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  • OlsenKilnBookExcerpt PDF

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    Janković Dušan
    35 Ansichten10 Seiten

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    35 Ansichten10 Seiten

    OlsenKilnBookExcerpt PDF

    Hochgeladen von

    Janković Dušan

    Copyright:

    © All Rights Reserved
    Als PDF herunterladen oder online auf Scribd lesen
    Markieren Sie unangemessene Inhalte
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    Chapter 2 ‘CHAPTER 2/ METHODS OF KILN CONSTHLCTION 18 Methods of Kiln Construction The laying of rebrck in kiln construction i 2 specialized masonry sil There ae rules that must be followed to ensure + strong, monolith structure that will function eficeny at high temperatures and be ‘Surabl, STRAIGHT-WALL CONSTRUCTION ‘There are thee vital rules in straght-wall con- struction’ (1) An supported wall 4112" thick ean not be higher than 3 feet (2) an unsupported wall ‘thick, ed by alteest header and stetcher courses, ‘ant be higher than 8 fet (3) an unsupported wall IDI? tice, ted by alternate header and stretcher ours, cannot be higher than 12 feet "There ate five base methods of laying staight wall header coure, seetcher course, altemate Reader and stretcher rowiock course, and. soldier HEADER COURSE Tn header course, bricks are Ini engthwise cose the wall withthe 2 U2" x9" debuting gaint ‘he next brick (Fig 2-1). AU header courses develop 3 ‘esonably sabe wall with minimum ho face expo fore (4 12° x2 U2) and the back side ofthe Brick ‘Subject oelatively low temperature, Header courses fe good for bricks facing near temperature limits, Fig. 2—1: Header course, with bricks aid across the wal. ‘Awall aid mainly of headers, which normally consis of hee or four rows of header courses to one tov of stretcher courses (Fig. 2-2) as the advantages ofan all Reader wal but has greater igi. Fig. 2-2: Alternating four header rows with (oe recher row gives eater rigidity. STRETCHER COURSE Sretcher couric are lid lengthwise, running swith the wall so thatthe 212" 9" surface Becomes the hot face (Fig. 2-3) An allstrecher wall isnot Tigi and isnot recommended for ove 3 fet In Fight unlesit ha other meas of suppor Fig. 28: Stretcher course, with Bricks raming along the wal. ‘A vrll aid msinly of stretchers, which normally consnts of three to fut 1s of stetcher courses fone header row a showin Fig. 2-5 a much ston: fer wll and has an important advantage In 2 kn Inet bricks ae subject slagging or ster exosive {ction suchas occurs in a wood-fired kn or salt lane ln, the exterior fe canbe easly repaed by feplacng the # 1/2" x 9" hace brick with another, ona 1/2" skin wall (am mix) ed into the remain Ingrid, ALTERNATE HEADER AND STRETCHER courses ‘Alternat headers and stretches in walle of" and 13 112 thicknesses ate exterely stable. This is con sidered good price in beckaying Fig. 2—A: Alternating four stretchers with one adr makes it easy t replace a hot fce brick Itis alo considered good practice to have alter- nating joints on each row, which means no joints run inastraigh line above cach other (Fg. 2"). Fig. 2-5: Alternating joints produc a stable wall. ‘This alternate header and stretcher walls some- times refered to at "English bond” ands the mort, ‘common method of construction uring dense ite ‘brik T begin 9" wall 9" 6 large Bick 1/2" Dat and straight bricks are used to setup the ot pat tern for subsequent rows (Fig. 2-8) Fig. 2-8: Layout for bac of" altrnate header and stretcher wall ROWLOCK AND SOLDIER COURSES In rowiock course bricks ae lad on their Sides (2 12° X9") side to-ide or end to-end (Fig. 2 ‘Dana solder course, bricks are laid on end (4 U2" 21/2), Sdetoside o end-toend (Fig 28) Rowlock course: left) side-to-side (right) end-o-end oe Fig. 28: Soldier course (eft) side-to-side: (ight) end-sovend, WALL CONSTRUCTION 13:1/2" WALLS “There are thee usual methods fr lying 13 1/2 wall: 1 One may use standard 9" x 4 U2" x 2 2" bricks with "36" 2 U2" bricks. The 13 1/2 wal (Ghoven in Fig. 2-9) has no joints running through it ‘Also (shown in