brick installation guide pdf

BRICKINSTALLATION

GUIDE

TECHNICAL INFORMATECHNICAL INFORMATECHNICAL INFORMATECHNICAL INFORMATECHNICAL INFORMATIONTIONTIONTIONTION

Harbison-Walker Brick Installation Guide- TC

Harbison-WalkerBrick InstallationGuide

Please contact your Harbison-WalkerRepresentative at any time for morespecific information on the use of refractoryproducts in your applications.

NOTE: Technical data within thisbrochure are subject to reasonablevariations and should not be used forspecification purposes. ASTM proce-dures, where applicable, are used fordetermination of data.

© Copyright 2008Harbison-Walker Refractories Company

Printed in U.S.A.

CONTENTS

INTRODUCTION ............................................................................................1

HARBISON-WALKER ON THE WEB ............................................................7

SELECTION OF REFRACTORIES ................................................................8

ORDERING REFRACTORIES........................................................................9

FURNACE REFRACTORY LINING AND CONSTRUCTION............................................................................10-12

ARCH CONSTRUCTION ........................................................................13-20

BRICK SIZES AND SHAPES ..................................................................21-25

EAF DOOR JAMBS/BLAST FURNACE........................................................26

BLAST FURNACE KEYS..............................................................................27

ELECTRIC FURNACE ROOF SHAPES..................................................28-29

SEMI-UNIVERSAL LADLE BRICK (SULB) ..................................................30

SKEWBACK SHAPES ............................................................................31-32

BRICK COUNTS FOR ROTARY KILNS..................................................33-35

COMBINATION LININGS FOR ROTARY KILNS........................................36-39

ISO AND VDZ COMBINATION ..............................................................40-42

RING COMBINATIONS ..........................................................................43-69

ARCH COMBINATIONS ..........................................................................70-80

APPENDIX (AREA & VOLUME) ..............................................................81-86

REFERENCE TABLES ............................................................................87-90

GLOSSARY ............................................................................................91-98

DISCLAIMER: The information presented in this book is for general educational use only. Itdoes not contain recommendations for any particular refractory for any particular use. It is notintended as, and should not be taken as, a warranty of any kind, including but not limited to awarranty of fitness.

WARNING: Some materials which are present in refractory products are harmful. One suchgroup is classified as substances known to cause cancer to humans. Other substances may beclassified as probably or possibly carcinogenic. These materials include minerals used in orformed during the manufacture of these products. The primary threat presented by many ofthese materials comes from inhaling respirable dust. The use of proper respiratory equipment,as well as other personal protective equipment is mandatory where required by applicable law.Please refer to the applicable Material Safety Data Sheet for such product.

Harbison-Walker Refractories Company400 Fairway Drive

Moon Township, PA 15108

Phone: (412) 375-6600 Fax: (412) 375-6783www.hwr.com

Harbison-Walker Brick Installation Guide - 1

INTRODUCTION

Out of the FireThe history of high heat manufacturing and refractory technology began withthe discovery of fire. Nature provided the first refractories, crucibles ofrock where metals were softened and shaped into primitive tools. Modernrefractories are customized, high-temperature ceramics designed to with-stand the destructive and extreme service conditions needed to manufacturemetals, glass, cement, chemicals, petroleum and other essentials of contem-porary life.

The History ofHarbison-WalkerThe refractories company known asHarbison-Walker opened onMarch 7, 1865, as the Star FireBrick Company. The firm wasfounded by J.K. Lemon, a Pitts-burgh entrepreneur who hoped tobuild a fortune on America�sgrowing demand for refractorybrick following the Civil War.

In 1866, Lemon hired SamuelPollock Harbison as a part-timebookkeeper. Within four years, theambitious accountant had acquiredenough stock and refractoryexpertise to be named GeneralManager of Star Fire Brick. In1875, Harbison teamed withanother stockholder, Hay Walker,to purchase the underachievingcompany, and renamed it Harbison-Walker.

Almost immediately, Harbisonand Walker realized a majoropportunity to grow their businessand its reputation. Through an on-going relationship with ThomasCarnegie, the fledging companylanded a contract from Kloman,Carnegie, and Company to buildthe Lucy Furnace, the largest blastfurnace ever designed.

The company garnered acco-

lades for the superior performanceof the Lucy Furnace and began toexpand rapidly, pushed in largemeasure by the explosive growth ofthe steel industry. In 1910, a 10-company merger created Harbison-WalkerRefractories Company, a 33-plantoperation that was the largest of itskind in the world. Harbison-Walker also thrived on its verticalstructure, exerting control overevery stage of its productionprocess, through mining and rawmaterialsmanagement to manufacturing,transportation and distribution.

In the decades that followed,Harbison-Walker established andfortified its position of industryleadership by building new facilitiesand acquiring related organizations.

� In 1916, Harbison-Walkerorganized the NorthwestMagnesite Company nearChewelah, WA. This gave thecompany a secure domesticsource of magnesite, a materialof choice for industrial furnacesin short supply during WorldWar I.

� In 1927, Harbison-Walkeracquired majority ownership of

Northwest Magnesite, andfollowing World War II,commissioned the company tobuild and operate a sea-watermagnesite facility at Cape May,NJ.

� In 1945, the company pur-chased Canadian RefractoriesLimited, makers ofMAGNECON, an outstandingrefractory for rotary cementkilns.

� In the 1950�s, Harbison-Walker built a high-qualitymagnesite facility at Ludington,Michigan. This keyed thedevelopment of several industrystandard products, includingdirect-bonded magnesite-chrome brick, pitch-bondedand pitch-impregnated magnes-ite products, and magnesite-carbon refractories.

� In 1954, Harbison-Walkerbecame the first U.S. companyto produce refractories for thebasic oxygen furnace.

� In 1962, the company discov-ered massive deposits of highpurity bauxitic kaolins at

2 - Harbison-Walker Brick Installation Guide

Eufaula, AL. This permitted thecompany�s Bessemer andFairfield, Alabama, plants tomanufacture significantlyimproved high-alumina brickthat became a refractory ofchoice for much of the refrac-tory consuming industries.

� In 1967, Harbison-Walker waspurchased by Dresser Indus-tries, prompting an accelerateddiversification into non-steelrelated industries.

� In 1994, the company becamea part of Global IndustrialTechnologies, a major manufac-turer of technologically ad-vanced industrial products.This development enabledHarbison-Walker to strengthenits presence in several keymarkets through alliances withother Global Industrial Tech-nologies companies. Theyincluded RefractoriesMexicanos (REFMEX) andRefractorios Chileanos(RESCA), two of LatinAmerica�s leading refractoryproducers; and MagnesitwerkAken, a German refractorymaker.

� In 1998, Harbison-Walkeracquired A.P. Green Industries,Inc. With 22 plants in sixcountries, A.P. Green, a major

refractory producer in its ownright, expanded considerablythe global resources atHarbison-Walker�s disposal.

� In 2000, RHI AG, an Austriancompany with many holdings inthe global refractories industry,completed its acquisition ofGlobal Industrial Technologies,Inc., the parent company ofHarbison-Walker. RHI AGsubsequently combined NorthAmerican Refractories Com-pany (NARCO) and Harbison-Walker, at the time naming theresulting organization RHIRefractories America.

Today, the U.S. and exportoperations have been reorganizedand operate independently underthe name ANH Refractories.Because of the strong reputationsthat Harbison-Walker andNARCO established over their longhistories, the companies haveretained their names and arecontinuing to be the refractorysuppliers of choice in their respec-tive market places. Harbison-Walker continues to provideoutstanding refractory materials tomeet the needs of the industrialmarkets, while NARCO serves theneeds of the steel industry.

Harbison-Walker TodayFollowing World War II and thesubsequent proliferation of techno-logical advances, Harbison-Walkerrecognized the need for additionalresearch capacity. In 1958, thecompany opened Garber ResearchCenter, now known as the Techni-cal Center West Mifflin. The new

facility vastly enhanced Harbison-Walker�s ability to test productsunder simulated service conditionsand to conduct �post-mortem�analyses of used refractorysamples.

Today, the Technical CenterWest Mifflin, ranks among theworld�s largest and most well-equipped refractory researchfacilities. A staff of outstandingphysicists, chemists, metallurgistsand engineers work closely withHarbison-Walker customers todevelop new products and to solveprocess or production problems.

In the mid-1990s, Harbison-Walker completed a multi-million-dollar investment in the TechnicalCenter West Mifflin aimed atproviding the company�s engineersand scientists with the very latesttesting and analytical equipment.This commitment, made at a timewhen many refractory companieswere diminishing their internalresearch capability, aggressivelypositioned Harbison-Walker for thenew century of refractory industryleadership.

The capabilities and equipment atthe Technical Center West Mifflinhave been further enhanced by itsadditional staff and equipmentacquired through its acquisition ofA.P. Green and merger withNARCO.


Application FocusedTechnical Marketing andSales SupportHarbison-Walker has adopted amarketing structure that enables itto function more like a network ofsmaller, industry-focused compa-nies. Throughout each of itsmarkets, Harbison-Walker employsapplication focused technicalmarketing support, each withspecific training in a particularindustry or series of related indus-tries. Individual market segmentsinclude glass, industrial metals,minerals processing and environ-mental, energy and chemicalsmarkets. Over the long term, this structureis specifically designed to promoteinnovation through a continuousdialogue between Harbison-Walkerand the individual industries thecompany serves. On a daily basis,this structure allows Harbison-Walker to respond more quickly tocustomer requests and to serve as areliable and ever present problem-solving partner. Over the years, this studied,individualized approach to customerservice has yielded an unendingstream of innovative refractoryproducts and application strategiesfor the entire range of heat-pro-cessing industries.Broad Based ExpertiseHarbison-Walker�s sales andtechnical support staff consists ofchemical, ceramic, metallurgical,industrial and mechanical engineers.With strong technical educationsand practical knowledge of theindustries they serve, these individu-als are highly skilled at working with

customers to identify and selectrefractories that can extend servicelife and improve process efficien-cies. Typical consultations explorespecific operating conditions in acustomer�s furnace and why thoseconditions suggest the implementa-tion of one refractory type overanother in a particular furnace zone.This process can be further aidedthrough interactive CAD systemsthat allows customers to select andpreview refractory linings andconfigurations. Another valuable serviceHarbison-Walker offers is perfor-mance assessments. This processis usually aimed at identifying causesfor deteriorating refractory perfor-mance resulting from changingoperating conditions within acustomer�s plant. Most often,diagnoses are based on post-mortem analyses of used refracto-ries to determine the modes ofrefractory wear. Test results may point to theadaptation of existing refractories,applying refractories in new combi-nations, the selection of differentrefractory brands or the customdesign of new refractories to bettermeet the altered service conditions. Helping customers understand andimplement a proper refractorymanagement strategy is the first stepin an on-going relationship betweenHarbison-Walker and the refractoryuser. Sales and technical represen-tatives are often on-site for refrac-tory installation and furnace start-up. Follow-up technical supportcan include orientation and trainingprograms, troubleshooting, and

service and performance assess-ments.

Quality ControlHarbison-Walker�s quality controlprograms encompass every facet ofthe organization, from the acquisi-tion of raw materials to the packag-ing and shipment of the finishedmaterial.

The company operates anaggressive program of mineral landacquisition, permitting it to control asignificant percentage of the rawmaterials it consumes. This pro-gram also helps ensure the uniformquality of raw materials whileinsulating the company from fluctu-ating supplies of key refractoryminerals. Imported minerals, suchas chrome ore, also are examinedand tested for quality by Harbison-Walker engineers. At the processing stage, manufac-turing sites are dedicated to a singleproduct or single class of products.This enables Harbison-Walker tomaintain a high degree of chemicalpurity, resulting in uniform products,free of contaminants and capable oftight dimensional tolerances. Inaddition, each plant maintains alaboratory and a staff of qualitycontrol engineers to measureproduct characteristics againststated specifications.

The company also operates acentralized Quality Control Depart-ment in West Mifflin, PA., which isresponsible for monitoring qualitystandards for all Harbison-Walkerbrands.


Industry DialogueHarbison-Walker encourages acontinuous dialogue among itsindustry �partners� by communicat-ing continuously with contractor/installers and soliciting regularcustomer input and feedback aboutall aspects of refractory perfor-mance.

Every year, the company bringstogether its engineers and selectinstallers to disseminate technicalinformation in an educational forum.This presents opportunities forinstallers to discuss their goals andexpectations of refractory perfor-mance, as well as plant safetyrequirements.

In turn, Harbison-Walkerengineers offer refractory productupdates, and a comprehensivereview of installation and construc-tion techniques. This mutualinformation exchange leavesparticipants more prepared to workcooperatively throughout the year

As the refractory industrycontinues to evolve and expand,Harbison-Walker pledges tomaintain this dialogue, seeking waysto better ways to contain the heat ofindustrial progress.


Atlanta, (Doraville) GA (770) 448-6266Baton Rouge, (Gonzales) LA (225) 644-2111Birmingham, AL (205) 788-1685Buffalo, (Tonawanda) NY (716) 692-1761Charlotte, NC (704) 599-6540Chicago, (Calumet City) IL (708) 474-5350Cincinnati, (Milford) OH (513) 576-6240Cleveland, OH (216) 398-1790Dallas, TX (214) 330-9243Davenport, IA (563) 445-1244Detroit, (Romulus) MI (734) 955-6025Houston, TX (713) 635-3200Kansas City, (Lenexa) MO (913) 888-0425

HARBISON-WALKER DISTRIBUTION CENTERS

Harbison-Walker Distribution CentersHarbison-Walker offers the only nation-wide refractories and insulationdistribution system. Our 26 locations continue to stock the best refractoriesin the industry, including fireclay and high alumina brick, mortars, plastics,and castables as well as a full line of ceramic fiber and mineral woolproducts. Kiln liners, anchoring systems and special shapes are alsoavailable.

Knoxville, TN (865) 546-4930Lakeland, FL (863) 669-1040Los Angeles, (Pico Rivera) CA (562) 942-2151New York, (Rahway) NY (732) 388-8686Philadelphia, (Trevose) PA (215) 364-5555Pittsburgh, (Leetsdale) PA (412) 741-3200Portland, (Clackamas) OR (503) 656-2854Roanoke, (Salem) VA (540) 375-2107Salt Lake City, UT (801) 886-0545San Francisco, (Richmond) CA (510) 236-7415Seattle, (Kent) WA (253)872-2552St Louis, MO (314) 521-3314West Haven, CT (203) 934-7960

Harbison-WalkerDistribution Centers

Visit our website at www.hwr.com orCall (800) 887-5555 to reach the location nearest you.

For your convenience we accept,American Express, MasterCard and VISA.


HARBISON-WALKER MANUFACTURING FACILITIES

Harbison-Walker Manufacturing FacilitiesAs part of the ANH Refractories Family of Companies, Harbison-Walkermaintains a number of manufacturing facilities. 20 ANH Refractories plants,spread across 9 U.S. states, 1 Canadian province and 4 foreign countries,manufacture Harbison-Walker brand refractory materials. Below is a list ofANH Refractories manufacturing locations:

• Acton, Ontario

• Bromborough, England

• Calle, Colombia

• Cilegon, Indonesia

• Fairfield, AL

• Fulton, MO

• Gary, IN

• Minerva, OH

• Monterrey, Mexico

• Oak Hill, OH

• Pryor, OK

• Smithville, Ontario

• Solon, OH

• South Shore, KY

• Sproul, PA

• Thomasville, GA

• Vandalia, MO

• West Mifflin, PA

• White Cloud, MI

• Windham, OH


Harbison-Walker on the WebSince the rise of the internet as a viable business tool, Harbison-Walker hasrealized the importance of providing relevant information to its customers viathe World Wide Web. By accessing www.hwr.com users can view all of themost up-to-date Material Data Sheets, MSDS and Mixing & UsingInstructions. Users may also request literature materials detailing refractoryuse in many of the industry�s most relevant applications.

HARBISON-WALKER ON THE WEB


OPERATING FACTORS• Function of the furnace• Nature of material being processed• Rate and continuity of operation• Range and rapidity of temperature

changes• Chemical attack by metals,

slags, ash, etc.• Fluidity of molten metal or slag• Velocity of furnace gases• Abrasion from contained solids or

gases• Impact from charging• Erosion by molten furnace contents

• Impinging flames or hot spots

FURNACE DESIGN ANDCONSTRUCTION• Type of furnace• Design and dimensions of walls

and arches• Loads imposed on the lining• Conditions of heating (one or

more sides)• Amount of insulation• Air- or water-cooling• Type of refractory construction

(brick or monoliths)• Methods of bonding or support• Provision for thermal expansion• Mechanics of any moving

furnace parts

SELECTION OF REFRACTORIES

Optimum use of refractories is achieved by careful study offurnace design and evaluation of operating conditions prior toselection of refractory products which meet the design andoperating requirements.

From the multiple factors listed below, it may appear that thechoice of most suitable material would be exceedingly difficult.Sometimes this is true. However, there are usually data on handfrom previous experience under similar conditions. Moreover, thebest refractory selection often depends on a few requirements soimportant that other factors play a minor role. In some cases, justrefractoriness alone, i.e., maximum service temperature, will bethe deciding factor. In others cases high refractoriness will have tobe coupled with resistance to thermal shock. Under other circum-stances, resistance to metals, slags, or disintegration by reducinggases may be the governing factors. Sometimes high insulatingvalue is desirable, but in other situations high thermal conductiv-ity may be needed. When selecting refractories, the followingmajor factors must be identified.

REFRACTORY-RELATEDFACTORS

Properties at room temperature –• Workmanship and physical strength• Density, porosity, permeability• Chemical and mineral composition• Uniformity• Size and design

Properties at high temperatures –• Refractoriness or maximum service

temperature• Reversible thermal expansion• Resistance to thermal shock• Resistance to chemical attack• Resistance to mechanical impact or stress• Resistance to abrasion or erosion• Permeability to gases or liquids• Volume stability (bloating or shrinkage)• Resistance to gases and fumes• Thermal conductivity• Heat capacity• Electrical resistance

Economic factors –• Delivered cost• Cost of installation (brick vs. monoliths)• Special shapes or forming required• Service life


ORDERINGREFRACTORIESRefractory technology is becomingincreasingly specialized, year after year,so that it is often necessary to thoroughlyunderstand an application area beforemaking refractory selections. Harbison-Walker Marketing Representatives havebeen trained to do this work and areready as an accommodation to discussyour application with you. Acess ourwebsite www.hwr.com for contactinformation.

In most cases, careful specification ofyour requirements and operation willhelp Harbison-Walker fill your ordercorrectly and without delay. When youorder various shapes and sizes, provide acomplete description and correctdimensions for the shapes that you need.If you order circle brick or other shapesdesigned to fit a circular lining, provideboth the inside and outside diameter ofthe lining.

Orders for brick should includeenough mortar material of the right kindto lay the brick. Information required tospecify the number, shape and size ofbrick as well as the quantity of mortarappears in the following tables and in theBrick Sizes and Shapes Section of theHandbook.

Approximate Pounds of Mortar per 1000 9-Inch Brick(9 X 41/2 X 21/2 Inch)*

Brick Laid withBrick Laid Dipped or Thinly

Mortar Materials Dry and Grouted Trowelled Joints

Heat-Setting MortarsSATANITE® 250 - 300 350 - 450

Air-Setting MortarsHARWACO BOND® 250 - 300 350 - 450‘SAIRSET® 250 - 300 350 - 450H-W® PERIBONDTM 300 - 400 500 - 600‘SAIRBOND® 250 - 300 350 - 450

* This is for 9-inch straights. Normally, for larger sizes the quantities required are reduced in porportion to the decrease in surface area covered by the mortar per 1000 9-inch equivalent.

NOTE: Minimum figures are used ordinarily for estimating.

TYPICAL BRICK GROSSING CHARTS

Quantity QuantitySpecified Overage Specified Overage

1-100 10% 5,001 - 10,000 2%101-1,000 7% Over 10,000 1%1,001-5,000 3%

Note: Not less than one shape. If in sets, one complete set.

Number of Refractory Straights Required PerSquare Foot ofWall or Floor

Wall or Floor 9 X 41/2 X 3 InchThickness, Inches Brick

3 3.64½ 5.36 7.2

7½ 8.99 10.7

12 14.213½ 21.418 21.427 32.1

Special ShapesOn initial orders for special shapes, senda drawing of the shape and the assemblyinto which it fits. The assembly drawingwill help Harbison-Walker engineersevaluate the design and verify that thecombination of refractories and designproduces the best results. On subsequentorders the Harbison-Walker drawingnumber or your drawing and shapenumber will ensure that the order isproperly filled. Refer to the previousorder by number and date.

When filling orders for special shapes,Harbison-Walker makes a slightly largernumber of shapes than specified to coverpossible breakage in firing. In somecases, all of the extra pieces will comefrom the kilns in perfect condition.

ORDERING REFRACTORIES

Then, Harbison-Walker will ship alimited quantity of extra pieces inaccordance with the following table,unless special instructions are entered onthe order. This standard procedure alsohelps avoid shortages resulting frombreakage during transit and handling.

Standard PackagingStandard packaging for monolithicrefractories are 55 lb. sacks, pails, andcartons, and 2,000 lb., 3,000 lb., and4,000 lb. bulk bags. Non standardpalletizing for brick or monoliths andnon standard packaging options includ-ing export palletizing are available foradditional charges.


OverviewSound furnace refractory lining and construction � whether carried out byexperienced masonry specialists working on a high production furnace or acontractor building a municipal incinerator � begins with a few fundamental ideasrequired to produce satisfactory performance.

FURNACE REFRACTORY LINING & CONSTRUCTION

FOUNDATIONThe foundation must function at thetemperature produced by the furnace.For many industrial furnaces, contrac-tors build foundations of concrete,consisting of a crushed stone aggregate,sand and binder of hydrated Portlandcement. Under normal conditions,Portland cement concrete has beensafely used for furnace foundations upto 700°F (371°C). When the tempera-ture reaches 900°F (483°C), dehydra-tion of the cement reaches a point wherethe concrete retains little mechanicalstrength.

Ordinary aggregates include quartzpebbles, silica gravel, crushed silicarock and/or crushed limestone. Anaggregate of silica rock in any form willexpand sufficiently at temperatures upto 1,000°F (538°C) to set up stresses inthe concrete and weaken the foundation.Limestone or dolomite rock in anaggregate will calcine at somewhathigher temperatures and weakenconsiderably. For temperatures above700°F (371°C), good practice points tothe choice of a castable refractory forthe foundation. Calcined fireclay, insizes up to 1 inch, can be substituted forconventional aggregate. Its thermalexpansion is low, and it will not shrinkat the highest temperature to whichconcrete can be subjected.

High temperature furnace operationalso calls for ventilation in the lowercourses of brickwork or the upper partof the foundation. Good furnace designoften requires placement of the furnaceon plates, girders or low brick piers, sothat air circulates under the vessel.Sometimes, cross flues are formed inthe top of the concrete foundation. Atothers, pipes, 3 inches in diameter orlarger, are embedded in the foundation.

Building furnaces is a specializedbranch of masonry, best placed in the

hands of bricklayers experienced infurnace construction. Walls, arches andother furnace details should be de-signed and constructed to assurestructural stability. Otherwise, a returnon your refractory investment may notbe realized.

WALL CONSTRUCTIONCourses of brick laid in a wall so thatthe lengths parallel the face of the wallare called stretchers. Brick with lengthsrunning at right angles to the face areheaders. In soldier courses, the brickstand on end, and in row-lock courses,they lie on one edge (See illustration, p.11).

Header courses tend to spall lessthan stretchers at the hot face of afurnace wall because they expose asmaller area to high temperature.However, stretcher courses exposefewer joints than headers, and thisprovides an advantage in applicationswhere joints tend to wear more rapidlythan brick.

Bonding, or tightening constructionthrough combinations of headers andstretchers and off-setting vertical joints,strengthens and stabilizes furnacewalls. The type of bond selected forany particular furnace will dependupon the design of the furnace,thickness of the walls, the need for gas-tight construction, severity of operatingconditions and the need for easymaintenance.

In any case, the wall should bebonded so that loads will be transferredto the cooler part of the wall when theinner, hotter portion loses its ability tocarry them. Walls must be designed tocarry structural loads at high tempera-tures.

Stretcher walls � one brickthick � usually have the least struc-tural stability, but they are sometimes

used in smaller furnaces and in furnaceswhere heat must pass through the walls.Double tongue and groove brickprovide stability for thin walls.

Alternate header and stretchercourses probably provide the mostcommon arrangement for standardindustrial furnaces. Large 9-inch brickbreak joints, start ends of walls and turncorners.

Courses consisting mostly of headersare often used advantageously in 9 and13½-inch walls subject to high tempera-tures, heavy loads and slag attack. Thisconstruction is usually preferred forbasic brick walls. The bond providesstability and easy replacement, but mostexpansion joints pass entirely through9-inch walls.

Courses consisting mainly or entirelyof headers on the inner face and mainlystretchers on the cold face are some-times considered desirable whenspalling conditions are severe. Three orfour stretcher courses to one headerprovide a wall to which a 4½-inch skinwall can be tied for repairs. However, itshould not be used where stretchercourses may fall into the furnace.

In composite wall constructionconsisting of two or more kinds of brickin inner and outer courses, the coursesare sometimes tied together. Usually, themore refractory brick go into theinterlocking courses.

However, when brick have markeddifferences in rates of thermal expan-sion, the backup courses should not betied to the inner courses. This isespecially true when the temperaturegradient through the wall makes asignificant difference in total expansion.

The number of refractory straightsrequired to build a simple wall can bedetermined from the chart on p.12.Multiply brick per square foot from theappropriate row, depending on wallthickness, by the area of the wall toprovide the brick count. For walls not ofsimple rectangular shapes, determinethe volume in cubic feet from theappropriate formula on this page andmultiply by the number of brick percubic foot.

Wall thickness must bear somerelation to height and unsupported


Wall 9 inches thick

Wall 13½ inches thick


Wall 18 inches thick


Wall 18 inches thick



Alternate header andstretcher courses


Three header courses toone stretcher course onexposed or hot face


Three stretcher courses to oneheader course on exposed or hot face

Only header course on hot face

Mainly stretcher course on cold face

Only header course on hot face

Alternate header andstretcher course on cold face

Five header courses to onestretcher course on hot face

Only stretcher course on cold face

Back-up bricknot tied to inner courses

BONDING OF WALLS BUILT WITH RECTANGULAR BRICK



length. In unsupported straight walls, a4½-inch thickness will carry heights upto 3 feet; 9 inches will carry heights of 3to 8 feet; 13½ inches, 8 to 12 feet; and18 inches, walls higher than 12 feet.

Walls with unsupported length morethan one and one half times their heightsshould be somewhat thicker, and thermalspalling conditions may indicate addi-tional thickness. Walls of cylindricalfurnaces and stacks, with adequatebacking, may be somewhat thinner for agiven height than straight walls.

Cylindrical walls, arches and domesare built with brick tapered to turncircles. Arch brick slope from edge toedge so that the length of the brickparallels the furnace wall like a stretcher,while the wedge tapers from end to endso that it faces into the furnace like aheader. A 9 x 4½ x 2½-inch arch brickmakes a 4½-inch lining, while the samewedge shape makes a 9-inch lining. Inbasic brick, key brick shapes may alsotaper along the edges. Combinations ofthese shapes taper in two dimensions toturn domes.

JOINT CONSIDERATIONSIn many cases, brick sizes and shapes orthe type of bond will be chosen tominimize the number of joints in thelining. Monoliths � not withoutconstruction or thermal expansion joints� present the fewest joints and opportu-nities for penetration by metal, slag orfurnace gases.

Ramming mixes or castable refractorymaterials are often used to fill placeswhere brick would be cut to fit. Forexample, ramming mixes or dry refrac-tory materials can be used to protect thetoe of the skewback (See discussion ofArch Construction, UR - 22). On manyinstallations, the irregular space betweenelectric furnace roof brick and electrodeports is filled with ramming mix orcastable refractories.

The thickness of joints betweenrefractory brick depends on the brick, themortar, the need for preventing gasleakage or slag penetration, and the

requirements for thermal expansion.When there is no need for an especiallystrong bond, the brick are laid withoutmortar. In some cases, the fusion thattakes place on the hot face will providethe bond required. Generally, however,the use of mortar is desirable to levelcourses and to provide smooth beddingfor the brick.

Brickwork laid with heat-settingmortars should have thin joints, eitherdipped or poured. The brick should berubbed or tapped into place to produceas much brick-to-brick contact aspossible. Joints made with an air-settingmortar generally can be somewhatthicker, but such joints should becompletely filled.

In furnace construction, properallowance must be made for thermalexpansion. Usually, vertical expansionallowances permit walls to move freelyupward and horizontal expansionallowances appear at joints in the brick.

