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Standard of Sichuan Boiler Works

CG1114-94

Technical Specifications for


Wall Setting Materials Make Up

Issued on December 30, 1994


Adopted on December 30, 1994
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Technical Specifications for Wall Setting Materials Make Up Page 2 of 21

1 Contents of this subject and the applying area


This standard defines how to make up anomalistic wall setting materials needed by
different kinds of steam boiler walls.

This standard applies to the anomalistic wall setting materials constructed according
to the drawings designed by our factory, if any changes took place, agreements from
our factory or from our delegates in the construction site dispatched by our factory
must be obtained.

2 Reference standards:
GB2994-82 High-aluminum fire-resisting cement
GB201-81 High-aluminum cement
GB175-92 Silicate cement, common silicate cement
GB1344-92 Slag silicate cement, Volcano ash silicate cement and fly ash
silicate cement
GB3712-83 Clay and high-aluminum fire-resisting casting materials
YB396-63 Clay fire-resisting mud

3 Fire-resisting concrete
Fire-resisting concrete is a special kind of concrete that can bear high temperature
perennially; it is made up of fire-resisting aggregates, appropriate binders, filtering
and combining materials and pure water. All of the components are mixed up in some
proportion and then it becomes a kind of fire-resisting material possessing several
physical capabilities.

Fire-resisting concrete is divided into two kinds according to different binders that
are used: cement and inorganic compound.

3.1 Fire-resisting concrete that use cement as binder


3.1.1 Fire-resisting concrete that use bauxite cement
3..1.1.1 It can be used as fire resisting inner lining materials of wall setting of boiler
furnace, ceiling and gas flues and its highest working temperature can be
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1200~1300℃

3.1.1.2 Mixing proportion is shown in table 1.

Table 1
Name of materials Wt%
Bauxite cement 15~20
Powder (R90<30%) 0~15
<5mm 30~40
Aggregate
5~15mm 30~40

3.1.1.3 Density range should be controlled at 2100~2300 kg/m3.


3.1.1.4 Aggregate and powder can select the second or third-level clinker of bauxite, the
first or second-level clinker of clay or refuse high-aluminum bricks and refuse
fire-resisting clays bricks.

3.1.2 Fire-resisting silicate cement concrete


3.1.2.1 It can be used as fire resisting inner lining materials of wall setting of boiler
furnace, ceiling and gas flues and its highest working temperature can be

1000~1100℃.

3.1.2.2 Mixing proportion is shown in table2.

Table 2
Name of materials Wt%
Silicate cement 15~20
Powder (R90<30%) ≤15
<5mm 35~40
Aggregate
5~15mm 30~40

3.1.2.3 Density range should be controlled at 2100~2300 kg/m3.


3.1.2.4 Aggregate and powder can select clay clinker and refuse fire-resisting clay
bricks.
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3.1.3 Fire-resisting slag cement concrete


3.1.3.1 It can be used as inner lining materials of wall setting of boiler tail flue and cold

ash hopper, and its highest working temperature can be 700℃.

3.1.3.2 Mixing proportion is shown in table 3.

Table 3
Name of materials Wt%
Slag silicate cement 16~20
Aggregate <5mm 35~40
5~15mm 40~45

3.1.3.3 Density range should be controlled at 2000 kg/m3.


3.1.3.4 Aggregate can select clay clinker and refuse fire-resisting clay bricks.

3.1.4 Low-calcium aluminate cement

3.1.4.1 The highest working temperature can be 1200~1350℃. It can be used as inner

lining materials of wall setting of boiler furnace ceiling and gas flue. It can also be used
as material of wall setting at burner port.
3.1.4.2 Mixing proportion is shown in table 4.

Table 4
Name of materials Wt%
Low-calcium aluminate cement 12~20
powder (R90<30%) 0~15
<5mm 30~35
Aggregate
5~15mm 30~40

3.1.4.3 Density range should be controlled at 2100~2200 kg/m3.


3.1.4.4 Aggregate and powder can select second or third-level clinker of bauxite or
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refuse high-aluminum bricks.

3.1.5 Heat-resisting cement fire-resisting concrete


3.1.5.1 It can be used as fire resisting inner lining materials of wall setting of boiler
furnace, ceiling and gas flues and its highest working temperature can be

~1300℃.

