Document YDwXRMwn3xRDVOonogY957ejN

Table of contents INTRODUCTION.................................................... 2 INSULATING FIRE BRICK General Information........................................... 4-5 Methoc ot Production........................................ 6-7 Tvpual Uses....................................................... 8-9 Heat Losses Table................................................. 10-13 Standard ann Large Sizes................................... 14 Special Shapes.................................................... 15 Pac.Lacinc and Palletizing.................................. 15 Construe iionJDetails Straight Walls.................................................... 16-17 Curved U'alis................................................... 18 Division Walls................................................. 19 Sprung Arches ............................................ 20 Domes and Crowns......................................... 21 Suspended Arches and Walls......................... 21 Periodic Kiln Domes......................................... 22-23 BONDING MORTARS General Information........................................ 24 Available Types.................................................24-25 Methods of Application.................................. 26 SUPEREX................................................................ 27 REFRACTORY-FIBER PRODUCTS........................ 27 GLOSSARY OF STANDARD TERMS..................... 28-29 Stnrr 1858. Johns-Manville has ci; \ ; >improved m> think arc; r.'.;irh:;>'s :i : manufacturing high quality insula*.:And the )-M Research Cento: nr.:Colorado, contains a fully equip; > refrat tories laboratory with th rtv testing equipment. Here. e larg- s: ; scientists, engineers ant: techr.ir in continual research and develop:: and existing refractory produc is. The performance of all J-M refrr.r to:.. regularly tested under high temperEt::.. conditions closely simulating th ,-e r:. during service in the field. Chcmic.-i physical tests are madt. and the indie.... raw materials are subjt uted to sc.i . The most advanced apparatus is used : temperature measurements, mic: os.'tor studies and X-ray. The ceramic engineers also carry cut assignments related to specific custom problems. This broad research pioctam y. major part in Johns-Manvillc s ability U . exactly the right insulating lire b: it.l: and refractory product for a given service. V NEED INFORMATION ON OTHER J-M PRODUCTS & SYSTEMS? Finding out about them couid save y:- t Call the new Jonr-t/a''vihe PRODUCT INFORMATION CENTE- &: (3031 770-1000 Ext 2745 G.ve us Modem Research Methods combined with a century ot Manufacturing Experience Assure Johns-Manvilie Refractory productr c( Highest Quality and lop Value 3 Johns-Manville insulating Fire Brick provide unsurpassed heat-control effectiveness to 3200F Johns-Manville's modem refractory plant at Zelienople. Pa. |belo>v). manufactures a complete line of insulating fire brick, cements and castable materials for tem peratures through 3200F. At Zehenople's control laboratory, trained ceramists continually conduct physical and chemical tests to in sure product uniformity and high quality. This control is of paramount importance in these days of higher op erating temperatures and mounting operating expenses l-M INSULATING FIRE BRICK - Produced from high quality refractory clays. All eight types contain a care fully graded organic filler which is burned out during manufacture, resulting in a uniform, controlled pore structure. Each insulating fire brick or shape is ac curately ground to size. With eight types of top-quality fire brick |uhnv Manville offers operators and builders of high tem perature equipment the opportunity to use the mu insulating fire brick that is right for a given service Each J-M Insulating Fire Brick has the correct balance of thermal, chemical and physical properties for its rec ommended use. In addition, oil J-M Insulating Fire Brick are the required purity (low reducible oxides), for use m prepared atmosphere furnaces and special ceramic kiln* that use salt glazing processes. All eight types h<m light weight low conductivity and high structural strength for the efficient and economical control of heat J-M Insulating Fire Brick are used as refractory lining or as back-up insulation behind other refractory materials Their light weight and high insulating value make pos sible thinner furnace walls, improved efficiency anr' lower operating costs. Furnaces can be brought up to operating temperatures with unusual speed, thus result ing in increased production. Johns-Manville also offers larger sizes than conventional straights (see pagei4l which make possible a wider variety of wall construction. Lower installed costs are possible since fewer pieces are handled to lay up a given volume. t B Complete line of insulating fire brick Thf -io line of J-M Insulating Fire Brick proven by mar = r s> of service in thousands of applications is dps* : 'I'nv. Jf>* 22 2200F) -- Johns-Manville has extended the len : - ' . limit of its regular IFB line by adding a eigr - tn 3200F. This new grade answers the de- mar. ' ' insulating fire brick to meet today's higher ter ;-' ' -'r requirements in furnace applications. JM 3000 to 3000F) - An outstanding high temperature ir.sr 1 . f ire brick made for back-up or exposed use. It h..- proven record of superior service in forge furnar- --ic kilns, chemical process and steel mill ferr and other types of high temperature equipment opt-: r: zorne JM-28's temperature range. JM-3000 will giv' - <-( riional service in many severe operations at low*" temperatures where regular or special fire brick are >::!.nnrily used. JM-28 r 2800F) -- With its comparatively light weight ar.d r.;.h spelling resistance, this brick can be used ex posed ' : back-up insulation in enameling furnaces, fore- furnaces. soaking pit covers, ceramic kilns and othe: locations where operating temperatures will not exceed 2R00F JM 26 ,;o 2600F) -- Combines high spalling resistance and :;cht weight. It is suitable for use exposed or back up insulation in calciners. ceramic kilns, heat-treating furnace? and iimilar equipment where the operating terr.tv rciure does not exceed 2600F. 2S JM-SL (to 2300F exposed, to 2500F back-up in limited service) --Designed for use in operating conditions where toughness and better abrasion resistance are more important than light weight and low conductivity. JM-23 (to 2300F) -- A lightweight high purity brick with low iron content which provides high resistance to the deleterious effects of prepared