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PRODUCTS
DATA SHEETS

JAY CERAMICS
Chotila Road, Thangadh - 363 530, Gujarat, India. Phone : 02751 220371 Fax : +91 (2751) 220771 E Mail : jayceramics@yahoo.com Visit us at : www.ec21.com/jaycera

JAY CERAMICS
INDUSTRIES WE SERVE
We supply our prouducts and provide our services to a variety of companies. Some of the Industries we serve include :

Aluminium Industries Cement Industires Ceramic Industries Chemicals Plants Dairy Plants Electroplating Industries Fertilizers Plants Forging Plants Foundry Industries Galvanizing Glass Industries Heat Treatment Plants Insulation Iron & Steel Industries

Oil Refineries Paints Industries Paper Industries Petrochemicals Plants Petroleum Industries Plastics Industries Porcelain Industries Refractories Industries Rolling Mills Rubber Plants Soap Sugar Plants Textiles Plants Tiles Industries

JAY CERAMICS
Manufacturers of Refractories & Kiln Furniture

No.
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19

Contents
Technical data on Jay AL - 40% Technical data on Jay AL - 50% Technical data on Jay AL - 60% Technical data on Jay AL - 70% Standard shape & size of Fire Bricks Standard shape of Fire Bricks (Drawings) Standard shape & size of Fire Tiles Standard shape & size of Burner Blocks Product data on Mortars Product data on Insulating bricks Furnace tempratures Colour scale for tempratures Calculation for bricks required per unit volume Calculation for bricks required per sq. foot

Page No.
04 05 06 07 08 09 10 10 11 11 12 12 13 13 14 16 17 18 19

Combinations to form a ring with two sizes of brick Radial brick formulas Table for use in Designing Radial type brick Elements of Arches Inquiry Form

JAY CERAMICS
TECHNICAL DATA JAY AL - 40%
JAY AL - 40% is 40% Alumina Brick based on calcined bauxite of Rotary Kiln with good thermal spalling resistance, medium porosity and good mechnical streingth. Applications includes Cement Rotary Kilns, Reheat Furnaces, Metallurgical Furnaces, Boiler Furnaces, Linings for general purpose usein steel plants including Tundish Lining and Ceramic Kilns.

CHEMICAL ANALYSIS
Alumina Al2O3 Silica SiO2 Ferric Oxide Fe2O3 Titania TiO2 Calcia CaO 38.00 - 40.00% 38.00 - 42.00% Max . 3.10% 2.90 1.00 3.50% 1.50%

PHYSICAL PROPERTIES
Pyrometric Cone Equivalent, Ortron Reheat change - at 1400 C - 2Hrs, % Refractoriness under Load - ta Value Apparent Porosity % 3 Bulk Density, gm /cm Cold Crushing, Strength, Kg/cm2 Thermal Conductivity, W/Mok at 650 C at 1000 C ........... ........... ........... ........... ........... ........... ........... ........... Min. 32 (1743 C) Max. (+/-) 0.5% Min 1400 C 17.0 - 20.0% 2.30 - 2.50 400 - 600 1.70 1.60

IMPORTANT NOTE THE ABOVE TEST DATA are based on average results of Control tests on dry pressed standard size bricks and are subject to normal variation on individual tests, hence these results shuold not be regarded as absolute limits.

Page No.: 04

JAY CERAMICS
TECHNICAL DATA JAY AL - 50%
JAY AL - 50% is 50% Alumina Brick based on calcined bauxite of Rotary Kiln with good thermal spalling resistance, low porosity and excellent mechanical strength, Applications includes Cement Rotary Kilns, Reheat Furnaces, Metallurgical Furnaces, Boiler Furnaces, Rosting Kilns, Linings for general purpose use in steel plants including Tundish Lining and Ceramic Kilns.