3.1.5.2 Mixing proportion is shown in table 5.

Table 5
Name of materials Wt%
Fire-resisting cement (above 500#) 25~30
<5mm 35~40
Aggregate
5~15mm 35~40

3.1.5.3 Density range should be controlled at 2100~2300 kg/m3.


3.1.5.4 Aggregate can select clay clinker or refuse fire-resisting clays bricks.

3.2 Fire-resisting concrete in which inorganic compound is used as viscid solvent


3.2.1 Fire-resisting Phosphoric acid concrete

3.2.1.1 The highest working temperature can be 1450~1600℃. it can be used as

materials for bottom of slag tap boiler and wall setting of burner port.
3.2.1.2 Mixing proportion is shown in table 6:

Table 6
Name of materials Wt%
Powder (R90<15%) 30
<5mm 40
Aggregate
5~15mm 30
Phosphoric acid (concentration: 40~45%) 15 (supplement)
Bauxite cement 2~5 (supplement)
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3.2.1.3 Density range should be controlled at 2400~2600 kg/m3.


3.2.1.4 Aggregates can select the first or second level clinker of bauxite.
3.2.2 fire-resisting water glass concrete

3.2.2.1 The highest working temperature can be 1000℃, fire-resisting water glass

concrete is capable of acid resistance, but it cannot be applied to the position


where often acted by water and steam.
3.2.2.2 Mixing proportion is shown in table 7

Table 7
Name of materials Wt%
Powder (R90<15%) 30
<5mm 40
Aggregate
5~15mm 30
Glass water 13~16 (supplement)
Sodium fluorosilicate 1.5~2 (supplement)

3.2.2.3 Density range should be controlled at 2100~2200 kg/m3.


3.2.2.4 Aggregate and powder can select the second or third level of clinker bauxite, the
first or second level clinker of clay or fire resisting refuse clay brick.

3.2.3 Fire-resisting zircon phosphate concrete

3.2.3.1 The highest working temperature can be 1600~1700℃, fire-resisting zircon

phosphate concrete can be used for the furnace bottom of slag tap boiler.
3.2.3.2 Mixing proportion is shown in table 8

Table 8
Name of materials Wt%
Aggregate: zircon (<3mm) 50
Powder: zircon powder (R90<15%) 50
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H3(PO4): concentration (50~60%) 6.5~12 (supplement)

3.2.3.3 Density range should be controlled at 2500kg/m3.

3.2.4 Fire resisting chromium water glass concrete (chromium painting).

3.2.4.1 The highest working temperature can be 1600℃. Fire-resisting chromium water

glass concrete can be used for refractory belt or furnace bottom of slag tap
boiler.
3.2.4.2 Mixing proportion is shown in table 9

Table 9
Name of materials Wt% Remark
Chromium sand 97
Binding clay 3
9 (supplement) Applied to furnace bottom of slag
Water glass tap boiler
7 (supplement) Applied to refractory belt

3.2.4.3 Density should be controlled at 3000kg/m3.

3.2.5 fire-resisting SiC AlPO4 concrete

3.2.5.1 The highest working temperature can be 1900℃, fire-resisting SiC AlPO4

concrete is applied to the inner lining of cyclone furnace boiler or the


furnace bottom of slag tap boiler.
3.2.5.2 Mixing proportion is shown in table 10

Table 10
Name of materials Wt%
1~0.5mm 50
SiC
<0.88mm 50
AlPO4 solution 15~18(supplement)
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3.2.5.3 Density range should be controlled at 2700~2800 kg/m3.

4 Heat-resisting concrete
Lightweight heat-insulating materials, such as diatomite brick, expansion vermiculite
and expansion pearlite are used as aggregate, and cement is used as binding agent.
Mix lightweight heat-insulating material with cement in proportion. After they are
cured, good heat-insulating material can be produced.

4.1 Diatomite heat-insulating concrete

4.1.1 Working temperature <900℃.

4.1.2 Mixing proportion is shown in table 11

Table 11
Name of materials Weight (kg) Wt%
<1mm, 25%
Diatomaceous brick particles 650 1~3mm, 50% 65
3~8mm, 25%
Asbestos 150 15
Silicate cement 200 20

4.1.3 Density: r=1000 kg/m3.

4.1.4 Thermal conductivity =0.23+0.00011×tep kcal/m.h℃.

4.2 Pearlite heat-insulating concrete

4.2.1 Working temperature is under 600℃ .

4.2.2 Mixing proportion is shown in table 12.

Table 12
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Name of materials Volume ratio


Silicate cement (above 525#) 1

Expansion pearlite (r≤110kg/m3), 10~12

4.2.3 Density r=500 kg/m3.

4.2.4 Thermal conductivity =0.09+0.0002×tep kcal/m.h℃.

4.3 Vermiculite heat-insulating concrete

4.3.1 Working temperature <600℃ .

4.3.2 Mixing proportion is shown in table13

Table 13
Name of materials Volume ratio
Silicate cement (above No 525) 1

Expansion vermiculite (r≤180kg/m3) 6~8

particle size: 3~10mm

4.3.3 Density r= 450~ 800 kg/m3.

4.3.4 Thermal conductivity =0.069+0.000142×tep kcal/m.h.℃.

5 Trowel finish material and sealing material


5.1 Trowel finish material is applied to the surface protection of surface-mounted wall
setting. Many mixing proportions are available
5.1.1 Mixing proportion of asbestos diatomite trowel finish is shown in table 14.