atmospheres. It is de signed for direct exposure or back-up insulating in such equipment as oil heaters, process furnaces, ceramic kilns, drawing furnaces, electric furnaces and hardening furnaces. JM-20 (to 2000F) -- It is made from carefully selected material with a low iron oxide content. The brick has good hot and cold crushing strength. It is used in anneal ing furnaces and various other types of equipment such as carburizing furnaces, lehrs, normalizing iumaces. oil stills and heaters, recuperators, regenerators, and for stack linings. C-22Z (to 2000F) -- An efficient high strength burnouttype insulating fire brick for use as a back-up insulation behind fire brick where the temperature on the brick will not exceed 2000F. This brick has a cold crushing strength of 450 psi and is recommended for locations where high compressive strength is desirable, such as hot blast stoves and soaking pits. Ask for Thermal Insulation Products Sheet IND-3033 with complete physical properties data. STANDARD SIZES All I-M Insulating Fire Brick are available in accuratelysized 9" straights and shapes in the 2,.i" and 3" series. Spe::.'<! sizes and shapes are also available up to a maximurr. of 23' x " x 3" for JM-20 and 23: a maximum of 24" x 9" \ 3" for JM-SL. 26. 28. 3000 and 32. LARGE SIZES Av affable in the following sizes and all types: 13' x 41 i" x 3" 13* x 9" x 3" 9" x 6s 4" x 3" 24" x 9" x 21 "* li1 V'x9"x3" 9" x 7>/t" x 3" 24" x 9" x 3"* Mr. iM-20 and 1M-23. the length is 231 " instead of 24". Shipped palletized only. COMPLIANCE WITH GOVERNMENT SPECS (A statement requesting compliance must appear on the pur chase order. Government regulations prohibit the certification of compliance after shipment has been made ] JM-20 complies with M1L-B-16305A. Class B JM-2B complies with M1L-B-16305A. Class B JM-SL complies with MIL-B-16008C 5 streamlined methods cut production time and speed delivery ot J-M insulating Fire Brick in standard, large and many special shapes In jchns-Manville's expanded refractory plant at Zelienonip. Pa . high quality insulating fire brick are made faster and belter by a unique process that utilizes large fired slabs to produce conventional, and large size brick, as well ac an almost unlimited variety of special shapes. The slabs are molded, fired rapidiy through tunnel kilns, then cut into the desired shape. Many shapes which normally have to be molded and processed as special items can now be produced directly from slabs. They are also superior to shapes made by joining individual brick and make possible larger sizes than conventional straights This streamlined operation provides the flexibility and basis for fast, efficient shipment to our customers of high quality standard, large size and special insulating fire brick shapes. SL/NGER METHOD (JM-SL JM-26. JM-28. JM-32 and JM 3000) Simper mochinc throws selected mix from pug mill i.rj fern continuous stiff column on pallets. CASTING METHOD (JM-20 and JM-23) (2) The column is first trimmed on the top and sides, then cut into slobs which rest on individual pallets. Ibcm.-s o' high purity relrociory mntenols. setting : - om: burn-out ore thoroughly mixed with water ....... r.<- niixc.* then pouted into o mold. 121 When mix hardens, the mold is moved to the strip ping machine where slohs ore removed from mold ant.' put on kiln car. The two types of fired slabs receive the same finishing procedure after they are removed from the tunnel kiln. They are ground and cut into conventional and special brick shapes by a sizing machine which slits the slabs to the proper width and length. The brick are then packed in cartons and stored in the plant warehouse to await shipment by rail or truck. ti* Slabs ore automatically transferred from the main conveyor onto dryer cars where they are stored and dried, then loaded on kiln cars. HI Kiln car with dried slabs wails to enter continuous tunnel kiln to star) carefully controlled schedule of firing The same procedure is repeated two more times If " until '.tie kiln car is loaded with three courses of slabs. i-t; Slab car emerging fiom continuous tunnel kiln oftei passing through piehentmc firinc and roolinc steps of drying nnri firm? operation 7 Typical uses for J-M insulating Fire Brick IN THE FERROUS METALS INDUSTRY Annealing furnaces Barrel furnaces Billet-heating furnaces Blast furnace stoves Butt weld furnaces Calorizing furnaces Carburizing furnaces Car tops Case-hardening furnaces IN THE NON-FERROUS METALS INDUSTRY Die-casting machines Electrolytic cells (magnesium) Galvanizing and tinning furnaces Heat-treating furnaces Annealing furnaces Reduction pots (aluminum) Crucible furnaces (lead) Brazing furnaces .Normalizing furnaces Open-hearth furnaces Plate-heating furnaces Pusher furnaces IN THE CERAMIC AND GLASS INDUSTRIES CERAMIC INDUSTRY Chamber kilns Tunnel kilns Shuttle kilns Rotary kilns Car seal backs Periodic kilns Movable hood kilns Porcelain enamel furnaces Flues and stacks Controlled atmosphere kilns Calcinin': furnaces . 8 Controlled-atmosphere furnaces Crucible furnaces Electric furnaces Flues (high temperature) Forge furnaces Hardening furnaces Laboratory furnaces Malleableizing furnaces Carbon baking furnaces Radiant tube annealing covers Recuperators Rolldown furnaces Rotary hearth furnaces Sintering furnaces Slab-heating furnaces Soaking pits Soaking pit covers Spheroidisring furnaces Stress-relieving furnaces Tempering furnaces Walking beam furnaces GLASS INDUSTRY Bending furnaces Flattening ovens Gas mains Glass tanks, regenerators, flues and uptakes Lehrs Ports Float glass process  IN THE PETROLEUM AND CHEMICAL INDUSTRIES PETROLEUM INDUSTRY Hot air and gas mains Breechings Catalytic reformers Ducts Flues Oil heaters or furnaces (walls, arch, floor] Reactor chambers Regenerators Stacks Stills Vessel linings CHEMICAL INDUSTRY Ammonia reformers Calcining furnaces Carbon baking oven covers Dryers High-temperature pressure vessels Hot gas mains Rotary calciners and dryers Special process furnaces Stacks and breechings Sulphur furnaces IN POWER PLANTS AND MARINE Boiler walls, floors, tops breechings Ducts Flues Stacks Fireboxes MISCELLANEOUS APPLICATIONS Core-drying ovens japanning ovens Enameling furnaces Bake ovens Burners Coke ovens Cross-over flues Domestic oil burners Furnaces Gas producers and mains Heaters Incinerators Kilns Ovens Retort benches Stacks Stoves Gas gcncratuis Duct linings SfflWEP mm jiwi m 9 Heat losses, heat storage and outside temperatures ot walls J-M insulating Fire Brick and Mali Thicanpu Construction 1000 HL JT ST HS 1200 HL JT ST HS 1400 HL JT ST HS 1600 HL JT ST HS 1800 HL JT ST HS 4 : JM 20 1SS - 156 1172 197 - 174 1463 243 - 191 1761 292 - 209 2066 344 - 227 2376 A . JM 23 A 7 JMSL 171 - 163 1262 346 - 228 1974 216 - 181 1574 263 - 199 1894 314 - 217 2220 368 - 235 255? 