The primary function of any anchoring system is to retain the refractory mass in place. In order to perform this
requirement successfully, anchoring systems must be selected and installed to match the service conditions under which the process vessels will operate.
Installation parameters will differ according to a number of variables including:
• Type of refractory being installed
• Lining thickness and number of lining components
• Method of refractory installation (gunning, ramming, casting, or shotcreting)
• Process vessel geometry
• Maximum and continuous vessel operating temperatures
• Vibration and/or severity of vessel operation
• Structural stability of vessel shell, bindings or support structure
• Exterior insulation
• Operating atmosphere or process
• Whether or not portions of existing lining remain or brick lining exist
Wire Anchors
Many anchoring systems for castable and gunned linings utilize the V-type alloy wire anchors they provide adequate support and holding power for the refractory, which also offers economy through simple installation.
Wire anchors are used for most anchor applications where the service
temperatures do need exceed
2000°F(1904°C). Metallic components should be based on the temperatures of the lining and should be installed in ways which will allow heat dissipation by conduction and/or circulation.
Harbison-Walker supplies wire anchors for a broad range of monolithic anchoring situations. Harbison-Walker wire anchors come in mild steel, 304, 309 or 310 stainless steels. The wire anchors presented represent the most commonly used types. Other available options include color coding anchor by metal type, using color plastic tips, stamping metal type and supply in special packaging upon request. Harbison-Walker also supplies custom made anchors to meet special requirements.
Anchor Spacing
Distance between anchors should be considered carefully. Edges, roofs, nose, and areas where vibration, mechanical movement or gravity impose loads on the lining, require more anchors. Standard spacing for various areas is suggested in the table below and indicated in the accompanying illustration. Anchors should be welded in a square pattern, rotating the anchor tines 90° from neighboring anchors.
Anchor Welding
Wire anchors require at least a half inch of weld fillet on both sides. Tack welding is not enough for wire anchors. Heavier rod anchors also may require more fillet weld on both sides of the leg.
Welds can be tested by striking half of them with a hammer. A ringing sound indicates a good weld. A dull thud indicates a potential failure. Then bend flat one of every 100 anchors to insure weld does not fail. If the test shows poor welds, check all the anchors and replace those that fail.
Anchor Length
Length of wire anchors should be 0.8 times 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 5 inches of anchor length.
Estimating Anchor Quantities
To determine the total number of anchors required, multiply the anchors per square foot by the total number of square feet in the lining. Anchor quantities based on typical anchor centers are shown in the table.
Estimating Anchor Quantities Anchor Spacing Anchors/Sq Ft
6 x 6 4
8 x 8 2.3
9 x 9 1.8
9 x 12 1.33
10 x 10 1.44
12 x 12 1
12 x 18 0.67
Typical Spacing Pattern
The majority of wire anchor installation linings are 9 inches thick or less. The inset illustration details the installation of a 4A wire anchor. The metal washer allows the anchor tines to be spread to retain the block insulation.
Wire Anchor Dimensions
Anchor Available Lengths, (in)*
1A 2 to 7
2A 3 to 9
3A 5 to 15
4A 5 to 11
1L 1 to 7
2L 1 to 7
* Lengths vary in ½-inch increments Wire and Rod Anchor Spacing
Locations Lining Anchor Thickness Centers (in.) (in.)
Walls, 2-4 6
Cylinders, 4-6 9
Slopes 6-13½ 12
Overhead, 2-4 6
Roofs, 4-7 9
Bullnoses 7-9 12
Floors 2-5 9
5-9 15
9+ 24
¼” AWAY FROM BEND
¾”
¼” 1”
1¼”
316”
NOTE: KEEP WELD ¼” AWAY FROM VERTICAL BEND
Wire Anchors
1A – This ¼ inch diameter anchor is designed for economical use with linings 5 inches or less. It may also be used with lightweight materials where loads are not high.
2A – This ¼ inch diameter anchor can be used for thicker linings where additional holding power is needed. An anchor configuration designed for holding power and a foot designed for added weld strength give the 2A the versatility needed for use with high density materials. A anchors can be used in high density linings 7 inches thick or less and for lightweight linings.
3A – This 5/16-inch diameter anchor is a larger version of the 2A. Also incorporating a foot for added weld strength, the 3A handles thick dense linings up to 9 inches, heavy overhead loads and areas subject to movement or vibration..
3A-3/8 – This 3/8 inch 3A anchor is designed for dense thick linings from 6 to 16 inches thick, heavy overhead loads areas subject to movement and vibration. The foot provides additional weld strength.
1L & 2L Clips – These metal clips are used with the 3A and 2A anchors respectively, for installing 2 component linings. 1L clips have a 5/16-inch notch for use with the 3A anchor. 2L clips have a 1/4- inch notch for incorporating the 2A anchors.
In the 2 component lining application, the clip permits the first component to be installed before the 3A or 2A anchors are attached and the hot face lining is installed.
4A – This ¼ inch diameter anchor is intended for use with monolithic linings with backup insulation.
A washer is furnished with the anchor which permits the anchor tines to be spread after the insulation is in place. The 4A is typically used in linings with a total thickness of 4 to 12 inches.
5A & 6A – These ¼ inch and 5/16 inch anchors are typically used for light duty monolithic linings.
In lengths from 3 to 10 inches, they are typically used for anchoring in door framings, corners, pockets and small voids.
7A – The “Christmas Tree” anchor, available in heights from 13 to 40 inches are typically used in specific applications where massive installations of refractories occur. Examples include rotary kiln dams and lifters.
KL – This 3/8 inch diameter anchor is for use in rotary kiln linings 4 ½ to 9 inches thick. The plate supplied with the anchor is welded to the shell.
The tack weld between the plate and the anchor can break during operation and thus allow limited movement between lining and shell. Expansion and contraction in the lining is assured while the lining is retained in place.
1A 2A & 3A
4A
1L & 2L CLIPS
FOR 2A & 3A ANCHORS
7A 3R
5A & 6A
KL
Grades of Steel Required for High Temperature Service Type of Steel Color Code Maximum Temp of
Metallic Components °F
Carbon Steel Blue 1000
304 SS No Color 1600
309 SS Red 1650
310 SS Yellow 1700
KL ANCHORS TOTAL
LINING
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 TOTAL
LINING
THICKNESS 5A-
6A-3 ½A-34; 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"
STANDARD WIRE ANCHORS TOTAL
LINING
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"
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
DimC DimD
2A Anchor and 2-L Clip Arrangement For 2 Component Cast Lining 3A Anchor and 1-L Clip Arrangement
For 2 Component Cast Lining
1-L CLIP 2-L CLIP
Hot Face
3-A Anchor
1-L Anchor Clip
½” Form Board
/ ” Std Washer
8 Ø
7
½” 15½”Max. 5½”Min.
7” Max.
1” Min.
Working Lining
Backup Lining 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-A Anchor
2-L Anchor Clip
½” Form Board
/ ” Std Washer
8 Ø
7
½” 9½”Max. 3½”Min.
6 ½” Max.
1” Min.
Working Lining
Backup Lining Casing LR
DimA Dim A
Dim C
1-R-T Clip 1-R Clip
1-R CLIP
Shape 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 ANCHOR
Shape 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