CHEMICAL ANALYSIS
Alumina Al2O3 Silica SiO2 Ferric Oxide Fe2O3 Titania TiO2 Calcia CaO 48.00 - 53.00% 38.00 - 42.00% Max . 3.10% 2.90 1.00 3.50% 1.50%

PHYSICAL PROPERTIES
Pyrometric Cone Equivalent, Ortron Reheat change - at 1400 C - 2Hrs, % Refractoriness under Load - ta Value Apparent Porosity. % 3 Bulk Density, gm/cm 2 Cold Crushing, Strength, Kg/cm Thermal Conductivity, W/Mok at 650 C at 1000 C
IMPORTANT NOTE THE ABOVE TEST DATA are based on average results of Control tests on dry pressed standard size bricks and are subject to normal variation on individual tests, hence these results shuold not be regarded as absolute limits.

.......... .......... .......... .......... .......... .......... .......... ..........

Min. 33 (1743 C) Max. (+/-) 0.5% Min 1400 C 17.0 - 20.0% 2.30 - 2.50 400 - 600 1.70 1.60

Page No.: 05

JAY CERAMICS
TECHNICAL DATA JAY AL - 60%
JAY AL - 60% is high Alumina Brick having 60% Alumina Contents based on Refractory grade bauxite calcined in Rotary kiln, High density and excellent strength, featuring low alkali contents, applications includes Cement and Lime Rotary and Saft Kilns, Re-heat Furnace, Incinerators, Ceramic Kilns, Boiler Furnaces, Reverbertory air or holding Furnaces.

CHEMICAL ANALYSIS
Alumina Al2O3 Silica SiO2 Ferric Oxide Fe2O3 Titania TiO2 Calcia CaO 58.00 - 62.00% 31.00 - 35.00% 2.50 2.75 0.50 3.10% 3.00% 1.70%

PHYSICAL PROPERTIES
Pyrometric Cone Equivalent, Ortron Reheat change - at 1400 C - 2Hrs, % Refractories under Load - ta Value Apparent Porosity. % 3 Bulk Density, gm/cm Cold Crushing, Strength, Kg/cm2 Thermal Conductivity, W/Mok at 700 C at 900 C .......... .......... .......... .......... .......... .......... .......... ........... Min. 35 (1785 C) Max. (+/-) 0.5% 1420 - 1450 C 19.0 - 22.0% 2.45 - 2.60 400 - 600 1.40 1.20

IMPORTANT NOTE THE ABOVE TEST DATA are based on average results of Control tests on dry pressed standard size bricks and are subject to normal variation on individual tests, hence these results shuold not be regarded as absolute limits.

Page No.: 06

JAY CERAMICS
TECHNICAL DATA JAY AL - 70%
JAY AL - 70% is dense, low porosity, 70% Alumina Brick based on Refractory grade bauxite calcined in Rotary kiln with excellent resistance to spalling, corrosive slags and hot metals, Successful applications in Burning zone linings of Tunnel Kiln and Hot Air Generators, Electric Arc Furnace Roof Steel Teeming Laddles, Induction Furnace, Sugar Mills, Chemical Plants and many others.

CHEMICAL ANALYSIS
Alumina Al2O3 Silica SiO2 Ferric Oxide Fe2O3 Titania TiO2 Calcia CaO 68.00 - 73.00% 19.00 - 25.00% 2.80 3.40 1.50 3.20% 3.90% 2.00%

PHYSICAL PROPERTIES
Pyrometric Cone Equivalent, Ortron Reheat change - at 1400 C - 2Hrs, % Refractories under Load - ta Value Spalling Test, Water quench - 1300 C Apparent Porosity. % 3 Bulk Density, gm/cm 2 Cold Crushing, Strength, Kg/cm Thermal Conductivity, W/Mok at 650 C at 1000 C
IMPORTANT NOTE THE ABOVE TEST DATA are based on average results of Control tests on dry pressed standard size bricks and are subject to normal variation on individual tests, hence these results shuold not be regarded as absolute limits.

.......... .......... .......... .......... .......... .......... .......... .......... ...........