HEARTHSThe construction of furnace hearthspresents special problems. Some furnacebottoms must withstand impact andabrasion from a charge of scrap metal.Liquid pressure may tend to float brick.Many hearths must resist penetration bymetal or slag accompanied by corrosionor erosion.

Furnace hearths, in many cases, arebuilt of refractory brick, usually seatedon a monolithic refractory bed. Othershave sub-bottoms built of brick withworking hearths composed of monolithicrefractories, such as dead-burnedmagnesite or a ramming mix.

Construction details, as well as therefractories themselves, depend onapplications. Even different furnaceswithin the same application area mayperform more efficiently with a differentrefractory design.

Sophisticated applications for refrac-tories call for specialists in refractoriesdesign. A number of engineering firmsspecialize in high temperature processdesign, and many contractor/installer

organizations concentrate on refractoryconstruction.

Harbison-Walker maintains closecontact with these organizations, lendingits engineering skills and applicationsknow-how to the search for solutions toany problem involving the use ofrefractories.

Number of Refractory StraightsRequired Per Square Foot of Wall

or FloorThickness, 9 x 4½ x 3” Brick

Inches3 3.6

4½ 5.36 7.2

7½ 8.99 10.7

12 14.213½ 16.018 21.427 32.1

Rammed plastic refractories used forarch construction minimize thenumber of joints.



ARCH CONSTRUCTION

OverviewArches form the roofs of most furnaces, combustion chambers andflues. Providing the standard solution to the problem of spanning thehigh temperature process with refractories. In some application, archesspan wall openings, and sometimes they carry the weight of walls orcheckerwork. Most arches are built of brick, but monolithic materialsare gaining popularity throughout the industry.

TYPES OF ARCHES

Sprung ArchesIn a true arch, the design of the wholedetermines the shape of each block orstructural unit. Theoretically, each jointis a small piece of the radius of the circleof which the arch is a segment. Each endof the arch rests on a skewback. Thearch becomes self-supporting after all ofthe pieces go into place, but it must besupported until the final, center shapesthe keys go into place. When it iscomplete, the arch springs from thesloping faces of the skewback shapes.The skewbacks cut off the arc of thecircle on the outside radii of the arc.

The sprung arch exerts a downwardvertical force and an outward horizontalforce on the skewbacks, essentially adistribution of its weight. The verticalforce may be carried by steel beams orby the furnace walls or a combination ofwalls and steel buttresses. Thehorizontal thrust of a roof arch travelsthrough the skewbacks to a steelsupporting system known as the bindingwhich is composed of beams and tierods. The tie rods, usually above thefurnace, link one side of the furnace tothe other, and balance opposing forces,one against the other.

In traditional furnace design, thebinding consists of:1. Horizontal buttress beams

running lengthwise to the furnacein contact with the skewbackswhere possible;

2. Vertical beams, or backstays,spaced at intervals along theconcrete; and

3. Horizontal tie rods, I-beams, orchannels extending across thefurnace above the roof to connectthe upper ends of oppositebuckstays.

Ring ArchesIn ring arches, each course of brickforms a separate ring running across theroof and the joints are continuous acrossthe roof. Ring arches require somewhatless labor for initial construction. Coldrepairs are easier to make and they offerbetter resistance to spalling. However,ring arches require support at the end ofthe furnace to forestall outwarddisplacement.

In bonded construction, all joints arebroken and the rings help bond oneanother in a stronger construction.Bonded roofs are better adapted for hotrepairs but they demand more skill ofthe brick masons and more uniformity inthe brick.

Sometimes, furnace designersstrengthen ring arch roofs by using alonger brick in every third or fourthring. This construction creates ribsacross the roof, which remain strongwhen the thinner parts of the roof wearaway. The strength of the ribs also helpswhen roofs must be patched.

Suspended ArchesIn suspended arches, a steel super-structure helps carry the weight of theroof, otherwise distributed through the

arch to the walls and binding.Suspended arches are often used withdense, heavy basic brick. Harbison-Walker has basic brick brands to providea method for attaching the brick to anoverhead steel superstructure.

In suspended construction,refractories carry smaller loads andtherefore, suffer less deformation at hightemperatures than they otherwise might.Using suspended construction, it is alsoeasier to make allowance for thermalexpansion to avoid thermal stresses andpinch spalling.

Monolithic ArchesMonolithic arches�cast over forms muchlike those required for brick arches�havereplaced brick in some applications.Skews may be eliminated in monolithicarches, but design considerations remainthe same as those for brick arches. Amonolithic arch provides all of theadvantages monolithic construction,including reduced cost and downtime.

ARCH GEOMETRYArch geometry determines all designcharacteristics. From the viewpoint ofarch design, the outside and inside arcs,or surfaces of the roof, are segments ofconcentric circles separated by thethickness of the roof. The skewbackslope cuts the arc, and its angular valueequals half the included central angle ofthe arch. The rise of the arch measuresthe distance from the inner chord - equalto the span and cutting the inside arc tothe center of the roof at midspan.

Hypothetical position of thurst in a simple sprung arch, when the bricks are in full contact at joints.

2

H

-F

F-H

-F

F

T

h

r

2S

W2

W2

CENTER OF GRAVITYLINE OF THRUST

CENTER OF PRESSURE


ARCH CONSTRUCTION

Ribbed arch roof

Ring arch roof

Bonded arch roof

Typical castableconstructionfor sprung arch


ARCH CONSTRUCTION

When span, thickness and rise areestablished, all other dimensions can becalculated using the formulas in thissection.

The stability of any arch will dependon its rise, thickness and weight, as wellas the thermal properties of therefractories. Hot strength and thermalexpansion are particularly important.Good arch design must take these factorsinto consideration.

Rise is normally expressed in inchesper foot of span, or in terms of thecentral angle. They are directly related.It should be easy to visualize a larger

for higher values. Silica roofs made withbrick that maintain dimensional stabilityand hot strength almost to their meltingpoint, normally rise from one to twoinches per foot.

High-alumina refractories used in archconstruction call for at least 1.608 inchper rise per foot of span. Basicrefractories need 21/4 to three inches ofrise in sprung arches. Insulatingfirebrick, which give up hot strength inexchange for low thermal conductivity,call for two to three inches of rise perfoot of span.

For many applications, a 1.608 inchrise, about 15/8-inch, is a logical standardin that it meets normal requirements forstrength and stability. The 60° centralangle equals one sixth of a circle and thespan equals the inside radius, so thenumber of brick required to build theroof is easy to calculate.

The reaction of refractory brick tofurnace operation, i.e., heat-up,establishes the practical limit for roofrise. Operation and thermal expansiontend to push the brick upward, openingjoints at the top and pinching brick at thebottom. Brick that soften at operatingtemperatures may become permanentlydeformed, shortening the radius of thearc and increasing the rise.

As the arch rises on heat-up, the lineof thrust, the line of force along whichthe arch distributes the vertical andhorizontal elements of its weight, shiftsdownward. As the line of thrustapproaches a horizontal position in thearch, the horizontal force approaches itsmaximum value.

In some furnaces allowance forthermal expansion of the brick will limitupward movement of the arch. Steelcasings can provide an allowance forexpansion. Paperboard placed betweenbrick will burn out and make room forexpansion. In some cases, horizontal tierods arc spring loaded or manuallyadjusted to permit thermal expansion ofthe refractories.

Without adequate provision forthermal expansion, the relationshipbetween arch thickness and rise* of thecold arch must be such that the line ofthrust does not drop out of the arch

angle including a higher rise and ashorter radius. On the other hand, theflatter roof with a smaller rise indicates asmaller included central angle and alonger radius.

Experiences suggests that a simpleroof arch should rise not less than onenor more than three inches per foot ofspan. For any particular furnace, the riseselected should depend on operatingconditions, chiefly temperature, thermalcycling and the refractories used. Typically, stable fireclay arches risefrom 11/2 to three inches per foot of span.High temperatures and soaking heat call

SpecialSkew

Approx.Line ofThrust

Ground Brick andMortar Mixture

Header Course

StandardSkew


Ground Brick andMortar Mixture

Header Course

Special skewbackA recommened construction

Built-up skewbackA recommened construction

StandardSkew



ButtressAngle

Top ofSkewback

Bulk Insulation

BuckstayButtress Block Skewback No. 60-9

Built-up skewbackA construction to be avoided.

A 60° skewback withbuttress block.

Special skewbackA construction occasionaly used

Arch with skewbackssupported outside of walls

Special Skew Special Shapes

Note: A stretcher course should never be used immediately below the skewback.


ARCH CONSTRUCTION

when it is heated. If it does, the arch willnot be stable.

The line of thrust in a cold archshould lie within the middle third of thebrick. Generally, selecting the propercombination of brick shapes and doing aprofessional job to assure face-to-facecontact between brick will keep thethrust where it belongs.

In practical construction problems, thevertical and horizontal components aremore important than the resultant force.The walls, with or without steel supports,must carry the vertical force, and thehorizontal binding, including buckstaysand tie rods, must contain the horizontalforce.

* Assuming that the absolute lower limitfor the rise of the line of thrust is 1/4 inch(1/48) per foot of span, the rise (h) mustexceed thickness (T) times the of thecosine of the central angle (0)plus 1/48

span (S). This implies that T should notexceed:

h-1/48S

Cosine 0/2

For a more complete discussion of archstresses see: J. Spotts Mcdowell, �Sprung-ArchRoots for High Temperature furnaces,� BlastFurnace and Steel Plant, September 1939.

ARCH CONSTRUCTIONCALCULATIONSThe brick count for many sizes can becalculated from the tables of brickcombinations for rings, since simplesprung arches are segments of circles.

Calculation of arch parameters, thearch numbers, is sometimes lengthy, butnot difficult, especially when carried outwith a pocket calculator. Equationsrequired to produce the necessary valuesare included in this section.

Suppose that a furnace design calls foran arch with a 12 foot span, 131/2 inchesthick built of NARMAG® 60DB brandbrick, on a furnace 20 feet long.NARMAG® 60DB basic brick, requiresa minimum rise of 21/4 inches per foot ofspan.

The table of Arch Constants belowprovides data to develop the requireddesign values. For a 21/4 inch rise,multiply the span by 0.76042 todetermine the inside radius, in this case,9.125 or 9 feet, 11/2 inches. That meansthe arch is a segment of a circle with an18 foot, three inch inside diameter, twicethe inside radius.

The table also indicates that thecentral angle for this arch will be 82°13.4�, equal to 2,284 ten thousandths of acircle.

Skewbacknot flush witharch at top

Skewbackflush witharch at top

On page IR - 45 the tables of brickcombinations for rings for 13½ inchlinings show that an 18 foot, 3 inch ringcan be built with:

82 pieces, No. 2 Wedge and176 pieces, No. 1 Wedge

If this design calls for 2,284 tenthousandths of a ring, then:

0.2284 x 82 = 18.73 or 19 pieces,No. 2 Wedge

0.2284 x 176 = 40.2 or 41 pieces,No. 1 Wedge

If the design specifies 13½ x 6 x 3 inchshapes, then two rings will cover arunning foot on the 20 foot roof, and 40rings will roof the furnace. Thus, thedesign calls for 40 times 19, a total of 760pieces, No. 2 Wedge, and 40 times 41, atotal of 1,640 pieces, No. 1 Wedge.

Arch Constants for Given Rises per Foot of Span

Rise Central Angle 0 Difference SkewbackInches Inside Inside Between

Per Foot Radius Degress Part of Arc Outside & H V Fof Span (r) Circle (aa) Inside Arc

(d) (Aa - aa)

(1) (2) (3) (4) (5) (6) (7) (8) (9)

1 1.54167S 37° 50.9’ 0.10514 1.01840S 0.66059T 0.32432T 0.94595T 0.34286Q11/4 1.25208S 47° 4.4’ 0.13076 1.02868S 0.82157T 0.39933T 0.91681T 0.43557Q11/2 1.06250S 56° 8.7’ 0.15596 1.04117S 0.97992T 0.47059T 0.88235T 0.53333Q

1.608 1.00000S 60° 0.0’ 0.16667 1.04720S 1.04720T 0.50000T 0.86603T 0.57735Q13/4 0.93006S 65° 2.5’ 0.18067 1.05579S 1.13519T 0.53760T 0.84320T 0.63757Q2 0.83333S 73° 44.4’ 0.20483 1.07251S 1.28701T 0.60000T 0.80000T 0.75000Q

21/4 0.76042S 82° 13.4’ 0.22840 1.09125S 1.43507T 0.65753T 0.75342T 0.87273Q2.302 0.74742S 83° 58.5’ 0.23326 1.09544S 1.46563T 0.66896T 0.74329T 0.90000Q21/2 0.70417S 90° 28.8’ 0.25133 1.11200S 1.57918T 0.71006T 0.70414T 1.00840Q23/4 0.66004S 98° 29.7’ 0.27360 1.13464S 1.71906T 0.75753T 0.65280T 1.160444Q3 0.62500S 106° 15.6’ 0.29517 1.15912S 1.85459T 0.80000T 0.60000T 1.333334Q

NOTE: The factors in the above tables are the following functions of 0: Column 2, 1/2 cosecant 1/2 0; column 4, Ø divided by 360°;column 5; 1/2 cosecant 1/2 0


ARCH CONSTRUCTION

SKEWBACK DESIGNSkewbacks may be built-upcombinations of rectangular brick sizes,as previously illustrated, or one-piecespecial skews designed to fit the arch.Built-up skews satisfy the requirementsof narrow spans, four feet or less, butthe one-piece skewback generallyprovides greater strength and bettersupport at the buttress.

The slope of the skewback must bedesigned to match the central angle ofthe arch, determined by the rise andspan. When the skewback is carried on achannel or angle, the line of thrustshould pass through, or slightly above,the corner of the supporting steel.

Skewback dimensions can bedetermined from the table of ArchConstants below. From the exampleabove, a 2¼ inch rise produces a centralangle of 82° 13.4'. The slope equals halfthe central angle, amounting to 41° 6.6'in this example. Other dimensions canbe calculated from constants in the sametable.

The V dimension is 0.75342 times thethickness of an arch with a 2¼ inch rise.In this example above, 0.75342 times13.5 equals approximately 10.17 inches.Other skewback dimensions can bedetermined in the same way.

The amount of stress in a furnace canbe only approximated because of thefollowing variables: (1) the exact position

Maximum Values on the following page. Consider the NARMAG® 60DB brickarch design described earlier in thischapter. Its design parameters are:

Span (S) = 12 ftThickness (T)= 1.125 ftInside Radius (r) = 9.125 ftDensity ofNARMAG® 60DB (D) = 192 lb/ft3

Rise (h) = 2.25 inches per foot ofspan=12 x 2.25 = 27 inches=2.25 ftOutside radius (R+T) = 10.25 ftCentral Angle (0) = 82°13.4'

The following calculations are basedon the assumption that the line of thrustpasses from the center of arch thicknessat midspan to the center of archthickness at the skewbacks.

As shown in the table below, theweight of the arch equals 1.17 DST. Thatis, for this arch, 1.17 times 192 times 12times 1.125 equals 3032.64 pounds perfoot of arch length. Since W/2 equals1516.32, the vertical force that the wallsand buttresses must carry amounts to1516.32 pounds per foot of arch length.

From the same table, the horizontalthrust of cold arch with a 2¼ inch riseper foot of span equals 0.64 time itsweight (W). For the arch underconsideration, 0.64 times 3032.64 equals1940.89 pounds per foot of arch length.

Constants for Calculation of Stresses in Unheated Arches

Forces Per Foot of Arch LengthRise inInches H F

Per Foot Central W Horizonal Resultant Thrust atof Span Angle (0) Weight Thrust Skewback

1 37° 50.9’ 1.05 DST 1.49 W 1.57 W11/4 47° 4.4’ 1.07 DST 1.18 W 1.28 W11/2 56° 8.7’ 1.09 DST 0.98 W 1.10 W

1.608 60° 0.0’ 1.10 DST 0.91 W 1.04 W13/4 65° 2.5’ 1.11 DST 0.83 W 0.97 W2 73° 44.4’ 1.14 DST 0.72 W 0.88 W

21/4 82° 13.4’ 1.17 DST 0.64 W 0.81 W2.302 83° 58.5’ 1.17 DST 0.62 W 0.80 W21/2 90° 28.8’ 1.19 DST 0.57 W 0.76 W23/4 98° 29.7’ 1.22 DST 0.51 W 0.71 W3 106° 15.6’ 1.25 DST 0.46 W 0.68 W

D= Density of brick in pounds per cubic foot. S=Span in feet. T=Thickness of arch in feet. W=Weight of brick per foot of arch length. Theconstants given in this table are based on the assumption that the line of thrust passes from the center of the arch thickness at the point ofmidspan, to the center of arch thickness at the skewbacks.

of the line of thrust, even when thearch is cold, is not known, (2)workmanship in construction of thearch may be less than perfect, (3) theposition of the line of thrust willchange when the furnace is heated, (4)tie rods can stretch and the furnacecan settle, changing arch parameters,and (5) arch stresses can be increasedby the weight of material adhering to,or absorbed by the bricks. The forceacting against the skewbacks dependsprimarily on the span, rise andthickness of the arch, the weight of thebrick, and conditions in the furnace.Vertical force equals one half theweight of the arch per running foot.

The horizontal force depends on theweight of the arch and on the span andrise.

The resultant thrust (F) acting at theskewback equals the square root of thesum of the squares of horizontal (H)and vertical (W) forces, that is:

F= H2+(W/2)2

However, the stresses of a coldarch, in which all adjoining brick are infull contact, can be approximatelydetermined from the table below. Thelimiting value which the horizontalthrust approaches in a heated arch,Hmax, can be calculated approximatelyfrom the constants in the table of


ARCH CONSTRUCTION

The resultant force, also determined fromthe table above, is 0.81 times 3032.64equals 2546.44 pounds per foot of archlength.

Maximum values approached byhorizontal thrust can be determined fromthe factors listed in the table. These dataindicate that the maximum valueapproached by horizontal thrust for aheated arch free to rise can bedetermined by multiplying the cold archhorizontal thrust by a factor dependenton the ratio of thickness to span. In theexample considered earlier, thicknessequals 9% of span, that is, 1.125/12equals 0.09. For a 2¼ inch rise,maximum thrust approaches 1.84H, or1.84 times 1940.89 equals 3571.24pounds per foot of arch length. Thisvalue is an approximation, but it lieswell within the requirements of practicalfurnace design.

The safety factor used in furnacebinding design is ordinarily higher thanthat used in conventional steel structuraldesign because the furnace binding maybecome overheated. For ordinarystructural steel bindings, many furnacedesigners limit tensile stress to 12,000pounds per square inch.

COMPLEX REFRACTORYDESIGN PROBLEMSCustomers who design or buildrefractory structures often tap Harbison-Walker resources, e.g., engineering skillsand advanced refractories technology,for solutions to complex problemsinvolving refractory applications.Harbison- Walker engineers havedeveloped computer programs, whichare used with customers, that canproduce complex arch or dome designparameters in a few minutes, oftensaving many man-hours of calculation.For assistance with your difficult designproblems, please call your Harbison-Walker representative.

Initial Heat-Up ConsiderationsIn most cases, a new furnace should beheated slowly with enough aircirculating over the walls to removemoisture. Steam trapped in the pores ofbrick or mortar may damage thebrickwork. Good practice permits afurnace to dry out thoroughly at atemperature not over 250°F(121°C) for 24hours or longer, depending on the size ofthe vessel and the refractories in use.

Maximum Value Approached by Horizonal Thrust in Heated Arch Free to Rise

Hmax Per Foot of Arch LengthInches Thickness of Arch in Precent of Span

Per Foot Centralof Span Angle (O) 4% 5% 6% 7% 8% 9% 10%

1 37° 50.9’ 1.88 H* 2.41 H 3.29 H 5.0 H ** ** **

11/4 47° 4.4’ 1.61 H 1.86 H 2.29 H 2.80 H 3.73 H 5.34 H **

11/2 56° 8.7’ 1.47 H 1.63 H 1.94 H 2.14 H 2.55 H 3.06 H 3.88 H

1.608 60° 0.0’ 1.43 H 1.59 H 1.79 H 1.98 H 2.31 H 2.75 H 3.30 H

13/4 65° 2.5’ 1.39 H 1.52 H 1.67 H 1.93 H 2.17 H 2.41 H 2.77 H

2 73° 44.4’ 1.33 H 1.43 H 1.56 H 1.69 H 1.86 H 2.04 H 2.22 H

21/4 82°13.4’ 1.29 H 1.38 H 1.47 H 1.58 H 1.70 H 1.84 H 2.00 H

2.302 83° 58.5’ 1.28 H 1.37 H 1.46 H 1.57 H 1.69 H 1.81 H 1.95 H

21/2 90° 28.8’ 1.26 H 1.33 H 1.42 H 1.51 H 1.60 H 1.72 H 1.82 H

23/4 98° 29.7’ 1.24 H 1.29 H 1.37 H 1.45 H 1.53 H 1.63 H 1.73 H

3 106° 15.6’ 1.22 H 1.26 H 1.33 H 1.41 H 1.48 H 1.57 H 1.63 H

* H = Horizonal thrust, as determined from the previous table.** Stress excessive.

Temperatures above 400°F to 600°F(205°C to 316°C) should be avoided untilall steaming ceases.

Furnace builders and refractoryconsumers should understand therequirements of the brands that line theirfurnaces. Careful drying of linings builtof magnesia and some of its compoundsis especially important. Water vapor orsteam under pressure can causehydration of the magnesia.

Flame impingement on brickworkduring heat-up can cause rapid, localizedexpansion with consequent spalling.Silica and basic brick, especially, tend tospall when subjected to excessivelyrapid changes in temperature.

In low temperature furnaces, it is oftengood practice to heat the refractories to ahigher temperature than that required foroperation for a short period of time. Thispreliminary heat-up develops theceramic bond in mortared joints andincreases their mechanical strength.


ARCH CONSTRUCTION

Arch Formulas

1. r = S2/8h + h/22. R = r+T3. h = r - r2-(S/2)2

4. Sine ½ 0 = S/2r5. Tan ¼ 0 = 2h/S6. Tan ¼ 0 = d/67. Part of circle = 0/360°8. H = T Sine ½09. d = 6 Tan ¼010. aa = 6.2832r (0/360°)11. Aa= 6.2832R (6/360°)12. V=T Cos½013. P=QTan ½0

Arch Symbols

The following symbols and variablesare used in the arch formulas:aa = Length of inside arcAa = Length of outside arcR = Outside radius of archr = Inside radius of archS = Span of archd = Rise in inches per foot of spanh = Total rise of archT = Thickness of arch0 = Central Angle (Theta)H, V, P, Q = Skewback dimensionsindicated in the Arch Constants table.

REFRACTORYCONSTRUCTIONCALCULATIONS

Calculations to determine thedimensions or numerical characteristicsof refractory structures are not difficult.Generally, they involve three steps: (1)pick out the formula that produces thedimension or other number that youneed; (2) substitute the numbers in yourproblem that fit the letter-variables inthe formula; and (3) perform thearithmetic operations required by theformula. Remember, once the span andrise of an arch are decided, all otherdimensions follow.

To use these formulas, all the algebrayou need to know is that parentheses tellyou to perform the arithmetic operationinside before carrying out the otheroperations.

All you have to know abouttrigonometry is that each sine, cosine ortangent is a particular numberassociated with one particular angle,and that an arcsine, arccosine orarctangent is a particular angleassociated with a particular number.That allows you to go from number toangle, or from angle to number, or backand forth, depending on therequirements of the problem. Sines,cosines or tangents are found in tables oftrigonometric functions or in pocketcalculators.

ArchesMany pocket calculators will makecalculation of arch parameters, i.e.numerical characteristics such asdimensions, quick and easy. Sine, cosineand tangent values are literally at yourfingertips on many models. Solutions toarch problems involve nothing morethan substituting numbers into theformulas and pushing buttons on thecalculator. For example in the designpreviously specified:

Sine ½0 =S/2r = 12 (2 x 9.125)= 0.6575

Arcsine 0.6575 = 41.11°= ½ The Central Angle

The Central Angle = 82.22° = 82° 13'

The problem is no more difficult withpaper, pencil and a table oftrigonometric functions, but themultiplication, division and reference tothe table take more time.

Skewbackflush witharch to top

Skewbacknot flush witharch to top


ARCH CONSTRUCTION

RingsThe number of brick of two sizes to forma ring can be calculated from formulaslisted below. When one brick, E, is astraight, and the other, F, is a radial, useFormulas 1-a, 1-b and 1-c. When bothbrick, E and F, are radial with outsidechord dimensions and inside chorddimensions unequal, use Formulas 2-a,2-b, and 2-c. When both brick, E and F.are radial and the inside and outsidechord dimensions of E differ from thoseof F, use Formulas 3-a, 3-b and 3-c for asingle combination, and 4-a, 4-b, and 4-cfor a series of combinations.

Ring Formulas Ring Symbols

E = Either a straight brick or a radialbrick used with a companion brickF; when brick E is radial it turns alarger diameter than brick F.

F = A radial brick, used with acompanion brick E which may beeither straight or radial; in thelatter case, brick F turns a smallerdiameter than brick E.

T = Radial dimension common to bothbrick E and F.

De = Outside diameter of ring formed bybrick E.

Df = Outside diameter of ring formed by

brick F.

Dg = A given outside diameter larger thanDf, if brick E is radial Dg must liebetween De and Df.

dg = A given inside diameter.

Ce= Outside chord dimension ofbrick E.

Cf = Outside chord dimension ofbrick F.

ce= Inside chord dimension ofbrick E.

cf= Inside chord dimension of brick F.

Ne=Number of pieces of brick E, whenused in combination with brick F, toform a ring having a given outsidediameter Dg.

Nf=Number of pieces of brick F, whenused in combination with brick E, toform a ring having a given out sidediameter Dg.

Nt=Total number of pieces of brick E andF used in combination to form a ringhaving a given outside diameter Dg.

Nx=Number of pieces of brick E requiredto form a complete ring having anoutside diameter De.

Ny=Number of pieces of brick F requiredto form a complete ring having anoutside diameter Df.

Outside Cord Dimensions Outside Cord Dimensions

RingCalculations

Inside Chord DimensionsCombination of a Straight Brick (E)

and a Radial Brick (F)to Form a Ring

Inside Chord DimensionsCombination of Two Radial Brick(E and F) to Form a Ring. Brick E

Turns a Large Diameter than Brick F

(1-a) N =f2 TC-c

�f f

(2-a) N = =t

�DC

g

e

�DC

g

f

(3-a) N c +NC = De e f f g�

(4-a) N = (D -D)e g fN

D -Dx

e f

(1-b) N =e

�D -NCCg f f

e

(2-b) N =e

�D -Ncc -c

g f f

e f

(3-b) N c +Nc = de e f f g�

(4-b) N = (D -D )f e gN

D -Dy

e f

(1-c) N = N +Nt e f

(2-c) N = N-Nf t e

(3-c) N = N +Nt e f

(4-c) N = N +Nt e f

Wherever furnace construction and operating conditions permit, refractorylinings are typically constructed with brick of standard sizes and shapes.Standard materials cost less than larger, more intricate shapes andfrequently are more serviceable. They are also more accessible, in that theyare likely to be routinely stocked by the manufacturer.

The most widely used standard size for all types of refractory brickis 9 x 41/2 by 3 inches. Most brands offer larger sizes, as well. Specialshapes, such as skewback brick, are important in the construction ofnumerous kinds of furnaces having sprung arches.

This section provides a comprehensive listing of standard brick sizesand shapes for a variety of furnace applications, as well as ring andarch combinations for standard size refractory brick. Additional sectionsaddress special shapes such as semi-universal ladle brick, brick counts forrotary kilns and rotary kiln brick shapes, including ISO, VDZ and CRtwo-shape systems for combination linings. Together, offer refractory usersa ready reference of information governing furnace refractory lining andconstruction.

If you require a special shape which is not included in this booklet,please contact your Harbison-Walker representative. Harbison-Walkermanufactures special shapes based on customer designs showingshape details and assembly in the furnace lining.


BRICK SIZES AND SHAPES

9 Inch Straight9 X 41/2 X 3

4 1/2"

9"3"

Small 9 Inch Straight9 X 31/2 X 3

3 1/2"

3"9"

9 Inch Soap9 X 21/4 X 3

2 1/4"

3"9"

9 – 2 Inch Split9 X 41/2 X 2

4 1/2"

9"2"

9 Inch Split9 X 41/2 X 11/2

4 1/2"

9"

1 1/2"

9 Inch No. 1-X Wedge9 X 41/2 X (3 – 27/8)

4 1/2"

9"

2 7/8"

3"

9 Inch No. 1 Wedge9 X 41/2 X (3 – 23/4)

4 1/2"

9"

2 3/4"

3"

9 Inch No. 2 Wedge9 X 41/2 X (3 – 21/2)

4 1/2"

9"

2 1/2"

3"

9 Inch No. 3 Wedge9 X 41/2 X (3 – 2)

4 1/2"

9"

2"

3"

OVERVIEWRefractory brick are classified on the basis of their form as RectangularShapes or Special Shapes.