443 - 257 2459 547 - 286 2955 659 - 313 3458 779 - 339 39&c 4'. JM 26 3S0 - 229 2247 440 - 256 2793 534 - 282 3350 633 - 307 3915 737 - 330 4487 4'; JM 28 418 - 250 2643 521 - 279 3275 628 - 305 3917 738 - 330 4566 853 _ 354 5222 4 : ' JM 3000 520 - 278 3062 645 - 309 3781 774 - 338 4510 906 - 364 5245 1040 - 389 5987 A'j ' JM 32 613 - 302 3641 761 - 335 4486 912 - 365 5340 1066 - 393 6201 1221 - 420 7070 4'. FIRECLAY BRICK 984 - 379 6300 1271 - 429 8300 1580 - 477 9400 1913 - 522 10800 2270 - 564 12700 4',, JM-20- IV SX 110 431 136 1649 140 517 150 2074 173 606 163 2514 207 697 177 2968 243 790 192 3431 4'i ' JM-23- IV sx 117 451 139 1791 148 539 153 2247 181 628 167 2718 215 719 181 3201 25? 811 195 3694 4'; JM, SL - IV sx 180 627 167 3003 229 754 186 3774 282 883 206 4568 338 1012 225 5379 399 1142 244 620-4 4 JM-26 - IV sx 179 622 166 3376 224 742 104 4223 273 862 203 5091 324 981 220 5974 378 1100 238 6B66 t 4 JM 28- IV sx 193 661 172 3979 242 785 191 4960 292 908 209 5959 346 1029 228 6970 402 1149 ?45 7991 4'; JM-3000 - 1 v sx JV 3? * I'-- sx V. JM 20 211 709 179 4622 225 744 185 5478 105 - 133 1714 264 840 199 5748 281 881 205 6805 134 - 147 2140 319 969 219 6889 376 1095 237 8040 436 1219 255 9197 340 1016 276 8147 401 1147 245 9498 466 1?76 264 1085? 165 - 160 2577 198 - 174 3025 233 - 188 3480 6`. JM-23 116 - 139 1843 147 - 152 2300 179 - 166 2769 214 - 180 3247 250 - 194 3735 6'4 ' JM SL 240 - 190 2844 306 - 214 3551 377 - 238 4274 453 - 260 5012 534 - 282 5760 6-." 6>. JM 26 243 - 192 3238 305 - 214 4035 369 - 235 4850 436 - 255 5679 506 - 275 6519 6:..' ' JM 28 293 - 210 3800 363 - 233 4723 436 - 255 5662 511 - 276 6615 589 - 296 7579 6Y JM 3000 367 - 234 4391 453 - 260 5441 541 - 284 6506 631 - 306 7584 723 - 327 867? EV JM 3? 6'..- JM 20 - VV sx 436 - 255 5213 63 348 123 2224 537 _ 283 6445 641 - 308 7692 746 - 33? 8951 853 _ 354 10220 105 415 134 2796 129 486 145 3389 155 558 158 4000 182 633 168 462c 6'.' ' JM 23 - IV sx 89 366 126 2417 112 436 137 3033 137 507 148 3669 163 580 159 4322 190 654 171 4990 6Y JM SL - rv sx 147 536 152 4087 187 644 169 5141 229 755 186 6229 275 866 203 7345 323 979 220 8483 BV 6Y JM 26- IV sx 146 533 152 4613 183 634 168 5775 222 735 183 6967 263 837 199 8184 305 938 214 9419 6-' JM 28 IV sx 161 574 158 5474 200 680 175 6827 242 785 191 8208 284 889 207 9608 329 992 222 11023 6Y JM 3000 1 r sx 180 627 167 64 07 224 741 184 7970 269 852 201 9556 316 962 218 11158 364 1069 234 12769 6Y JV 3? - IV sx 195 667 173 7649 742 787 191 9501 291 905 209 11377 34? 10?1 226 13266 395 1134 243 15162 7 r' JV 20 95 - 129 1894 121 - 141 2365 149 - 153 2848 179 - 166 3342 210 - 179 3846 7:/ JM 23 105 - 133 2036 133 - 146 2540 162 - 159 3058 193 - 172 358B 226 - 185 4126 7 JM SL 7 r: JM 26 r: JM 28 rr JM 3000 2- JV 3? 218 - 182 3131 221 - 183 3565 266 - 200 4180 335 - 224 4825 398 - ?44 5726 277 - 704 3910 277 - 204 4443 330 - 222 5197 413 - 749 5984 490 - 271 7085 342 335 396 493 5B4 - 226 4708 410 - 274 5343 396 - 243 6235 464 - 271 7160 574 - 795 846? 679 - 248 5523 483 - 243 6259 459 - 263 72BB 534 - 292 8352 657 - 317 9853 775 - 269 6350 - 262 7188 - 28? 8354 - 312 9554 - 338 11755 H. = Heat Less a: Steady State Condition. BTU SO FT HR JT = Jur::,;1-Tr-'pe'alure between 6'ick and Bacmp insulation F 'Arb.en: = EC Stii. Air ST = Outside Surface Temperature, f. HS = Heat Storage BTU SQ FT SX = JM Superei block insulation HOT FACE TEMPERATURE* --F Superex compared to fireclay brick 2000 2200 2400 2600 2800 3000 3200 HL JT ST HS HL JT ST HS HL JT ST HS HL JT ST HS HL JT ST HS HL JT ST HS HL JT ST HS 399 - 244 2690 - - - - -- - - - - - - -- - -- - - - - - <24 - 252 2887 483 - 269 3226 90 - 364 4484 1040 - 389 5006 845 - 352 5065 957 - 374 5648 1074 - 395 6236 1195 - 416 6829 970 - 376 5884 1091 - 398 6551 1215 - 419 7223 1342 - 440 7899 1472 - 460 8579 1176 - 413 6735 1314 - 436 7488 1455 - 458 8245 1597 - 479 9005 1741 - 499 9766 1888 - 518 10529 - - - - 1378 2670 - 446 7944 1536 586 14100 3070 - 470 8822 1696 619 15500 3510 - 493 9702 1858 - 514 10583 2022 642 17200 3990 - 656 18700 44 50 - 534 11465 2187 - 554 12347 2352 - 703 20500 4950 - 723 22000 5480 - 573 13234 737 23500 282 883 206 3903 291 904 209 4195 332 998 223 4702 464 1272 263 7040 533 1401 282 7883 43E 1217 255 7772 496 1334 272 8681 560 1450 289 9595 628 1565 305 10511 461 1267 262 9017 523 1383 279 10046 588 1497 296 11077 656 1610 312 12107 727 1721 328 13137 499 1340 273 10356 565 1459 290 11515 1402 2s: 12206 604 1525 300 13560 2K - 202 3942 634 1575 307 12672 677 1644 317 14908 705 1688 323 13825 754 1761 333 16250 780 1799 339 14975 833 1875 350 17585 857 1908 355 16119 - - IMfi 1986 366 18911 Itim 2093 3R7 - 2Sc - 206 4229 328 - 222 4729 620 - 302 6518 71J - 324 7283 579 iSi - 294 7369 656 - 312 8227 734 - 315 8552 751 - 333 9532 835 - 329 9092 816 350 10519 921 - 346 9963 367 11513 1009 - 383 12511 '- - 346 9766 910 9?: - 374 114991058 r <' 706 176 5264 365 10872 1005 394 12785 1177 - 383 11983 1102 413 14078 1287 - 400 13100 1200 431 15378 1398 - 417 14222 1299 - 449 16682 1509 - 433 15349 - 466 17990 1621 - -482 19300 ;i9 729 182 5671 250 806 194 6361 275 1093 237 9638 430 1206 254 10807 1040 229 10668 39B 1140 244 11929 447 1241 259 13199 499 1340 273 14474 276 1094 237 12449 424 1195 252 13882 ' 1 $ 1175 249 14386 467 1278 264 16005 4C 1244 259 17060 505 1351 275 18956 244 - 192 4357 475 1294 266 15320 520 1379 279 17625 563 1456 290 20848 527 1391 280 16760 576 1478 293 19241 623 1558 304 72734 582 1488 294 18200 634 1574 307 20854 685 1657 318 24612 693 1669 320 22462 749 1754 332 26481 --- 814 184B 346 78340 263 - 19B 4673 296 - 211 5226 56' 525 - idt - 269 7187 643 - 280 8128 594 300 9430 680 - 309 8033 297 9077 665 - 317 10514 756 - 314 10034 739 - 334 11607 834 - 330 1099B 350 12705 914 - 365 13810 - -- -- -- - - * **1 - 331 10767 826 358 12666 971 - 348 11987 912 376 14090 1069 - 365 13216 1000 394 15519 1169 - 382 14450 1088 411 16955 1269 - 397 15691 1178 - 413 16937 - 428 18397 1369 - 4A4 19844 1471 -- - - 460 21295 11 HOT FACE TEMPERATURE*-F Wall 1000 1200 1400 1600 1800 Thickness Construction HL JT ST HS HI JT ST HS HL JT ST HS HL JT ST HS HL JT ST HS 9" 10" 9" 10.;" 12" 17" 7 V JM-20 154" SX 76 328 120 2411 97 391 130 3031 119 457 140 3673 153 552 155 4605 168 595 162 5014 7V JM-23 114" SX 82 346 123 2621 104 411 133 3288 127 477 143 3978 151 546 154 4686 176 616 165 5411 