Min. 36 (1804 C) Max. (+/-) 2.5% 1430 - 1480 C Min 10 Cycles 18.0 - 22.0% 2.65 - 2.75 Min 500 1.60 1.65

Page No.: 07

JAY CERAMICS
STANDARD SHAPE AND SIZE OF BRICKS.
Dimension in Inches A 9" 9" 9" 9" 9" x x x x x
1

Dimension in Milimetres C

B 4 /2" 4 /2" 4 /2" 4 /2" 4 /2"


1 1 1 1

A
230 230 230 230 230 x x x x x

B
115 115 115 115 115 x x x x x

C
75 65 50 40 25

x x x x x

3" 2 /2" 2" 1 /2" 1"


1 1

C
B

C A

A B D

B C D

ARCH BRICKS
A 9" x 9" x 9" x 9" x 9" x 9" x 9" x 9" x 9" x
B
1 1 1 1 1 1 1 1 1

END ARCH
C D x x x x x x x x x 2.75" 2 /2" 2 /4" 2" 1.75" 1 /2" 1 /4" 1"
1 1 1 1 1

SIDE ARCH
B 115 115 115 115 115 115 115 115 115 x x x x x x x x x C 75 75 75 75 75 75 75 75 75 x x x x x x x x x D 70 65 55 50 45 40 30 25 06

B 4 /2 " 4 /2 " 4 /2 " 4 /2 " 4 /2 " 4 /2 " 4 /2 " 4 /2 " 4 /2 " x x x x x x x x x

A 230 x 230 x 230 x 230 x 230 x 230 x 230 x 230 x 230 x

3" 3" 3" 3" 3" 3" 3" 3" 3"

/4"
C

D D
A

D
A

KEY

SIDE SKEW

END SKEW
Page No.: 08

JAY CERAMICS
STANDARD SHAPE AND SIZE OF FIRE TILES
Dimension in Inches
A 9" 12" 15" 18" 24" 15" 18" 24" 12" 18" 24" 12" x x x x x x x x x x x x B 9" 12" 12" 12" 12" 15" 18" 18" 12" 12" 12" 12" x x x x x x x x x x x x C 3" 3" 3" 3" 3" 3" 3" 3" 6" 6" 6" 4.5"

Dimension in Milimetres
A 230 310 385 460 620 385 460 620 310 460 620 310 x x x x x x x x x x x x B 230 310 310 310 310 385 460 460 310 310 310 310 x x x x x x x x x x x x C 75 75 75 75 75 75 75 75 150 150 150 115

FIRE TILES

STANDARD SHAPE AND SIZE OF BURNER BLOCKS


Size 9" x 9" x 9" x 9" x 9" 9"
1

Hole Size 6" x 4" 5 /2" x 5 /2" 8" x 4" 10" x 4" 10" x 6"
1

Design Standard Wesman Standard Wesman Standard


Page No.: 09

12" x 12" x 12" 14" x 14" x 14" 15" x 15" x 15"

JAY CERAMICS

BEVEL BRICK

BONDER

BULLENOSE OR JAMB BRICK

CIRCLE BRICK

CIRCLE BRICK ONE EDGE

DOME BRICK

END ARCH

END SKEW ON FLAT

FEADHER END

FEADHER END ON EDGE

FEADHER SIDE

KEY BRICK

PUP,SOAP OR CLOSER

SIDE ARCH

SPLIT OR SCONE

WHELP

LARGE FACE / FLAT EDGE / SIDE

END FACE STANDARD SQUARE SPRINGER / SKEW BACK

Page No.: 10

JAY CERAMICS
MORTARS

Type Jay Jay Jay Jay Jay Jay 30 40 50 60 70 80

Al2O3 % (Min.) 30 40 50 60 70 80

Fe2O3 % (Max.) 2.0 2.0 2.5 3.0 3.5 3.5

PCE (o.c.) (Min.) 30 32 34 35 37 38

Grain Size (mm.) 0 - .0.5 0 - .0.5 0 - .0.5 0 - .0.5 0 - .0.5 0 - .0.5

INSULATING BRICK

Analysis
Bulk Density (Max.) (gm/cc) Apparent Porosity (Min.) % (Volume) Cold Crushing Strenghth 2 (Min. Kg/cm ) Al2O3 (Min.) % Fe2O3 (Min.) % Service Temperature
O