Fig. 2-9) alternating heade/stretcher ‘with suetchectheader, use 9° x 6" 2 12" brick fr ‘Staggering joins. Fig. 2—9: Method 1 for lay ing 1312" wal, 2. In the second method, the wali laid with four rows of hot-face stretchers backed by headers, and one row ofheades, which, in tun, sbacked with Stretchers (ig, 2-10). The advantage ofthis eonstuc- ‘oni that ie makes for eae rept. Fig. 210: Method 2 or layinga 13 1/2" wal. 3. In the third method of lying 13 1/2" wall, ‘very fith-tow header course has 4131/2" brick init ‘with alternating joints on each row. “Ths type of construction makes an extremely stable wall ha easy repair. Its also good for set- ting sprung arches Pimow — MexT stows SR ROW Fig, 211: Metso 3 for laying a 1312" wall, FLUES ‘When building flues into the lla wall, the nor- ral distance between flues will be 9, or one brick ‘The average sie of Tues wl bone brick standing on end (974 129). (Fasng the? 12" brick sere, our rows of bricks wil tse the Ave hoes tobe 41/2" CumPren 2/MEMI0B OF KAN CONETIVCTION-3¢ 10" Thre bricks ofthe 21/2 series wil be sufficient in almost ll cases however itt better to erin bat= ing flues too large, rather than too smal.) All fue holes shouldbe but on aheader couse with the ue opening directly sbove a header (Fig, 212). The rex fon iz thatthe header brick becomes a knockout brick incase the fue bo smal. tn ain the 9° five separator, alternate header and stretcher courses Should be weed CURVED WALLS Cursed wall are found in domed, downdraft and beehive Hlne. The exon curved wal ae ed that they ate much stronger and mote stable than a ‘night wall The curve creates 3 wedging aco, which hegpe the brick fram fling inva. The only Timing ftctor on height he compression strength of the bottom bricks. This ie why many early Kine ‘with walls 18-22 1/4 hick (n some cases up to 3to5 Tet) cou ary the thru ofthe dome without rein forcing suppor. Material choices for curved wall 4 "wall thickness (rch brick can be sed, but not recommended) wall hicknes-fy (or combination ofcirle and key bik) A713 1/2 and greater wall thicknes-key (or combination of lr snd key brick: wedge bricks not recommended) ‘Carved walls ae laid with the same alternating Soins straight walls (213). SE EE Fig. 2-13: joints are aerated in curved wall, Neo 22. TH 000K DIVISION OR COMMON WALLS ‘A division walls the common wall between 0 chambers. In anormal chamber wall, the temperate {drops from the inside out, whereas a common wall ‘maybe subject to hot-ie temperate om both ides, Thus, the division must be made of good quality refractory mater. The common wall 0 spporte the thrust of wo aches (Hig 2-18), Fig. 214: A common wal supports he thrust of two arches ad has to hot faces. Its good practice to build common walls 412" seater in thickness than the ordinary il wall and a ‘Common wall should never be leis han the width of the wo skewbacks used ARCHES ‘SPRUNG ARCHES ‘Kn arches perform two duties — forming roofs for the kiln chamber and forming doors and open Ings. Speung describes the arch of a einer, and is ‘hemos common arch used in kn bulding “Thearch eon a skewback on bath ends. kew- backs determine the atch re and te the ach to he wall Fig. 2-15), The force ofthe arch is down and out ‘pins the wal. If the skewbacs fl, the ach ail ‘owe; therefore the walls and skewbacks must be ig. {aly constructed, Standard sizes have been developed for arch, wedge and key brick, because dense fre bricks ae molded to sie and fied, thus they eat be easly machined. These special sizes ae called No Fig, 218: An arch est om showhacs, xarting ite forcedown and ot, 1, No. 2, and No. 3, and, when used by theses, tira cre, Arches are bul using a combination oF No", 2,and 3 bricks with straights to tra almost any given crl, For the combinations of arhes and Straights in a given radius, see Estimating Firebrick Arches in Appendix “The following list gives shapes and combinations ‘ofbrick forthe arch thicknes spect: 4 12 Arch brick, oF combination of uch and stright <6 314" or 7 U2" Large 9 arch, or combination oflarge9" arch and large" aight. “Tor: Wedge brick ora combination