.00 3.00

1-R-T-4.5 4.50 3.50

1-R-T-5 5.00 4.00

1-R-T-5.5 5.50 4.50

1-R-T-6 6.00 5.00

1-R-T-6.5 6.50 5.50

1-R-T-7 7.00 6.00

1-R-T-7.5 7.50 6.50

3-R ANCHORShape No. Dim C Shape No. Dim C

3-R-2 2.00 3-R-8.5 8.50

3-R-2.5 2.50 3-R-9 9.00

3-R-3 3.00 3-R-9.5 9.50

3-R-3.5 3.50 3-R-10 10.00

3-R-4 4.00 3-R-10.5 10.50

3-R-4.5 4.50 3-R-11 11.00

3-R-5 5.00 3-R-11.5 11.50

3-R-5.5 5.50 3-R-12 12.00

3-R-6 6.00 3-R-12.5 12.50

3-R-6.5 6.50 3-R-13 13.00

3-R-7 7.00 3-R-13.5 13.50

3-R-7.5 7.50 3-R-14 14.00

3-R-8 8.00 3-R-15 15.00

Detail of 3-R Anchor and1-R or 1-R-T Clip Assembly

3-R Anchor assembly to be used with two component lining (Gunned)

Dim

C


Harbison-Walker Standard Stock Anchorsfor Castable and Plastic Refractories

REFRACTORY ANCHORS

Refractory Anchor Solid (RAS) are ceramic anchors for flat suspendedroof and wall applications.

Refractory Anchor with Hole (RAH) are ceramic anchors for wallapplications.

Rotary Kiln Anchor (RKA) are ceramic anchors for rotary kiln applicationsand wall applications.

Ceramic Anchor SystemsMost castable and refractoryinstallations operating at temperaturesabove 2000°F are best served byselecting anchors made of refractorymaterials compatible with the refractorybeing installed. Included in the selectionof stock H-W ceramic anchors areRefractory Anchor Solid (RAS),Refractory Anchor with Hole (RAH),Rotary Kiln Anchor (RKA) and a choiceof special H-W custom producedceramic anchors. Harbison-Walkerceramic anchors should be used in allinstallations where temperatures in thefurnace will routinely exceed 2000°F(1094°C). Generally, castable and plasticrefractory lining thicknesses for heavy-duty service range betweenapproximately 9 and 19 inches. Forthese types of constructions, fired H-Wceramic anchors are recommended.Ceramic anchors have severaladvantages over other typesof anchoring components. They extendthrough the refractory mass to the hotface, providing an extra measure ofretention. The design of H-W stockceramic anchors also provides moresurface area in contact with therefractory mass for greater holdingpower than most metal anchors. The overall length of ceramic anchorsshould place the cold face end of theanchor as close as possible to the vesselshell or supporting steelwork. When theceramic anchor is attached in thismanner, the metallic hanger bracket,which secures it, will then be exposed tolower temperatures.

The portion of the metal hanger whichengages the overhead I-beam, or suspensionrod, should remain exposed to ambient airto permit heat dissipation. Insulation placedover the cold face of the roof should notcover the anchor clip.

Anchor Brackets and ClipsRefractory anchors are normally used inmonolithic refractory installations whereoperating temperatures routinely exceed2000F (1094C). H-W ceramic anchors forcastable and plastic refractories aredesigned to accept C-Clips which arewelded or bolted to the shell, Slip-Oncastings and Ice-Tong Clips for overheadattachment to a standard I-beam. Someinstallations may use U-Series Rod with nutwelded to steel shell wall or bolt and nutassembly positioned within Rotary KilnAnchor that is welded to steel wall. Acertain amount of movement can occurbetween the refractory anchor and its metalattachment to accommodate expansion andcontraction of the lining. The followingpages illustrate a variety of anchorarrangements, primarily for roofconstruction and sidewall installations.

CC-Series Anchor Clips (see page IR-72)These are used to attach the RAS refractoryceramic anchors directly to the steel shell.

They are available in several metal typesto accommodate a range of serviceconditions. When installed, they aretypically welded to the vessel shell. Theyare available in three standard lengths tohandle the many lining thicknesses withstandard anchors. The RAS anchor chartsshow the combinations of the longestanchor and the shortest metallics for thelining thickness shown.

Ice Tong Anchor Clips (see page IR-73)Ice tong anchor clips are designed tosupport RAS refractory ceramic anchorsfor overhead attachment to standard 3 or 4–inch I beams. They allow for somemovement of the anchor system duringheat-up and subsequent operation. Whenordering, it is necessary to specify the sizeand alloy to be used. An example wouldbe IT-3-1.5-304. These specs are calledout in the anchor charts.

Refractory Anchor Length and AnchorSpacingThe length of refractory anchors usuallyequals the lining thickness. Suggestedspacing for ceramic anchors is covered inthe Anchor spacing chart. Distancebetween anchors should be consideredcarefully. Edges, roof and nose, and areaswhere vibration, mechanical movement orgravity impose loads on the lining, requiremore anchors.

STANDARD STOCK ANCHORS

Suggested Spacing for Ceramic Refractory Anchors

Locations Lining Thickness (In.) Anchoring Spacing (in.)Vertical and circular units 9-12 15

12-15 1815+ 24

Roofs, noses and arches 6+ 12

(2 Required per Anchor)

3" @ 5.7I

Beam Hanger

Refractory Anchor

Lini

ngT

hick

ness

Temperature Limitat this Point

Drop

1 / ”13 16

"A"

IT-3 Series

RAS-Series

304 Alloy: 1600°F (870°C)

310 Alloy: 1700°F (926°C)

330 Alloy: 1800°F (981°C)


RAH & RAS-Series Anchor Lengthsand Anchor Spacing Selection Charts

Anchor Spacing Chart

RAH & RAS Series Anchors in 9Lengths RAS-Series

AnchorRAH-Series

Anchor“A”(In.)

RAS-7.5

RAS-9

RAS-10.5

RAS-12

RAS-13.5

RAS-15

RAS-16.5

RAS-18

RAS-20

RAH-7.5

RAH-9

RAH-10.5

RAH-12

79/16

815/16

105/16

1113/16

13 5/16

1413/16

16 5/16

1713/16

1913/16

6 - 13½

6 - 13½

15

6 - 13½

All Thicknesses

18

12 15

15 18

12 12

Castable Linings

Thickness(In.)

CentersLocation Vert.

(In.)Horiz.(In.)

Plastic Linings

Walls & Slopes

Arches& Bullnoses

Walls & Slopes

Arches& Bullnoses

Note:Anchors will be stocked in CORAL® BP brands.Other brands available on a made-to-order basis.

Refractory Anchor with Hole Series (RAH) for Wall Applicationsand Refractory Anchor Solid Series (RAS) for Flat Suspended Roof and Wall Applications

"A"

Top View

Side View

RASRefractory

AnchorSolid

4 ½"

4"

Top View

Side View(Cut-away)

RAHRefractory

AnchorHole

"A"

Hole7/ ” Diameter8

REFRACTORY ANCHORS RAH & RAS SERIES


RAH & U-Series / Z-SeriesAnchor Rods

Ordering InformationWhen ordering U-Series or Z-Series Rodsthe alloy must be specified (Example U-2-304).

U-Series

RAH-Series

½” Anchor Rod(Comes withSquare Nut)

SteelShell

Refractory Anchor

304 Alloy: 1600°F (870°C)

310 Alloy: 1700°F (926°C)

330 Alloy: 1800°F (981°C)

Anchor RodTemperature Limitat this Point

½” (Approx.)

C\v" Square NutWelded toSteel Shell

Lining Thickness

Side View(Cut-away)

Top Viewfor RAH & U-Series

Z-Series

RAH-Series

½” Anchor Rod(Comes withSquare Nut)

C\v" Square NutWelded toSteel Shell

Refractory Anchor

½” (Approx.)

Side View(Cut-away)

SteelShell

REFRACTORY ANCHORS RAH-U SERIES

Note: The combinations above provide the longest anchorand the shortest metallics for the lining thickness shown.

Other sizes of U-Series and Z-Series Rods are available.

Other RAH refractory anchors lengths are available but not forstandard stock, and are available on a made to order basis.

Lining Thickness(In.)

RefractoryAnchor

AnchorRod

8.59

9.5

10

10.5

10

10.511

11.5

RAH-7.5RAH-7.5

RAH-7.5

RAH-7.5

RAH-7.5

RAH-9

RAH-9RAH-9

RAH-9

12

11.5

12

12.5

13

13.5

13

13.5

14

RAH-9

RAH-10.5

RAH-10.5

RAH-10.5

RAH-10.5

RAH-10.5

RAH-12

RAH-12

RAH-12

14.5

15

RAH-12

RAH-12

U-1 or Z-1U-1.5 or Z-1.5

U-2 or Z-2

U-2.5 or Z-2.5

U-3 or Z-3U-1 or Z-1

U-1.5 or Z-1.5

U-2 or Z-2

U-2.5 or Z-2.5

U-3 or Z-3

U-1 or Z-1U-1.5 or Z-1.5

U-2 or Z-2

U-2.5 or Z-2.5

U-3 or Z-3

U-1 or Z-1

U-1.5 or Z-1.5

U-2 or Z-2

U-2.5 or Z-2.5

U-3 or Z-3


Ordering InformationWhen ordering CC-Series Anchor Clipsthe alloy must be specified(Example CC-1-304).

Note: The combinations above provide the longest anchorand the shortest metallics for the lining thickness shown.

REFRACTORY ANCHORS RAS & H-W 3184 SERIES

9.5

10

10.5

11

11.5

12

RAS-9

RAS-9

RAS-9

RAS-10.5

RAS-10.5

RAS-10.5

12.5

13

13.5

14

14.5

15

15.5

16

16.5

RAS-12

RAS-12

RAS-12

RAS-13.5

RAS-13.5

RAS-13.5

RAS-15

RAS-15

RAS-15

17

17.5

RAS-16.5

RAS-16.5

18

18.5

19

19.5

RAS-16.5

RAS-18

RAS-18

RAS-18

CC-0.5

CC-1

CC-1.5

CC-0.5

CC-1

CC-1.5

CC-0.5

CC-1

CC-1.5

CC-0.5

CC-1

CC-1.5

CC-0.5

CC-1

CC-1.5

CC-0.5

CC-1

CC-1.5

CC-0.5

CC-1

CC-1.5

LiningThickness (In.)

RefractoryAnchor

AnchorClip

6

6.5

7

HW-3184

HW-3184

HW-3184

CC-A

CC-C

CC-E

8

8.5

9

RAS-7.5

RAS-7.5

RAS-7.5

CC-0.5

CC-1

CC-1.5

(Weld or Bolt)

Anchor Clip

Front View Side View

Refractory Anchor

Steel Shell

C-ClipTemperature Limitat this Point

CC-Series

RAS-Series

9/ ” Diameter Hole16

LiningThickness

304 Alloy: 1600°F (870°C)

310 Alloy: 1700°F (926°C)

330 Alloy: 1800°F (981°C)

Front View

Weld Along Both Sides


Ordering InformationWhen orderingIT-3 Series BeamHangersthe alloy mustbe specified(Example: IT-3-1.5-304).

Refractory Anchor Solid Series (RAS)for Flat Suspended Roof Applications

MaximumLining

Thickness (In.)

5.5 RAS-7.5

“A”(In.)

RefractoryAnchor

AnchorRod

Drop(In.)

8

8.5

9

IT-3-0.5

IT-3-1

IT-3-1.5

11/16

13/16

111/16

7 RAS-99.5

10

10.5

IT-3-0.5

IT-3-1

IT-3-1.5

11/16

13/16

111/16

8.5 RAS-10.511

11.5

12

IT-3-0.5

IT-3-1

IT-3-1.5

11/16

13/16

111/16

10 RAS-1212.5

13

13.5

IT-3-0.5

IT-3-1

IT-3-1.5

11/16

13/16

111/16

11.5 RAS-13.514

14.5

15

IT-3-0.5

IT-3-1

IT-3-1.5

11/16

13/16

111/16

13 RAS-1515.5

16

16.5

IT-3-0.5

IT-3-1

IT-3-1.5

11/16

13/16

111/16

14.5 RAS-16.517

17.5

18

IT-3-0.5

IT-3-1

IT-3-1.5

11/16

13/16

111/16

16 RAS-1818.5

19

19.5

IT-3-0.5

IT-3-1

IT-3-1.5

11/16

13/16

111/16

RAS-Series & IT-3SeriesAnchor Rod


3" @ 5.7I

Beam Hanger

Refractory Anchor

Lini

ngT

hick

ness


Drop

1 / ”13 16

"A"

IT-3 Series

RAS-Series

304 Alloy: 1600°F (870°C)

310 Alloy: 1700°F (926°C)

330 Alloy: 1800°F (981°C)

REFRACTORY ANCHORS RAS SERIES

304 Alloy: 1600°F (870°C)

309 Alloy: 1650°F (899°C)

310 Alloy: 1700°F (926°C)


RAS-Series & IT-4SeriesAnchor Rod


4" @ 7.7I

Beam Hanger

Refractory Anchor

Lini

ngT

hick

ness


Drop

1 / ”13 16

"A"

IT-4 Series

RAS-Series

304 Alloy: 1600°F (870°C)

310 Alloy: 1700°F (926°C)

330 Alloy: 1800°F (981°C)

REFRACTORY ANCHORS RAS SERIES

Ordering InformationWhen orderingIT-4 Series Beam Hangersthe alloy mustbe specified(Example: IT-4-1.5-304).

5.5 RAS-7.5

“A”(In.)

RefractoryAnchor

AnchorRod

Drop(In.)

8

8.5

9

IT-4-0.5

IT-4-1

IT-4-1.5

11/16

13/16

111/16

7 RAS-99.5

10

10.5

IT-4-0.5

IT-4-1

IT-4-1.5

11/16

13/16

111/16

8.5 RAS-10.511

11.5

12

IT-4-0.5

IT-4-1

IT-4-1.5

11/16

13/16

111/16

10 RAS-1212.5

13

13.5

IT-4-0.5

IT-4-1

IT-4-1.5

11/16

13/16

111/16

11.5 RAS-13.514

14.5

15

IT-4-0.5

IT-4-1

IT-4-1.5

11/16

13/16

111/16

13 RAS-1515.5

16

16.5

IT-4-0.5

IT-4-1

IT-4-1.5

11/16

13/16

111/16

14.5 RAS-16.517

17.5

18

IT-4-0.5

IT-4-1

IT-4-1.5

11/16

13/16

111/16

16 RAS-1818.5

19

19.5

IT-4-0.5

IT-4-1

IT-4-1.5

11/16

13/16

111/16

MaximumLining

Thickness (In.)

304 Alloy: 1600°F (870°C)

309 Alloy: 1650°F (899°C)

310 Alloy: 1700°F (926°C)


RAS-Series & RNP-1Beam Hanger

MaximumLining

Thickness (In.)5.5 RAS-7.5

“A”(In.)

RefractoryAnchor

8.5

7 RAS-910

8.5 RAS-10.511.5

10 RAS-1213

11.5 RAS-13.514.5

13 RAS-1516

14.5 RAS-16.517.5

16 RAS-1819

Ordering InformationWhen orderingRNP-1 Beam Hangersthe alloy mustbe specified(Example: RNP-1-304).

REFRACTORY ANCHORS RAS & H-W 3184 SERIES

3" @ 5.7I

Refractory Anchor

Lini

ngT

hick

ness

Drop

1 /13 16

1 /13 16

"A"

RAS-Series


Beam HangerRNP-1

304 Alloy: 1600°F (870°C)

310 Alloy: 1700°F (926°C)

330 Alloy: 1800°F (981°C)

304 Alloy: 1600°F (870°C)

309 Alloy: 1650°F (899°C)

310 Alloy: 1700°F (926°C)

HW-3184 Anchor AssemblyBolt Arrangement

Lining Refractory AnchorThickness (in.) Anchor Bolt

6 H-W 3184 HW-878-2½

6.5 H-W 3184 HW-878-3

7 H-W 3184 HW-878-3½

HW-875-2½

Front View

Weld Nut To Shell

6.00

0(1

52.4

)

HW-3184


RKA-6/KAC Series

Rotary Kiln Anchor Series (RKA)for Wall Applications

Hardware Assembly Data

Ordering Information

1. When ordering KAC-Series Clips the alloy must be specified.(Example: KAC-2.5-304)

2. Other lengths of KAC Clips can be manufactured upon request.

3. RKA-6, 9, 12 & KAC uses one F-95 Carbon Steel Nut &F-38 Carbon Steel Washer.

Clip*

KAC

“A”(In.)

6

KAC-1 7

KAC-1.5 7.5

KAC-2 8

KAC-2.5 8.5

KAC-3 9

KAC-3.5 9.5

KAC-4 10

“B”(In.)

0

1

1.5

2

2.5

3

3.5

4

KAC-4.5 10.5

KAC-5 11

KAC-5.5 11.5

KAC-6 12KAC-6.5 12.5

KAC-7 13

KAC-7.5 13.5

4.5

5

5.5

66.5

7

7.5KAC-8 14

KAC-9 15

8

9

*See Ordering Information at Left.

KACSeriesClip

Min.10 Ga. Pl.

3/16”

½ 13 UNC-2B Heavy-

Hex. Nut (F-95 Carbon Steel)

½ 13 UNC-2B Heavy Hex. Nut-

(Same Alloy as KAC. F-223 304 Alloyor F-129 310 Alloy)

orFor Use In Rotary Kiln

or Other Dynamic Applications9/ /16 8” I.D. x 1 3 " O.D.xM\nv" Thick Metal Washer(Same Alloy as KAC.F-260 304 Alloy orF-429 310 Alloy)

9/ ” I.D. X16 1/16” O.D.x1/8” Thick Plastic Washer(F-94) for Walls, Roofs, andOther Static Applications

"A"

"B"(Cut-away)6 Nominal

Side View

Bottom View


RKA-6

5/8”

3"

4"

304 Alloy: 1600°F (870°C)

310 Alloy: 1700°F (926°C)

330 Alloy: 1800°F (981°C)

REFRACTORY ANCHORS RKA SERIES

304 Alloy: 1600°F (870°C)

309 Alloy: 1650°F (899°C)

310 Alloy: 1700°F (926°C)


RKA-9/KAC Series RKA-12/KAC Series

Clip*

KAC 9

KAC-1 10

KAC-1.5 10.5

KAC-2 11

KAC-2.5 11.5KAC-3 12

KAC-3.5 12.5

KAC-4 13

0

1

1.5

2

2.53

3.5

4

KAC-4.5 13.5

KAC-5 14

KAC-5.5 14.5

KAC-6 1516KAC-7

KAC-7.5 16.5

4.5

5

5.5

67

7.5KAC-8 17

KAC-9 18

8

9

“A”(In.)

“B”(In.) Clip*

KAC 0

KAC-1 1

KAC-1.5 1.5

KAC-2 2

KAC-2.5 2.5KAC-3 3

KAC-3.5 3.5

KAC-4 4

12

13

13.5

14

14.515

15.5

16

KAC-4.5 4.5

KAC-5 5

KAC-5.5 5.5

KAC-6 6

7KAC-7

KAC-7.5 7.5

16.5

17

17.5

18

1919.5

KAC-8 8

KAC-9 9

20

21

“A”(In.)

“B”(In.)

"A"

"B"9 Nominal(Cut-away)Side View

Bottom View


RKA-9

5/8”

3"

4"

304 Alloy: 1600°F (870°C)

310 Alloy: 1700°F (926°C)

330 Alloy: 1800°F (981°C)

"A"

"B"

5/8

3"

4"

12 Nominal

(Cut-away)

RKA-12

Bottom View

Side View


304 Alloy: 1600°F (870°C)

310 Alloy: 1700°F (926°C)

330 Alloy: 1800°F (981°C)

REFRACTORY ANCHORS RKA/KAC SERIES

304 Alloy: 1600°F (870°C)

309 Alloy: 1650°F (899°C)

310 Alloy: 1700°F (926°C)

304 Alloy: 1600°F (870°C)

309 Alloy: 1650°F (899°C)

310 Alloy: 1700°F (926°C)










CUSTOM ANCHORS

Suggested Spacing for Ceramic Refractory Anchors

Locations Lining Thickness (In.) Anchoring Spacing (in.)Vertical and circular units 9-12 15

12-15 1815+ 24

Roofs, noses and arches 6+ 12

Roof AnchorsHarbison-Walker supplies a varietyof pre-welded metal anchor assem-blies referred to as the HW 20Series. Although these assemblesare adaptable for wall construction,they are most often used in roofs,suspended from supporting steel-work.

Bullnose AnchorsPre-welded metal anchorassemblies can be used where theshell geometry does not allow forconventional ceramic anchor orwire anchors to be used. These aregenerally fabricated from 310ss.

Special Roof AnchorsOther available roof anchorassemblies include the S-191-075pre-welded assembly and theS-191-082, S-191-083, S-191-084special nose anchors shown below.

Contact your local H-Wrepresentative for more detailedanchor drawings.

(Above) Illustration shows threedifferent metal anchors as used forroof construction. The metallic anchorsare suspended from overhead rods,pipes or I-beams and extend into therefractory mass to within approxi-mately one inch of the vessel’s hotface.

(Below) In some plastic and castableinstallations where vessel geometry,loading or other considerations makethe use of wire or ceramic anchorsimpractical, metal anchors can beused. An example of thisusage is the bull noseconfiguration illustrated.

1¼” 1¼”

½” Dia.½” Dia.

3”4¾”

4 ”1 8/

11 16/1 ”7 32/1 ”1 ” 7 32/1 ”

1932/

9

”

316/

1

”13

32/5

”

3”

1½”

S-191-075

Assembly No. Dim A Dim B Typical Support Member

HW-20-247-F6 11/16" 3 15/16" 3 or 4-inch I-beam

HW-20-247-F-90

HW-20-249-F8 9/16" 5 13/16" 3 or 4-inch I-beam

HW-20-249-F-90

HW-20-2412-F11 7/16" 8 11/16" 3 or 4-inch I-beam

HW-20-2412-F-90

HW-20-548-F9 3/4" 7" 5-inch I-beam

HW-20-548-F-90

3-inch I-beam, 5.7 pounds per foot; 4-inch I-beam, 7.7 pounds per foot“90” assembly indicates anchor shank is turned 90 degrees to assembly without “90”

Special Roof Anchors

2

1 8/1

½ Dia.

4¾

1¼1

8/4

5

8/1

3

1¼1

8/6

5

8/1

3

1¼1

8/9

5

8/1

3

S-1

91-0

82S

-191

-083

S-1

91-0

84

S-191-082,3 &4


B-21280 & B-2180-3Anchor Assembly

B-43401 & B-43401-3Anchor Assembly

“A” “B” PART NO.

1” 10” MH-2042” 11” MH-302

2½” 11½” MH-4003” 12” MH-402

3½” 12½” MH-5004½” 13½” MH-6005” 14” MH-608

“A” “B” PART NO.

1” 5½” MH-1001½” 6” MH-2002” 6½” MH-205

2½” 7” MH-3003” 7½” MH-301

3½” 8” MH-4014” 8½” MH-403

4½” 8½” MH-5015½” 10” MH-6016” 10½” MH-607

NOTE:To insure proper locationof B-2180 anchors, weldF-21 clip to steel shellas brickwork progress.

NOTE:To insure proper locationof brick anchors, weldF-21 clip to steel shellas brickwork progress.

ANCHORS TIE BACK SYSTEM


Wall Seat AssemblyTo reduce the stresses placed on anchors,wall seat assemblies like H-W WS WallSeat with WSC Clip’s should be usedwhere extremely heavy vertical or slopingwall loads are encountered. Wall seat arealso important in areas above arches, portsor bull noses that might collapse underheavy loading. Consider wall seats whenusing a dense monolith over 6 inches thickand /or 4 feet or more in height. Wall seatsare available in lengths from 5 to 10inches. The HW WSC can be welded tothe vessel shell.

HW-4053– Wall Tie-Back Brick–In large refractory brick walls or thosesubject to particularly severe operationalproblems, tie-back brick are used to helpmaintain the structural integrity of thebrick wall. Harbison-Walker supplies theHW-4053 brick shape in severalrefractory compositions and lengths.Tie-back plates and clip assembly(S-191-038/039) are used.

Tie-back brick may be located atintervals as close as 12 inches on thevertical and 2 to 3 feet on the horizontal,and are dependent on structural and loadconsiderations. Please review thesearrangements with your Harbison-Walkerrepresentative.

HW-4053

Shape LiningNumber Thickness A

HW-4053-6 6 4½

HW-4053-9 9 7½

HW-4053-10½ 10½ 9

HW-4053-12 12 10½

HW-4053-13½ 13½ 12

HW-4053-15 15 13½

HW-4053-18 18 16½

S-191-036

S-191-039

S-191-038

Metal ArrangementsFor Tie-Back Brick

Wall SeatAssembly

LiningThickness

A

3

3

HW-4053

HW-4053

Tie Back BrickArrangement

ANCHORS TIE BACK SYSTEM


The ceramic anchor systems shown hereare nonstandard systems that can beordered. Standard stock ceramic anchorsare available in the RAS, RAH andRKA series.

Ceramic Anchors876 SeriesRefractory anchor designed to acceptslipover castings. Primary use is in roofconstruction, but this anchor may be usedin wall construction applications with theuse of C-Clips.

WC SeriesRefractory wiggle anchor made inUFALA® brand only. This anchormaintains a constant cross section of 4½"x 4½". This is primarily a roof andbullnose anchor.

TC SeriesRefractory tapered anchor for use in roofconstruction. Made in UFALA® brand,this anchor accepts a variety of C-Clip andslipover castings, depending on applica-tion. The tapered design helps wedge therefractory lining in addition to the tonguesand grooves.

TI SeriesRefractory tapered anchors for use in wallconstruction. Available in UFALA®

brand, these anchors are attached with Z-RODS to the sidewall. They provideflexible attachment to accommodate liningthicknesses from 9 to 18 inches. There are

876 Series TC Series

WC Series TI Anchor

VS and QVS Series

“V” Metallic Anchor Series (VS) and (QVS)for Roof and Wall Applications

"B"

"C"

"A"

60˚

VS or QVS Serieswith Welded Nut

Note: These anchors are not standard stock.When ordering “VS” & “QVS” (-N-Series) anchors alloy must be specified.(Example VS-50-N-304)

Cross refrerence chart is on page IR-82

Bolting“VS” & “QVS” (-N-Series) anchors, -80-N and smaller, use 3/8” diameter bolt or stud.“VS” & “QVS” (-N-Series) anchors, -90-N and longer, use ½” diameter bolt or stud.

Rod Diameters“QVS”-15 thru -100 (-N-Series) anchors are all ¼” diameter rod.“VS”-15 thru -80 (-N-Series) anchors are 5/16” diameter rod.“VS”-90 thru -200 (-N-Series) anchors are 3/8” diameter rod.

Brand

VS-15/10

“A”

1½

VS-20/15 21/8VS-25/20 25/8VS-30/25 31/8VS-35/30 35/8VS-40/35 4¼

VS-50/45 5

VS-60/55 6

“B”

21/825/831/825/83½

4

4

VS-70/65 7

VS-80/75 8

VS-90/85 9

VS-100/95 10

VS-110/105 11

VS-120/115 12

4

4

4

5

6

6

1½

“C”

1

¾

1

2

3

4

5

5

5

6

Dimension Table (In.)

Brand Brand Brand

QVS-15/10

QVS-20/15

QVS-25/20

QVS-30/25

QVS-35/30

QVS-40/35

QVS-50/45

QVS-60/55

QVS-70/65

QVS-80/75

QVS-90/85

QVS-100/95

VS-15

VS-20

VS-25

VS-30

VS-35

VS-40

VS-50

VS-60

VS-70

VS-80

VS-90

VS-100

QVS-15

QVS-20

QVS-25

QVS-30

QVS-35

QVS-40

QVS-50

QVS-60

QVS-70

QVS-80

QVS-90

QVS-100

VS-110

VS-120

NON-STANDARD CREAMIC ANCHORS & “V” METALLIC ANCHORS


Cross Reference Table for Single Component Wire Anchors

H-W ANCHOR ANCHOR DIA. BRAND BRAND BRAND BRAND

1A-1 ½ ¼” DIA. VS-15/10 VS-15 QVS-15/10 QVS-15

1A-2 ¼” DIA. VS-20/15 VS-20 QVS-20/15 QVS-20

1A-2 ½ ¼” DIA. VS-25/20 VS-25 QVS-25/20 QVS-25

1A-3 ¼” DIA. VS-30/25 VS-30 QVS-30/25 QVS-30

2A-3 ½ ¼” DIA. VS-35/30 VS-35 QVS-35/30 QVS-35

2A-4 ¼” DIA. VS-40/35 VS-40 QVS-40/35 QVS-40

2A-5 5/16” DIA. VS-50/45 VS-50 QVS-50/45 QVS-50

3A-6 5/16” DIA. VS-60/55 VS-60 QVS-60/55 QVS-60

3A-7 5/16” DIA. VS-70/65 VS-70 QVS-70/65 QVS-70

3A-8 3/8” DIA. VS-80/75 VS-80 QVS-80/75 QVS-80

3A-9- 3/8 3/8” DIA. VS-90/85 VS-90 QVS-90/85 QVS-90

3A-10- 3/8 3/8” DIA. VS-100/95 VS-100 QVS-100/95 QVS-100

3A-11- 3/8 3/8” DIA. VS-110/105 VS-110

3A-12- 3/8 3/8” DIA. VS-120/115 VS-120

3A-12 ½- 3/8 3/8” DIA.

3A-13- 3/8 3/8” DIA.

CROSS REFERENCE

Appendix

Area and Volume A-1

Reference Tables A-7

Decimal Fractions

Atomic Weights

Melting Points

Conversion Tables

Temperature Conversion

Glossary A-13

H-W Distribution Centers A-21

Standard Terms Of Sales A-22

SECTION 8

Harbison-Walker A - 1

The following simple formulas make it possible to calculate the area

and volume associated with most refractory structures. No matter

how complex the shape of a figure, it is possible to derive a working

approximation by dividing it by straight lines and arcs into a distinct

number of units whose areas may be calculated and summed by simple

arithmetic. Volumes of regular figures will equal the area of a surface

multiplied by its length or height. Volumes of shells are inside volume

subtracted from outside volume.

RECTANGLE

TRIANGLE

TRAPEZIUM REGULAR POLYGON

Area = ab

Area = cd

Area = s(s–a) (s–b) (s–c)

Area = [s(e+d)+bd+ce]Area = nsr

Numberof Sides Area

6 2.5981s2 = 3.4641r2

6 4.8284s2 = 3.3137r2

6 6.1818s2 = 3.2757r2

10 7.6942s2 = 3.2492r2

12 11.1962s2 = 3.2154r2

when n = Number of sides

when s = (a + b+ c)

ab

e

c

b a d

c

s

r

ab

d

c

ba d

PARALLELOGRAM

Area = ab

a

b

a

1/2

1/2

1/21/2

AREA AND VOLUME

A -2 Harbison-Walker

Area = LRTangent =

Area = [LR–C(R–h)]

Length of Arc, L = x 2πR =

CIRCLE

SEGMENT OF A CIRCLE

(Theta) = included angle in degrees. Area = 0.7854D2 = πR2

θ

θ

θ

θ

(pi) = 3.1416 Chord. C = 2 h(D–h) = 2R x sine

Height of Arc, h = R – R2 –(C÷2)2

Height of Arc, h = R – (2R+C) (2R–C)

θ

360 0.017453R

Circumference =

Diameter, D = 2R = 2 Area ÷ π

Radius, R = D = Area ÷π

= 28.648L÷R

Sine = C÷2R

1˚ = 0.017453 Radians, 1 radian = 57.296˚

Radius, R = Circumference ÷2π

Radius, R = (C ÷ 2)2+h2 2h

πD = 2πR = 2 π x Area

π

CDR

L

h

1/2

1/2

θ

1/4θ

CR

L

h

1/2

Area = πR2 x

Area = 0.0087266R2Area = πR2 x

C2h

θ

θ

360

θ

360

2C(R–h)

θ1/2

1/2

1/2

θ1/2

SECTOF OF A CIRCLE

θ

R

L

AREA AND VOLUME

THE TRAPEZOIDAL RULE

SEGMENT OF A SPHERE SEGTOR OR A SPHERE

Area = h( y0+ y1+y2 + y3+ y4) approximately

h = distance between equally spaced ordinates

yn = length of appropriate ordinate

Spherical Surface = Total Surface = 1.5708r(4h+ c)

Volume = πr2h = 2.0944r2hTotal Surface = 0.7854(c2 +8rh)

Volume = πh2(3r –h) = 1.0472h2(3r– h)

Volume = πh2(3r –h) = 1.0472h2(3r– h)

Cylindrical Surface =πdh = 2πrh = 6.2832rh

Total Surface =2πr(r+ h) = 6.2832r(r+ h)

Volume =πr2h = πd2h = 0.7854d2h

Volume = πh(3c2 +4h2) = 0.1309h(3c2 +4h2)

2πrh = 0.7854(c2+4h2)

h

1/2

1/24

1/4

1/3

2/3

1/2

h h h

CYLINDER

y0 y1 y2 y3y4

r

c

h

r

c

h

d

h

r


AREA AND VOLUME

Volume = πd3 = 0.5236d3

Volume = πr3 = 4.1888r3

Area = sh

SPANDREL CIRCULAR RING

PARABOLIC SEGMENT

SPHERE

RING OF CIRCULAR CROSS SECTION (Torus)

ELLIPSE

4/3

1/6

2/3Area = πab = 3.1416ab

Surface = 4πr2 = 12.566r2 = πd2

Area of Surface = 4π2Rr = 39.478Rr

Volume = 2π2Rr2 = 19.739Rr2

Area = 0.7854(D2— d2)Area = 0.7854(D+d) (D—d)

Area = 0.2146R2

Area = 0.1073C2

a

b

C

R Dd

h

s

d

r

dR

D

r

A - 4 Harbison-Walker

AREA AND VOLUME

AREA AND VOLUME

PYRAMID

A = area of base

P = perimeter of base

Volume = Ah

Lateral Area = Ps

FRUSTUM OF A PYRAMID

CONE

A = Area of base

a = Area of top

m = Area of midsection

P = Perimeter of base

p = Perimeter of top

Lateral Area = s(P+p)

Volume = h(a +A+ aA)

Volume = h(a +A+4m)

Volume = πr2 h = 1.0472r2h = 0.2618d2h

Conical Area =πrs = πr r2 +h2

hs

1/2

1/3

hs

d

hs

r

1/2

1/3

1/3

1/6


AREA AND VOLUME

FRUSTUM OF A CONE

A = Area of base

Area of Conical Surface = πs(D+d)

a = Area of top

m = Area of midsection

Volume = h(a + aA +A)

Volume = πh(r2 +rR +R2)

Volume = h(a +4m +A)

1/2

1/3

1/6 D

R

hs

rd


REFERENCE TABLE

Decimal Fractions of an Inch for Each 1/64

Common CommonFraction Decimal Fraction Decimal

1/2 .5

1/64 .015625 33/64 .5156251/32 .03125 17/32 .531253/64 .046875 35/64 .5468751/16 .0625 9/16 .56255/64 .078125 37/64 .5781253/32 .09375 19/32 .593757/64 .109325 39/64 .609375

1/8 .125 5/8 .625

9/64 .140625 41/64 .6406255/32 .15625 21/32 .6562511/64 .171875 43/64 .6718753/16 .1875 11/16 .687513/64 .203125 45/64 .7031257/32 .21875 23/32 .7187515/64 .234375 47/64 .734375

1/4 .25 3/4 .75

17/64 .265625 49/64 .7656259/32 .28125 25/32 .7812519/64 .296875 51/64 .7968755/16 .3125 13/16 .812521/64 .328125 53/64 .82812511/32 .34375 27/32 .8437523/64 .359375 55/64 .859375

3/8 .375 7/8 .875

25/64 .390625 57/64 .89062513/32 .40625 29/32 .9062527/64 .421875 59/64 .9218757/16 .4375 15/16 .937529/64 .453125 61/64 .95312515/32 .46875 31/32 .9687531/64 .484375 63/64 .984375


REFERENCE TABLE

Atomic Weights of Selected Elements*

AtomicName Symbol Number Weight

Aluminum Al 13 26.9815Antimony Sb 51 121.75Argon Ar 18 39.948Arsenic As 33 74.9216Barium Ba 56 137.34Beryllium Be 4 9.01218Bismuth Bi 83 208.9806Boron B 5 10.81Bromine Br 35 79.904Cadmium Cd 48 112.40Calcium Ca 20 40.08Carbon C 6 12.011Chlorine Cl 17 35.453Chromium Cr 24 51.996Cobalt Co 27 58.9332Copper Cu 29 63.54Fluorine F 9 18.9984Gold Au 79 196.9665Helium He 2 4.003Hydrogen H 1 1.0079Iodine I 53 126.9045Iron Fe 26 55.84Krypton Kr 36 83.80Lead Pb 82 207.2Lithium Li 3 6.941Magnesium Mg 12 24.305Manganese Mn 25 54.9380Mercury Hg 80 200.59Molybdenum Mo 42 95.94Neon Ne 10 20.17Nickel Ni 28 58.70Nitrogen N 7 14.0067Oxygen O 8 15.9994Phosphorous P 15 30.9738Platinum Pt 78 195.09Potassium K 19 39.098Silicon Si 14 28.08Silver Ag 47 107.868Sodium Na 11 22.9898Sulfur S 16 32.06Tin Sn 50 118.69Titanium Ti 22 47.90Tungsten W 74 183.85Uranium U 92 238.029Vanadium V 23 50.9414Xenon Xe 54 131.30Zinc Zn 30 65.38Zirconium Zr 40 91.22

*International Atomic Weights (1970).