Table 14
Name of materials Wt%
Asbestos fiber (3~4 grade) 20~25
Diatomite powder 50~60
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Silicate cement (above 425#) 25~30


Hemp (supplement) I

5.1.2 Mixing proportion of fly ash trowel finish is shown in table 15.

Table 15
wt%
Name of materials
I II
Coal cinder (1~3mm) 50 50
Asbestos diatomite 25 20
Silicate cement (above 425#) 25 20
Asbestos fiber 10
Hemp (supplement) 1.5 1.5

5.1.3 Mixing proportion of asbestos pearlite trowel finish is shown in table16.

Table 16
Name of materials Weight (kg)
Silicate cement 400
Asbestos mud 100
Asbestos fiber 20
Pearlite 120

5.1.4 Mixing proportion of mixed trowel finish is shown in table 17.

Table 17
Name of materials Weight (kg)
Cement 250
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Pearlite powder 100


Asbestos fiber 125
Diatomite powder 125
Hemp (supplement) 1~2%

5.2 Bitumen oil ointment


Bitumen oil ointment is applied to surface protective coating of wall setting of the
boiler with outdoor arrangement.
5.2.1 Mix proportion: The first ingredient is shown in table 18.
Table 18
Name of materials Wt%
Asbestos (3~4 grade) 34

bitumen (softening point>90℃) 50

Silicate cement (above 400#) 16


Kerosene 45 (supplement)

The second ingredient is shown in table19

Table 19
Name of materials Ratio
Bitumen oil ointment (Ref: the first ingredient) 1
Cement paste 0.1~0.3 (remark)

Remark:
a. The ratio of water and cement paste: water/cement=0.40:1
b. The quantity of cement paste value: 20%~30% for pipe line, 10%~15% for wall
setting.

5.2.2 Mixing technologies

Step one: firstly, heat bitumen up to 200℃ slowly; secondly, dehydrate and cool to

120℃, remove from fire and add kerosene till they are mixed homogenously.
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At the same time, asbestos and cement are agitated in proportion, then heated

up to 30~40℃. Mix and agitate them with hot kerosene bitumen. In this way,

black oil ointment can be produced


Step two: add 10%~30% cement paste to oil ointment which is made in step one
and agitate them at once till bitumen oil ointment being produced.

5.3 Asbestos agent

Asbestos agent is used as filling material and its working temperature can be 500℃.

Mixing proportion of asbestos agent is shown in table 20.


Table 20
Name of materials Weight (kg)
Asbestos fiber 280
Red clay 480

6 Mortars
6.1 Fire-resisting mortar
YB396 regulates that clay mortar which is used in the bricking clay products can be
divided into four grades according to chemical and physical quota.

Table 21
Grade and value
Quota
(NF)-40 (NF)-38 (NF)-34 (NF)-28

refractoriness ℃≥ 1730 1690 1650 1580

water content (%)≥ 6

Mid-size fire-resisting mud is adopted for the wall setting of boiler and its mixing
proportion is shown in table 22.

Table 22
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Name of materials Wt%


Clay clinker 60~70
Binding clay 40~80
Water 30 (supplement)

Size requirement to raw and roasted materials:


a. The percentage of particles which pass through sieve pores of 0.125mm is not less
than 25%.
b. The percentage of particles which pass through sieve pores of 1mm is not less
than 97%.
c. The percentage of particles which pass through sieve pores of 2mm is 100%.
6.2 Fire-resisting high aluminum mud
GB2994 regulates that fire-resisting high aluminum mud which is used for the bricking
high aluminum bricks can be divided into three grades according to chemical and
physical quota.

Table 23
Grade and value
Quota
(LF)-70 (LF)-60 (LF)-50
AL2O3 content (%) 70~75 60~70 50~60

refractoriness ℃≥ 1770 1750

firing loss (%)≤ 5

The composition of fire-resisting high aluminum earth particle is shown in Table 24.

Table 24
Passing through sieve pore Value

0.125mm, % ≥ 50

0.5mm, % ≥ 97
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1.0mm, % ≥ 100

6.3 Heat-insulating mortar (diatomite, pearlite, vermiculite)


Aggregate of mortar should be same with bricking material in the selection of mortars,
which are used for the bricking various heat-insulating materials.

Table 25
Weight (kg)
Name of materials
I II
Diatomite powder 570 450
Silicate cement 185
Water 450 450

Remark: diatomite powder can be replaced by vermiculite powder and pearlite powder.

6.4 Red clay and sand mortar


6.4.1 Application scope: for the bricking red bricks whose working temperature is lower

than 600℃.

