Brick Lining Installation

Brick lining installation

golden rules
JULY 2007 / Version 2
These Golden Rules for Brick Lining should be guidelines for the
personnel in charge of kiln rebricking in the plants.
This booklet contains the most important rules and should therefore be
handed out to all involved persons before starting the lining.
It deals only with the most common dry lining method, but other
methods (mainly mortar) are important in special cases.
It is a good idea to discuss the content with the persons involved to
ensure it is fully understood.
As it only contains the most important rules and does not cover specific
situations, it cannot replace necessary training, especially for safety!
Information given is not sufficient for the person responsible for
Refractory in the plant. He will need to study the related procedures of
the Cement Portals Refractory Domain carefully.
(connect to: http://webcementportal.lafarge.com)
We hope that this booklet will make your work more successful.
Foreword
1 Safety gear
2 Safety equipment
3 Reference lines are drawn axially & radially
4 General rule: Lining patterns are staggered
5 Mixed ratio is adjusted
6 Mortar is used to correct deformed shell / welding
7 Key bricks are not in one line
8 Shims are not installed close to key bricks
9 Rings are closed using hydraulic jack
10 Bricks are cut with a brick cutting machine
11 Cut bricks are always in between full bricks
12 Closing of the last ring is done properly
13 Cardboard spacers are placed adequately
14 Additional guidelines
Content
Safety gear
For all personnel
Overalls
Hard hat
Safety shoes
Gloves
Safety glasses
Dust mask
Ear protections
Long
sleeved
Polyester
Non-skid
Abrasion resistant
Remark: Follow the detailed safety procedures published on the Cement Portals
Refractory domain:
How to ensure safety for brick demolition & brick lining works
How to ensure safety for brick cutting
How to ensure safety for castable mixing
Face shield
Apron
Heavy duty
rubber apron
For cutting bricks
Polycarbonate
Scratch resistant
1
Safety equipment
Using a brick rig is the only safe kiln
bricking method
Equipped with compressed
air reservoir (5l) + nonreturn valve
Alarm if pressure < 4.5 bars
If you have to pass through the coating, a

safe way is to use Tunnel cages
Compressed air
hosepipes and
couplings
are in good
condition
Inside the kiln, all electrical

equipment used must be class II
(double insulation) supplied by
safety transformers situated outside
the kiln
Reference lines are drawn axially &

radially
Axial
2nd point
1st point
Base lines
Parallel
Radial
Parallel
Welding
General rule: Lining patterns are

staggered
Use a rubber
hammer for brick
installation
Ensure the kiln shell surface

is clean and smooth
4
Mixing ratio is adjusted
Wrong
Right
Wrong
Right
No brick upside down

Check hot face marking
Mortar is used to correct deformed shell /

welding
Right
Wrong
Key bricks are not in one line
Right
Key bricks
Key bricks side to side
Wrong
Key bricks
face to face
7
Shims are not installed close to key bricks

Shim thickness = 2 mm max.
Maximum of 2 to 3 shims per ring
Shims
2 shims
Use shim driver
Rings are closed using hydraulic jack
Pressure to be applied = brick cold

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

Example: ANKRAL-ZE
Cold crushing strength = 70 N/mm2
Pressure to be applied = 350 bars or 5000 PSI
Conversion factor:
1 N/mm2 = 10 bars = 145 PSI
9
Bricks are cut with brick cutting machine
Minimum brick
cutting length is
respected.
Dry cut for basic
bricks
Do not cut
in this
direction
Mandatory
direction
of cut
Brick original
length
Minimum cut
200 mm
140 mm
300 mm
200 mm
Minimum cut
2/3 of original length
10
Cut bricks are always in between full

bricks
Cut
bricks
Old
bricks
It is recommended
to have 300 mm
long bricks
Full bricks
Cut
bricks
Full bricks
Retaining ring
11
Closing of the last ring is done properly

Tight lining must be ensured for the last ring, too.
n
Closure brick
Mortar, liquid
enough
Y
Piece of
wood
Hammer
Shims
Instead of mortar, additional
metal shims can be used
12
Cardboard spacers are placed adequately
To allow expansion
Bricks type
Cardboard spacers
Magnesia
1 cardboard of 2 mm
between each ring
Dolomite
1 cardboard of 1 mm
between each ring
Alumina
No cardboard
Remark:
These are general rules.
Follow exactly the
instructions given by the
refractory suppliers.
Never remove the
cardboards from the
original bricks!
Nosering
No cardboard
spacers
Retaining ring
Remark:
For installation of the retaining ring, see details in the How to install & line
a retaining ring procedure in the Cement Portals Refractory domain.
13
Additional guidelines
On deformed areas
bricks should be laid
with mortar
Mortar
Dont change the

quality under the tires
or the girth-gear
Dont hesitate to discuss with your

TC Refractory Expert if you have any doubt!
Notes
14
Notes
Notes
15
Direction des Performances Cimentires (DPC)

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

Brick Lining Installation

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