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JULY 2007 / Version 2

Brick lining installationgolden rules

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Foreword

• These Golden Rules for Brick Lining should be guidelines for thepersonnel in charge of kiln rebricking in the plants.

• This booklet contains the most important rules and should therefore be handed out to all involved persons before starting the lining.

• It deals only with the most common dry lining method, but other methods (mainly mortar) are important in special cases.

• It is a good idea to discuss the content with the persons involved to ensure it is fully understood.

• As it only contains the most important rules and does not cover specific situations, it cannot replace necessary training, especially for safety!

• Information given is not sufficient for the person responsible for Refractory in the plant. He will need to study the related procedures of the Cement Portal’s Refractory Domain carefully. (connect to: http://webcementportal.lafarge.com)

We hope that this booklet will make your work more successful.

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Content1 – Safety gear2 – Safety equipment3 – Reference lines are drawn axially & radially4 – General rule: Lining patterns are staggered5 – Mixed ratio is adjusted6 – Mortar is used to correct deformed shell / welding7 – Key bricks are not in one line8 – Shims are not installed close to key bricks9 – Rings are closed using hydraulic jack10 – Bricks are cut with a brick cutting machine11 – Cut bricks are always in between full bricks12 – Closing of the last ring is done properly13 – Cardboard spacers are placed adequately14 – Additional guidelines

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Safety gear

Long sleeved

For all personnel

OverallsHard hatSafety shoesGlovesSafety glassesDust maskEar protections

PolyesterNon-skidAbrasion resistant

Remark: Follow the detailed safety procedures published on the Cement Portal’s Refractory domain:

How to ensure safety for brick demolition & brick lining worksHow to ensure safety for brick cuttingHow to ensure safety for castable mixing

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PolycarbonateScratch resistant

Heavy dutyrubber apron

For cutting bricks

Face shield

Apron

1

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Safety equipment

Equipped with compressedair reservoir (5l) + non-return valveAlarm if pressure < 4.5 bars

Using a brick rig is the only safe kilnbricking method

If you have to pass through the coating, a safe way is to use Tunnel cages

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Inside the kiln, all electricalequipment used must be class II (double insulation) supplied by safety transformers situated outsidethe kiln

Compressed air hosepipes and couplingsare in goodcondition

2

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Axial

Reference lines are drawn axially & radially

2nd point

1st point

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Radial

3

Base lines

Parallel

Welding

Parallel

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General rule: Lining patterns are staggered

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tionUse a rubber

hammer for brick installation

Ensure the kiln shell surface is clean and smooth

4

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Mixing ratio is adjusted

Right

Wrong

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Check hot face marking

5

Wrong Right

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Mortar is used to correct deformed shell / welding

Right

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Wrong

6

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Key bricks are not in one line

Right

Key bricks

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Key bricks face to face

Key bricks side to side

Wrong

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Shims are not installed close to key bricks

Shims

Maximum of 2 to 3 shims per ring

Shim thickness = 2 mm max.

2 shims

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8

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Rings are closed using hydraulic jack

Pressure to be applied = ½ brick cold crushing strengthTypical CCS ranges are 50 to 70 N/mm2

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Example: ANKRAL-ZECold crushing strength = 70 N/mm2

Pressure to be applied = 350 bars or 5000 PSI

9

Conversion factor:1 N/mm2 = 10 bars = 145 PSI

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Bricks are cut with brick cutting machine

Do not cutin this

direction

Mandatorydirection

of cut

Minimum brick cutting length is respected.

Dry cut for basic bricks

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2/3 of original length

200 mm300 mm

140 mm200 mm

Minimum cutBrick original length

10

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Cut bricks are always in between full bricks

Cutbricks

Oldbricks

Full bricks

It is recommendedto have 300 mm long bricks

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Cutbricks

Full bricks

Retaining ring

11

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Closing of the last ring is done properly

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

Hammer

Mortar, liquid enoughClosure brick

Piece of wood

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12

Instead of mortar, additional metal shims can be used

Shims

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Cardboard spacers are placed adequately

To allow expansion

No cardboardAlumina

1 cardboard of 1 mm between each ring

Dolomite

1 cardboard of 2 mm between each ring

Magnesia

Cardboard spacersBricks typeRemark:

These are general rules.

Follow exactly the instructions given by the refractory suppliers.

Never remove the cardboards from the original bricks!

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Nosering

No cardboardspacers

Retaining ring

13

Remark: For installation of the retaining ring, see details in the “How to install & line a retaining ring” procedure in the Cement Portal’s Refractory domain.

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Additional guidelines

Don’t change the quality under the tires or the girth-gear

On deformed areas bricks should be laid with mortar

Don’t hesitate to discuss with your TC Refractory Expert if you have any doubt!

Mortar

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Notes

14

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Notes

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Notes

15

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Direction des Performances Cimentières (DPC)95, rue du Montmurier - BP 70

38291 St-Quentin-Fallavier Cedex - FranceTel. + 33 4 74 82 16 16