Rectangular Sizes are brick of relatively simple design, with certaindefinite shapes, that are marketed in sufficient amounts to permit quanti-ty production. Rectangular sizes are preferred wherever furnace con-struction and operating conditions permit. These brick cost less thanlonger and more intricate shapes.

Special Shapes are refractory brick of special design of either sim-ple or intricate form. Some special shapes may be considered as mod-ifications of rectangular tile having the same overall dimensions.

For initial orders of special shapes, drawings showing completedetails of the shapes, as well as their assembly in the furnace, shouldbe included. The drawing and shape numbers should be provided onall subsequent orders.

Nine-Inch Sizes ( 9 X 41/2 X 3 )




Nine-Inch Sizes ( 9 X 41/2 X 3 )

9 Inch No. 1 Arch9 X 41/2 X (3 – 23/4)

4 1/2"

9"

2 3/4"

3"

9 Inch No. 3 Arch9 X 41/2 X (3 – 2)

4 1/2"

9"

2"

3"

9 Inch No. 1 Key9 X (41/2 – 4) X 3

4 1/2"

4"

3"

9"

9 Inch No. 2 Key9 X (41/2 – 31/2) X 3

4 1/2"

3 1/2"

3"

9"

9 Inch No. 3 Key9 X (41/2 – 3) X 3

4 1/2"

3"

3"

9"

9 Inch No. 4 Key9 X (41/2 – 21/4) X 3

4 1/2"

2 1/4 "

3"

9"

9 Inch Edge Skew9 X (41/2 – 11/2) X 3

9"3"

4 1/2"

1 1/2"

9 Inch – 60° End Skew(9 – 71/4) X 41/2 X 3

3"

9"

7 1/4"

4 1/2"

9 Inch No. 2 Arch9 X 41/2 X (3 – 21/2)

4 1/2"

9"

2 1/2"

3"

9 Inch – 48° Side Skew9 X (41/2 – 113/16) X 3

4 1/2"

3"

1 13/16"

9"

9 Inch – 60° Side Skew9 X (41/2 – 23/4) X 3

4 1/2"

3"

2 3/4"

9"

9 Inch Jamb9 X 41/2 X 3

3"

4 1/2"

9"

9 Inch Featheredge9 X 41/2 X (3 – 1/8)

4 1/2"

3"

1/8"

9"

9 Inch Neck9 X 41/2 X (3 – 5/8)

4 1/2"

3"

5/8"

9"

9 Inch – 48° End Skew(9 – 65/16) X 41/2 X 3

3"

9"

6 5/16"

4 1/2"



12 x 9 x 3 No. 1 ArchNo. 2 ArchNo. 3 Arch

StraightNo. 1-X WedgeNo. 1 WedgeNo. 2 WedgeNo. 3 Wedge

12 x 9 x (3-23/4)12 x 9 x (3-21/2)12 x 9 x (3-2)

12 x 9 x 312 x 9 x (3-27/8)12 x 9 x (3-23/4)12 x 9 x (3-21/2)12 x 9 x (3-2)

3.072.932.67

3.203.133.072.932.67

12 x 41/2 x 3

12 x 6 x 3

12 x 63/4 x 3

StraightNo. 1 ArchNo. 2 ArchNo. 3 Arch

No. 1-X WedgeNo. 1 WedgeNo. 2 WedgeNo. 3 Wedge



No. 1 KeyNo. 2 KeyNo. 3 Key


12 x 41/2 x 312 x 41/2 x (3-23/4)12 x 41/2 x (3-21/2)12 x 41/2 x (3-2)

12 x 41/2 x (3-27/8)12 x 41/2 x (3-23/4)12 x 41/2 x (3-21/2)12 x 41/2 x (3-2)

12 x 6 x 312 x 6 x (3-23/4)12 x 6 x (3-21/2)12 x 6 x (3-2)

12 x 6 x (3-27/8)12 x 6 x (3-23/4)12 x 6 x (3-21/2)12 x 6 x (3-2)

12 x (6-51/2) x 312 x (6-5) x 312 x (6-3) x 3

12 x 63/4 x 312 x 63/4 x (3-27/8)12 x 63/4 x (3-23/4)12 x 63/4 x (3-21/2)12 x 63/4 x (3-2)

1.601.531.471.33

1.571.531.471.33

2.132.041.961.78

2.092.041.961.78

2.041.961.87

2.402.352.302.202.00

Sizes

9 x 6 x 3

9 x 63/4 x 3

9 x 9 x 3

Name






Dimensions (In.)

9 x 6 x 39 x 6 x (3-23/4)9 x 6 x (3-21/2)9 x 6 x (3-2)

9 x 6 x (3-27/8)9 x 6 x (3-23/4)9 x 6 x (3-21/2)9 x 6 x (3-2)

9 x (6-53/8) x 39 x (6-413/16) x 39 x (6-3) x 3

9 x 63/4 x 39 x 63/4 x (3-27/8)9 x 63/4 x (3-23/4)9 x 63/4 x (3-21/2)9 x 63/4 x (3-2)

9 x 9 x 39 x 9 x (3-27/8)9 x 9 x (3-23/4)9 x 9 x (3-21/2)9 x 9 x (3-2)

Equivalent

1.601.531.471.33

1.571.531.471.33

1.521.441.20

1.801.761.721.651.50

2.402.352.302.202.00

Sizes

9 x 41/2 x 21/2

9 x 31/2 x 21/2

9 x 21/4 x 21/2

9 x 41/2 x 21/2

9 x 41/2 x 21/2

9 x 41/2 x 21/2

9 x 41/2 x 39 x 31/2 x 39 x 21/4 x 39 x 41/2 x 11/2

9 x 41/2 x 3

9 x 41/2 x 3

9 x 6Flat Back

Name

StraightSoap2" SplitSplit

No. 1-X WedgeNo. 1 WedgeNo. 2 WedgeNo. 1 ArchNo. 2 ArchNo. 3 ArchNo. 1 KeyNo. 2 KeyNo. 3 KeyNo. 4 Key

48° End Skew60° End Skew48° Side Skew60° Side SkewEdge SkewFeatheredgeNeckJamb

StraightSm. StraightSoapSplit

No. 1 ArchNo. 2 ArchNo. 3 ArchNo. 4 Arch


No. 1 KeyNo. 2 KeyNo. 3 KeyNo. 4 Key

48° End Skew60° End Skew48° Side Skew60° Side SkewEdge SkewFeatheredgeNeckJamb

StraightSplitNo. 1 ArchNo. 2 Arch

Dimensions (In.)

9 x 41/2 x 21/2

9 x 21/4 x 21/2

9 x 41/2 x 21/2

9 x 41/2 x 11/4

9 x 41/2 x (21/2-21/4)9 x 41/2 x (21/2-17/8)9 x 41/2 x (21/2-11/2)9 x 41/2 x (21/2-21/8)9 x 41/2 x (21/2-13/4)9 x 41/2 x (21/2-1)9 x (41/2-4) x 21/2

9 x (41/2-31/2) x 21/2

9 x (41/2-3) x 21/2

9 x (41/2-21/4) x 21/2

(9-63/4) x 41/2 x 21/2

(9-79/16) x 41/2 x 21/2

9 x (41/2-21/4) x 21/2

9 x (41/2-31/16) x 21/2

9 x (41/2-11/2) x 21/2

9 x 41/2 x (21/2-1/8)9 x 41/2 x (21/2-5/8)9 x 41/2 x 21/2

9 x 41/2 x 39 x 31/2 x 39 x 21/4 x 39 x 41/2 x 11/2

9 x 41/2 x (3-23/4)9 x 41/2 x (3-21/2)9 x 41/2 x (3-2)9 x 41/2 x (3-1)

9 x 41/2 x (3-27/8)9 x 41/2 x (3-23/4)9 x 41/2 x (3-21/2)9 x 41/2 x (3-2)

9 x (41/2-4) x 39 x (41/2-31/2) x 39 x (41/2-3) x 39 x (41/2-21/4) x 3

(9-65/16) x 41/2 x 3(9-71/4) x 41/2 x 39 x (41/2-113/16) x 39 x (41/2-23/4) x 39 x (41/2-11/2) x 39 x 41/2 x (3-1/8)9 x 41/2 x (3-5/8)9 x 41/2 x 3

9 x 6 x 21/2

9 x 6 x 11/4

9 x 6 x (31/2-21/2)9 x 6 x (31/2-2)

Equivalent

1.000.500.800.50

0.950.880.800.930.850.700.940.890.830.75

0.880.920.750.840.670.530.630.89

1.200.930.600.60

1.151.101.000.80

1.171.151.101.00

1.131.071.000.90

1.021.080.840.970.800.630.731.07

1.330.671.601.47


High-Alumina, Basic and Silica BrickTYPICAL STRAIGHT, ARCH, WEDGE AND KEY BRICK

Straight Arch Wedge Key

15 x 9 x 3 StraightNo. 1-X WedgeNo. 1 WedgeNo. 2 WedgeNo. 3 Wedge

15 x 9 x 315 x 9 x (3-27/8)15 x 9 x (3-23/4)15 x 9 x (3-21/2)15 x 9 x (3-2)

4.003.923.833.673.33

131/2 x 63/4 x 3

131/2 x 9 x 3

15 x 41/2 x 3

15 x 6 x 3








131/2 x 63/4 x 3131/2 x 63/4 x (3-27/8)131/2 x 63/4 x (3-23/4)131/2 x 63/4 x (3-21/2)131/2 x 63/4 x (3-2)

131/2 x 9 x 3131/2 x 9 x (3-23/4)131/2 x 9 x (3-21/2)131/2 x 9 x (3-2)

131/2 x 9 x (3-27/8)131/2 x 9 x (3-23/4)131/2 x 9 x (3-21/2)131/2 x 9 x (3-2)

15 x 41/2 x 315 x 41/2 x (3-23/4)15 x 41/2 x (3-21/2)15 x 41/2 x (3-2)

15 x 41/2 x (3-27/8)15 x 41/2 x (3-23/4)15 x 41/2 x (3-21/2)15 x 41/2 x (3-2)

15 x 6 x 315 x 6 x (3-27/8)15 x 6 x (3-23/4)15 x 6 x (3-21/2)15 x 6 x (3-2)

15 x (6-5) x 315 x (6-43/8) x 315 x (6-3) x 3

2.702.642.592.472.25

3.603.453.303.00

3.523.453.303.00

2.001.921.831.67

1.961.921.831.67

2.672.612.562.442.22

2.562.312.00

Sizes

131/2 x 41/2 x 3

131/2 x 6 x 3

Dimensions (In.)

131/2 x 41/2 x 3131/2 x 41/2 x (3-23/4)131/2 x 41/2 x (3-21/2)131/2 x 41/2 x (3-2)

131/2 x (41/2-4) x 3131/2 x (41/2-31/2) x 3131/2 x (41/2-3) x 3131/2 x (41/2-21/4) x 3

131/2 x 6 x 3131/2 x 6 x (3-23/4)131/2 x 6 x (3-21/2)131/2 x 6 x (3-2)

131/2 x 6 x (3-27/8)131/2 x 6 x (3-23/4)131/2 x 6 x (3-21/2)131/2 x 6 x (3-2)

131/2 x (6-5) x 3131/2 x (6-43/8) x 3131/2 x (6-3) x 3

Name


No. 1 KeyNo. 2 KeyNo. 3 KeyNo. 4 Key




Equivalent

1.801.721.651.50

1.701.601.501.35

2.402.302.202.00

2.352.302.202.00

2.202.071.80

18 x 41/2 x 3

18 x 6 x 3

18 x 9 x 3

21 x 6 x 3

21 x 9 x 3

Misc. Straights






StraightStraightStraightStraightStraightStraightStraightStraight

18 x 41/2 x 318 x 41/2 x (3-27/8)18 x 41/2 x (3-23/4)18 x 41/2 x (3-21/2)18 x 41/2 x (3-2)

18 x 6 x 318 x 6 x (3-27/8)18 x 6 x (3-23/4)18 x 6 x (3-21/2)18 x 6 x (3-2)

18 x 9 x 318 x 9 x (3-27/8)18 x 9 x (3-23/4)18 x 9 x (3-21/2)18 x 9 x (3-2)

21 x 6 x 321 x 6 x (3-27/8)21 x 6 x (3-23/4)21 x 6 x (3-21/2)21 x 6 x (3-2)

21 x 9 x 321 x 9 x (3-27/8)21 x 9 x (3-23/4)21 x 9 x (3-21/2)21 x 9 x (3-2)

9 x 6 x 29 x 7 x 29 x 71/2 x 2101/2 x 41/2 x 3101/2 x 41/2 x 41/2

131/2 x 41/2 x 41/2

18 x 63/4 x 318 x 9 x 41/2

2.402.352.302.202.00

3.203.133.072.932.67

4.804.704.604.404.00

3.733.653.583.423.11

5.605.485.375.134.67

1.071.241.331.392.102.703.607.20

Sizes Dimensions (In.)Name Equivalent

Harbison-Walker Brick Installation Guider - 25


9"

4 1/2"

3"

Nine-Inch Sizes(9 X 4 1/2 X 3)

High-Alumina Circle Brick

* The first two numbers of theCircle Number indicate the inside and outside diame-ters,respectively, of the ringproducedby each shape. Forexample, 24 - 33 - 3 CircleBrick will produce a ringwith a 24-inchinside diame-ter and 33-inch outsidediameter for a 4½inch lining.

Circle Brick NumberNumber* Chord Per(3 Inch) (Inch) Ring

24 - 33 - 3 6 17/32 12

36 - 45 - 3 7 3/16 16

48 - 57 - 3 7 19/32 20

60 - 69 - 3 7 13/16 24

72 - 81 - 3 8 29

84 - 93 - 3 8 1/8 33

96 - 105 - 3 8 7/32 37

108 - 117 - 3 8 5/16 41

120 - 129 - 3 8 3/8 45

METALKASE DOOR JAMB BRICK

B

A D

C

NameA B C D

(In) (In) (In) (In)

DJ-1-3 9 4 1/2 11/2 3

DJ-2-3 9 6 3/4 3 3/4 3

DJ-3-3 9 9 6 3

BS-115-3 13 1/2 6 3/4 2 3/4 3

BS-116-3 13 1/2 9 5 3

DJ-18-1-3 18 6 3/4 2 3/4 3

DJ-18-2-3 18 9 5 3

BLAST-FURNACE BOTTOM BLOCKS(18 X 9 X 4 1/2 Inches)Number per course for blocks laid on end

Diameter ofNo. of

Diameter ofNo. ofHearth Jacket

BlocksHearth Jacket

Blocks(Ft In) (Ft In)

17 6 897 27 6 217618 0 947 28 0 225518 6 999 28 6 233519 0 1053 29 0 241719 6 1108 29 6 2500

20 0 1164 30 0 258420 6 1222 30 6 266921 0 1281 31 0 275621 6 1342 31 6 284522 0 1403 32 0 2935

22 6 1467 32 6 302623 0 1531 33 0 311923 6 1598 33 6 321324 0 1665 34 0 330824 6 1734 34 6 3405

25 0 1804 35 0 350325 6 1876 35 6 360326 0 1949 36 0 370426 6 2023 36 6 380627 0 2099 37 0 3909


EAF DOOR JAMBS/ BLAST FURNACE


BLAST FURNACE KEYS

6"

5 11/16"

3"

13 1/2"

13 1/2-Inch – X-1

6"

5 11/16"

3"

13 1/2"

13 1/2-Inch – X-2

5 29/32"

5 11/16"

3"

9"

9-Inch – X-1

5 29/32"

9"

9-Inch – X-2

5 11/16"

3"

SHAPES FOR ALL-KEY BLAST FURNACE LININGS

NOTE: Blast Furnace keys X-1 and X-2 are also regulary manufactured in 6, 101/2 and 15-inch lengths. The brick com-binations for rings (see Brick Combinations for All-Key Linings table) are applicable for X-1 and X-2 keys of alllengths.

BRICK COMBINATIONS FOR ALL-KEY LININGS

Diameter Inside Number Required Per RingBrickwork(Ft In) X-2 X-1 Total

13 3 98 — 9813 6 96 3 9913 9 95 6 10114 0 95 8 10314 6 93 13 106

15 0 91 18 10915 6 89 23 11216 0 87 28 11516 6 85 33 118

17 0 84 37 12117 6 82 42 12418 0 80 48 12818 6 79 52 131

19 0 77 57 13419 6 75 62 13720 0 73 67 14020 6 71 72 143

21 0 70 76 14621 6 68 82 15022 0 66 87 15322 6 65 91 156

23 0 63 96 15923 6 61 101 16224 0 59 106 16524 6 57 111 168

25 0 56 116 17225 6 54 121 17526 0 52 126 17826 6 51 130 181

Diameter Inside Number Required Per RingBrickwork(Ft In) X-2 X-1 Total

27 0 49 135 t8427 6 47 140 18728 0 45 145 19028 6 44 150 194

29 0 42 155 19729 6 40 160 20030 0 38 165 20330 6 37 169 206

31 0 35 174 20931 6 33 179 21232 0 32 184 21632 6 30 189 219

33 0 28 194 22233 6 26 199 22534 0 24 204 22834 6 23 208 231

35 0 21 213 23435 6 19 219 23836 0 18 223 24136 6 16 228 244

37 0 14 233 24737 6 12 238 25038 0 10 243 25338 6 9 247 256

39 0 7 253 26039 6 5 258 26340 0 4 262 26640 6 2 267 26941 0 — 272 272

ELECTRIC FURNACE ROOF-SHAPES9 X 41/2 X 3-Inch Arch-Key-Wedge Shapes

Spherical Radius Range H-W Shape Designations

6’6” to 7’9” HW-2721-BHW-2721-S

7’9” to 9’6”HW-2746-BHW-2746-A

9’6” to 12’6”HW-2745-BHW-2745-A

12’6” to 16’0”HW-2592-BHW-2592-A

16’0” to 22’4”HW-2704-BHW-2704-A

Annular rings are laid from thecombinations for your specific roofdesign. Consideration must begiven to the best design to providecost-effective service life. The two-shape, triple taper brick uses twobricks that conform to the roof contour.Bricklaying is simplified using onlytwo shapes, in that inventory levelsmay be reduced and faster installation ispossible.

The chart below displays two-shapeelectric furnace roof brick combina-tions for 9-inch roof thicknesses. Bycombining both shapes, all annularrings for a given diameter can be cal-culated. The center of the range indi-cates the ideal spherical radius for thegiven system. Shape identification isdone by a notching system at the coldend of the brick shape, as illustrated onp. 29. The two-shape system is also

available in 13½-inch sizes for largerelectric furnace roofs.

Providing your Harbison-Walkerrepresentatives with the dimensions ofyour electric furnace roof or a currentdrawing of your roof enables them toproduce an accurate ring count andassembly detail.

OVERVIEWElectric furnace roofs may be constructed using many different shapesand combinations. The combination of standard size key-arch andkey-wedge shapes with standard shapes design, and the two-shape(arch-key-wedge) brick design are the most common in electric fur-nace roof construction.


ELECTRIC FURNACE ROOF SHAPES


ELECTRIC FURNACE ROOF SHAPES

A

B

B

B

B B

BA

A

A

A

A

A

A

A

A

“A” and “B” Arch-Key-Wedge Brick

Two-Shape Electric FurnaceRoof ConstructionTwo-Shape (arch-key-wedge) roof brick designs are available in a variety of 9-inch sizes to fit EAF roof contours and spherical radii.

In all four series, the width of the brick,equivalent to the thickness of the lin-ing, is positioned in the rectangularframe . For example, a 5-inchthick lining in a ladle about 120 inchesin diameter would require an SU 5-45series brick. SULB’s are also availablein two additional thicknesses — 4-inchand 100 mm. A universal starter set thatsuits all series and wall thicknesses upto 7 inches is available. The 12-pieceUL-7-SS12 set is illustrated below. A

regular 18-piece starter set for 9-inchthick walls is also available.

The number of SULB shapesrequired for a lining can be calculated bymultiplying the average diameter of theladle by 3.1416, then dividing by 8.25(length of brick) to find the number perring. The height in inches of the ladlewall divided by 3 equals the number ofrings. The number of pieces per ringtimes the number of rings equals thetotal number of SULB shapes required.

For a ladle with an average diameter of 120 inches (outsidediameter of SULB lining) and a height of96 inches, the calculations follow:

OVERVIEWHarbison-Walker manufactures Semi-Universal Ladle Brick (SULB) infireclay, high-alumina and basic refractories in four series of brick toline sidewalls of iron and steel teeming ladles of various diametersand configurations. All series can be produced in widths to constructlinings 3 to 9 inches thick. A SULB lining usually includes a tilt backcourse to lay the rings square against the sloping sides of a ladle andone or more starter sets to start the upward spiral. For guidance inselecting the proper series for any ladle, the following chart identifies

1

2

3

4

56

78

9 10 11 12

Series Ladle Diameter (Inch)

SU - - 20 45 to 70

SU - - 30 70 to 100

SU - - 45 100 to 140

SU - - 60 140 and Up

AName Size

SU 4-20 6.983

SU 4-30 7.414

SU 4-45 7.690

SU 4-60 7.831

3.1416 x 120

8.25= 46 pieces per

9 6

3= 32 rings

46 x 32 = 1472 SULB brick per lining

Half brick to bond course

Regular Semi-Universal (to close the first course-cut the ends square of two bricks)

One tilt back course (to close ring-cut the ends square of two bricks)

8.250"

A3"

4"

(All series for a 4-inch thick wall)


SEMI-UNIVERSAL LADLE BRICK (SULB)


SKEWBACK SHAPES

9"

9" 4 1/2 "

1 13/16 "

4 1/2 "

9 "

4 1/2"

29/32"9"

4 1/2"

4 1/2"

9"

4 3/4 "

4 3/4 "

9 1/2"11/16"

2 1/8"

4 1/2"

4 1/2 "

2 1/4 "

4 1/2"

19/32"

12"

4 1/2"12"

1 19/32"

6"

4 1/2"

3 19/32"

9"

9"

13/16"

7 1/2"

2 1/4"

9"9"

9"

13 1/2"

6 3/4"

13 1/2"

1 13/18"

4 1/2"

9"

9"

17/32"

4 1/2"

4 1/2"

For Arch 4 1/2 Inches ThickRise 1 1/2 Inches Per Foot of SpanCentral Angle 56° 8.7’

Skewback Consists of 1–9 Inch – 2 Inch Split1–9 Inch Featheredge

Shape 56-9For Arch 9 Inches ThickRise 1 1/2 Inches Per Foot of SpanCentral Angle 56° 8.7’

Shape No. 60-40 1/2for Arch 4 1/2 Inches Thick

Rise 1.608 (119/32) InchesPer Foot of Span

Shape No. 60-9for Arch 9 InchesThick

Shape No. 60-12for Arch 12

Shape No. 60-13 1/2for Arch 13 1/2 Inches Thick

Shape 74-4 1/2For Arch 4 1/2 Inches ThickRise 2 Inches Per Foot ofSpan

Shape 74-9For Arch 9 Inches ThickRise 2 Inches Per Foot of SpanCentral Angle 73° 44.4’

For Arch 4 1/2 Inches ThickRise2.302 (2 5/16) Inches Per Foot of Span, Central Angle 83° 58.5’

Skewback Consists of 2–9 Inch – 48° End Skew1–9 Inch – 48° Side Skew1–9 Inch Soap

For Arch 9 Inches ThickRise 2.302 (2 5/16) Inches Per Foot of Span, Central Angle 83° 58.5’Skewback Consists of 2 – 9 Inch – 48° End Skew2 – 9 Inch – 48° Side Skew1 – 9 Inch Soap

NINE-INCH SIZES ADDITIONAL SIZES FOR ARCHES WITH60° CENTRAL ANGLE

8 1/4 " 4 1/2 "

3 3/4 "

9"

17/32 "

8 1/4 " 4 1/2 "

5 "

9"

17/32 "

13 1/2"

12 3/8"

1 13/16"

4 1/2"

5 5/8"

13 1/2"

12 11/16"

1 13/16"

4 1/2"

3"2 15/16"

2 1/2"1 1/4"

2 1/2"2 1/4"

9"

8 1/4"

17/32"

4 1/2"

12"

1 19/32"

11 1/4" 4 1/2"

SKEWBACK BRICK WITH CUTOUTS FOR STEELANGLE AND CHANNEL SUPPORTING FRAMEWORK

For Arches with 60° Central AngleRise 1.608 (1 19/32) Inches Per Foot of Span

Shape No. 60-9-A Shape No. 60-9-CFor Arch 9 Inches Thick For Arch 9 Inches Thick

Shape No. 60-12-A Shape No. 60-12-CFor Arch 12 Inches Thick For Arch 12 Inches Thick

Shape No. 60-13 1/2-A Shape No. 60-13 1/2-CFor Arch 13 1/2 Inches Thick For Arch 13 1/2 Inches Thick

STEEL ANGLEMaximum Dimensions

ShorterLeg ThicknessSkewback(in) (in)

60-9-A 4 3/4

60-12-A 6 1

60-13 1/2-A 8 11/8

STEEL CHANNELMaximum Dimensions

Channel Flange WebSize Width ThicknessSkewback(in) (in) (in)

60-9-C 12 3 13/32 3/4

60-12-C 12 3 13/32 3/4

60-13 1/2-C 15 3 13/16 13/16

Note:Brick Combinations required for arch construction are detailed in the tablesstarting on pages 71. These tablesare useful for estimating the quanti-ties of brick required for the construc-tion of arches.


SKEWBACK SHAPES


BRICK COUNTS FOR ROTARY KILNS

HIGH-ALUMINA BRICK

ROTARY KILN BLOCKS Arch-Type (9 x 6 x 31/2)

The numbers in the RKB column indi-cate the inside and outside diameters,respectively, of the ring produced by theshape. For example, RKB 162-A-174 willproduce a ring with a 162-inch insidediameter and 174-inch outside diameter.

Ins. Dia. RKB Inside Number Kiln Shell Number Chord (In.) Per Ring

3’-6” 30-A-42 2 1/2 374’-0” 36-A-48 2 5/8 424’-6” 42-A-54 2 23/32 475’-0” 48-A-600 2 13/16 525’-6” 54-A-66 2 7/8 58

6’-0” 60-A-72 2 29/32 636’-6” 66-A-78 2 31/32 687’-0” 72-A-84 3 747’-6” 78-A-90 3 1/32 79

8’-0” 84-A-96 3 1/16 848’-6” 90-A-102 3 3/32 899’-0” 96-A-108 3 1/8 959’-6” 102-A-114 3 1/8 100

10’-0” 108-A-120 3 5/32 10510’-6” 114-A-126 3 5/32 11111’-0” 120-A-132 3 3/16 11611’-3” 123-A-135 3 3/16 11911’-6” 126-A-138 3 3/16 121

12’-0” 132-A-144 3 7/32 12612’-6” 138-A-150 3 7/32 13213’-0” 144-A-156 3 7/32 13713’-6” 150-A-162 3 1/4 142

14’-0” 156-A-168 3 1/4 14814’-6” 162-A-174 3 1/4 15315’-0” 168-A-180 3 9/32 15815’-6” 174-A-186 3 9/32 164

16’-0” 180-A-192 3 9/32 16916’-6” 186-A-198 3 9/32 17417’-0” 192-A-204 3 9/32 17917’-6” 198-A-210 3 5/16 185

18’-0” 204-A-216 3 5/16 190

To facilitate the keying of arch-type rotary kiln blocks, keying bricks of two-thirdsthickness, RKA-2/3, and of three-quarters thickness, RKA-3/4, are made. Two ofeach keying brick should be ordered for each ring.

* All brick quantities per ring have been calculated from theoretical diameter turnedby the brick to which a steel plate (1.5 mm thickness) has been attached.

HIGH-ALUMINA BRICK

ROTARY KILN BLOCKS Nine-Inch Size (9 x 9 x 4)

The numbers in the RKB column indi-cate the inside and outside diameters,respectively, of the ring produced by theshape. For example, 48-66 RKB willproduce a ring with a 48-inch insidediameter and 66-inch outside diameterfor a 9-inch lining.


