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Brick lining installation

Brick lining installation


golden rules

JULY 2007 / Version 2

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

Foreword

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

Content

Brick lining installation

Safety gear
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

Face shield
Apron

Heavy duty
rubber apron

Brick lining installation

For cutting bricks

Polycarbonate
Scratch resistant
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Brick lining installation

Safety equipment
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

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

Base lines
Parallel

Brick lining installation

Radial

Parallel

Welding

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
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Brick lining installation

Mixing ratio is adjusted

Wrong
Right

Wrong

Right

Brick lining installation

No brick upside down


Check hot face marking

Brick lining installation

Mortar is used to correct deformed shell /


welding
Right

Brick lining installation

Wrong

Brick lining installation

Key bricks are not in one line

Right

Key bricks

Key bricks side to side

Brick lining installation

Wrong

Key bricks
face to face
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Brick lining installation

Shims are not installed close to key bricks


Shim thickness = 2 mm max.

Maximum of 2 to 3 shims per ring

Shims

2 shims

Brick lining installation

Use shim driver

Brick lining installation

Rings are closed using hydraulic jack

Pressure to be applied = brick cold


crushing strength
Typical CCS ranges are 50 to 70 N/mm2

Brick lining installation


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
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Brick lining installation

Bricks are cut with brick cutting machine

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

Do not cut
in this
direction

Mandatory
direction
of cut

Brick original
length

Minimum cut

200 mm

140 mm

300 mm

200 mm

Brick lining installation

Minimum cut
2/3 of original length

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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

Brick lining installation

Cut
bricks

Full bricks
Retaining ring
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Brick lining installation

Closing of the last ring is done properly


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

n
Closure brick

Mortar, liquid
enough

Y
Piece of
wood
Hammer

Shims
Instead of mortar, additional
metal shims can be used

Brick lining installation

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Brick lining installation

Cardboard spacers are placed adequately

To allow expansion
Bricks type

Cardboard spacers

Magnesia

1 cardboard of 2 mm
between each ring

Dolomite

1 cardboard of 1 mm
between each ring

Alumina

No cardboard

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

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.
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Brick lining installation

Additional guidelines
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!

Brick lining installation

Notes

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Brick lining installation

Notes

Brick lining installation

Notes

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Brick lining installation

Direction des Performances Cimentires (DPC)


95, rue du Montmurier - BP 70
38291 St-Quentin-Fallavier Cedex - France
Tel. + 33 4 74 82 16 16