Installation method of refractory bricks
2024-08-12 10:33:38
Refractory bricks are a kind of building material that can withstand high temperature, chemical erosion and mechanical wear. They are widely used in the lining of high-temperature industrial equipment such as metallurgy, petrochemical, ceramics, glass, etc. The correct installation method can not only extend the service life of refractory bricks, but also improve the overall efficiency of the equipment. This article will introduce the installation method and precautions of refractory bricks in detail to ensure the installation quality and use effect.
1. Preparation before installation
Before starting to install refractory bricks, sufficient preparation is required to ensure the smooth progress of the construction process:
Material preparation: Ensure that the required refractory bricks, refractory mud, anchors, tools and other materials and equipment are fully prepared. Refractory bricks should be inspected according to the specifications, sizes and materials required by the design, and avoid using bricks with defects such as cracks and missing corners.
Base cleaning: The base should be thoroughly cleaned before installation to ensure that its surface is flat, clean, and free of impurities such as oil, dust, etc. If the base is uneven, it can be leveled with refractory mud.
Environmental conditions: The construction environment should be kept dry, and avoid installing refractory bricks under humid or extreme temperature conditions, because humidity and temperature changes will affect the bonding strength of refractory materials.
2. Refractory brick installation steps
Refractory brick installation is usually divided into two main steps: masonry and bonding:
(1) Masonry refractory bricks
Masonry refers to placing refractory bricks in designated positions according to design requirements, usually using staggered masonry to increase the stability and overall strength of the structure. The specific steps are as follows:
Staggered masonry: Arrange refractory bricks in staggered positions according to the requirements of the design drawings to ensure that the joints of adjacent bricks are staggered to avoid the formation of straight joints. Staggered masonry can effectively prevent thermal stress concentration and thus reduce the occurrence of cracks.
Maintain flatness: During the masonry process, use a level and ruler to check the flatness and verticality of the brick layer at any time to avoid structural instability due to uneven brick layers. If necessary, fine-tune with refractory mud.
Controlling gaps: The gaps between refractory bricks should be uniform, usually 1-3 mm. Too large gaps will affect the stability of the overall structure, while too small gaps may cause bricks to be squeezed and deformed during thermal expansion.
(2) Bonding refractory bricks
The bonding of refractory bricks is to fix the bricks to the base or adjacent bricks through refractory mud or glue. The quality of bonding is directly related to the firmness and service life of the refractory bricks, so it must be strictly operated in accordance with the specifications:
Preparation of refractory mud: Refractory mud should be prepared on site according to construction requirements. When preparing, the components should be accurately weighed according to the proportion and stirred evenly. The prepared mud should have an appropriate consistency to facilitate construction and bonding.
Applying mud: Apply a layer of refractory mud evenly on the bottom and side of each refractory brick. The thickness should be controlled between 1-3 mm. When applying, pay attention to uniformity and fullness to avoid hollowing.
Installation and correction: Gently place the refractory bricks coated with mud in the predetermined position, and tap the top of the bricks with a rubber hammer to ensure that they are in close contact with the adjacent bricks and remain flat. If necessary, the flatness and verticality of the bricks can be corrected again with a level.
3. Maintenance after installation
After the installation of the refractory bricks, proper maintenance is required to ensure their bonding firmness and overall strength:
Natural curing: The mud of the refractory bricks needs to be naturally cured for at least 24 hours at room temperature, and vibration and heavy pressure should be avoided during the period. During the natural curing process, the construction site should be kept dry to avoid water entering the brick joints.
Drying treatment: For refractory bricks installed in large furnaces or in humid environments, drying treatment should be carried out. Drying treatment usually adopts slow heating to prevent cracks in the refractory bricks due to rapid evaporation of water.
Gradual heating: Before the equipment is put into use, it is necessary to gradually increase the temperature to avoid sudden heating that causes excessive temperature difference between the inside and outside of the refractory bricks, resulting in thermal stress and damage to the bricks. It is generally recommended to increase the temperature at a rate of 30℃~50℃ per hour until the normal operating temperature of the equipment is reached.
4. Precautions
During the installation of refractory bricks, special attention should be paid to the following points:
Brick quality: The appearance and quality of each refractory brick should be carefully checked before installation. Bricks with defects such as cracks and deformation should be removed in time to avoid affecting the stability of the overall structure.
Construction specifications: During construction, the design drawings and construction specifications should be strictly followed to ensure the accuracy and consistency of each step to avoid damage to the refractory bricks or loose installation due to improper operation.
Safety protection: Safety protection measures should be taken at the construction site to prevent bricks from falling or construction tools from injuring people. Construction workers should wear personal protective equipment such as gloves and goggles.