REFERENCE TABLE

Melting Points of Selected Metals and Alloys*

Degrees Degrees DegreesFahrenheit Centigrade Kelvin

Aluminum 1220 660 933Antimony 1166.9 630.5 903.6Beryllium 2341 1283 1556Cadmium 609.6 320.9 594.258Chromium ~3445 ~1895 2130Cobalt 2718 1492 1768Columbium 4380 2415 2743Copper

(reducing atmosphere) 1981 1083 1366.6Gold 1945.4 1063.0 1336.2Iridium 4430 2443 2727Iron, pure 2795 1535 1809

Cast iron, white ~2100 ~1150 ~1423Cast iron, gray ~2245 ~1230 ~1503Steel, plain carbon

(1% carbon and less) ~2680 ~1470Lead 621.1 327.3 600.58Magnesium 1202 650 922 0.5Molybdenum ~4750 ~2620 ~2892 10Nickel 2647 1453 1744Palladium 2826 1552 1827Platinum 3216 1769 2045Rhodium 3560 1960 2236Silver 1761.4 960.8 1235.08Tantalum 5425 2996 3258 10Tin 449.4 231.9 505.1181Titanium ~3034 ~1668 1933 10Tungsten 6115 3380 3660 20Uranium 2071 1133Vanadium ~3450 ~1900 ~2190Zinc 787.1 419.5 692.73Zirconium ~3360 ~1850 2125 20

Melting Points of Selected Mineral Oxides*

Chromic Oxide (Cr2O3) ~4080 ~2250 2603 15Corundum (Al2O3) ~3720 ~2050 2327 6Cristobalite (SiO2) 3133 1723 1996 5Lime (CaO) ~4660 ~2570 ~3200 50Magnetite (Fe3O4) 2901 1594 1864 5Periclase (MgO) ~5070 ~2800 3098 20Rutile (TiO2) 3326 1830 2130 20Zirconia

Unstabilized (ZrO2) 4890 2700 31235% Calcia stabilized (ZrO2) 4710 2599 ~28727% Calcia stabilized (ZrO2) 4532 2500 ~2773

* In converting temperatures from Centigrade to Fahrenheit,temperatures above 3,300°F are given to the nearest five degrees.~ = Approximate.

++

+

++

+

+++

++

++


REFERENCE TABLE

Conversion Table

To Convert Multiply By: To Obtain:

BTU 7.7816 x 102 foot-poundsBTU 2.52 x 102 gram-caloriesBTU 2.52 x 10-1 kilogram-caloriesBTU/Hr 7.0 x 10-2 gram-cal/sec

°C (°C x 1.8) + 32 Fahrenheit

centimeters 3.281 x 10-2 feetcentimeters 3.937 x 10-2 inchescubic centimeters 3.531 x 10-5 cubic feetcubic centimeters 6.102 x 10-2 cubic inchescubic centimeters 1.308 x 10-6 cubic yardscubic centimeters 2.642 x 10-4 gallons (U.S. liquid)cubic centimeters 1.0 x 10-3 literscubic feet 2.832 x 104 cubic centimeterscubic feet 1.728 x 103 cubic inchescubic feet 2.832 x 10-2 cubic meterscubic feet 3.704 x 10-2 cubic yardscubic inches 16.39 cubic centimeterscubic inches 5.787 x 10-4 cubic feetcubic inches 1.639 x 10-5 cubic meterscubic inches 2.143 x 10-5 cubic yardscubic meters 35.31 cubic feetcubic meters 6.102 x 104 cubic inchescubic meters 1.308 cubic yardscubic meters 1.0 x 103 literscubic meters 2.642 x 102 gallons (U.S. liquid)cubic yards 7.646 x 105 cubic centimeterscubic yards 27 cubic feetcubic yards 0.7646 cubic meters

°Fahrenheit .556(F-32) Centigrade or Celsius

feet 30.48 centimetersfeet 0.3048 metersfeet 3.048 x 102 millimeters

gallons 3.785 x 103 cubic centimetersgallons 0.134 cubic feetgallons 3.785 x 10-3 cubic metersgallons 4.951 x 10-3 cubic yardsgallons 3.785 litersgrams 3.527 x 10-2 ounces (avdp.)grams 2.205 x 10-3 poundsgrams/cm3 62.43 pounds/ft3

grams/cm2 2.0481 pounds/sq/ftgrams-calories 3.968 x 10-3 BTU


REFERENCE TABLE

Conversion Table - continued

To Convert Multiply By: To Obtain:

inches 2.540 centimetersinches 25.4 millimeters

kilograms 2.2046 poundskilograms/meters3 6.243 x 10-2 pounds/ft3

kilometers 0.6214 miles (statute)

liters 3.531 x 10-2 cubic feetliters 61.02 cubic inchesliters 1.0 x 10-3 cubic metersliters 1.308 x 10-3 cubic yardsliters 0.2642 gallons (U.S. liquid)

miles (statute) 1.609 kilometersmillimeters 3.937 x 10-2 inches

ounces 28.349 grams

pounds 4.536 x 102 gramspounds 0.4536 kilogramspounds of water 27.68 cubic inchespounds of water 0.1198 gallonspounds/ft3 1.602 x 10-2 grams/cm3

pounds/ft3 16.02 kgs/meter3

pounds/in3 27.68 grams/cm3

pounds/in2 7.03 x 10-2 kgs/cm2

quarts (liquid) 9.464 x 102 cubic centimetersquarts (liquid) 3.342 x 10-2 cubic feetquarts (liquid) 1.238 x 10-3 cubic yardsquarts (liquid) 0.9463 liters

square centimeters 0.1550 square inchessquare feet 9.29 x 102 square centimeterssquare inches 6.452 square centimeters

tons (metric) 1000 kilogramstons (metric) 2.205 x 103 poundstons (short) 9.0718 x 102 kilogramstons (short) 0.9078 tons (metric)

yards 0.9144 meters


REFERENCE TABLE

Convertto to0C 0F

-17.78 0 32-12.22 10 50-6.67 20 68-1.11 30 860.00 32 904.44 40 104

10.00 50 12215.56 60 14021.11 70 15826.67 80 17632.22 90 19437.78 100 212

43.33 110 23048.89 120 24854.44 130 26660.00 140 28465.56 150 30271.11 160 320

76.67 170 33882.22 180 35687.78 190 37493.33 200 39298.89 210 410

100.0 212 414

104.4 220 428110.0 230 446115.6 240 464121.1 250 482126.7 260 500132.2 270 518

137.8 280 536143.3 290 554148.9 300 572154.4 310 590160.0 320 608165.6 330 626

171.1 340 644176.7 350 662182.2 360 680187.8 370 698193.3 380 716198.9 390 734

204.4 400 752215.6 420 788226.7 440 824237.8 460 860248.9 480 896

260.0 500 932271.1 520 968282.2 540 1004293.3 560 1040304.4 580 1076

Convertto to0C 0F

315.6 600 1112326.7 620 1148337.8 640 1184348.9 660 1220360.0 680 1256371.1 700 1292

398.9 750 1382426.7 800 1472454.4 850 1562482.2 900 1652510.0 950 1742537.9 1000 1832

565.6 1050 1922593.3 1100 2012621.1 1150 2102648.9 1200 2192676.7 1250 2282704.4 1300 2372

732.2 1350 2462760.0 1400 2552787.8 1450 2642815.6 1500 2732843.3 1550 2922871.1 1600 2912

898.9 1650 3002926.7 1700 3092954.4 1750 3182982.2 1800 3272

1010 1850 33621038 1900 3452

1066 1950 35421093 2000 36321121 2050 37221149 2100 38121177 2150 39021204 2200 3992

1232 2250 40821260 2300 41721288 2350 42621316 2400 43521343 2450 44421371 2500 4532

1427 2600 47121482 2700 48921538 2800 50721593 2900 52521649 3000 5432

1704 3100 56121760 3200 57921816 3300 59721871 3400 61521927 3500 63321982 3600 6512

F or C F or C

Temperature Scale Conversions


* ASTM Standard Definitions C 71-88; or ASTM “Tentative Definitions” are used where applicable.

Harbison-Walker A-13

GLOSSARY

Abrasion of Refractories: Wearing away ofthe surfaces of refractory bodies in service bythe scouring action of moving solids.

Absorption: As applied to ceramic products,the weight of water which can be absorbed bythe ware, expressed as a percentage of theweight of the dry ware.

Abutment: The structural portion of a furnacewhich withstands the thrust of an arch.

Acid-Proof Brick : Brick having low porosi-ty and permeability, and high resistance tochemical attack or penetration by most com-mercial acids and some other corrosive chemi-cals.

Acid Refractories: Refractories such as silicabrick which contain a substantial proportion offree silica and which when heated, can reactchemicallywith basic refractories, slags andfluxes.

Aggregate: As applied to refractories, aground mineral material, consisting of parti-cles of various sizes, used with much finersizes for making formed or monolithic bodies.

Air-Ramming *: A method of forming refrac-tory shapes, furnace hearths, or other furnaceparts by means of pneumatic hammers.

Air-Setting Refractories: Compositions ofground refractory materials which develop astrong bond upon drying. Theserefractoriesinclude mortars, plastic refractories, rammingmixes and gunningmixes. They are marketed inboth wet and dry condition. The dry composi-tions require tempering with water to develop thenecessary consistency.

Alumina : Al2O3, the oxide of aluminum;melt-ing point 3,720°F (2,050°C); in combinationwith H2O (water), aluminaforms the mineralsdiaspore, bauxite and gibbsite; in combinationwith SiO2 and H2O, alumina forms kaoliniteand other clay minerals.

Alumina-Silica Refractories: Refractoriescon-sisting essentially of alumina and silica, andincluding high-alumina, fireclay and kaolinrefractories.

Amorphous: Lacking crystallinestructure ordefinite molecular arrangement; without definiteexternal form.

Andalusite: A brown, yellow, green, red orgray orthorhombic mineral; Al2SiO5. Specificgravity 3.1 - 3.2. Decomposes on heating,

beginning at about 2,460°F (1,350°C) to formmullite (Al6Si2O13) and free silica.

Anneal: To remove internal stress by firstheating and then cooling slowly.

Arc : As applied to circles, any portion of a cir-cumference; as applied to electricity, the lumi-nous bridge formed by the passage of a currentacross a gap between two conductors or termi-nals.

Arch, Flat: In furnace construction, a flatstructure spanning an opening and supportedby abutments at its extremities. The arch isformed by a number of special tapered brick,and the brick assembly is held in place by thekeying action of the brick. Also called a jackarch.

Arch, Sprung: In furnace construction, abowed or curved structure which is supportedby abutments at the sides or ends only, andwhich usually spans an opening or spacebetween two walls.

Arch, Suspended: A furnace roof consistingof brick shapes suspended from overhead sup-porting members.

Arch Brick : A brick shape having six planefaces (two sides, two edges and two ends), inwhich two faces (the sides) are inclined towardeach other and one edge face is narrower than theother.

Ash: The noncombustible residue whichremains after burning a fuel or other com-bustible material.

Attrition : Wearing away by friction; abrasion.

Auger Machine: A machine for extrudingground clays in moist and stiffly plastic form,through a die by means of a revolving screw orauger.

Baddeleyite: A mineral composed of zirconia(ZrO2). Specific gravity 5.8. Melting point4,890°F (2,700°C).Bagasse: The fibrous material remainingafter theextraction of the juice from sugar cane.

Ball Clay: A highly plastic refractory bondclay of very fine grain, which has a wide rangeof vitrification and which burns to a lightcolor. Often high in carbonaceous matter.

Basic Refractories: Refractories which con-sist essentially of magnesia, lime, chrome ore

or mixtures of two or more of these and,when heated, can react chemically with acidrefractories, slags and fluxes.

Bauxite: An off-white, grayish, brown, yellow,or reddish-brown rock composedof a mixture ofvarious amorphous or crystalline hydrous alu-minum oxides and aluminum hydroxides(principally gibbsite, some boehmite), andcontaining impurities in the form of free silica,silt, iron hydroxides, and especially clay miner-als; a highly aluminous laterite.

Bauxitic Clay: A natural mixture of bauxiteand clay containing not less than 47% normore than 65% alumina on a calcined basis.

Bentonite: A kind of clay derived from vol-canic ash and characterized by extreme fine-ness of grain. Its main constituent is the claymineral montmorillonite. It is somewhat vari-able in composition and usually contains 5 to10% of alkalies or alkaline earth oxides. Onetype has the capacity for absorption of largeamounts of water, with enormous increase involume.

Bessemer Process: An older process for mak-ing steel by blowing air throughmolten pigiron, whereby most of the carbon and impuri-ties are removed by oxidation. The process is carried out in a ves-sel known as a converter.

Bloating: Swelling of a refractory when in thethermo-plastic state, caused by temperatures inexcess of that for which the material is intend-ed. Bloating impairs the useful properties ofrefractories. An exception to this rule occurs inone type of ladle brick (See SecondaryExpansion).

British Thermal Unit (BTU) : The amount ofheat required to raise the temperature of onepound of water one degree Fahrenheit at stan-dard barometric pressure.

Brucite: A mineral having the compositionMg(OH)2. Specific gravity 2.38 - 2.40. A soft,waxy, translucent mineral which dissociates atmoderate temperatures with the formation ofMgO.

Bunker Oil : A heavy fuel oil formed by stabi-lization of the residual oil remaining after thecracking of crude petroleum.

Burn : The degree of heat treatment to whichrefractory brick are subjected in the firing


process. Also, the degree to which desiredphysical and chemical changes have beendeveloped in the firing of a refractory materi-al.

Burning (Firing) of Refractories*: The finalheat treatment in a kiln to which refractorybrick are subjected in the process of manufac-ture, for the purpose of developing bond andother necessaryphysical and chemical proper-ties.

Calcination: A heat treatment to which manyceramic raw materialsare subjected, prepara-tory to further processing or use, for the pur-pose of driving off volatile chemically combinedcomponents and affecting physical changes.

Calcite: A mineral having the compositionCaCO3. Specific gravity 2.71 for pure calcitecrystals. Calcite is the essential constituentof limestone, chalk and marble and a minorconstituent of many other rocks.

Calorie (Large): One thousand small calories.

Calorie (Small): The amount of heat requiredto raise the temperature of one gram of waterone degree Centigrade at standard barometricpressure.

Cap or Crown: The arched roof of a furnace,especially a glass tank furnace.

Carbon Deposition: The deposition of amor-phous carbon, resulting from the decomposi-tion of carbon monoxide gas into carbondioxide and carbon within a critical tempera-ture range. When deposited within the poresof refractory brick, carbon can build up suffi-cient pressure to destroy the bond and causethe brick to disintegrate.

Carbon Refractory*: A manufactured refrac-tory comprised substantially or entirely of car-bon (including graphite).

Carbon-Ceramic Refractory*: A manufac-tured refractory comprised of carbon(includinggraphite) and one or more ceramic materialssuch as fire clay and silicon carbide.

Castable Refractory: A mixture of a heat-resistant aggregate and a heat-resistanthydraulic cement. For use, it is mixed withwater and rammed, cast or gunned into place.

Catalyst: A substance which causes or accel-erates a chemical change withoutbeing perma-nently affected by the reaction.

Cement: A finely divided substance which isworkable when first prepared, but whichbecomes hard and stonelike as a result ofchemical reaction or crystallization; also,the compact groundmass which surroundsand binds together the larger fragments or par-ticles in sedimentary rocks.

Ceramic Bond: In a ceramic body, themechanical strength developed by a heat treat-ment which causes the cohesion of adjacentparticles.

Ceramics: Originally, ware formed from clayand hardened by the action of heat; the art ofmaking such ware. Current usage includes allrefractory materials, cement, lime, plaster, pot-tery, glass, enamels, glazes, abrasives, electricalinsulating products and thermal insulating prod-ucts made from clay or from other inorganic,nonmetallic mineral substances.

Checkers: Brick used in furnace regenerators to recover heat from outgoinghot gases and later to transmitthe heat to coldair or gas entering the furnace; so-calledbecause the brick are arranged in checkerboardpatterns, with alternating brick units and openspaces.

Chemically-Bonded Brick: Brick manufac-tured by processes in which mechanicalstrength is imparted by chemical bondingagents instead of by firing.

Chord: As applied to circles, a straight linejoining any two points on a circumference.

Chrome Brick*: A refractory brick manufac-tured substantially or entirely of chrome ore.

Chrome-Magnesite Brick: A refractorybrickwhich can be either fired or chemically bond-ed, manufactured substantially of a mixture ofchrome ore and dead-burned magnesite, inwhich the chrome ore predominates by weight.

Chrome Ore: A rock having as its essentialconstituent the mineral chromite or chromespinel, which is a combination of FeO andMgO with Cr2O3, Al2O3, and usually a smallproportion of Fe2O3. The composition, whichis represented by the formula (Fe,Mg) (Cr, Al)2

O4, is extremely variable. Refractory gradechrome ore has only minor amounts of acces-sory minerals and has physical properties thatare suitable for the manufacture of refractoryproducts.

Clay: A natural mineral aggregate, consistingessentially of hydrousaluminum silicates (Seealso Fire Clay).

Colloid: (1 ) A particle-size range of less than0.00024 mm, i.e. smaller than clay size; (2)originally, any finely divided substance thatdoes not occur in crystalline form; in a moremodern sense, any fine-grained material insuspension, or any such material that can beeasily suspended.

Conductivity : The property of conductingheat, electricity or sound.

Congruent Melting: The change of a sub-stance, when heated, from the solid form to aliquid of the same composition. The meltingof ice is an example of congruent melting.

Convection: The transfer of heat by the circu-lation or movement of the heated parts of a liq-uid or gas.

Corbel: A supporting projection of the face ofa wall; an arrangement of brick in a wall inwhich each course projects beyond the oneimmediately below it to form a support, baffle orshelf.

Corrosion of Refractories: Deterioration orwearing away of refractory bodies largely attheir surface through chemical action of exter-nal agencies.

Corundum: A natural or synthetic mineraltheoretically consisting solely of alumina(Al 2O3). Specific gravity 4.00 - 4.02. Meltingpoint 3,720°F (2,050°C). Hardness 9.

Course: A horizontal layer or row of brick in astructure.

Cristobalite: A mineral form of silica (SiO2);stable from 2,678°F (1,470°C) to the meltingpoint, 3,133°F (1,723°C). Specific gravity2.32. Cristobalite is an important constituentof silica brick.

Crown: A furnace roof, especially one whichis dome-shaped; the highest point of an arch.

Cryptocrystalline : A crystalline structure inwhich the individual crystals are so small thatthey cannot be made visible by means of thepetrographic microscope, but can be seen withan electronmicroscope. Various so-called amor-phousminerals are actually cryptocrystalline.

Crystal: (1 ) A homogeneous, solid body of achemical element, compound or isomorphousmixture having a regularly repeating atomicarrangement that can be outwardly expressedby plane faces; (2) rock crystal.


GLOSSARY


Crystalline: Composed of crystals.

Dead-Burned Dolomite: A coarsely granularrefractory material prepared by firing rawdolomite with or without additives, to a tem-perature above 2,800°F (1,538°C), so as toform primarily lime and magnesia in amatrix that provides resistance tohydrationand carbonation.

Dead-Burned Magnesite: A coarsely granu-lar dense refractory material composed essen-tially of periclase (crystalline magnesiumoxide); prepared by firing raw magnesite (orother substances convertible to magnesia) attemperatures sufficiently high to drive off prac-tically all of the volatile materials,and to affectcomplete shrinkage of the resultant magnesia,thereby producing hard dense grains whichare entirely inert to atmospheric hydrationand carbonation and free from excessiveshrinkage when again subjected to a high tem-perature.

De-airing: Removal of air from firebrickmixesin an auger machine before extrusion bymeans of a partial vacuum.

Density: The mass of a unit volume of a substance. It is usually expressed either ingrams per cubic centimeter or in pounds percubic foot.

Devitrification : The change from a glassy to acrystalline condition.

Diaspore: A mineral having the theoreticalcomposition Al2O3 • H2O (85% alumina; 15%water). Specific gravity 3.45.

Diaspore Clay: A rock consisting essentiallyof diaspore bonded by flint clay. Commercialdiaspore clay of the purest grade usually con-tains between 70 and 80% alumina after calci-nation.

Diatomaceous Earth: A hydrous form of sili-ca which is soft, light in weight and consistsmainly of microscopic shells of diatoms orother marine organisms. It is widely used forfurnaceinsulation.

Direct Bonded Basic Brick: A fired refracto-ry in which the grains are joined predomi-nantly by a solid state of diffusion mechanism.

Direct Bonded Magnesite-Chrome Brick: Aterm applied to fired magnesite-chrome composi-tions when the amount of bonding mineralphase (silicates, forsterite, etc.) present in thematrix is sufficiently low that under microscopic

examination the chrome ore grains appear tobe bonded “directly” to the magnesite grains.The actual bonding mechanism in this instanceis usually a combination of types, of whichone may be direct (diffusion) bonding.

Division Wall : Wall dividing any two majorsections of a furnace.

Dobie: A molded block of ground clay orother refractory material, usually crudelyformed and either raw or fired.

Dolomite: The mineral calcium-magnesium carbonate, CaMg (CO3)2. Specificgravity 2.85 - 2.95. The rock called dolomiteconsists mainly of the mineral of that nameand can also contain a large amount of the min-eral calcite (CaCO3).

Dry Pan: A pan-type rotating grindingmachine, equipped with heavy steel rollers ormullers which do the grinding and having slot-ted plates in the bottom through which theground material passes out.

Dusting: Conversion of a refractory material,either wholly or in part, into fine powder ordust. Dusting usually results from (1 ) chemi-cal reactions such as hydration; or (2) min-eral inversion accompanied by large andabrupt change in volume, such as the inversionof beta to gamma dicalcium silicate upon cool-ing.

Dutch Oven: A combustion chamber builtoutside and connected with a furnace.

Electron Beam Furnace: A furnace in whichmetals are melted in a vacuum at very hightemperatures by bombardment with electrons.

Emissivity, Thermal: The capacity of a mate-rial for radiating heat; commonly expressed asa fraction or percentage of the ideal “blackbody” radiation of heat which is the maxi-mum theoretically possible.

Erosion of Refractories: Mechanical wearingaway of the surfaces of refractory bodies inservice by the washing action of moving liq-uids, such as molten slags or metals.

Eutectic Temperature: The lowest meltingtemperature in a series of mixtures of two ormore components.

Exfoliate: To expand and separate into rudelyparallel layers or sheets, under the action ofphysical, thermal or chemical forces producing

differentialstresses.

Extrusion: A process in which plastic materi-al is forced through a die by the application ofpressure.

Fayalite: A mineral having the compositionFe2SiO4. Specific gravity 4.0 - 4.1. Meltingpoint 2,201°F (1,205°C).

Feldspar: A group of aluminum silicate min-erals with a general formula MAl (Al,Si) 3 O8

where M=K, Na, Ca, Br, Rb, Sr and Fe. Themost important feldspars are: (1) the potashgroup, of which orthoclase and microcline (K)are the most common, and (2) the soda-limegroup, of which albite (Na) and anorthite (Ca)form the end members of a continuous seriesof solid solutions. Specific gravity 2.55 - 2.76.Melting points 2,050 to 2,820°F (1,120° to1,550°C).

Fillet : The concave curve junction of two sur-faces which would otherwise meet at an angle.Fillets are used at re-entrant angles in thedesign of brick shapes to lessen the danger ofcracking.

Firebrick : Refractory brick of any type.

Fire Clay: An earthy or stony mineral aggre-gate which has as the essential constituenthydrous silicates of aluminum with or withoutfree silica; plastic when sufficiently pulver-ized and wetted, rigid when subsequentlydried, and of sufficient purity and refrac-toriness for use in commercial refractory prod-ucts.

Fireclay Brick : A refractory brick manufac-tured substantially or entirely from fire clay.

Flat Arch : An arch in which both outer andinner surfaces are horizontal planes.

Flint : A hard, fine-grained cryto-crystallinerock, composed essentially of silica.

Flint Clay : A hard or flint-like fire clay whichhas very low natural plasticity and which usual-ly breaks with a smooth or shell-like fracture. Itsprincipalclay mineral is halloysite.

Flux: A substance or mixture which promotesfusion of a solid material by chemical action.

Fluxing: Fusion or melting of a substance as aresult of chemical action.


GLOSSARY

Forsterite: A mineral having the composition Mg2SiO4. Specific gravity 3.21.Melting point approximately 3,450°F(1,900°C).

Freeze-Plane: An irregular plane lyingbetween the hot face and cold face of a refrac-tory lining — any point on which the tempera-ture corresponds to the freezing point of a liq-uid phase present on the hot face side of theplane.

Friable: Easily reduced to a granular or pow-dery condition.

Furnace Chrome: A mortar material preparedfrom finely ground chrome ore, suitable forlaying brick or for patching or daubing in fur-naces.

Furnace Magnesite: A mortar materialpre-pared from finely ground dead-burnedmagnesite,suitable for use as a joint material in layingmagnesite brick, and for patching or daubingfurnace masonry.

Fused-Cast Refractories: Refractoriesformed by electrical fusion followed by cast-ing and annealing.

Fused Quartz: Silica in the glassy state pro-duced by melting clear quartz crystalline feed.It is clear withoutentrapped gas bubbles orother impurities or diluents. Synonymsinclude quartz glass and vitreous quartz.

Fused Silica: Silica in the glassy or vitreousstate produced by arc-melting sand. It alwayscontains gas bubbles. Synonyms include vitre-ous silica and silica glass.

Fusion: A state of fluidity or flowing in conse-quence of heat; the softening of a solid body,either through heat alone or through heat andthe action of a flux, to such a degree that it willno longer support its own weight, but willslump or flow. Also the union or blending ofmaterials, such as metals, upon melting,with theformation of alloys.

Fusion Point: The temperature at whichmelting takes place. Most refractory materi-als have no definite melting points, but softengradually over a range of temperatures.

Ganister: A dense, high-silica rock (quartzite),suitable for the manufacture of silica brick.Confusion sometimes results from the use ofthis term, because it is also applied in someparts of the United States to crushed firebrick

or to mixtures of either crushed firebrick orsilica rock with clay, for use in tamped linings.

Gibbsite: A white or tinted monoclinic mineral;Al(OH)3. Specific gravity 2.3 - 2.4.

Glass*: An inorganic product of fusion whichhas cooled to a rigid condition without crystal-lizing.

Grain Magnesite: Dead-burned magnesite inthe form of granules, generallyranging in sizefrom about 5/8 inch in diameter to very fineparticles.

Grain Size: As applied to ground refractorymaterials, the relative proportions of particlesof different sizes; usually determined by sepa-ration into a series of fractions by screening.

Grog: A granular product produced by crush-ing and grinding calcined or burned refracto-ry material, usually of alumina-silica composi-tion.

Ground Fire Clay: Fire clay or a mixture of fireclays that have been subjected to no mechanicaltreatment other than crushing and grinding.

Grout : A suspension of mortar material inwater, of such consistency that it will flowinto vertical open joints when it is poured onhorizontal courses of brick masonry.

Gunning: The application of monolithic refrac-tories by means of air-placementguns.

Halloysite: One of the clay minerals; a hydrat-ed silicate of alumina similar in composition tokaolinite, but amorphousand containing morewater; Al2Si2O5(OH)4 • 2H2O.

Header: A brick laid on flat with its longestdimension perpendicular to the face of a wall.

Heat-Setting Refractories: Compositions ofground refractory materials which require rela-tively high temperatures for the development ofan adequate bond, commonly called the ceramicbond.

Hematite: The mineral Fe2O3 (red iron ore).Specific gravity 4.9 - 5.3.

High-Alumina Refractories: Alumina-silicarefractories containing 45 % or more alumina.The materials used in their productioninclude diaspore, bauxite, gibbsite, kyanite,sillimanite, andalusite and fused alumina (arti-ficial corundum).

High-Duty Fireclay Brick : Fireclay brickwhich have a PCE not lower than Cone 31½ orabove 32½ - 33.

Hydrate (verb): To combine chemically withwater.

Hydraulic-Setting Refractories:Compositions of ground refractory materialsin which some of the components react chemi-cally with water to form a strong hydraulicbond. These refractories are commonlyknown as castables.

Illite : A group of three-layer, mica-like miner-als of small particle size, intermediate in com-position and structure between muscovite andmontmorillonite.

Impact Pressing: A process for forming refrac-tory shapes in which the ground particles ofrefractory material are packed closely together byrapid vibration.

Incongruent Melting: Dissociation of a com-pound on heating, with the formation of anoth-er compound and a liquid of different compo-sition from the original compound.

Ingot Mold : A mold in which ingots are cast.

Insulating Refractories: Lightweight, porousrefractories with much lower thermal conduc-tivity and heat-storage capacity than otherrefractories. Used mostly as backing for brickof higher refractoriness and higher thermalconductivity. These materials provide fueleconomy through lower heat losses,increasedproduction due to shorter heat-up time, econo-my of space (size and weight) because of thin-ner walls and improved working conditions.Insulating refractories are available as brick or monoliths.

Inversion: A change in crystal form withoutchange in chemical composition; as for example,the change from low-quartz to high-quartz, or,the change from quartz to cristobalite.

Isomorphous Mixture: A type of solid solu-tion in which mineral compounds of analo-gous chemical composition and closely relat-ed crystal habit crystallize together in variousproportions.

Jack Arch: See Arch, Flat.



GLOSSARY

Jamb: (1 ) A vertical structural memberform-ing the side of an opening in a furnace wall;(2) a type of brick shape intended for use inthe sides of wall openings.

Kaldo Process (Stora): An oxygen processfor making steel.

Kaliophilite : A hexagonal mineral of volcanicorigin; KAlSiO4.

Kaolin : A white-burning clay having kaolin-ite as its chief constituent. Specific gravity2.4 - 2.6. The PCE of most commercial kaolinsranges from Cone 33 to 35.

Kaolinite : A common white to grayish or yel-lowish clay mineral; Al2Si2O5 (OH)4. Kaoliniteis the principal constituent of most kaolins andfire clays. Specific gravity is 2.59. The PCE ofpurekaolinite is Cone 35.

Key: In furnace construction, the uppermost orthe closing brick of a curved arch.

Key Brick : A brick shape having six planefaces (two sides, two edges and two ends), inwhich two faces (the edges) are inclinedtoward each other and one of the end faces isnarrower than the other.

K-factor : The thermal conductivity of a mater-ial, expressed in standard units.

Kyanite (Cyanite): A blue or light-greentri-clinic mineral; Al2SiO5. Specific gravity3.56 - 3.67. Decomposition begins at about2,415°F (1,325°C) with the formation of mul-lite and free silica.

Ladle: A refractory-lined vessel used for thetemporary storage or transfer of molten metals.

L-D Process: A process for making steel byblowing oxygen on or throughmolten pig iron,whereby most of the carbon and impurities areremoved by oxidation.

Limestone: A sedimentary rock composedessen-tially of the mineral calcite(CaCO3) or of cal-cite mixed with dolomite, CaMg(CO3)2.Specific gravity 2.6 - 2.8.

Limonite : A mineral consisting of hydrousferric oxides; the essential component of“brown ore.” Specific gravity 3.6 - 4.0.

Lintel : A horizontal member spanning a wallopening.

Loss on Ignition: As applied to chemicalanaly-ses, the loss in weight which results fromheating a sample of material to a high tem-perature, after preliminary drying at a tempera-ture just above the boiling point of water. Theloss in weight upon drying is called “free mois-ture”; that which occurs above the boiling point,“loss on ignition.”

Low-Duty Fireclay Brick : Fireclay brickwhich have a PCE not lower than Cone 15 norhigher than 28 - 29.

Magnesioferrite: One of the spinel group ofminerals; (Mg,Fe)Fe2O4. Rarely found in nature;usually constitutes the brown coloring materialin magnesite brick. Specific gravity 4.57 - 4.65.

Magnesite: A mineral consisting of magne-sium carbonate; MgCO3. A rock containing themineral magnesite as its essential constituent(See also Magnesite, Caustic and Dead-Burned Magnesite).

Magnesite Brick: A refractory brick manufac-tured substantially or entirely of dead-burnedmagnesite which consistsessentially of magnesiain crystalline form (periclase).

Magnesite-Carbon Brick: A refractory brickmanufactured of substantially magnesite(dead-burned, fused, or a combination there-of) and carbon, which may be in the form ofvarious carbon-bearing materials. Conventionaltar-bonded and tar-impregnated brick do notfall into this class. Magnesite-carbon brick aredistinct in that carbon is present in the composi-tion to providespecific refractory propertiesbeyond filling pores or acting as a bond.

Magnesite, Caustic: The product obtained bycalcining magnesite, or other substances convert-ible to magnesia,upon heating at a temperaturegenerally not exceeding 2,200°F (1,205°C).The product is readily reactive to water andto atmospheric moisture and carbon dioxide.

Magnesite-Chrome Brick: A refractorybrickwhich can be either fired or chemicallybonded, manufactured substantially of a mix-ture of dead-burnedmagnesite (magnesia) andrefractory chrome ore, in which the magnesitepredominates by weight.

Magnesium Hydroxide: The compound ofmagnesium oxide and chemically combinedwater; Mg(OH)2. Naturally occurring magne-sium hydroxide is known as brucite.

Magnetite: A black, isometric, strongly mag-netic, opaque mineral of the spinel group; (Fe,Mg) Fe2O4. Specific gravity 5.17 - 5.18.Melting point about 2,901°F (1,594°C).

Medium-Duty Fireclay Brick : A fireclay brickwith a PCE value not lower than Cone 29 norhigher than 31 - 311/2.

Melting Point: The temperature at whichcrystalline and liquid phases having the samecomposition coexist in equilibrium. Metalsand most pure crystalline materials have sharpmeltingpoints, i.e. they change abruptly fromsolid to liquid at definite temperatures.However, most refractory materials have notrue melting points, but melt progressivelyover a relatively wide range of temperatures.

Metalkase Brick: Basic brick provided withthin steel casings.

Mica: A group of rock minerals having nearlyperfect cleavage in one directionand consistingof thin elastic plates. The most common vari-eties are muscovite and biotite.

Micron : The one-thousandth part of a mil-limeter (0.001 mm); a unit of measurementused in microscopy.

Mineral : A mineral species is a naturalinor-ganic substance which is either definite inchemical composition and physical charac-teristics or which varies in these respectswithin definite natural limits. Most mineralshave a definite crystalline structure; a few areamorphous.

Modulus of Elasticity (Physics): A measureof the elasticity of a solid body; the ratio ofstress (force) to strain (deformation) within theelastic limit.

Modulus of Rupture: A measure of the trans-verse or “crossbreaking” strength of a solidbody.

Monolithic Lining : A furnace lining withoutjoints, formed of material which is rammed,cast, gunned or sintered into place.

Monticellite : A colorless or gray mineralrelatedto olivine; CaMgSiO4. Specific gravity 3.1 -3.25. Melts incongruently at 2,730°F(1,499°C) to form MgO and a liquid.



GLOSSARY

Montmorillonite : A group of expanding-latticeclay minerals containing variablepercentagesof one or more of the cations of magne-sium, potassium, sodium and calcium. Acommon constituent of bentonites.

Mortar (Refractory) : A finely ground refrac-tory material which becomes plastic whenmixed with water and is suitable for use in lay-ing refractory brick.

Mullite : A rare orthorhombic mineral;Al 6Si2O13. Specific gravity 3.15. An importantconstituent of fireclay and high-aluminabrick. Melting point under equilibrium condi-tions approximately 3,362°F (1,850°C).

Mullite Refractories*: Refractory productsconsisting predominantly of mullite (Al6Si2O13)crystals formed either by conversion of one ormore of the sillimanite group of minerals or bysynthesis from appropriate materials employingeither melting or sinteringprocesses.

Muscovite: A mineral of the mica group;KA 12(AlSi3)O10(OH)2. It is usuallycolorless,whitish or pale brown and is a common miner-al in metamorphic and igneous rocks and insome sedimentary rocks.

Nepheline (Nephelite): A hexagonal mineralof the feldspathoid group; (Na,K)AlSiO4. Acommon reaction product in furnaces whereinslags or vapors of high soda content come intocontact with fireclay or high-alumina brick.Stable at 2,278°F (1,248°C) at which temper-ature it inverts to the artificial mineralcarnegieite, which hasthe same composition,but a different crystalline form. Naturalnepheline contains a small amount of potash.Specific gravity 2.67.

Neutral Refractory: A refractory materialwhichis neither acid nor base, such as carbon,chrome or mullite.

Nine Inch Equivalent: A brick volume equalto that of a 9 x 4 1/2 x 2 1/2 inch straight brick(101.25 cubic inches); the unit of measure-ment of brick quantities in the refractoriesindustry.

Nodule Clay: A rock containing aluminous orferruginous nodules, or both, bonded by flintclay; called “burley” clay or “burley flint” clayin some districts.

Nosean (Noselite): A feldspathoid mineral ofthe sodalite group; Na8Al6Si6O24(SO4). It is gray-ish, bluish or brownish and is related to hauyne.

Nozzle Brick: A tubular refractory shape used ina ladle; contains a hole throughwhich steel isteemed at the bottom of the ladle, the upper endof the shape serving as a seat for the stopper.

Olivine: (l) An olive-green, grayish-green orbrown orthorhombic mineral;(Mg,Fe)2SiO4. It comprises the isomorphous solid-solution series forsterite-fayalite. (2) A name applied to a group of min-erals forming the isomorphous system(Mg,Fe,Mn,Ca) 2SiO4, including forsterite,fayalite, tephroite and a hypothetical calciumorthosilicate. Specific gravity 3.27 - 3.37,increasing with the amount of iron present.