Cold Face
0.7 + 0.05

Hot Face
1.0 + 0.05

70

58

10 35

30 45

2.0
C 1250 1200

1.5
1400 1350

Permenent Linear Changer O ( < 2% at C for 2 hrs.) Thermal Conductivity (Max.) O O O (Kcal/mh C at 350 C + 10 C)

0.20

0.30

Page No.: 11

JAY CERAMICS
FURNACE TEMPERATURES
KIND OF FURNACES Boilers................................................ By - Product Coke Ovens.................. Cement Kilns, Hot Zone..................... Copper Converters............................. Copper Refining Furnaces................. Copper Reverberatories.................... Copper Roasters................................ Gas Producer..................................... Gas Annealing Furnaces................... Glass Tanks-bottle............................. Glass Tanks-plate.............................. Iron and Steel Furnaces : Annealing Oven............................ Blast Furnaces, tapping................ Bessemer Converter..................... Electric Furnaces.......................... Heating Furnaces......................... Malleable Furnaces...................... Open Hearths Melting Chamber...................... Checkers.................................. Soaking Pits............................. DEGREES C 1000 to 1600 1000 to 1500 1300 to 1600 1200 to 1300 1250 to 1550 1300 to 1570 700 to 810 1260 to 1370 430 to 540 1370 to 1600 1370 to 1650 760 to 980 1370 to 1540 1540 to 1650 1450 to 1700 980 to 1310 1300 to 1650 650 to 1680 200 to 1430 1150 to 1370 DEGREES F 1800 to 2900 1830 to 2730 2400 to 2900 2200 to 2400 2300 to 2800 2400 to 2850 1300 to 1500 2300 to 2500 800 to 1000 2500 to 2900 2500 to 3000 1400 to 1800 2500 to 2800 2800 to 3000 2650 to 3100 1800 to 2400 2400 to 3000 1200 to 3050 400 to 2600 2100 to 2500

COLOUR SCALE FOR TEMPERATURES


Lowest Visible Red............................ Lowest Visible Red to Dark Red........ Dark Red to Cherry Red.................... Cherry Red to Bright Cherry Red...... Bright Cherry Red to Orange............. Orange to Yellow ............................... Yellow to Light Yellow......................... Light Yellow to White.......................... White to Dazzling White..................... 475 475 to 650 650 to 750 750 to 815 815 to 900 900 to 1090 1090 to 1315 1315 to 1540 1540 to ......... 885 885 to 1200 1200 to 1380 1380 to 1500 1500 to 1650 1650 to 2000 2000 to 2400 2400 to 2800 2800 to ........
Page No.: 12

JAY CERAMICS

CALCULATION FOR BRICKS REQUIRED PER UNIT VOLUME

A Cubic Metre Of Brickwork requires A Cubic Feet Of Brickwork requires Volume of 1000 Nos. standard 230 X 115 X 75 mm Straights Closly stacked (approx.) Volume of 1000 Nos. Standard 1 9" X 4 /2" X 3" Straights Closly Stacked (approx.)

513 Nos. 230 X 115 X 75mm Strainghts 14.2 Nos. 9" X 41/2" X 3" Straights

1.95 Cubic metres

71 Cubic Feet

BRICKS REQUIRED PER SQ. FEET OF WALL

Wall Thickness 65 mm. (2.5") 75 mm. (3.0") 115 mm. (4.5") 230 mm. (9.0") 340 mm. (13.5") 460 mm. (18.0") 575 mm. (22.5") 690 mm. (27.0")

230 x 113 x 65 mm 3.56 ........ 6.40 12.80 19.20 25.60 32.00 38.40

230 x 113 x 75 mm .......... 3.56 5.30 10.70 16.00 21.30 26.70 32.00

Page No.: 13

JAY CERAMICS
COMBINATIONS TO FORM A RING WITH TWO SIZES OF BRICK

OUTSIDE CHORD DIMENTIONS

C
B

A
B

A
B
A

A
e
E

INSIDE CHORD DIMENTIONS

A - A radial brick used with a streight or another radial B, which turns a larger circle than A. B - A streight brick or a radial brick which turns a larger circle than A, both a and B forming the same thickness of arch T. T - The thickness of the arch formed by A and B. C - The outside chord of brick A. c - The outside chord of brick B.