5’-6” 48-66 6 17/32 236’-0” 54-72 6 3/4 266’-6” 60-78 6 17/16 287’-0” 66-84 7 1/16 307’-6” 72-90 7 3/16 32

8’-0” 78-96 7 5/16 348’-6” 84-102 7 13/32 369’-0” 90-108 7 1/2 389’-6” 96-114 7 19/32 40

10’-0” 102-120 7 21/32 4210’-6” 108-126 7 23/32 4411’-0” 114-132 7 25/32 4611’-3” 117-135 7 13/16 4811’-6” 120-138 7 13/16 49

12’-0” 126-144 7 7/8 5112’-6” 132-150 7 29/32 5313’-0” 138-156 7 31/32 5513’-6” 144-162 8 57

14’-0” 150-168 8 1/32 5914’-6” 156-174 8 1/16 6115’-0” 162-180 8 3/32 6315’-6” 168-186 8 1/8 65

16’-0” 174-192 8 5/32 6716’-6” 180-198 8 3/16 7017’-0” 186-204 8 7/32 7217’-6” 192-210 8 7/32 74

18’-0” 198-216 8 1/4 7618’-6” 204-222 8 9/32 7819’-0” 210-228 8 9/32 8019’-6” 216-234 8 5/16 82

20’-0” 222-240 8 5/16 8420’-6” 228-246 8 11/32 8621’-0” 234-252 8 11/32 8821’-6” 240-258 8 3/8 90





HIGH-ALUMINA BRICK

ROTARY KILN BLOCKS Six-Inch Size (9 x 6 x 4)

The numbers under the RKB column indi-cate the inside and outside diameters,respectively, of the ring produced byeach shape. For example, 144-156 RKBwill produce a ring with a 144-inchinside diameter and 156-inch outsidediameter for a 6-inch lining.


3’-6” 30-42 6 7/16 154’-0” 36-48 6 3/4 174’-6” 42-54 7 195’-0” 48-60 7 3/16 215’-6” 54-66 7 3/8 23

6’-0” 60-72 7 1/2 266’-6” 66-78 7 5/8 287’-0” 72-84 7 23/32 307’-6” 78-90 7 13/16 32

8’-0” 84-96 7 7/8 348’-6” 90-102 7 15/16 369’-0” 96-108 8 389’-6” 102-114 8 1/16 40

10’-0” 108-120 8 3/32 4210’-6” 114-126 8 5/32 4411’-0” 120-132 8 3/16 4611’-3” 123-135 8 3/16 4811’-6” 126-138 8 7/32 49

12’-0” 132-144 8 1/4 5112’-6” 138-150 8 9/32 5313’-0” 144-156 8 5/16 5513’-6” 150-162 8 11/32 57

14’-0” 156-168 8 11/32 5914’-6” 162-174 8 3/8 6115’-0” 168-180 8 13/32 6315’-6” 174-186 8 13/32 65

16’-0” 180-192 8 7/16 6716’-6” 186-198 8 15/32 7017’-0” 192-204 8 15/32 7217’-6” 198-210 8 1/2 74

18’-0” 204-216 8 1/2 7618’-6” 210-222 8 1/2 7819’-0” 216-228 8 17/32 8019’-6” 222-234 8 17/32 82

20’-0” 228-240 8 9/16 8420’-6” 234-246 8 9/16 86 21’-0” 240-252 8 9/16 88


KA AND KW BLOCKS FORROTARY KILNS

Harbison-Walker developed the KAand KW system to simplify andeliminate problems associated with thelinings of rotary kilns. KA and KWblocks are 9 x 6 x 4-inch kiln linersmade in the arch or wedge shape forhigh-alumina brick. Each shape is fur-nished in four sizes, two of which willline any kiln (see chart below).

In addition, two thirds and threequarter splits are designed to work withall KA and KW linings to eliminate theneed for cutting keys.

Using the proper combination of KAand KW blocks also can reduce shim-ming, thereby producing a tighter liningwith less chance of dropout or spiral-ing. Because these shapes fit kilns ofmany sizes, operators with kilns of dif-ferent sizes can reduce their in-plantinventories.

Kiln Diameter Combinations

6 to 8 feet 8 to 13 feet 13 to 21 feet

Linings 6 inches thick KA-3, KA-2 KA-2, KA-l KA-l, KA-lX

Linings 9 inches thick KW-3, KW-2 KW-2, KW-l KW-l, KW-lX

6"

9"9"9"

6" 6" 6"

KA-2 KA-3 KA-1X

KW-1 KW-2 KW-3 KW-1X

9"

KA-1 6"

9"

COMBINATION LININGS FOR ROTARY KILNS



Number of KA Blocks Required for Kilns

504438322519136

————————————

————————————

————————————

——————————————————

715243241505867

767268646056524844403633

2824211713951

————

————————————

——————————————————

————————

—6

13192532384451576369

76828894

100107113119118114111107

10410097939086827976726965

625854514744403733302623191512852

————————

————————————

————————5

111723

283540465258647075828793

99105111117123128135140146152158164170176182188193199

5759626466697173

7678818385889092959799

102

104106109111113116118120123125128130

132135137139142144146149151154156158

161163165168170172175177179182184187189191194196198201

675951433426188

————————————

————————————

————————————

——————————————————

1020324355677890

1029691868075706459544844

38322823181271

————

————————————

——————————————————

————————

—8

18263443515968768492

102110118126134143151159157152148143

139133130124120115110106102969287

8378726863595449444035312520161173

————————

————————————

————————7

152331

3747536270778593

100110116124

132140148156164

171180187195203211219227235243251257265

7779838689939698

102104109112114118121123127130132136

140142146149 152155158160164167171174

176180183186190192195199202206208211

215218220224227230234236239243246250252255259262264268

55556666

777788889999

101010101111111112121212

131313131414141415151515

161616161717171718181818191919192020

03690369

036903690369

036903690369

036903690369

036903690369036903

66667777

88889999

10101010

111111111212121213131313

141414141515151516161616

171717171818181819191919202020202121

03690369

036903690369

036903690369

036903690369

036903690369036903

InsideLining

Number Required Per RingInsideShell

DiametersNumber Required Per Linear Ft

KA-3 KA-2 KA-1 KA-1X Total KA-3 KA-2 KA-1 KA-1X TotalFt In Ft In

NOTE: When using KA - 1x shape, order two pieces each ring KW - 2/3 x and KW - 3/4 x to facilitate keying.


445555

666677778888

9999

1010101011111111

121212121313131314141414

151515151616161617171717

690369

036903690369

036903690369

036903690369

036903690369

666677

7788889999

1010

101011111111121212121313

131314141414151515151616

161617171717181818181919

504438322519

136

——————————

————————————

————————————

————————————

71524324150

586776726864605652484440

36332824211713951

——

————————————

————————————

——————

———6

1319253238445157

636976828894

100107113119117112

10810398948984797570656056

51464237322823181494

—

——————

————————————

——————————6

13

202734414855636976849198

105112119126133140147154161168175182

575962646669

717376788183858890929597

99102104106109111113116118120123125

128130132135137139142144146149151154

156158161163165168170172175177179182

036903

690369036903

690369036903

690369036903

690369036903

NOTE: For each ring, order two (2) pieces each KW-2/ and KW-3/ or KW-2/ x and KW-3/ x to facilitate keying.

1008876645038

2612——————————

————————————

————————————

————————————

1430486482

100

116134152144136128120112104968880

7266564842342618102

——

————————————

————————————

——————

———12263850647688

102114

126138152164176188200214226238234224

216206196188178168158150140130120112

1029284746456463628188

—

——————

————————————

——————————1226

4054688296

110126138152168182196

210224238252266280294308322336350364

114118124128132138

142146152156162166170176180184190194

198204208212218222226232236240246250

256260264270274278284288292298302308

312316322326330336340344350354358364

Number of KW Blocks Required for Kilns

InsideLining

Number Required Per RingInsideShell

DiametersNumber Required Per Linear Ft

KW-3 KW-2 KW-1 KW-1X Total KW-3 KW-2 KW-1 KW-1X TotalFt In Ft In

NOTE: When using KA - 1x shape, order two pieces each ring KW - 2/3 x and KW - 3/4 x to facilitate keying.


CR COMBINATIONLININGSCR (Combination Ring) rotary kiln brickare designed to line kilns from 8 to 24feet in diameter for a 9-inch liningthickness. The appropriate combina-tions of the two kiln liners are calculatedfor the best fit for the given diameter.



Kiln Diameter

Feet Meters CR-89 CR-249

9’-10” 3.00 72 33

10’- 0” 3.04 71 3510’- 2” 3.10 71 3710’- 6” 3.20 69 4310’-10” 3.30 67 48

11’- 0” 3.36 67 5011’- 2” 3.40 66 5311’- 6” 3.50 64 5811’-10” 3.60 63 63

12’- 0” 3.66 61 6612’- 2” 3.70 61 6612’- 6” 3.80 59 7412’-10” 3.90 57 79

13’- 0” 3.96 57 8113’- 1” 4.00 56 8313’- 5” 4.10 54 8913’- 6” 4.12 54 9013’- 9” 4.20 53 94

14’- 0” 4.26 51 9914’- 1” 4.30 51 9914’- 3” 4.34 50 10214’- 5” 4.40 50 10314’- 6” 4.42 49 10514’- 9” 4.50 48 109

15’- 0” 4.58 47 11215’- 1” 4.60 46 11415’- 5” 4.70 45 11915’- 6” 4.72 44 12115’- 9” 4.80 43 124

16’- 0” 4.88 42 12816’- 1” 4.90 41 13016’- 5” 5.00 40 13416’- 6” 5.02 39 13616’- 9” 5.10 38 140

17’- 0” 5.18 37 14317’- 1” 5.20 36 14517’- 5” 5.30 35 15017’- 6” 5.34 34 15217’- 9” 5.40 33 155

18’- 0” 5.48 32 15918’- 1” 5.50 32 16018’- 4” 5.60 30 16518’- 6” 5.64 29 16718’- 8” 5.70 29 169

19’- 0” 5.80 27 175

To facilitate the keying of wedge-type rotary kiln blocks, keying bricks of two-thirdsthickness, RKW-2/3, and of three-quarters thickness, RKW-3/4, are made. Two ofeach keying brick should be ordered for each ring.

Combination Linings – CR Series

CR Series Dimensions (Inches)

SHAPE A B L H

CR-89 31/2 213/16 6 9

CR-249 31/2 39/32 6 9

ISO AND VDZ COMBINATION LININGS


B

A

H

L

C

International System

ISO and VDZCombination LiningsStandard practice in many NorthAmerican minerals processing plantsis to use one brick of a size manu-factured to fit a specific rotary kilndiameter. On the other hand, inter-national practice is to use combina-tion linings. Within practical limits, anyrotary kiln can be lined with an ap-propriate combination of two kiln lin-ers, one of which fits a kiln of largerdiameter and the other a kiln ofsmaller diameter.

As good engineering practice,Harbison-Walker suggests brickblending ratios between 3:1 and 1:3for the two-shapes. This helps tominimize the small amount of step-ping which can occur, allowing for abetter fit.The principal advantages ofcombination linings are:

• In plants which have several kilnsizes, the number of kiln linershapes can be reduced, since twoshapes in appropriate combintionswill fit many kilns.

EXAMPLE: Designation 320 ISOThe first digit (3) denotes tapered brick which turn a circle of 3.0 meters diameteroutside brickwork.

The last two digits (20) denote a lining thickness of 200 mm.Using ISO series combination lining charts, combinations are made using outside

diameter brickwork dimensions. A chart showing a 2M, 6M brick combination is fortapered brick which turn a diameter between 2.0 meters to 6.0 meters, in any liningthickness from 160 mm to 250 mm.

ISO Series - Dimensions (mm)

L - running LENGTH 198

H - lining THICKNESS 160180200220250

A - BACK Chord (cold face) 103

B - INSIDE Chord (hot face) VARIABLE

• Liner to liner contact is maintained,while following minor deformationsin kiln shells. This results in a tightlining and minimizes the need forcorrecting shims.

INTERNATIONAL SYSTEM

ISO VDZ

BACK CHORD (A) 103 VARIABLE

INSIDE CHORD (B) VARIABLE VARIABLE

MIDDLE CHORD (C) VARIABLE 71.5

LENGTH (L) 198 198

HEIGHT (H) 160 160180 180200 200220 220

250 250

BASIC LINING X

NON-BASIC LINING X



Schematic diagram showing criticaldimensions of ISO and VDZ shapes

B

A

H

L

C

B

A

L

H

ISO brick outside chord (A)dimension is constant at

103mm (4.05”)

VDZ brick mean chord (C)dimension is constant at

71.5mm (2.81”)

ISO SHAPESSHAPE No. DIMENSIONS VOL. TAPER

A B H L dm3

216 103 86160

2.99 17

716 103 98.3 3.19 4.7

218 103 84180

3.33 19

718 103 97.7 3.58 5.3

320 103 89200 198 3.80 21

820 103 97.8 3.98 5.2

222 103 80 3.99 23

322 103 88220

4.16 15

622 103 95.5 4.33 11.5

822 103 97.3 4.36 5.7

B

A

H

L



RECOMMENDED LINING THICKNESS

ROTARY KILN DIAMETER *RECOMMENDED BRICK THICK

<3.6M (12’-0”) I.D. 160 mm

Up to 4M (13’-6”) I.D. 180 mm

Up to 4.5M (16’-6”) I.D. 200 mm

Up to 5.8M (19’-0”) I.D. 220 mm

Over 5.8M (19’-0”) I.D. 250mm

*Recommendations are based on kiln diameter only,not taking operating data into consideration.

B

A

H

L

VDZ SHAPES

SHAPE No. DIMENSIONS VOL. TAPER

A B H L dm3

B-216 78 65160

2.27 13

B-416 75 68 2.27 7

B-218 78 65180

2.55 13

B-418 75 68 2.55 7

B-220 78 65200

1982.83 13

B-620 74 69 2.83 5

B-222 78 65 3.11 13

B-322 76.5 66.5 220 3.11 10

B-622 74 69 3.11 5


BRICK COMBINATIONS REQUIRED FOR RINGSThe tables on the following pages are useful in estimating the quantitiesof brick required for the construction of circular linings, roofs andarches. These tables give the combinations of brick sizes required for rings of given diameters.

In calculating the tables, no allowance was made for mortar orexpansion joints or for size deviations of the brick. Fractional partsequal to or greater than one tenth of a brick were counted as an entirebrick. For these reasons, the brick combinations shown may lay up todiameters which differ slightly from the theoretical diameters. The num-ber of brick required for a ring, as given in the tables, may be slightlyin excess of the number actually required.

In laying a ring course of brick, it is often necessary to cut one ortwo pieces, and in some instances several pieces, to complete the ring.

For brick combinations required for rings not shown in the following tables, or to calculate the ring combinations for brick of two different sizes, refer to the formulas found on page 19 whichcovers ring calculations.

RING COMBINATIONS

Diam. Inside Number Required per Ring

Brickwork No.3 No.2 No.1Ft. In. Arch Arch Arch Straight Total

0 6 19 — — — 190 7 18 3 — — 210 8 17 5 — — 220 9 15 8 — — 230 10 14 10 — — 240 11 13 13 — — 261 0 12 15 — — 271 1 10 18 — — 281 2 9 20 — — 291 3 8 23 — — 311 4 7 25 — — 321 5 5 28 — — 331 6 4 30 — — 341 7 3 33 — — 361 8 2 35 — — 371 9 — 38 — — 381 10 — 36 3 — 391 11 — 36 5 — 412 0 — 34 8 — 422 1 — 33 10 — 432 2 — 31 13 — 442 3 — 31 15 — 462 4 — 29 18 — 472 5 — 28 20 — 482 6 — 26 23 — 492 7 — 26 25 — 512 8 — 24 28 — 522 9 — 23 30 — 532 10 — 21 33 — 542 11 — 20 36 — 563 0 — 19 38 — 573 1 — 18 40 — 583 2 — 16 43 — 593 3 — 15 46 — 613 4 — 14 48 — 623 5 — 13 50 — 633 6 — 11 53 — 643 7 — 10 56 — 663 8 — 9 58 — 673 9 — 8 60 — 683 10 — 7 63 — 703 11 — 5 66 — 714 0 — 4 68 — 724 1 — 3 70 — 734 2 — 2 73 — 754 3 — — 76 — 764 4 — — 76 1 774 6 — — 76 4 804 8 — — 76 6 824 10 — — 76 9 855 0 — — 76 11 875 2 — — 76 14 905 4 — — 76 16 925 6 — — 76 19 955 8 — — 76 21 975 10 — — 76 24 100

Diam. Inside Number Required per RingBrickwork No.3 No.2 No.1Ft. In. Arch Arch Arch Straight Total

6 0 — — 76 26 1026 2 — — 76 29 1056 4 — — 76 31 1076 6 — — 76 34 1106 8 — — 76 36 1126 10 — — 76 39 1157 0 — — 76 41 1177 2 — — 76 44 1207 4 — — 76 46 1227 6 — — 76 49 1257 8 — — 76 51 1277 10 — — 76 54 1308 0 — — 76 56 1328 2 — — 76 59 1358 4 — — 76 61 1378 6 — — 76 64 1408 8 — — 76 66 1428 10 — — 76 69 1459 0 — — 76 71 1479 2 — — 76 74 1509 4 — — 76 76 1529 6 — — 76 79 1559 8 — — 76 81 1579 10 — — 76 84 160

10 0 — — 76 87 16310 2 — — 76 89 16510 4 — — 76 92 16810 6 — — 76 94 17010 8 — — 76 97 17310 10 — — 76 99 17511 0 — — 76 102 17811 2 — — 76 104 18011 4 — — 76 107 18311 6 — — 76 109 18511 8 — — 76 112 18811 10 — — 76 114 19012 0 — — 76 117 19312 2 — — 76 119 19512 4 — — 76 122 19812 6 — — 76 124 20012 8 — — 76 127 20312 10 — — 76 129 20513 0 — — 76 132 20813 2 — — 76 134 21013 4 — — 76 137 21313 6 — — 76 139 21513 8 — — 76 142 21813 10 — — 76 144 22014 0 — — 76 147 22314 2 — — 76 149 22514 4 — — 76 152 22814 6 — — 76 154 23014 8 — — 76 157 23314 10 — — 76 159 23515 0 — — 76 162 238

41/2 Inch Lining - 21/2 Inch Arch Brick9 x 41/2 x 21/2 or 131/2 x 41/2 x 21/2 Inch

41/2 Inch Lining - 21/2 Inch Arch Brick9 x 41/2 x 21/2 or 131/2 x 41/2 x 21/2 Inch

RING COMBINATIONS



Brickwork No.2 No.1 No.1-XFt. In. Wedge Wedge Wedge Straight Total

2 3 57 — — — 572 4 55 3 — — 582 5 52 7 — — 592 6 51 10 — — 612 7 48 14 — — 622 8 46 17 — — 632 9 44 20 — — 642 10 42 24 — — 662 11 40 27 — — 673 0 38 30 — — 683 1 36 34 — — 703 2 34 37 — — 713 3 32 40 — — 723 4 29 44 — — 733 5 28 47 — — 753 6 25 51 — — 763 7 23 54 — — 773 8 21 57 — — 783 9 19 61 — — 803 10 17 64 — — 813 11 15 67 — — 824 0 13 70 — — 834 1 11 74 — — 854 2 9 77 — — 864 3 6 81 — — 874 4 4 84 — — 884 5 2 88 — — 904 6 — 91 — — 914 7 — 90 2 — 924 8 — 89 4 — 934 9 — 88 7 — 954 10 — 87 9 — 964 11 — 86 11 — 975 0 — 85 13 — 985 1 — 85 15 — 1005 2 — 84 17 — 1015 3 — 83 19 — 1025 4 — 82 21 — 1035 5 — 82 23 — 1055 6 — 81 25 — 1065 7 — 80 27 — 1075 8 — 79 29 — 1085 9 — 78 32 — 1105 10 — 77 34 — 1115 11 — 76 36 — 1126 0 — 75 38 — 1136 1 — 75 40 — 1156 2 — 74 42 — 1166 3 — 73 44 — 1176 4 — 72 47 — 1196 5 — 72 48 — 1206 6 — 71 50 — 1216 7 — 70 52 — 1226 8 — 69 55 — 1246 9 — 68 57 — 1256 10 — 67 59 — 1266 11 — 66 61 — 127

9 Inch Lining - 21/2 Inch Wedge Brick9 x 41/2 x 21/2, 9 x 63/4 x 21/2 or 9 x 9 x 21/2 Inch


Brickwork No.2 No.1 No.1-XFt. In. Wedge Wedge Wedge Straight Total

7 0 — 66 63 — 1297 1 — 65 65 — 1307 2 — 64 67 — 1317 3 — 63 69 — 1327 4 — 62 72 — 1347 5 — 61 74 — 1357 6 — 60 76 — 1367 7 — 59 78 — 1377 8 — 59 80 — 1397 9 — 58 82 — 1407 10 — 57 84 — 1417 11 — 56 86 — 1428 0 — 56 88 — 1448 1 — 55 90 — 1458 2 — 54 92 — 1468 3 — 53 94 — 1478 4 — 52 97 — 1498 5 — 51 99 — 1508 6 — 50 101 — 1518 7 — 49 103 — 1528 8 — 49 105 — 1548 9 — 48 107 — 1558 10 — 47 109 — 1568 11 — 46 111 — 1579 0 — 46 113 — 1599 1 — 45 115 — 1609 2 — 44 117 — 1619 3 — 43 120 — 1639 4 — 42 122 — 1649 5 — 41 124 — 1659 6 — 40 126 — 1669 7 — 40 128 — 1689 8 — 39 130 — 1699 9 — 38 132 — 1709 10 — 37 134 — 1719 11 — 36 137 — 173

10 0 — 35 139 — 17410 1 — 35 140 — 17510 2 — 34 142 — 17610 3 — 33 145 — 17810 4 — 32 147 — 17910 5 — 31 149 — 18010 6 — 30 151 — 18110 7 — 30 153 — 18310 8 — 29 155 — 18410 9 — 28 157 — 18510 10 — 27 159 — 18610 11 — 26 162 — 18811 0 — 25 164 — 18911 1 — 24 166 — 19011 2 — 23 168 — 19111 3 — 23 170 — 19311 4 — 22 172 — 19411 5 — 21 174 — 195


RING COMBINATIONS



Brickwork No.2 No.1 No.1-XFt. In. Wedge Wedge Wedge Straight Total11 6 — 20 176 — 19611 7 — 20 178 — 19811 8 — 19 180 — 19911 9 — 18 182 — 20011 10 — 17 184 — 20111 11 — 16 187 — 20312 0 — 15 189 — 20412 1 — 14 191 — 20512 2 — 13 193 — 20612 3 — 13 195 — 20812 4 — 12 197 — 20912 5 — 11 199 — 21012 6 — 10 202 — 21212 7 — 10 203 — 21312 8 — 9 205 — 21412 9 — 8 207 — 21512 10 — 7 210 — 21712 11 — 6 212 — 21813 0 — 5 214 — 21913 1 — 4 216 — 22013 2 — 4 218 — 22213 3 — 3 220 — 22313 4 — 2 222 — 22413 5 — 1 224 — 22513 6 — — 227 — 22713 7 — — 227 1 22813 8 — — 227 2 22913 9 — — 227 3 23013 10 — — 227 5 23213 11 — — 227 6 23314 0 — — 227 7 23414 6 — — 227 15 24215 0 — — 227 22 24915 6 — — 227 30 25716 0 — — 227 37 26416 6 — — 227 45 27217 0 — — 227 52 27917 6 — — 227 60 28718 0 — — 227 67 29418 6 — — 227 75 30219 0 — — 227 83 31019 6 — — 227 90 317



Brickwork No.2 No.1 No.1-XFt. In. Wedge Wedge Wedge Straight Total20 0 — — 227 98 32520 6 — — 227 105 33221 0 — — 227 113 34021 6 — — 227 120 34722 0 — — 227 128 35522 6 — — 227 135 36223 0 — — 227 143 37023 6 — — 227 150 37724 0 — — 227 158 38524 6 — — 227 165 39225 0 — — 227 173 40025 6 — — 227 181 40826 0 — — 227 188 41526 6 — — 227 196 42327 0 — — 227 203 43027 6 — — 227 211 43828 0 — — 227 218 44528 6 — — 227 226 45329 0 — — 227 233 46029 6 — — 227 241 46830 0 — — 227 248 47530 6 — — 227 256 48331 0 — — 227 263 49031 6 — — 227 271 49832 0 — — 227 279 50632 6 — — 227 286 51333 0 — — 227 294 52133 6 — — 227 301 52834 0 — — 227 309 53634 6 — — 227 316 54335 0 — — 227 324 55135 6 — — 227 331 55836 0 — — 227 339 56636 6 — — 227 346 57337 0 — — 227 354 58137 6 — — 227 362 58938 0 — — 227 369 59638 6 — — 227 377 60439 0 — — 227 384 61139 6 — — 227 392 61940 0 — — 227 399 62640 6 — — 227 407 63441 0 — — 227 414 64141 6 — — 227 422 64942 0 — — 227 429 65642 6 — — 227 437 66443 0 — — 227 444 67143 6 — — 227 452 67944 0 — — 227 460 68744 6 — — 227 467 69445 0 — — 227 475 702


RING COMBINATIONS


41/2 Inch Lining — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch

00000000

111111111111

222222222222

333333333333

444444

151413121110

87

654431

——————

————————————

————————————

——————

—13579

1214

161820222427292826252423

222120191817161514131210

1098765321

———

——————

————————

———————

2579

11

131517192123252729313336

384042444648515355575655

545251504948

————————

————————————

————————————

——————————

24

69

11131517

————————

————————————

————————————

————————————

——————

1515161718192021

222324262728293031323334

353637383940414243444546

484950515253545556575859

606162636465

Number Required Per Ring

456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

012345

1/2

No. 2Arch

No. 1Arch

No. 3Arch

No. 4Arch TotalStraight

Diam. InsideBrickwork

Ft In

41/2 Inch Lining — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch — Continued

444444

555555555555

666666666666

777777777777

88888

9101112131415

6789

1011

0123456789

1011

0123456789

1011

0123456789

1011

01236

0000000

——————

————————————

————————————

————————————

—————

———————

——————

————————————

————————————

————————————

—————

———————

474645444342

414039383736353433323129

282726252423222120191817

16151413121110

97654

321

——

———————

192123262830

323436384042444648505255

575961636567707274767880

828486889092949699

101103105

107109111113113

113113113113113113113

——————

————————————

————————————

————————————

————

4

10223548607385

666768707172

737475767778798081828384

858687888990929394959697

9899

100101102103104105106107108109

110111112113117

123135148161173186198


No. 2Arch

No. 1Arch

No. 3Arch



Ft In

RING COMBINATIONS


41/2 Inch Lining — 3 Inch Circle Brick9 x 41/2 x 3 Inch

24-33-3Circle

36-45-3Circle

48-57-3Circle

60-69-3Circle

72-81-3Circle

Total

222222222222

333333333333

444444444444

555555555555

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

121110

987654321

————————————

————————————

————————————

—1345789

11121315

1614131211

9875432

————————————

————————————

————————————

—24579

101214151718

20191715141210

97542

————————————

————————————

————————————

—2468

10121416182022

2422201816141210

8642

————————————

————————————

————————————

—358

1012151719222426

121213131314141415151516

161617171818181919192020

202121212222222323232424

242525262626272727282828

Number Required Per RingDiam. InsideBrickwork

Ft In

41/2 Inch Lining — 3 Inch Circle Brick9 x 41/2 x 3 Inch — Continued

666666666666

777777777777

888888888888

999999999999

10

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

0

2926242219161412

9753

————————————

————————————

————————————

—

—358

1114171922252730

333027252219161411

853

————————————

————————————

—

————————————

—379

1216192125283134

373431282422181512

973

————————————

—

————————————

————————————

—37

101417212428313438

41383431282420171410

74

—

————————————

————————————

————————————

—48

111519232730343841

45

292929303030313131323233

333334343435353536363637

373738383839393940404141

414242424343434444444545

45


96-105-3Circle

108-117-3Circle

120-129-3Circle

84-93-3Circle

72-81-3Circle Total


Ft In

RING COMBINATIONS


6 Inch Lining — 3 Inch Arch Brick12 x 6 x 3 or 131/2 x 6 x 3 Inch

222222222222

333333333333

444444444444

555555555555

66666666

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

01234567

383736353432313029292827

262423222120191817161514

131211

987765421

————————————

————————

—2468

11131517192123

252830323436384042444648

505254575961636567697274

767574727170696867666564

6362616059585756

————————————

————————————

————————————

—2479

11131517192123

2527293234363840

————————————

————————————

————————————

————————————

————————

383940414243444546484950

515253545556575859606162

636465666768707172737475

767778798081828384858687

8889909293949596


No. 1Arch

No. 2Arch



Ft In

6 Inch Lining — 3 Inch Arch Brick12 x 6 x 3 or 131/2 x 6 x 3 Inch — Continued

6666

777777777777

888888888888

999999999999

101010101010101010101010

11121314

89

1011

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

0000

————

————————————

————————————

————————————

————————————

————

55545352

514948474645444342414039

383736353433323130292726

252423222120191817161514

13121110

98754321

————

42444648

505355575961636567697173

757880828486889092949799

101103105107109111113115117119122124

126128130132134136138141143145147149

151151151151

————

————————————

————————————

————————————

————————————

—132538

979899

100

101102103104105106107108109110111112

113115116117118119120121122123124125

126127128129130131132133134135137138

139140141142143144145146147148149150

151164176189


No. 1Arch

No. 2Arch



Ft In

RING COMBINATIONS


6 Inch Lining — Rotary Kiln or Cupola Blocks9 x 6 x 4 Inch

444444

555555

555555

666666

666666

777777

777777

888888

6789

1011

012345

6789

1011

012345

6789

1011

012345

6789

1011

012345

54-6623201511 8 4

60-7226211713 9 4

66-7828231814 9 5

72-843025201510 5

78-903226211611 6

84-963428231711 6

90-1023630241812 6

96-1083831251913 7

60-72— 4 9131721

66-78— 5 9141823

72-84— 510152024

78-90— 510162126

84-96— 612172228

90-102— 612182430

96-108— 613192532

102-114— 714202633

232424242525

262626272727

282828292929

303030313131

323233333334

343435353536

363637373738

383839393940

NOTE: In orders, the complete names of the blocks desired should be given, as for example “54-66 RKB” or “60-72 Cupola.”