Overfiring : A heat treatment which causesdeformation or bloating of clay or clay ware.

Oxiduction: Alternate oxidation and reduc-tion.

Oxygen Process: A process for makingsteel inwhich oxygen is blown on or through moltenpig iron, whereby most of the carbon andimpurities are removed by oxidation.

Periclase: An isometric mineral; MgO.Specific gravity 3.58. Melting point approxi-mately 5,070°F (2,800°C).

Perlite: A siliceous glassy rock composed ofsmall spheroids varying in size from smallshot to peas; combined water content 3 to 4%. When heated to a suitable temperature,perlite expands to form a lightweight glassymaterial with a cellular structure.

Permeability: The property of porous materi-als which permits the passage of gases and liq-uids under pressure. The permeability of abody is largely dependent upon the number,size and shape of the open connecting poresand is measured by the rate of flow of a standardfluid under definite pressure.

Plasma Jet: Ionized gas produced by passingan inert gas through a high-intensity arc causingtemperatures up to tens of thousands of degreescentigrade.

Plastic Chrome Ore: An air-setting rammingmaterial having a base of refractory chromeore and shipped in plastic form ready for use.

Plastic Fire Clay: A fire clay which has suffi-cient natural plasticity to bond together othermaterials which have little or no plasticity.

Plastic Refractory: A blend of ground refrac-tory materials in plastic form, suitable for

ramming into place to form monolithic lin-ings.

Plasticity: That property of a material thatenables it to be molded into desiredformswhich are retained after the pressure of mold-ing has been released.

Pores: As applied to refractories, the smallvoids between solid particles. Pores aredescribed as “open” if permeable to fluids;“sealed” if impermeable.

Porosity of Refractories: The ratio of the vol-ume of the pores or voids in a body to thetotal volume, usually expressed as a percent-age. The “true porosity” is based on the totalpore-volume; “apparent porosity” on the openpore-volume only.

Power Pressing: The forming of refractorybrick shapes from ground refractorymaterialcontaining an optimum amount of addedwater by means of high pressure applied verti-cally in a power-driven press.

Pug Mill : A machine used for blending andtempering clays in a moist or stifflyplastic con-dition.

Pyrite: The most common sulfide mineral;FeS2. Specific gravity 4.9 - 5.2. Color, brass-yellow. Used mainly for making sulfuric acidand sulfates.

Pyrometric Cone: One of a series of pyrami-dal-shaped pieces consisting of mineral mix-tures and used for measuringtime-temperatureeffect. A standard pyrometric cone is a three-sided truncated pyramid; and is approximatelyeither 25/8 inches high by 5/8 inch wide at thebase or 11/8 inches high by 3/8 inch wide at thebase. Each cone is of a definite mineral com-position and has a number stamped on oneface; when heated under standard conditions itbends at a definite temperature.

Pyrometric Cone Equivalent (PCE)*: Thenumber of that Standard Pyrometric Conewhose tip would touch the supporting plaquesimultaneously with a cone of the refractorymaterial being investigated when tested inaccordance with the Method of Test forPyrometric Cone Equivalent (PCE) ofRefractory Materials (ASTM DesignationC24).

Pyrophyllite : A mineral consisting of hydrat-ed silicate of aluminum; AlSi2O5(OH).



GLOSSARY

Pyroplasticity: The physical state induced bysoaking heat which permits a refractory bodyto be readily deformed under pressure or by itsown weight.

Quartz: A common mineral consisting of silica(SiO2). Sandstones and quartzites are com-posed largely of quartz. Specific gravity 2.65.

Quartzite: A hard compact rock consistingpredominantly of quartz. There are two types:(1) metaquartzite, a metamorphic rock usuallyderived from sandstone; and (2) orthoquartzite, asedimentary rock consisting of grains of sili-ca sand cemented together by at least 10 % ofprecipitated silica.

Ramming Mix: A ground refractory materialwhich is mixed with water and rammed intoplace for patching shapes or for formingmonolithic furnace linings; usually of a lessplastic nature than plastic refractories.

Recuperator: A system of thin-walled refrac-tory ducts used for the purpose of transferringheat from a heated gas to colder air or gas.

Refractories: Nonmetallic materials suitablefor use at high temperatures in furnace con-struction. While their primary function is resis-tance to high temperature, they are usuallycalled on to resist other destructive influencessuch as abrasion, pressure, chemical attackand rapid changes in temperature.

Refractory (adj.): Chemically and physicallystable at high temperatures.

Refractory Clay: An earthy or stony mineralaggregate which has as the essential con-stituent hydrous silicates of aluminum with orwithout free silica;plastic when sufficientlypulverized and wetted, rigid when subsequent-ly dried and of sufficient purity and refractori-ness for use in commercial refractory products.

Regenerator: A refractory structure in whichthermal energy from hot furnace gases is alter-nately absorbed by checkerbrick work andreleased to cold air or gas.

Regenerator Checkers: Brick used in furnaceregenerators to recover heat from hot outgo-ing gases and later to release this heat tocold air or gas entering the furnace; so-calledbecause of the checkerboard pattern in whichthe brick are arranged.

Rise of Arches: The vertical distance betweenthe level of the spring lines and the highestpoint of the under surface of an arch.

Rock: A naturally occurring mineral aggregateconsisting of one or more minerals. For exam-ple, quartzite rock is an aggregate consistingessentially of crystals of the mineral quartz;granite is an aggregate consisting essentiallyof spar and quartz.

Rotary Kiln : A cylindrical, refractory-lined,gas-fired kiln that rotates at an angle and inwhich the charge is introduced into the higherend and travels down the slope of the kiln tothe discharge end.

Rowlock Course: A course of brick laid onedge with their longest dimensions perpendicu-lar to the face of a wall.

Rutile: A mineral consisting of titanium diox-ide (Ti2O). Specific gravity 4.18 - 4.25.

Screen Analysis: The size distribution of non-cohering particles as determined by screeningthrough a series of standard screens.

Secondary Expansion: The property exhibit-ed by some fireclay and high-alumina refracto-ries of developing permanent expansion attemperatures within their useful range; notthe same as overfiring. A behavior not to beconfused with the bloating caused by exces-sive temperatures which impair the usefulproperties of a refractory.

Semi-Silica Fireclay Brick: A fireclay brickcontaining not less than 72% silica.

Serpentine: A group of rock forming miner-als; (Mg,Fe)3Si2O5(OH)4. Specific gravity 2.5 -2.7. Also, a common rock consisting essential-ly of serpentine minerals.

Silica: SiO2, the oxide of silicon. Quartz andchalcedony are common silica materials;quartzite, sandstone and sand are composedlargely of free silica in the form of quartz.

Silica Brick: A fired refractory consistingessentially of silica and usually made fromquartzite bonded withabout 1.8 to 3.5 % ofadded lime.

Silica Fire Clay*: A refractory mortar consist-ing of a finely ground mixture of quartzite, sil-ica brick and fire clay of various proportions;often called silica cement.

Silicon Carbide: A compound of silicon andcarbon; SiC.

Silicon Carbide Refractories*: Refractoryprod-ucts consisting predominantly of silicon car-bide.

Sillimanite: A brown, grayish, pale-green or whiteorthorhombic mineral; Al2SiO5. Specific gravity3.24. At about 2,785°F (1,530°C) it begins todissociate into mullite and free silica.

Sintering: A heat treatment which causesadjacent particles of material to cohere at atemperature below that of complete melting.

Skewback: The course of brick, having aninclined face, from which an arch is sprung.

Slag: A substance formed in any one of sever-al ways by chemical action and fusion at fur-nace operating temperatures: (1) in smeltingoperations, through the combination of aflux, such as limestone, with the gangue orwaste portion of the ore; (2) in the refiningmetals, by substances, such as lime, addedfor the purpose of effecting or aiding therefining; (3) by chemical reaction betweenrefractories and fluxing agents, such as coal,ash or between two different types of refrac-tories.

Slagging of Refractories*: Destructive chemi-cal action between refractories and external agen-cies at high temperatures resulting in the forma-tion of a liquid.

Sleeves: Tubular refractory shapes used toprotect the metal rod which holds the stopperhead in the valve assembly of a bottom-pour-ing ladle.

Slurry : A suspension of finely pulverizedsolid material in water of creamy consistency.

Soapstone: A metamorphic rock consistingmainly of talc and derived from the alterationof ferromagnesian silicate minerals.

Soldier Course: A course of brick set on end;little used in the case of refractories exceptin the bottoms of some types of furnaces.

Solid Solution: A homogeneous crystallinephase with a variable composition. The mostcommon solid solutions involve two or moresubstances having the same crystallinestruc-ture. However, the term can also refer to thesolution of small proportions of a material in aseemingly unrelated substance.



GLOSSARY

Spalling of Refractories: The loss of frag-ments (spalls) from the face of a refractorystructure, through cracking and rupture, withexposure of inner portions of the originalrefractory mass.

Specific Gravity: The ratio between the weightof a unit volume of a substanceand that ofsome other standard substance under standardconditions of temperature and pressure. Forsolids and liquids the specific gravity is basedon water as the standard. The “true specificgravity” of a body is based on the volume ofsolid material excluding all pores. The bulk orvolume specific gravity is based on the volumeas a whole, i.e. the solid material with allincluded pores. The apparent specific gravityis based on the volume of the solid materialplus the volume of the sealed pores.

Specific Heat: The quantity of heat requiredto raise the temperature of a unit mass of asubstance one degree.

Spinel: (1) The mineral composed of magne-sium aluminate; MgAl2O4. Specific gravi-ty 3.6. Melting point 3,875°F (2,135°C). (2)A group of minerals of general formula; AB2O4

where A represents magnesium, ferrous iron,zinc or manganese or any combination of theseminerals and B represents aluminum ferriciron or chromium.

Spring Line: The line of contact betweentheinside surface of an arch and the skewback.

Sprung Arch: An arch which is supportedbyabutments at the side or ends only.

Stack Losses: The flue gas loss, the sensibleheat carried away by the dry flue gas plus thesensible heat and latent heat carried away bythe water vapor in the flue gas.

Stretcher: A brick laid on flat with its lengthparallel to the face of the wall.

Superduty Fireclay Brick: Fireclay brickwhich have a PCE not lower than Cone 33 andwhich meet certain other requirements as out-lined in ASTM Designation C 27-84.

Suspended Arch: An arch in which the brickshapes are suspended from overhead support-ing members.

Taconite: A compact ferruginous chert or slatein which the iron oxide is so finely disseminat-ed that substantially all of the iron-bearing par-ticles are smaller than 20 mesh. Typical analy-ses of the ore grade show total iron at 32%.

Talc: A hydrous magnesium silicate mineral;Mg3Si4O10(OH)2. Specific gravity 2.7 - 2.8.Hardness 1.

Thermal Conductivity : The property of mat-ter by virtue of which heat energyis transmittedthrough particles in contact.

Thermal Expansion: The increase in lineardimensions and volume which occurs whenmaterials are heated and which is counterbal-anced by contraction of equal amount when thematerials are cooled.

Thermal Shock: A sudden transient tempera-ture change.

Tolerance: The permissible deviation in adimension or property of a materialfrom anestablished standard or from an average value.

Tridymite : A mineral form of silica; SiO2.Stable from 1,598 to 2,678°F (870 to1,470°C). Specific gravity 2.26. An importantconstituent of silica brick.

Tweel: A refractory shape used to control theflow of molten glass from the glass tank to thetin bath in the float glass process.

Trough: An open receptacle through whichmolten metal is conveyed from a holdingdevice or furnace to a castingmold or anotherreceptacle.

Tuyere Brick: A refractory shape containingone or more holes through which air and othergases are introducedinto a furnace.

TREFOIL ® Heat Exchanger: A refractoryconstruction in a rotary kiln with threeopenings which in cross-section are clover-shaped. Over its length, the TREFOIL heatexchanger divides the kiln into three equal parts,thus improvingheat exchange between thecharge and the hot combustion gases.

Vacuum Pressing: A method of forming brickshapes by which they are subjected to a partialvacuum during pressing in a power press.

Vermiculite : A group of micaceous minerals,all hydrated silicates, varyingwidely in com-position; (Mg,Fe,Al)3 (AlSi)4O10(OH)2 - 4H2O.When heated above 302°F (150°C), vermi-culite exfoliates and increases greatly in vol-ume.

Vesicular: Having a cellular structure; appliedto fire clays which have become bloated byoverfiring.

Vibratory Pressing: A process for formingrefractory shapes in which the ground parti-cles of refractory material are packed closelytogether by rapid impact-type vibrations of thetop and bottom dies; also called impact press-ing.

Vitrification : A process of permanent chemi-cal and physical change at high temperaturesin a ceramic body, such as fire clay, with thedevelopment of a substantial proportion ofglass.

Warpage: The deviation of the surface of arefractory shape from that intended, caused bybending or bowing duringmanufacture.

Wedge Brick: A brick shape having six planefaces (two sides, two edges and two ends), inwhich two faces (the sides) are inclinedtoward each other and one end face is narrow-er than the other.

Wetting: The adherence of a film of liquid tothe surface of a solid.

Wollastonite: A triclinic mineral; CaSiO3.Specific gravity 2.9. Inverts at 2,192°F(1,200°C) to pseudowollastonite. Melts incongru-ently at 2,811°F (1,544°C).

Young’s Modulus: In mechanics, the ratio oftensile stress to elongation within the elasticlimit; the modulusof elasticity.

Zircon : A mineral; ZrSiO4. Specific gravity4.7. Begins to melt incongruently at 3,045°F(1,685°C) forming ZrO2 solid solution plusliquid; completely melted at about 4,800°F(2,650°C).

Zirconia : Zirconium oxide; ZrO2. Specificgravity 5.8. Melting point 4,890°F (2,700°C).Its chief source is the mineral baddeleyite.



GLOSSARY

H-W Refractories maintains stocks of a variety of standard brick, mortars, IFB, plastics, castables, gun mixes, patchingmaterials, ceramic fiber, insulating board,gasketing, metallic anchors, and associatedproducts at distribution centers throughoutthe U.S. If you need material to complete arepair or for an emergency, give us a call.We are nearby and ready to service you.Call 1-800-887-5555 to reach the location nearest you.

Atlanta, (Doraville) GA (770) 448-6266

Baton Rouge, (Gonzales) LA (225) 644-2111

Birmingham, AL (205) 788-1685

Buffalo, (Tonawanda) NY (716) 692-1761

Charlotte, NC (704) 599-6540

Chicago, (Calumet City) IL (708) 474-5350

Cincinnati, (Milford) OH (513) 576-6240

Cleveland, OH (216) 398-1790

Dallas, TX (214) 330-9243

Davenport, IA (563) 445-1244

Detroit, (Taylor) MI (734) 287-2150

Houston, TX (713) 635-3200

Kansas City, (Lenexa) MO (913) 888-0425

Knoxville, TN (865) 546-4930

Los Angeles, (Pico Rivera) CA (562) 942-2151

New Haven, (West Haven) CT (203) 934-7960

New York, (Rahway) NJ (732) 388-8686

Philadelphia, (Trevose) PA (215) 364-5555

Pittsburgh, (Leetsdale) PA (412) 741-3200

Portland, OR (503) 227-7944

Roanoke, (Salem) VA (540) 375-2107

Salt Lake City, UT (801) 886-0545

San Francisco, (Richmond) CA (510) 236-7415

St Louis, MO (314) 521-3314

Tampa, (Lakeland) FL (713) 635-3200

Harbison-Walker Refractories CompanyDistribution Centers

Offering A.P. Green, NARCO and Harbison-Walker products

HARBISON-WALKER REFRACTORIES DISTRIBUTION



STANDARD TERMS OF SALE

Harbison-Walker Refractories CompanySTANDARD TERMS OF SALE

1.GENERALA. Seller’s prices are based on these sales terms and (i) this document, together with any additional writings signed by Seller, represents a final, complete and exclusive statement of the agreement betweenthe parties and may not be modified, supplemented, explained or waived by parole evidence, Buyer’s purchase order, a course of dealing, Seller’s performance or delivery, or in any other way except in writingsigned by an authorized representative of Seller, and (if) these terms are intended to cover all activity of Seller and Buyer hereunder, including sales and use of products and all related matters including technicaladvice and services. Any references by Seller to Buyer’s specifications and similar requirements are only to describe the products covered hereby and no warranties or other terms therein shall have any force oreffect. Catalogs, circulars and similar pamphlets of the Seller are issued for general information purposes only and shall not be deemed to modify the provisions hereof.B. The agreement formed hereby and the language herein shall be construed and enforced under the Uniform Commercial Code as in effect in the State of Pennsylvania on the date hereof.

2. TAXESAny sales, use or other similar type taxes imposed on this sale or on this transaction are not included in the price. Such taxes shall be billed separately to the Buyer. Seller will accept a valid exemptioncertificate from the Buyer if applicable, however, if an exemption certificate previously accepted is not recognized by the governmental taxing authority involved and the Seller is required to pay the tax coveredby such exemption certificate, Buyer agrees to promptly reimburse Seller for the taxes paid.

3. PERFORMANCE, INSPECTION AND ACCEPTANCEA. Unless Seller specifically assumes responsibility for work, all products shall be finally inspected and accepted within ten (10) days after arrival at point of delivery. All claims whatsoever by Buyer(including claims for shortages) excepting only those provided for under the WARRANTY AND LIMITATION OF REMEDY AND LIABILITY and PATENTS Clauses hereof must be asserted in writing by Buyerwithin said ten (10) day period or they are waived. If this contract involves partial performances, all such claims must be asserted within said ten (10) day period for each partial performance. There shall be norevocation of acceptance. Rejection may be only for defects substantially impairing the value of products or work and Buyer’s remedy for lesser defects shall be those provided for under the WARRANTY ANDLIMITATION OF REMEDY AND LIABILITY Clause.B. Seller shall not be responsible for nonperformance or delays in performance occasioned by any causes beyond Seller’s reasonable control, including, but not limited to, labor difficulties, delays of vendors

or carriers, fires, governmental actions and material shortages. Any delays so occasioned shall effect a corresponding extension of Seller’s performance dates which are, in any event understood to beapproximate. In no event shall Buyer be entitled to incidental or consequential damages for late performance or a failure to perform.

C. If Buyer wrongfully rejects or revokes acceptance of items tendered under this agreement or fails to make a payment due on or before delivery or repudiates this agreement, Seller shall at its option have aright to recover as damages either the price as stated herein (upon recovery of the price the items involved shall become the property of the Buyer) or the profit (including reasonable overhead) which theSeller would have made from full performance together with incidental damages and reasonable costs.

4. TITLE AND RISK OF LOSSFull risk of loss (including transportation delays and losses) shall pass to the Buyer upon delivery of products to the f.o.b. point. However, Seller retains title, for security purposes only, to all products until paidfor in full in cash and Seller may, at Seller’s option repossess the same upon Buyer’s default in payment hereunder and charge Buyer with any deficiency.

5. WARRANTY AND LIMITATION OF REMEDY AND LIABILITYA. Seller warrants only that its products, when shipped, will meet all applicable specifications and other specific product requirements (including those of performance), if any, of this agreement and will befree from defects in material and workmanship. Drawing Services furnished hereunder shall conform to the standards of practice customary in the refractories business for drawing services of a similar nature. Allclaims under this warranty must be made in writing immediately upon discovery and, in any event within one (1) year from shipment of the applicable product or drawing. Defective and nonconforming items mustbe held for Seller’s inspection and returned to the original f.o.b. point upon request. THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER, EXPRESS IMPLIED ANDSTATUTORY, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS. Technical advice is furnished as an accommodation to the Buyer. Seller assumesno liability therefor, and Buyer accepts such advice at Buyer’s sole riskB. Upon Buyer’s submission of a claim as provided above and its substantiation, Seller shall at its option either (i) repair o replace its product or work at the original F.O.B. point or (ii) refund an equitable

portion of the purchase price or (iii) reperform drawing services at no cost to customers.C. THE FOREGOING IS SELLER’S ONLY OBLIGATION AND BUYER’S EXCLUSIVE REMEDY FOR BREACH OF WARRANTY AND, EXCEPT FOR GROSS NEGLIGENCE, WILLFUL MISCONDUCT AND

REMEDIES PERMITTED UNDER THE PERFORMANCE INSPECTION AND ACCEPTANCE AND THE PATENTS CLAUSES HEREOF, THE FOREGOING IS BUYER’S EXCLUSIVE REMEDYAGAINST SELLER FOR ALL CLAIMS ARISING HEREUNDER OR RELATING HERETO WHETHER SUCH CLAIMS ARE BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE ANDSTRICT LIABILITY) OR OTHER THEORIES. BUYER’S FAILURE TO SUBMIT A CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR DAMAGES OR OTHER RELIEF,INCLUDING BUT NOT LIMITED TO CLAIMS BASED ON LATENT DEFECTS. IN NO EVENT SHALL BUYER BE ENTITLED TO INCIDENTAL OR CONSEQUENTIAL DAMAGES. ANY ACTION BYBUYER ARISING HEREUNDER OR RELATING HERETO, WHETHER BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES,MUST BE COMMENCED WITHIN ONE (1) YEAR AFTER THE CAUSE OF ACTION ACCRUES OR IT SHALL BE BARRED.

D. Refractory brick and shapes should be handled with care to avoid scuffing and breaking. All refractories should be stored in a dry place, protected against weather, especially in seasons when alternatefreezing and thawing occur.

6. PATENTSSeller agrees to assume the defense of any suit for infringement of any United Stales patents brought against Buyer to the extent such suit charges infringement of an apparatus or product claim by Seller’sproduct in and of itself provided (i) said product is built entirely to Seller’s design, (ii) Buyer notifies Seller in writing of the filing of such suit within ten (10) days after the service of process thereof and (iii) Selleris given complete control of the defense of such suit including the right to defend, settle and make changes in the product for the purpose of avoiding infringement Seller assumes no responsibility for charges ofinfringement of any process o method claims unless infringement of such claims is the result of following specific instructions furnished by Seller.

7. SPECIAL TOOLINGNotwithstanding any molds, outfits, tool, die or pattern changes or amortization in connection herewith, all special tooling and related items shall be and remain the property of Seller.

8. ALLOWABLE VARIATION, OVERSHIPMENT AND PALLET RETURNSA. Allowable variations from specified dimensions are plus 2% to minus 2% on dimensions over 4’’ and plus 3% to minus 3% on dimensions of 4’’ or less.B. Overage shall be allowable on all shipments of sizes and shapes that are not carried in stock in accordance with the following: 1-100: 10%, but not less than one shape or, if in sets, one complete set-101 -1,000: 7%, 1,001- 5,000:3%, 5,001-10,000 – 2%, Over- 10,000 – 1%.C. Before returning any pallets, Buyer should communicate with Seller, for consigning and routing instructions. Only standard pallets suitable for reuse are acceptable.

9. MINIMUM INVOICE CHARGEIndividual orders or shipments from any of seller’s plants will be subject to a minimum charge of $250.00.

10. PALLET BREAKAGE CHARGE Individual orders or shipments from Seller’s plant warehouse or service center requiring less than a full pallet are subject to a charge of $25.00 for each pallet less than a full pallet.

11. DRAWING SERVICESDrawing Services are quoted and provided to offer suggested methods of installation. Buyer’s approval of drawings and/or Buyer’s decision to rely upon them for construction purposes is at the sole risk ofBuyer/Installer. Buyer’s payment for any drawing services recognizes that the information contained in the drawings is proprietary and is the intellectual property of Harbison-Walker. Buyer agrees to keep theinformation confidential and shall not reproduce or make the drawings available to third parties.

12. NOTICEHarbison-Walker Refractories Company values highly the confidence and good will of its customers and suppliers. We offer our products only on their merit and we expect our customers to judge and purchaseour products and services solely on the basis of quality, price, delivery and service. Likewise, Harbison-Walker buys only on merit and we judge and purchase solely on the basis of quality, price, delivery andservice. This Harbison-Walker Company policy applies in all relationships with our customers and suppliers.

Literature

Products L-1

Applications L-2

SECTION 9

Harbison-Walker LR-1

H-W LITERATURE BY PRODUCT

H-W Industrial Products

Alumina-Chrome Brick

Coarse Aggregate Castables

- VERSAFLOW® C & 2-TOUGH®

EmisshieldTM

EXCELrate

Extra-High Alumina Brick

High Alumina Brick

INSWOOL® Blanket Products

INSBOARD Ceramic Fiber Boards

INSWOOL® Fiber Modules

INSWOOL® Utility Paper

INSWOOL® 2300 Paper

INSWOOL® Rope and Braids

INSWOOL® Pumpable

MAGSHOT® Gun Mix

Super-Duty Fireclay Brick

VIB-TECH Engineered Shapes

LR-2 Harbison-Walker

H-W LITERATURE BY APPLICATION

Aluminum Industry

Aluminum Melting/Holding Furnaces

Aluminum Transfer Trough

Cement & Lime

H-W Long Brick for Rotary Kilns

High Alumina & Basic Brick for Rotary Kiln Systems

Light Weight Castable/Gunning for Rotary Kiln

MAGSHOT® for Cement & Line

Refractories for the Lime Industry

THOR AZS/AZSP for Cement Nose Ring

THOR AZSP Pumpable Castable for Cement & Lime

TZ 352 DRY MORTAR Anti-Buildup for Existing Linings

VERSAFLOW® 70 ADTECH® for Cement Kiln Nose Ring

Industrial Foundry

AOD Refractories for Industrial Foundries

Breast Wall & Trough CUPOLA

Channel Induction Refractories for Industrial Foundries

Electric Arc Furnace for Industrial Foundries

Ladle Refractories for Industrial Foundries

NARGON® Porous Plugs for Industrial Foundries

Upper Stack to Melt Zone for CUPOLA

Pulp & Paper Industry

Lime Recovery Kiln

MAGSHOT® Gun Mix

Petroleum Refining

Fluid Cat Cracking Unit

Sulfur Recovery Units

Power Industry

Ash Hopper Refractories

Boiler Refractory Applications

Coal Fired Cyclone Boilers

Refractory Block Slag Dam

Alumina-ChromeBrick


Harbison-Walker Refractories Company’s alumina-chrome brick consist of combinations of the twooxides fired to develop a solid-solution bond.This means that all ratios of alumina andchrome can be combined without the forma-tion of any low-melting eutectic phases. Equallyimportant is the absence of any silicate bondphases. The solid solution bond developed infiring results in brick with exceptional hot strengthand load bearing ability. The chromic oxide isvery resistant to many corrosive agentsencountered in ferrous foundry, slagginggasifier, and chemical incinerator service.

Brick are available with chromic oxide contentranging from 5 to 95%. Following is a summaryof selected products

RUBY®: This is a 10% chromic oxide, 90% alumi-na brick, designed for extremely high temperatureand corrosive service. It provides extraordinaryresistance to chemical attack, corrosion andsevere slag attack.

RUBY® DM: A version of RUBY utilizingthe Densified Matrix (DM) technology to achievelower porosity and improved slag resistance.

RUBY® SR: A version of RUBY utilizing theShock Resistance (SR) technology to provideexcellent resistance to thermal shock. In prismspall testing, consisting of cycling from 2200˚F toa water quench, RUBY SR withstands 25 cycles,compared to 3 for the standard RUBY product.

RUBY® LW: A lightweight version of RUBYintended for service in corrosive hot face andback-up applications.

AUREX® 20 SR: A shock resistant alumina-chrome brick with 20% chromic oxide to provideenhanced corrosion resistance.

AUREX® 30 SR: A high purity thermalshock resistant product with 30% chromicoxide. Used in the burning zone of chemicalincinerators.

AUREX® 75 & AUREX® 75 SR: This is avery dense, high purity, fused grain refracto-ry containing 75% chromic oxide. Available inthe regular and shock resistant (SR) versions.These products are used in coal gasifiers andother highly corrosive applications.

SERV 80, AUREX® 90 and AUREX® 95:These extremely dense, refractories con-taining 80 to 95% chromic oxide for exception-al corrosion resistance and refractoriness.These products are used in the highest wearareas of coal gasifiers. Contact your H-W SalesRepresentative for information on these prod-ucts.

RUBY® RUBY® DM RUBY® SR RUBY® LW

Bulk Density, pcf 201 213 200 124

Apparent porosity, % 17.2 12.6 17.5 49.9

Modulus of Rupture, psiAt 70˚F 5,400 7,150 1,650 1,660At 2,700˚F 1,890 4,000 1,490 –

Chemical Analysis %: Approx.(Calcined Basis)

Silica (SiO2) 0.5 0.3 2.0 0.4

Alumina (Al2O3) 89.7 89.6 83.0 89.4

Titania (TiO2) 0.1 Trace Trace Trace

Iron Oxide (Fe2O3) 0.2 0.1 0.1 0.2

Lime (CaO) 0.3 0.1 0.1 Trace

Magnesia (MgO) 0.1 Trace Trace 0.1

Alkalies (Na2O + K2O) 0.1 0.1 0.2 0.1

Chromic Oxide (Cr2O3) 9.0 9.8 11.2 9.8

Other Oxides – – 3.4 –


AUREX® 20 SR AUREX® 30 SR AUREX® 75 AUREX® 75 SRBulk Density, pcf 204 217 258 151

Apparent porosity, % 17.5 15.5 14.4 15.4

Modulus of Rupture, psiAt 70˚F 1,520 1,350 3,850 1,900At 2,700˚F 2,200 – 2,250 2,600

Chemical Analysis %: Approx.(Calcined Basis)

Silica (SiO2) 0.4 2.1 0.2 0.3

Alumina (Al2O3) 75.6 64.9 22.1 24.2

Titania (TiO2) 0.1 1.9 Trace Trace

Iron Oxide (Fe2O3) 0.1 0.1 0.1 0.2

Lime (CaO) 0.1 0.1 0.2 0.2

Magnesia (MgO) Trace 0.2 0.1 0.1

Alkalies (Na2O + K2O) 0.1 0.2 Trace Trace

Chromic Oxide (Cr2O3) 19.1 27.7 77.3 74.5

Other Oxides 3.3 2.8 – –

The data given above are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable.Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements, informa-tion, and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed orimplied.

Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that suchuse is free of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.

© 2002 Harbison-Walker Refractories Company. All Rights Reserved. Cat# HW 88 (11/02) 3C



Phone: (412) 375-6600 w Fax: (412) 375-6783www.hwr.com

CASTABLESCOARSE AGGREGATE

VERSAFLOW® C & 2-TOUGHTM CastablesHigh Strength Castables

for Mechanical Abuse at High Temperature

What makes a refractory castable durable enough to withstand the abuse of highmechanical impact applications? Toughness.

The conventional method of increasing toughness is adding wire fibers. Wire fibers arecompressible, and flexible. They help to dissipate the force of an impact over a larger surface area, reducing the potential for cracking. They also oxidize and adversely affectthermal shock resistance.

What makes a refractory castable tough enough to withstand the abuse of high mechani-cal impact at high temperatures? Coarse Aggregates.

Similar to wire fibers, coarse aggregates aid in the dissipation of the force of an impact.At high temperatures, coarse aggregate-containing castables have significant advantagesover wire fiber-containing products...

Increasing Wire Fiber Content.After Firing to 2910°F





VERSAFLOW®

45 C 55/AR C 65/AL C 70 C 80 CADTECH® ADTECH® ADTECH® ADTECH® ADTECH®

Maximum Service Temperature (°F) 2700 3000 2400 3100 2800Density (lb/ft3)

After drying at 230 °F 135 152 168 171 175Modulus of Rupture (psi)

After drying at 230 °F 1560 2300 1570 2000 2100After heating at 1500 °F 1410 2520 1670 1800 2100

Cold Crush Strength (psi)After drying at 230 °F 9470 9470 13870 8300 12000After heating at 1500 °F 7620 7620 10760 11800 14000

Abrasion Resistance (cc loss)After heating at 1500 °F 9.6 – – – 3.8

Chemical Analysis,%:Al2O3 44.6 56.0 67.0 71.9 80.0SiO2 49.4 38.0 25.0 22.9 12.5TiO2 2.2 2.0 2.2 2.5 2.8Fe2O3 0.7 0.9 1.0 1.0 1.4CaO 2.4 2.8 3.2 1.4 2.4MgO 0.2 0.1 0.2 0.1 0.2P2O5 – – – – 0.4Na2O & K2O 0.5 0.2 0.4 0.2 0.3Other Oxides – – 1.0 – –

TECHNICAL DATA

TECHNICAL DATA 2-TOUGHTM HP 2-TOUGHTM FA 2-TOUGHTM ALADTECH® ADTECH® ADTECH®

Maximum Service Temperature (°F) 3300 3200 2500Density (lb/ft3)

After drying at 230 °F 200 208 210Modulus of Rupture (psi)

After drying at 230 °F 800 2000 1900After heating at 1500 °F 900 – –

Cold Crush Strength (psi)After drying at 230 °F 7000 12400 9800After heating at 1500 °F 5000 – –After heating at 2500 °F 17000 11000 –

Hot Modulus of Rupture (psi)At 2700 °F 1500 – –

Chemical Analysis (%):Al2O3 95.5 92.2 90.0SiO2 0.1 0.9 1.1TiO2 – 2.3 2.6Fe2O3 – 0.2 0.1CaO 1.4 1.6 2.3MgO 2.7 2.8 0.8Na2O & K2O 0.3 0.1 0.1Other Oxides – – 3.0

The data given above are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable. Variationfrom the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and datagiven herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use isfree of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.

Thermal Shock Resistance& 2000ºF Hot MOR

Vs Wire Content

VERSAFLOW® C Castables


Fireclay-based low cement castable for use inhigh impact and abrasion environments up to2700ºF. Typical uses; chain sections, ashhoppers and ladle covers.

VERSAFLOW® 55/AR C ADTECH®

A 55% alumina low cement, coarse graincastable based on bauxitic calcines.Specifically designed for impact and abrasionresistance in high alkali environments. Typicaluses; incinerators and aluminum furnaceroofs.

VERSAFLOW® 65/AL C ADTECH® (pictured left)A 65% alumina, aluminum resistant, coarsegrain castable. For use in high wear areas inaluminum contact such as ramps, sills andcruce bottoms.


70% alumina, coarse grain castable with highstrength, high refractoriness and excellentabrasion and impact resistance. Typical uses;foundry ladles, rotary kiln nose rings andlifters, incinerator charge zones, and precasttundish furniture.

VERSAFLOW® 80 C ADTECH® (pictured above)An 80% alumina low cement coarse castablewith excellent strength. Typical uses; rotary kilnlifters and feed ends, aluminum furnace jambsand lintels, and reheat furnace skid block.

2-TOUGHTM Castables2-TOUGHTM Castables take the coarse grain concept to the next level. They were developed for the most severe mechanical abuse environments.

2-TOUGHTM castables are comprised of 50% coarse grain having a diameter up to about 1-inch. The other 50% of the product is a high purity, EXPRESS®-type bonding matrix. Even though 2-TOUGHTM products utilize EXPRESS® technology, they still require vibration to achieve their full density.

2-TOUGHTM HP ADTECH®

The combination of a coarse tabular alumina aggre-gate and a fine tabular alumina matrix gives this highpurity mix outstanding corrosion resistance. 2-TOUGHTM HP ADTECH® has set a record in theimpact test, surviving almost 70 impacts!! This uniqueproduct has solved severe wear problems in severalsteel applications including well blocks, ladle bottomsand electric furnace deltas.

2-TOUGHTM FA ADTECH®

Exceptionally high strength and impact resistancecharacterize this product. Its fused alumina coarseaggregate has a higher density than tabular alumina,resulting in significantly lower porosity than traditional90% alumina castables. Typical uses for 2-TOUGHTM FA ADTECH® include ladle bottoms, alu-minum furnace jambs and lintels, and rotary kiln lifters.

2-TOUGHTM AL ADTECH®

Rounding out the product line, 2-TOUGHTM ALADTECH® is specifically designed for use in aluminumcontact. It is essentially silica free, and contains analuminum penetration inhibitor. This makes it veryresistant to aluminum corrosion. Typical used includeprecast hearths, ramps and sills, belly bands, troughs,and cruces.

Density (pcf)

2-TOUGHTM HP ADTECH® 200

2-TOUGHTM FA ADTECH® 208

2-TOUGHTM AL ADTECH® 210

VERSAFLOW® 65/AL C ADTECH® - Aluminum Cup Test


2-TOUGHTM AL ADTECH® - Aluminum Cup Test

2-TOUGHTM HP ADTECH®

2-TOUGHTM FA ADTECH®


VERSAFLOW® C family of castables offermultiple benefits:

InstallationVERSAFLOW® C castables can be mixed,within a specific water range, from a vibcast toa pumpable consistency with little effect onphysical properties. This means you canselect the installation method best suited toyour application, whether it’s vibration casting,conventional casting, or pumping.

VersatilityVERSAFLOW® C castables feature an excel-lent balance of physical properties. Each isspecially engineered to combat the problemsassociated with today’s demanding furnaceenvironments.

Impact ResistantAt our Technology Center West Mifflin, we testimpact resistance by repeatedly firing a 1/2 -inch projectile at a refractory sample, heatedto 2000°F. VERSAFLOW® C castables sur-vive close to 40 cycles in this test, comparedto traditional low cement castables which typi-cally fail after 15 to 20 cycles.

Special FeaturesVERSAFLOW® C castables are available in avariety of compositions to meet your specificneeds. Formulations range from fireclay to80% alumina, and include both aluminum andalkali resistant variations.

CASTABLESCOARSE AGGREGATE

VERSAFLOW® C & 2-TOUGHTM CastablesHigh Strength Castables

for Mechanical Abuse at High Temperature

What makes a refractory castable durable enough to withstand the abuse of highmechanical impact applications? Toughness.