5. Summary
The installation of refractory bricks is a highly technical job and must be carried out in strict accordance with construction specifications. Through scientific installation methods and meticulous maintenance measures, the service life of refractory bricks can be effectively extended and the safety and operating efficiency of equipment can be improved.
1. Preparation before installation
Before starting to install refractory bricks, sufficient preparation is required to ensure the smooth progress of the construction process:
Material preparation: Ensure that the required refractory bricks, refractory mud, anchors, tools and other materials and equipment are fully prepared. Refractory bricks should be inspected according to the specifications, sizes and materials required by the design, and avoid using bricks with defects such as cracks and missing corners.
Base cleaning: The base should be thoroughly cleaned before installation to ensure that its surface is flat, clean, and free of impurities such as oil, dust, etc. If the base is uneven, it can be leveled with refractory mud.
Environmental conditions: The construction environment should be kept dry, and avoid installing refractory bricks under humid or extreme temperature conditions, because humidity and temperature changes will affect the bonding strength of refractory materials.
2. Refractory brick installation steps
Refractory brick installation is usually divided into two main steps: masonry and bonding:
(1) Masonry refractory bricks
Masonry refers to placing refractory bricks in designated positions according to design requirements, usually using staggered masonry to increase the stability and overall strength of the structure. The specific steps are as follows:
Staggered masonry: Arrange refractory bricks in staggered positions according to the requirements of the design drawings to ensure that the joints of adjacent bricks are staggered to avoid the formation of straight joints. Staggered masonry can effectively prevent thermal stress concentration and thus reduce the occurrence of cracks.
Maintain flatness: During the masonry process, use a level and ruler to check the flatness and verticality of the brick layer at any time to avoid structural instability due to uneven brick layers. If necessary, fine-tune with refractory mud.
Controlling gaps: The gaps between refractory bricks should be uniform, usually 1-3 mm. Too large gaps will affect the stability of the overall structure, while too small gaps may cause bricks to be squeezed and deformed during thermal expansion.
(2) Bonding refractory bricks
The bonding of refractory bricks is to fix the bricks to the base or adjacent bricks through refractory mud or glue. The quality of bonding is directly related to the firmness and service life of the refractory bricks, so it must be strictly operated in accordance with the specifications:
Preparation of refractory mud: Refractory mud should be prepared on site according to construction requirements. When preparing, the components should be accurately weighed according to the proportion and stirred evenly. The prepared mud should have an appropriate consistency to facilitate construction and bonding.
Applying mud: Apply a layer of refractory mud evenly on the bottom and side of each refractory brick. The thickness should be controlled between 1-3 mm. When applying, pay attention to uniformity and fullness to avoid hollowing.
Installation and correction: Gently place the refractory bricks coated with mud in the predetermined position, and tap the top of the bricks with a rubber hammer to ensure that they are in close contact with the adjacent bricks and remain flat. If necessary, the flatness and verticality of the bricks can be corrected again with a level.
3. Maintenance after installation
After the installation of the refractory bricks, proper maintenance is required to ensure their bonding firmness and overall strength:
Natural curing: The mud of the refractory bricks needs to be naturally cured for at least 24 hours at room temperature, and vibration and heavy pressure should be avoided during the period. During the natural curing process, the construction site should be kept dry to avoid water entering the brick joints.
Drying treatment: For refractory bricks installed in large furnaces or in humid environments, drying treatment should be carried out. Drying treatment usually adopts slow heating to prevent cracks in the refractory bricks due to rapid evaporation of water.
Gradual heating: Before the equipment is put into use, it is necessary to gradually increase the temperature to avoid sudden heating that causes excessive temperature difference between the inside and outside of the refractory bricks, resulting in thermal stress and damage to the bricks. It is generally recommended to increase the temperature at a rate of 30℃~50℃ per hour until the normal operating temperature of the equipment is reached.
4. Precautions
During the installation of refractory bricks, special attention should be paid to the following points:
Brick quality: The appearance and quality of each refractory brick should be carefully checked before installation. Bricks with defects such as cracks and deformation should be removed in time to avoid affecting the stability of the overall structure.
Construction specifications: During construction, the design drawings and construction specifications should be strictly followed to ensure the accuracy and consistency of each step to avoid damage to the refractory bricks or loose installation due to improper operation.
Safety protection: Safety protection measures should be taken at the construction site to prevent bricks from falling or construction tools from injuring people. Construction workers should wear personal protective equipment such as gloves and goggles.
5. Summary
The installation of refractory bricks is a highly technical job and must be carried out in strict accordance with construction specifications. Through scientific installation methods and meticulous maintenance measures, the service life of refractory bricks can be effectively extended and the safety and operating efficiency of equipment can be improved.