6.4.2 Mixing proportion of red clay and sand mortar is shown in table 26.

Table 26
Name of materials Weight (kg) Volume ratio
Red clay 1120 1
Sand 720 1.5~2
Water 400~600

6.5 Cement mortar


6.5.1 Application scope: for the bricking red bricks whose working temperature is lower

than 200℃.
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6.5.2 Mixing proportion of cement mortar is shown in table 27.

Table 27
Mortar grade
Grade of cement Composite
200 250 300 400
80 Cement: sand 1:3 1:3 1:3.50 1:4
50 Cement: sand 1:3.50 1:4 1:4.50 1:5
30 Cement: sand 1:4.50 1:5 1:6

6.6 Micro-porous calcium silicate mortar


6.6.1 Application scope: for the bricking micro-porous calcium silicate products.
6.6.2 Mixing proportion of micro-porous calcium silicate mortar is shown in table 28.

Table 28
Name of materials Weight (kg)
Water glass 100
Water 300
Micro-porous calcium silicate powder 200

7. Compounding specification
7.1 General regulations
7.1.1 Raw material used for the making up wall setting materials must conform to the
design requirements and should be checked according to relevant standards.
7.1.2 Fire-resisting concrete should be compounded strictly in proportion (generally,
weight ratio), the amounts of various binding agents, setting agents and water
should be accurate, and its mixing proportion cannot be changed at random.
7.1.3 Machines and equipment used for the transportation or agitation of concrete and
mortar should be washed in time. When the kind of concrete or mortar is changed,
these machines and equipment must also be washed strictly to prevent the mix of
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different concrete or mortar.


7.1.4 All kinds of raw materials should be piled up respectively according to different
categories, grade, date of delivery and not be mixed with each other in order to

keep them away from noxious substances (for example: limestone、silica、

railroad dreg and earth).

7.2 The requirement of raw material


7.2.1 Bauxite cement should conform to regulations of GB201 and its grade should not
be lower than 425#.
7.2.2 Silicate cement should conform to regulations of GB175. Slag silicate cement
should conform to regulations of GB1344. Their grade should not be lower than
425#. Limestone and others should not be mixed in.
7.2.3 Water glass commonly uses sodium silicate aqueous solution, mode number>2.2,
density>1.36.
7.2.4 Phosphoric acid commonly uses industrial phosphoric acid. Its concentration is
85%. Water quantity should be added to phosphoric acid with different
concentration is shown in table 29.

Table 29
Phosphoric acid Density Water quantity should be added to 100kg industrial
concentration % At 20℃ phosphoric acid with concentration of 85%

85 1.689 0
80 1.633 6.25
75 1.579 13.3
70 1.526 21.4
65 1.475 30.8
60 1.426 41.7
55 1.379 54.5
50 1.335 70.0
45 1.293 88.9
42.5 1.274 100.0
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40 1.254 112.5
35 1.216 142.7

7.2.5 Aggregate and powder of bauxite clinker should conform to the technical
specifications of fire-resisting raw material issued by formal Ministry of metallurgic
Industry. Refuse clay brick and refuse high aluminum brick should conform to
requirement of table 30.

Table 30
Characteristic
Name of material AL2O3 content % Refractoriness ℃

Refuse clay brick >35 ≥1690

Refuse high aluminum brick >48 ≥1750

7.2.6 Sodium fluorosilicate: purity≥90%, water content≤1%; Fineness: the percentage

of particles which pass through sieve pores of 0.15mm is 100%.


7.2.7 Requirement of zircon: ZrO2 content >64%.
7.2.8 Requirement of chromium sand: Cr2O3 content >35% .The particle composition is
shown in table 31.

Table 31
Particle size (mm) 7~2 2~0.088 <0.088
Content % 20~35 25~45 25~40

7.2.9 Refractoriness of binding clay is not less than 1630℃. When AL2O3>35%,

sintering temperature is not less than 1000℃~1100℃.

7.2.10 The particle size of aggregate of fire-resisting concrete can be divided into two
grades. Big particle is 5~15mm and small particle is less than 5mm. The
ingredient of aggregate is shown in table32 when the thickness of concrete is less
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than 60mm.

Table 32
Particle size (mm) 6~8 3~6 1~3 <1
Content % 20 20 35 25

7.2.11 The make up method of AlPO4 solution is shown as follows and the ingredent is
shown in table 33.
Chemical composition of solution
Al2O3: P2O5 =1:3.2
Water content: 55%.
Table 33
Name of materials
Phosphoric acid (Concentration 85%) 3500 A g
Aluminum hydrate 740 A g
Water 1645 A g

Remark: Coefficient A is a time number defined according to actual need.

Additional explanation:
This standard is firstly made in 1986,and amended in 1994.
CG1114—86 is abolished when this standard is adopted.