The conventional method of increasing toughness is adding wire fibers. Wire fibers arecompressible, and flexible. They help to dissipate the force of an impact over a larger surface area, reducing the potential for cracking. They also oxidize and adversely affectthermal shock resistance.

What makes a refractory castable tough enough to withstand the abuse of high mechani-cal impact at high temperatures? Coarse Aggregates.

Similar to wire fibers, coarse aggregates aid in the dissipation of the force of an impact.At high temperatures, coarse aggregate-containing castables have significant advantagesover wire fiber-containing products...

Increasing Wire Fiber Content.After Firing to 2910°F





VERSAFLOW®

45 C 55/AR C 65/AL C 70 C 80 CADTECH® ADTECH® ADTECH® ADTECH® ADTECH®

Maximum Service Temperature (°F) 2700 3000 2400 3100 2800Density (lb/ft3)

After drying at 230 °F 135 152 168 171 175Modulus of Rupture (psi)

After drying at 230 °F 1560 2300 1570 2000 2100After heating at 1500 °F 1410 2520 1670 1800 2100

Cold Crush Strength (psi)After drying at 230 °F 9470 9470 13870 8300 12000After heating at 1500 °F 7620 7620 10760 11800 14000

Abrasion Resistance (cc loss)After heating at 1500 °F 9.6 – – – 3.8

Chemical Analysis,%:Al2O3 44.6 56.0 67.0 71.9 80.0SiO2 49.4 38.0 25.0 22.9 12.5TiO2 2.2 2.0 2.2 2.5 2.8Fe2O3 0.7 0.9 1.0 1.0 1.4CaO 2.4 2.8 3.2 1.4 2.4MgO 0.2 0.1 0.2 0.1 0.2P2O5 – – – – 0.4Na2O & K2O 0.5 0.2 0.4 0.2 0.3Other Oxides – – 1.0 – –

TECHNICAL DATA

TECHNICAL DATA 2-TOUGHTM HP 2-TOUGHTM FA 2-TOUGHTM ALADTECH® ADTECH® ADTECH®

Maximum Service Temperature (°F) 3300 3200 2500Density (lb/ft3)

After drying at 230 °F 200 208 210Modulus of Rupture (psi)

After drying at 230 °F 800 2000 1900After heating at 1500 °F 900 – –

Cold Crush Strength (psi)After drying at 230 °F 7000 12400 9800After heating at 1500 °F 5000 – –After heating at 2500 °F 17000 11000 –

Hot Modulus of Rupture (psi)At 2700 °F 1500 – –

Chemical Analysis (%):Al2O3 95.5 92.2 90.0SiO2 0.1 0.9 1.1TiO2 – 2.3 2.6Fe2O3 – 0.2 0.1CaO 1.4 1.6 2.3MgO 2.7 2.8 0.8Na2O & K2O 0.3 0.1 0.1Other Oxides – – 3.0

The data given above are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable. Variationfrom the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and datagiven herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use isfree of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.

Thermal Shock Resistance& 2000ºF Hot MOR

Vs Wire Content

Refractories/CeramicEmisshield™ ST coatings reduce the temperature exposure of refrac-

tories and ceramics by absorbing and re-radiating thermal energy to

the furnace load. They protect them from corrosion by acids, alkalies,

slags, and many molten metals, especially aluminum, and provide

increased abrasion resistance. The use of Emisshield™ coatings will

provide longer refractory life and reduced operating costs.

Emisshield™ was developed and

refined from NASA technology

used to protect the next generation

of Space Orbiters (X-33, X-34,

etc.) from the extreme tempertures

and abrasion of atmospheric reen-

try. Emisshield™ coatings may be applied to many

materials where heat and thermal degradation are fac-

tors.

Most substrates have a rela-

tively high emissivity value

at room temperature.

However when temperatures

increase, these values fall

dramatically. Emisshield™

not only has an emissivity value of 0.8 - 0.9 at

room temperature, it maintains that value at tem-

peratures up to 3000º F and beyond.

X-34

Emissivity - the absorption and release of energy rated on a scale of 0.0 - (Low) to 1.0 - (High)

Benefits of Emisshield™ Coatings

Metals (Patent Pending)Emisshield™ STG and M coatings can be applied to most ferrous and

non-ferrous alloys to protect them from high temperatures, oxidation,

corrosion, and abrasion. These coatings can withstand process tem-

peratures in excess of 3000ºF and can extend the use temperature of

metal components in high temperature industrial processes. The use of

Emisshield™ will increase thermal transfer to water tubes in boilers and

power generation units.

Harbison-Walker Refractories Company400 Fairway Drive Moon Township, PA 15108

Phone:(412) 375-6901 Fax: (412) 375-6783

Cat# HW 150 (5/04)

X-33

When a cooler furnace load or atmosphere is available,

an Emisshield™ coating on metal will absorb and emit

the heat to the load, preventing heat loss through the

metal and thermal oxidation of the substrate. Typical

applications for Emisshield™ STG and M formulations

include water-cooled electric furnace roofs, rotary kiln

nose ring castings, air

blasters and grates, ladle

retaining rings, kiln car

skirts, alloy injector

tubes, metal slag and

dross removal tools, and

exposed furnace structur-

al steel.

For applications where there is not a cooler load pres-

ent to absorb the emitted heat energy, Emisshield™ will

conduct the absorbed heat through to the metal sub-

strate which conducts the heat to the cold face of the

substrate. Applications where this property of

Emisshield™ is particularly effective include boiler

tubes and water wall tubes in power plants.

Emisshield™ will increase the conductive heat transfer

to these tubes, improving the uniformity of heating and

the efficiency of steam generation. Coating these tubes

with Emisshield™ also prevents scale buildup and

increases the service life of the tubes.

MetalSeveral Emisshield™

products have been

designed specifically for

metal substrates. These coatings will provide the same

high emissivity properties as the refractory/ceramic

compositions, but they also protect metal substrates

from oxidation and chemical attack. The Emisshield™

STG- and M-series of coatings for metal substrates will

adhere to most ferrous and non-ferrous alloys, raising

the effective service temperatures of all alloys. Many

metals and alloys have relatively high emissivities at

room temperature, however their emissivities decrease

markedly at higher temperatures. Metals that easily oxi-

dize, such as carbon steel and aluminum, are particular-

ly prone to severe emissivity degradation at high tem-

peratures.

EmisshieldTM is a trademark of WESSEX INCORPORATEDwww.hwr.com© 2004 Harbison-Walker Refractories Company

EmisshieldTM manufactured under license from NASA byWESSEX INCORPORATED.

EmisshieldTM is a trademark of WESSEX INCORPORATED.

1.0

0.8

0.6

0.4

0.2

0

Emis

sivt

y

0 500 1000 1500 2000 2500

Temperature F0

Steel Coated with Emisshield M-1TM

Cold Rolled Steel

Zirconia onInconnel

AluminumAlloy-A3003

WESSEX INCORPORATED

Emisshield™ coated steel kiln carskirts resist oxidation and warping

NASA Technology

Technical Information

Conduction of energy through a substrate can be greatly reduced with application of an Emisshield™ coating when a colder load is present. This redirection of heat can save energy and increase production. By protectingthe substrate from the high heat, Emisshield™ will prolong the life of thesubstrate which will result in reduced maintenance and operating costs.

SubstrateDecreased

conduction ofThermal Energy

Conduction

EmisshieldTM

Coating

Thermal Energy

The value of emissivity assigned to a substrate indicates its ability to absorb and reradiate energy in relation to the electromagnetic spectrum. A substrate that has an emissivity value of 1.0 is known as a black body. A black body will absorb all energy regardless of wavelength. A black body will also reradiate all of the energy it absorbs. To date, no such perfect black body exists. Those that come close to black body capabilities, with emissivity values of 0.85 to 0.9, are known as grey bodies. Emisshield™ coatings are grey bodies. In other words, a black body is 100% efficient at absorbing and reradiating the same energy; thus the rating of 1.0. An Emisshield™ coating will absorb and reradiate the same energy at an 85% to 90% efficiency rate and therefore has an emissivity value of 0.85 to 0.9.

All energy (heat) has a measured wavelength that corresponds to a point on the electromagnetic spectrum.Humans can see visible light, ranging in color from red to purple. Red light has a wavelength of about 0.7µm while purple light has a wavelength of about 0.4µm in the visible spectrum. When white light is refracted through a prism to show all the visible colors (red through purple)and temperatures are taken of the refracted light, the red

measures hotter in temperature than the purple. FriedrickWilliam Herschel discovered the infrared portion of theeletromagnetic spectrum. While measuring the tempera-tures of the visible spectrum, he moved his thermometerpast the visible red and noticed the temperature rose still.The majority of thermal energy falls into this infrared zone.

According to the second law of thermodynamics, energywill always flow from hot to cold. Therefore, Emisshield™coatings will always reradiate the absorbed energy to thecoolest surrounding. This can have a major benefit in pro-ductivity, safety for people, decreasing fuel consumptionand protection of the underlying substrate.

Emisshield™ utilizes the property of emissivity, a materi-al's ability to absorb and re-radiate energy. Emissivity ismeasured on a scale of 0.0 to 1.0, where 1.0 is a perfectblack body, absorbing and re-radiating all radiant energythat hits its surface. Emisshield™ exhibits a relativelyconstant emissivity of 0.85 to 0.90 through the entiretemperature range from room temperature to over3000ºF. Many substrate materials have a high emissivityat lower temperatures, but their emissivity drops dramati-cally at elevated temperatures. Unlike other high emissivi-ty coatings, Emisshield™ will maintain its high emissivityduring prolonged high temperature service.

The amount of energy re-radiated increases with increasingemissivity and rises exponentially as the difference betweenthe surface temperature of the Emisshield™ and the temper-ature of the cooler furnace load increases. At a very low ∆Tand in applications such as boilers and power generationunits where the furnace atmosphere or load is hotter than thecoating, Emisshield™ will increase the amount of heat con-ducted through the substrate. This causes furnaces to coolfaster and increases the amount of energy conductedthrough water tubes.

Refractory / Ceramic

Decreasedconduction of

Thermal Energy

Conduction0.8-0.9

EmisshieldTM

Coating

Thermal Energy

Thermal Energy

Refractory / Ceramic

Conduction

0.2-0.5

Conduction of energy through a substrate can be greatly reduced with application of an Emisshield™ coating when a colder load is present. This redirection of heat can save energy and increase production. By protectingthe substrate from the high heat, Emisshield™ will prolong the life of thesubstrate which will result in reduced maintenance and operating costs.

One of the distinguishing features of Emisshield™ compared

to previous high emissivity coatings is its binder system.

There are numerous Emisshield™ products that have been

designed specifically for dense refractories, lightweight refrac-

tories, and refractory fiber products. These binders are totally

inorganic and emit no hydrocarbon volatiles or combustion

products. In addition, the binders, combined with the emissivi-

ty agent, provide improved resistance to alkali and acid attack,

and good resistance to reactions with ferrous and non-ferrous

metals, particularly aluminum. In service, Emisshield™ com-

positions form strong, highly abrasion-resistant, crystalline or

glassy coatings that can reduce erosion caused by high veloc-

ity gases and particulates.

Using space age technology

licensed from NASA, Wessex

Incorporated has created

Emisshield™ Coatings. These coatings have many

beneficial uses in the Refractory/Ceramic industry that

help save time and money. The technology that

NASA developed and Emisshield™ uses is based

upon the property of emissivity, but the Emisshirld™

products are unique and different than previous emis-

sive coatings.

Emissivity is defined as a refractory's ability to

absorb and subsequently release energy from its sur-

face to a furnace load. Emissivity is rated on a scale

of 0.0 (low) to 1.0 (high). While many refractories

have a high emissivity value at ambient temperatures,

most refractories will steadily lose their ability to rera-

diate that energy as the temperature increases, par-

ticularly in the infrared zone of the electromagnetic

spectrum where 90% of radiant energy is found. As

determined by NASA scientists, Emisshield™ not only

has an emissivity value of 0.85 to 0.9 at ambient tem-

perature, it maintains that level of emissivity as tem-

peratures increase above 3000°F. At these high tem-

peratures, refractories will only have an emissivity

value of 0.2 to 0.5 depending on their composition.

One of the benefits of Emisshield™ is the ability to

keep the substrate it is protecting cooler. By reradiat-

ing energy back to a cooler load, Emisshield™ pre-

vents heat transfer via conduction through the furnace

wall. This results in decreased energy usage and

lower operating costs. In addition, the cooler refracto-

ry tempera-

ture prolongs

the life of the

refractory

and reduces

maintenance

costs.

Refractory/Ceramic

EmisshieldTM is a trademark of WESSEX INCORPORATED

The equation describing the relationship between re-radiated energy and emissivity is shown in the nextcolumn:

Not to Scale

RadioWaves

Micro-waves

InfraredLight

VisibleLight

VisibleLight

UVRays

XRays

GammaRays

3km 30cm 3cm 0.7µm 0.4µm 0.3µm 0.03nm 0.003nm

If a refractory is not protected with an Emisshield™ coating, a large portion of thermal energy will conduct throughout the refractory.

Emisshield™ coated brick (right) in a tunnel kilnpreheat zone abut uncoated brick in firing zone.

Refractories/CeramicEmisshield™ ST coatings reduce the temperature exposure of refrac-

tories and ceramics by absorbing and re-radiating thermal energy to

the furnace load. They protect them from corrosion by acids, alkalies,

slags, and many molten metals, especially aluminum, and provide

increased abrasion resistance. The use of Emisshield™ coatings will

provide longer refractory life and reduced operating costs.

Emisshield™ was developed and

refined from NASA technology

used to protect the next generation

of Space Orbiters (X-33, X-34,

etc.) from the extreme tempertures

and abrasion of atmospheric reen-

try. Emisshield™ coatings may be applied to many

materials where heat and thermal degradation are fac-

tors.

Most substrates have a rela-

tively high emissivity value

at room temperature.

However when temperatures

increase, these values fall

dramatically. Emisshield™

not only has an emissivity value of 0.8 - 0.9 at

room temperature, it maintains that value at tem-

peratures up to 3000º F and beyond.

X-34

Emissivity - the absorption and release of energy rated on a scale of 0.0 - (Low) to 1.0 - (High)

Benefits of Emisshield™ Coatings

Metals (Patent Pending)Emisshield™ STG and M coatings can be applied to most ferrous and

non-ferrous alloys to protect them from high temperatures, oxidation,

corrosion, and abrasion. These coatings can withstand process tem-

peratures in excess of 3000ºF and can extend the use temperature of

metal components in high temperature industrial processes. The use of

Emisshield™ will increase thermal transfer to water tubes in boilers and

power generation units.

Harbison-Walker Refractories Company400 Fairway Drive Moon Township, PA 15108

Phone:(412) 375-6901 Fax: (412) 375-6783

Cat# HW 150 (5/04)

X-33

When a cooler furnace load or atmosphere is available,

an Emisshield™ coating on metal will absorb and emit

the heat to the load, preventing heat loss through the

metal and thermal oxidation of the substrate. Typical

applications for Emisshield™ STG and M formulations

include water-cooled electric furnace roofs, rotary kiln

nose ring castings, air

blasters and grates, ladle

retaining rings, kiln car

skirts, alloy injector

tubes, metal slag and

dross removal tools, and

exposed furnace structur-

al steel.

For applications where there is not a cooler load pres-

ent to absorb the emitted heat energy, Emisshield™ will

conduct the absorbed heat through to the metal sub-

strate which conducts the heat to the cold face of the

substrate. Applications where this property of

Emisshield™ is particularly effective include boiler

tubes and water wall tubes in power plants.

Emisshield™ will increase the conductive heat transfer

to these tubes, improving the uniformity of heating and

the efficiency of steam generation. Coating these tubes

with Emisshield™ also prevents scale buildup and

increases the service life of the tubes.

MetalSeveral Emisshield™

products have been

designed specifically for

metal substrates. These coatings will provide the same

high emissivity properties as the refractory/ceramic

compositions, but they also protect metal substrates

from oxidation and chemical attack. The Emisshield™

STG- and M-series of coatings for metal substrates will

adhere to most ferrous and non-ferrous alloys, raising

the effective service temperatures of all alloys. Many

metals and alloys have relatively high emissivities at

room temperature, however their emissivities decrease

markedly at higher temperatures. Metals that easily oxi-

dize, such as carbon steel and aluminum, are particular-

ly prone to severe emissivity degradation at high tem-

peratures.

EmisshieldTM is a trademark of WESSEX INCORPORATEDwww.hwr.com© 2004 Harbison-Walker Refractories Company

EmisshieldTM manufactured under license from NASA byWESSEX INCORPORATED.

EmisshieldTM is a trademark of WESSEX INCORPORATED.

1.0

0.8

0.6

0.4

0.2

0

Emis

sivt

y

0 500 1000 1500 2000 2500

Temperature F0

Steel Coated with Emisshield M-1TM

Cold Rolled Steel

Zirconia onInconnel

AluminumAlloy-A3003

WESSEX INCORPORATED

Emisshield™ coated steel kiln carskirts resist oxidation and warping

NASA Technology

EXCELERATE ABR PLUSDescription:

A one-component, 80% alumina, phosphate bonded

monolithic refractory that takes an air set. This product

can be rammed, hand packed, cast, or gunned.

Features and Benefits:

Maximum continuous service temperature of 2400OF

One component requires the addition of water only

Can be vib-cast, rammed, hand packed, gunned.

Cement free, yielding good performance in exposure to alkali/salt conditions

Set in four hours, no air cure required, can be heated immediately after set

Rapid dryout

Superior abrasion resistance

Suitable for manufacturing precast shapes

Typical Uses:

Non-ferrous ladles and crucibles

FCCU cyclones, air rings, feed lines, slide valves, regenerator return lines

CFB cyclones, down comers, return lines

Precast shapes

Air Heaters

Cement preheaters

Paper kiln firing hoods, dams, nose rings

Brass rotary and induction furnace repairs

Incinerators feed chutes, firing hoods

Boilers

Annealing furnace

Coke calciners

General repairs

Packaging:Shipped in 55lb bags

erate

TECHNICAL DATA

EXCELERATE ABR PLUS

Physical Properties; (Typical) VIBRATION CAST

English Units Si UnitsMaximum Service Temperature: 2400OF 1316OC

Approximate Amount of Water RequiredPer 55 lbs., U.S. Pints 3.5Per 24.95 kg., Liters 1.6

Dry Weight Required for Installing lb/tf3 kg/m3

172 2,754Bulk Density .

After Drying at 230OF (110OC) 179 2,866After Heating at 1500OF (816OC) 172 2,745

Modulus of Rupture lb/in2 MPaAfter Drying at 230OF (110OC) 1650 11.3After Heating at 1500OF (816OC) 2200 15.1

Crushing StrengthAfter Drying at 230OF (110OC) 13,400 91.8After Heating at 1500OF (816OC) 14,950 102.5

Apparent Porosity, %After Drying at 230OF (110OC) 16.5After Heating at 1500OF (816OC) 21.4

Abrasion Test -ASTM C-704 (cc loss)After Heating at 1500OF (816OC) 4.0

Permanent Linear ChangeAfter Drying at 230OF (110OC) NegligibleAfter Heating at 1500OF (816OC) -0.3

Chemical Analysis: (Approximate)(Calcined Basis)

Silica (SiO2) 8.4%Alumina (Al2O3) 77.9Titania (TiO2) 2.6Iron Oxide (Fe2O3) 1.0Lime 3(CaO) 2.9Magnesia 3(MgO) 1.9Alkalies (Na2O) 1.9Phosphorus Pentoxide (P2O5) 3.4

The data given above are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable.Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements, information,and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.





Phone: (412) 375-6600 Fax: (412) 375-6783www.hwr.com


The term extra-high alumina brick refers to refractory brickbased on high-purity alumina and having an overall alumi-na content of more than 80%. Those products with silicaadditions rely on the development of mullite as thebonding phase. Other products rely on corundum asthe bonding phase. Special versions of these products,members of the TUFLINE® Family, have enhancedresistance to thermal shock. All of these extra-high alumina brick possess excellent hot strength asmeasured by hot modulus of rupture, load test, and creeptest. The high purity formulation and low porosity of theDM (dense matrix) technology yields excellentresistance to corrosive slags, particularly those con-taining iron oxide.

The members of this family of extra-high alumina brickinclude:

GREENAL 80 P: This is a burned, phos-added 80%alumina brick based on tabular alumina. It offersenhanced resistance to alkali.

TUFLINE® 90: This is an economical, thermal shockresistant extra-high alumina brick. Its high purity matrixprovides excellent physical properties.

GREENAL 90: A 90% alumina, mullite bonded brick,with phosphorous pentoxide addition. This brick has highrefractoriness and excellent physical properties.

KORUNDAL XD®: This product has been the premier mullite-bonded 90% alumina brick since the1960’s. It continues to offer the best hot load strength inthe industry. KORUNDALXD is used in a wide rangeof applications includingferrous foundry, ceramickilns, chemical processingunits, and incinerators.

KORUNDAL XD® DM: A version of KORUNDALXD offering the proprietary dense matrix (DM) formulation.This product provides even lower porosity and better hotstrength than the standard product.

TUFLINE® 90 DM: A version of KORUNDAL XDoffering both the DM technology and enhanced resistanceto thermal shock.

TUFLINE® 95 DM: This is a high-purity, corundum-bonded product offering both the DM and thermalshock resistance technology. This product is primarilyused in chemical incinerators and quench chambers ofincinerators processing fluorine-containing waste.

TUFLINE® 98 DM: This product is the highest puritymember of our corundum-bonded TUFLINE Family. Itoffers excellent high temperature strength and thermalshock resistance along with low porosity. The very low sil-ica content makes it suitable for service in corrosiveenvironments such as to fluorine and hydrogen atmos-pheres.

H-W® CORUNDUM DM: A 99% alumina refracto-ry brick, which utilizes the DM technology to achieve,improved bonding and lower porosity. Also available with-out DM technology.

Cycl

es -

To

- Fa

ilure

40*

35

30

25

20

15

10

5

0

Prism Spalling Test 2,200˚F With Water Quench

KOR

UN

DAL

XD

® D

M (

5)

KOR

UN

DAL

XD

® (

10)

TUFL

INE™

98

DM

(26

)

TUFL

INE™

90

(35)

TUFL

INE™

95

DM

(40

+)

TUFL

INE™

90

DM

(40

+)

* Test concluded with maximum of 40 cycles.

Extra-HighAlumina Brick

GREENAL 80P TUFLINE® 90 GREENAL 90 KORUNDAL XD® KORUNDAL XD®DM

Bulk Density, pcf 177 182 189 186 195Apparent porosity, % 15.5 17.6 13.0 16.1 12.4

Modulus of Rupture, psiAt 70°F 2,990 1,730 4,000 2,330 3,840

At 2,700˚F 2,230 1,050 2,500 1,320 1,930

Chemical Analysis: % Approximate(Calcined Basis)

Silica (SiO2) 14.2 9.7 7.7 9.5 9.2

Alumina (Al2O3) 81.4 89.3 90.0 90.1 90.3

Titania (TiO2) 1.2 0.6 Trace Trace Trace

Iron Oxide (Fe2O3) 0.5 0.3 0.1 0.1 0.1

Lime (CaO) <0.1 0.1 0.1 0.1 0.1

Magnesia (MgO) <0.1 Trace Trace Trace 0.1

Alkalies (Na2O + K2O) 0.1 0.1 0.2 0.2 0.2

Phosphorus Pentoxide (P2O5) 2.6 – 1.9 – –


TUFLINE® TUFLINE® TUFLINE® H-W® H-W®

90 DM 95 DM 98 DM CORUNDUM DM CORUNDUMBulk Density, pcf 199 205 210 208 192

Apparent porosity, % 13.1 13.4 12.0 12.9 19.4

Modulus of Rupture, psiAt 70°F 2,210 2,040 2,760 4,500 2,800

At 2,700˚F 1,370 1,070 1,080 810 –

Chemical Analysis: % Approximate(Calcined Basis)

Silica (SiO2) 6.3 2.1 0.1 0.2 0.2

Alumina (Al2O3) 89.9 94.1 97.5 99.6 99.6

Titania (TiO2) Trace Trace 0.1 Trace Trace

Iron Oxide (Fe2O3) 0.1 0.1 0.1 0.1 0.1

Lime (CaO) 0.1 Trace Trace Trace Trace

Magnesia (MgO) Trace 0.2 0.2 Trace Trace

Other Oxides 3.5 3.4 1.9 – –

Alkalies (Na2O + K2O) 0.1 0.1 0.1 0.1 0.1



© 2004 Harbison-Walker Refractories Company. All Rights Reserved. Cat# HW 87R (5/04) 3C




High AluminaBrickHigh Alumina Brick (50 to 70% Al2O3)

The term high-alumina brick refers to refractory brick hav-ing an alumina content of 47.5% or higher. This descrip-tive title distinguishes them from brick made predomi-nantly of clay or other alumino-silicates which have alower alumina content. Brick of this class typically arebased on low alkali, bauxitic kaolins. The principlebond phase is mullite with some amount of free silicaand glass. The presence of certain impurities is crit-ical in determining refractoriness. Most naturallyoccurring minerals contain amounts of alkalies (soda,potash and lithia), iron oxide and titania. Alkalies can beparticularly harmful since they ultimately react with sili-ca to form a low melting glass when the brick are firedor reach high temperatures in service. The properties ofthese brick an be modified by the addition of othermaterials. Of particular interest is the addition ofandalusite which enhances the load bearing ability. Theminor addition of phosphoric acid can improve the alkaliresistance of these products.

KALA®: High-purity, 50% alumina refractory withlow porosity and exceptional resistance to alkaliattack and c reep unde r sus ta ined l oads .P r i m a r y applications include carbon-bakingflues, glass tank regenerators, and incinerators.

KALA® SR: A shock resistant version of KALA .Itpossesses a similar degree of alkali and creepresistance, but with much improved resistance to ther-mal cycling.

ARCO® 60: Is a 60% alumina firebrick exhibitinggood properties for use at intermediate temperatures.

UFALA®: This product manufactured from highpurity bauxitic kaolin displays low porosity, very goodhot strength, and good resistance to thermal shock andalkali attack. Major applications are chemical incinera-tors and lime sludge kilns.

NIKE 60 AR: A 60% alumina andalusite conteningbrick,with excellent creep and abrasion resistance.This product has good acceptance in CFB’s and incin-erators.

UFALA® XCR: A further improvement to UFALAwith additional andalusite. This product has been widelyused in applications requiring excellent creep resistancesuch as sodium silicate melter and regenerator crowns.

UFALA® UCR: A special version of this family uti-lizing a high-purity mullite bond. This productoffers excellent resistance to both thermal cycling andcreep. It’s principle use has been in carbon black reac-tor quench zones.

RESISTAL SM60C: This andalusite contening,phosphorus pentoxide added, 60% alumina brick showsvery good physical properties and corrosion resistance.

KRUZITE® -70: Is a dense, low porosity, 70% alu-mina brick with, good spalling resistance, hot loadstrength, and the ability to withstand attack by corro-sive slags.

VALOR® 70P: this burned 70% alumina brick utl-izes an addition of phosphoric acid. This redues poros-ity and enhances alkali resistance. It also offers excel-lent thermal shock resistance.

KALA® KALA® SR ARCO® 60 UFALA® NIKE 60 AR

Density, pcf 153 153 155 157 159

Modulus of Rupture, psi 2,060 1,500 1,600 2,640 2,400

Load Test, 25 psiAt 2,640°F 0.3 2.9 1.2 0.6 0.4Subsidence, %

Prism Spalling TestAt 2,200°F with Water 5-8 37-40 – 10-13 18-21Quench Cycles to Failure

Chemical Analysis %

Alumina (Al2O3) 50.0 51.6 61.0 58.1 63.0

Phosphorus Pentoxide (P2O5) – – – – –

Alkalies (Na2O + K2O) 0.1 0.4 0.7 0.1 0.2

High Alumina Brick

UFALA® XCR UFALA® UCR RESISTAL SM60C KRUZITE® -70 VALOR® P70

Density, pcf 159 160 155 165 166

Modulus of Rupture, psi 2,200 2,150 2,820 1,700 2,350

Load Test, 25 psiAt 2,640°F 0.2 0.0 – 1.0 –Subsidence, %

Prism Spalling TestAt 2,200°F with Water 18-21 37-40 – 19-22 23-36Quench Cycles to Failure

Chemical Analysis %

Alumina (Al2O3) 60.3 62.3 60.8 71.0 69.3

Phosphorus Pentoxide (P2O5) – – 2.0 – 1.6

Alkalies (Na2O + K2O) 0.3 0.4 0.3 0.6 0.2







INSWOOL® CG is an alumina silica blanket used inapplications up to 2000 0F. It is a high quality productthat can be used as back up insulation for most furnace applications.

Typical Applications

INSWOOL® HPFurnace Linings for Ceramic, Petrochemicaland Metals MarketsRemovable Insulating Blankets & PadsFurnace & Boiler RepairFurnace Door LiningsGlass Furnace Crown InsulationSoaking Pit SealsFlexible High Temperature Pipe Insulation Insulation for Steam & Gas TurbinesExpansion Joint SealsHigh Temperature Gasketing

INSWOOL® HTZReheat FurnacesSoaking Pit SealsRefractory and Ceramic KilnsBoiler LiningsGlass Furnace Crown InsulationRefractory KilnsFurnace Linings & Seals

INSWOOL® CGBackup for Fiber LiningsExpansion Joint MaterialInsulation Pads Furnace Packing Material

Blanket productsINSWOOL

INSWOOL® Ceramic Fiber Blankets are a complete

product line for applications temperatures up to 2600oF.

These products are produced from a spun ceramic fiber

which is needled into lightweight, flexible blankets.

INSWOOL® Ceramic Fiber Blankets provide excellent

handling strength, low thermal conductivity, low heat

storage and are resistant to thermal shock.

Lower Thermal ConductivityHeat losses are reduced at high temperatures

Lower Heat StorageFaster heat up and cool down for increased productivity

Reduces Fuel Consumption

Lowers Operating Costs

Thermal Shock Resistance

Lightweight

Allows for extreme change in temperatures

Longer furnace campaigns

Allows flexibility in firing cycles

Completely inorganic with no binders

INSWOOL® blanket products are easy to install. No special forming is required and plant personnel can beused to install the product. Furnace structures can bemade lighter and furnace components can be shop fabricated with fiber linings. Also, there is no curing ordry out time when using INSWOOL® ceramic fiber blankets. These linings can be fired to peak operatingtemperature immediately after installation.

INSWOOL® fiber blankets have excellent chemical stability and are unaffected by most chemicals. The onlyexceptions are hydrofluoric and phosphoric acid.

INSWOOL® HP is a high purity blanket that is madefrom a 50/50 blend of alumina and silica that has superior tensile strength and handling capabilities. This product can be used in applications up to 2300 0Fand is available in 4, 6 and 8 pound densities.

INSWOOL® HTZ is a blanket used in higher temperatureapplications up to 2600 0F with low shrinkage characteristics. The product is made from a blend ofalumina, silica and zirconia.

®

Typical Physical PropertiesINSWOOL® HP INSWOOL® HTZ INSWOOL® CG

Color: white white whiteMaximum Recommended Temperture:Intermittent Use, oF: 2300 2600 2000Continous Use, oF: 2150 2450 1800Melting Point, oF: 3200 3200 2750Fiber Diameter, microns: 3 3 3 - 4.5Average Fiber Length, inches: 3 3 3Tensile Strength - 8lb/ft2, 1 in.:

Machine Direction, lb./in2: 10 10 8Cross Direction, lb./in2: 6 6 5

Chemical Analysis: (approximate), %(Calcined Basis)

Alumina (Al2O3) 45.0 36.0 44.0

Silica (SiO2) 54.3 48.0 54.0

Zirconia (ZrO2) -- 15.4 --

Iron Oxide (Fe2O3) 0.2 0.1 <1.2

Lime (CaO3) 0.1 0.1 --

Titania (TiO2 0.1 0.1 --

Magnesia (MgO)2 0.1 0.1 --

Alkalies (Na2O+K2O) 0.2 0.2 <0.5

Typical Thermal Conductivity, BTU-in/ hr ft2 0F: INSWOOL® HP and INSWOOL® HTZ BLANKET

600oF 800oF 1000oF 1200oF 1400oF 1600oFBlanket Density

4# 0.63 0.85 1.16 1.4 1.8 2.2

6# 0.56 0.73 0.97 1.2 1.55 1.85

8# 0.43 0.7 0.78 1.0 1.2 1.43





TECHNICAL DATA

The data given above are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable.Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements, information, anddata given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.

Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use isfree of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.

Fiber MODULESINSWOOL Ceramic

INSWOOL® Ceramic Fiber Modules are aproduct line designed for full thickness linings in furnace applications. The CSW(Center Stud Weld) and FQW (FoldedQuick Weld) modules are made from highquality spun INSWOOL® HP and HTZblanket. Spun INSWOOL® blanket hassuperior handling characteristic andstrength characteristics. Both attachmentsystems provide for quick installation andless downtime for the installer.

Standard sizes for both types of modulesare 12" long x 12" wide. Special sizemodules are also available upon request.Various densities are available; 9.3# isstandard. 8#, 10#, 10.7# and 12# densities are available. The modules arecompressed to the specific density's toprevent shrinkage for longer module lifeand durability.

CSW Modules (Center Stud Weld)The CSW Module system is a moduleusing a 304 stainless steel channel andtwo rods that runs through the blanket.This module is installed by using a pre-positioned stud pattern. This is done bywelding a 304 stainless steel 3/8" stud tothe furnace wall. Each CSW module isthen attached over the stud and tightenedwith a bolt.

CSW modules linings can be installed in parquet or soldier course pattern usingbatten strips. Dual studs and holesattachments can be added for larger sizeCSW modules upon request.

®

FQW Modules (Folded Quick Weld)The FQW Module system is a folded blanket module that is made into 2 halves with a Quick Weld attachment. This new design provides for no blind welds in the lining design.The advantage to the FQW module is the speedof installation. It requires no stud pattern or layout. Using a quick weld stud gun, simplyplace the module on the wall and pull the trigger. FQW modules can be installed in a parquet or soldier course pattern using battenstrips.

CSW Modules

Hot Face Cold Face

Hot Face Cold Face

FQW Modules





Applications

· Stress Relieving Furnaces

· Annealing Furnaces

· Car Bottom Furnaces

· Process Heaters

· Refinery Heaters

· Reheat Furnaces

· Furnace Linings for Kilns & Boilers

· Soaking Pit Covers

· Pre- heat Ladles Covers

· Forge Furnaces

Specifications

Blanket Options· HP - 15000F - 21500F· HTZ - > 21500F

Thickness · 4" -12" Thick

Sizes· CSW - 12" x 12", 12" x 24"· FQW - 12" x 12"· Sidewalls only 24" x 24"· Special sizes available upon request

Density· 8#, 9.3#, 10#, 10.7# & 12#

Hardware · 304 SS Standard Base and Rods· Special Hardware available upon request

o 310SS, 316SS, 330SS and Inconel - add 2-3 weeks delivery for special hardware

Furnace Design Perimeters

PARQUETParquet Design - For applications of 20000 F and less

WELD STUD ASSEMBLY - SOLDIERSoldier Course Design- For applications of20000 F to 21500F use one batten strip -over 21500F use a double batten strip

3’ - 0”

6” 1’ - 0” 1’ - 0” 6”

3’-

2½”

6”1’

- 1¾

”1’

- 1¾

”6”

FoldOrientation

1¼” NOM. GAP.ONE FOLD1” 8PCF BLANKET

3’ - 0”

3’-

0”

FoldOrientation

INSWOOL® Ceramic Fiber Modules

Applications 2300LW 2300HD 2600 3000

Full Thickness Furnace Linings x x x

Board over Blanket Linings x x x x

Refractory Backup Insulation x x x x

Rigid High Temperature Gaskets x x

Hot Face Linings for Ceramic Kilns & Petrochemical Furnaces x x

Glass Tank Side & End Wall Insulation x x x x

Insulation with High Velocities x x x x

Hot Gas Duct Linings x x x x

Expansion Joint Material x x

Heat Shields for Personnel Protection x x x x

Pouring Forms for Castable x

Combustion Chambers x x x x

High Temperatures Dryers x x x x

Industrial Heat Shields x x x x

Flue & Chimney Linings / Kilns & Furnaces x x x x

High Temperature Muffles x x x

Heat Treating Furnaces x

Ceramic Fiber BoardsINSBOARD

INSBOARD® is a family of vacuum-formed,ceramic fiber boards with excellent insulatingproperties and high mechanical strength. Theyoffer good thermal stability. It is manufacturedfrom bulk ceramic fiber and special binders.This yields a strong, dense product that haslow thermal conductivity and excellent resistance to thermal shock and chemicalattack.

INSBOARD® is an excellent choice for applications with high velocity, vibration ormechanical stress. The products possesssuperior strength and good handling characteristics. INSBOARD® is lightweightand easy to install. These products are rigidand self supporting which makes installationsimple. INSBOARD® products can also bemachined or cut into shapes.

INSBOARD® comes in standard size of 36"x 48" with thicknesses of 1/4", 1/2", 1", 11/2"and 2". The product line has three typesof products for applications that rangefrom 2300oF to 3000oF.

