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 Portal’s Refractory Domain carefully.
(connect to: http://webcementportal.lafarge.com)
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
Brick lining installation
Safety gear
Long
sleeved
For all personnel
Overalls
Hard hat
Safety shoes
Gloves
Safety glasses
Dust mask
Ear protections
Polyester
Non-skid
Abrasion resistant
Remark: Follow the detailed safety procedures published on the Cement Portal’s
Refractory domain:
How to ensure safety for brick demolition & brick lining works How to ensure safety for brick cutting
Brick lining installation
Polycarbonate
Heavy duty
rubber apron
For cutting bricks
Face shield
Apron
Brick lining installation
Safety equipment
Equipped with compressed air reservoir (5l) +
non-return valve
Alarm if pressure < 4.5 bars
Using a brick rig is the only safe kiln
bricking method
If you have to pass through the coating, a
safe way is to use Tunnel cages
Brick lining installation
Inside the kiln, all electrical
equipment used must be class II
(double insulation) supplied by
safety transformers situated outside
the kiln
Compressed air
hosepipes and
couplings
are in good
condition
Brick lining installation
Axial
Reference lines are drawn axially &
radially
2
ndpoint
Brick lining installation
Radial
Base lines
Parallel
Welding
Parallel
Brick lining installation
General rule: Lining patterns are
staggered
Brick lining installation
Use a rubber
hammer for brick
installation
Ensure the kiln shell surface
is clean and smooth
Brick lining installation
Mixing ratio is adjusted
Right
Brick lining installation
No brick upside down
Check hot face marking
Brick lining installation
Mortar is used to correct deformed shell /
welding
Brick lining installation
Brick lining installation
Key bricks are not in one line
Right
Brick lining installation
Key bricks
face to face
Key bricks side to side
Brick lining installation
Shims are not installed close to key bricks
Shims
Maximum of 2 to 3 shims per ring
Shim thickness = 2 mm max.
Brick lining installation
Brick lining installation
Rings are closed using hydraulic jack
Pressure to be applied = ½ brick cold
crushing strength
Brick lining installation
Example: ANKRAL-ZE
Cold crushing strength = 70 N/mm
2Brick lining installation
Bricks are cut with brick cutting machine
Do not cut
in this
direction
Mandatory
direction
of cut
Minimum brick
cutting length is
respected.
Dry cut for basic
bricks
Brick lining installation
Minimum cut
2/3 of original length
200 mm
300 mm
140 mm
200 mm
Minimum cut
Brick original
length
Brick lining installation
Cut bricks are always in between full
bricks
Cut
bricks
Old
bricks
Full bricks
It is recommended
to have 300 mm
long bricks
Brick lining installation
Cut
bricks
Full bricks
Retaining ring
Brick lining installation
Closing of the last ring is done properly
Tight lining must be ensured for the last ring, too.
Hammer
n
Mortar, liquid
enough
Closure brick
Piece of
wood
Y
Brick lining installation
q
Instead of mortar, additional
metal shims can be used
Shims
Brick lining installation
Cardboard spacers are placed adequately
To allow expansion
No cardboard Alumina
1 cardboard of 1 mm between each ring Dolomite
1 cardboard of 2 mm between each ring Magnesia
Cardboard spacers Bricks type
Remark:
These are general rules. Follow exactly the
instructions given by the refractory suppliers.
Never remove the cardboards from the original bricks!
Brick lining installation
Nosering
No cardboard
spacers
Retaining ring
Brick lining installation
Additional guidelines
Don’t change the
quality under the tires
or the girth-gear
On deformed areas
bricks should be laid
with mortar
Don’t hesitate to discuss with your
TC Refractory Expert if you have any doubt!
Brick lining installation
Brick lining installation
Brick lining installation
Brick lining installation
Direction des Performances Cimentières (DPC)95, rue du Montmurier - BP 70
38291 St-Quentin-Fallavier Cedex - France Tel. + 33 4 74 82 16 16
