1 Process procedure
Mixing masonry mud → process inspection → sawing and processing heat-insulating refractory bricks → masonry.
2 Mixing masonry mud
(1) When the masonry mud is made of finished refractory mud or diatomite powder combined with clay mud, mechanical stirring should be used as much as possible, and the stirring time should not be less than 5 minutes. The mud consistency is controlled by adding water.
(2) In the case of no mechanical stirring, it is advisable to use the soaking method, that is, the raw materials used for mixing masonry mud are flooded with water, naturally infiltrated, and the soaking time shall not be less than 24 hours. After soaking, the excess water is decanted and mixed.
3 Process inspection
(1) Before laying diatomite bricks, check whether the contact surface between the diatomite bricks and the kiln shell meets the requirements.
(2) When building heavy furnace walls, check whether the quality of the front refractory masonry meets the requirements and whether the accessories are installed correctly.
4 Sawing processing
(1) Bricks used for thermal insulation masonry staggered joints or other processed bricks should be sawed with a hand saw or hacksaw, and cannot be cut with a brick knife.
(2) When batch processing of heat-insulating refractory bricks, it is advisable to use a template to control, and use a saw blade or a steel needle to directly mark the line.
(3) In order to improve the processing accuracy, the processing line should be determined by the imprinting method at the contact between the heat-insulating refractory brick and the special-shaped steel member.
5 Masonry of heat-insulating refractory bricks
(1) The masonry sequence and masonry height of heat-insulating refractory bricks should be determined according to the masonry structure.
(3) Thick mud should be used for the leveling of heat-insulating refractory brick masonry. When the local out of tolerance or the obstruction of embedded parts and special-shaped bricks, it is advisable to use processed bricks for leveling.
(4) When laying heat-insulating refractory bricks, the ash laying method should be adopted at the flat joints, and the knife ash method should be adopted at the vertical joints.
(5) Expansion joints should not be left in the insulating refractory brick masonry, but when the movable ends of other equipment and components face the insulating refractory bricks and the expansion value is large, refractory fibers or Other resilient insulating materials replace insulating refractory bricks.
(6) When the expansion joint of refractory masonry. Especially when the straight-through expansion joint is facing the heat-insulating masonry, the heat-insulating refractory bricks must be replaced by refractory bricks. Generally, standard refractory bricks should be used to lay one layer horizontally or vertically to cover the expansion joints.
(7) The heat-insulating refractory bricks should be extruded and aligned by hand, and it is not advisable to strike with a mallet, and the dry-solid heat-insulating masonry should not be knocked, collided or otherwise vibrated.
(8) The width of the brick joints of the thermal insulation masonry shall be less than 5 mm. The grade and mix ratio of the mud must meet the design requirements, and the plumpness of the wet-laid heat-insulating refractory brick joints shall not be less than 80%.
2. Dry laying process of heat-insulating refractory bricks
1 General Provisions
(2) The appearance of dry-laid heat-insulating refractory bricks should be intact, and those with serious damage should not be used.
(3) The filler used for the joints should be dry and have good filling performance. If it is damp or agglomerated, it should be dried and screened before it can be used.
(4) Dry-laid heat-insulating refractory bricks should be built with staggered joints.
2 Inspection of the pre-dry laying process
(1) Before masonry, the kiln shell and related accessories should be installed and passed the process inspection.
(2) When laying refractory bricks or pouring refractory castables first, the construction quality of brick masonry and castable body should be able to meet the normal construction conditions of thermal insulation masonry, and the height should be appropriate.
(3) When filling and masonry in the narrow groove between the shell wall and the masonry, the brick chips, mud and other debris in the narrow groove must be completely removed.
3 Masonry methods
(1) Dry-laid heat-insulating refractory bricks should be built with the kiln shell or the front masonry as the guide surface, and if there are obstacles, they should be processed.
(2) If there is no requirement in the design, except for the upper part (upper semicircle) of the inner lining of the masonry pipeline, the upper semicircle of the inner lining of the fixed cylindrical equipment and the conical inner lining, the ring masonry method can be used, and the rest should be masonry with staggered joints.
(3) Staggered seam processing, leveling processing, and modification processing should meet the requirements of sawing processing.
(4) Dry-laying joints should be filled with dry heat-insulating filler powder. If necessary, a small amount of ordinary cement can be added to the filler to mix evenly. The filler mixed with cement should be filled at one time.
(5) Dry-laid thermal insulation refractory bricks should be filled in time after the completion of one layer, and then the next layer can be built.
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