Total


Ft In

6 Inch Lining — Rotary Kiln or Cupola Blocks9 x 6 x 4 Inch — Continued

888888

999999

999999

101010

101010

101010101010

111111111111

6789

1011

012345

6789

1011

012

345

6789

1011

012345

102-1144034272014 7

108-1204235282114 7

114-1264437292215 7

120-132463115

123-135483216

126-1384940322416 8

132-1445142342517 8

108-120— 714212835

114-126— 815223037

120-132— 816233139

123-135—1632

126-138—1632

132-144— 917263442

138-150— 917273544

404141414242

424343434444

444545454646

464747

484848

494949505050

515151525252



Total


Ft In

RING COMBINATIONS



111111111111

121212121212

121212121212

131313131313

131313131313

141414141414

6789

1011

012345

6789

1011

012345

6789

1011

012345

138-1505344352618 9

144-1565545372718 9

150-162574738281910

156-168594939292010

162-174615141302110

168-180635342312111

144-156— 918283646

150-162—1019293848

156-168—1020303949

162-174—1021314051

168-180—1021324253

174-186—1122334454

535353545455

555556565657

575758585859

595960606061

616162626363

636464646565



TotalFt In


141414141414

151515151515

151515151515

161616161616

161616161616

17

6789

1011

012345

6789

1011

012345

6789

1011

0

174-186655443322211

180-192675645332311

186-198705846352312

192-204726048362412

198-210746149372512

204-21676

180-192—1223344556

186-198—1223354658

192-204—1224364859

198-210—1224374961

204-216—1325385063

210-222—

656666666767

676868686969

707070717171

727272737373

747474757575

76



TotalFt In

RING COMBINATIONS


6 Inch Lining — Rotary Kiln Blocks9 x 6 x 4 Inch Arch Type —Two Shape System

55556666

777788889999

101010101111111112121212

131313131414141415151515

16161616171717171818

03690369

036903690369

036903690369

036903690369

0369036903

66667777

88889999

10101010

111111111212121213131313

141414141515151516161616

17171717181818181919

50443832251913

6

————————————

————————————

————————————

——————————

715243241505867

767268646056524844403633

2824211713

951

————

————————————

——————————

————————

—6

13192532384451576369

76828894

100107113119118114111107

104100

97939086827976726965

62585451474440373330

————————

————————————

————————

5111723

283540465258647075828793

99105111117123128135140146152

5759626466697173

7678818385889092959799

102

104106109111113116118120123125128130

132135137139142144146149151154156158

161163165168170172175177179182

03690369

036903690369

036903690369

036903690369

0369036903

NOTE: For each ring, order two (2) pieces each KA-2/3 and KA-3/4 to facilitate keying. For additional information, see discussion of KA and KW Blocks for Rotary Kilns.


KW-1

KW-1X

TotalKW-2

KW-3

InsideLining

Ft In

InsideShell

Ft In

9 Inch Lining — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch

333333333333

444444444444

555555555555

666666666666

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

575655545251504948474645

444342414039383736353433

323129282726252423222120

19181716151413121110

97

—2469

11131517192123

262830323436384042444648

505255575961636567707274

767880828486889092949699

————————————

————————————

————————————

————————————

————————————

————————————

————————————

————————————

575859606162636465666768

707172737475767778798081

828384858687888990929394

9596979899

100101102103104105106

NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting Nos. 1, 2 and 3 arch brick for the corresponding wedge brick.


No. 1

WedgeNo. 2

WedgeNo. 3

Wedge TotalStraightFt In

RING COMBINATIONS


9 Inch Lining — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.

777777777777

888888888888

999999999999

101010101010101010101010

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

654321

——————

————————————

————————————

————————————

101103105107109111113112111110109108

107106105104103102101100

99979695

949392919089888786858483

828180797877767473727170

———————

3579

11

131517192123252729323436

384042444749515355575961

636567697173757880828486

————————————

————————————

————————————

————————————

107108109110111112113115116117118119

120121122123124125126127128129130131

132133134135137138139140141142143144

145146147148149150151152153154155156



No. 1

WedgeNo. 2

WedgeNo. 3



111111111111111111111111

121212121212121212121212

131313131313131313131313

141414141414141414141414

151515151515

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

012345

————————————

————————————

————————————

————————————

——————

696967666564636261605958

575655545251504948474745

444342414039383736353433

323029282726252523222120

191817161514

889093959799

101103105107109111

113115117119122124126128130132134137

139141143145147149151153155157159161

163166168170172174176178181183185187

189191193195197199

————————————

————————————

————————————

————————————

——————

157159160161162163164165166167168169

170171172173174175176177178179181182

183184185186187188189190191192193194

195196197198199200201203204205206207

208209210211212213



No. 1

WedgeNo. 2

WedgeNo. 3


RING COMBINATIONS



151515151515

16161616161616171718181919

2020212122222323242425252626272728282929

3030313132323333343435353636

6789

1011

0123456060606

06060606060606060606

06060606060606

——————

—————————————

————————————————————

——————————————

13121110

87

654331

———————

————————————————————

——————————————

201203205207210212

214216218220222225227227227227227227227

227227227227227227227227227227227227227227227227227227227227

227227227227227227227227227227227227227227

——————

———————

61218253137

445056626975818894

100106113119125132138144150157163

169176182188194201207213220226232238245251

214215216217218219

220221222223225226227233239245252258264

271277283289296302308315321327333340346352359365371377384390

396403409415421

428434440447453459465472478



No. 1

WedgeNo. 2

WedgeNo. 3


9 Inch Lining — 3 Inch Key Brick9 x 41/2 x 3 Inch

111

222222

333333

444444

5555555

666666

777777

888888

999999

101010

68

10

02468

10

02468

10

02468

10

023468

10

02468

10

02468

10

02468

10

02468

10

024

262320

171412

963

——————

——————

———————

——————

——————

——————

——————

———

—48

131721252934

383532292724

2118151310

7

41

—————

——————

——————

——————

——————

———

——————————

—49

131721

253034384246

51555756555352

504948464543

424139383635

343231292827

252422212018

171514

——————————

——————

——————

———

247

10

131618212427

303235384144

464952555860

636669727477

808386

——————————

——————

——————

———————

——————

——————

——————

——————

———

262728

303133343537

383941424445

464849515253

55565758596062

636566676970

727374767779

808183848687

889091939495

9798

100



No. 2Key

No. 1Key

No. 3Key

No. 4Key

TotalStraightFt In

RING COMBINATIONS


9 Inch Lining — 3 Inch Key Brick9 x 41/2 x 3 Inch — Continued

101010

111111111111

121213131414

151516161717

181819192020

212122222323

242425252626

272728282929

303031313232

33333435

68

10

02468

10

060606

060606

060606

060606

060606

060606

060606

0600

——————————

——————

——————

—————————————

——————

——————

——————

————

——————————

——————

——————

—————————————

——————

——————

——————

————

131110

976432

——————

——————

—————————————

——————

——————

——————

————

889194

96100102105108110

113113113113113113

113113113113113113

113113113113113113

113113113113113113

113113113113113113

113113113113113113

113113113113113113

113113113113

——————————

—59

131721

263034384247

515559636872

768084889397

101105109114118122

126130135139143147

151155160164168172

176181185193

101102104

105107108109111112

113118122126130134

139143147151155160

164168172176181185

189193197201206210

214218222227231235

239243248252256260

264268273277281285

289294298306



No. 2Key

No. 1Key

No. 3Key

No. 4Key TotalStraightFt In

9 Inch Lining — 3 Inch Key Brick9 x 6 x 3 Inch

111

222222

333333

444444

555555

666666

777777

888888

999999

68

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

191818

171615151414

1312121110

9

987765

543221

——————

——————

——————

——————

—23

579

111314

161819212325

262830313335

363840424345

484746454443

414039383736

343332313028

272625242322

———

——————

——————

——————

——————

—2468

10

131517192123

262830323437

394143464850

———

——————

——————

——————

——————

——————

——————

——————

——————

192021

222324262728

293031323334

353637383940

414243444546

484950515253

545556575859

606162636465

666768707172

*NOTE: For brickwork of inside diameters less than 6 feet, involving the use of 9 x 6 inch No. 3 Keys which have a very sharp taper, a better bricklaying fit can be obtained by the use of the 9 x 41/2 inch Key-brick combinations.


No. 1Key

No. 2Key


RING COMBINATIONS


9 Inch Lining — 3 Inch Key Brick9 x 6 x 3 Inch — Continued

101010101010

111111111111

121212121212

131314141515

161617171818

192021222324

252627282930

313233343536

3738394041

02468

10

02468

10

02468

10

060606

060606

000000

000000

000000

00000

——————

——————

——————

——————

——————

——————

——————

——————

—————

211918171615

13121110

98

65432

—

——————

——————

——————

——————

——————

—————

525557596163

666870727476

798183858790

919191919191

919191919191

919191919191

919191919191

919191919191

9191919191

——————

——————

——————

—47

101316

192226293235

384451576370

76828895

101107

114120126132139145

151158164170176

737475767778

798081828384

858687888990

919598

101104107

110113117120123126

129135142148154161

167173179186192198

205211217223230236

242249255261267


No. 1Key

No. 2Key

No. 3Key

TotalStraightFt In

9 Inch Lining — Rotary Kiln Blocks9 x 9 x 4 Inch

555555

555555

666666

666666

777777

777777

012345

6789

1011

012345

6789

1011

012345

6789

1011

60-7828231814 9 5

66-843025201510 5

72-903226211611 6

78-963428231711 6—

82-1023630241812 6—

90-1083831251913 7

66-84— 510152024

72-90— 510162126

78-96— 612172228

84-102— 612182430

90-108— 613192532

96-114— 714202633

282828292929

303030313131

323233333334

343435353536

363637373738

383839393940

NOTE: In orders, the complete names of the blocks should be given, as for example “60-78 RKB.”


TotalFt In

RING COMBINATIONS


9 Inch Lining — Rotary Kiln Blocks9 x 9 x 4 Inch — Continued

888888

888888

999999

999

999

101010

012345

6789

1011

012345

678

91011

012

96-1144034272014 7

102-1204235282114 7

108-1264437292215 7

114-132463115

117-135483216

120-138493216

102-120— 714212835

108-126— 815223037

114-132— 816233139

117-135—1632

120-138—1632

123-141—1713

404141414242

424343434444

444545454646

464747

484848

494949



TotalFt In


101010

101010101010

111111111111

111111111111

121212121212

121212121212

131313131313

345

6789

1011

012345

6789

1011

012345

6789

1011

012345

123-141503316

126-1445142342517 8

132-1505344352618 9

138-1565545372718 9

144-162574738281910

150-168594939292010

156-174615141302110

126-144—1734

132-150— 917273544

138-156— 918283646

144-162—1019293848

150-168—1020303949

156-174—1021314051

162-180—1021324253

505050

515151525252

535353545455

555556565657

575758585859

595960606061

616162626363



TotalFt In

RING COMBINATIONS



131313131313

141414141414

141414141414

151515151515

151515151515

161616161616

161616161616

6789

1011

012345

6789

1011

012345

6789

1011

012345

6789

1011

162-180635342312111—

168-186655443322211—

174-192675645332311

180-198705846352312

186-204726048362412

192-210746149372512

198-216766350382513

168-186—1122334454

174-192—1223344556

180-198—1223354658

186-204—1224364859

192-210—1224374961

198-216—1325385063

204-222—1326395265

636464646565

656666666767

676868686969

707070717171

727272737373

747474757575

767676777778



TotalFt In


171717171717

171717171717

181818181818

181818181818

191919191919

191919191919

20—

012345

6789

1011

012345

6789

1011

012345

6789

1011

0

204-222786552392613

210-228806653402714

216-234826855412714

222-240847056422814

228-246867257432914

234-252887459443015

240-25890

210-228—1327405367

216-234—1428415468

222-240—1428425670

228-246—1529435872

234-252—1530445974

240-258—1530456075

——

787879797980

808081818182

828283838384

848585858686

868787878888

888989899090

90



TotalFt In

RING COMBINATIONS


9 Inch Lining — Rotary Kiln Blocks9 x 6 x 4 Inch Wedge Type —Two Shape System

445555

666677778888

9999

1010101011111111

121212121313131314141414

151515151616161617171717

690369

036903690369

036903690369

036903690369

036903690369

666677

7788889999

1010

101011111111121212121313

131314141414151515151616

161617171717181818181919

504438322519

136

——————————

————————————

————————————

————————————

71524324150

586776726864605652484440

36332824211713

951

——

————————————

————————————

——————

———

61319253238445157

636976828894

100107113119117112

108103

98948984797570656056

514642373228231814

94

—

——————

————————————

——————————

613

202734414855636976849198

105112119126133140147154161168175182

575962646669

717376788183858890929597

99102104106109111113116118120123125

128130132135137139142144146149151154

156158161163165168170172175177179182

036903

690369036903

690369036903

690369036903

690369036903

NOTE: For each ring, order two (2) pieces each KW-2/3 and KW-3/4 to facilitate keying. For additional information, see discussion of KA and KW blocks for Rotary Kilns.


KW-1

KW-1X

TotalKW-2

KW-3

InsideLining

Ft In

InsideShell

Ft In

12 Inch Lining — 3 Inch Wedge Brick12 x 41/2 x 3, 12 x 6 x 3 or 12 x 9 x 3 Inch

4444

5555

6666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

76726966

63605754

51474441

38353229

25221916

1310

73

————

————

————

————

————

————

—7

1319

25323844

50576369

75828894

101107113119

126132138145

151148144142

139135132129

126122120117

113110107104

101989591

88858279

————

————

————

————

————

————

—6

1319

25323844

50576369

76828894

100107113120

126132138144

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

76798285

88929598

101104107110

113117120123

126129132135

139142145148

151154157161

164167170173

176179183186

189192195198

201205208211

214217220223



No. 1Wedge

No. 1-XWedge Straight

No. 2Wedge

No. 3Wedge TotalFt In

RING COMBINATIONS


12 Inch Lining — 3 Inch Wedge Brick12 x 41/2 x 3, 12 x 6 x 3 or 12 x 9 x 3 Inch–Cont’d.

16161616

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

————

————

————

————

————

————

————

————

————

————

————

————

76736966

63605754

51474441

38353229

25221916

1310

73

————

————

————

————

————

————

151157164170

176182188195

201208214220

226232239245

252258264270

276283289296

302299295292

289286283280

277273270267

264261258255

251248245242

239236233229

————

————

————

————

————

————

—6

1319

26323844

50576370

76828894

101107114120

126132138145

————

————

————

————

————

————

————

————

————

————

————

————

227230233236

239242245249

252255258261

264267271274

277280283286

289293296299

302305308311

315318321324

327330333337

340343346349

352355359362

365368371374



No. 1Wedge


No. 2Wedge



28282828

29292929

30303030

31313131

32323232

33333333

34343434

35353535

36363636

37373737

38383838

39393939

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

226223220217

214211207204

202198195192

189185182180

176173170167

163160158154

151148145141

138135132129

126123119116

113110107104

101979491

88858279

151158164170

176182189195

201208214220

226233239245

252258264270

277283289296

302308314321

327333340346

352358365371

377384390396

402409415421

428434440446

————

————

————

————

————

————

————

————

————

————

————

————

377381384387

390393396399

403406409412

415418421425

428431434437

440443447450

453456459462

465468472475

478481484487

490494497500

503506509512

516519522525



No. 1Wedge


No. 2Wedge


RING COMBINATIONS



40404040

41414141

42424242

43434343

44444444

45454545

46464646

47474747

48484848

49495050

51515252

53535454

0369

0369

0369

0369

0369

0369

0369

0369

0369

0606

0606

0606

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

76726966

63605754

50474441

38353228

25221916

1310

63

————

————

————

————

————

————

452459465472

478484490496

503509516522

528534540547

553560566572

578584591597

604604604604

604604604604

604604604604

604604604604

604604604604

604604604604

————

————

————

————

————

————

—369

12151822

25283134

37445056

62697581

8894

100106

528531534538

541544547550

553556560563

566569572575

578582585588

591594597600

604607610613

616619622626

629632635638

641648654660

666673679685

692698704710



No. 1Wedge


No. 2Wedge


12 Inch Lining — 3 Inch Key Brick12 x 6 x 3 Inch

101010101010

111111111111

121212121212

131313131313

141414141414

151515151515

161616161616

171717171717

181818181818

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

767574727170

696867666564

636261605958

575655545352

514948474645

444342414039

383736353433

323130292726

252423222120

—2479

11

131517192123

252729323436

384042444648

505355575961

636567697173

757880828486

889092949799

101103105107109111

——————

——————

——————

——————

——————

——————

——————

——————

——————

767778798081

828384858687

888990929394

9596979899

100

101102103104105106

107108109110111112

113115116117118119

120121122123124125

126127128129130131

Number Required Per RingDiam. InsideBrickwork No. 1

KeyNo.2Key TotalStraightFt In

RING COMBINATIONS


12 Inch Lining — 3 Inch Key Brick12 x 6 x 3 Inch — Continued

191919191919

202020202020

212121212121

222222222323

242425252626

272728282929

303031313232

333334343535

363637373838

02468

10

02468

10

02468

10

024606

060606

060606

060606

060606

060606

191817161514

13121110

98

754321

——————

——————

——————

——————

——————

——————

113115117119122124

126128130132134136

138141143145147149

151151151151151151

151151151151151151

151151151151151151

151151151151151151

151151151151151151

151151151151151151

——————

——————

——————

—1236

10

131619222528

323538414447

505457606366

697276798285

88919498

101104

132133134135137138

139140141142143144

145146147148149150

151152153154157161

164167170173176179

183186189192195198

201205208211214217

220223227230233236

239242245249252255


KeyNo. 2Key

TotalStraightFt In

131/2 Inch Lining — 3 Inch Wedge Brick131/2 x 41/2 x 3, 131/2 x 6 x 3 or 131/2 x 9 x 3 Inch

44

5555

6666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

69

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

8582

79767369

66636057

54514744

41383532

29252219

161310

7

3———

————

————

————

————

—6

13192532

38445056

63697682

8894

100107

113120126132

138144151157

164170167163

160157154151

148145141138

135132129126

123119116113

——

————

————

————

————

————

————

——

613

19263238

44505763

70768288

94101107114

——

————

————

————

————

————

————

————

————

————

————

————

——

————

————

————

————

————

————

————

————

————

————

————

8588

929598

101

104107110113

117120123126

129132135139

142145148151

154157161164

167170173176

179183186189

192195198201

205208211214

217220223227



No. 1Wedge


No. 2Wedge

No. 3Wedge

TotalFt In

RING COMBINATIONS


131/2 Inch Lining — 3 Inch Wedge Brick131/2 x 41/2 x 3, 131/2 x 6 x 3 or 131/2 x 9 x 3 Inch – Continued

16161616

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

————

————

————

————

————

————

————

————

————

————

————

————

110107104101

97949288

85827975

72706663

60575350

48444138

35312826

22191613

964

—

————

————

————

120126132138

145151157164

170176182189

195201208214

220226233239

245252258264

270277283289

296302308314

321327333340

336333330327

324321318314

311308305302

————

————

————

————

————

————

————

————

————

7131925

31384451

57636975

————

————

————

————

————

————

————

————

————

————

————

————

230233236239

242245249252

255258261264

267271274277

280283286289

293296299302

305308311315

318321324327

330333337340

343346349352

355359362365

368371374377



No. 1 Wedge

No. 1-X Wedge

Straight

No. 2 Wedge

No. 3 Wedge TotalFt In

28282828

29292929

30303030

31313131

32323232

33333333

34343434

35353535

36363636

37373737

38383838

39393939

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

————

————

————

————

————

————

————

————

————

————

————

————

299296292289

286283280277

274270267264

261258255252

248245242239

236233230227

223220217214

210208205201

198195192188

186183179176

173170166164

161157154151

828895

101

107113119126

132139145151

157163170176

183189195201

207214220226

233239245251

258264270277

283289295302

308314321327

333339346352

358365371377

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

381384387390

393396399403

406409412415

418421425428

431434437440

443447450453

456459462465

468472475478

481484487490

494497500503

506509512516

519522525528




No. 1Wedge


No. 2Wedge


RING COMBINATIONS


40404040

41414141

42424242

43434343

44444444

45454545

46464646

47474747

48484848

49494949

50505050

51515151

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

————

148144142139

135132129126

122120117113

110107104101

98959188

85827976

73696663

60575451

47444138

35322925

22191613

1073

—

383390396402

409415421427

434440446453

459465471477

484490497503

509515521528

534541547553

559565572578

585591597603

609616622629

635641647653

660666673679

————

————

————

————

————

————

————

————

————

————

————

————

531534538541

544547550553

556560563566

569572575578

582585588591

594597600604

607610613616

619622626629

632635638641

644648651654

657660663666

670673676679




No. 1Wedge

No. 1-XWedge

Straight

No. 2Wedge


131/2 Inch Lining — 3 Inch Key Brick131/2 x 6 x 3 Inch

22222

333333

444444

555555

666666

777777

888888

999999

101010101010

3468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

02468

10

2928262524

232120191817

1614131211

9

876432

——————

——————

——————

——————

——————

—1468

101315182022

242729313336

384042454749

525149484644

434140383635

333130282624

232119181614

1311

9865

—————

——————

——————

——————

—257

1013

161921242729

323537404346

485154565962

646770737678

—————

——————

——————

——————

——————

——————

——————

——————

——————

2929303132

333435373839

404142434445

464748495051

525354555657

596061626364

656667686970

717273747576

777879818283

*NOTE: For brickwork of inside diameters less than 6 feet, involving the use of 131/2 x 6 inch No. 3 Keys which have a very sharp taper, appreciable cutting may be necessary in some cases to secure the best bricklaying fit.


No. 1Key

No. 2Key


RING COMBINATIONS


131/2 Inch Lining — 3 Inch Key Brick131/2 x 6 x 3 Inch — Continued

11111111

121213131414

151516161717

181819192020

212122222323

242425252626

272728282929

3030313132

33343536

37383940

0236

060606

060606

060606

060606

060606

060606

06060

0000

0000

————

——————

——————

——————

——————

——————

——————

—————

————

————

31

——

——————

——————

——————

——————

——————

——————

—————

————

————

81848585

858585858585

858585858585

858585858585

858585858585

858585858585

858585858585

8585858585

85858585

85858585

———

2

58

11141821

242730333639

434649525558

616568717477

808387909396

99102105109112115

118121124127131

137143149156

162168175181

84858587

90939699

103106

109112115118121124

128131134137140143

146150153156159162

165168172175178181

184187190194197200

203206209212216

222228234241

247253260266


No. 1Key

No. 2Key


15 Inch Lining — 3 Inch Wedge Brick15 x 6 x 3 or 15 x 9 x 3 Inch

55555

6666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

01369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

9594918885

82797573

69666360

57535147

44413835

31292522

191613

9

73

——

————

————

————

————

—27

1319

25313844

51576369

75828895

101107113119

126132139145

151157163170

176183189186

182179176173

170167164160

157154151148

145142138135

—————

————

————

————

————

————

————

———

6

13192532

38445057

63697682

8894

101107

959698

101104

107110113117

120123126129

132135139142

145148151154

157161164167

170173176179

183186189192

195198201205

208211214217

220223227230

233236239242

Number Required Per RingDiam. InsideBrickwork No.2

WedgeNo.1

WedgeNo. 3

Wedge TotalFt In

RING COMBINATIONS


15 Inch Lining — 3 Inch Wedge Brick15 x 6 x 3 or 15 x 9 x 3 Inch — Continued

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

132129126123

120116113110

107104101

98

94918885

82797672

69666360

57545047

44413835

32282522

19161310

63

——

————

113120126132

138145151157

164170176182

189195201208

214220226233

239245252258

264270277283

289296302308

314321327333

340346352358

365371377374

371368365361

————

————

————

————

————

————

————

————

————

————

———

7

13192532

245249252255

258261264267

271274277280

283286289293

296299302305

308311315318

321324327330

333337340343

346349352355

359362365368

371374377381

384387390393


WedgeNo. 1-XWedge



No. 1-XWedge

No. 1Wedge

29292929

30303030

31313131

32323232

33333333

34343434

35353535

36363636

37373737

38383838

39393939

40404040

41414141

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

358355352349

346343339336

333330327324

321317314311

308305302299

295292289286

283280277273

270267264261

258255252248

245242239236

233230226223

220217214211

208204201198

38445157

63697682

8895

101107

113120126132

139145151157

164170176182

189195201208

214220226233

239245251258

264270277283

289295302308

314321327333

339346352358

396399403406

409412415418

421425428431

434437440443

447450453456

459462465468

472475478481

484487490494

497500503506

509512516519

522525528531

534538541544

547550553556


TotalFt In

RING COMBINATIONS



42424242

43434343

44444444

45454545

46464646

47474747

48484848

49494949

50505050

51515252

53535454

55555656

57575858

0369

0369

0369

0369

0369

0369

0369

0369

0369

0606

0606

0606

0606

195192189186

182179176173

170167164160

157154151148

145142138135

132129126123

120116113110

107104101

98

94918885

82766963

57504438

32251913

6———

365371377383

390396402409

415421427434

440446453459

465471478484

490497503509

515522528534

541547553559

566572578585

591603616629

641654666679

691704717729

742754754754

————

————

————

————

————

————

————

————

————

————

————

————

——

713

560563566569

572575578582

585588591594

597600604607

610613616619

622626629632

635638641644

648651654657

660663666670

673679685692

698704710717

723729736742

748754761767

Number Required Per RingDiam. InsideBrickwork No. 1-X

WedgeNo. 1


18 Inch Lining — 3 Inch Wedge Brick18 x 6 x 3 or 18 x 9 x 3 Inch

666666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

17171717

012369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

113112111110107104

101979491

88858279

76726966

63605754

50474441

38353228

25221916

1310

63

————

————

————

—357

1319

25323844

51576369

75828895

101107113119

126132139145

151157163170

176183189195

201207214220

227223220217

214211207205

201198195192

——————

————

————

————

————

————

————

————

————

—7

1319

25313844

51576369

113115116117120123

126129132135

139142145148

151154157161

164167170173

176179183186

189192195198

201205208211

214217220223

227230233236

239242245249

252255258261


WedgeNo. 1

WedgeNo. 3

Wedge TotalFt In

RING COMBINATIONS



18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

29292929

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

189185183179

176173170167

163161157154

151148145141

139135132129

126123119117

113110107104

101979591

88858279

75736966

63605753

51474441

75828895

101107113119

126132139145

151157163170

176183189195

201207214220

227233239245

251258264271

277283289295

302308315321

327333339346

352359365371

————

————

————

————

————

————

————

————

————

————

————

————

264267271274

277280283286

289293296299

302305308311

315318321324

327330333337

340343346349

352355359362

365368371374

377381384387

390393396399

403406409412


WedgeNo. 1-XWedge



30303030

31313131

32323232

33333333

34343434

35353535

36363636

37373737

38383838

39393939

40404040

41414141

42424242

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

38353129

26221916

13974

————

————

————

————

————

————

————

————

————

————

377383390396

402409415421

427434440446

453449446443

440437434431

427424421418

415412409406

402399396393

390387384380

377374371368

365362358355

352349346343

340336333330

————

————

————

—7

1319

25313844

51576369

75828894

101107113119

126132138145

151157163170

176182189195

201207214220

226233239245

415418421425

428431434437

440443447450

453456459462

465468472475

478481484487

490494497500

503506509512

516519522525

528531534538

541544547550

553556560563

566569572575


WedgeNo. 1-XWedge


RING COMBINATIONS



43434343

44444444

45454545

46464747

48484949

50505151

52525353

54545555

56565757

58585959

60616263

64656667

68697071

0369

0369

0369

0606

0606

0606

0606

0606

0606

0606

0000

0000

0000

327324321318

314311308305

302299296292

289283277270

264258252245

239233226220

214208201195

189182176170

164157151145

138132126120

113101

8876

63513825

13———

251258264270

277283289295

302308314321

327339352365

377390402415

427440453465

478490503515

528541553566

578591603616

629641654666

679704729754

779804829855

880905905905

————

————

————

————

————

————

————

————

————

————

————

————

——1325

578582585588

591594597600

604607610613

616622629635

641648654660

666673679685

692698704710

717723729736

742748754761

767773780786

792805817830

842855867880

893905918930

Number Required Per RingDiam. InsideBrickwork No. 1-X

WedgeNo. 1


RING COMBINATIONS


BRICK COMBINATIONS REQUIRED FOR ARCHESThe following tables are useful in estimating the quantities of brickrequired for the construction of arches. These tables give the combina-tions of brick sizes required for arches of given spans and rises.