E - The inside chord of brick A. e - The inside chord of brick B. D - Given outside diameter of desired ring. d - Given inside diameter of desired ring.

G - Outside diameter of ringformed by radial brick A alone. J g j x y S - Number of brick A to form a ring of outside diameter G. - Outside diameter of ring formed by brick B alone if it is ardial. - Number of brick B to form a ring of outside diameter g. - Number of pieces of brick A, used with brick B to form a ring of outside diameter D. - Number of pieces of brick B, used with brick A to form a ring of outside diameter D. - Total number of pieces of brick A and brick B to form a ring of outside diameter D.

Page No.: 14

JAY CERAMICS
COMBINATIONS TO FORM A RING WITH TWO SIZES OF BRICK (Contd...)
I. WHEN BOTH BRICK A AND B ARE RADIAL AND OUTSIDE CHORDS ARE EQUAL (C =C) BUT INSIDE CHORD ARE UNEQUAL. (1) S =

pD

pD

C C (2) Y = d - SE e-E

II. WHEN BRICK B IS A STRIGHT BRICK AND BRICK A IS REDIAL, C = E AND (3) x = 2pT = 6.2832T C-E (4) y = C-E

pD - xC
c

III. WHEN BRICK A AND B ARE RADIAL AND BOTH CHORD DIMENSIONS OF A DIFFER FROM THOSE OF B. (5) Cx + cy = (6) EX + ey =

pD pd

IV. WHEN CALCULATING A SERIES OF COMBINATION THE FOLLOWING FORMULAS ARE CONVENIENT : (1) X = J (g - D) g-G (2) Y = J (g - D) g-G

Page No.: 15

JAY CERAMICS
RADIAL BRICK FORMULAS

CIRCLE TYPE

C A

T r

a c

WEDGE TYPE

KEY TO SYMBOLS

a - Inside arc of circle type brick A - Outside arc of circle type brick c - Inside chord of circle or wedge type brick C - Outside chord of circle or wedge type brick r - Inside radius of radial brick R - Outside radius of radial brick d - Inside diameter of ring formed by radial Brick

FORMULAS :
c = C =

rC rC = r+T R (r + T) c r

Rc r

Sine /2 =

= 360 S

D - Outside diameter of ring formed by radial brick T - Radial dimension of brick - Theta, the included angle of brick p - Pi - 3.1416 S - Total number of a given radial brick required to form a ring

S = C 2R or c 2r

2p T C-c

pD
C

pd
c

Page No.: 16

JAY CERAMICS
TABLE FOR USE IN DESIGNING RADIAL TYPE BRICK
If the outside chord of a radial brick is desired for a given number of pieces per ring, find the number of pieces in coloum 1 and multiply the corresponding sine of the half angle in colomn 2 by the outside diameter of the ring. If brick with an outside chord of approxymately 9'' is desired, find the diameter in colomn 3 that comes closest to the desired outside diameter. Then multiply the corresponding sine of the half angle in colomn 2 by the desired outside diameter to obtain the actual chord. The number of pieces to form a ring will be found in colomn 1.

No.of brick Sine of Dia. for 9"Chord to Circle (1) Half Angle (2) in inches (3)
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 0.58779 0.50000 0.43388 0.38268 0.34202 0.30902 0.28173 0.25882 0.23932 0.22252 0.20791 0.19509 0.18375 0.17365 0.16459 0.15643 0.14904 0.14231 0.13616 0.13053 0.12533 0.12054 0.11609 0.11197 0.10812 0.10453 0.10117 0.09802 0.09506 0.09227 0.08964 0.06716 0.08481 0.08258 0.08047 0.07846 0.07655 0.07473 0.07299 0.07134 0.06776 0.06825 0.06680 0.06540 0.06407 0.06279 0.06159 0.06038 15.312 18.000 20743 23.518 26.314 29.124 31.945 34.773 37.607 40.446 43.288 46.133 48.980 51.681 54.681 57.534 60.386 63.242 66.099 68.950 71.810 74.664 77.526 80.379 83.241 86.100 88.959 91.818 94.670 97.540 100.402 103.258 106.120 108.985 111.843 114.708 117.570 120.434 123.305 126.156 129.014 131.868 134.731 137.615 140.471 143.335 146.199 149.056