7VJMSL* IX" SX 139 512 149 4430 176 615 165 5574 216 721 181 6756 259 828 197 7968 304 936 214 9205 7 V JM 26* 114" SX 138 509 148 5005 172 605 163 6267 209 702 178 7562 247 799 193 8885 287 896 208 10229 714" JM-28* IV SX 153 551 155 5947 190 652 171 7418 229 752 186 8920 269 852 201 10445 311 951 216 11986 7V JM-3000 + IV SX 172 604 163 6972 213 713 180 8673 256 821 196 10401 300 926 212 12146 346 1029 226 13904 7VJM 32 IKSX 7 V JM-20 1 214" SX 187 645 169 8336 212 761 187 10356 278 875 205 12401 326 986 221 14462 376 1094 237 16531 67 418 115 2703 86 502 124 3401 105 588 134 4126 126 678 143 4871 148 769 153 5635 7V JM -23 2V SX 72 43B 117 2937 90 523 127 3687 110 611 136 4462 132 700 146 5257 154 791 155 6070 714" JMSL * 254" 111 615 136 4939 141 740 ISO 6211 173 868 164 7523 208 996 178 8867 245 1125 192 10235 7V JM26 + 2V SX 110 610 136 5556 138 728 149 6954 168 846 161 8388 199 964 174 9849 232 1082 187 11332 7 V JM-28 + 2V4" SX 120 650 140 6556 149 772 153 8177 180 893 167 9829 213 1013 180 11505 247 1132 193 13196 7V JM-3000 + 2 V SX 7'4" JM 32 * 2V SX 9" JM-20 131 69B 145 HO 734 149 80 - 121 7625 9048 2254 163 828 159 9487 174 870 164 11244 102 - 132 2813 197 955 173 11377 232 1081 187 13285 268 1204 201 15204 710 1004 179 13469 247 1135 193 15709 286 12E3 207 17959 125 - 143 3388 150 - 154 3976 176 - 165 4575 9" JM 23 88 - 125 2421 111 - 136 3020 136 - 148 3636 162 - 159 4266 189 - 170 4907 9" JM SL 184 - 168 3701 234 - 188 4623 288 - 208 5570 346 - 228 6537 407 - 247 7520 9" JM-2S - 186 - 169 4213 234 - 188 5255 283 - 206 6322 334 - 224 7411 387 - 241 8516 9" JM-28 226 - 185 4934 280 - 205 6140 335 - 224 7372 392 - 242 8624 451 - 260 9892 9" JM-3000 285 - 207 5686 351 - 229 7059 418 - 250 84 57 486 - 269 9873 556 - 288 11305 9" JM 32 340 - 226 6740 417 - 250 8352 496 - 272 9987 576 - 293 11641 657 - 312 13310 9" FIRECLAY BRICKS 9" JM -20 * IV SX 556 - 288 11400 710 - 324 14600 876 - 359 17600 1052 - 392 21000 1239 - 474 23400 66 297 115 2784 84 352 123 3497 103 410 133 4237 124 470 142 4999 146 532 152 5760 9" JM-23 - IV SX 71 313 117 3024 90 370 126 3793 110 430 136 4587 131 490 145 5404 153 553 155 EJ: 9" JNT-SL 1VSX 124 471 142 5098 158 565 157 6415 194 662 172 7778 232 761 187 9178 272 861 202 r 9" JM-2C* IV SX 124 469 142 5768 155 556 156 7224 187 645 169 8720 221 734 183 10249 257 823 197 11. 9" JM-28 * IV SX 138 511 149 6865 172 603 163 8567 206 696 177 10305 242 787 191 12071 280 878 205 1385L 9" JM 3000* IV SX 157 565 157 8067 195 666 173 10038 233 765 188 12041 273 862 203 14067 314 958 217 16108 S" JM 32 * SX 9 JM-20 *3" SX 173 606 163 9668 214 715 180 12012 256 820 196 14388 299 924 212 16784 344 1075 277 1919' 56 414 no 3229 72 498 117 4064 88 584 125 4929 106 672 134 5821 124 763 142 6735 9" JM-23 * 3"SX 60 434 112 3509 76 519 119 4405 92 606 127 5332 110 695 136 6283 129 785 144 7255 9" JM SL 3" SX 94 612 128 5905 119 736 140 7427 146 863 152 8997 174 991 164 10606 205 1120 177 12245 9"JM 26* 3" SX 93 607 128 6643 116 724 139 8316 141 842 150 10033 167 960 161 11782 195 1077 173 1355E 9" JM 28 * 3" SX 100 647 131 7842 125 768 143 9782 151 889 154 11760 178 1009 166 13766 207 1128 177 15793 9" JM 3000* 3" SX 110 696 136 9124 137 825 148 11353 165 952 160 13616 195 1077 172 15902 225 1200 185 18201 9" JM 32 3" SX 13 V JM 20 * 314" SX 118 732 139 10830 146 867 152 13460 176 1000 165 16174 208 1131 178 18809 240 1259 191 21504 40 360 102 4519 52 431 107 5685 63 505 113 6894 76 581 119 8141 89 660 126 9420 13V JM-23 3V SX 43 379 103 4913 55 452 109 6167 67 527 115 7465 80 603 121 8798 93 682 128 10163 13'-;-- JM SL * 3*4" SX 71 552 117 8313 90 665 126 10462 110 780 136 12684 132 896 146 14965 155 1014 156 17292 13V JM-26 + 3Vi" SX 70 548 117 9376 88 654 125 11744 107 759 134 14175 126 866 143 16658 147 972 152 19182 13 V JM-28 3 V SX 77 590 120 11118 96 700 129 13873 116 809 13B 16687 136 918 148 19544 158 1026 157 27433 13 ;" JM 3000 3'4" SX 86 642 124 13001 107 760 134 16181 128 876 144 19412 151 990 154 22678 174 1103 164 25966 13':" JM 32 * 3'-;" SX 93 681 128 15505 115 806 138 19772 139 929 149 230B9 163 1049 159 26939 Jfl 1167 170 30B05 HL = Heat Loss at Steady State Condition. BTU.'SQFT HR. JT = Junclmn Temperature between Brick and Backup Insulation F Ambient = 80 F. Still Air ST = Outside Surface Temperature F HS = Heat Storage. BTU SQ FT SX = J-M Superei block insulation 2000 HI JT ST HS 2200 HI JT ST HS 2400 HL JT ST KS 2600 HL JT ST HS 2100 HL JT ST HS 3000 HL JT ST HS 3200 HL JT ST HS 195 666 173 5706 203 687 176 6149 231 759 187 6898 353 1045 230 10462 404 1154 246 11734 329 993 222 11589 374 1089 237 12963 420 1185 251 14346 468 1281 264 15737 354 1048 230 13540 400 1144 245 15102 447 1239 259 16671 496 1333 272 18242 546 1426 285 19816 393 1130 243 15668 442 1229 257 17435 427 1200 253 18603 4B0 1304 268 20674 172 661 163 6415 492 1326 271 19202 534 U04 282 22742 544 1421 285 20968 591 1502 296 24803 597 1514 298 22731 648 1598 310 26856 652 1605 311 24489 707 1691 323 28900 768 1782 336 30935 177 882 165 6897 202 975 175 7736 284 1255 206 11622 326 1384 221 13023 267 1199 200 12830 303 1316 213 14341 342 1432 226 15859 382 1546 239 17383 282 1250 206 14899 320 1366 219 16609 359 1480 232 18322 400 1593 245 20037 442 1704 257 21751 306 1325 214 17129 346 1443 228 19055 387 1559 241 20979 430 1673 254 22899 475 1784 266 24812 521 1892 279 26718 327 1388 221 20210 370 1511 235 224 58 414 1630 249 24701 460 1747 262 26934 507 1861 275 29156 557 1971 288 31366 608 2080 301 tscc 204 178 5184 T 218 182 5558 248 - 193 6217 472 266 8517 541 - 284 9524 442 257 9635 500 512 276 1117? 574 626 305 12749 698 739 330 14991 821 - 1427 455 26000 645 - 16: 596 162 6578 273 10766 559 292 12466 637 321 14203 770 347 16682 904 486 29000 1864 289 11907 621 308 13768 702 337 15666 844 364 18383 988 515 33000 2094 304 13055 322 15078 769 352 17136 918 379 20092 1072 543 35000 2334 337 16394 366 18614 993 - 380 20098 395 21808 1156 - 409 23531 1241 - 424 25259 571 39000 2580 - 597 42000 2850 - 607 45000 176 616 165 7091 201 661 175 7956 316 962 2111 12063 361 1063 233 13537 294 912 210 13381 333 1001 223 14974 374 1090 237 16580 416 1179 250 18197 319 968 219 15662 359 1058 232 17477 400 1146 245 19301 443 1233 258 21131 488 1319 270 22964 356 1052 231 18158 400 1144 245 20215 444 1234 258 22273 490 1323 271 24332 537 1409 283 26388 586 1494 295 28440 390 1124 242 21603 437 1220 256 74016 485 1314 269 26477 535 1406 782 28832 586 1495 295 31229 638 1582 308 33618 692 1667 370 35998 144 855 151 7667 146 876 153 8245 169 968 162 9249 238 1249 190 13907 773 1379 203 15586 224 1194 184 15353 254 1310 196 17163 266 1426 207 18983 320 1541 219 20811 237 1245 189 17633 268 1361 201 19882 301 1475 212 71937 335 1587 224 23993 370 1698 235 26049 257 1320 197 20507 274 1384 703 24203 103 740 133 10727 290 1438 209 22816 310 1506 216 26898 324 1554 221 25123 347 1626 278 29587 360 1668 232 27426 385 1742 240 32266 397 1779 244 29771 425 1856 257 34932 436 1888 255 3200B 466 1967 264 37583 mas i 509 2075 776 wed 107 761 134 11553 122 842 141 12965 180 1133 167 19656 206 1252 177 22050 T69 1078 162 71737 191 1184 171 74317 215 1290 181 26916 240 1395 190 29528 180 1133 167 25346 203 173B 176 28276 227 1343 185 31216 252 1446 195 34163 278 1547 204 37113 198 1713 174 29269 722 1371 184 32577 248 1428 193 35867 774 1532 203 39194 307 1634 213 4 2494 330 1734 222 45784 213 128? 