®

Physical Properties INSBOARD®

2300 LW 2300 HD 2600 3000

Density, lbs/ft2: 14-18 26 18 12

Continuous Use Limit, oF: 2300 2300 2600 3000

Recommended Use Limit, oF: 2100 2100 2400 2700

Melting Point, OF: 3200 3200 3200 3200

Modulus of Rupture, psi: 75 200 120 70

Compressive Strength, psi:

10% Deformation: 20 50 30 18

25% Deformation: 65 110 50 30

Hardness, lbs.:

10% Deformation: 18 50 30 15

25% Deformation: 40 120 60 40

Shrinkage (24hrs.), %:

After 2000OF 2.4 2.3 – –

After 2200OF 3.1 2.8 2.8 –

After 2400OF – – 2.9 1.5

After 2600OF – – 3.1 1.9

After 2800OF – – – 2.6

After 3000OF – – – 3.4

Thermal Conductivity, Btu-in/hr-ft2 - oF:

400oF 0.3 0.4 – –

800oF 0.6 0.6 0.6 0.6

1200oF 0.8 0.8 0.8 0.9

1600oF 1.0 1.0 1.0 1.4

2000oF 1.2 1.2 1.2 1.9

2400oF – – – 2.4





TECHNICAL DATA



Utility PaperINSWOOL

INSWOOL® Utility Paper is processed fromunwashed spun, high purity alumina-silicafibers formed into a highly flexible sheet. It is recommended for continuous use at temperatures up to 2300OF in applicationswhere insulating efficiency is less critical.INSWOOL® Utility Paper is designed for useprimarily in applications where thermal stabilityand high temperature protection up to 2300OFare most important. It is avaiable in twogrades, UG-F and UG-J

INSWOOL® Utility Paper contains an organicbinder to provide increased handling strengthat room temperature. It possesses excellentchemical stability and resists attack from corrosive agents. Exceptions are hydrofluoricand phosphoric acids and concentrated alkalis.Because of its high-purity chemistry,INSWOOL® Utility Paper resists both oxidationand reduction. If it becomes wet due to water,steam, or oil, its thermal and physical properties with return upon drying.

UG-F UG-JTensile Strength - gms.in.

Machine Direction: 3500 5800

Cross Direction: 2400 5000

Mullen Burst - lbs./in2: 8 22

Thickness Specifications

Nominal: 1/16" 1/8"

Features

Easy to Cut, Wrap or Form

Low Thermal Conductivity

Thermal Shock Resistant

Temperature Stability

Resilient

Lightweight

Low Heat Storage

Good Dielectric Strength

Excellent Corrosion Resistance

High Heat Reflectance

Applications

Ware Separator

Ceramic and Glass

Metal Clad Brick

Glass Tank Backup

Kiln Car Deck Covering

Petrochemical

Transfer Line Protection

Welding & Brazing Protection

Steel & Nonferrous

Investment Casting Mold Wrap

Ladle Refractory Backup

Backup Linings for Metal Troughs

Hot Top Linings

Coke Oven Door Seals

®

Typical Physical PropertiesINSWOOL® Utility Paper

Melting Point, OF: 3200

Maximum Use Temperature, OF: 2300


Alumina (Al2O3) 47.0

Silica (SiO2) 52.6

Alkalies (Na2O) 0.18

Iron Oxide (Fe2O3) 0.03

Others2 0.17

Loss on Ignition, LOI: 8%

Density lbs/ft2: 6-9

Dielectric Strength: 50

Thermal Conductivity, Btu-in/hr-ft2 - OF:Mean Temperature OF

500 0.47

800 0.71

1300 1.19

1600 1.67





TECHNICAL DATA



2300 PaperINSWOOL

INSWOOL® 2300 Paper is processed fromwashed, spun, high purity fibers formed intohighly flexible sheet. It is recommended forcontinuous use at temperatures up to 2300OFin applications where insulating efficiency andhigh strength are important. It is available inthree grades, A, F, and J.

Because it is processed from washed fiber,INSWOOL® 2300 Paper is clean, has low shotcontent and offers low thermal conductivity.It’s highly uniform structure assures homogeneous thermal conductivity throughout,and its high tensile strength makes it ideal as agasket, seal or spacer material.

INSWOOL® 2300 Paper contains an organicbinder to provide increased handling strengthat room temperature. It possesses excellentchemical stability and resists attack from mostcorrosive agents. Exceptions are hydrofluoricand phosphoric acids and concentrated alkalis.Because of its high purity chemistry,INSWOOL® 2300 Paper resists both oxidationand reduction. If it becomes wet due to water,steam or oil, its thermal and physical properties will return upon drying.

INSWOOL® 2300 PaperA F J

Tensile Strength - gms.in.

Machine Direction 2400 3200 6000

Cross Direction 2200 2700 5200

Mullen Burst - lbs./in2 7 10 24

Thickness SpecificationsNominal 1/32" 1/16" 1/8"

Features

Easy to Cut, Wrap or Form

Low Thermal Conductivity

Thermal Shock Resistant

Temperature Stability

Resilient

Lightweight

Low Heat Storage

Good Dielectric Strength

Excellent Corrosion Resistance

High Heat Reflectance

Applications

Ware Separator

Ceramic and Glass

Metal Clad Brick

Glass Tank Backup

Kiln Car Deck Covering

Petrochemical

Transfer Line Protection

Welding & Brazing Protection

Steel & Nonferrous

Investment Casting Mold Wrap

Ladle Refractory Backup

Backup Linings for Metal Troughs

Hot Top Linings

Coke Oven Door Seals

®

Typical Physical PropertiesINSWOOL® 2300 Paper

Melting Point, OF: 3200

Maximum Use Temperature, OF: 2300


Alumina (Al2O3) 47.0Silica (SiO2) 52.6

Alkalies (Na2O) 0.18


Others2 0.17

Loss on Ignition, LOI: 8%

Density lbs/ft2: 6-9

Dielectric Strength: 50

Thermal Conductivity, Btu-in/hr-ft2 - OF:Mean Temperature OF

500 0.39

800 0.55

1300 0.87

1600 1.05





TECHNICAL DATA



INSWOOLRopes & Braids

®

INSWOOL® Ropes and BraidsH-W Refractories provides a family of ropes and braids for industrial use in temperatures up to

2300°F (1260°C). Typical applications for these products include gasketing, packing and sealingin and around high-temperature heating equipment. Produced from ceramic fibers, these prod-ucts exhibit excellent chemical stability, resisting attack from most corrosive agents. Exceptionsare hydrofluoric and phosphoric acids and concentrated alkalies. These fiber ropes and braidsalso resist oxidation and reduction. If wet by water or steam, thermal properties are completelyrestored upon drying. No water of hydration is present.

In choosing the most appropriate product for a particular application, the following productdescriptions should be considered:

3-Ply Twisted RopeProduced by twisting 3-plys of ceramic fiber wicking, this product is relatively soft and lower in

density than other ropes or braids. 3-ply Twisted Rope is the most economical choice. This prod-uct is also available with an inconel insert which drastically increases resistance to mechanicalabuse.

High Density RopeHigh Density Rope is made from many strands of ceramic fiber yarn formed into three plys and

then twisted, resulting in a product that is higher in density and thus more durable than 3-plyTwisted Rope.

Round Braid and Square BraidThe highest density of all our rope offerings, the ceramic fiber is braided to provide maximum

resistance to mechanical abuse. Aside from its superior strength, round and square braids alsoexhibit minimal unravelling when cut.

3-PlyTwisted Rope

High DensityRope

SquareBraid

Round Braid

Diameter of Feet Per Approximate Yield Section (Inches) Roll (Feet/Lb.)

1/4 2250 110

1/4 900 110

3/8 1300 45

3/8 500 45

1/2 725 30

1/2 300 30

5/8 525 18.6

3/4 375 16.2

7/8 275 11.8

1 225 10.3

1-1/4 175 6.5

1-1/2 125 4.3

2 50 2.4

Diameter of Feet Per Approximate YieldSection (Inches) Roll (Feet/Lb.)

1/4 500 101.3

3/8 300 51.3

1/2 200 28.6

5/8 200 21.3

3/4 100 15.0

7/8 100 10.6

1 50 8.8

1-1/4 75 6.2

1-1/2 50 4.4

2 50 2.0


1/4 1700 91.9

1/4 700 91.9

3/8 900 42.5

3/8 400 42.5

1/2 500 23.5

1/2 200 23.5

5/8 350 11.2

3/4 250 9.1

7/8 175 7.1

1 125 5.1

1-1/4 100 3.5

1-1/2 75 2.4

2 50 1.5


1/4 1075 58.1

1/4 450 58.1

3/8 575 26.3

3/8 250 26.3

1/2 325 17.8

1/2 150 17.8

5/8 250 9.5

3/4 175 7.3

7/8 125 5.7

1 100 4.1

1-1/4 75 2.8

1-1/2 50 2.0

2 35 1.3

INSWOOL® ROPES AND BRAIDSProduct Availabilty

Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such useis free of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.

Round Braid Square Braid

3-Ply Twisted Rope High Density Twisted Rope




Phone: (412) 375-6600 w Fax: (412) 375-6783

INSWOOL® PUMPABLE 23000F Ceramic Fiber Pumpable Material

High temperature caulking putty

Now available in standard 101/2 oz. and 29 oz.caulking tubein addition to standard 5 gallon buckets

Ready to use

Easy to apply

INSWOOL® PUMPABLE is a 23000Fceramic fiber, putty-like consistency material and was especially formulated forpumping with special equipment. It is nowavailable in 101/2 oz. caulking tube (12 percase) and 29 oz. caulking tubes (6 percase) and are available through our Plantor Distribution Centers. It can be used tofill hot spots behind existing hot face liningor can be used to fill small voids and thincracks.

INSWOOL® PUMPABLE is a lightweightmaterial with very low thermal conductivity.It is an excellent thermal insulator. It driesto a firm, but compressible board-like consistency. It is suitable for expansionjoints, and for filling contraction cracks.

INSWOOL® PUMPABLE has excellentthermal shock resistance, and can generally be dried or put into heat containment service without preheating.

INSWOOLPUMPABLE

®

Maximum temperature ratings: 23000F

Wet Density (lbs./ft.3): 68

Dried Density (lbs./ft.3): 27

Permanent Linear Change:

After heating to 15000F + 0.1%

After heating to 20000F -3.1%

Chemical Analysis - Calcined basis

Silica SiO2 60.0%

Alumina Al2O3 31.6%

Iron Oxides Fe2O3 0.2%

Lime CaO 7.3%

Alkalies Na2O + K2O 0.9%

Physical Properties

The data given above are based on averages of tests results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable.Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements, information,and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.


© 2002 Harbison-Walker Refractories Company. All rights reserved. Cat. # HW106 (8/02) 3C

Harbison-Walker Refractories Company400 Fairway DriveMoon Township, PA 15108Phone: (412) 375-6600Fax: (412) 375-6783

For Industrial Sales:

Exclusively serving the iron and steelmaking industries…

North American Refractories Company (NARCO) is a leadingsupplier of refractory solutions to the iron and steel industries. The compa-ny makes high-performance products for BOFs, EAFs, LMFs, ladles, finish-ing, alternative ironmaking, casthouses, blast furnaces, and flow controlapplications. In addition to providing complete technical support services,NARCO also can design and implement a turnkey refractory managementprogram to meet your facility’s specialized requirements.

Exclusively serving the non-ferrous metals, ferrous foundry, glass, hydro-carbon, incineration, minerals processing and other industries…

Harbison-Walker Refractories Company (H-W) provides high-per-formance refractory solutions to all non-steel-related industries. In additionto its own outstanding line of products, many of which have become indus-try standards, H-W is recognized worldwide for its technical support andexpertise. Founded in 1875, the company is North America’s oldest refrac-tory maker.

Manufacturing products exclusively for NARCO and Harbison-Walker…

A.P. Green Refractories (APG) makes products for the iron and steel,aluminum, cement, copper, glass, and hydrocarbon and minerals processingindustries. The company also has one of the world’s top capabilities for cus-tomized pre-cast shapes, along with a full line of insulating ceramic fibers.

Products from all these companies are available through:

MAGSHOT® GUN MIXMagnesite-based chrome-free gun mix, proven togive superior life in recovery boiler systems in pulpand paper mills.

• Superior Smelt Resistance• Chrome-Free Composition• Good Thermal Conductivity• Ease of Installation• Proven Track Record

MAGSHOT was developed to help meet the environmental and performance needs of thepulp and paper industry. Its chrome-free compositioneliminates concerns about disposal of possiblyhazardous chrome-containing refractory waste.As for performance, laboratory tests have shownthat this unique dicalcium si l icate bonded magnesite product provides an exceptional levelof chemical resistance to molten smelt.

A long record of success in numerous recoveryboiler systems throughout the industry testifies tothe durability of MAGSHOT where it matters most –under demanding field conditions.

Superior Smelt Resistance Demonstrated inDrip Slag TestsSamples After Drip Test:

MAGSHOT installed in the lower section of a recovery boiler.

Ease of InstallationEase of installation makes MAGSHOT® the productof choice for quick-turnaround repairs. It can begunned, hand-packed, or cast. For larger castinstallations this product is available asMAGSHOT® CASTABLE. Both products require mini-mal curing time – heat-up (100˚F/hr.) can begintwo hours after installation. Other features include:

• Low dust and rebounds

• Quick dry-out schedule

• Up to one year shelf life

MAGSHOTRemarks: No Erosion, NoAlteration, No Build-up

Typical 80% Alumina-Phosphate Bonded PlasticRemarks: Eroded, Cracked,

Bloated Slag Build-up

MAGSHOT®

MAGSHOT® MAGSHOT® CASTABLE

MAGSHOTTECHNICAL DATA

Physical Properties; (Typical)

Maximum Service Temperature, ˚F 2700°F 2700°FBulk Density, pcf

After 230°F 160 179Modulus of Rupture, psi

After 230°F 1,690 1,510After 1500°F 1,560 1,480

Crushing Strength, psi

After 230°F 5,870 10,100After 1500°F 5,930 7,000

Chemical Analysis, % Approximate(Calcined Basis)

Silica (SiO2) 7.2 5.8Alumina (Al2O3) 1.9 1.7Titania (TiO2) 0.1 0.1Iron Oxide (Fe2O3) 5.8 10.0Lime (CaO) 6.1 9.5Magnesia (MgO) 76.7 68.7Alkalies (Na2O + K2O) 0.7 1.2Phosphorous Pentoxide (P2O5) 1.5 2.9

The data given above are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applica-ble. Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements,information, and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind,expressed or implied.

Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or thatsuch use is free of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.





KX-99®-BF KX-99® CLIPPER® DP ALAMO®

StacksBoiler LiningsAir HeatersCharcoal FurnacesHot Gas DuctsRotary KilnsZinc Galvanizing FurnacesLow Temp IncineratorsBlast Furnace StovesBlast Furnace SidewallsCheckersOil Heater Division WallsOil Heater FloorsLow Temp Metal LadlesFloors Around FurnacesHeat ExchangersCement Preheaters

Super-Duty Fireclay Brick

KX-99®-BF is our high fired dry-pressed coarse grain super-duty fireclay brick. It exhibits very goodthermal shock resistance for this type brick. KX-99®-BF provides very high strength and excellentresistance to attack by alkalies and carbon monoxide. KX-99®-BF is available in a large number ofsizes and shapes.

KX-99® is our high fired dry-pressed super-duty fireclay brick. It is similar toKX-99®-BF but without the coarse grains. KX-99® offers similar strength andresistance to alkalies and carbon monoxide as does KX-99®-BF. It is availablein a large number of sizes and shapes.

CLIPPER® DP is our regular fired premium dry-pressed super-duty fireclaybrick. It offers very good resistance to thermal shock and alkali attack. CLIPPER® DP also provides excellent strength to better resist conditions suchas impact from process feed. CLIPPER® DP is available in a large number ofsizes and shapes.

ALAMO® is our regular fired conventionally dry-pressed super-duty fireclaybrick. It is intended for general service conditions. ALAMO® is available instandard 9 x 4.5 x 2.5" and 3" sizes.

Typical Applications





Physical properties KX-99®-BF KX-99® CLIPPER® DP ALAMO®

Type High Fired High Fired Regular Fired Regular FiredCoarse

Aggregate

Bulk Density, lbs/ft3: 142 143 142 141

g/cm3: 2.28 2.29 2.27 2.26

Apparent Porosity, %: 12.2 12.7 15.3 16.1

Modulus of Rupture, lbs/in2: 1950 2050 1350 1000

Cold Crushing Strength, lbs/in2: 8000 8500 6300 4000

Pyrometric Cone Equivalent

Orton Standard Cones: 33-34 33-34 33-34 33-34

Permanent Linear Change

After 2910oF, %: -0.3 -0.4 -0.3 +0.5

Hot Load, 2640oF, % subsidence: 0.7 0.6 1.3 1.7

Chemistry Analysis, Approximate

(Calcined Basis), %:

Alumina Al2O3 42.2 42.2 42.2 42.6

Silica Si02 52.6 52.6 52.6 52.3

Iron Oxide Fe2O3 1.4 1.4 1.4 1.4

Titania TiO2 2.3 2.3 2.3 2.2

Lime 2CaO 0.2 0.2 0.2 0.3

Magnesia 2MgO 0.3 0.3 0.3 0.3

Alkalies Na2O+K2O 0.9 0.9 0.9 0.9

H-W Super-Duty Fireclay Brick

The data given above are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable. Variationfrom the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and data givenherein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.


Shapes for High Performace

VIB-TECH shapes from Harbison-Walkerprovide our customers with complex shapesmade from the same proven compositionsfound in Harbison-Walker’s high-performacerefractory bricks.

PRODUCTS

• KORUNDAL® XD/C

• TUFLINE® 90 DM/C



• TUFLINE® DM/C AL

• H-W® CORUNDUM DM/C

• RUBY® SR/C

• AUREX® 75 SR/C

• AUREX® 75/C

• VISIL/C®

• HARBIDE® /C

Engineered Complex Shapes

• Thixotropic-Formed Shapes

• High Fired/Ceramic Bond

• Brick-Like Properties

• Improved Properties

– Density

– Porosity

– Strength

• Execellent Thermal ShockResistant

VIB-TECH Engineered Shapes

The Ultimate Combination ofProducts and Processes

When compared to traditional shape formingtechniques, such as air ramming or cement-bonded precast shapes, Harbison-Walker’s VIB-TECH family of fired ceramic-bondedshapes yield dramatic improvement in density,hot strength and thermal shock resistance. They can be manufactured in intricate shapes.

VIB-TECH ProductsDensity Porosity MOR CCS Major

Products* pcf % psi psi Chemistry

AUREX® 75/C 258 14.4 3,850 12,82077.3% Cr2O3

22.1% Al2O3

AUREX® 75 SR/C` 262 13.5 1,560 8,84073.4 Cr2O3

20.1 Al2O3

H-W® CORUNDUM DM/C 198 16.9 1,160 - 99.5% Al2O3

HARBIDE® /C 157 17.0 4,080 16,400 82.7% SIC2

KORUNDAL® XD/C 188 14.5 4,140 12,700 90.1% Al2O3

RUBY®SR/C 204 15.5 1,380 12,90083.1% Al2O3

11.1% Cr2O3

TUFLINE® 90 DM/C 197 14.6 1,710 11,120 89.3%Al2O3

TUFLINE® 95 DM/C 200 15.8 1,720 8,590 94.2% Al2O3

TUFLINE® 98 DM/C 203 16.0 - - 97.6% Al2O3

TUFLINE® DM/C AL 211 14.2 2,250 - 91.0% Al2O3

VISIL/C® 118 14.7 620 5,520 99.5% SiC

VIB-TECH Family of Proven Products





Three current commercial methods of special shape manufacture are shown in the table below.Only the VIB-TECH shapes from Harbison-Walker combine outstanding hot strenth with excellentthermal shock resistance.

Harbison-Walker currently manufactures VIB-TECH shapes in the following high performance brickcompostions:

Note: Data subject to reasonable variation and should not be used for specification purposes.Consult your local sales representative for additional information.

TUFLINE® 90 DM/C vs.CONVENTIONAL PRODUCTS90%AL2O3 90% AL2O3

Properties TUFLINE 90 DM/C* AIR RAMMED SHAPE** ULTRA-LOW CASTABLE**

Heat Treatment Fired (ceramic bond) Fired (ceramic bond) Dried

Density (pcf) 195 186 184

Porosity (%) 14.5 16-18 15-17

Hot MOR @ 2700OF (psi) 1,500 1,000-1,200 600-800

Shock Resistance Excellent Fair Fair to Good

Shape Complexlly Excellent Poor to Fair Fair to Good

*Data subject to reasonable deviation and should not be used for specification purposes.**Typical data meant to represent comparable air rammed and cast product.

Melting/Holding FurnaceALUMINUM


Harbison-Walker Refractories Company400 Fairway DriveMoon Township, PA 15108Phone: 1-800-377-4497Fax: (412) 375-6826


Exclusively serving the glass, iron and steelmaking industries…

North American Refractories Company (NARCO) is a leadingsupplier of refractory solutions to the iron and steel industries. The compa-ny makes high-performance products for BOFs, EAFs, LMFs, ladles, finish-ing, alternative ironmaking, casthouses, and blast furnaces. In addition to pro-viding complete technical support services, NARCO also can design andimplement a turnkey refractory management program to meet your facility’sspecialized requirements.

Exclusively serving the non-ferrous metals, ferrous foundry, hydrocarbon,incineration, minerals processing and other industries…





Many modern aluminum meltingand holding furnaces are continu-ously being pushed harder andharder to produce more metal inshorter time. In many cases, thefurnaces are being pushed to pro-duce a variety of different alu-minum alloys. These operatingconditions have created ademand for refractories that canwithstand the more severe envi-ronment.

Some of the destructive condi-tions that these modern operatingpractices generate include:

TemperatureTemperature is generally the simplest methodof increasing throughput. While higher temper-atures do decrease melt times, they can causeproblems. Higher temperatures increase therates of reaction between the metal and therefractories, leading to corundum formation andaccelerated wear.

FluxingFluxing practices, while necessary for efficientmetal melting, are damaging to refractories.Alkali based fluxes can have the same effect onalumino-silicate refractories as they have onaluminum metal. Chlorine containing fluxescan degrade the bond system of cement-bond-ed refractory castables.

ChargingScrap quality and charging practice can also bedetrimental to refractory performance. Paintedor other contaminated scrap can introducecomponents that are highly reactive with refrac-tory linings. The size and charging method can

be abusive too. Pushing large scrap into thefurnace causes abrasion on the sill, and resultsin high mechanical impact on the ramp andhearth.

AlloysVarious alloying components can degraderefractories. Silicon alloys tend to be highlyfluid and can penetrate further into furnace lin-ings. Magnesium alloys are prone to thermitingwhich produces extremely high temperatures,and can lead to corundum formation. Zincalloys also tend to promote corundum forma-tion.

CleaningIn all cases, it is very important to employ thor-ough furnace cleaning practices. Good furnacecleaning can help minimize corundum growth,and refractory wear. Efficient cleaning can alsohelp to improve heat transfer to the bath, reduc-ing thermal gradients and melt losses.

The data given in this flyer are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable.Variation from the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information,and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.


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20.

1-

-

Na2

O &

K2 O

0.7

0.4

0.2

0.1

0.2

0.3

0.2

0.2

-0.

30.

10.

80.

10.

20.

1

ZrO

2-

--

3.2

--

--

--

--

--

57.4

SiC

--

--

--

--

--

--

-59

.0-

Oth

er1.

0-

6.2

--

-3.

5-

5.0

3.7

3.1

3.0

1.0

--

ARMORKAST65ALNARCOTUFFTM SUPER AL

VERSAFLOW® 65/ALPLUS®

GREENKLEEN-60 PLUS

ARMORKAST80ALADTECH®

ULTRA-EXPRESS 70 AL ALSTOP GREFCON®80 A

VERSAFLOW® XPUR/ALADTECH®

ARMORKASTXPUR/AL

ADTECH®

GREENLITE®-45-LAL

VERSAFLOW® THERMAX®ALADTECH®


NARCON ZRAL

H-W®ES CASTABLE C AL

VERSAFLOW® 45/ALADTECH®

FIRECLAY CASTABLES

60-65% ALUMINA CASTABLES

70-80% ALUMINA CASTABLES

90+% ALUMINA CASTABLES

MISCELLANEOUS CASTABLES

Harbison-Walker Castables for Aluminum Melting/Holding Furnaces

VERSAFLOW® 45/AL ADTECH®

A 45% alumina, pumpable, low-cement castable withimproved strength versus conventional castables.

H-W® ES CASTABLE C ALAn industry standard for aluminum furnace safety lin-ings, H-W® ES CASTABLE C AL is a coarse aggregatecastable with excellent impact and thermal shock resistance.

ARMORKAST 65ALARMORKAST 65AL is a very high purity low cementcastable. Its unique bonding matrix provides exception-ally high strength and ultimate corrosion resistance.

VERSAFLOW® 65/AL PLUS®

A 65% alumina, low cement castable with high strengthand versatile installation characteristics. VERSAFLOW®

65/AL C ADTECH® is the coarse aggregate containingversion. Coarse aggregates provide improved impactand thermal shock resistance.

NARCOTUFFTM SUPER ALWith a minor zircon addition, NARCOTUFFTM SUPERAL is an excellent choice for the lower sidewall or bellyband in a furnace with slight corundum growth.

GREENKLEEN-60 PLUSAmong the most popular maintenance materials avail-able, GREENKLEEN-60 PLUS is a 60% alumina,andalusite containing, low cement castable. It has highstrength and excellent aluminum resistance.

ARMORKAST 80AL ADTECH®

This high purity, pumpable, 80% alumina castable is builtfor corrosion resistance. It has exceptional strength andaluminum resistance. ARMORKAST 80AL is designedfor the most severe aluminum contact applications.

ALSTOP GREFCON® 80 AAn industry standard for more than 15 years, ALSTOPGREFCON® 80A is a high strength, high corrosion resistance, 80% alumina low cement castable.

ULTRA-EXPRESS 70 ALAn ultra-low cement, 70% alumina castable designedwith enhanced flow, and self-leveling characteristics. ULTRA-EXPRESS 70 AL is very strong and is ideal forpumping over long distances and for casting into intri-cate form patterns.

VERSAFLOW® XPUR/AL ADTECH®

A tabular alumina based, silica-free, pumpable, lowcement castable. VERSAFLOW® XPUR/AL ADTECH®

has excellent strength and non-wetting characteristics.Because it is silica free, it is an excellent choice for highcorundum belly bands.

ARMORKAST XPUR/AL ADTECH®

This tabular alumina based castable is also silica-free,and is designed to be a more cost effective corundumfighter. It also shows very high strength and excellentaluminum resistance.

GREENLITE®-45-L ALThis lightweight castable has a very high strength toweight ratio. It is ideally suited for insulating sub-hearths, and crucibles.

VERSAFLOW® THERMAX® AL ADTECH®

A vitreous silica based low cement castable. It hasexceptional thermal shock and abrasion resistance. VERSAFLOW® THERMAX® AL ADTECH® is an excel-lent choice for troughs.


60% silicon carbide castable with very high strengthand abrasion resistance. THOR 60 ABR ADTECH® is aproven problem solver in hearths, ramps and sills.

NARCON ZRALA 60% zirconia castable with excellent corundum resist-ance. Zoning belly bands with NARCON ZRAL hasproven to be very successful in furnaces prone to corundum formation.

Typical ApplicationsSub-Hearth

Hearth

Lower Sidewall

Belly Band

Tap Blocks

Trough

Crucibles

Aluminum Resistance Good Good Excellent Excellent Good Good Excellent Excellent Good Excellent Excellent Good Good Excellent Excellent

Corundum Resistance Fair Fair Excellent Excellent Good Good Excellent Good Good Excellent Excellent Fair Poor Good Excellent

Density (lb/ft3)

After drying at 230 °F 144 136 163 162 161 161 171 169 176 193 196 74 129 165 214

Modulus of Rupture (psi)

After drying at 230 °F 1520 970 1900 1800 1790 2350 1850 1500 1600 1680 1500 500 1660 2400 2100

After heating at 1500 °F 1770 380 2300 2200 2800 2000 2200 2800 1600 1330 - 320 1650 - 2600

Hot Modulus of Rupture (psi)

At 1500 °F - - 4000 4650 3300 3800 3250 5000 3000 - - - - 4900 3600

Cold Crush Strength (psi)

After drying at 230 °F 9840 7100 - 11500 16820 15000 10900 7000 6300 9220 - 3000 11370 - 11000

After heating at 1500 °F 6970 4100 10000 13000 14780 10000 10900 22000 7700 10800 - 1450 8630 15000 13000

Chemical Analysis,%:

Al2O3 42.4 49.1 62.5 57.6 64.0 59.6 80.4 69.1 81.6 92.2 90.8 42.5 23.8 23.4 7.3

SiO2 49.8 37.7 27.7 30.6 29.3 34.0 10.8 24.4 8.2 0.3 0.8 38.3 72.0 14.4 33.4

TiO2 1.9 2.5 1.3 1.4 2.1 1.3 1.7 1.6 2.6 0.1 1.7 2.5 0.1 - 0.5

Fe2O3 0.8 1.1 0.7 0.9 0.8 0.8 0.8 1.0 1.1 0.1 0.1 2.5 0.1 0.1 0.1

CaO 3.2 8.9 1.4 1.4 3.5 3.8 2.4 2.6 1.3 3.2 3.2 10.2 2.8 2.7 1.1

MgO 0.2 0.3 - 0.1 0.1 0.2 0.2 0.1 0.1 0.1 0.2 0.2 0.1 - -

Na2O & K2O 0.7 0.4 0.2 0.1 0.2 0.3 0.2 0.2 - 0.3 0.1 0.8 0.1 0.2 0.1

ZrO2 - - - 3.2 - - - - - - - - - - 57.4

SiC - - - - - - - - - - - - - 59.0 -

Other 1.0 - 6.2 - - - 3.5 - 5.0 3.7 3.1 3.0 1.0 - -

AR

MO

RK

AS

T65

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NA

RC

OT

UF

FT

MS

UP

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AL

VE

RS

AF

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GR

EE

NK

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AR

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RK

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ULT

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PG

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AR

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GR

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LV

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AB

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LU

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AC

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TAB

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70-80% A

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AC

AS

TAB

LE

S

90+% A

LU

MIN

AC

AS

TAB

LE

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MIS

CE

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AN

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US

CA

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Harb

ison

-Walker C

astables fo

r Alu

min

um

M

elting

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ldin

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urn

aces

VE

RS

AF

LO

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45/AL

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A45%

alumina, pum

pable, low-cem

ent castable with

improved strength versus conventional castables.

H-W

®E

S C

AS

TAB

LE

C A

LA

n industry standard for aluminum

furnace safety lin-ings, H

-W®

ES

CA

STA

BLE

C A

Lis a coarse aggregate

castable with excellent im

pact and thermal shock

resistance.

AR

MO

RK

AS

T 65A

LA

RM

OR

KA

ST

65AL

is a very high purity low cem

entcastable. Its unique bonding m

atrix provides exception-ally high strength and ultim

ate corrosion resistance.

VE

RS

AF

LO

W®

65/AL

PL

US

®

A65%

alumina, low

cement castable w

ith high strengthand versatile installation characteristics. V

ER

SA

FLO

W®

65/AL

C A

DT

EC

H®

is the coarse aggregate containingversion. C

oarse aggregates provide improved im

pactand therm

al shock resistance.

NA

RC

OT

UF

FT

M S

UP

ER

AL

With a m

inor zircon addition, NA

RC

OT

UF

FT

MS

UP

ER

AL

is an excellent choice for the lower sidew

all or bellyband in a furnace w

ith slight corundum grow

th.

GR

EE

NK

LE

EN

-60 PL

US

Am

ong the most popular m

aintenance materials avail-

able, GR

EE

NK

LEE

N-60 P

LUS

is a 60% alum

ina,andalusite containing, low

cement castable. It has high

strength and excellent aluminum

resistance.

AR

MO

RK

AS

T 80A

LA

DT

EC

H®

This high purity, pum

pable, 80% alum

ina castable is builtfor corrosion resistance. It has exceptional strength andalum

inum resistance. A

RM

OR

KA

ST

80AL

is designedfor the m

ost severe aluminum

contact applications.

AL

STO

PG

RE

FC

ON

®80 A

An industry standard for m

ore than 15 years, ALS

TO

PG

RE

FC

ON

®80A

is a high strength, high corrosion resistance, 80%

alumina low

cement castable.

ULT

RA

-EX

PR

ES

S 70 A

LA

n ultra-low cem

ent, 70% alum

ina castable designedw

ith enhanced flow, and self-leveling characteristics.

ULT

RA

-EX

PR

ES

S70 A

Lis very strong and is ideal for

pumping over long distances and for casting into intri-

cate form patterns.

VE

RS

AF

LO

W®

XP

UR

/AL

AD

TE

CH

®

Atabular alum

ina based, silica-free, pumpable, low

cement castable. V

ER

SA

FLO

W®

XP

UR

/AL

AD

TE

CH

®

has excellent strength and non-wetting characteristics.

Because it is silica free, it is an excellent choice for high

corundum belly bands.

AR

MO

RK

AS

T X

PU

R/A

LA

DT

EC

H®

This tabular alum

ina based castable is also silica-free,and is designed to be a m

ore cost effective corundumfighter. It also show

s very high strength and excellentalum

inum resistance.

GR

EE

NL

ITE

®-45-LA

LT

his lightweight castable has a very high strength to

weight ratio. It is ideally suited for insulating sub-

hearths, and crucibles.

VE

RS

AF

LO

W®

TH

ER

MA

X®

AL

AD

TE

CH

®

Avitreous silica based low

cement castable. It has

exceptional thermal shock and abrasion resistance.

VE

RS

AF

LOW

®T

HE

RM

AX

®A

LA

DT

EC

H®

is an excel-lent choice for troughs.

TH

OR

60 AB

R A

DT

EC

H®

60% silicon carbide castable w

ith very high strengthand abrasion resistance. T

HO

R 60 A

BR

AD

TE

CH

®is a

proven problem solver in hearths, ram

ps and sills.

NA

RC

ON

ZR

AL

A60%

zirconia castable with excellent corundum

resist-ance. Z

oning belly bands with N

AR

CO

N Z

RA

Lhas

proven to be very successful in furnaces prone to corundum

formation.

Melting/Holding FurnaceALUMINUM











Many modern aluminum meltingand holding furnaces are continu-ously being pushed harder andharder to produce more metal inshorter time. In many cases, thefurnaces are being pushed to pro-duce a variety of different alu-minum alloys. These operatingconditions have created ademand for refractories that canwithstand the more severe envi-ronment.

Some of the destructive condi-tions that these modern operatingpractices generate include:

TemperatureTemperature is generally the simplest methodof increasing throughput. While higher temper-atures do decrease melt times, they can causeproblems. Higher temperatures increase therates of reaction between the metal and therefractories, leading to corundum formation andaccelerated wear.

FluxingFluxing practices, while necessary for efficientmetal melting, are damaging to refractories.Alkali based fluxes can have the same effect onalumino-silicate refractories as they have onaluminum metal. Chlorine containing fluxescan degrade the bond system of cement-bond-ed refractory castables.

ChargingScrap quality and charging practice can also bedetrimental to refractory performance. Paintedor other contaminated scrap can introducecomponents that are highly reactive with refrac-tory linings. The size and charging method can

be abusive too. Pushing large scrap into thefurnace causes abrasion on the sill, and resultsin high mechanical impact on the ramp andhearth.

AlloysVarious alloying components can degraderefractories. Silicon alloys tend to be highlyfluid and can penetrate further into furnace lin-ings. Magnesium alloys are prone to thermitingwhich produces extremely high temperatures,and can lead to corundum formation. Zincalloys also tend to promote corundum forma-tion.

CleaningIn all cases, it is very important to employ thor-ough furnace cleaning practices. Good furnacecleaning can help minimize corundum growth,and refractory wear. Efficient cleaning can alsohelp to improve heat transfer to the bath, reduc-ing thermal gradients and melt losses.

The data given in this flyer are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable.Variation from the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information,and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.


Transfer Trough Conditions:ErosionAbrasionThermal ShockAluminum PenetrationMechanical Abuse

TRANSFER TROUGHSALUMINUM

GREENKLEEN-60 PLUSA 60% alumina, andalusite containing castable.GREENKLEEN-60 PLUS has excellent resistanceto molten aluminum, and has been a standard foraluminum troughs for more than 10 years.

ARMORKAST 65ALA 65% alumina, low cement, pumpable castable.ARMORKAST 65AL has a very high purity bond-ing matrix, leading to very high physical proper-ties, and outstanding corrosion resistance.

ULTRA-EXPRESS 70 ALAn ultra-low cement, 70% alumina castabledesigned with enhanced flow, and self-levelingcharacteristics. ULTRA-EXPRESS 70 AL is verystrong and is ideal for pumping over long dis-tances and for casting into intricate form patterns.


A silica free, coarse aggregate containingcastable, designed for precast trough sections.This 2-component mix contains 50% coarseaggregate, providing outstanding thermal shock,impact and abrasion resistance.


A 60% silicon carbide castable. SiC offersimproved thermal shock and abrasion resistance.THOR 60 ABR ADTECH® has exceptional resist-ance to molten aluminum.

HARBIDE® PLASTIC 70 ALA 70% silicon carbide, phosphate bonded plastic with an aluminum penetration inhibitor. HARBIDE® PLASTIC 70 AL is an excellentchoice for patching.

NOVACON® SNOVACON® S is a cement-free, vitreous silicabased castable. It shows outstanding hot properties, as well as thermal shock and abrasion resistance.

VERSAFLOW® THERMAX® AL ADTECH®

A vitreous silica based, low-cement castablewith an aluminum penetration inhibitor. VERSAFLOW® THERMAX® AL ADTECH®

offers exceptional thermal shock and abrasionresistance, as well as volume stability.

VISIL®/C ALA unique, vitreous silica product developed forcustom shapes. VISIL®/C AL has excellent thermal shock and abrasion resistance and volume stability.