In calculating the tables, no allowance was made for mortar orexpansion joints or for size deviations of the brick. Fractional partsequal to or greater than one tenth of a brick were counted as an entirebrick. For these reasons, the number of brick required for an arch, asgiven in the tables, may be slightly in excess of the number actuallyrequired.

In laying an arch course of brick, it is often necessary to cut one ortwo pieces, and in some instances several pieces, to complete the course.

For the brick combinations required for arches not included in thefollowing tables, or to determine the dimensions or other numericalcharacteristics of arches, refer to the arch formulas found on page UR - 28, which detail arch calculations.

ARCH COMBINATIONS


41/2 Inch Arch Thickness — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

111111111111

222222222222

333333333333

44444

5566

0123456789

1011

0123456789

1011

0123456789

1011

01236

0606

119/32

1 3/4 1 7/8 2 2 5/32

2 9/32

213/32

217/32

211/16

213/16

215/16

3 3/32

3 7/32

311/32

315/32

3 5/8 3 3/4 3 7/8 4 1/32

4 5/32

4 9/32

4 7/16

4 9/16

411/16

413/16

431/32

5 3/32

5 7/32

511/32

5 1/2 5 5/8 5 3/4 529/32

6 1/32

6 5/32

6 9/32

6 7/16

6 9/16

611/16

627/32

7 1/4

8 1/32

827/32

921/32

10 7/16

111111111111

222222222222

333333333333

44444

5566

0123456789

1011

0123456789

1011

0123456789

1011

01236

0606

44333222111—

————————————

————————————

—————

————

234456678899

998887776665

554443322211

1————

————

———————————

1

123345567789

101011121213141515161717

1819191919

19191919

————————————

————————————

————————————

———

12

468

10

6777888999

1010

101111111212121313131414

151515161616171717181818

1919192021

23252729

SpanFt In

RiseFt In

InsideRadius

Ft In

Number Required Per Course

No. 3 No. 2 No. 1 Arch Arch Arch Straight Total

41/2 Inch Arch Thickness — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch2 Inch Rise Per Foot of Span

11

111111111111

222222222222

333333

4444444

5566

0123456789

1011

0123456789

1011

02468

10

02468

1011

0606

2 2 5/32

211/32

2 1/2 221/32

227/32

3 3 5/32

311/32

3 1/2 321/32

327/32

4 4 5/32

411/32

4 1/2 421/32

427/32

5 5 5/32

511/32

5 1/2 521/32

527/32

6 611/32

621/32

7 711/32

721/32

8 811/32

821/32

9 911/32

921/32

927/32

1011 0 1

111111111

111112222222

222233

3333344

4455

101027/32

1121/32

0 1/2 111/32

2 5/32

3 327/32

421/32

5 1/2 611/32

7 5/32

8 827/32

921/32

10 1/21111/32

0 5/32

1 127/32

221/32

3 1/2 411/32

5 5/32

6 721/32

911/32

11 021/32

211/32

4 521/32

711/32

91021/32

011/32

1 5/32

2 7 0 5

655544432222

111—————————

——————

———————

————

122344567889

1010111211111110101099

887665

433211

—

————

————————————

————12234456

78

10111214

15171820212223

23232323

————————————

————————————

——————

———————

1357

777888999

101011

111112121213131314141415

151617171819

19202122222323

24262830

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 3 No. 2 No. 1 Arch Arch Arch

Straight Total

ARCH COMBINATIONS


41/2 Inch Arch Thickness — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch2.302 Inch (2 5/16 Inch) Rise Per Foot of Span

111111111111

22222222

333333

444444

555555

66

0123456789

1011

0123468

10

02468

10

02468

10

02468

10

06

1111

11

2 5/16

2 1/2 211/16

2 7/8 3 1/16

3 1/4 315/32

321/32

327/32

4 1/32

4 7/32

413/32

419/32

425/32

5 5 3/16

5 3/8 5 3/4 6 1/8 617/32

629/32

7 9/32

711/16

8 1/16

8 7/16

813/16

9 7/32

919/32

931/32

10 3/810 3/411 1/8

11 1/21129/32

0 9/32

021/32

1 1/16

1 7/16

113/16

231/32

1111111

11111112

222222

233333

333444

44

831/32

923/32

1015/32

11 7/32

1131/32

023/32

115/32

2 3/16

215/16

311/16

4 7/16

5 3/16

515/16

611/16

7 7/16

8 3/16

815/16

10 7/16

1129/32

113/32

229/32

413/32

529/32

713/32

8 7/810 3/8

11 7/8 1 3/8 2 7/8 4 3/8 527/32

711/32

827/32

1011/32

1127/32

111/32

213/16

4 5/16

513/16

10 5/16

766655544333

22211———

——————

——————

——————

——

—12234466788

910101112141312

111010

987

766543

321

———

——

————————————

——————

13

5679

1112

131516171921

222325272727

2727

————————————

————————

——————

——————

—————

1

24

7788899

1010101111

1112121213141415

161617181919

202122222324

252526272728

2931

SpanFt In

RiseFt In

InsideRadius

Ft In



41/2 Inch Arch Thickness — 3 Inch Arch Brick9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch11/2 Inch Rise Per Foot of Span

111111111111

222222222222

333333333333

4444

5555

66

0123456789

1011

0123456789

1011

0123456789

1011

0369

0369

06

1 1/21 5/81 3/41 7/82 2 1/82 1/42 3/82 1/22 5/82 3/42 7/8

3 3 1/83 1/43 3/83 1/23 5/83 3/43 7/84 4 1/84 1/44 3/8

4 1/24 5/84 3/44 7/85 5 1/85 1/45 3/85 1/25 5/85 3/45 7/8

6 6 3/86 3/47 1/8

7 1/27 7/88 1/48 5/8

9 9 3/4

111111111112

222222222233

333333333344

4445

5556

66

0 3/4 113/16

2 7/8 315/16

5 6 1/16

7 1/8 8 3/16

9 1/410 5/16

11 3/8 0 7/16

1 1/2 2 9/16

3 5/8 411/16

5 3/4 6 3/16

7 7/8 815/16

1011 1/16

0 1/8 1 3/16

2 1/4 3 5/16

4 3/8 5 7/16

6 1/2 7 9/16

8 5/8 911/16

10 3/41113/16

0 7/8 115/16

3 6 3/16

9 3/8 0 9/16

3 3/4 615/16

10 1/8 1 5/16

4 1/210 7/8

333222111

———

————————————

————————————

————

————

——

334556778998

887776665554

443332221

———

————

————

——

——————————

12

23445667889

10

101112121314141516171818

18181818

18181818

1818

————————————

————————————

————————————

1234

5678

911

6677788899

1010

101111111212121313131414

141515151616161717171818

19202122

23242526

2729

SpanFt In

RiseFt In

InsideRadius

Ft In



ARCH COMBINATIONS


9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch11/2 Inch Rise Per Foot of Span

111111

222222222222

333333333333

444444444444

555555

6789

1011

0123456789

1011

0123456789

1011

0123456789

1011

012345

2 1/4 2 3/8 2 1/2 2 5/8 2 3/4 2 7/8

3 3 1/8 3 1/4 3 3/8 3 1/2 3 5/8 3 3/4 3 7/8 4 4 1/8 4 1/4 4 3/8

4 1/2 4 5/8 4 3/4 4 7/8 5 5 1/8 5 1/4 5 3/8 5 1/2 5 5/8 5 3/4 5 7/8

6 6 1/8 6 1/4 6 3/8 6 1/2 6 5/8 6 3/4 6 7/8 7 7 1/8 7 1/4 7 3/8

7 1/2 7 5/8 7 3/4 7 7/8 8 8 1/8

111112

222222222233

333333333344

444444444555

555555

7 1/8 8 3/16

9 1/410 5/16

11 3/8 0 7/16

1 1/2 2 9/16

3 5/8 411/16

5 3/4 613/16

7 7/8 815/16

10 11 1/16

0 1/8 1 3/16

2 1/4 3 5/16

4 3/8 5 7/16

6 1/2 7 9/16

8 5/8 911/16

10 3/41113/16

0 7/8 115/16

3 4 1/16

5 1/8 6 3/16

7 1/4 8 5/16

9 3/810 7/16

11 1/2 0 9/16

1 5/8 211/16

3 3/4 413/16

5 7/8 615/16

8 9 1/16

988877

766655544433

322111

——————

————————————

——————

122344

5667889

1010111212

131415161617181817171616

161515151414141313131212

121211111110

——————

————————————

————————

2234

45667889

10101112

121314141516

101010111111

121212131313141414151515

161617171718181819191920

202021212122222223232324

242525252626

NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No. 1, 2, and 3 arch brick for the corresponding wedge brick.

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 3 No. 2 No. 1 Wedge Wedge Wedge

NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No. 1 and 2 arch brick for the corresponding wedge brick.

9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.11/2 Inch Rise Per Foot of Span

555555

666666666666

777777777777

8899

1010

111112121313

141415

6789

1011

0123456789

1011

0123456789

1011

060606

060606

060

111111

111111

111

8 1/4 8 3/8 8 1/2 8 5/8 8 3/4 8 7/8

9 9 1/8 9 1/4 9 3/8 9 1/2 9 5/8 9 3/4 9 7/810 10 1/810 1/410 3/8

10 1/210 5/810 3/410 7/811 11 1/811 1/411 3/811 1/211 5/811 3/411 7/8

0 0 3/4 1 1/2 2 1/4 3 3 3/4

4 1/2 5 1/4 6 6 3/4 7 1/2 8 1/4

9 9 3/410 1/2

556666

666666667777

777777788888

899

101011

111212131314

141515

10 1/811 3/16

0 1/4 1 5/16

2 3/8 3 7/16

4 1/2 5 9/16

6 5/8 711/16

8 3/4 913/16

10 7/81115/16

1 2 1/16

3 1/8 4 3/16

5 1/4 6 5/16

7 3/8 8 7/16

9 1/210 9/16

11 5/8 011/16

1 3/4 213/16

3 7/8 415/16

6 0 3/8 6 3/4 1 1/8 7 1/2 1 7/8

8 1/4 2 5/8 9 3 3/8 9 3/4 4 1/8

10 1/2 4 7/811 1/4

1099888

777666555444

333322211

———

——————

——————

———

161818192020

212222232424252626272828

293030313232333434363636

363636363636

363636363636

363636

——————

————————————

————————————

13579

11

131517192124

262830

262727272828

282929293030303131313232

323333343434353535363636

373941434547

495153555760

626466

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 2 No. 1 Wedge Wedge Total Straight Total

ARCH COMBINATIONS


ARCH COMBINATIONS


9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch2 Inch Rise Per Foot of Span

NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No. 1, 2, and 3 arch brick for the corresponding wedge brick.

11

222222222222

333333333333

444444444444

555555555555

1011

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

321/32

327/32

4 4 5/32

411/32

4 1/2 421/32

427/32

5 5 5/32

511/32

5 1/2 521/32

527/32

6 6 5/32

611/32

6 1/2 621/32

627/32

7 7 5/32

711/32

7 1/2 721/32

727/32

8 8 5/32

811/32

8 1/2 821/32

827/32

9 9 5/32

911/32

9 1/2 921/32

927/32

1010 5/32

1011/32

10 1/21021/32

1027/32

1111 5/32

1111/32

11 1/21121/32

1127/32

11

111112222222

222222223333

333333333344

444444444444

611/32

7 5/32

8 827/32

921/32

10 1/21111/32

0 5/32

1 127/32

221/32

3 1/2 411/32

5 5/32

6 627/32

721/32

8 1/2 911/32

10 5/32

111127/32

021/32

1 1/2 211/32

3 5/32

4 427/32

521/32

6 1/2 711/32

8 5/32

9 927/32

1021/32

11 1/2 011/32

1 5/32

2 227/32

321/32

4 1/2 511/32

6 5/32

7 727/32

821/32

9 1/21011/32

11 5/32

1211

11101010

99988877

766555444333

222111

——————

————————————

—1

23445667889

10

101112131414151616171818

192020212222242323222221

212120202019191919181817

——

————————————

————————————

———————

11334

55677899

10111113

1212

131314141415151516161617

171718181919192020202121

212222222323242424252525

262626272727282829292930

SpanFt In

RiseFt In

InsideRadius

Ft In



9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.2 Inch Rise Per Foot of Span


666666666666

777777777777

888888888888

999999

10101112131415

0123456789

1011

0123456789

1011

0123456789

1011

02468

10

0600000

111111111111

111111111111

111111111111

111111

1112222

0 0 5/32

011/32

0 1/2 021/32

027/32

1 1 5/32

111/32

1 1/2 121/32

127/32

2 2 5/32

211/32

2 1/2 221/32

227/32

3 3 5/32

311/32

3 1/2 321/32

327/32

4 4 5/32

411/32

4 1/2 421/32

427/32

5 5 5/32

511/32

5 1/2 521/32

527/32

6 611/32

621/32

7 711/32

721/32

8 910 0 2 4 6

555555555555

555666666666

666667777777

777788

889

10101112

0 027/32

121/32

2 1/2 311/32

4 5/32

5 527/32

621/32

7 1/2 811/32

9 5/32

10 1027/32

1121/32

0 1/2 111/32

2 5/32

3 327/32

421/32

5 1/2 611/32

7 5/32

8 827/32

921/32

10 1/21111/32

0 5/32

1 127/32

221/32

3 1/2 411/32

5 5/32

6 721/32

911/32

11 021/32

211/32

4 9 2 010 8 6

171616161515151514141413

13121211111110101010

99

988776665555

44321

—

———————

131415151617171819192021

212323242525262727282929

303131333334353536373738

394041434546

47474747474747

————————————

————————————

————————————

——————

—249

131722

303031313132323333333434

343535353636363737383838

393939404040414141424243

434444454646

47495156606469

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 2 No. 1 Wedge WedgeTotal Straight Total

ARCH COMBINATIONS


9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch2.302 Inch (2 5/16 Inch) Rise Per Foot of Span

NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No. 1, 2 and 3 arch brick for the corresponding wedge brick.

222222222222

333333333333

444444444444

555555555555

0123456789

1011

0123456789

1011

0123456789

1011

0123456789

1011

111111111

419/32

425/32

5 5 3/16

5 3/8 5 9/16

5 3/4 515/16

6 1/8 611/32

617/32

623/32

629/32

7 3/32

7 9/32

715/32

711/16

7 7/8 8 1/16

8 1/4 8 7/16

8 5/8 813/16

9 1/32

9 7/32

913/32

919/32

925/32

931/32

10 5/32

10 3/810 9/16

10 3/41015/16

11 1/811 5/16

11 1/21123/32

1129/32

0 3/32

0 9/32

015/32

021/32

027/32

1 1/16

1 1/4 1 7/16

1 5/8

111111111222

222222222222

233333333333

333334444444

515/16

611/16

7 7/16

8 3/16

815/16

911/16

10 7/16

11 5/32

1129/32

021/32

113/32

2 5/32

229/32

321/32

413/32

5 5/32

529/32

621/32

713/32

8 1/8 8 7/8 9 5/810 3/811 1/8

11 7/8 0 5/8 1 3/8 2 1/8 2 7/8 3 5/8 4 3/8 5 3/32

527/32

619/32

711/32

8 3/32

827/32

919/32

1011/32

11 3/32

1127/32

019/32

111/32

2 1/16

213/16

3 9/16

4 5/16

5 1/16

141313121211111110101010

998877766665

44433332221

—

————————————

—11334556778

99

11111213131415151617

181919202121222323242526

272626262525252424232323

————————————

————————————

————————————

—11234456778

141414151515161616171718

181819191920202021212222

222323232424252525262626

272727282829292930303031

SpanFt In

RiseFt In

InsideRadius

Ft In



9 Inch Arch Thickness — 3 Inch Wedge Brick9 x 41/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.2.302 Inch (2 5/16 Inch) Rise Per Foot of Span


666666666666

777777777777

888888

999999

101010101010

111112131415

0123456789

1011

0123456789

1011

02468

10

02468

10

02468

10

060000

111111111111

111111111111

111111

111111

111222

222222

113/16

2 2 3/16

2 3/8 219/32

225/32

231/32

3 5/32

311/32

317/32

323/32

315/16

4 1/8 4 5/16

4 1/2 411/16

4 7/8 5 1/16

5 9/32

515/32

521/32

527/32

6 1/32

6 7/32

613/32

613/16

7 3/16

7 9/16

731/32

811/32

823/32

9 3/32

9 1/2 9 7/810 1/410 5/8

11 1/32

1113/32

1125/32

0 3/16

0 9/16

015/16

1 5/16

215/32

3 5/8 515/16

8 1/41017/32

444444444555

555555555555

566666

666777

777778

8889

1011

513/16

6 9/16

7 5/16

8 1/16

813/16

9 9/16

10 5/16

11 1/32

1125/32

017/32

1 9/32

2 1/32

225/32

317/32

4 9/32

5 1/32

525/32

617/32

7 9/32

8 1/32

8 3/4 9 1/210 1/411

11 3/4 1 1/4 2 3/4 4 1/4 523/32

7 7/32

823/32

10 7/32

1123/32

1 7/32

211/16

4 3/16

511/16

7 3/16

811/16

10 3/16

1121/32

1 5/32

221/32

7 5/32

11 5/8 819/32

5 9/16

217/32

222222212120202019191918

181817171616161515151414

141312111110

988766

543321

——————

99

10111213131415151617

171819202121222323242525

262829313234

353738394142

444547485051

535353535353

————————————

————————————

——————

——————

——————

—249

1318

313132323333333434343535

353636373737383838393939

404141424344

444546464748

494950515252

535557626671

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 2 No. 1 Wedge Wedge Total Straight Total

ARCH COMBINATIONS


12 Inch Arch Thickness — 3 Inch Wedge Brick12 x 41/2 x 3,12 x 6 x 3 or 12 x 9 x 3 Inch1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

6666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

11

1111

1111

1111

1111

1111

1111

1111

2222

921/32

10 1/16

10 7/16

1027/32

11 1/41121/32

0 1/16

015/32

0 7/8 1 1/4 121/32

2 1/16

215/32

2 7/8 3 9/32

311/16

4 1/16

415/32

4 7/8 5 9/32

511/16

6 3/32

6 1/2 6 7/8

7 9/32

711/16

8 3/32

8 1/2

829/32

9 5/16

911/16

10 3/32

10 1/21029/32

11 5/16

1123/32

0 1/8 017/32

029/32

1 5/16

6666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

21201918

17161514

13121110

8765

4431

————

————

————

————

————

9111315

17192123

25272931

34363840

42444649

51504847

46454443

42414039

38373635

34323231

————

————

————

————

————

—257

9111315

17192123

25272931

33363840

30313233

34353637

38394041

42434445

46484950

51525354

55565758

59606162

63646566

67687071

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 2 No. 1 No. 1-X Wedge Wedge Wedge

12 Inch Arch Thickness — 3 Inch Wedge Brick12 x 41/2 x 3,12 x 6 x 3 or 12 x 9 x 3 Inch–Cont’d.1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

16161616

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

2222

2222

2222

2222

2222

2222

2233

3333

3333

3333

123/32

2 1/8 217/32

215/16

311/32

323/32

4 1/8 417/32

415/16

511/32

5 3/4 6 5/32

617/32

615/16

711/32

7 3/4

8 5/32

8 9/16

831/32

911/32

9 3/410 5/32

10 9/16

1031/32

11 3/81125/32

0 3/16

0 9/16

031/32

1 3/8 125/32

2 3/16

219/32

3 3 3/8 325/32

4 3/16

419/32

5 513/32

16161616

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

30292827

25242322

21201918

17161514

13121010

9876

5321

————

————

————

42444648

51535557

59616365

67697173

75778082

84868890

92959799

101101101101

101101101101

101101101101

————

————

————

————

————

————

————

—123

4567

89

1011

72737475

76777879

80818283

84858687

88899092

93949596

979899

100

101102103104

105106107108

109110111112

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 1 No. 1-X Wedge Wedge Total Straight Total

ARCH COMBINATIONS


131/2 Inch Arch Thickness — 3 Inch Wedge Brick131/2 x 41/2 x 3, 131/2 x 6 x 3 or 131/2 x 9 x 3 Inch1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

6666

7777

8888

9999

10101010

11111111

1212121212

13131313

14141414

15151515

16161616

0369

0369

0369

0369

0369

0369

03

4 1/269

0369

0369

0369

0369

11

1111

1111

1111

1111

11111

1111

1111

2222

2222

921/32

10 1/16

10 7/16

1027/32

11 1/41121/32

0 1/16

015/32

0 7/8 1 1/4 121/32

2 1/16

215/32

2 7/8 3 9/32

311/16

4 1/16

415/32

4 7/8 5 9/32

511/16

6 3/32

6 1/2 6 7/8

7 9/32

711/16

7 29/32

8 3/32

8 1/2

829/32

9 5/16

911/16

10 3/32

10 1/21029/32

11 5/16

1123/32

0 1/8 017/32

029/32

1 5/16

123/32

2 1/8 217/32

2 15/16

6666

7777

8888

9999

10101010

11111111

1212121212

13131313

14141414

15151515

16161616

0369

0369

0369

0369

0369

0369

03

4 1/269

0369

0369

0369

0369

27262524

22212120

19181716

14131211

10987

6543

21

———

————

————

————

————

3579

12141618

20222426

29313335

37394143

45474951

5355575655

54535251

50494847

46454443

41403938

————

————

————

————

————

————

———

14

68

1012

14161820

22242628

31333537

30313233

34353738

39404142

43444546

47484950

51525354

5556575759

60616263

64656667

68697071

72737475

SpanFt In

RiseFt In

InsideRadius

Ft In



17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252626

27272828

29293030

0369

0369

0369

0369

0369

0369

0369

0369

0606

0606

0606

2222

2222

2222

2222

2222

2233

3333

3333

3333

3333

3344

311/32

323/32

4 1/8 417/32

415/16

511/32

5 3/4 6 5/32

617/32

615/16

711/32

7 3/4

8 5/32

8 9/16

831/32

911/32

9 3/410 5/32

10 9/16

1031/32

11 3/81125/32

0 3/16

0 9/16

031/32

1 3/8 125/32

2 3/16

219/32

3 3 3/8 325/32

4 3/16

5 513/16

619/32

713/32

8 7/32

9 913/16

10 5/811 7/16

0 7/32

1 1/32

17171717

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252626

27272828

29293030

0369

0369

0369

0369

0369

0369

0369

0369

0606

0606

0606

37363534

33323130

29282726

25242322

21191817

16151413

121210

9

8765

42

——

————

————

39414345

48505254

56586062

64666870

72757779

81838587

89919496

98100102104

106110113113

113113113113

113113113113

————

————

————

————

————

————

————

————

——

13

579

11

14161820

76777879

81828384

85868788

89909192

93949596

979899

100

101103104105

106107108109

110112114116

118120122124

127129131133

131/2 Inch Arch Thickness — 3 Inch Wedge Brick131/2 x 41/2 x 3, 131/2 x 6 x 3 or 131/2 x 9 x 3 Inch – Continued1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 1 No. 1-X Wedge Wedge

Total Straight Total

ARCH COMBINATIONS


15 Inch Arch Thickness — 3 Inch Wedge Brick15 x 6 x 3 or 15 x 9 x 3 Inch1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

17171717

369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

11

1111

1111

1111

1111

1111

1111

1111

2222

2222

2222

10 1/16

10 7/16

1027/32

11 1/41121/32

0 1/16

015/32

0 7/8 1 1/4 121/32

2 1/16

215/32

2 7/8 3 9/32

311/16

4 1/16

415/32

4 7/8 5 9/32

511/16

6 3/32

6 1/2 6 7/8

7 9/32

711/16

8 3/32

8 1/2

829/32

9 5/16

911/16

10 3/32

10 1/21029/32

11 5/16

1123/32

0 1/8 017/32

029/32

1 5/16

123/32

2 1/8 217/32

215/16

311/32

323/32

4 1/8 417/32

666

7777

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

17171717

369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

323130

28272625

24232221

20191817

16151413

121110

9

8754

321

—

————

————

————

————

—24

79

1113

15171921

23252729

32343638

40424446

48505355

57596163

62616059

58575655

54535251

49484746

———

————

————

————

————

————

————

————

2468

10131517

19212325

28303234

323334

35363738

39404142

43444546

48495051

52535455

56575859

60616263

64656667

68707172

73747576

77787980

SpanFt In

RiseFt In

InsideRadius

Ft In



15 Inch Arch Thickness — 3 Inch Wedge Brick15 x 6 x 3 or 15 x 9 x 3 Inch — Continued1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

29293031

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0600

2222

2222

2222

2222

2233

3333

3333

3333

3333

3333

3333

3344

415/16

511/32

5 3/4 6 5/32

617/32

615/16

711/32

7 3/4

8 5/32

8 9/16

831/32

911/32

9 3/410 5/32

10 9/16

1031/32

11 3/81125/32

0 3/16

0 9/16

031/32

1 3/8 125/32

2 3/16

219/32

3 3 3/8 325/32

4 3/16

419/32

5 513/32

513/16

6 3/16

619/32

7

713/32

713/16

8 7/32

8 5/8

9 913/32

913/16

10 7/32

10 5/811 7/16

0 7/32

127/32

18181818

19191919

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

29293031

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0600

45444342

41403938

37363534

33323130

29282625

24232221

20191817

16151413

121110

9

8764

321

—

————

36384042

44464850

52545759

61636567

69717476

78808284

86889092

949698

100

103105107109

111113115118

120122124126

126126126126

————

————

————

————

————

————

————

————

————

————

————

1359

81828384

85868788

89909293

94959697

9899

100101

102103104105

106107108109

110111112113

115116117118

119120121122

123124125126

127129131135

SpanFt In

RiseFt In

InsideRadius

Ft In


No. 1 No. 1-X Wedge Wedge Total Straight Total

ARCH COMBINATIONS


18 Inch Arch Thickness — 3 Inch Wedge Brick18 x 6 x 3 or 18 x 9 x 3 Inch1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

17171717

18181818

19191919

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

1111

1111

1111

1111

1111

1111

1111

2222

2222

2222

2222

2222

0 7/8 1 1/4 121/32

2 1/16

215/32

2 7/8 3 9/32

311/16

4 1/16

415/32

4 7/8 5 9/32

511/16

6 3/32

6 1/2 6 7/8

7 9/32

711/16

8 3/32

8 1/2

829/32

9 5/16

911/16

10 3/32

10 1/21029/32

11 5/16

1123/32

0 1/8 017/32

029/32

1 5/16

123/32

2 1/8 217/32

215/16

311/32

323/32

4 1/8 417/32

415/16

511/32

5 3/4 6 5/32

617/32

615/16

711/32

7 3/4

8888

9999

10101010

11111111

12121212

13131313

14141414

15151515

16161616

17171717

18181818

19191919

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

36353432

31302929

28272524

23222120

19181716

15141312

11987

7654

21

——

————

————

————

468

11

13151719

21232628

30323436

38404244

46485052

54575961

63656769

72747675

74727170

69686766

65646362

————

————

————

————

————

————

————

————

———

2

479

11

13151719

21232527

40414243

44454648

49505152

53545556

57585960

61626364

65666768

70717273

74757677

78798081

82838485

86878889

SpanFt In

RiseFt In

InsideRadius

Ft In



18 Inch Arch Thickness — 3 Inch Wedge Brick18 x 6 x 3 or 18 x 9 x 3 Inch — Continued1.608 Inch (119/32 Inch) Rise Per Foot of Span(60° Central Angle)

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

29292929

30303030

31313131

32

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0

2222

2222

2233

3333

3333

3333

3333

3333

3333

3333

4444

4444

4

8 5/32

8 9/16

831/32

911/32

9 3/410 5/32

10 9/16

1031/32

11 3/81125/32

0 3/16

0 9/16

031/32

1 3/8 125/32

2 3/16

219/32

3 3 3/8 325/32

4 3/16

419/32

5 513/32

513/16

6 3/16

619/32

7

713/32

713/16

8 7/32

8 5/8

9 913/32

913/16

10 7/32

10 5/811 1/32

11 7/16

1113/16

0 7/32

0 5/8 1 1/32

1 7/16

127/32

2 1/4 221/32

3 1/32

3 7/16

20202020

21212121

22222222

23232323

24242424

25252525

26262626

27272727

28282828

29292929

30303030

31313131

32

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0369

0

————

————

————

————

————

————

————

————

————

————

————

————

—

61605958

57565554

53525049

48474645

44434241

40393837

36353433

32313029

27262524

23222120

19181716

15141312

11

29323436

38404244

46485153

55575961

63656769

71737578

80828486

88909294

9799

101103

105107109111

113115117119

122124126128

130

90929394

95969798

99100101102

103104105106

107108109110

111112113115

116117118119

120121122123

124125126127

128129130131

132133134135

137138139140

141

SpanFt In

RiseFt In

InsideRadius

Ft In



Total Total

ARCH COMBINATIONS



The following simple formulas make it possible to calculate the areaand volume associated with most refractory structures. No matterhow complex the shape of a figure, it is possible to derive a workingapproximation by dividing it by straight lines and arcs into a distinctnumber of units whose areas may be calculated and summed by simplearithmetic. Volumes of regular figures will equal the area of a surfacemultiplied by its length or height. Volumes of shells are inside volumesubtracted from outside volume.