No.of brick to Circle (1)


53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

Sine of Dia. for 9"Chord Half Angle (2) in inches (3)


0.05924 0.05815 0.05709 0.05607 0.05508 0.05414 0.05322 0.05234 0.05147 0.05065 0.04985 0.04907 0.04832 0.04758 0.04687 0.04618 0.04552 0.04486 0.04423 0.04362 0.04302 0.04244 0.04188 0.04132 0.04079 0.04027 0.03975 0.03926 0.03878 0.03830 0.03784 0.03739 0.03695 0.03652 0.03610 0.03569 0.03529 0.03490 0.03452 0.03414 0.03377 0.03341 0.03306 0.03272 0.03238 0.03205 0.03173 0.03141 151.924 154.772 157.646 160.514 163.399 166.236 169.109 171.953 174.859 177.590 180.542 183.411 186.258 189.155 192.020 194.890 197.715 200.624 203.482 206.327 209.205 212.064 214.900 217.612 220.642 223.491 226.415 229.241 232.078 234.987 237.844 240.706 243.572 246.540 249.307 252.171 255.030 257.880 260.718 263.620 266.509 269.380 272.232 275.061 277.949 280.811 283.643 286.533

Page No.: 17

JAY CERAMICS
A Y

a 0 S

ELEMENTS OF ARCHES

Formulas
To find the rise when radius and span are given : H = r - /2
1

KEY TO SYMBOLS
4r
2

- S

To find the inside radius when rise and span are given : 2 2 r = S + 4H 8H To find the angle 0 when the radius and span are given :
1 Sin /2 = S

S= H= R= r = T= A= a = e =

Span of arch Rise of arch Outside radius of arch Inside radius of arch Thikness of arch Outer arch length Inner arch length Central Angle

2r

To find the lengths when the radius and central angle are given : Outer arc : Inner arc : A = 2pR 360 a = 2pr 360

VALUES FOR GIVEN RISES PER FOOT OF SPAN Rise in Inches Per Foot of Span
1 1 /4 1 /2 1.608 1 /4 2 2 /4 2.302 2 /2 2 /4 3
3 1 1 3 1 1

Inside * Arc is Factor xS


1.5417 1.2521 1.0625 1.0000 0.9301 0.8333 0.7604 0.7474 0.7072 0.6600 0.6250

Central Angle Degrees Part of Circle


37"50.9' 47"4.4' 56"8.7' 60"0.0' 65"2.5' 73"44.4' 82"13.4' 83"58.5' 90"28.8' 98"29.7' 106"15.6' 0.1051 0.1308 0.1560 0.1667 0.1807 0.2048 0.2284 0.2333 0.2513 0.2736 0.2952

Inside * Arc is Factor xS


0.0184 1.0287 1.0412 1.0472 1.0558 1.0725 1.0913 1.0954 1.1120 1.1346 1.1591

Diff.of Skewback Outer and X * is Y * is Ineer Arcs factor xT Factor x T Factor x T


0.0184 1.0287 1.0412 1.0472 1.0558 1.0725 1.0913 1.0954 1.1120 1.1346 1.1591 0.3243 0.3993 0.4706 0.5000 0.5376 0.6000 0.6575 0.6690 0.7101 0.7575 0.8000 0.9460 0.9168 0.8824 0.8660 0.8432 0.8000 0.7534 0.7433 0.7041 0.6528 0.6000

* Inside radius, inside arc, difference of outer and inner arcs, x and y arcs, x and y are obtained by multiplying the factor in respect with S or T, whichever applies. Page No.: 18

JAY CERAMICS
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