GREENLITE®-45-L ALA lightweight, insulating mix, with an exceptionalstrength to density ratio. GREENLITE®- 45-L ALalso contains a penetration inhibitor, which provides resistance to molten aluminum.

Harbison-Walker offers a complete line ofrefractory castables, plastics and shapes foraluminum transfer troughs.

© 2003 Harbison-Walker Refractories Company. All Rights Reserved. Cat# HW 192 (07/03))




TECHNICAL DATA



GREENKLEEN- ARMORKAST ULTRA-EXPRESS 2-TOUGHTM AL THOR 6060 PLUS 65AL 70 AL ADTECH® ABR ADTECH®

Form Castable Castable Self-Flowing Vib-Cast Castable Castable

Density, pcf

After 230˚F 161 163 158 169 210 165

Ater 1500˚F 157 160 157 169 -- 162

Modulus of Rupture, psi

After 230˚F 2,350 1,900 1,000 1,500 1,900 2,400

After 1500˚F 5,000 2,300 2,700 2,800 -- --

@ 1500˚F 3,800 4,000 4,700 5,000 -- 4,900

@2000˚F -- 3,000 -- -- -- 5,500

C-704 Abrasion TestCC Loss After 1500˚F 6 -- 4 3 -- 6

Chemical Analysis,%(Approximate)Silica (SiO2) 34.0 27.7 24.4 1.1 14.4Alumina (Al2O3) 59.6 62.5 69.1 90.0 23.4Silicon Carbide (SiC) -- -- -- -- 59.0

HARBIDE® VERSAFLOW® THERMAX®

PLASTIC 70 AL NOVACON® S AL ADTECH® VISIL®/C AL GREENLITE®-45-L AL

Form Plastic Castable Castable Shape Castable Vib-Cast

Density, pcf

After 500˚F 57 113 129 117 69 74

After 1500˚F -- -- -- 64 67 --

Apparent Porosity, % -- -- 14 -- -- --


After 500˚F -- -- -- 620 400 500

After 1500˚F 2,230 1,060 1,650 -- 250 320

@ 1500˚F -- -- -- -- -- --

C-704 Abrasion Test

CC Loss After 1500˚F 4.5 -- -- -- -- --

Chemical Analysis,%(Approximate)Silica (SiO2) 6.5 96.9 72.0 96.4 38.3Alumina (Al2O3) 20.4 2.1 23.8 0.6 42.5Silicon Carbide (SiC) 67.0 -- -- -- --

For Rotary Kilns

Long Brick from Harbison-Walker

Eliminates double cuts

Use for your cut rows 8” up to 12”

Greater flexibility when old section is spiraled

Reduce the number of rings to install

Reduce downtime - Labor savings

Available in High Alumina and Basic Brick qualities

From two courses to One 12” (305 mm) brick

More stable construction

More mass

More Strength

H-W LONG BRICK

Closure Courses

Retainer Rings

Manufactured in Canada

Manufactured in U.S.A.

Shape #B-222-LB-322-LB-622-LB-822-L

Key-UpsB-228-L-K-1B-228-L-K-2

H-W LONG BRICK for Rotary Kilns

H-W Long brick are available in the following sizes:

© 2002 Harbison-Walker Refractories Company. All Rights Reserved. Cat# HW131 R(8/02) 2C

Shape #VDZ B222/30VDZ B322/30VDZ B622/30

Key-UpsP220/30P221/30

Shape #ISO 222/30ISO 322/30ISO 822/30

Key-UpsP221/30P222/30

Shape #ISO 325/30ISO 825/30

Key-UpsP251/30AP252/30A

* All ring counts follow standard ring combinations


Moon Township, PA 15108Phone: (412) 375-6600 1-800-377-4497

Fax: (412) 375-6846

For Rotary Kiln SystemsHigh Alumina & Basic Bricks

SUPER DUTYCLIPPER® DP

HIGH ALUMINAARCO® 50

KALA®

ARCO® 60

UFALA®

KRUZITE® - 70

ALTEX® 75B

ALADIN® 80

CORAL® BP

© 2003 Harbison-Walker Refractories Company. All rights reserved. Cat. # HW132 R(7/03) 3C

Harbison-Walker Refractories Company400 Fairway DriveMoon Township, PA 15108Phone: (412) 375-6600 • 1-800-377-4497Fax: (412) 375-6846

For Cement and Lime Sales:








BASIC ANKRAL - R1

ANKRAL - R2

ANKRAL - ZE

MAGNEL® RS

MAGNEL® RSV

MAGNEL® RSX

MAGNEL® RS/AF

CLIPPER® DP A dry-pressed, superduty brick that exhibits goodstrengths, low shrinkage, and good thermal shock resistance.Used in the preheating zones of long wet and long dry processkilns and preheater tower vessels.

ARCO® 50 A conventional 50% alumina brick that has good phys-ical properties up to 2600oF. Can be used in preheating zones oflong wet and long dry kilns and preheater tower vessels.

KALA® A high purity 50% alumina brick with low porosity andexcellent high temperature strength. Ideally suited for use in pre-heating and calcining zones where alkali salts are present. Canalso be used as an upgrade to conventional fireclay brick in pre-heater vessels.

ARCO® 60 A conventional 60% alumina brick manufactured fromimported bauxitic calcines. A cost effective alternative to higherpurity 60% alumina products. Can be used in preheating zonesalong with selected calcining zones.

UFALA® A 60% alumina brick manufactured from high puritydomestic calcines. Exhibits excellent resistance to alkali saltattack and has good thermal shock resistance. Can be used inpreheating and calcining zones where chemical attack is prevalent.

KRUZITE® – 70 A conventional 70% alumina brick manufacturedfrom imported bauxitic calcines. Ideally suited for use in calciningand cooling zones where normal operating conditions are pres-ent.

ALTEX® 75B A 75% alumina, burned, phosphate-bonded brickwith high hot strengths and low porosity. It's low porosity gives itexcellent resistance to alkali salt attack. It also exhibits excellentresistance to mechanical abuse from abrasion and impact. Canbe used in the lower calcining zone and the cooling zone.

ALADIN® 80 An 80% alumina brick produced from imported cal-cined bauxite. Has good hot strength, predictable reheat expan-sion characteristics, and good thermal shock resistance. Can beused in the lower calcining and cooling zones where greaterrefractoriness is required.

CORAL® BP An 80% alumina, phosphate-bonded, burned brickthat has excellent high temperature strength and low porosity.High degree of phosphate bonding gives this product excellentstrength and abrasion resistance throughout all temperatureranges. Ideally suited for use in the cooling zones and selectedlower calcining zones areas.

ALUMINA BRICK CLIPPER® DP ARCO® KALA® ARCO® UFALA® KRUZITE® ALTEX® ALADIN® CORAL®

(SUPER DUTY) 50 60 70 75B 80 BP

Bulk Density, lb/ft3 142 149 153 155 157 165 175 170 177

Apparent Porosity, % 15.3 17.0 13.8 17.5 14.3 18.7 15.0 19.5 17.4

Crushing Strength, lb/in2

At 70OF (21OC) 6,300 7,100 8,700 7,000 8,410 8,500 13,000 9,610 20,750

Modulus of Rupture, lb/in2

At 70OF (21OC) 1,350 1,700 2,060 1,600 2,640 1,700 2,700 1,610 3,320

Reheat TestPermanent Linear Change, %After Heating at 2910OF (1600OC) -0.3 +1.5 +0.8 +3.4 -0.1 +4.5 +2.3 +1.2 -0.6


Silica (SiO2) 52.6% 42.1% 46.6% 32.6% 38.2% 23.0% 15.5% 15.2% 7.2%

Alumina (Al2O3) 42.2 51.5 49.6 61.0 58.1 71.0 76.0 78.6 83.3

Titania (TiO2) 2.3 3.3 2.2 3.3 2.2 3.4 3.2 3.4 2.7

Iron Oxide (Fe2O3) 1.4 1.8 1.3 1.8 1.2 1.6 1.4 1.8 1.3

Lime (CaO) 0.2 0.3 0.1 0.3 0.1 0.2 0.2 0.3 0.2

Magnesia (MgO) 0.3 0.3 0.1 0.3 0.1 0.2 0.2 0.3 0.1

Alkalies (Na2O+K2O) 0.9 0.7 0.1 0.7 0.1 0.6 0.5 0.4 0.2

Phosphorous Pentoxide (P2O3) — — — — — — 3.0 — 5.0

BASIC BRICK ANKRAL ANKRAL ANKRAL MAGNEL® MAGNEL® MAGNEL® MAGNEL®

R1 R2 ZE RS RSV RSX RS/AF

Bulk Densit,y lb/ft3 187 186 187 182 187 187 188

Apparent Porosity, % 14.5 15.0 16.0 17.4 15.0 15.0 15.0


At 70OF (21OC) 8,000* 8,700* 10,700* 4,000 7,100 9,100 5,950


At 70OF (21OC) 800 870 900 690 840 1,250 670At 2300OF (1260OC) -- -- -- 920 1,100 1,100 910

Reheat TestPermanent Linear Change, %After Heating at 2910OF (1600OC) -- -- -- 0.0 0.0 0.0 0.0


Silica (SiO2) 0.2% 0.2% 0.5% 0.4% 0.3% 0.3% 0.4%

Alumina (Al2O3) 7.4 10.5 2.6 15.2 9.6 5.0 14.4

Titania (TiO2) -- -- -- 0.3 0.1 0.1 0.3

Iron Oxide (Fe2O3) 0.5 0.5 6.3 0.2 0.2 0.2 0.5

Lime (CaO) 1.2 1.1 1.3 1.5 1.4 1.5 1.1

Magnesia (MgO) 90.7 87.7 89.0 82.4 88.4 92.9 83.4

ANKRAL-R1 Manufactured from high purity magnesite and spinelgrains. Ideally suited for high thermal stress zones of rotary cementkilns. It is highly resistant to cyclical redox conditions and attack bysulfur, alkali salts, and chlorine. The unique spinel formation andsubsequent distribution within the matrix makes this productextremely coating friendly. Can be used in all areas of the lowerand upper transition zones and the burning zone.

ANKRAL-R2 A high-purity synthetic sintered magnesite and sin-tered spinel makes this product well suited for lower and upper tran-sition zones where alkalis and sulfates are present.

ANRKAL-ZE This product is manufactured from natural sinteredmagnesia and a fused spinel consisting of iron and alumina (her-cynite). This patented combination yields a product that is excep-tionally coating friendly. It is extremely flexible and has excellentcorrosion resistance. It is ideally suited for burning and upper tran-sition zones. It's mechanical flexibility is important when higher thannormal shell flexing is present.

MAGNEL® RS A combination high-purity synthetic magnesite, fusedspinel, and a matrix of reinforced spinel (RS) give this product itsexcellent physical properties. The high amount of fused spinel pro-vides low thermal conductivity and low thermal expansion. Thematrix spinel aids in the formation and retention of coating. Ideallysuited for all areas of the basic zone of a cement and lime kiln.

MAGNEL® RSV A combination high-purity synthetic magnesite,fused spinel, and a matrix of reinforced spinel give this product itsexcellent physical properties at a cost-effective price. The moder-ate amount of spinel yields a product that has excellent resistanceto clinker liquids while maintaining lower thermal conductivity andthermal expansion than similar products of the same class. Canbe used in all basic zones but best suited for lower transition andburning zones areas.

MAGNEL® RSX Manufactured from the same raw materials asMAGNEL RS and MAGNEL RSV. Lower spinel levels in conjunc-tion with the higher magnesia levels yields a product that is highlyresistant to clinker liquid infiltration and alkali salt attack. Low per-meability values also give it excellent resistance to sulfur andchlorine.

MAGNEL® RS/AF A combination high-purity synthetic magnesite,fused magnesite, fused spinel and a matrix of reinforced spinelmake this patented product unique. Large crystalline magnesiagrains make it extremely corrosion resistant. Designed for use inthe high wear areas of the lower transition zones of kilns burningwaste fuel and/or high levels of petroleum coke. Also well suitedfor kilns utilizing oxygen enrichment.

The data given above are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable. Variationfrom the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and data givenherein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.

Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is freeof patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.

The data given above are based on averages of test results on samples selected from routine plant production by standard ASTM procedures where applicable. Variationfrom the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied. *-DIN Test

Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is

For Rotary Kiln SystemsHigh Alumina & Basic Bricks

SUPER DUTYCLIPPER® DP

HIGH ALUMINAARCO® 50

KALA®

ARCO® 60

UFALA®

KRUZITE® - 70

ALTEX® 75B

ALADIN® 80

CORAL® BP

© 2003 Harbison-Walker Refractories Company. All rights reserved. Cat. # HW132 R(7/03) 3C










BASIC ANKRAL - R1

ANKRAL - R2

ANKRAL - ZE

MAGNEL® RS

MAGNEL® RSV

MAGNEL® RSX

MAGNEL® RS/AF

LIGHTWEIGHT CASTABLES AND GUNNING MIXES FOR ROTARY KILN SYSTEMS

GUNNING MIXES

GREENLITE® -45-L GR

KAST-O-LITE® 19 L

KAST-O-LITE® 22 G

KAST-O-LITE® 26 LI G


CASTABLES

KAST-O-LITE® 20

KAST-O-LITE® 20 LI

KAST-O-LITE® 20-45

KAST-O-LITE® 22

KAST-O-LITE® 23 ES

KAST-O-LITE® 23 LI

KAST-O-LITE® 26 LI

KAST-O-LITE® 30 LI

2600°F Series

3000°F Series

2200°F Series

1900°F Series

6

5.5

5

4.5

4

3.5

3

2.5

2

1.5

1

0.5

0

K-V

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s

0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000

Mean Temperature (Btu/Hr ft F/in)2

2600°F Series

3000°F Series

2000°F Series

1900°F Series

6

5.5

5

4.5

4

3.5

3

2.5

2

1.5

1

0.5

0

K-V

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s

0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000






North American Refractories Company (NARCO) is a leadingsupplier of refractory solutions to the iron and steel industries. The com-pany makes high-performance products for BOFs, EAFs, LMFs, ladles, fin-ishing, alternative ironmaking, casthouses, and blast furnaces. In addition toproviding complete technical support services, NARCO also can design andimplement a turnkey refractory management program to meet your facility’sspecialized requirements.

Exclusively serving the non-ferrous metals, ferrous foundry, hydro-carbon,incineration, minerals processing and other industries…



A.P. Green Refractories (APG) makes products for the iron and steel,aluminum, cement, copper, glass, and hydro-carbon and minerals processingindustries. The company also has one of the world’s top capabilities for cus-tomized pre-cast shapes, along with a full line of insulating ceramic fibers.


Gunning Mixes

Castables

GREENLITE® -45-L GR is a 2,500˚F insulating gunningcastable combining exceptional strengths and low den-sities. It is an ideal candidate for fluid catalytic crackingunits, fluid coking units and other industrial liningsrequiring low densities and high strength.

KAST-O-LITE® 19 L is an insulating castable that caneasily conform to an irregular shell and will not smoke.It is ideally used as a gunned or cast back-up liningbehind other hot face refractory lining to lower shelltemperatures.

KAST-O-LITE® 20 is a hydraulic setting insulatingcastable that can be installed by pouring, pumping orgunning. Ideal for back-up linings behind dense refrac-tories or as an exposed lining where slagging, flameimpingement or mechanical wear does not present aproblem.

KAST-O-LITE® 20 LI is a high efficiency insulatingcastable usable in direct contact with hot gases undercontinuous or intermittent operation without loss of ther-mal efficiency. KAST-O-LITE® 20 LI can be used to2,000°F (1,095°C) is extremely resistant to thermalshock and has low thermal conductivity.

KAST-O-LITE® 20-45 is a hydraulic setting insulatingcastable that can be installed by pouring or gunning. Itis ideal for back-up linings behind dense refractories oras an exposed lining where slagging, flame impinge-ment or mechanical wear does not present a problem.

KAST-O-LITE® 22 is a lightweight castable for tempera-tures to 2,200°F (1,205°C). It features low thermal con-ductivity and good strength for such a lightweight mate-rial. Recommendations include oil stills and heaters,lightweight panel construction, flue and duct linings,complete monolithic linings, and as a back-up material.

KAST-O-LITE® 22 G is an economical 2,200°F(1,205°C) insulating gunning castable. It is especiallyformulated for gunability, easily flowing through thehose with minimum rebound. KAST-O-LITE® 22 G isideal for overhead gunning applications.

KAST-O-LITE® 23 ES is an intermediate strength insu-lating castable with standard calcium-aluminate binder.It combines good strength with high insulating valueand excellent volume stability. KAST-O-LITE® 23 ESmay be cast or gunned in place and is suitable for hotface or back-up linings.

KAST-O-LITE® 23 LI is a 2,300°F (1,260°C) maximumservice temperature insulating castable. It contains lowiron to resist detrimental reducing furnace conditions.Typical applications are: flues, stacks, breechings, con-trolled atmosphere furnaces, petrochem transfer andriser back-up linings, catalytic reforming linings behindstainless steel shroud, and waste heat boilers.

KAST-O-LITE® 26 LI has now been improved to meetthe demands of severe furnace environments. Low ironcontent minimizes destructive CO disintegration attackby reducing furnace atmospheres. Its vastly improvedstrengths reduce cracking from mechanical abuse orsteel shell flexing. Higher alumina content improves itsmaximum service temperature to 2,600°F (1,425°C).Lower water content for placement reduces internalsteam pressure during initial heat up. It is ideal for boil-ers, reheat furnace floor backup, furnace stacks andflues, air heaters, aluminum furnace roof backup andpetrochem oil heaters.

KAST-O-LITE® 26 LI G is a low iron content 2,600°F(1,425°C) maximum service temperature limit insulatinggunning castable. Vastly improved strengths reducecracking from mechanical abuse or steel shell flexing.It is ideal for boilers, furnace stacks and flues, airheaters and petrochem oil heaters.

KAST-O-LITE® 30 LI is a high-alumina, lightweight,3,000°F (1,650°C) maximum service temperature, insu-lating castable. It exhibits moderate density, excellentstrengths, low iron, and low thermal conductivity.Typical applications are aluminum furnace stacks, alu-minum holding furnace doors, reheat furnace dischargedoors, carbon black back-up linings, air heaters andreheat furnace backup linings.

KAST-O-LITE® 30 LI G is a high-alumina, lightweight,3000°F (1650°C) maximum service temperature insulat-ing gunning castable. It exhibits moderate density,excellent strengths, low iron, low thermal conductivity,and low rebound. Typical applications are aluminumfurnace stacks, aluminum holding furnace doors, reheatfurnace discharge doors, petrochem heaters, sulphurrecovery unit back-up linings, air heaters, reheat fur-nace back-up linings, and catalytic reformer back-up lin-ing behind stainless steel shroud.

LIGHTWEIGHTGUNNING GREENLITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE®

MIXES 45-L GR 19 L 20 20 LI 20-45 22

Bulk Density, lb/ft3 - - 36 41 50 53

Maximum Service Temperature, ˚F 2500 1900 2000 2000 2000 2200


At 220˚F (105˚C) 3200 35 150 310 200 575


At 220˚F (105˚C) 600 20 75 100 150 140

Reheat Test

Permanent Linear Change,

After Heating at 1500˚F (815˚C) -0.2% -0.6% -0.5% -0.7% -0.5% -0.8%

Chemical Analysis: (Approximate)

(Calcined Basis)

Silica (SiO2) 40.0% 26.3% 25.0% 43.9% 46.2% 34.0%

Alumina (Al2O3) 45.0 31.5 42.0 39.3 30.5 41.0

Titania (TiO2) 2.0 2.2 2.0 0.2 1.1 2.0

Iron Oxide (Fe2O3) 1.3 6.7 2.5 0.6 3.4 4.0

Lime (CaO) 10.0 20.0 21.0 12.7 16.6 17.0

Magnesia (MgO) 0.3 11.0 6.0 0.2 0.2 0.4

Alkalies (Na2O+K2O) 1.0 2.3 1.5 3.1 2.0 1.5

LIGHTWEIGHTGUNNING KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE®

MIXES 22 G 23 ES 23 LI 26 LI 26 LI G 30 LI 30 LI G

Bulk Density, lb/ft3 76 86 53 92 111 95 102

Maximum Service Temperature, ˚F 2200 2300 2300 2600 2600 3000 3000


At 220˚F (105˚C) 810 2350 300 3000 2400 2850 2200


At 220˚F (105˚C) 460 490 90 700 720 550 525

Reheat Test

Permanent Linear Change,

After Heating at 1500˚F (815˚C) -0.4% -0.3% -0.8% -0.2% -0.2% -0.3% -0.1%

Chemical Analysis: (Approximate)

(Calcined Basis)

Silica (SiO2) 34.1% 39.0% 54.8% 38.2% 44.6% 35.5% 35.0%

Alumina (Al2O3) 41.2 36.3 33.5 46.5 44.5 57.5 57.0

Titania (TiO2) 2.0 1.7 0.7 2.0 2.3 1.5 1.5

Iron Oxide (Fe2O3) 3.3 5.1 0.7 1.3 1.0 0.7 0.9

Lime (CaO) 15.4 14.6 8.5 10.5 6.4 4.2 4.7

Magnesia (MgO) 2.5 1.2 0.2 0.4 0.3 0.2 0.2

Alkalies (Na2O+K2O) 1.5 2.1 1.6 1.0 0.9 0.4 0.7

The data given above are based on averages of test results on samples selected from routine plant production by standard ASTM procedures where applicable. Variationfrom the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and datagiven herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.


The data given above are based on averages of test results on samples selected from routine plant production by standard ASTM procedures where applicable. Variationfrom the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and datagiven herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.


LIGHTWEIGHT CASTABLES AND GUNNING MIXES FOR ROTARY KILN SYSTEMS

GUNNING MIXES

GREENLITE® -45-L GR

KAST-O-LITE® 19 L

KAST-O-LITE® 22 G



CASTABLES

KAST-O-LITE® 20

KAST-O-LITE® 20 LI

KAST-O-LITE® 20-45

KAST-O-LITE® 22

KAST-O-LITE® 23 ES

KAST-O-LITE® 23 LI

KAST-O-LITE® 26 LI

KAST-O-LITE® 30 LI

2600°F Series

3000°F Series

2200°F Series

1900°F Series

6

5.5

5

4.5

4

3.5

3

2.5

2

1.5

1

0.5

0

K-V

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s

0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000


2600°F Series

3000°F Series

2000°F Series

1900°F Series

6

5.5

5

4.5

4

3.5

3

2.5

2

1.5

1

0.5

0

K-V

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s

0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000






North American Refractories Company (NARCO) is a leadingsupplier of refractory solutions to the iron and steel industries. The com-pany makes high-performance products for BOFs, EAFs, LMFs, ladles, fin-ishing, alternative ironmaking, casthouses, and blast furnaces. In addition toproviding complete technical support services, NARCO also can design andimplement a turnkey refractory management program to meet your facility’sspecialized requirements.

Exclusively serving the non-ferrous metals, ferrous foundry, hydro-carbon,incineration, minerals processing and other industries…



A.P. Green Refractories (APG) makes products for the iron and steel,aluminum, cement, copper, glass, hydro-carbon and minerals processingindustries. The company also has one of the world’s top capabilities for cus-tomized pre-cast shapes, along with a full line of insulating ceramic fibers.


Gunning Mixes

Castables

MAGSHOT®

Description: Magnesite-based chrome-free gunning mix

Features & Benefits:

• Chemistry similar to basic brick• Ease of installation• Quick turnaround for repairs

- Heat-up can begin 2 hours after installation- Does not require lengthy cure times or slow heat-up schedules

• Low dust and rebounds• Prolong existing lining until scheduled outage• Castable variant (MAGSHOT® CASTABLE) for larger installations• Proven track record

Uses:• Burning zone patches in cement and lime rotary kilns • Nose rings in lime kilns• Flash coating basic brick in vertical lime shaft kilns• Throat areas of cement coolers• Patch where needed• Manways or access doors

Packaging: Shipped in 55 pound - multi-wall moisture - resistant sacks

MAGSHOT Patch in place

Wire AnchorsWelded to the shell

For Cement & Lime Kilns


MAGSHOT®

TECHNICAL DATA

Physical Properties; (Typical)Bulk Density, pcf


After 230°F 1,690 1,510After 1500°F 1,560 1,480

Cold Crushing Strength, psi

After 230°F 5,870 10,100After 1500°F 5,930 7,000



The data given above are based on averages of tests results on samples selected from routine plant production by standard A.S.T.M. procedures where applica-ble. Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements,information, and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind,expressed or implied.


© 2002 Harbison-Walker Refractories Company. All Rights Reserved. Cat# HW133R (9/02) 2C



Fax: (412) 375-6846

Refractories for theLime Industry

Precast lifters or tumblers are large kiln blocks made out of our castable refractories. When installed in a kiln sectionthe lifters act to increase the tumbling efficiency of the kiln feed which exposes a larger percentage of feed to hot kilngas and thereby reduces the heat consumption and improves fuel efficiency of the kiln system. Equipment manufactur-ers generally place the lifter section within the preheating zone of a rotary lime kiln.

Our precast lifters can be made to fit any kiln diameter and can be incorporated with any brick shape or castable lining.The lifters are typically designed to be 5” to 6” taller than the existing refractory lining. The sections generally consist offour (4) to six (6) rows running parallel with the kiln axis.

Installation requires welding a piece of carbon steel bar stock for each row to the kiln shell, again running parallel withthe kiln axis. Lifters within the same row interlock together through a unique steel footing system which is also weldedto the carbon steel bar. Once the lifters are in place the main lining can then be installed.

If you are interested in more information on increasing your kiln’s fuel efficiency contact your local HW representative.

PRECAST LIFTERS

© 2001 Harbison-Walker Refractories Company... All Rights Reserved. Cover Photo Courtesy of Dravo Lime Inc. Cat# HW135 (9/02) 2C

Harbison-Walker Refractories Company.400 Fairway Drive


Fax: (412) 375-6846

PRECAST KILN TUMBLER BLOCK

BASIC BRICK MAGNEL® MAGNEL® NOKROME® NOKROME®

RS RSV 87LK 92LK

Bulk Density, lb/ft3 182 187 180 182

Apparent Porosity, % 17.4 15.0 18.0 16.5


At 70OF (21OC) 4,000 7,100 5,100 7,800


At 70OF (21OC) 690 840 800 960At 2300OF (1260OC) 920 1,100 1,200 1,500

Reheat TestPermanent Linear Change, %After Heating at 2910OF (1600OC) 0.0 0.0 — —


Silica (SiO2) 0.4% 0.3% 0.5% 0.5%

Alumina (Al2O3) 15.2 9.6 11.0 6.0

Titania (TiO2) 0.3 0.1 — —

Iron Oxide (Fe2O3) 0.2 0.2 0.25 0.4

Lime (CaO) 1.5 1.4 1.6 1.5

Magnesia (MgO) 82.4 88.4 86.5 91.4

ALUMINA BRICK KRUZITE®-70 ALTEX® 75B KALA® UFALA® ALADIN® 80

Bulk Density, lb/ft3 165 175 152 157 170

Apparent Porosity, % 18.7 15.0 14.4 14.3 19.5


At 70OF (21OC) 8,500 13,000 7,400 8,410 9,610


At 70OF (21OC) 1,700 2,700 1,730 2,640 1,610

Reheat TestPermanent Linear Change, %After Heating at 2910OF (1600OC) +4.5 +2.3 +0.6 -0.1 +1.2


Silica (SiO2) 23.0% 15.5% 46.6% 38.2% 15.2%

Alumina (Al2O3) 71.0 76.0 49.6 58.1 78.6

Titania (TiO2) 3.4 3.2 2.2 2.2 3.4

Iron Oxide (Fe2O3) 1.6 1.4 1.3 1.2 1.8

Lime (CaO) 0.2 0.2 0.1 0.1 0.3

Magnesia (MgO) 0.2 0.2 0.1 0.1 0.3

Alkalies (Na2O+K2O) 0.6 0.5 0.1 0.1 0.4

Phosphorous Pentoxide (P2O5) — 3.0 — — —

The data given in this brochure are based on averages of tests results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable.Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and datagiven herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.


VERSAFLOW® CASTABLES - Dense, low cementcastables exhibiting high mechanical strength andexcellent abrasion resistance. Can be vibcast, conven-tionally cast or pump cast into place. Uses include pre-heater shelves, feed end linings, precast lifter sections,cast dams, and nose/tail rings. Products includeVERSAFLOW® 45C, VERSAFLOW® 57A,VERSAFLOW® 60, VERSAFLOW® 70, and VERSAFLOW® 80C. VERSAFLOW products are alsoavailable in shotcrete versions (PNEUCRETE®).

NARCON CASTABLES - Dense, low cement castablesexhibiting excellent mechanical strength and excellentabrasion resistance. Can be vibcast, conventionallycast or pump cast into place. Uses include preheatershelfs, feed end linings, precast lifter sections, castdams, and nose/tail rings. Products include NARCON60, NARCON 65. NARCON products are also availablein shotcrete versions (SHOTKAST®).

HPVTM CASTABLES - Unique group of products thatare light in weight yet exhibit physical propertiesapproaching those of denser materials. Possible usesinclude precast lifter shapes and feed end linings.Products include HPV 3000, HPV CASTABLE and HPV GUN MIX.

LO-ABRADE® - Conventional, high strength 2600O Fcastable that exhibits good resistance to abrasion and ero-sion. Can be used for general-purpose repairs in all areas.Also available in a gunning version (LO-ABRADE® GR).

MAGSHOT® - Magnesia based gunning mix that is ideallysuited for temporary repairs. Magnesia base makes itcompatible for use in burning zone areas where conven-tional alumina products do not have enough refractoriness.Unique bonding mechanism does not require a 24-hour aircure therefore it can be heated immediately after place-ment to allow for quick turnaround.

EXPRESS® 27 C PLUS® is a 2700oF (1480oC) dense, free-flowing refractory castable. It has unique property thatvibration is not required to remove air voids. It can beeither cast or pumped. Its density together with very goodabrasion resistance make it an ideal hot face lining material.

CASTABLES

PLASTIC NARPHOS 55S REDD RAMM NARPHOS 80S

Maximum Service Temperature 3000oF (1649oC) 3100oF (1740oC) 3200oF (1760oC)

Approximate Amount RequiredAs Rammed lb/ft3 (kg/m3) 156 (2,499) 166 (2,659) 184 (2,948)

Bulk Density, lb/ft3

After Drying at 230OF (110OC) 147 154 170After Drying at 1500OF (816OC) 144 151 166

Modulus of Rupture, lb/in2 (Mpa)At 230OF (110OC) 1,250 (8.6) 1,450 (10.0) 1,650 (11.4)At 1500OF (816OC) 1,250 (8.6) 1,500 (10.3) 1,800 (12.4)At 2700OF (1482OC) 1,500 (10.3) 2,000 (13.8) 1,500 (10.3)

Permanent Linear Change, %After Drying at 230OF (110OC) -0.8 -0.8 -0.8After Heating at 1500OF (816OC) -0.8 -0.7 -0.8After Heating at 3000OF (1649OC) +0.5 +0.3 -0.2


Silica (SiO2) 35.98% 24.22% 9.22%

Alumina (Al2O3) 55.86 68.00 83.31

Titania (TiO2) 1.08 1.26 1.91

Iron Oxide (Fe2O3) 0.73 0.77 1.14

Lime (CaO) 0.52 0.09 0.05

Magnesia (MgO) 0.19 0.18 0.11

Alkalies (Na2O+K2O) 0.59 0.11 1.91

Phosphorus Pentoxide (P2O5) 3.61 3.59 2.86

L.O.I 1.03 1.59 1.33

Refractories for theLime Industry

Precast lifters or tumblers are large kiln blocks made out of our castable refractories. When installed in a kiln sectionthe lifters act to increase the tumbling efficiency of the kiln feed which exposes a larger percentage of feed to hot kilngas and thereby reduces the heat consumption and improves fuel efficiency of the kiln system. Equipment manufactur-ers generally place the lifter section within the preheating zone of a rotary lime kiln.

Our precast lifters can be made to fit any kiln diameter and can be incorporated with any brick shape or castable lining.The lifters are typically designed to be 5” to 6” taller than the existing refractory lining. The sections generally consist offour (4) to six (6) rows running parallel with the kiln axis.

Installation requires welding a piece of carbon steel bar stock for each row to the kiln shell, again running parallel withthe kiln axis. Lifters within the same row interlock together through a unique steel footing system which is also weldedto the carbon steel bar. Once the lifters are in place the main lining can then be installed.

If you are interested in more information on increasing your kiln’s fuel efficiency contact your local HW representative.

PRECAST LIFTERS

© 2001 Harbison-Walker Refractories Company... All Rights Reserved. Cover Photo Courtesy of Dravo Lime Inc. Cat# HW135 (9/02) 2C

Harbison-Walker Refractories Company.400 Fairway Drive


Fax: (412) 375-6846

PRECAST KILN TUMBLER BLOCK

THOR AZSP ADTECH® - a premium anti-buildup product

THOR AZSP ADTECH® is a pumpable special low-moisture fused zirconia-mullitecastable with a silicon carbide addition that can also be shotcreted with GT activator.The zircon is tied up with the mullite and will not reduce. It is totally inert and will notreact with alkalis, chlorides and sulfates. Like others in the THOR family, it has excellentabrasion and anti- buildup resistance, and high refractoriness. It is unique in that it ispumpable giving you a faster turnaround in tight outage situations.

Pumpable Castable for Cement & Lime Kiln Systems

THOR AZSP ADTECH®

TECHNICAL DATA THOR AZSP ADTECHT®

Physical Properties (Typical)

Maximum Service Temperature, °F 2800

Material Required, lb/ft3 177

Bulk Density, pcfAfter 230°F 178After 1500°F 175

Water Required to Cast, weight - % 5.5

Modulus of Rupture, psiAfter 230°F 1,750After 1500°F 2,050

Crushing Strength, psiAfter 230°F 8,600After 1500°F 8,200

Abrasion ResstanceAfter 1500°F 6.8 cc

Chemical Analysis, wt. %Zirconia (ZrO2) 23.7Silica (SiO2) 21.4Alumina (Al2O3) 47.3Iron Oxide (Fe2O3) 0.2Titania (TiO2) 0.2Lime (CaO) 1.9Silicon Carbide (SiC) 4.8Alkalies (Na2O) 0.5

The data given above are based on averages of test results on samples selected from routine plant production and are determinedby standard ASTM procedures where applicable. Variation from the above data may occur in individual tests. These results cannotbe taken as minima or maxima for specification purposes. All statements, information, and data given herein are believed to beaccurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.

Statements or suggestions concerning possible use of our products are made without representation or warranty that any such prod-uct is fit for such use or that such use is free of patent infringement of a third party. The suggested use assumes that all safetymeasures are taken by the user.



For Mineral Processing:








THOR AZS CASTABLETHOR AZSP ADTECH®

Description: A Special Low-Moisture, Zirconia-Mullite Castable that can be conventionally cast or pumped


• 2800°F Service Temperature

• High Hot Strength

• Excellent Thermal Shock Resistance

• Ease of Installation

• Conventional Casting or Pumping

• High Refractoriness

• Proven Track Record

• Unique Flex-O-Anchor design


For Cement Kiln Nose Rings

CONSTRUCTIONJOINTS

FLEX-O-ANCHOR

RAS ANCHOR1/8” CERAMIC PAPER

RETAINING RING

THOR AZS CASTABLEOR THOR AZSP ADTECH

TECHNICAL DATA

THOR AZS CASTABLE THOR AZSP ADTECH®


After 230°F 180 179

Hot Modulus of Rupture, psi

After 1500°F 4,000 1,950

After 2000°F 5,100 --

After 2500°F 1,000 --


After 230°F 12,300 11,600

After 1500°F 10,800 10,500

After 2200°F 15,200 --


Silica (SiO2) 17.8% 18.4%

Alumina (Al2O3) 55.2 53.3

Titania (TiO2) 0.2 0.2

Iron Oxide (Fe2O3) 0.1 0.1

Lime (CaO) 1.4 1.4

Silicon Carbide (SiC) 5.0 5.0

Zirconia (ZrO2) 20.1 21.4

Alkalies (Na2O + K2O) 0.2 0.2

The data given above are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable.Variation from the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, infor-mation, and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed orimplied.


Warning: If proper procedures for preparation, application and heat-up of this material are not observed, steam spalling during heat-up may occur.

© 2003 Harbison-Walker Refractories Company. All Rights Reserved.Cat# HW134 R (03/03) 2C

Harbison-Walker Refractories Company400 Fairway DriveMoon Township, PA 15108

Phone: 1-800-377-4497 Fax: (412) 375-6846

Anti-Buildup For Existing Linings

TZ 352 DRY MORTAR

TZ 352 DRY MORTAR

TZ 352 DRY MORTAR is a heat-set Zircon-containing dry mortar that is an effective anti-buildup material for nonbasic refractory linings. It can be installed over monolithic orbrick linings thereby saving time and money. The application method is either by trowelor spraying. TZ 352 DRY MORTAR is chemically inert and if a buildup does occur, it iseasily removed.

TECHNICAL DATA TZ 352 DRY MORTAR

Physical Properties (Typical)

Maximum Service Temperature, °C - (°F) 1732 - (3150)

Cement Required, tons per 1000 ft2 1

Required Installation Thickness, inches 0.125 - .25

Water Required:

For trowelling add 12-15%

For spraying add 20-25%

Chemical Analysis, wt. %

Zirconia (ZrO2) 60.0

Silica (SiO2) 32.0

Alumina (Al2O3) 1.0

Phosphorous Pentoxide (P2O5) 4.7

Alkalies (Na2O+K2O) 1.6

The data given above are based on averages of test results on samples selected from routine plant production and are determinedby standard ASTM procedures where applicable. Variation from the above data may occur in individual tests. These results cannotbe taken as minima or maxima for specification purposes. All statements, information, and data given herein are believed to beaccurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.