RECTANGLE

TRIANGLE

TRAPEZIUM REGULAR POLYGON

Area = ab

Area = cd

Area = s(s–a) (s–b) (s–c)

Area = [s(e+d)+bd+ce]Area = nsr

Numberof Sides Area

6 2.5981s2 = 3.4641r2

6 4.8284s2 = 3.3137r2

6 6.1818s2 = 3.2757r2

10 7.6942s2 = 3.2492r2

12 11.1962s2 = 3.2154r2

when n = Number of sides

when s = (a + b+ c)

ab

e

c

b a d

c

s

r

ab

d

c

ba d

PARALLELOGRAM

Area = ab

a

b

a

1/2

1/2

1/21/2

AREA AND VOLUME


Area = LRTangent =

Area = [LR–C(R–h)]

Length of Arc, L = x 2πR =

CIRCLE

SEGMENT OF A CIRCLE

(Theta) = included angle in degrees. Area = 0.7854D2 = πR2

θ

θ

θ

θ

(pi) = 3.1416 Chord. C = 2 h(D–h) = 2R x sine

Height of Arc, h = R – R2 –(C÷2)2

Height of Arc, h = R – (2R+C) (2R–C)

θ

360 0.017453R

Circumference =

Diameter, D = 2R = 2 Area ÷ π

Radius, R = D = Area ÷π

= 28.648L÷R

Sine = C÷2R

1˚ = 0.017453 Radians, 1 radian = 57.296˚

Radius, R = Circumference ÷2π

Radius, R = (C ÷ 2)2+h2 2h

πD = 2πR = 2 π x Area

π

CDR

L

h

1/2

1/2

θ

1/4θ

CR

L

h

1/2

Area = πR2 x

Area = 0.0087266R2Area = πR2 x

C2h

θ

θ

360

θ

360

2C(R–h)

θ1/2

1/2

1/2

θ1/2

SECTOF OF A CIRCLE

θ

R

L

AREA AND VOLUME

THE TRAPEZOIDAL RULE

SEGMENT OF A SPHERE SEGTOR OR A SPHERE

Area = h( y0+ y1+y2 + y3+ y4) approximately

h = distance between equally spaced ordinates

yn = length of appropriate ordinate

Spherical Surface = Total Surface = 1.5708r(4h+ c)

Volume = πr2h = 2.0944r2hTotal Surface = 0.7854(c2 +8rh)

Volume = πh2(3r –h) = 1.0472h2(3r– h)

Volume = πh2(3r –h) = 1.0472h2(3r– h)

Cylindrical Surface =πdh = 2πrh = 6.2832rh

Total Surface =2πr(r+ h) = 6.2832r(r+ h)

Volume =πr2h = πd2h = 0.7854d2h

Volume = πh(3c2 +4h2) = 0.1309h(3c2 +4h2)

2πrh = 0.7854(c2+4h2)

h

1/2

1/24

1/4

1/3

2/3

1/2

h h h

CYLINDER

y0 y1 y2 y3y4

r

c

h

r

c

h

d

h

r


AREA AND VOLUME

Volume = πd3 = 0.5236d3

Volume = πr3 = 4.1888r3

Area = sh

SPANDREL CIRCULAR RING

PARABOLIC SEGMENT

SPHERE

RING OF CIRCULAR CROSS SECTION (Torus)

ELLIPSE

4/3

1/6

2/3Area = πab = 3.1416ab

Surface = 4πr2 = 12.566r2 = πd2

Area of Surface = 4π2Rr = 39.478Rr

Volume = 2π2Rr2 = 19.739Rr2

Area = 0.7854(D2— d2)Area = 0.7854(D+d) (D—d)

Area = 0.2146R2

Area = 0.1073C2

a

b

CR D

d

h

s

d

r

dR

D

r


AREA AND VOLUME

AREA AND VOLUME

PYRAMID

A = area of base

P = perimeter of base

Volume = Ah

Lateral Area = Ps

FRUSTUM OF A PYRAMID

CONE

A = Area of base

a = Area of top

m = Area of midsection

P = Perimeter of base

p = Perimeter of top

Lateral Area = s(P+p)

Volume = h(a +A+ aA)

Volume = h(a +A+4m)

Volume = πr2 h = 1.0472r2h = 0.2618d2h

Conical Area =πrs = πr r2 +h2

hs

1/2

1/3

hs

d

hs

r

1/2

1/3

1/3

1/6


AREA AND VOLUME

FRUSTUM OF A CONE

A = Area of base

Area of Conical Surface = πs(D+d)

a = Area of top

m = Area of midsection

Volume = h(a + aA +A)

Volume = πh(r2 +rR +R2)

Volume = h(a +4m +A)

1/2

1/3

1/6 D

R

hs

rd

86 Harbison-Walker Brick Installation Guide

REFERENCE TABLE


Decimal Fractions of an Inch for Each 1/64

Common CommonFraction Decimal Fraction Decimal

1/2 .5

1/64 .015625 33/64 .5156251/32 .03125 17/32 .531253/64 .046875 35/64 .5468751/16 .0625 9/16 .56255/64 .078125 37/64 .5781253/32 .09375 19/32 .593757/64 .109325 39/64 .609375

1/8 .125 5/8 .625

9/64 .140625 41/64 .6406255/32 .15625 21/32 .65625

11/64 .171875 43/64 .6718753/16 .1875 11/16 .6875

13/64 .203125 45/64 .7031257/32 .21875 23/32 .71875

15/64 .234375 47/64 .734375

1/4 .25 3/4 .75

17/64 .265625 49/64 .7656259/32 .28125 25/32 .78125

19/64 .296875 51/64 .7968755/16 .3125 13/16 .8125

21/64 .328125 53/64 .82812511/32 .34375 27/32 .8437523/64 .359375 55/64 .859375

3/8 .375 7/8 .875

25/64 .390625 57/64 .89062513/32 .40625 29/32 .9062527/64 .421875 59/64 .9218757/16 .4375 15/16 .937529/64 .453125 61/64 .95312515/32 .46875 31/32 .9687531/64 .484375 63/64 .984375

REFERENCE TABLE


Conversion Table

To Convert Multiply By: To Obtain:

BTU 7.7816 x 102 foot-poundsBTU 2.52 x 102 gram-caloriesBTU 2.52 x 10-1 kilogram-caloriesBTU/Hr 7.0 x 10-2 gram-cal/sec

°C (°C x 1.8) + 32 Fahrenheit

centimeters 3.281 x 10-2 feetcentimeters 3.937 x 10-2 inchescubic centimeters 3.531 x 10-5 cubic feetcubic centimeters 6.102 x 10-2 cubic inchescubic centimeters 1.308 x 10-6 cubic yardscubic centimeters 2.642 x 10-4 gallons (U.S. liquid)cubic centimeters 1.0 x 10-3 literscubic feet 2.832 x 104 cubic centimeterscubic feet 1.728 x 103 cubic inchescubic feet 2.832 x 10-2 cubic meterscubic feet 3.704 x 10-2 cubic yardscubic inches 16.39 cubic centimeterscubic inches 5.787 x 10-4 cubic feetcubic inches 1.639 x 10-5 cubic meterscubic inches 2.143 x 10-5 cubic yardscubic meters 35.31 cubic feetcubic meters 6.102 x 104 cubic inchescubic meters 1.308 cubic yardscubic meters 1.0 x 103 literscubic meters 2.642 x 102 gallons (U.S. liquid)cubic yards 7.646 x 105 cubic centimeterscubic yards 27 cubic feetcubic yards 0.7646 cubic meters

°Fahrenheit .556(F-32) Centigrade or Celsius

feet 30.48 centimetersfeet 0.3048 metersfeet 3.048 x 102 millimeters

gallons 3.785 x 103 cubic centimetersgallons 0.134 cubic feetgallons 3.785 x 10-3 cubic metersgallons 4.951 x 10-3 cubic yardsgallons 3.785 litersgrams 3.527 x 10-2 ounces (avdp.)grams 2.205 x 10-3 poundsgrams/cm3 62.43 pounds/ft3

grams/cm2 2.0481 pounds/sq/ftgrams-calories 3.968 x 10-3 BTU

REFERENCE TABLE


Conversion Table - continued

To Convert Multiply By: To Obtain:

inches 2.540 centimetersinches 25.4 millimeters

kilograms 2.2046 poundskilograms/meters3 6.243 x 10-2 pounds/ft3

kilometers 0.6214 miles (statute)

liters 3.531 x 10-2 cubic feetliters 61.02 cubic inchesliters 1.0 x 10-3 cubic metersliters 1.308 x 10-3 cubic yardsliters 0.2642 gallons (U.S. liquid)

miles (statute) 1.609 kilometersmillimeters 3.937 x 10-2 inches

ounces 28.349 grams

pounds 4.536 x 102 gramspounds 0.4536 kilogramspounds of water 27.68 cubic inchespounds of water 0.1198 gallonspounds/ft3 1.602 x 10-2 grams/cm3

pounds/ft3 16.02 kgs/meter3

pounds/in3 27.68 grams/cm3

pounds/in2 7.03 x 10-2 kgs/cm2

quarts (liquid) 9.464 x 102 cubic centimetersquarts (liquid) 3.342 x 10-2 cubic feetquarts (liquid) 1.238 x 10-3 cubic yardsquarts (liquid) 0.9463 liters

square centimeters 0.1550 square inchessquare feet 9.29 x 102 square centimeterssquare inches 6.452 square centimeters

tons (metric) 1000 kilogramstons (metric) 2.205 x 103 poundstons (short) 9.0718 x 102 kilogramstons (short) 0.9078 tons (metric)

yards 0.9144 meters

REFERENCE TABLE

Convertto to0C 0F

-17.78 0 32-12.22 10 50-6.67 20 68-1.11 30 860.00 32 904.44 40 104

10.00 50 12215.56 60 14021.11 70 15826.67 80 17632.22 90 19437.78 100 212

43.33 110 23048.89 120 24854.44 130 26660.00 140 28465.56 150 30271.11 160 320

76.67 170 33882.22 180 35687.78 190 37493.33 200 39298.89 210 410

100.0 212 414

104.4 220 428110.0 230 446115.6 240 464121.1 250 482126.7 260 500132.2 270 518

137.8 280 536143.3 290 554148.9 300 572154.4 310 590160.0 320 608165.6 330 626

171.1 340 644176.7 350 662182.2 360 680187.8 370 698193.3 380 716198.9 390 734

204.4 400 752215.6 420 788226.7 440 824237.8 460 860248.9 480 896

260.0 500 932271.1 520 968282.2 540 1004293.3 560 1040304.4 580 1076

Convertto to0C 0F

315.6 600 1112326.7 620 1148337.8 640 1184348.9 660 1220360.0 680 1256371.1 700 1292

398.9 750 1382426.7 800 1472454.4 850 1562482.2 900 1652510.0 950 1742537.9 1000 1832

565.6 1050 1922593.3 1100 2012621.1 1150 2102648.9 1200 2192676.7 1250 2282704.4 1300 2372

732.2 1350 2462760.0 1400 2552787.8 1450 2642815.6 1500 2732843.3 1550 2922871.1 1600 2912

898.9 1650 3002926.7 1700 3092954.4 1750 3182982.2 1800 3272

1010 1850 33621038 1900 3452

1066 1950 35421093 2000 36321121 2050 37221149 2100 38121177 2150 39021204 2200 3992

1232 2250 40821260 2300 41721288 2350 42621316 2400 43521343 2450 44421371 2500 4532

1427 2600 47121482 2700 48921538 2800 50721593 2900 52521649 3000 5432

1704 3100 56121760 3200 57921816 3300 59721871 3400 61521927 3500 63321982 3600 6512

F or C F or C

Temperature Scale Conversions


* ASTM Standard Definitions C 71-88; or ASTM “Tentative Definitions” are used where applicable.


GLOSSARY

Abrasion of Refractories: Wearing away ofthe surfaces of refractory bodies in service bythe scouring action of moving solids.

Absorption: As applied to ceramic products,the weight of water which can be absorbed bythe ware, expressed as a percentage of theweight of the dry ware.

Abutment: The structural portion of a furnacewhich withstands the thrust of an arch.

Acid-Proof Brick: Brick having low porosi-ty and permeability, and high resistance tochemical attack or penetration by most com-mercial acids and some other corrosive chemi-cals.

Acid Refractories: Refractories such as silicabrick which contain a substantial proportion offree silica and which when heated, can reactchemically with basic refractories, slags andfluxes.

Aggregate: As applied to refractories, aground mineral material, consisting of parti-cles of various sizes, used with much finersizes for making formed or monolithic bodies.

Air-Ramming*: A method of forming refrac-tory shapes, furnace hearths, or other furnaceparts by means of pneumatic hammers.

Air-Setting Refractories: Compositions ofground refractory materials which develop astrong bond upon drying. These refractoriesinclude mortars, plastic refractories, rammingmixes and gunning mixes. They are marketed inboth wet and dry condition. The dry composi-tions require tempering with water to develop thenecessary consistency.

Alumina: Al2O3, the oxide of aluminum; melt-ing point 3,720°F (2,050°C); in combinationwith H2O (water), alumina forms the mineralsdiaspore, bauxite and gibbsite; in combinationwith SiO2 and H2O, alumina forms kaoliniteand other clay minerals.

Alumina-Silica Refractories: Refractories con-sisting essentially of alumina and silica, andincluding high-alumina, fireclay and kaolinrefractories.

Amorphous: Lacking crystalline structure ordefinite molecular arrangement; without definiteexternal form.

Andalusite: A brown, yellow, green, red orgray orthorhombic mineral; Al2SiO5. Specificgravity 3.1 - 3.2. Decomposes on heating,

beginning at about 2,460°F (1,350°C) to formmullite (Al6Si2O13) and free silica.

Anneal: To remove internal stress by firstheating and then cooling slowly.

Arc: As applied to circles, any portion of a cir-cumference; as applied to electricity, the lumi-nous bridge formed by the passage of a currentacross a gap between two conductors or termi-nals.

Arch, Flat: In furnace construction, a flatstructure spanning an opening and supportedby abutments at its extremities. The arch isformed by a number of special tapered brick,and the brick assembly is held in place by thekeying action of the brick. Also called a jackarch.

Arch, Sprung: In furnace construction, abowed or curved structure which is supportedby abutments at the sides or ends only, andwhich usually spans an opening or spacebetween two walls.

Arch, Suspended: A furnace roof consistingof brick shapes suspended from overhead sup-porting members.

Arch Brick: A brick shape having six planefaces (two sides, two edges and two ends), inwhich two faces (the sides) are inclined towardeach other and one edge face is narrower than theother.

Ash: The noncombustible residue whichremains after burning a fuel or other com-bustible material.

Attrition: Wearing away by friction; abrasion.

Auger Machine: A machine for extrudingground clays in moist and stiffly plastic form,through a die by means of a revolving screw orauger.

Baddeleyite: A mineral composed of zirconia(ZrO2). Specific gravity 5.8. Melting point4,890°F (2,700°C).Bagasse: The fibrous material remaining after theextraction of the juice from sugar cane.

Ball Clay: A highly plastic refractory bondclay of very fine grain, which has a wide rangeof vitrification and which burns to a lightcolor. Often high in carbonaceous matter.

Basic Refractories: Refractories which con-sist essentially of magnesia, lime, chrome ore

or mixtures of two or more of these and,when heated, can react chemically with acidrefractories, slags and fluxes.

Bauxite: An off-white, grayish, brown, yellow,or reddish-brown rock composed of a mixture ofvarious amorphous or crystalline hydrous alu-minum oxides and aluminum hydroxides(principally gibbsite, some boehmite), andcontaining impurities in the form of free silica,silt, iron hydroxides, and especially clay miner-als; a highly aluminous laterite.

Bauxitic Clay: A natural mixture of bauxiteand clay containing not less than 47% normore than 65% alumina on a calcined basis.

Bentonite: A kind of clay derived from vol-canic ash and characterized by extreme fine-ness of grain. Its main constituent is the claymineral montmorillonite. It is somewhat vari-able in composition and usually contains 5 to10% of alkalies or alkaline earth oxides. Onetype has the capacity for absorption of largeamounts of water, with enormous increase involume.

Bessemer Process: An older process for mak-ing steel by blowing air through molten pigiron, whereby most of the carbon and impuri-ties are removed by oxidation. The process is carried out in a ves-sel known as a converter.

Bloating: Swelling of a refractory when in thethermo-plastic state, caused by temperatures inexcess of that for which the material is intend-ed. Bloating impairs the useful properties ofrefractories. An exception to this rule occurs inone type of ladle brick (See SecondaryExpansion).

British Thermal Unit (BTU): The amount ofheat required to raise the temperature of onepound of water one degree Fahrenheit at stan-dard barometric pressure.

Brucite: A mineral having the compositionMg(OH)2. Specific gravity 2.38 - 2.40. A soft,waxy, translucent mineral which dissociates atmoderate temperatures with the formation ofMgO.

Bunker Oil: A heavy fuel oil formed by stabi-lization of the residual oil remaining after thecracking of crude petroleum.

Burn: The degree of heat treatment to whichrefractory brick are subjected in the firing


process. Also, the degree to which desiredphysical and chemical changes have beendeveloped in the firing of a refractory materi-al.

Burning (Firing) of Refractories*: The finalheat treatment in a kiln to which refractorybrick are subjected in the process of manufac-ture, for the purpose of developing bond andother necessary physical and chemical proper-ties.

Calcination: A heat treatment to which manyceramic raw materials are subjected, prepara-tory to further processing or use, for the pur-pose of driving off volatile chemically combinedcomponents and affecting physical changes.

Calcite: A mineral having the compositionCaCO3. Specific gravity 2.71 for pure calcitecrystals. Calcite is the essential constituentof limestone, chalk and marble and a minorconstituent of many other rocks.

Calorie (Large): One thousand small calories.

Calorie (Small): The amount of heat requiredto raise the temperature of one gram of waterone degree Centigrade at standard barometricpressure.

Cap or Crown: The arched roof of a furnace,especially a glass tank furnace.

Carbon Deposition: The deposition of amor-phous carbon, resulting from the decomposi-tion of carbon monoxide gas into carbondioxide and carbon within a critical tempera-ture range. When deposited within the poresof refractory brick, carbon can build up suffi-cient pressure to destroy the bond and causethe brick to disintegrate.

Carbon Refractory*: A manufactured refrac-tory comprised substantially or entirely of car-bon (including graphite).

Carbon-Ceramic Refractory*: A manufac-tured refractory comprised of carbon (includinggraphite) and one or more ceramic materialssuch as fire clay and silicon carbide.

Castable Refractory: A mixture of a heat-resistant aggregate and a heat-resistanthydraulic cement. For use, it is mixed withwater and rammed, cast or gunned into place.

Catalyst: A substance which causes or accel-erates a chemical change without being perma-nently affected by the reaction.

Cement: A finely divided substance which isworkable when first prepared, but whichbecomes hard and stonelike as a result ofchemical reaction or crystallization; also,the compact groundmass which surroundsand binds together the larger fragments or par-ticles in sedimentary rocks.

Ceramic Bond: In a ceramic body, themechanical strength developed by a heat treat-ment which causes the cohesion of adjacentparticles.

Ceramics: Originally, ware formed from clayand hardened by the action of heat; the art ofmaking such ware. Current usage includes allrefractory materials, cement, lime, plaster, pot-tery, glass, enamels, glazes, abrasives, electricalinsulating products and thermal insulating prod-ucts made from clay or from other inorganic,nonmetallic mineral substances.

Checkers: Brick used in furnace regenerators to recover heat from outgoinghot gases and later to transmit the heat to coldair or gas entering the furnace; so-calledbecause the brick are arranged in checkerboardpatterns, with alternating brick units and openspaces.

Chemically-Bonded Brick: Brick manufac-tured by processes in which mechanicalstrength is imparted by chemical bondingagents instead of by firing.

Chord: As applied to circles, a straight linejoining any two points on a circumference.

Chrome Brick*: A refractory brick manufac-tured substantially or entirely of chrome ore.

Chrome-Magnesite Brick: A refractory brickwhich can be either fired or chemically bond-ed, manufactured substantially of a mixture ofchrome ore and dead-burned magnesite, inwhich the chrome ore predominates by weight.

Chrome Ore: A rock having as its essentialconstituent the mineral chromite or chromespinel, which is a combination of FeO andMgO with Cr2O3, Al2O3, and usually a smallproportion of Fe2O3. The composition, whichis represented by the formula (Fe, Mg) (Cr, Al)2

O4, is extremely variable. Refractory gradechrome ore has only minor amounts of acces-sory minerals and has physical properties thatare suitable for the manufacture of refractoryproducts.

Clay: A natural mineral aggregate, consistingessentially of hydrous aluminum silicates (Seealso Fire Clay).

Colloid: (1 ) A particle-size range of less than0.00024 mm, i.e. smaller than clay size; (2)originally, any finely divided substance thatdoes not occur in crystalline form; in a moremodern sense, any fine-grained material insuspension, or any such material that can beeasily suspended.

Conductivity: The property of conductingheat, electricity or sound.

Congruent Melting: The change of a sub-stance, when heated, from the solid form to aliquid of the same composition. The meltingof ice is an example of congruent melting.

Convection: The transfer of heat by the circu-lation or movement of the heated parts of a liq-uid or gas.

Corbel: A supporting projection of the face ofa wall; an arrangement of brick in a wall inwhich each course projects beyond the oneimmediately below it to form a support, baffle orshelf.

Corrosion of Refractories: Deterioration orwearing away of refractory bodies largely attheir surface through chemical action of exter-nal agencies.

Corundum: A natural or synthetic mineraltheoretically consisting solely of alumina(Al2O3). Specific gravity 4.00 - 4.02. Meltingpoint 3,720°F (2,050°C). Hardness 9.

Course: A horizontal layer or row of brick in astructure.

Cristobalite: A mineral form of silica (SiO2);stable from 2,678°F (1,470°C) to the meltingpoint, 3,133°F (1,723°C). Specific gravity2.32. Cristobalite is an important constituentof silica brick.

Crown: A furnace roof, especially one whichis dome-shaped; the highest point of an arch.

Cryptocrystalline: A crystalline structure inwhich the individual crystals are so small thatthey cannot be made visible by means of thepetrographic microscope, but can be seen withan electron microscope. Various so-called amor-phous minerals are actually cryptocrystalline.

Crystal: (1 ) A homogeneous, solid body of achemical element, compound or isomorphousmixture having a regularly repeating atomicarrangement that can be outwardly expressedby plane faces; (2) rock crystal.


GLOSSARY


Crystalline: Composed of crystals.

Dead-Burned Dolomite: A coarsely granularrefractory material prepared by firing rawdolomite with or without additives, to a tem-perature above 2,800°F (1,538°C), so as toform primarily lime and magnesia in amatrix that provides resistance to hydrationand carbonation.

Dead-Burned Magnesite: A coarsely granu-lar dense refractory material composed essen-tially of periclase (crystalline magnesiumoxide); prepared by firing raw magnesite (orother substances convertible to magnesia) attemperatures sufficiently high to drive off prac-tically all of the volatile materials, and to affectcomplete shrinkage of the resultant magnesia,thereby producing hard dense grains whichare entirely inert to atmospheric hydrationand carbonation and free from excessiveshrinkage when again subjected to a high tem-perature.

De-airing: Removal of air from firebrick mixesin an auger machine before extrusion bymeans of a partial vacuum.

Density: The mass of a unit volume of a substance. It is usually expressed either ingrams per cubic centimeter or in pounds percubic foot.

Devitrification: The change from a glassy to acrystalline condition.

Diaspore: A mineral having the theoreticalcomposition Al2O3 • H2O (85% alumina; 15%water). Specific gravity 3.45.

Diaspore Clay: A rock consisting essentiallyof diaspore bonded by flint clay. Commercialdiaspore clay of the purest grade usually con-tains between 70 and 80% alumina after calci-nation.

Diatomaceous Earth: A hydrous form of sili-ca which is soft, light in weight and consistsmainly of microscopic shells of diatoms orother marine organisms. It is widely used forfurnace insulation.

Direct Bonded Basic Brick: A fired refracto-ry in which the grains are joined predomi-nantly by a solid state of diffusion mechanism.

Direct Bonded Magnesite-Chrome Brick: Aterm applied to fired magnesite-chrome composi-tions when the amount of bonding mineralphase (silicates, forsterite, etc.) present in thematrix is sufficiently low that under microscopic

examination the chrome ore grains appear tobe bonded “directly” to the magnesite grains.The actual bonding mechanism in this instanceis usually a combination of types, of whichone may be direct (diffusion) bonding.

Division Wall: Wall dividing any two majorsections of a furnace.

Dobie: A molded block of ground clay orother refractory material, usually crudelyformed and either raw or fired.

Dolomite: The mineral calcium-magnesium carbonate, CaMg (CO3)2. Specificgravity 2.85 - 2.95. The rock called dolomiteconsists mainly of the mineral of that nameand can also contain a large amount of the min-eral calcite (CaCO3).

Dry Pan: A pan-type rotating grindingmachine, equipped with heavy steel rollers ormullers which do the grinding and having slot-ted plates in the bottom through which theground material passes out.

Dusting: Conversion of a refractory material,either wholly or in part, into fine powder ordust. Dusting usually results from (1 ) chemi-cal reactions such as hydration; or (2) min-eral inversion accompanied by large andabrupt change in volume, such as the inversionof beta to gamma dicalcium silicate upon cool-ing.

Dutch Oven: A combustion chamber builtoutside and connected with a furnace.

Electron Beam Furnace: A furnace in whichmetals are melted in a vacuum at very hightemperatures by bombardment with electrons.

Emissivity, Thermal: The capacity of a mate-rial for radiating heat; commonly expressed asa fraction or percentage of the ideal “blackbody” radiation of heat which is the maxi-mum theoretically possible.

Erosion of Refractories: Mechanical wearingaway of the surfaces of refractory bodies inservice by the washing action of moving liq-uids, such as molten slags or metals.

Eutectic Temperature: The lowest meltingtemperature in a series of mixtures of two ormore components.

Exfoliate: To expand and separate into rudelyparallel layers or sheets, under the action ofphysical, thermal or chemical forces producing

differential stresses.

Extrusion: A process in which plastic materi-al is forced through a die by the application ofpressure.

Fayalite: A mineral having the compositionFe2SiO4. Specific gravity 4.0 - 4.1. Meltingpoint 2,201°F (1,205°C).

Feldspar: A group of aluminum silicate min-erals with a general formula MAl (Al,Si)3 O8

where M=K, Na, Ca, Br, Rb, Sr and Fe. Themost important feldspars are: (1) the potashgroup, of which orthoclase and microcline (K)are the most common, and (2) the soda-limegroup, of which albite (Na) and anorthite (Ca)form the end members of a continuous seriesof solid solutions. Specific gravity 2.55 - 2.76.Melting points 2,050 to 2,820°F (1,120° to1,550°C).

Fillet: The concave curve junction of two sur-faces which would otherwise meet at an angle.Fillets are used at re-entrant angles in thedesign of brick shapes to lessen the danger ofcracking.