180 34679 240 1394 190 38553 767 1504 200 42419 295 1612 711 46274 325 1716 271 50114 355 1819 231 53936 386 1918 240 57739 13 Standard shapes of J-M insulating Fire Brick Large shapes (all 3" thick, unless noted) This series has a standard 3" thickness and is available in the following sizes: r a "T Special shapes ]nhr. ' 1 ..i!c also fabricates many special shapes to me<' . -dual requirements. These shapes would have to b- : and processed as specialty items, but since j-M . . . - large slabs by a patented process, the shn; : :t made directly from the 9" x 24" slabs. Cort1nee: ar;: nter* local J-M representative whenever you -rapes. He will go over your specifications . develop the particular shape or shapes to .vr. needs. 20 i few Mat. cus: ii.-low show (top) a product assembled from :.,,:>es made from large slabs and (bottom) a -Vs of the various special shapes Johns .= fabricated to meet diverse demands of Information on packaging & palletized shipments CARTONS All Johns-Manville brick are packed in cardboard car tons. The quantity varies with the size and shape of brick type. Consult your local J-M representative for information on your specific needs. PALLETS Carload shipments of standard sizes, large sizes and special shapes of Johns-Manville Insulating Fire Brick can be ordered in pallet-load units. Palletizing is done according to the basic recommendations on packaging and loading standards of The Refractories Institute Pal letizing Committee. Standard pallets measure 48'x 36' and each will normally contain 1000 to 1200 brick equivalent lr 40-foot car there are usually 23 pallet loads of material with the doorway filled with loose cartons. The number of loose cartons varies, but it is usually about 150 cartons. In a 50-foot rail car there are usually 33 pallets, with the doorway filled with approximately 25 loose cartons. Special palletizing is available to our customers if the standard method is unsuitable for their particular re quirements. TITE-PAK Johns-Manville offers its refractory customers J-M TITEPAK--a loaded pallet encased in tough, contour-fitting plastic that resists abuse and shields the refractories from moisture and dust. The heavy-duty transparent film facil itates handling during transit and protects the contents against breakage and pilferage en route and during storagp. It also provides high stability to the load, thus making it possible to tilt the pallet without shifting or spilling the refractories. 15 Types of straight wall construction RECOMMENDED CONSTRUCTIONS - The most com mon constructions where |-M Insulating Fire Brick is used are those consisting of all headers or of alternate header and stretcher courses. These constructions are recommended unless other factors influence the type of wall used PERMISSIBLE UNSUPPORTED HEIGHT-Unsup ported wall 4's' thick, should be no higher than 3 ft Unsupported wall 9' thick, tied in by combinations of header and stretcher courses, can be used up to 8-ft. heights: 13* walls under same conditions are suitable up to 12-ft. heights. HEADER COURSES ALL HEADERS -- Many 9"-thick insulating fire brick walls arc built of all-header courses. This is especially true of bell-type annealing furnaces. Advantages are a reasonably stable wall with the back side of all brick under comparatively low temperatures. Hence, a pre ferred construction for walls operating near their tem perature limit. MAINLY OF HEADERS -- This type of wall possesses many of the advantages of one constructed entirely of headers, but has greater rigidity. This wall is usually laid with three to four header courses to each stretcher course. STRETCHER COURSES t ALL STRETCHERS -- Not very rigid and is not recom mended except for walls under 3 ft. in height, or walls f\:'. me other means of support, such as suspended walls o: \Liuer courses between a heavier wall and exterior c .ix:nc Lvcn for walls under 3 ft. high other types of construction are preferable MAINLY OF STRETCHERS -- This type of wall is exten sively used where the brick are subiected to slagging or other erosive action. The advantage of this type is that the exterior face can be repaired by applying a 4' skin wall tied into the remaining brick work. ALTERNATE HEADERS AND STRETCHERS-Walls of lmth T and 13' thicknesses constructed of alternate hunters and stretchers make a very stable wall and is considered "good practice." Walls of this type are most common in mill-furnace construction, especially where dense fire brick is used. CO 17 Curved walls Most curved walls are used as linings of stacks or of circular-pit type furnaces. An exception is sometimes encountered in the side walls of furnaces made in the form of a curve to give greater stability than can be obtained with straight walls. ADVANTAGES A properly constructed curved wall is much more stable than a straight wall, thickness for thickness. Therefore, such walls can generally be constructed higher than straight walls. When walls of sufficient curvature are enclosed in a casing (such as in a stack lining), the wedging action of the brick prevents them from falling toward the inside and the casing prevents them from falling outward, so the only limiting factor on height is the ability of the brick to carry the weight of the overhead material under operating conditions. BRICK SHAPES Curved wall sections are usually constructed by using circle brick and key brick, either alone or in combina tion. When necessary, arch and wedge brick can also be used, but are much less desirable. When using insulating fire brick to make curved walls or roofs, it is always preferable to use specially cut brick to fit the curvature rather than a combination of straight brick and standard shapes as is customary practice with dense fire brick. CONSTRUCTION GUIDE Wall Thickness Recommended Brick Other Possible Brick 6fc" > 9- 13 Id" and heavier Circle Key Key Arch brick are sometimes used. but are not recommended lor 4Vj". Combination of circle and key brick may be laid up. using any combination used tor straight walls. Same as for 9" brick. If necessary. wedge brick can be used on low walls, but their use is not recommended. MAXIMUM HEIGHT On walls where the curvature is sufficient to make the wall self-supporting, the height is limited only by the ability of the brick in the lowest course to carry the weight of the courses above. Since the crushing strength of all refractories varies with temperature, the safe height of such linings will depend upon the type of brick used and operating temperature. 