Statements or suggestions concerning possible use of our products are made without representation or warranty that any such prod-uct is fit for such use or that such use is free of patent infringement of a third party. The suggested use assumes that all safetymeasures are taken by the user.



For Mineral Processing:









Description: A 70% High Alumina Low Cement Castable


• 31000F Service Temperature

• High Hot Strength

• Excellent Abrasion Resistance

• Ease of Installation• Vibcasting• Conventional Casting• Pumping

• High Refractoriness

• Proven Track Record

• Unique Flex-O-Anchor Design


For Cement Kiln Nose Rings

CONSTRUCTIONJOINTS

FLEX-O-ANCHOR

RAS ANCHOR1/8” CERAMIC PAPER

RETAINING RING


VIBCASTING CONV. CASTING/PUMPING


TECHNICAL DATA


After 230°F 158 153


After Drying at 230°F 1,990 1,980

After Heating at 1500°F 3,300 2,500

At 2500 °F 750 --


After 230°F 21,660 18,160

After 1500°F 15,000 14,770


Silica (SiO2) 27.0%


Titania (TiO2) 2.4


Lime (CaO) 2.1

Magnesia (MgO) 0.1

Alkalies (Na2O + K2O) 0.2

The data given above are based on averages of tests results on samples selected from routine plant production by standard A.S.T.M. procedures where applica-ble. Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements,information, and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind,expressed or implied.


Warning: If prpoer procedures for prepration, application and Heat-up of this material are not observed, steam spalling during heat-up may occur.

This product is covered by Patent No. 4,430,439




Fax: (412) 375-6846

Mag-Chrome Brick Selections

SUPER NARMAG® FG: This product is aburned 100% fused Mg-Cr grain brick withchrome enhancement. This yields extremelylow porosity, very high density, and excellentstrength. SUPER NARMAG® FG is intendedfor the most extreme basic steel and iron con-taining conditions with regards to slag corro-siveness and temperature.

NARMAG® FG: This product is a burned 100%fused Mg-Cr grain brick. This yields excellentporosity, density, and strength. NARMAG® FGis intended for extreme basic steel and ironcontaining conditions.

SUPER NARMAG® 142: This product is aburned 20% fused Mg-Cr grain brick. It offersvery good porosity, density, and strength. Thisproduct is for normal basic steel and iron con-taining conditions.

NARMAG® 142: This product is a burnedMg-Cr brick containing no fused grain.Compared to the above products,NARMAG® 142 has slightly higher porosityalong with lower density and strength. Thisproduct is for normal basic steel and ironcontaining conditions.

Problem Solvers: SUPER NARMAG®145 with50% fused grain and TOMAHAWK® withimproved thermal shock resistance.

Other Brands: NARMAG® 60DB andNARMAG® 60DBR can be considered aseconomical alternatives in zoned linings.

Other Selections

Mortars: Mag-Chrome brick should be laidwith NARMAG® FG FINE MORTAR DRY.

Bottom Leveling: H-W® C Mix is a high purity,periclase ramming mix with chemical bonds.

NARMAG® 95LS CASTABLETAYCOR® 414-C HYDROCASTFASTDRY 8 CASTABLE

Castable Selections

NARMAG® 95LS CASTABLE: This is a 96%magnesia castable with high density and out-standing hot strength. It is intended for basic steeland iron operations.

TAYCOR® 414-C HYDROCAST: This is a coarsegrained, 96% alumina castable. The coarsegrained structure provides for very good thermalshock resistance.

FASTDRY 8 CASTABLE: This is a high alumi-na, cement free castable with an alumina richspinel matrix. It offers good resistance to steeland iron slags. The cement free formulationallows the dry out to begin sooner than forcement containing castables.

NARMAG® FG

NARMAG® 142

SUPERNARMAG® 142

NARMAG® 60DB

SUPERNARMAG® FG

NARMAG® 60DB

NARMAG® FG NARMAG® 60DB

AOD Refractoriesfor Industrial Foundries

H-W® C Mix

The data given above are based on averages of test results on samplesselected from routine plant production by standard A.S.T.M. procedureswhere applicable. Variation from the above data may occur in individual test.These results cannot be taken as minima or maxima for specification purpos-es. All statements, information, and data given herein are believed to beaccurate and reliable but are presented without guarantee, warranty, orresponsibility of any kind, expressed or implied.

Statements or suggestions concerning possible use of our products aremade without representation or warranty that any such product is fit for suchuse or that such use is free of patent infringement of a third party. The sug-gested use assumes that all safety measures are taken by the user.

AOD Refractories BRICK CASTABLES

SUPER SUPER NARMAG® TAYCOR® FASTDRYNARMAG® NARMAG® NARMAG® NARMAG® 95LS 414-C 8

Typical Test Data FG FG 142 142 CASTABLE HYDROCAST CASTABLE

Bulk Density, pcfAfter 230°F 210 207 205 204 178 182 195

Modulus of Rupture, psiAt 70°F 1,700 1,500 700 600 500 1,800 1,900At 2700°F 850 700 300 400 1,600 -- 700

Apparent Porosity % 12 13 14 15 -- -- --Chemical Analysis, %(Approximate)

Silica (SiO2) 0.5 % 0.6% 0.5% 0.3% 0.7% 0.2% 1.0%Alumina (Al2O3) 6.1 6.3 6.8 6.9 0.2 96.5 90.8Iron Oxide (Fe2O3) 12.0 12.0 12.0 13.0 0.2 0.1 0.1Lime (CaO) 0.5 0.8 0.7 0.8 2.8 2.5 0.1Magnesia (MgO) 58.0 62.0 61.0 59.0 96.0 -- 7.8Chromic Oxide (Cr2O3) 22.0 18.0 19.0 20.0 -- -- --Alkalies (Na2O + K2O) -- -- -- -- -- 0.1 0.2

Photo shows AOD vessel with NARMAG® FG andSUPER NARMAG® 142 zoned by brand and thickness for optimal performance.




Phone: (412) 375-6600 w Fax: (412) 375-6783

SUPER SUPER SUPER

NARCARB NARCARB GRAPHPAK GRAPHPAK GRAPHPAK GREENPAK NARCARB NARCARB RAMAL

PLASTIC ZP -85 -85 -45 85 MP RAM XZR 85G

Max. Service Temp, oF 3275 3275 3200 3100 2950 3000 3275 3275 3275Material Required, lb/ft3 184 178 185 166 142 178 184 188 160Modulus of Rupture, lb/in2

After Heating to 300°F 1,300 800 900 350 250 750 1,300 2,600 200After Heating to 1500°F -- -- -- 125 200 1,300 -- -- --After Heating to 1800°F 700 900 -- -- -- -- 1,200 640 --

At 2000°F -- 900 -- -- -- -- -- 1,660 760

At 2500°F 1,100 -- -- -- -- -- 1,300 -- --

Apparent Porosity, %

After Heating to 1800oF 20 22.5 -- -- -- -- 18 17 --

Chemical Analysis: %(Approximate)

Silica (SiO2) 8.7 7.8 13.5 11.4 46.7 11.0 6.6 6.5 9.1

Alumina (Al2O3) 61.8 70.0 62.7 72.1 39.6 80.0 64.0 68.9 76.1

Titania (TiO2) 1.4 1.5 1.9 2.4 2.3 2.5 1.3 1.6 1.7

Iron Oxide (Fe2O3) 0.4 0.7 0.7 1.3 1.5 1.4 0.7 0.3 1.5

Lime (CaO) 0.1 0.2 0.1 0.2 0.5 0.1 0.1 0.1 0.6

Magnesia (MgO) 0.2 0.3 0.1 0.2 0.4 0.1 0.1 0.1 0.1

Alkalies (Na2O+K2O) 0.1 0.2 0.1 0.4 1.1 0.2 0.1 0.1 0.3

Phosphorus Pentoxide (P2O5) -- -- -- -- -- 4.0 -- -- --

Silicon Carbide + Carbon (SiC+C) 27.3 19.0 20.9 12.0 8.0 -- 27.1 22.4 10.6

Iron RunnerD-CAST TRC-SR-CCRAMAL 85GGREENPAK-85-MP

Taphole Shapes

Precast OptionsRUBY® SR/CTUFLINE® 95 DM/CTUFLINE® 90 DM/CD-CAST TRC-SRVERSAFLOW® 70/CU ADTECH®

Monolithic OptionsSUPER NARCARB PLASTIC/RAMNARCARB ZP PLASTICNARCARB XZR RAMSUPER GRAPHPAK-85

Breast WallSUPER NARCARB PLASTICNARCARB ZP PLASTICSUPER GRAPHPAK-85

Slag TroughD-CAST TRC-SR-CCSUPER NARCARB PLASTIC/RAMSUPER GRAPHPAK-85RAMAL 85G

Front Slagger & DamD-CAST TRC-SR-CCSUPER NARCARB PLASTIC/RAMSUPER GRAPHPAK-85RAMAL 85G

Bottom*NARCARB ZP PLASTICRAMAL 85GNARPHOS 55R (FINE)*All used in combination with sand




Phone: (412) 375-6600 w Fax: (412) 375-6783

Service Conditions• Temperature (2000oF - 3000oF)

• Slag, Metal, Oxygen Reactions

• Metal Erosion and Velocity



NARCARB ZP Plastic lining a cupola well zoneInstallation of RAMAL 85 G in cupola trough application.

Breast Wall & Trough Plastics Ram Mixes

CUPOLA RefractoriesBreast Wall & Trough

WellD-CAST TRC 69VERSAFLOW® 70/CU ADTECH®

MaintenanceSUPER NARCARB PLASTICNARCARB ZP PLASTIC

Examples of VIBTECH® shapes. Such shapescan provide excellent performance in cupolawell blocks and taphole applications.

TUFLINE® TUFLINE®

VERSAFLOW® D-CAST 90 DM/C 95 DM/C RUBY® SR/C D-CAST NARPHOS

70/CU ADTECH® TRC-SR-CC VIBTECH® VIBTECH® VIBTECH® TRC 69 55R (FINE)

Cast & Shapes Cast & Shapes Shape Shape Shape Castable Ram

Max. Service Temp, oF 2850 3100 3300 3400 3300 3100 3000


After Heating to 230oF 173 194 197 200 204 185 156


At 70°F -- -- 1,710 1,720 1,360 -- --

After Heating to 230°F 1,890 1,900 -- -- -- 1,800 1,100

After Heating to 1500°F 2,600 -- -- -- -- -- 700

At 2500°F 700 600 -- -- -- 1,100 650

At 2700°F -- 400 1,320 -- -- 300 --

Apparent Porosity, % -- -- 14.6 15.8 15.5 -- --

Chemical Analysis: % (Approximate)

Silica (SiO2) 11.7 6.1 7.0 2.1 1.9 8.7 39.3

Alumina (Al2O3) 68.5 72.5 89.3 94.2 83.0 69.0 54.4

Titania (TiO2) 2.2 1.6 -- -- 0.1 2.4 1.5

Iron Oxide (Fe2O3) 1.0 0.1 0.1 0.1 0.1 0.9 1.0

Lime (CaO) 2.2 1.2 0.1 0.1 0.1 1.2 Trace

Magnesia (MgO) 0.2 0.1 -- -- Trace 0.1 0.1

Alkalies (Na2O+K2O) 0.2 0.1 -- -- 0.2 0.2 0.3

Chromic Oxide (Cr2O3) -- -- -- -- 11.1 -- --

Silicon Carbide + Carbon (SiC+C) 14.0 18.0 -- -- -- 17.5 --

Other Oxides -- -- 3.5 3.5 3.5 -- 3.3

The data given above are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable.Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima or specification purposes. All statements, information, anddata given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.


Taphole Well and Bottom MaterialsCupola Brand DescriptionSiC / Graphite Plastic & Ram Selections:

SUPER NARCARB These products are based on fused alumina with SiC and oxidation inhibitors. This yields very low PLASTIC & RAM: porosity for enhanced corrosion resistance to cupola slags. Both of these SUPER NARCARB

materials are intended for extended cupola campaigns and the most severe service conditions. Both products offer the highest level of carbon containing, non-wetting components. These products offer a more environmentally friendly bond system than the phenolic resin bonded materials.

NARCARB This is a phenolic resin bonded ramming mix with the second highest amount of non-wetting compo-XZR RAM: nents. This mix offers high density, low porosity and high hot strengths. NARCARB XZR RAM provides

excellent performance in maintenance situations or as the original lining in Cupola bottoms and troughs.

NARCARB ZP This phenolic resin bonded plastic provides high strengths at iron producing temperatures. It PLASTIC: contains SiC with oxidation inhibitors. NARCARB ZP provides excellent performance in extended

cupola campaigns under severe conditions. This material is ideally suited for well zone and melt zone maintenance during bottom drops.

SUPER This air-setting, silicon carbide and graphite containing, oxidation resistance plastic contains no GRAPHPAK-85: pitch or resins. As a result, it does not give off polluting emissions. This plastic possesses good

resistance to hot metal and slag erosion and represents an economical alternative to NARCARB ZPand SUPER NARCARB in less severe conditions.

GRAPHPAK-85, These are high alumina and fireclay, graphite containing materials. They exhibit better corrosion GRAPHPAK-45 resistance to molten iron and slag than conventional materials. These are workhorse type materials & RAMAL 85G: for cupolas. GRAPHPAK-45 and GRAPHAK-85 are plastics while RAMAL 85G is a wet ramming mix.

Taphole Material Selections:

VIBTECH® Shapes: These are thixotropic-formed shapes which are fired to high temperatures to achieve properties equivalent to brick. Depending on the specific mix, VIBTECH shapes can provide longer service life, high hot strengths, low porosity, and excellent thermal shock resistance. Options for cupola taphole service include TUFLINE® 90 DM/C, TUFLINE® 95 DM/C, and RUBY® SR/C.

D-CAST TRC-SR: This SiC and carbon containing castable can also be ordered as a precast shape. Either way, it provides exceptional properties such as 9% porosity, excellent hot strengths, and excellent thermal shock resistance. It is non-wetting to iron and slag, contains oxidation inhibitors, and exhibits slag resistance comparable to resin-bonded plastis. D-CAST TRC-SR is an excellent choice for taphole blocks, well blocks, or long iron runners.

VERSAFLOW® This is a 70% alumina low cement castable containing SiC. It can be ordered as a castable or 70/CU ADTECH®: precast shape. The SiC provides enhanced corrosion resistance in taphole blocks, well blocks, or long iron

runners.

Castables for Cupola Applications

D-CAST TRC-SR-CC This is a low cement, SiC containing castable with improved slag resistance compared with other D-CAST materials. It features improved strengths above 1500oF, excellent thermal shock resistance, a modified matrix for enhanced slag resistance, and volume stability for negligible sintering cracks during service. These properties make D-CAST TRC-SR-CC an outstanding option for severe slag and metal contact applications.

D-CAST TRC 69 This a low cement, SiC and carbon containing castable. This product is a lower cost version of the other D-CAST products but is not as oxidation resistant. This product is used in applications where service demands are less severe.

SUPER SUPER SUPER

NARCARB NARCARB GRAPHPAK GRAPHPAK GRAPHPAK GREENPAK NARCARB NARCARB RAMAL

PLASTIC ZP -85 -85 -45 85 MP RAM XZR 85G

Max. Service Temp, oF 3275 3275 3200 3100 2950 3000 3275 3275 3275Material Required, lb/ft3 184 178 185 166 142 178 184 188 160Modulus of Rupture, lb/in2

After Heating to 300°F 1,300 800 900 350 250 750 1,300 2,600 200After Heating to 1500°F -- -- -- 125 200 1,300 -- -- --After Heating to 1800°F 700 900 -- -- -- -- 1,200 640 --

At 2000°F -- 900 -- -- -- -- -- 1,660 760

At 2500°F 1,100 -- -- -- -- -- 1,300 -- --

Apparent Porosity, %

After Heating to 1800oF 20 22.5 -- -- -- -- 18 17 --

Chemical Analysis: %(Approximate)

Silica (SiO2) 8.7 7.8 13.5 11.4 46.7 11.0 6.6 6.5 9.1

Alumina (Al2O3) 61.8 70.0 62.7 72.1 39.6 80.0 64.0 68.9 76.1

Titania (TiO2) 1.4 1.5 1.9 2.4 2.3 2.5 1.3 1.6 1.7

Iron Oxide (Fe2O3) 0.4 0.7 0.7 1.3 1.5 1.4 0.7 0.3 1.5

Lime (CaO) 0.1 0.2 0.1 0.2 0.5 0.1 0.1 0.1 0.6

Magnesia (MgO) 0.2 0.3 0.1 0.2 0.4 0.1 0.1 0.1 0.1

Alkalies (Na2O+K2O) 0.1 0.2 0.1 0.4 1.1 0.2 0.1 0.1 0.3

Phosphorus Pentoxide (P2O5) -- -- -- -- -- 4.0 -- -- --

Silicon Carbide + Carbon (SiC+C) 27.3 19.0 20.9 12.0 8.0 -- 27.1 22.4 10.6

Iron RunnerD-CAST TRC-SR-CCRAMAL 85GGREENPAK-85-MP

Taphole Shapes

Precast OptionsRUBY® SR/CTUFLINE® 95 DM/CTUFLINE® 90 DM/CD-CAST TRC-SRVERSAFLOW® 70/CU ADTECH®

Monolithic OptionsSUPER NARCARB PLASTIC/RAMNARCARB ZP PLASTICNARCARB XZR RAMSUPER GRAPHPAK-85

Breast WallSUPER NARCARB PLASTICNARCARB ZP PLASTICSUPER GRAPHPAK-85

Slag TroughD-CAST TRC-SR-CCSUPER NARCARB PLASTIC/RAMSUPER GRAPHPAK-85RAMAL 85G

Front Slagger & DamD-CAST TRC-SR-CCSUPER NARCARB PLASTIC/RAMSUPER GRAPHPAK-85RAMAL 85G

Bottom*NARCARB ZP PLASTICRAMAL 85GNARPHOS 55R (FINE)*All used in combination with sand




Phone: (412) 375-6600 w Fax: (412) 375-6783

Service Conditions• Temperature (2000oF - 3000oF)

• Slag, Metal, Oxygen Reactions

• Metal Erosion and Velocity



NARCARB ZP Plastic lining a cupola well zoneInstallation of RAMAL 85 G in cupola trough application.

Breast Wall & Trough Plastics Ram Mixes

CUPOLA RefractoriesBreast Wall & Trough

WellD-CAST TRC 69VERSAFLOW® 70/CU ADTECH®

MaintenanceSUPER NARCARB PLASTICNARCARB ZP PLASTIC

KRUZITE® UFALA® TUFLINE® KORUNDAL KORUNDAL RUBY® RUBY®

Brand -70 DV-38 XCR 90 XD® XD® DM DM

Density, pcf 165 179 159 182 186 195 198 213

Apparent Porosity, % 18.7 14.0 14.1 17.6 16.1 12.4 17.8 12.6Crushing Strength, psi

At 70oF 8,500 18,000 7,400 11,500 11,350 16,000 12,500 19,450


At 70oF 1,700 3,400 2,200 1,730 2,330 3,840 4,500 7,150

At 2700oF -- -- -- 1,050 1,320 1,930 1,890 4,000

Chemical Analysis, %

(Approximate)

Alumina (Al2O3) 71.0 80.4 60.3 89.1 90.1 90.3 89.7 89.6

Silica (SiO2) 23.0 11.0 36.8 9.7 9.5 9.2 0.5 0.3

Titania (TiO2) 3.4 2.5 1.3 0.6 Trace Trace 0.1 Trace

Iron Oxide (Fe2O3) 1.6 1.3 1.1 0.3 0.1 0.1 0.2 0.1

Lime 3(CaO) 0.2 0.1 0.1 0.1 0.1 0.1 0.3 0.1

Magnesia 3(MgO) 0.2 0.1 0.1 Trace Trace 0.1 0.1 Trace

Alkalies (Na2O+K2O) 0.6 0.2 0.3 0.2 0.2 0.2 0.1 0.1

Chromic Oxide (Cr2O3) -- -- -- -- -- -- 9.0 9.8

Phosphorus Pentoxide (P2O5) -- 4.4 -- -- -- -- -- --

Horizontal Channel Induction Furnace Refractory Selection

CHANNEL INDUCTION REFRACTORIES for Industrial FoundriesTechnical Data Brick

Service Conditions

Gray & Malleable Iron: Ductile Iron:- Temperatures of 2750oF + - Temperatures of 2800oF +- Slag Buildup - CaC2 & MgO Attack

- Slag Line Erosion- More Use of Chrome Containing Brick

Channel Induction Refractories

For Industrial Foundries

HORIZONTAL CHANNEL INDUCTION FURNACES

Technical Data Monolithic Products

The data given above are based on averages of tests results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable. Variation from the above data mayoccur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and data given herein are believed to be accurate and reliable butare presented without guarantee, warranty, or responsibility of any kind, expressed or implied. Statements or suggestions concerning possible use of our products are made without representation orwarranty that any such product is fit for such use or that such use is free of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.





Operating Slag & Metal Slag & Metal Receivers & Repair &Conditions Contact Backup Crown Pour Spouts Mainteance

CORAL® BP CLIPPER® DP CORAL® BP KORUNDAL® PLASTIC KORUNDAL® PLASTICGray Iron KORUNDAL® XD D-CAST 85TMCC

GREENCAST®-94

TUFLINE® 90 KRUZITE® 70 CORAL® BP KORUNDAL® PLASTIC GREENPAK-90-PMalleable Iron KORUNDAL® XD CORAL® BP UFALA® XCR D-CAST TRC-SR-CC

KORUNDAL XD® DM KORUNDAL XD® FUSECRETE® C, C6, C10

KORUNDAL XD® KRUZITE®-70 UFALA® XCR RUBY® PLASTIC AMC RUBY® PLASTIC 10

Ductile Iron KORUNDAL XD® DM DV-38 TUFLINE® 90 RUBY® PLASTIC 10RUBY® KORUNDAL XD® FUSECRETE® C, C6, C10

RUBU® DM

KORUNDAL® KORUNDAL® GREENCAST® HP-CAST D-CAST RUBY® FUSECRETE® D-CAST RUBY®

Brand PLASTIC HOT GUN 94 ULTRA 85TMCC PLASTIC AMC C10 TRC-SR-CC RAM MIX

Density, pcf After Drying, 175 146 172 195 182 167 192 194 203


After 230OF -- 680 9,000 7,000 9,200 -- 3,225 6,500 12,500

After 1500OF -- 980 9,500 9,500 13,200 -- 2,580 -- 14,800

Modulus of Rupture, psi (500oF)

After 230OF -- 340 1,700 2,000 1,400 1,160 1,040 1,900 3,000

After 1500OF 2,180 340 1,750 2,500 2,600 1,400 720 -- 3,700Chemical Analysis, %(Approximate)

Alumina (Al2O3) 87.1 88.8 94.1 96.3 83.1 61.0 85.6 72.5 83.8

Silica (SiO2) 8.5 8.4 0.2 0.1 11.0 18.1 0.6 6.1 1.8

Titania (TiO2) 0.1 0.5 0.1 -- 2.8 1.7 1.7 1.6 Trace

Iron Oxide (Fe2O3) 0.2 0.4 0.2 0.1 1.0 0.7 0.2 0.1 0.1

Lime 2(CaO) 0.1 1.6 5.1 2.5 1.4 0.1 1.7 1.2 0.1

Magnesia 2(MgO) 0.1 0.1 0.1 0.8 0.1 0.2 0.2 0.1 0.1

Alkalies (Na2O+K2O)3 0.2 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2

Phosphorous Pentoxide (P2O5) 3.7 -- -- -- -- 3.7 -- -- 3.8

Chromic Oxide (Cr2O3) -- -- -- -- -- 14.3 9.9 -- 10.1

Silicon Carbide + Carbon (SiC + C) -- -- -- -- -- -- -- 18.0 --

Pressure Pour Channel Induction Refractory SelectionOperating Slag & Metal Slag & Metal Receivers & Repair &Conditions Contact Backup Roof Pour Spouts Mainteance

NARPHOS 90R RAM KAST-O-LITE® 23 ES KAST-O-LITE® 97-L KORUNDAL® PLASTIC KORUNDAL® PLASTICGray Iron D-CAST 85TMCC D-CAST 85TMCC

GREENCAST®-94

HP CAST ULTRA KAST-O-LITE® 26 LI KAST-O-LITE® 97-L KORUNDAL® PLASTIC GREENPAK-90-PMalleable Iron D-CAST TRC-SR-CC D-CAST TRC-SR-CC

FUSECRETE® C, C6, C10

RUBY® RAMMING MIX KAST-O-LITE® 26 LI KAST-O-LITE® 97-L RUBY® PLASTIC AMC RUBY® PLASTIC 10Ductile Iron FUSECRETE® C, C6, C10 RUBY® PLASTIC 10

FUSECRETE® C, C6, C10

Vertical Channel Induction Furnace Refractory Selection

Service Conditions

Gray & Malleable Iron:- Temperatures of 2750OF +- Slag Buildup

Ductile Iron:- Temperatures of 2800OF +- CaC2 & MgO Attack- Slag Line Erosion

Thermal Shock a Concern forFurnaces Without a Receiver.

VERTICAL CHANNEL INDUCTION FURNACES PRESSURE POUR CHANNEL INDUCTION FURNACES

RUBY® RAMMING MIX lining the upper caseand KORUNDAL XD® forming the jack archand floor.

D-CAST TRC-SR-CC being pump cast into the pourspout and receiver.

D-CAST TRC-SR-CC showing little signs of wear after 1 plus years of service in a pouring arm.

Service Conditions

Narrow Inlet & Outlets Prone to Choking

Pressure Can Force Metal into Open Cracks & Porosity

Milder Operating Conditions due to Reduction in Slag Generation,and the Absence of Tilting or Rolling Movements

Potential Reducing AtmosphereCan Reduce SiO2 in Refractories

Operating Slag & Metal Slag & Metal Slag & Metal Receivers & Repair &Conditions Contact Brick Contact Monolithic Backup Roof Pour Spouts Maintenance

CORAL® BP NARPHOS 85R RAM CLIPPER® DP KAST-O-LITE® 97-L KORUNDAL® PLASTIC KORUNDAL® PLASTIC

Gray Iron KORUNDAL® XD D-CAST 85TMCC EXPRESS®-30 D-CAST 85TMCC GREFCOTE® 50

MIZZOU CASTABLE® GREENCAST®-94

TUFLINE® 90 HP CAST ULTRA KRUZITE®-70 KAST-O-LITE® 97-L KORUNDAL® PLASTIC GREENPAK-90-P Malleable Iron KORUNDAL XD® D-CAST TRC-SR-CC CORAL® BP EXPRESS®-30 D-CAST TRC-SR-CC GREFCOTE® 70

KORUNDAL XD® DM MIZZOU® CASTABLE® FUSECRETE® C, C6, C10

KORUNDAL XD® RUBY® RAMMING MIX KRUZITE®-70 KAST-O-LITE® 97-L RUBY® PLASTIC AMC RUBY® PLASTIC 10

Ductile IronKORUNDAL XD® DM FUSECRETE C, C6, C10 DV-38 EXPRESS®-30 RUBY® PLASTIC 10 KORUNDAL® HOT GUN

RUBY® MIZZOU CASTABLE® FUSECRETE® C, C6, C10RUBY® DM

KRUZITE® UFALA® TUFLINE® KORUNDAL KORUNDAL RUBY® RUBY®

Brand -70 DV-38 XCR 90 XD® XD® DM DM

Density, pcf 165 179 159 182 186 195 198 213

Apparent Porosity, % 18.7 14.0 14.1 17.6 16.1 12.4 17.8 12.6Crushing Strength, psi

At 70oF 8,500 18,000 7,400 11,500 11,350 16,000 12,500 19,450


At 70oF 1,700 3,400 2,200 1,730 2,330 3,840 4,500 7,150

At 2700oF -- -- -- 1,050 1,320 1,930 1,890 4,000


(Approximate)

Alumina (Al2O3) 71.0 80.4 60.3 89.1 90.1 90.3 89.7 89.6

Silica (SiO2) 23.0 11.0 36.8 9.7 9.5 9.2 0.5 0.3

Titania (TiO2) 3.4 2.5 1.3 0.6 Trace Trace 0.1 Trace

Iron Oxide (Fe2O3) 1.6 1.3 1.1 0.3 0.1 0.1 0.2 0.1

Lime 3(CaO) 0.2 0.1 0.1 0.1 0.1 0.1 0.3 0.1

Magnesia 3(MgO) 0.2 0.1 0.1 Trace Trace 0.1 0.1 Trace

Alkalies (Na2O+K2O) 0.6 0.2 0.3 0.2 0.2 0.2 0.1 0.1

Chromic Oxide (Cr2O3) -- -- -- -- -- -- 9.0 9.8

Phosphorus Pentoxide (P2O5) -- 4.4 -- -- -- -- -- --

Horizontal Channel Induction Furnace Refractory Selection

CHANNEL INDUCTION REFRACTORIES for Industrial FoundriesTechnical Data Brick

Service Conditions

Gray & Malleable Iron: Ductile Iron:- Temperatures of 2750oF + - Temperatures of 2800oF +- Slag Buildup - CaC2 & MgO Attack

- Slag Line Erosion- More Use of Chrome Containing Brick

Channel Induction Refractories


HORIZONTAL CHANNEL INDUCTION FURNACES

Technical Data Monolithic Products

The data given above are based on averages of tests results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable. Variation from the above data mayoccur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and data given herein are believed to be accurate and reliable butare presented without guarantee, warranty, or responsibility of any kind, expressed or implied. Statements or suggestions concerning possible use of our products are made without representation orwarranty that any such product is fit for such use or that such use is free of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.





Operating Slag & Metal Slag & Metal Receivers & Repair &Conditions Contact Backup Crown Pour Spouts Mainteance

CORAL® BP CLIPPER® DP CORAL® BP KORUNDAL® PLASTIC KORUNDAL® PLASTICGray Iron KORUNDAL® XD D-CAST 85TMCC

GREENCAST®-94

TUFLINE® 90 KRUZITE® 70 CORAL® BP KORUNDAL® PLASTIC GREENPAK-90-PMalleable Iron KORUNDAL® XD CORAL® BP UFALA® XCR D-CAST TRC-SR-CC

KORUNDAL XD® DM KORUNDAL XD® FUSECRETE® C, C6, C10

KORUNDAL XD® KRUZITE®-70 UFALA® XCR RUBY® PLASTIC AMC RUBY® PLASTIC 10

Ductile Iron KORUNDAL XD® DM DV-38 TUFLINE® 90 RUBY® PLASTIC 10RUBY® KORUNDAL XD® FUSECRETE® C, C6, C10

RUBU® DM

KORUNDAL® KORUNDAL® GREENCAST® HP-CAST D-CAST RUBY® FUSECRETE® D-CAST RUBY®

Brand PLASTIC HOT GUN 94 ULTRA 85TMCC PLASTIC AMC C10 TRC-SR-CC RAM MIX

Density, pcf After Drying, 175 146 172 195 182 167 192 194 203


After 230OF -- 680 9,000 7,000 9,200 -- 3,225 6,500 12,500

After 1500OF -- 980 9,500 9,500 13,200 -- 2,580 -- 14,800

Modulus of Rupture, psi (500oF)

After 230OF -- 340 1,700 2,000 1,400 1,160 1,040 1,900 3,000

After 1500OF 2,180 340 1,750 2,500 2,600 1,400 720 -- 3,700Chemical Analysis, %(Approximate)

Alumina (Al2O3) 87.1 88.8 94.1 96.3 83.1 61.0 85.6 72.5 83.8

Silica (SiO2) 8.5 8.4 0.2 0.1 11.0 18.1 0.6 6.1 1.8

Titania (TiO2) 0.1 0.5 0.1 -- 2.8 1.7 1.7 1.6 Trace

Iron Oxide (Fe2O3) 0.2 0.4 0.2 0.1 1.0 0.7 0.2 0.1 0.1

Lime 2(CaO) 0.1 1.6 5.1 2.5 1.4 0.1 1.7 1.2 0.1

Magnesia 2(MgO) 0.1 0.1 0.1 0.8 0.1 0.2 0.2 0.1 0.1

Alkalies (Na2O+K2O)3 0.2 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2

Phosphorous Pentoxide (P2O5) 3.7 -- -- -- -- 3.7 -- -- 3.8

Chromic Oxide (Cr2O3) -- -- -- -- -- 14.3 9.9 -- 10.1

Silicon Carbide + Carbon (SiC + C) -- -- -- -- -- -- -- 18.0 --

Electric Arc Furnace Refractories


UPPER SIDE WALLAcid Practice

ALADIN® 80KRUZITE®-70

Basic PracticeNARMAG® 80DBNARMAG® 60DB

SLAG LINEAcid Practice


Basic PracticeSUPER NARMAG® B NARMAG® 142NARMAG® FG

LOWER SIDE WALLAcid Practice


Basic PracticeSUPER NARMAG® BNARTAR 7

BOTTOM/HEARTHAcid Practice

GANNISTER MIX

MAINTENANCEAcid Practice

GREFCOTE® 70

SLAG DOOR & SPOUTAcid Practice

GREENPAK-85-MPRUBY® PLASTIC AMCFUSECRETE® C10

Basic PracticeSUPER NARMAG® BNARTAR 7NARMAG® FG RAM MIX

ROOFAcid & Basic Practice


DELTA/ELECTRODE RINGSAcid & Basic Practice

GREENPAK-85-MPSUPER HYBOND 80

PrecastNOVACON® 65D-CAST 85TMCCULTRA-GREEN SR

© 2003 Harbison-Walker Refractories Company. All Rights Reserved. Cat# HW119 (1/03) 2C



Phone: (412) 375-6600 w Fax: (412) 375-6783

ACID PRACTICE BRICK & MONOLITHICS

BASIC PRACTICE BRICK & MONOLITHICS

The data given above are based on averages of tests results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable. Variation from the above data may occurin individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and data given herein are believed to be accurate and reliable but are presentedwithout guarantee, warranty, or responsibility of any kind, expressed or implied.

Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of athird party. The suggested use assumes that all safety measures are taken by the user.

RUBY®

BRAND ALADIN® KRUZITE®- D-CAST GREENPAK- NOVACON® PLASTIC FUSECRETE® GREFCOTE®

80 70 85TMCC 85-MP 65 AMC C10 70

Density, lb/ft3 170 165 182 178 155 180 189 130

Modulus of Rupture, lb/in2 (500oF)

At 70oF/After 230oF 1,610 1,700 1,400 750 1,490 1,160 1,040 600


At 70oF/After 230oF 9,610 8,500 9,200 -- 7,950 -- 3,225 2,000

Apparent Porosity, % 19.5 18.7 13.5 -- -- -- -- --


(Approximate)

Silica (SiO2) 15.2% 23.0% 11.0% 11.0% 31.1% 18.1% 0.6% 22.0%

Alumina (Al2O3) 78.6 71.0 83.1 80.0 64.8 61.0 85.6 70.5

Titania (TiO2) 3.4 3.4 2.8 2.5 2.2 1.7 1.7 3.3

Iron Oxide (Fe2O3) 1.8 1.6 1.0 1.4 0.9 0.7 0.2 1.4

Lime (CaO)3 0.3 0.2 1.4 0.1 0.1 0.1 1.7 2.0

Magnesia3 (MgO) 0.3 0.2 0.1 0.1 0.1 0.2 0.2 0.2

Alkalies (Na2O+K2O) 0.4 0.6 0.2 0.2 0.4 0.2 0.1 0.6

Chromic Oxide (Cr2O3) -- -- -- -- -- 14.3 9.9 --

Phosphorous Pentoxide (P2O5) -- -- -- 4.0 0.4 3.7 -- --

BRAND SUPER NARMAG® NARMAG® NARMAG®FGNARMAG® FG NARMAG® 142 NARMAG® B NARTAR 7 80DB 60DB RAM MIX

Density, lb/ft3 207 204 185 197 191 191 195


At 70oF 1,500 600 2,500 3,000 750 650 1,000

AT 2700oF 700 400 -- -- 160 220 --

At 2800oF -- -- 1,700 1,400 -- -- --

Crushing Strength, lb/in2, At 70oF 12,000 -- 8,700 14,000 -- 5,800 --

Apparent Porosity, % 13.0 15.0 14.0 15.0 16.0 18.0 21.0


(Approximate)

Silica (SiO2) 0.6% 0.3% 0.9% 1.0% 1.3% 2.5% 0.7%

Alumina (Al2O3) 6.3 6.9 0.2 0.1 3.6 7.3 6.8

Iron Oxide (Fe2O3) 12.0 13.0 0.3 0.3 6.1 10.0 12.0

Lime (CaO)3 0.8 0.8 2.1 2.4 0.9 1.4 0.5

Magnesia3 (MgO) 62.0 59.0 96.5 96.2 78.8 62.0 59.0

Chromic Oxide (Cr2O3) 18.0 20.0 -- -- 9.3 16.0 21.0

LADLE REFRACTORIES


Iron & Steel Ladle Refractory Selections

Performance FactorsDimensional Stability

Resistance to Slags,Molten Iron & Steel

Thermal Shock Resistance

High Strength

Ease of Installation

Proven Performance Record

Fast Turn-around

Brick Castables Vibratables Plastics &Application Rams

Steel & Alloy COMANCHE® FASTDRY 8 GREFVIBE® 850 GREENPAK-90-P

ALADIN® 85 HP-CAST ULTRA

ALADIN® 80 D-CAST 85TMCC

Iron Transfer ALADIN® 80 D-CAST 85TMCC GREFVIBE® 850 GREENPAK-85-MP

& Inoculation KRUZITE®-70 ULTRA-GREEN 70 TASIL® 570 LM RAMAL 80

KRUZITE® CASTABLE GREFVIBE 700

Iron Pouring KRUZITE®-70 EXPRESS®-30 PLUS GREFVIBE® 700 H-W® BULL

ULTRA-GREEN 45 RAM PLASTIC

MIZZOU CASTABLE



Phone: (412) 375-6600 w Fax: (412) 375-6783

CASTABLES FASTDRY 8 HP-CAST D-CAST ULTRA-GREEN KRUZITE® EXPRESS®-30 ULTRA-GREEN MIZZOUCASTABLE ULTRA 85TMCC 70 CASTABLE PLUS 45 CASTABLE

Maximum Service Temperature 3300oF 3400oF 3200oF 3100oF 3200oF 3000oF 3000oF 3000oFQuantity Required - Net, lb/ft3 195 195 182 166 155 154 146 139Modulus of Rupture, lb/in2

After 230OF (110OC) 1,700 2,000 1,400 1,550 550 2,500 1,750 1,080After 1500OF (816OC) 1,100 2,500 2,600 2,700 400 3,000 2,500 700


After 230OF (110OC) -- 7,000 9,200 8,700 3,500 20,000 9,400 5,000After 1500OF (816OC) 5,300 9,500 13,200 11,500 2,500 20,000 14,000 3,000

Chemical Analysis: (Approximate) Silica (SiO2) 1.0% 0.1% 11.0% 24.0% 17.0% 32.7% 46.0% 32.5%Alumina (Al2O3) 90.8 96.3 83.1 71.0 76.0 60.0 48.3 60.0Titania (TiO2) -- -- 2.8 2.5 2.8 2.3 2.4 2.5Iron Oxide (Fe2O3) 0.1 0.1 1.0 1.0 1.4 1.0 1.2 1.5Lime (CaO) 0.1 2.5 1.4 0.8 1.7 3.1 1.2 2.5Magnesia (MgO) 7.8 0.8 0.1 0.1 0.2 0.2 0.1 0.4Alkalies (Na2O+K2O) 0.2 0.2 0.2 0.3 0.5 0.7 0.6 0.6

BRICK COMANCHE® ALADIN® 85 ALADIN® 80 KRUZITE®-70

Density, lb/ft3 189 172 170 165Porosity, % 7.0 20.0 19.5 18.7Modulus of Rupture, lb/in2 3,100 1,700 1,610 1,700

Chemical Analysis: (Approximate) Silica (SiO2) 3.9% 12.9% 15.2% 23.0%Alumina (Al2O3) 82.4 81.4 78.6 71.0Titania (TiO2) -- 3.3 3.4 3.4Iron Oxide (Fe2O3) -- 1.6 1.8 1.6Lime (CaO) -- 0.3 0.3 0.2Magnesia (MgO) 8.5 0.2 0.3 0.2Carbon (C) 5.0 -- -- --Alkalies (Na2O+K2O) -- 0.3 0.4 0.6

The data given above are based on averages of tests results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable. Variationfrom the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and data givenherein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is freeof patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.