Firebrick: Refractory brick of any type.

Fire Clay: An earthy or stony mineral aggre-gate which has as the essential constituenthydrous silicates of aluminum with or withoutfree silica; plastic when sufficiently pulver-ized and wetted, rigid when subsequentlydried, and of sufficient purity and refrac-toriness for use in commercial refractory prod-ucts.

Fireclay Brick: A refractory brick manufac-tured substantially or entirely from fire clay.

Flat Arch: An arch in which both outer andinner surfaces are horizontal planes.

Flint: A hard, fine-grained cryto-crystallinerock, composed essentially of silica.

Flint Clay: A hard or flint-like fire clay whichhas very low natural plasticity and which usual-ly breaks with a smooth or shell-like fracture. Itsprincipal clay mineral is halloysite.

Flux: A substance or mixture which promotesfusion of a solid material by chemical action.

Fluxing: Fusion or melting of a substance as aresult of chemical action.


GLOSSARY

Forsterite: A mineral having the composition Mg2SiO4. Specific gravity 3.21.Melting point approximately 3,450°F(1,900°C).

Freeze-Plane: An irregular plane lyingbetween the hot face and cold face of a refrac-tory lining — any point on which the tempera-ture corresponds to the freezing point of a liq-uid phase present on the hot face side of theplane.

Friable: Easily reduced to a granular or pow-dery condition.

Furnace Chrome: A mortar material preparedfrom finely ground chrome ore, suitable forlaying brick or for patching or daubing in fur-naces.

Furnace Magnesite: A mortar material pre-pared from finely ground dead-burned magnesite,suitable for use as a joint material in layingmagnesite brick, and for patching or daubingfurnace masonry.

Fused-Cast Refractories: Refractoriesformed by electrical fusion followed by cast-ing and annealing.

Fused Quartz: Silica in the glassy state pro-duced by melting clear quartz crystalline feed.It is clear without entrapped gas bubbles orother impurities or diluents. Synonymsinclude quartz glass and vitreous quartz.

Fused Silica: Silica in the glassy or vitreousstate produced by arc-melting sand. It alwayscontains gas bubbles. Synonyms include vitre-ous silica and silica glass.

Fusion: A state of fluidity or flowing in conse-quence of heat; the softening of a solid body,either through heat alone or through heat andthe action of a flux, to such a degree that it willno longer support its own weight, but willslump or flow. Also the union or blending ofmaterials, such as metals, upon melting, with theformation of alloys.

Fusion Point: The temperature at whichmelting takes place. Most refractory materi-als have no definite melting points, but softengradually over a range of temperatures.

Ganister: A dense, high-silica rock (quartzite),suitable for the manufacture of silica brick.Confusion sometimes results from the use ofthis term, because it is also applied in someparts of the United States to crushed firebrick

or to mixtures of either crushed firebrick orsilica rock with clay, for use in tamped linings.

Gibbsite: A white or tinted monoclinic mineral;Al(OH)3. Specific gravity 2.3 - 2.4.

Glass*: An inorganic product of fusion whichhas cooled to a rigid condition without crystal-lizing.

Grain Magnesite: Dead-burned magnesite inthe form of granules, generally ranging in sizefrom about 5/8 inch in diameter to very fineparticles.

Grain Size: As applied to ground refractorymaterials, the relative proportions of particlesof different sizes; usually determined by sepa-ration into a series of fractions by screening.

Grog: A granular product produced by crush-ing and grinding calcined or burned refracto-ry material, usually of alumina-silica composi-tion.

Ground Fire Clay: Fire clay or a mixture of fireclays that have been subjected to no mechanicaltreatment other than crushing and grinding.

Grout: A suspension of mortar material inwater, of such consistency that it will flowinto vertical open joints when it is poured onhorizontal courses of brick masonry.

Gunning: The application of monolithic refrac-tories by means of air-placement guns.

Halloysite: One of the clay minerals; a hydrat-ed silicate of alumina similar in composition tokaolinite, but amorphous and containing morewater; Al2Si2O5(OH)4 • 2H2O.

Header: A brick laid on flat with its longestdimension perpendicular to the face of a wall.

Heat-Setting Refractories: Compositions ofground refractory materials which require rela-tively high temperatures for the development ofan adequate bond, commonly called the ceramicbond.

Hematite: The mineral Fe2O3 (red iron ore).Specific gravity 4.9 - 5.3.

High-Alumina Refractories: Alumina-silicarefractories containing 45 % or more alumina.The materials used in their productioninclude diaspore, bauxite, gibbsite, kyanite,sillimanite, andalusite and fused alumina (arti-ficial corundum).

High-Duty Fireclay Brick: Fireclay brickwhich have a PCE not lower than Cone 31½ orabove 32½ - 33.

Hydrate (verb): To combine chemically withwater.

Hydraulic-Setting Refractories:Compositions of ground refractory materialsin which some of the components react chemi-cally with water to form a strong hydraulicbond. These refractories are commonlyknown as castables.

Illite: A group of three-layer, mica-like miner-als of small particle size, intermediate in com-position and structure between muscovite andmontmorillonite.

Impact Pressing: A process for forming refrac-tory shapes in which the ground particles ofrefractory material are packed closely together byrapid vibration.

Incongruent Melting: Dissociation of a com-pound on heating, with the formation of anoth-er compound and a liquid of different compo-sition from the original compound.

Ingot Mold: A mold in which ingots are cast.

Insulating Refractories: Lightweight, porousrefractories with much lower thermal conduc-tivity and heat-storage capacity than otherrefractories. Used mostly as backing for brickof higher refractoriness and higher thermalconductivity. These materials provide fueleconomy through lower heat losses, increasedproduction due to shorter heat-up time, econo-my of space (size and weight) because of thin-ner walls and improved working conditions.Insulating refractories are available as brick or monoliths.

Inversion: A change in crystal form withoutchange in chemical composition; as for example,the change from low-quartz to high-quartz, or,the change from quartz to cristobalite.

Isomorphous Mixture: A type of solid solu-tion in which mineral compounds of analo-gous chemical composition and closely relat-ed crystal habit crystallize together in variousproportions.

Jack Arch: See Arch, Flat.



GLOSSARY

Jamb: (1 ) A vertical structural member form-ing the side of an opening in a furnace wall;(2) a type of brick shape intended for use inthe sides of wall openings.

Kaldo Process (Stora): An oxygen processfor making steel.

Kaliophilite: A hexagonal mineral of volcanicorigin; KAlSiO4.

Kaolin: A white-burning clay having kaolin-ite as its chief constituent. Specific gravity2.4 - 2.6. The PCE of most commercial kaolinsranges from Cone 33 to 35.

Kaolinite: A common white to grayish or yel-lowish clay mineral; Al2Si2O5 (OH)4. Kaoliniteis the principal constituent of most kaolins andfire clays. Specific gravity is 2.59. The PCE ofpure kaolinite is Cone 35.

Key: In furnace construction, the uppermost orthe closing brick of a curved arch.

Key Brick: A brick shape having six planefaces (two sides, two edges and two ends), inwhich two faces (the edges) are inclinedtoward each other and one of the end faces isnarrower than the other.

K-factor: The thermal conductivity of a mater-ial, expressed in standard units.

Kyanite (Cyanite): A blue or light-green tri-clinic mineral; Al2SiO5. Specific gravity3.56 - 3.67. Decomposition begins at about2,415°F (1,325°C) with the formation of mul-lite and free silica.

Ladle: A refractory-lined vessel used for thetemporary storage or transfer of molten metals.

L-D Process: A process for making steel byblowing oxygen on or through molten pig iron,whereby most of the carbon and impurities areremoved by oxidation.

Limestone: A sedimentary rock composed essen-tially of the mineral calcite (CaCO3) or of cal-cite mixed with dolomite, CaMg(CO3)2.Specific gravity 2.6 - 2.8.

Limonite: A mineral consisting of hydrousferric oxides; the essential component of“brown ore.” Specific gravity 3.6 - 4.0.

Lintel: A horizontal member spanning a wallopening.

Loss on Ignition: As applied to chemical analy-ses, the loss in weight which results fromheating a sample of material to a high tem-perature, after preliminary drying at a tempera-ture just above the boiling point of water. Theloss in weight upon drying is called “free mois-ture”; that which occurs above the boiling point,“loss on ignition.”

Low-Duty Fireclay Brick: Fireclay brickwhich have a PCE not lower than Cone 15 norhigher than 28 - 29.

Magnesioferrite: One of the spinel group ofminerals; (Mg,Fe)Fe2O4. Rarely found in nature;usually constitutes the brown coloring materialin magnesite brick. Specific gravity 4.57 - 4.65.

Magnesite: A mineral consisting of magne-sium carbonate; MgCO3. A rock containing themineral magnesite as its essential constituent(See also Magnesite, Caustic and Dead-Burned Magnesite).

Magnesite Brick: A refractory brick manufac-tured substantially or entirely of dead-burnedmagnesite which consists essentially of magnesiain crystalline form (periclase).

Magnesite-Carbon Brick: A refractory brickmanufactured of substantially magnesite(dead-burned, fused, or a combination there-of) and carbon, which may be in the form ofvarious carbon-bearing materials. Conventionaltar-bonded and tar-impregnated brick do notfall into this class. Magnesite-carbon brick aredistinct in that carbon is present in the composi-tion to provide specific refractory propertiesbeyond filling pores or acting as a bond.

Magnesite, Caustic: The product obtained bycalcining magnesite, or other substances convert-ible to magnesia, upon heating at a temperaturegenerally not exceeding 2,200°F (1,205°C).The product is readily reactive to water andto atmospheric moisture and carbon dioxide.

Magnesite-Chrome Brick: A refractory brickwhich can be either fired or chemicallybonded, manufactured substantially of a mix-ture of dead-burned magnesite (magnesia) andrefractory chrome ore, in which the magnesitepredominates by weight.

Magnesium Hydroxide: The compound ofmagnesium oxide and chemically combinedwater; Mg(OH)2. Naturally occurring magne-sium hydroxide is known as brucite.

Magnetite: A black, isometric, strongly mag-netic, opaque mineral of the spinel group; (Fe,Mg) Fe2O4. Specific gravity 5.17 - 5.18.Melting point about 2,901°F (1,594°C).

Medium-Duty Fireclay Brick: A fireclay brickwith a PCE value not lower than Cone 29 norhigher than 31 - 311/2.

Melting Point: The temperature at whichcrystalline and liquid phases having the samecomposition coexist in equilibrium. Metalsand most pure crystalline materials have sharpmelting points, i.e. they change abruptly fromsolid to liquid at definite temperatures.However, most refractory materials have notrue melting points, but melt progressivelyover a relatively wide range of temperatures.

Metalkase Brick: Basic brick provided withthin steel casings.

Mica: A group of rock minerals having nearlyperfect cleavage in one direction and consistingof thin elastic plates. The most common vari-eties are muscovite and biotite.

Micron: The one-thousandth part of a mil-limeter (0.001 mm); a unit of measurementused in microscopy.

Mineral: A mineral species is a natural inor-ganic substance which is either definite inchemical composition and physical charac-teristics or which varies in these respectswithin definite natural limits. Most mineralshave a definite crystalline structure; a few areamorphous.

Modulus of Elasticity (Physics): A measureof the elasticity of a solid body; the ratio ofstress (force) to strain (deformation) within theelastic limit.

Modulus of Rupture: A measure of the trans-verse or “crossbreaking” strength of a solidbody.

Monolithic Lining: A furnace lining withoutjoints, formed of material which is rammed,cast, gunned or sintered into place.

Monticellite: A colorless or gray mineral relatedto olivine; CaMgSiO4. Specific gravity 3.1 -3.25. Melts incongruently at 2,730°F(1,499°C) to form MgO and a liquid.



GLOSSARY

Montmorillonite: A group of expanding-latticeclay minerals containing variable percentagesof one or more of the cations of magne-sium, potassium, sodium and calcium. Acommon constituent of bentonites.

Mortar (Refractory): A finely ground refrac-tory material which becomes plastic whenmixed with water and is suitable for use in lay-ing refractory brick.

Mullite: A rare orthorhombic mineral;Al6Si2O13. Specific gravity 3.15. An importantconstituent of fireclay and high-aluminabrick. Melting point under equilibrium condi-tions approximately 3,362°F (1,850°C).

Mullite Refractories*: Refractory productsconsisting predominantly of mullite (Al6Si2O13)crystals formed either by conversion of one ormore of the sillimanite group of minerals or bysynthesis from appropriate materials employingeither melting or sintering processes.

Muscovite: A mineral of the mica group;KA12(AlSi3)O10(OH)2. It is usually colorless,whitish or pale brown and is a common miner-al in metamorphic and igneous rocks and insome sedimentary rocks.

Nepheline (Nephelite): A hexagonal mineralof the feldspathoid group; (Na,K)AlSiO4. Acommon reaction product in furnaces whereinslags or vapors of high soda content come intocontact with fireclay or high-alumina brick.Stable at 2,278°F (1,248°C) at which temper-ature it inverts to the artificial mineralcarnegieite, which has the same composition,but a different crystalline form. Naturalnepheline contains a small amount of potash.Specific gravity 2.67.

Neutral Refractory: A refractory material whichis neither acid nor base, such as carbon,chrome or mullite.

Nine Inch Equivalent: A brick volume equalto that of a 9 x 4 1/2 x 2 1/2 inch straight brick(101.25 cubic inches); the unit of measure-ment of brick quantities in the refractoriesindustry.

Nodule Clay: A rock containing aluminous orferruginous nodules, or both, bonded by flintclay; called “burley” clay or “burley flint” clayin some districts.

Nosean (Noselite): A feldspathoid mineral ofthe sodalite group; Na8Al6Si6O24(SO4). It is gray-ish, bluish or brownish and is related to hauyne.

Nozzle Brick: A tubular refractory shape used ina ladle; contains a hole through which steel isteemed at the bottom of the ladle, the upper endof the shape serving as a seat for the stopper.

Olivine: (l) An olive-green, grayish-green orbrown orthorhombic mineral;(Mg,Fe)2SiO4. It comprises the isomorphous solid-solution series forsterite-fayalite. (2) A name applied to a group of min-erals forming the isomorphous system(Mg,Fe,Mn,Ca) 2SiO4, including forsterite,fayalite, tephroite and a hypothetical calciumorthosilicate. Specific gravity 3.27 - 3.37,increasing with the amount of iron present.

Overfiring: A heat treatment which causesdeformation or bloating of clay or clay ware.

Oxiduction: Alternate oxidation and reduc-tion.

Oxygen Process: A process for making steel inwhich oxygen is blown on or through moltenpig iron, whereby most of the carbon andimpurities are removed by oxidation.

Periclase: An isometric mineral; MgO.Specific gravity 3.58. Melting point approxi-mately 5,070°F (2,800°C).

Perlite: A siliceous glassy rock composed ofsmall spheroids varying in size from smallshot to peas; combined water content 3 to 4%. When heated to a suitable temperature,perlite expands to form a lightweight glassymaterial with a cellular structure.

Permeability: The property of porous materi-als which permits the passage of gases and liq-uids under pressure. The permeability of abody is largely dependent upon the number,size and shape of the open connecting poresand is measured by the rate of flow of a standardfluid under definite pressure.

Plasma Jet: Ionized gas produced by passingan inert gas through a high-intensity arc causingtemperatures up to tens of thousands of degreescentigrade.

Plastic Chrome Ore: An air-setting rammingmaterial having a base of refractory chromeore and shipped in plastic form ready for use.

Plastic Fire Clay: A fire clay which has suffi-cient natural plasticity to bond together othermaterials which have little or no plasticity.

Plastic Refractory: A blend of ground refrac-tory materials in plastic form, suitable for

ramming into place to form monolithic lin-ings.

Plasticity: That property of a material thatenables it to be molded into desired formswhich are retained after the pressure of mold-ing has been released.

Pores: As applied to refractories, the smallvoids between solid particles. Pores aredescribed as “open” if permeable to fluids;“sealed” if impermeable.

Porosity of Refractories: The ratio of the vol-ume of the pores or voids in a body to thetotal volume, usually expressed as a percent-age. The “true porosity” is based on the totalpore-volume; “apparent porosity” on the openpore-volume only.

Power Pressing: The forming of refractorybrick shapes from ground refractory materialcontaining an optimum amount of addedwater by means of high pressure applied verti-cally in a power-driven press.

Pug Mill: A machine used for blending andtempering clays in a moist or stiffly plastic con-dition.

Pyrite: The most common sulfide mineral;FeS2. Specific gravity 4.9 - 5.2. Color, brass-yellow. Used mainly for making sulfuric acidand sulfates.

Pyrometric Cone: One of a series of pyrami-dal-shaped pieces consisting of mineral mix-tures and used for measuring time-temperatureeffect. A standard pyrometric cone is a three-sided truncated pyramid; and is approximatelyeither 25/8 inches high by 5/8 inch wide at thebase or 11/8 inches high by 3/8 inch wide at thebase. Each cone is of a definite mineral com-position and has a number stamped on oneface; when heated under standard conditions itbends at a definite temperature.

Pyrometric Cone Equivalent (PCE)*: Thenumber of that Standard Pyrometric Conewhose tip would touch the supporting plaquesimultaneously with a cone of the refractorymaterial being investigated when tested inaccordance with the Method of Test forPyrometric Cone Equivalent (PCE) ofRefractory Materials (ASTM DesignationC24).

Pyrophyllite: A mineral consisting of hydrat-ed silicate of aluminum; AlSi2O5(OH).


GLOSSARY


Pyroplasticity: The physical state induced bysoaking heat which permits a refractory bodyto be readily deformed under pressure or by itsown weight.

Quartz: A common mineral consisting of silica(SiO2). Sandstones and quartzites are com-posed largely of quartz. Specific gravity 2.65.

Quartzite: A hard compact rock consistingpredominantly of quartz. There are two types:(1) metaquartzite, a metamorphic rock usuallyderived from sandstone; and (2) orthoquartzite, asedimentary rock consisting of grains of sili-ca sand cemented together by at least 10 % ofprecipitated silica.

Ramming Mix: A ground refractory materialwhich is mixed with water and rammed intoplace for patching shapes or for formingmonolithic furnace linings; usually of a lessplastic nature than plastic refractories.

Recuperator: A system of thin-walled refrac-tory ducts used for the purpose of transferringheat from a heated gas to colder air or gas.

Refractories: Nonmetallic materials suitablefor use at high temperatures in furnace con-struction. While their primary function is resis-tance to high temperature, they are usuallycalled on to resist other destructive influencessuch as abrasion, pressure, chemical attackand rapid changes in temperature.

Refractory (adj.): Chemically and physicallystable at high temperatures.

Refractory Clay: An earthy or stony mineralaggregate which has as the essential con-stituent hydrous silicates of aluminum with orwithout free silica; plastic when sufficientlypulverized and wetted, rigid when subsequent-ly dried and of sufficient purity and refractori-ness for use in commercial refractory products.

Regenerator: A refractory structure in whichthermal energy from hot furnace gases is alter-nately absorbed by checker brick work andreleased to cold air or gas.

Regenerator Checkers: Brick used in furnaceregenerators to recover heat from hot outgo-ing gases and later to release this heat tocold air or gas entering the furnace; so-calledbecause of the checkerboard pattern in whichthe brick are arranged.

Rise of Arches: The vertical distance betweenthe level of the spring lines and the highestpoint of the under surface of an arch.

Rock: A naturally occurring mineral aggregateconsisting of one or more minerals. For exam-ple, quartzite rock is an aggregate consistingessentially of crystals of the mineral quartz;granite is an aggregate consisting essentiallyof spar and quartz.

Rotary Kiln: A cylindrical, refractory-lined,gas-fired kiln that rotates at an angle and inwhich the charge is introduced into the higherend and travels down the slope of the kiln tothe discharge end.

Rowlock Course: A course of brick laid onedge with their longest dimensions perpendicu-lar to the face of a wall.

Rutile: A mineral consisting of titanium diox-ide (Ti2O). Specific gravity 4.18 - 4.25.

Screen Analysis: The size distribution of non-cohering particles as determined by screeningthrough a series of standard screens.

Secondary Expansion: The property exhibit-ed by some fireclay and high-alumina refracto-ries of developing permanent expansion attemperatures within their useful range; notthe same as overfiring. A behavior not to beconfused with the bloating caused by exces-sive temperatures which impair the usefulproperties of a refractory.

Semi-Silica Fireclay Brick: A fireclay brickcontaining not less than 72% silica.

Serpentine: A group of rock forming miner-als; (Mg,Fe)3Si2O5(OH)4. Specific gravity 2.5 -2.7. Also, a common rock consisting essential-ly of serpentine minerals.

Silica: SiO2, the oxide of silicon. Quartz andchalcedony are common silica materials;quartzite, sandstone and sand are composedlargely of free silica in the form of quartz.

Silica Brick: A fired refractory consistingessentially of silica and usually made fromquartzite bonded with about 1.8 to 3.5 % ofadded lime.

Silica Fire Clay*: A refractory mortar consist-ing of a finely ground mixture of quartzite, sil-ica brick and fire clay of various proportions;often called silica cement.

Silicon Carbide: A compound of silicon andcarbon; SiC.

Silicon Carbide Refractories*: Refractory prod-ucts consisting predominantly of silicon car-bide.

Sillimanite: A brown, grayish, pale-green or whiteorthorhombic mineral; Al2SiO5. Specific gravity3.24. At about 2,785°F (1,530°C) it begins todissociate into mullite and free silica.

Sintering: A heat treatment which causesadjacent particles of material to cohere at atemperature below that of complete melting.

Skewback: The course of brick, having aninclined face, from which an arch is sprung.

Slag: A substance formed in any one of sever-al ways by chemical action and fusion at fur-nace operating temperatures: (1) in smeltingoperations, through the combination of aflux, such as limestone, with the gangue orwaste portion of the ore; (2) in the refiningmetals, by substances, such as lime, addedfor the purpose of effecting or aiding therefining; (3) by chemical reaction betweenrefractories and fluxing agents, such as coal,ash or between two different types of refrac-tories.

Slagging of Refractories*: Destructive chemi-cal action between refractories and external agen-cies at high temperatures resulting in the forma-tion of a liquid.

Sleeves: Tubular refractory shapes used toprotect the metal rod which holds the stopperhead in the valve assembly of a bottom-pour-ing ladle.

Slurry: A suspension of finely pulverizedsolid material in water of creamy consistency.

Soapstone: A metamorphic rock consistingmainly of talc and derived from the alterationof ferromagnesian silicate minerals.

Soldier Course: A course of brick set on end;little used in the case of refractories exceptin the bottoms of some types of furnaces.

Solid Solution: A homogeneous crystallinephase with a variable composition. The mostcommon solid solutions involve two or moresubstances having the same crystalline struc-ture. However, the term can also refer to thesolution of small proportions of a material in aseemingly unrelated substance.



GLOSSARY

Spalling of Refractories: The loss of frag-ments (spalls) from the face of a refractorystructure, through cracking and rupture, withexposure of inner portions of the originalrefractory mass.

Specific Gravity: The ratio between the weightof a unit volume of a substance and that ofsome other standard substance under standardconditions of temperature and pressure. Forsolids and liquids the specific gravity is basedon water as the standard. The “true specificgravity” of a body is based on the volume ofsolid material excluding all pores. The bulk orvolume specific gravity is based on the volumeas a whole, i.e. the solid material with allincluded pores. The apparent specific gravityis based on the volume of the solid materialplus the volume of the sealed pores.

Specific Heat: The quantity of heat requiredto raise the temperature of a unit mass of asubstance one degree.

Spinel: (1) The mineral composed of magne-sium aluminate; MgAl2O4. Specific gravi-ty 3.6. Melting point 3,875°F (2,135°C). (2)A group of minerals of general formula; AB2O4

where A represents magnesium, ferrous iron,zinc or manganese or any combination of theseminerals and B represents aluminum ferriciron or chromium.

Spring Line: The line of contact between theinside surface of an arch and the skewback.

Sprung Arch: An arch which is supported byabutments at the side or ends only.

Stack Losses: The flue gas loss, the sensibleheat carried away by the dry flue gas plus thesensible heat and latent heat carried away bythe water vapor in the flue gas.

Stretcher: A brick laid on flat with its lengthparallel to the face of the wall.

Superduty Fireclay Brick: Fireclay brickwhich have a PCE not lower than Cone 33 andwhich meet certain other requirements as out-lined in ASTM Designation C 27-84.

Suspended Arch: An arch in which the brickshapes are suspended from overhead support-ing members.

Taconite: A compact ferruginous chert or slatein which the iron oxide is so finely disseminat-ed that substantially all of the iron-bearing par-ticles are smaller than 20 mesh. Typical analy-ses of the ore grade show total iron at 32%.

Talc: A hydrous magnesium silicate mineral;Mg3Si4O10(OH)2. Specific gravity 2.7 - 2.8.Hardness 1.

Thermal Conductivity: The property of mat-ter by virtue of which heat energy is transmittedthrough particles in contact.

Thermal Expansion: The increase in lineardimensions and volume which occurs whenmaterials are heated and which is counterbal-anced by contraction of equal amount when thematerials are cooled.

Thermal Shock: A sudden transient tempera-ture change.

Tolerance: The permissible deviation in adimension or property of a material from anestablished standard or from an average value.

Tridymite: A mineral form of silica; SiO2.Stable from 1,598 to 2,678°F (870 to1,470°C). Specific gravity 2.26. An importantconstituent of silica brick.

Tweel: A refractory shape used to control theflow of molten glass from the glass tank to thetin bath in the float glass process.

Trough: An open receptacle through whichmolten metal is conveyed from a holdingdevice or furnace to a casting mold or anotherreceptacle.

Tuyere Brick: A refractory shape containingone or more holes through which air and othergases are introduced into a furnace.

TREFOIL® Heat Exchanger: A refractoryconstruction in a rotary kiln with threeopenings which in cross-section are clover-shaped. Over its length, the TREFOIL heatexchanger divides the kiln into three equal parts,thus improving heat exchange between thecharge and the hot combustion gases.

Vacuum Pressing: A method of forming brickshapes by which they are subjected to a partialvacuum during pressing in a power press.

Vermiculite: A group of micaceous minerals,all hydrated silicates, varying widely in com-position; (Mg,Fe,Al)3 (AlSi)4O10(OH)2 - 4H2O.When heated above 302°F (150°C), vermi-culite exfoliates and increases greatly in vol-ume.

Vesicular: Having a cellular structure; appliedto fire clays which have become bloated byoverfiring.

Vibratory Pressing: A process for formingrefractory shapes in which the ground parti-cles of refractory material are packed closelytogether by rapid impact-type vibrations of thetop and bottom dies; also called impact press-ing.

Vitrification: A process of permanent chemi-cal and physical change at high temperaturesin a ceramic body, such as fire clay, with thedevelopment of a substantial proportion ofglass.

Warpage: The deviation of the surface of arefractory shape from that intended, caused bybending or bowing during manufacture.

Wedge Brick: A brick shape having six planefaces (two sides, two edges and two ends), inwhich two faces (the sides) are inclinedtoward each other and one end face is narrow-er than the other.

Wetting: The adherence of a film of liquid tothe surface of a solid.

Wollastonite: A triclinic mineral; CaSiO3.Specific gravity 2.9. Inverts at 2,192°F(1,200°C) to pseudowollastonite. Melts incongru-ently at 2,811°F (1,544°C).

Young’s Modulus: In mechanics, the ratio oftensile stress to elongation within the elasticlimit; the modulusof elasticity.

Zircon: A mineral; ZrSiO4. Specific gravity4.7. Begins to melt incongruently at 3,045°F(1,685°C) forming ZrO2 solid solution plusliquid; completely melted at about 4,800°F(2,650°C).

Zirconia: Zirconium oxide; ZrO2. Specificgravity 5.8. Melting point 4,890°F (2,700°C).Its chief source is the mineral baddeleyite.


GLOSSARY


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Knoxville, TN (865) 546-4930Lakeland, FL (863) 669-1040Los Angeles, (Pico Rivera) CA (562) 942-2151New York, (Rahway) NY (732) 388-8686Philadelphia, (Trevose) PA (215) 364-5555Pittsburgh, (Leetsdale) PA (412) 741-3200Portland, (Clackamas) OR (503) 656-2854Roanoke, (Salem) VA (540) 375-2107Salt Lake City, UT (801) 886-0545San Francisco, (Richmond) CA (510) 236-7415Seattle, (Kent) WA (253)872-2552St Louis, MO (314) 521-3314West Haven, CT (203) 934-7960

Products from all these companies are available through:For Industrial Sales: Harbison-Walker Refractories Company

400 Fairway Drive, Moon Township, PA 15108Phone: (412) 375-6600 • Fax: (412) 375-6783www.hwr.com

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