18 Division walls Occasionally, furnaces are designed having healing chambers side by side, with a common wall between. This construction is usually more expensive than two separate walls and is subject to the weaknesses outlined below. OPERATING TEMPERATURE In the ordinary single furnace, only one side of each wall is heated. thus resulting in a temperature drop from the inside to the outside. The outside of the brick remains strong, while the hot exposed sections may be approach ing their softening point. TYPE OF BRICK Because of the high operating temperature, a higher quality brick may be required for a division wall than oh the remainder of the furnace. In addition, the brick in the interior of the division wall will be subjected to the same temperature as the exposed brick, so the same high quality brick used on the exposed portion should also be used in the center of the wall. CONSTRUCTION In Fig 1. the skewbacks are supported by a solid course of relractory brick. Fig. 2 illustrates the skewbacks sup ported by channels resting on brick spacers. This con struction. either with or without flues, permits one arch to be repaired without disturbing the other. However, it :s necessary to space out the brick between the channels to dissipate the heal. The a:r fiues in the center of the division walls (Fig. 3) allow the heat to escape to the outside air. They arc formed when laying the brick, providing openings that are either vertical or horizontal, or both. Where horizon tal flues are used alone, air is frequently blown through by mechanical means or by connection to a vertical flue nr stack at one end THICKNESS The thickness of division walls should be at least 4' greater than for ordinary walls. If the wall is to support two sprung arches, the thickness should be no less than the width of the two skewbacks involved. FIG. 1 BRICK SPACER AT INTERVALS HORIZONTAL CONNECTING FLUE AT BOTTOM FIG. 2 FIG. 3 19 sprung arches r; arches are the most common type of arch used in They are fairly easy to erect and require the .aborate mechanical means of support. ~ arches rest at bolli ends on skewbacks which the arch stresses to the supporting parts of the The "built-up" skewback of cut standard 9-inch - :s the most accepted form, but the special one skewback is also widely used. Since movement of -- v.backs may cause failure of the arch, furnaces : rigidly constructed. . arches for direct exposure can be made from ins.. ire brick or dense fire brick. The same practices v ::..ng proper arch construction apply to both types r. Although insulating fire brick may have less s- ru:h per unit of weight than some types of fire brick, s-.-r\ e for as wide a span, because any deficiency in is overcome by lower weight and more uniform s:.-.:-.. of the insulating fire brick. This uniformity results i.\: i\cr distribution of the load over all the brick in r.rrh. BRICK SHAPES USED S.:. ricnsp fire brick are molded to size and burned cr.: or not be machined readily, standard sizes were a .i ;.' i d for arch, wedge and key brick; designating them N r l. No. 2. and No. 3 arch. Arches are built using a comb.natron of No. 1, 2. and 3 brick and straights in quanti ties sufficient to turn a given circle. I-N! Insulating Fire Brick, however, are machined to size attc: firing and are furnished with the correct taper for art specific arch. This results in a sturdier construction and simplifies the laying operation, as only one brick sir is involved, although, when necessary, the standard shapes can be used. The standard shapes used for vari ous arch thicknesses are: Arct- Thtctness Shaoes and Cembmatiens i p Aren brick er a combination of arch and straight. 6:. I Large 9" arch or combination of large 9" arch and large 9" *': i straight 9 Wedge brick or a combination or wedge and straight. (Conj struction of key brick or combination of key and straight are I not common as the load is placed on the narrow tace of the b'ick this construction is only used where special conditions 1 mane it desirable.' Ovf 9 Constructed, necessarily, of special wedge brick However, ; 13'-?' wedge buck are lurmshed as standard by some manu facturers. RISE OF ARCHES The minimum rise for an arch should be l'.t" per foot of spar. Arches with a rise of 1.608' per foot of span are rommon. as this rise results in an included angle of 60 degrees with the inside radius equal to the span. Wher- ever possible, however, for wide spans, it is recom mended that the rise be at least l*..T per foot of span. The maximum rise of an arch has generally been set as 3" per ft. Above that, arches become unstable. A preferable range for an arch rise is 1 Vi" to 2 W per ft. TYPES OF SPRUNG ARCHES The "bonded" arch is the most commonly used arch and the best for most conditions, because the entire construc tion is tied together. If one or several bricks fail in the bonded arch, the load will be taken by the brick on either side and the arch will remain in place until replacement is made. With the "ring" type arch, however, if one brick in a ring fails, the entire ring drops, thus making repair difficult. The chief advantage of this type arch is ease in laying, especially when a combination of standard shapes is used. The "ribbed" arch is used chiefly for open hearth fur naces. The ribs strengthen the arch and give it stability after the intermediate brick have eroded away. "Jack" arches are very seldom used except over open ings. since they are costly and possess few advantages over the other types. TM< Mt- Ik DtklCMtD tfil- ,,T,,G Oi'l * a,D',. uc O' ,-L paM* nuu,; iOiM-*iICuDiaa-Pctt'MlD'Oo- I'iDa'O-tInaacl-tk,:M-,(*fc-' fMNfrUMMDYC latCaoat **D 1C tmc tmmc ,.