cf wedge and saight (Construction of ky brick, or combina tion of key and suaight, isnot common, asthe oad is placed onthe nartow face. This construction is only "sed when special conditions make it desirable) — ‘Over 9": Necessary constructed of special ‘wedge bricks However, 13 1/2" wedge bricks se san- Unliomonemmacuren. “There are four major types of sprung arches Bonded aches, rng arches, ribbed arcs and tight archer ‘Bonded arches. The bonded arch isthe most commonly ied arch and i considered th test The Joints ae staggered ying the whol arch intoa single Unit (Fig. 216). If one or several bricks ful ina ‘onded rch the rick on either side absorb he load and the arch remains in place EY BRS Fig, 2—16: Joints are staggered in a bondedarch. ing arches: The sing arch i, as the name implies one where each row of bricks arose ach Iba tng of brik (Fig. 2-17). Fone brick nthe rng fas the whole rng drops. es dificult to replace 8 og fbrieleTused ring archon achamberhin sn found that, during firing, the rings expandsl open most 12° Perhaps if the lin had been tied gether ‘with sel would have helped. A bonded arc bow ‘re, doesn't have this problem. The main advantage fof a ing ach isthe ease of laying, especialy when ‘sing combination of standard shapes. "Ribbed wren Pe sua we puny sme in openshearth fornaes, The ibs give the asc abi gees mS Fig. 2-17: Ring arches expand during fre and, if one brick fai, the whole ving fal. iy and strength afer the intermediate bricks have ttoded (Fg. 218). ce Fig. 2—18: Ris provide stability and sinength aginst erosion Straight arches ‘The sesight arch is « bonded arch made with standard "x4 1/272 1/2 steaght bricks andr ured when ene doce’ have ach brick salable or when one wants t produce freeform arch ee Fig 2-9). Fig. 219: Proper laying and wedging technique fora sprang arch CHaprER?2 / METHODS OF KAN CONSTRUCTION +23 “The important cori sing rights to make a sprang ac isto sct the corner the rick cartel tbe Pig 219, oie A) Brick ad ono the arch frame The ine edge of rick 2 must be above and touching the ote ed: of ick In oe words, {heh brick act as ip er the brik on top of The Soh a from both ade sntancossy then the iy bricks eat to fi The rch prong othe form by saring tthe boom and woring sp both sider, ving wedges (bits and paces of sal eactores) Sato the gape bewen he brick vows and spreading. them apart whe diving the bottoms into athe Atif however one over wedges or dies foo big a wedge too dep wl pt the reson the baton. This col also eli weakened rice When mor. tating the ach ri, ee should be taken © apy themortrin wee form, ths helping tose up be Proper wedge reese S ae roe Ge BEIGE Bet TOM oF WSICE Fig. 2-20: Applying mortar to forma wedge ‘The hey brick must be pounded down below its negioring brs ts ening» song by Ug monrTaR — cwuoses ey erenp98 BRICK Fig, 2-21: The hey shouldbe forced below neigh- boring brik ‘SUSPENDED ARCHES ‘Asuspended arch ir mechanically eld together and supported in place, nd doesnot ie deci into the side walle, The suppers usually a meal fame: “work fiting into holes or grooves or around specially ‘Shaped brieks, and held together by tod pipe tee bar and 40 forth (Fig. 22). The most common thickness for suspended arches are 412" and "The advantages of using «suspended ach are readily seni top loading decric or gas hls Repalt to there arches is quite en, unless sidewall Bracing required. Also, its ea to acornmodate thermal ‘expansion, oth horizontally and verily, which reduces break: causing sts inthe bres oat SUSPENDED Ate Fig. 2-22: Metal framework for a suspended arch, ‘The dsadvantageis that it usually costs more for the additional metal framework and Connection rod assembly than isthe case with a sprung ach CORBEL ARCHES ‘A type of ach sedom mentioned is the corbe, ‘This particular arch cas be used to span portholes fle hoes where other inte! shape ate too smal (Fg 2-28) Use the corbal ach to span up to 24" ST, Fig. 2-23: Corbl arches can be wed to spans flues or portioles. ‘ave seen smal, 10- to 16-cubic fot kis with

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