Brick lining installation golden rules

JULY 2007 / Version 2

Brick lining installation

Foreword
These Golden Rules for Brick Lining should be guidelines for the personnel in charge of kiln rebricking in the plants. This booklet contains the most important rules and should therefore be handed out to all involved persons before starting the lining. It deals only with the most common dry lining method, but other methods (mainly mortar) are important in special cases. It is a good idea to discuss the content with the persons involved to ensure it is fully understood. As it only contains the most important rules and does not cover specific situations, it cannot replace necessary training, especially for safety! Information given is not sufficient for the person responsible for Refractory in the plant. He will need to study the related procedures of the Cement Portals Refractory Domain carefully.
(connect to: http://webcementportal.lafarge.com)

We hope that this booklet will make your work more successful.

Brick lining installation

Content
1 Safety gear 2 Safety equipment 3 Reference lines are drawn axially & radially 4 General rule: Lining patterns are staggered 5 Mixed ratio is adjusted 6 Mortar is used to correct deformed shell / welding 7 Key bricks are not in one line 8 Shims are not installed close to key bricks 9 Rings are closed using hydraulic jack 10 Bricks are cut with a brick cutting machine 11 Cut bricks are always in between full bricks 12 Closing of the last ring is done properly 13 Cardboard spacers are placed adequately 14 Additional guidelines

Brick lining installation

Safety gear
Brick lining installation For all personnel
Overalls Hard hat Safety shoes Gloves Safety glasses Dust mask Ear protections Long sleeved

Polyester Non-skid Abrasion resistant

Remark: Follow the detailed safety procedures published on the Cement Portals Refractory domain:
How to ensure safety for brick demolition & brick lining works How to ensure safety for brick cutting How to ensure safety for castable mixing

For cutting bricks

Face shield Apron

Heavy duty rubber apron

Polycarbonate Scratch resistant

1

Brick lining installation

Safety equipment
Brick lining installation

Using a brick rig is the only safe kiln bricking method

Equipped with compressed air reservoir (5l) + nonreturn valve Alarm if pressure < 4.5 bars

If you have to pass through the coating, a safe way is to use Tunnel cages

Compressed air hosepipes and couplings are in good condition

Brick lining installation

2

Inside the kiln, all electrical equipment used must be class II (double insulation) supplied by safety transformers situated outside the kiln

Brick lining installation

Reference lines are drawn axially & radially

Axial

2nd point 1st point

Radial
Base lines Parallel

Parallel

Welding

Brick lining installation

3

Brick lining installation

General rule: Lining patterns are staggered

Use a rubber hammer for brick installation

Ensure the kiln shell surface is clean and smooth

4

Brick lining installation

Mixing ratio is adjusted

Brick lining installation

Wrong Right

Wrong

Right

Brick lining installation

5

No brick upside down Check hot face marking

Brick lining installation

Mortar is used to correct deformed shell / welding Right

Wrong

Brick lining installation

Key bricks are not in one line

Brick lining installation

Right

Key bricks

Wrong

Key bricks side to side

Key bricks face to face

7

Brick lining installation

Shims are not installed close to key bricks

Brick lining installation

Shim thickness = 2 mm max.

Maximum of 2 to 3 shims per ring

Shims

2 shims

Use shim driver

Brick lining installation

Rings are closed using hydraulic jack

Brick lining installation

Pressure to be applied = brick cold crushing strength Typical CCS ranges are 50 to 70 N/mm2

Example: ANKRAL-ZE Cold crushing strength = 70 N/mm2 Pressure to be applied = 350 bars or 5000 PSI
Conversion factor: 1 N/mm2 = 10 bars = 145 PSI
9

Brick lining installation

Bricks are cut with brick cutting machine

Brick lining installation

Minimum brick cutting length is respected. Dry cut for basic bricks

Do not cut in this direction

Mandatory direction of cut

Brick original length 200 mm 300 mm

Minimum cut 140 mm 200 mm

Brick lining installation

10

Minimum cut 2/3 of original length

Brick lining installation

Cut bricks are always in between full bricks Cut bricks Old bricks

It is recommended to have 300 mm long bricks

Full bricks

Full bricks Retaining ring

11

Brick lining installation

Cut bricks

Closing of the last ring is done properly

Brick lining installation
Tight lining must be ensured for the last ring, too.

n
Closure brick

Mortar, liquid enough

Y
Piece of wood Hammer

p
Brick lining installation
12

Shims
Instead of mortar, additional metal shims can be used

Cardboard spacers are placed adequately

Brick lining installation

To allow expansion
Bricks type Magnesia Cardboard spacers 1 cardboard of 2 mm between each ring 1 cardboard of 1 mm between each ring No cardboard

Remark: These are general rules. Follow exactly the instructions given by the refractory suppliers. Never remove the cardboards from the original bricks!

Dolomite

Alumina

Nosering
Brick lining installation
No cardboard spacers Retaining ring
Remark: For installation of the retaining ring, see details in the How to install & line a retaining ring procedure in the Cement Portals Refractory domain.
13

Additional guidelines
Brick lining installation
On deformed areas bricks should be laid with mortar
Mortar

Dont change the quality under the tires or the girth-gear

Dont hesitate to discuss with your TC Refractory Expert if you have any doubt!

Notes

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Brick lining installation

Brick lining installation

Notes

Notes

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Brick lining installation

Brick lining installation

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