( tHwauys Domes and crowns A dome or crown differs from a sprung arch in that a sprung arch describes a portion of a cylinder, while a dome or crown describes a portion of a sphere. The recommended thickness of a J-M Insulating Fire Brick dome is 9', made up of key brick used in combina tion with wedge key and arch key brick. Each brick is marked at the factory on the large end of the shape for quick identification on the job. All brick have the same key cut to accommodate the dif ference between the inside and outside arch lengths of the dome. In addition, some brick also have 8 wedge taper and others an arch taper. The brick are laid up in A' rings until the dome is closed except for the hole in the center. During construction, a template is fre quently used. This consists of a wood frame attached to a pipe vertically positioned directly below the top of the dome. The template is free to rotate around the vertical pipe and. having a shape that conforms to the final in side surface of the dome, acts as a guide for each brick course. TYPICAL DOME SKEWBACK The drawings (at right) show a typical dome skewback. These skewbacks are the same as those used in sprung arches except that they are tapered so they can be laid in a circle of the proper diameter. <'n **1 mirunOtioR*f*oCbUtTmt*sc t'f MARK NUMBER |OWCHSION REQUIRED DfMfMBlONj > * (M | JJ4- nt- MB 2J9` 2 13- c JBJ JOT' j D 0 2 IS' j.01- ! c At i 2 10* 1 BA' ! f 5? j 2 01 * i at* j c *5 . 1J- Ur- : - 1 1 ' 107- | 2* | iJ9 | 10 STRAIGHT BRICK t a VT a RE0U*RCO FOR CENTER RlUC ***** S REQUIREDRRRBOKtMATELV SOO LB O' BLAKfTE * Oftau. Of mar* 14* RCQOIRC0 NOTES ALL BRICK TO BE MARKfO 'TM QUANTITIES GIVEN INCLUDE NO AlLO*Nt FOR Suspended arches and walls A suspended arch or wall is one which is not selfsupporting. but which is held in place mechanically. This support is usually obtained by metal hangers fitting into holes or grooves, or over projections on the brick. In some constructions, special ceramic shapes are also used lor this purpose. While there are literally hundreds of different types of suspended arch constructions, a few of the more popular types are: Pipe. Tee Bar, Rod, and Special Formed Member. There are two types of suspended walls: Air-cooled -- Where there is a lane for the flow of air directly in back of the refractory: and Insulated -- Where insulation is placed directly behind the refractory. Both the air lane and the insulation serve to protect the metal structure from high temperatures. WHY USED The main reasons for using suspended arches and walls are: 1) It is possible to erect wide span flat arches and thin, lightweight walls with high thermal efficiency and structural stability. The height of the wall or width ol the arch is limited only by the ability of the structural, members to carry the load. 2) To permit the use of special furnace designs making possible the use of special conveying mechanism or control of combustion or radiation. With selfsupporting walls and sprung arches or domes. th> variation in furnace shapes is quite limited, while with suspended construction, a shell of any desired size or shape may be constructed of structural steel and then lined with refractory 3) A saving in overhead space, especially on wide-arch spans. 4) To permit the construction of large, removable sec tions. 5) To act as occasional anchorage in otherwise selfsupporting walls. 21 ADVANTAGES Repair costs are generally lower, because of the ease with which brick can be removed and replaced, and also because repairs can be confined to the brick which are actually damaged. In some cases, there is the further ad vantage in that hot repairs can be made without loss of production. In suspended arches, the main load is carried on the structural steel while the refractories carry relatively light loads and therefore have less tendency to deform at high temperatures than in other arch and wall structures. Definite allowance can conveniently be made to take care of thermal expansion, both horizontally and verti cally. to avoid stresses which can cause breaking. Provi sion can easily be made for ventilation or for water cooling as conditions may require. If the weiehl of the roof is supported by suspended con struction, the top courses of the walls may necessarily be tied to the furnace binding by metal hangers or clips to keep the walls from bowing inward. NOTE: Where suspended construction is used, only one insuloting fire brick of sufficient thickness to obtcm the desired insulating effect should be used. Do not use o combination of insulating refractories and back-up in sulation. as such construction may cause too high a tem perature on hangers or support members and cause failures. Periodic Kiln domes Round periodic kilns are widely used in structural clay plants which manufacture such products as ceramic tile, brick, pipe and other clay ware. These kilns vary m diameter from 15 to 40 feet, typically constructed as shown in figure 2. The rise is usually 2,/s" to 3" per foot of span. The sidewalls are normally constructed of dense fire brick although a layer of insulating fire brick is recommended to effectively reduce heat transfer through this area. The kilns are either coal, gas. or oil fired. DISADVANTAGES The chief disadvantage to suspended construction is its cost. For equal thickness, the cost of most suspended construction will be higher than the cost of self-support ing brickwork. This is brought about not only by the cost of supporting steel work but also by the additional cost of necessary special shapes. Many suspended construc tions also are unable to stand as much mechanical abuse as self-supporting brickwork. THICKNESS The thickness of suspended-arch and wall construction is limited only by the manufacturing limits of the brick shapes. Most common thicknesses in insulating refrac tories are 41 s" and 9". Very few suspended arches or walls are constructed with a thickness less than 4` s" or more than 9". SIZE OF UNITS Brick shapes for suspended arches and walls require absolute uniformity of size to assure close fitting and to eliminate the possiblity of air infiltration and gas leakage. The most common insulating fire brick unit for this construction is the 21 series straight, although many suspended constructions employ 9~ large brick. The large brick are used to reduce the amount of steel work and hangers required. In most cases, the use of large brick results in a lower overall cost of steel, labor and refractories than when the 2' size is used. Calculation of Brick Quantities and Shapes 1) Refer to Figure 1. "Kiln Dome Layout For Calcula tion Data." The following calculations are based on the trigonometric relationships shown in this figure. 