Technical Information

Guide 30:Rotary Kiln Brick Installation 04/08

Page 1 of 2
Rotary Kiln Brick Installation Guidelines
1 Rotary Kiln Shell: !"ell s"ould #e ins$ected and free of de#ris% ie scaling% e&isting
refractory% etc
2 Reference Lines: Reference lines s"ould #e identified for a #asis of e'aluating installation
accuracy General reco((endation is to $lace reference lines e'ery fi'e linear feet
3 Into the Kiln: Brick s"ould start against a reference $oint t"at is $er$endicular to t"e a&is of
t"e kiln )n e&isting retainer ring and/or refractory s"ould #e closely e&a(ined for *trueness+
If t"e reference $oint is ,uestiona#le% a *cut-ro.+ is reco((ended to ensure t"e #rick are
closely follo.ing t"e $er$endicular a&is of t"e kiln
4 In the Kiln: /"e #rick s"ould #e installed in t"e #otto( of t"e kiln u$ to t"e s$ring-line of t"e
kiln /"e #rick courses s"ould #e installed in a #onded fas"ion% ie o'erla$$ing eac" #rick
.it" eac" additional course 0oints s"ould #e staggered fro( ring to ring #y 1/3 t"e #rick
.idt" 1"en t"e #rick (eets t"e s$ring-line% careful attention s"ould #e gi'en to dri'ing t"e
#rick do.n-kiln using a ru##er or ra."ide-"eaded "a((er 2o not use (etal "a((ers to
set #rick 1e generally reco((end #edding-out only 13 linear feet of #rick #efore closing
t"e rings o'er"ead
3 Brick Installation: Brick s"ould #e fir(ly seated on t"e kiln s"ell Brick t"at tilts or "acks
against t"e s"ell s"ould #e corrected 4or (agnesia and dolo(ite #rick% correction can #e
(ade .it" (etal $lates 5s"i(s6 4or fireclay and "ig" alu(ina #rick% corrections s"ould #e
(ade .it" refractory (ortar 2o not use c"i$s or ru##le to fill 'oids% or to $ro$ #rick 1"en
laying cu$ola #lock 5RKB7s6% t"e #rand face 5notc"ed6 s"ould #e alternated to acco((odate
any draft (olded into t"e s"a$e
8 Brick Installation Overhead: Brick s"ould #e installed using a #rick su$$ort rig or $ogo
sticks 1e do not reco((end t"e use of ad"esi'es to install #rick )s t"e #rick is installed
o'er"ead% care s"ould #e taken to s$read t"e key.ay using a "ydraulic $orta-$o.er or
$neu(atic 9ack 1"ile s$reading t"e ring% #rick at and a#o'e t"e s$ring lines s"ould #e
ins$ected for contact .it" t"e s"ell ) general rule of t"u(# is to e&ert no (ore t"an :3; of
t"e $u#lis"ed cold-crus"ing strengt" of t"e installed $roduct )fter s$reading t"e ring% t"e
#rick s"ould #e dri'en do.n-kiln using t"e sa(e tec"ni,ue as descri#ed a#o'e /"e #rick
s"ould #e keyed using fitting #rick 5key #rick6 and s"i(s /"e fitting s"ould #e installed using
an alternating $lace(ent (et"od% ie full #rick #et.een fitting #rick and ne'er line u$ fitting
#rick fro( #rick course to #rick course Place(ent of key #rick s"ould #e 'aried fro( one
course to anot"er 2o not key e'ery ring in t"e sa(e area of t"e s"ell /"e #rick s"ould #e
installed tig"t enoug" so t"e #rick does not se$arate fro( t"e s"ell as t"e rig is released or
t"e $ogo sticks re(o'ed /"e #rick needs to #e fir(ly seated against t"e s"ell #ot" on t"e
#otto( as .ell as t"e to$ of t"e kiln
: Brick Installation < Sawing Shapes < Brick s"ould #e cut using a #rick sa. 2o not use a
"a((er to c"i$ edges or si=e #rick to fit a gi'en area In addition% cut #rick s"ould not #e
less t"an 2/3 t"e original si=e 1"en installing cu$ola #lock 5RKB7s6% $lace t"e cut key a.ay
fro( t"e center and close .it" a full% uncut #rick
Guide 30:Rotary Kiln Brick Installation 04/08
Page 2 of 2
Technical Information
8 Brick Installation Alignent: /"e #rick courses need to #e referenced on a regular #asis
to insure t"e align(ent is $er$endicular to t"e a&is of t"e kiln and ensure t"e rings are
straig"t /"e (a9ority of t"e $ressure is $laced on t"e slo$ed% linear side of t"e #rick
> Brick Installation !opletion: ?areful ins$ection s"ould #e (ade after co($leting t"e
#rick installation )n atte($t s"ould #e (ade to dri'e s"i(s in #rick courses to ensure
tig"tness If t"e #rick "as loosened fro( t"e s"ell% e'ery atte($t s"ould #e (ade to re-seat
t"e #rick and tig"ten accordingly If t"e kiln is turned cold after installation due to (ec"anical
or ot"er reasons% t"e refractory needs to #e ins$ected and re-s"i((ed if necessary
10 Shis: /"e nu(#er of s"i(s used in a #rick course s"ould #e ke$t to a (ini(u( #y
correctly si=ing t"e key #ricks% "o.e'er% eac" ring (ust #e tig"tened until no (ore s"i(s can
#e dri'en into t"e ring ) good rule of t"u(# is insert only one s"i( or $late $er 9oint )
large nu(#er of s"i(s re,uired in a lining can suggest t"at installation $rocedures need to
#e e&a(ined or t"e kiln s"ell needs to #e ins$ected for distortion ) t.o-s"a$e #rick syste(
is an o$tion for reducing t"e need for s"i(s in #rick installations
11 Brick Installation "nita# $%& < 1"en laying Resco Products% Inc $atented @nita# *A+
e&$ansion design% (etal $lates or card#oard s$acers are not attac"ed 5glued6 to t"e #rick
Brick c"a(fer (arks easily assist .it" identifying t"e "ot-face side of t"e #rick A&$ansion
ga$s on #ot" circu(ferential and longitudinal sides of t"e #rick $ro'ide t"e end-user .it"
additional insurance to assist .it" increasing o$erational ca($aigns