PLASTIC & RAMMING MIXES GREENPAK-90-P RAMAL 80 GREENPAK-85-MP H-W® BULL RAM

Maximum Service Temperature 3200OF 3200OF 3000OF 3000OFQuantity Required - Net, lb/ft3 195 160 178 168Modulus of Rupture, lb/in2 After1500OF (816OC) 2,600 500 1,300 1,070

Chemical Analysis: (Approximate) Silica (SiO2) 3.5% 13.6% 11.0% 21.7%Alumina (Al2O3) 91.0 80.0 80.0 71.5Titania (TiO2) 0.1 2.7 2.5 1.8Iron Oxide (Fe2O3) 0.2 1.4 1.4 1.1Lime (CaO) 0.1 0.4 0.1 0.2Magnesia (MgO) 0.1 0.2 0.1 0.3Alkalies (Na2O+K2O) 0.2 0.2 0.2 0.2Phosphorus Pentoxide (P2O5) 4.8 -- 4.0 3.2


H-W LADLE REFRACTORIES For Industrial Foundries

VIBRATABLES & PLASTICS Vibratable Plastics Patching MaterialsGREFVIBE® 850 GREFVIBE® 700 WET TASIL® 570 LM GREFPATCH 85 NARCOLINE C & M MORTAR

Maximum Service Temperature 3200oF 3100oF 3200oF 3100oF 3000oFQuantity Required - Net, lb/ft3 175 174 176 165 --Modulus of Rupture, lb/in2

After 2500OF (1371OC) 1,500 2,080 4,600 1,800 --Crushing Strength, lb/in2

After 1500OF (816OC) 5,600 7,500 -- -- --After 2550OF (1400OC) -- 5,850 -- 15,000 --

Chemical Analysis: (Approximate) Silica (SiO2) 9.5% 23.3% 28.0% 10.2% 52.6%Alumina (Al2O3) 82.8 69.8 68.8 83.7 29.4Titania (TiO2) 2.8 1.9 2.0 1.9 1.7Iron Oxide (Fe2O3) 1.1 1.4 1.1 1.0 2.1Lime (CaO) 0.2 <0.1 0.1 <0.1 0.4Magnesia (MgO) 0.2 <0.1 0.3 <0.1 0.3Alkalies (Na2O+K2O) 0.3 0.4 0.5 0.4 1.5Phosphorus Pentoxide (P2O5) 3.1 3.1 -- 2.8 --Carbon (C) -- -- -- -- 12.0

NARGON® Porous PlugsFor Industrial Foundries

NARGON® Porous Ladle Plugs allow theintroduction of inert gases via one or morepermeable plugs in the ladle bottom. The gas bub-bles rise and produce the following effects:

Dispersion & Stirring of Additives

Temperature Adjustments forOptimum Teeming & Homogeneity

Removal of Non-Metallic Inclusions

Degassing

REDUCINGVALVE

OPERATINGVALVE

ARGON ORNITROGENGAS CYLINDER

Typical arrangement

FLOWMETER

PRESSUREMETER These illustrations show

typical porous plugarrangements and piping

used for ferrous foundry ladle

applications.

BOTTOM OF LADLE

POROUS ORSOLID PLUG

HOLE FORSTOPPER RODOR SLIDE GATE

Recommended location of NARGON® Porous Plug.

Porous Plug Typical Test Data

NARGON® NARGON®

A-90 A-94

Bulk Density, lbs/ft3 165 184

Apparent Porosity, % 24 23

Permeability, Centidarcy 570 950

Mean Pore Diam., microns 55-70 50-70


Alumina (Al2O3) 90.0% 95.0%

Silica (SiO2) 7.6 2.4

Chromic Oxide (Cr2O3) -- 1.5

NP - G - 11(3.8) - 6 .5 - 5 - M

CAN MATERIALPIPE LENGTHPIPE DIAMETEROPTION NUMBERNARGON PLUG SIZEGEOMETRIC SHAPE CHANGENARGON PLUG

NARGON® Porous Plugs areavailable with a variety ofoptions. This information givesthe specific details for theseparts. Please contact your H-W sales representative orTechnical Marketing for furtherdetails.

NARGON® A-90This permeable composition is based onhigh-purity sintered alumina. It is designedfor applications where erosion and thermalshock are severe. This plug is best suitedfor shops requiring periods of gentle bubbling with small bubbles.

NARGON® A-94This permeable composition is based onhigh-purity fused alumina. It is designed forapplications where erosion and metal penetration are more severe.






Phone: (412) 375-6600 w Fax: (412) 375-6783

*S-Castable sleeve between plug and can.

Available NARGON® Porous Plug Sizes (Dimension in Inches)

Plug Dimensions Sleeve Dimensions

(A) (B) (C) (D) (E)Top Bottom Top BottomDia Dia Height Dia Dia

NP-3 2.9 3.2 3.1

NP-5 3.38 4.9 5

NP-8 3.38 5.8 8.3

NP-11 & NPG-11 3.8 4.5 10.8

NP-11S* 3.8 4.5 10.8 5.2 6.9

NPG-11S 3.8 4.5 10.8 5.8 9.2

NP-15 & NPG-15 3.8 6.1 15.1

NPG-15S 3.0 6.1 15.1 4.3 9.2

Service Conditions

CHARGE ZONE PREHEAT ZONE MELT ZONE

• Abrasion from Charging • Abrasion from Charge Movement • Slag Attack

• Thermal Shock • Thermal Shock Reduced • Metal Corrosion

• 600 - 2000 oF Temperature • 2000 - 2400 oF Temperature • 2000 - 3200 oF Temperature

CUPOLA RefractoriesUpper Stack to Melt Zone

UPPER STACKPremium Work Horse & Maintenance

UFALA® TUFSHOT® LI/OT

KRUZITE®-70 VERSAGUN® 50 ADTECH®

CLIPPER® DP NARCO GUNCRETE AR

VERSAGUN® 60, 70 ADTECH® KS-4V® GR PLUS

CHARGE ZONEPremium Work Horse & Maintenance

TUFLINE® 90 ALADIN® 80

UFALA® XCR KRUZITE®-70

UFALA® KX-99®

VERSAGUN® 50, 60, 70 ADTECH®

PREHEAT ZONEPremium Work Horse & Maintenance

TUFLINE® 90 ALADIN® 80

GREENAL®-80 KRUZITE®-70

ALADIN® 85 KX-99®

VERSAGUN® 50, 60, 70 ADTECH®

MELT ZONEPremium Work Horse & Maintenance

KORUNDAL XD® ALADIN® 85/80

TUFLINE® 90 KRUZITE®-70

DV-38 NARCARB ZP PLASTIC

NARCOGUN BSC-DS

KORUNDAL XD® TUFLINE® 90 DV-38 ALADIN® 80 ALADIN® 85 UFALA® XCR KRUZITE®-70 KX-99® UFALA®

Bulk Density, lb/ft3 186 182 179 170 172 159 165 143 157


At 70°F 2,330 1,730 3,400 1,610 1,700 2,200 1,700 2,200 2,640

At 2700°F 1,320 1,050 -- -- -- -- -- -- --

Apparent Porosity, % 16.1 17.6 14.0 19.5 20.0 14.1 18.7 12.0 14.3

Chemical Analysis: %

(Approximate)

Silica (SiO2) 9.5 9.7 11.0 15.2 12.9 36.8 23.0 52.6 38.2

Alumina (Al2O3) 90.1 89.1 80.4 78.6 81.4 60.3 71.0 42.2 58.1

Titania (TiO2) Trace 0.6 2.5 3.4 3.3 1.3 3.4 2.3 2.2

Iron Oxide (Fe2O3) 0.1 0.3 1.3 1.8 1.6 1.1 1.6 1.4 1.2

Lime (CaO) 0.1 0.1 0.1 0.3 0.3 0.1 0.2 0.2 0.1

Magnesia (MgO) Trace Trace 0.1 0.3 0.2 0.1 0.2 0.3 0.1

Alkalies (Na2O+K2O) 0.2 0.2 0.2 0.4 0.3 0.3 0.6 0.9 0.1

Phosphorus Pentoxide (P2O5) -- -- 4.4 -- -- -- -- -- --

The data given above are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable. Variationfrom the above data may occur in individual test. These results cannot be taken as minima or maxima or specification purposes. All statements, information, and data givenherein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.


BRICK

KS-4V® NARCARB VERSAGUN® VERSAGUN® VERSAGUN® TUFSHOT® NARCO NARCOGUNGR PLUS ZP PLASTIC 50 ADTECH® 60 ADTECH® 70 ADTECH® LT/OT GUNCRETE AR BSC-DS

Bulk Density, lb/ft3 120 169 143 151 153 127 132 146

Crushing Strength, lb/in2, After 1500oF 1,500 -- 7,720 7,670 7,700 3,340 7,300 2,600

Chemical Analysis: % (Approximate)

Silica (SiO2) 40.0 7.8 40.8 30.6 23.1 40.7 37.4 10.7

Alumina (Al2O3) 46.0 70.0 53.1 63.6 70.1 45.9 48.3 66.4

Titania (TiO2) 3.2 1.5 1.8 1.7 2.0 2.4 1.3 0.4

Iron Oxide (Fe2O3) 1.5 0.7 0.6 0.7 0.9 0.9 1.2 1.1

Lime (CaO) 8.0 0.2 3.0 3.1 3.5 9.3 9.5 2.3

Magnesia (MgO) 0.4 0.3 0.2 0.2 0.2 0.4 0.4 0.1

Alkalies (Na2O+K2O) 0.9 0.3 0.5 0.1 0.2 0.4 0.3 0.1

Silicon Carbide + Carbon (SiC+C) -- 19.0 -- -- -- -- -- 18.5

MONOLITHICS





SECTIONSCHAIN TUMBLER PREHEATING BURNING ZONE DAM NOSE

LIMERECOVERY KILN

Harbison-Walker Refractories Company manufactures bothhigh alumina and basic brick for burning zones of limerecovery kiln. UFALA is the industry standard for 60% alumi-na brick. It offers superior hot strength and alkali resistancecompare to 70% alumina and other 60% alumina products.For kilns requiring basic brick, H-W has proven performancewith the MAGNEL and NOKROME families of products.

Three H-W burning zone refractories:(from left) UFALA, KRUZITE 70 andMAGNEL N/XT.

REFRACTORY ISSUES SOLUTIONS

CHAIN Abrasion & Impact LO-ABRADE GR Gun MixMC-25® PLUS CastablesPNEUCRETE® BF ADTECH® Spray Mix

TUMBLER Strength & Lining Stability VERSAFLOW® 45 C ADTECH® Precast

PREHEATING Alkali & Insulation GREENLITE® HSCLIPPER® DP

BURNING Temperature & Alkali UFALA®

ZONE KRUZITE® 70 MAGNEL® N/XTNOKROME® 92 LKMAGNEL® RS & RSV

DAM Strength & Abrasion UFALA®

VERSAFLOW® 60 PLUS

NOSE Volume Stability & Strength NARPHOS 85P PLASTICVERSAFLOW® 60 PLUS

BRICK MAGNEL® NOKROME® MAGNEL® MAGNEL® KRUZITE® UFALA® CLIPPER® GREENLITE®

N/XT 92 LK RS RSV -70 DP -HS

Bulk Densit,y lb/ft3 183 182 186 187 165 157 142 75

Apparent Porosity, % 17.0 16.5 15.5 15.0 18.7 14.3 15.2 -


At 70OF 7,100 7,800 6,000 7,100 8,500 8,410 5,750 2,800


At 70OF 930 950 710 840 1,700 2,640 1,250 950

At 2300OF 870 1,500 920 1,100 -- 2,135 -- --

Chemical Analysis: (Approximate) %

(Calcined Basis)

Silica (SiO2) 2.3% 0.8% 0.4% 0.2% 23.0% 38.2% 52.6% 57.2

Alumina (Al2O3) 9.7 6.0 14.4 4.6 71.0 58.1 42.2 36.8

Titania (TiO2) 0.2 -- 0.3 0.1 3.3 2.2 2.3 1.8

Iron Oxide (Fe2O3) 0.9 0.4 0.3 0.2 1.6 1.2 1.4 1.6

Lime (CaO)3 1.8 1.5 1.4 1.4 0.2 0.1 0.2 0.8

Magnesia (MgO)3 85.1 91.4 83.2 88.4 0.2 0.1 0.3 0.4

Alkalies (Na2O+K2O) -- -- -- -- 0.6 0.1 0.9 1.4

MONOLITHIC LO-ABRADE GR NARPHOS 85P VERSAFLOW® 45C PNEUCRETE® BF MC-25 PLUS

PLASTIC ADTECH® ADTECH®

Maximum Service Temperature 2600OF 3150OF 2700OF 2800OF 2550OF

Approximate Amount Required As Installed(No Allowance for Rebound Loss) lb/ft3 1127 171 132 133 125

Bulk Density lb/ft3

After Drying at 230OF 136 -- 135 135 130

After Drying at 500OF -- 164 -- -- --

Modulus of Rupture lb/in2

After 1500OF 1,150 980 1,410 1,310 350

Permanent Linear Change, %After Heating at 1500OF -0.2 -0.8 -0.3 -0.3 -0.2

Chemical Analysis: (Approximate)%

(Calcined Basis)

Silica (SiO2) 40.3% 11.0% 49.4% 50.8% 42.5%

Alumina (Al2O3) 49.0 80.0 44.6 43.6 42.5

Titania (TiO2) 2.5 2.1 2.2 2.0 2.5

Iron Oxide (Fe2O3) 1.3 1.1 0.7 0.5 1.3

Lime (CaO)3 6.0 0.1 2.4 2.1 6.0

Magnesia (MgO)3 0.2 0.1 0.2 0.2 0.3

Alkalies (Na2O+K2O) 0.7 0.4 0.5 0.7 1.0

Phosphorous Pentoxide (P2O5) -- 2.7 -- -- --

The data given above are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable. Variationfrom the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and data givenherein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.






MAGSHOT® GUN MIXMagnesite-based chrome-free gun mix, proven togive superior life in recovery boiler systems in pulpand paper mills.

• Superior Smelt Resistance• Chrome-Free Composition• Good Thermal Conductivity• Ease of Installation• Proven Track Record

MAGSHOT was developed to help meet the environmental and performance needs of thepulp and paper industry. Its chrome-free compositioneliminates concerns about disposal of possiblyhazardous chrome-containing refractory waste.As for performance, laboratory tests have shownthat this unique dicalcium si l icate bonded magnesite product provides an exceptional levelof chemical resistance to molten smelt.

A long record of success in numerous recoveryboiler systems throughout the industry testifies tothe durability of MAGSHOT where it matters most –under demanding field conditions.

Superior Smelt Resistance Demonstrated inDrip Slag TestsSamples After Drip Test:

MAGSHOT installed in the lower section of a recovery boiler.

Ease of InstallationEase of installation makes MAGSHOT® the productof choice for quick-turnaround repairs. It can begunned, hand-packed, or cast. For larger castinstallations this product is available asMAGSHOT® CASTABLE. Both products require mini-mal curing time – heat-up (100˚F/hr.) can begintwo hours after installation. Other features include:

• Low dust and rebounds

• Quick dry-out schedule

• Up to one year shelf life

MAGSHOTRemarks: No Erosion, NoAlteration, No Build-up

Typical 80% Alumina-Phosphate Bonded PlasticRemarks: Eroded, Cracked,

Bloated Slag Build-up

MAGSHOT®


MAGSHOTTECHNICAL DATA

Physical Properties; (Typical)

Maximum Service Temperature, ˚F 2700°F 2700°FBulk Density, pcf


After 230°F 1,690 1,510After 1500°F 1,560 1,480


After 230°F 5,870 10,100After 1500°F 5,930 7,000



The data given above are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applica-ble. Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements,information, and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind,expressed or implied.






REGENERATOR & REACTOR WALLS

Service Conditions:• Relatively mild• Reducing environment• CokingSolutions: Highest strength to densityratio with use of GREENLITE® aggregatefor superior service with:• Gun Mix – GREENLITE®-45L GR,

KAST-O-LITE® 26 LI G, KAST-O-LITE® 23 ES, HPV GUN MIX

• Spraying – PNEULITE SPRAY 26

TRANSFER LINES

Service Conditions:• Severe erosion and abrasion• Coke penetrationSolutions:High strength, low porosity castable withsuperior erosion and thermal shockresistance:• Vibracast – GREENKLEEN-60 PLUS,

VERSAFLOW® THERMAX® PLUS, • Self Leveling Pumpable –

EXPRESS®-27 Plus, COREX EXPRESS®,EXPRESS® THERMAX®

• Gun Mix – VERSAGUN® THERMAX®, HPV GUN MIX

STRIPPER

Service Conditions:• Mild to moderate erosionSolutions: Medium weight castables withsuperior strength:• Gun Mix – GREENLITE®-45-L GR,

LO-ABRADE® GR, KAST-O-LITE® 26 LI G,COREX GUN MIX, KAST-O-LITE® 23 ES,HPV GUN MIX

• Spraying – PNEULITE® SPRAY 26

CYCLONES

Service Conditions:• Severe erosion and impingementSolutions: High strength, phosphatebonded plastics or castables with excellent installation characteristics.• CORAL PLASTIC® (28-82)• GREENPAK-85-P• EXCELERATE ABR PLUS

FLUE GAS LINES AND SEAL POT

Service Conditions:• Thermal shock • Chemical reaction• Mild to moderate erosionSolutions: Low iron, high strengthcastable providing volume stability with resistance to chemical attack:• Self Leveling Pumpable –

EXPRESS®-27 PLUS, EXPRESS® THERMAX®

• Gun Mix – LO-ABRADE® GR, GREENLITE®-45-L GR, COREX GUN MIX, VERSAGUN® THERMAX®, HPV GUN MIX

CRACKING UNITFLUID CATALYTIC

TYPICAL DATA After 1500oF

CORAL GREENPAK VERSAFLOW® EXECELERATE VERSAGUN COREX COREX LO-ABRADE® HPVPLASTIC® 85-P THERMAX® ABR PLUS THERMAX® GUN MIX EXPRESS® GR GUN(28-82) PLUS ADTECH™ MIX

Type Dense Dense Dense Dense Med. Weight Med. Weight Med. Weight Dense Med. WeightSevere Erosion Severe Erosion Mod. to Sev. Erosion Mod. Erosion Mod. Erosion Mod. Erosion Mod. Erosion Mod. Erosion Erosion

Plastic Plastic Castable Gun/Castable Gun Mix Self Leveling Gun Mix Gun Mix

Density, pcf 169 183 126 172 120 100 116 127 110

Modulus of Rupture, psi 1,980 1,500 1,000 2,200 820 750 1,300 1,150 1,000

Crushing Strength, psi 8,000 – 11,800 14,950 5,190 4,100 8,900 6,500 6,200

Permanent Linear Change, % -0.1 -0.2 -0.1 -0.3 -0.1 -0.3 0.2 -0.2 -0.3

C-704 Abrasion, cc: 3.1 5.1 7.8 4.0 15.0 19.0 12.0 12.0 12.0

EXPRESS® PNEULITE™ KAST-O-LITE® KAST-O-LITE® GREENLITE® GREENKLEEN EXPRESS®

27-PLUS SPRAY 26 23 ES 26 LI G 45-L GR -60 PLUS THERMAX®

Type Dense Med. Wt. Med. Wt. Med. Wt. Med. Wt. Dense DenseMod. to Sev. Erosion Insulation Insulation Insulation Insulation Severe Erosion Mod. to Sev. Erosion

Self-Leveling Spray Cast./Gun Gun Mix Gun Mix Castable Self-Leveling

Density, pcf 135 92 78/91 105 71 157 124

Modulus of Rupture, psi 1,200 – 300/480 500 350 2,000 1,000

Crushing Strength, psi 11,500 1,480 1,370/2,630 1,580 2,500 10,000 8,000

Permanent Linear Change, % -0.2 -0.4 -0.2/-0.3 -0.2 -0.2 -0.2 -0.1

C-704 Abrasion, cc: 12.0 – – – – 6.0 8.3

FLUID CATALYTIC CRACKING UNIT



Names: KAST-O-LITE 23 ES (formerly H-W LIGHTWEIGHT ES REFRACTORY)KAST-O-LITE 26 LI G (formerly H-W LIGHTWEIGHT GUN MIX 26)GREENLITE 45 L GR (formerly GREENCAST 45-L-GR)



Phone: (412) 375-6600 w Fax: (412) 375-6783

THERMAL REACTORSULFUR RECOVERY UNIT

Notes:

1) Mortar for laying brick linings with KORUNDAL®, GREENAL and TUFLINE® SERIES BRICK, use KORUNDAL® BOND.2) Most Severe = Oxygen Enrichment (up to 3,000˚F)

Severe = Higher Temperatures (2,400-2,700˚F)Less Severe = Lower Temperatures (2,000-2,400˚F)

Severe

MostSevere

LessSevere

BURNER THROAT COMBUSTION CHAMBER CHECKER WALL TUBE SHEETSERVICE LOCATION BRICK MONOLITH BRICK MONOLITH BRICK MONOLITH

Hot-Face TUFLINE® 98 DM NOVACON® 95 KORUNDAL XD® KORUNDAL XD® DMNOVACON® 95

H-W® CORUNDUM DM

Back-Up G-3000 LI KAST-0-LITE® 30 LI G

Hot-Face KORUNDAL® XD GREENPAK-90-P KORUNDAL XD® KORUNDAL XD®

GREENCAST®-94 PLUSGREENAL-90 GREENCAST® 94 PLUS GREENAL-90 GREENAL-90

Back-UpG-28 LI

KAST-O-LITE® 30 LI GG-3000 LI

Hot-Face UFALA® UCRGREENCAST®-94 PLUS

KRUZITE®-70NOVACON® 95

UFALA® UCRGREENCAST®-94 PLUS

GREENPAK-90-P GREENCAST®-94- GR PLUS GREENCAST®-94-GR PLUS

Back-Up G-28 LI KAST-O-LITE® 26 LI G

The data given above are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable.Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements, information,and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied.Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such useis free of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.

SULFUR RECOVERY UNIT THERMAL REACTOR

BRICK DATATUFLINE® 98 DM KORUNDAL XD® DM KORUNDAL XD® H-W CORUNDUM DM® KRUZITE®-70

Bulk Density, lb/ft3 210 195 186 208 165Apparent Porosity, % 12.0 12.4 16.1 12.9 18.7Modulus of Rupture, lb/in2 — At 70˚F 2,760 3,840 2,330 4,500 1,700Modulus of Rupture, lb/in2 — At 2,700˚F 1,080 1,930 1,320 – –Chemical Analysis % (Calcined Basis)Silica (SiO2) 0.12 9.2 9.5 0.2 23.0Alumina (Al2O3) 97.6 90.3 90.1 99.7 71.0Titania (TiO2) 0.05 Trace Trace Trace 3.4Iron Oxide (Fe2O3) 0.09 0.1 0.1 0.1 1.6Lime (CaO) 0.04 0.1 0.1 Trace 0.2Magnesia (MgO) 0.16 0.1 Trace Trace 0.2Alkalies (Na2O + K2O) - 0.2 0.2 – 0.6Other Oxides 1.94 – – – –

GREENAL-90 UFALA® UCR G-3000 LI G-28 LIBulk Density, lb/ft3 189 160 62 51Apparent Porosity, % 13.0 14.1 - -Modulus of Rupture, lb/in2 — At 70˚F 4,000 2,150 284 210Modulus of Rupture, lb/in2 — At 2,700˚F 2,500 620 - -Chemical Analysis % (Calcined Basis)Silica (SiO2) 7.7 36.1 25.1 51.3Alumina (Al2O3) 90.0 62.3 73.4 45.0Titania (TiO2) Trace 0.2 0.1 2.0Iron Oxide (Fe2O3) 0.1 0.8 0.1 1.0Lime (CaO) 0.1 0.1 Trace 0.3Magnesia (MgO) Trace 0.1 Trace 0.1Alkalies (Na2O + K2O) 0.2 0.4 0.6 0.3Phosphorus Pentoxide (P2O5) 1.9 – – –

MONOLITH DATANOVACON® 95 GREENCAST®-94 GR KAST-O-LITE® 26 LI G KAST-O-LITE® 30 LI G GREENCAST®-94 GREENPAK-90-P


After Heating to 1,500˚F185 158 105 99 163 195


After Heating at 1,500˚F2,630 1,000 500 375 1,750 2,600


After Heating at 1,500˚F9,280 6,070 1,580 1,750 9,500 10,000

Permanent Linear ChangeAfter Heating at 1,500˚F

0.0 0.0 -0.2 -0.1 0.0 –

Chemical Analysis % (Calcined Basis)Silica (SiO2) 5.1 Trace 44.6 35.0 0.2 3.5Alumina (Al2O3) 93.9 93.2 44.5 57.0 94.1 91.0Titania (TiO2) <0.1 Trace 2.3 1.5 0.1 0.1Iron Oxide (Fe2O3) 0.1 0.2 1.0 0.9 0.2 0.2Lime (CaO) 0.1 6.4 6.4 4.7 5.1 0.1Magnesia (MgO) – Trace 0.3 0.2 0.1 0.1Alkalies (Na2O + K2O) 0.5 0.2 0.9 0.8 0.2 0.Phosphorus Pentoxide (P2O5) 0.3 – – – – 4.8



Phone: (412) 375-6600 w Fax: (412) 375-6783

Ash-Hopper ServiceAsh hopper service includes a number of conditions, which can be detrimental to arefractory lining. Refractories used in this service must show good resistance to a variety of destructive conditions.

• Airborne particulate generated duringcombustion can cause severely abrasive conditions.

• Slag can fall into the hopper in large chunkscalled “clinker”. The impact of this clinkerupon the refractory can be quite severe.

• In the case of wet-bottom ash hoppers, the splash generated by falling clinker can introduce severe thermal shock.

• Products installed in ash hoppers can be cast, gunned or sprayed.

THERMALSERVICE INSTALLATION IMPACT SHOCK ABRASION

CLASSIFICATION METHOD RESISTANCE RESISTANCE RESISTANCE

TUFSHOT® LI/OT Less Severe Gun Good Fair Fair

NARCO® GUNCRETE AR Less Severe Gun Excellent Good Good

LO-ABRADE® GR PLUS Severe Gun Excellent Good Good

VERSAFLOW® 45 Severe Cast Excellent Fair Good

PNEUCRETE® 45 Severe Spray Excellent Fair Good

VERSAFLOW® THERMAX® Most Severe Cast Excellent Excellent Excellent

VERSAGUN® THERMAX® Most Severe Gun Excellent Excellent Good

PNEUCRETE® THERMAX® Most Severe Spray Excellent Excellent Good

Less Severe: Low impact, mild abrasion, and minimal thermal shock.

Severe: High impact, moderate abrasion and thermal shock.

Most Severe: High impact, severe abrasion and thermal shock.

REFRACTORIESASH HOPPER

LESS SEVERE SERVICE SEVERE SERVICE MOST SEVERE SERVICE

ASH HOPPER REFRACTORIES

TECHNICAL DATA






Phone: (412) 375-6600 l Fax: (412) 375-6783

TUFSHOT® NARCO® LO-ABRADE® VERSAFLOW® PNEUCRETE® VERSAFLOW® VERSAGUN® PNEUCRETE®

LI/OT GUNCRETE AR GR PLUS 45 45 THERMAX® THERMAX® THERMAX®

Maximum Service Temperature,̊ F 2600 2500 2600 2700 2700 2000 2000 2000

Density, pcf

After Drying at 230˚F 127 132 136 136 131 126 126 125


After Drying at 230˚F 770 1,500 1,700 1,050 1,270 1,350 1,520 1,030

After Heating at 1500˚F 480 1,400 1,150 1,200 540 1,000 820 840


After Drying at 230˚F 3,620 8,600 10,000 8,500 6,260 10,500 6,180 5,560

After Heating at 1500˚F 3,340 7,300 6,500 5,000 4,800 7,600 5,190 5,620

C-704 Abrasion Test

CC Loss After 1500˚F – 12.0 12.0 – 16.0 7.8 15.0 10.0

Chemical Analysis,% (Approximate)

Silica (SiO2) 40.7 37.4 40.3 49.2 51.3 75.1 73.4 76.0

Alumina (Al2O3) 45.9 48.3 49.0 44.6 43.0 21.6 23.1 21.3

Titania (TiO2) 2.4 1.3 2.5 2.2 2.0 0.5 0.2 0.5

Iron (Fe2O3) 0.9 1.2 1.3 0.7 0.8 0.3 0.1 0.1

Lime (CaO) 9.3 9.5 6.0 2.4 2.1 2.1 3.1 1.9

Magnesia (MgO) 0.4 0.4 0.2 0.2 0.2 0.1 – 0.1

Alkalies (Na2O & K2O) 0.4 0.3 0.7 0.5 0.6 0.3 0.1 0.1

Product / ApplicationUpdate

Boiler Refractory Applications

Harbison-Walker Refractories

Industrial Chemicals and Metals

Superheater

Penthouse

Burners Ducts

Furnace Walls

Ash Hopper

Boiler Application Guide

KA

ST

-O-L

ITE

19-

L

KA

ST

-O-L

ITE

22

GR

EE

NLI

TE

22

GR

EE

NLI

TE

45

L G

R

VE

RS

AF

LOW

TH

ER

MA

X

VE

RS

AG

UN

TH

ER

MA

X

PN

EU

CR

ET

E T

HE

RM

AX

CO

RE

X G

UN

MIX

NA

RC

O G

UN

CR

ET

E A

R

LO-A

BR

AD

E

KS

-4

TU

FS

HO

T L

I/OT

GR

EE

NC

AS

T 9

4

TH

OR

80

AD

TE

CH

NA

RC

OG

UN

SiC

-80

AR

MA

GS

HO

T

GR

EE

NP

AK

50-

P

H-W

BU

LL R

AM

PLA

ST

IC

GR

EE

NP

AK

-90-

P

EC

LIP

SE

60-

P

EC

LIP

SE

70-

P

EC

LIP

SE

80-

P

GR

EE

NG

UN

EC

LIP

SE

73-

P

RU

BY

PLA

ST

IC

INS

WO

OL

PU

MP

AB

LE

INS

BO

AR

D 2

300

INS

WO

OL

HP

BLA

NK

ET

GR

EE

NP

AT

CH

421

INS

ULA

TIN

G C

EM

EN

T

Inside Casing & Tangent Wall Outside Casing 44 44 44 44 44 44 44 44

Furnace WallsTangent Wall Inside Casing 44 44 44 44 44 44 44 44 44 44 44 44Opening Patch and Access Doors 44 44 44 44 44 44 44 44

Floor 44 44 44 44 44

PenthouseHeaders, Tubes, Nipples 44 44 44

Drum Head Insulation 44 44 44 44

Ash Hopper Lining 44 44 44 44 44 44 44 44 44

Ducts Inside Lining 44 44 44 44 44 44 44 44Outside Lining and Piping Insulation 44 44 44

Burners Tangential and Front Fired 44 44 44 44 44 44 44 44 44 44 44

Slagging Bottom Boiler 44 44 44 44 44 44 44 44

Cyclone Boiler Studded Tubes 44 44 44 44 44 44 44 44

Special Applications Baffles and Boiler Seals 44 44 44 44

Floors (Industrial Boilers) 44 44

Stoker Pier (Industrial Boilers) 44 44 44 44Hearth (Recovery Boilers) 44 44

CIRCULATING FLUIDIZED BED COMBUSTOR

CFB OPERATIONFuel to be burned is injected into the fluidized bed of inert media

Efficient combustion at relatively low temperatures, avoiding theformation of harmful pollutants.

Partly burned fuel and ash flow through the system to a cycloneseparator

Paticulates separate from the gas stream in the cyclone andre-circulate to the fluid-bed

Hot gases escape from the cyclone and move down stream tovarious boilers, economizers, super-heaters, and other heatexchange equipment to create steam and electricity.

The solids that return to the fluid-bed enjoy an effectively longresidence time in the combust

COMBUSTOR

Service Conditions:

- abrasion

- thermal cycling

Solutions: silicon carbide, high aluminaphosphate bonded plasticsECLIPSE PLASTICS, NARPHOS 85 P,NARCOGUN SIC 80AR

LOOP SEAL

Service Conditions:

- most severe abrasion

- media collection and return

Solutions: vitreous silica to minimizethermal shock and withstand abrasionTHERMAX PRODUCTS

CROSS-OVER DUCT

Service Conditions:

- thermal cycling potential

- zoning may be required

Solutions: volume stable, abrasion resistantgun mixes and phosphate bonded plasticsLO-ABRADE GR PLUS, VERSAGUN 60ADTECH, NARMUL P

CYCLONE

Service Conditions:

- particulate removed from gas

- severe abrasion

- thermal shock

Solutions: volume stable, abrasion resistant brick and gun mixes KX-99 BF, KALA, NIKE 60AR, VERSAGUN 60, GREFCON 70GR

Loop Seal

Combustor

Cross-Over Duct

Cyclone

SLAG DAMREFRACTORY BLOCK

RUBY® SR/CRefractory Block Slag Dam.In a continued effort to improve the life of theirrefractory around the slag tap of their boiler floors,Exelon Generation (formerly CommonwealthEdison) has designed and patented their"Refractory Block Slag Dam*."

Harbison Walker has been given the rights tomake, manufacture and sell the dams.

Features:

Improved slag flow characteristics and floor sintering

Reduced floor repairs by extending floor life

Reduce repairs of frozen slag taps

Unit output increased based on reduction ofplanned unit outages, thus eliminating lostgeneration capacity

Slag Dams are made of RUBY® SR/C.

High Density

Low Porosity

Shock Resistant

Slag Resistant

The dams are made of 8 piecesthat come together to form anOctagon.

The dams protect the tubesaround the slag tap.*The design is covered by U.S. Patent No. 5,800,775

RUBY® SR/C

Classification: Spall Resistant Chrome - Alumina Vib-Cast/Fired Shapes

Bulk Density: 204 /b/ft3

Apparent Porosity, %: 15.5

Modulus of Rupture:

At 70oF (21oC) 12,900 lb/in2

Crushing Strength:

At 70oF (21oC) 1,360 lb/in2


Silica (SiO2) 1.9%


Titania (TiO2) 0.1


Lime (CaO) 0.1

Magnesia (MgO) Trace

Chromic Oxide (Cr2O3) 11.1

Alkalies (Na2O+K2O) 0.2

Other Oxides 3.5

This design is covered by U.S. Patent No. 5,800,775

TECHNICAL DATA







harbison walker 2005 refractory handbook

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