2) Determine the length of the outside arc L.. from the 1 of the dome to the base of the dome. .K (inch, es), =-2--r---R--^--x---1--i-D---o-m---e--A--n--g--l-e 3) Since the brick are laid the 4Vj" way, the total num ber of courses is~4r.5^. The center hole will reduce the number of courses just calculated by 1its diam eter in inches divided by 4.5. 4) Determine the angle o formed by a single brick (projected to the dome center). See Figure 1. oc 4.5 . 360 (4.5) 360 _ 2irR0 -- 2irR,, 5) At this point, the total number of courses as deter mined in step 3 may be checked by -V---i-D--o--m--a-e--A--n--g--le = _Tot.a.l num,ber o,f courses ,,(less center hole). 6) All brick in the dome are key cut, and the key taper is determined bv X___ R, _ 4.5R, 4.5 " Ru : x _ K = [4.5- x-) Kev cut on all brick. 7) Set up a table of eleven columns across and of a length equal to the number of courses. The first column indicates the course number. 22 6) In Column 2 list the angle between the vertical L of the dome and the farthest edge of each course (see Figure 1). This angle is of the Dome Angle minus the sum of = s to each course. For example, for a 120 Dome, course No. 1 is 60.000 --0 = 60.000: Course No. 2 is 60.000 minus a ; Course No. 3 is 60.000 --2 ec ; etc. 9)Convert the decimal portion of each angle to minutes of a degree to facilitate determining its size or use decitrig tables. 10) In Column 3 list Pe. the horizontal distance from the / to the lower edge of each course on the outer arc (Point C on Fig. 1) P,, = R0 sin Col 2 angle. Use a calculator and 5 place trigonometric tables. 11) In Column 4 list the circumference (in a horizontal plane) of the loci of point C about the / . This cir cumference Co = 2 * P0. ric i a..h 00*1 1**00' fO*CA^CUt>TC9*** ; Bi = C.. (similar triangles) Ri R# R*. Therefore C,, -B, = C,, - |i- C. = Cv (l - ^ ^1 -- is a constant. 13) In Column 6 list the total number of brick per course. This is C0 (Column 4) divided by 2'.;", the width of the outside end of each brick regardless of shape. To speed calculation by avoiding a division for each course, remember that C,, = 2 r P... so that Total Number of brick per course = irP,. 2.5 /2r V 2.5 . *S a constant. 2.513 28 j . 14) In Column 7 list the number of wedge keys required per course. The difference in circumferences. Cu --Bj (Col. 5) must be satisfied by inserting a num ber of wedge-cut brick in each course. For example, if a (2'/t" -- 2") wedge cut is selected, each wedge key tapers so if C0 --Bj is 10" for a course. 20 wedge keys must be used to turn the circle of that course. Therefore Column 7, Number of it re ictoo ktot*T*iC r*l * C*Ovfc l * "((M*'C.*- BtKU lf Nr> aUMW lu*U'( cmn* ^.i Wedge Keys = --wed~ge---cu7t ;t-a-p--e--r 15) In Figure 1, note that for any course. Point C swings a larger circle about the L than Point A. the upper outer edge of the same course. Point A is, however, the same as Point C for the next higher course. So, to determine the difference in circumference be tween the loci of points A and C, use C,, course No. 1 minus C0 course No. 2, C,, course No. 2 --Co course No. 3, etc. This difference is listed for each course in Column 8. 16) In Column 9 list the number of arch key required per course. The difference in circumferences shown in Column 8 between Point C and Point A must be satisfied by inserting a number of arch cut brick in each course. For example, if a (21 s" --2") arch cut is selected, it tapers So, if the difference in cir cumferences in Column 8 is 10" for a course. 20 arch keys must be used. Therefore, Col. 9. number of , . Column 8 arch keys = X^ut Taper 12) In Column 5 list the difference (C. -- B,) between the outside circumference of each course. Q, (Column 4) and the inside circumference (Point B -- Fig. 1) of the inside edge of the same course about the L This inside circumference isB. Co--B,= (l - Co. This is derived as follows: It is necessary, sometimes, to use two or more de grees of arch taper on the arch key brick. The key taper remains the same, but on courses approaching the top of the dome, the arch taper is increased so that the difference in circumference (Column 8) can be satisfied with fewer arch key brick. This is im portant in the upper courses because there are so few brick per course. 17) In Column 10 list the total number of arch key and wedge key for each course. This figure is the sum of Column 7 and Column 9. 18) In Column 11 list the number of key brick required per course. After the arch and wedge requirements have been met. all the remaining brick in a course are keys. Therefore. Column 11 = Column 6 minus Column 10. 23 j-M Bonding Mortars Refractory mortars are finely ground refractory materials which become plastic and trowelabie when mixed or tempered with water. }-M mortars are suitable for laying and bonding insulating fire brick and most clay based fire brick. Fire brick performs best when laid with a mortar capable of withstanding the same conditions as the brick. Masonry built of fire brick consists of many relatively small units, laid together to conform toa definite prescribed plan or design The strength of the masonry depends upon the strength of the individual brick, the manner in which thex are laid and the nature of the mortar material used in the joints. With the exception of furnaces built in a shop and then shipped to the site, a furnace should not rely solely on bonding mortar to achieve its structural strength A well-designed refractory construction relies primarilv on design rather than mortar to obtain satisfac tory strength of the total structure. Mortars serve the following purposes: . 1 They bond the brickwork into a solid unit with greater resistance to mechanical and thermal shocks and stresses. ' 2 The> provide a cushion between the slightly irreg ular surfaces of the brick to provide a firm bearing for each course. 3 The> provide resistance to infiltration of air or hot gases 4 The\ prevent penetration of slag and molten metal into the loints. PoorK qiade loints. or joints filled with improper material greatly shorten the life of the structure. Mortar should be as carefulK selected as the brick with which it is used. The compositions and methods of preparation of all J-M mortars have been developed through extensive laboratory investigations to develop the particular combination of properties each bonding mortar should possess. Among the factors included are workability, plasticity, water retention, drying and firing shrinkages, chemical compo sition. refractoriness, bonding strength, vitrification, and resistance to chemical attack. For economy and convenience, a mortar should have ex cellent workability and water retention over a range of consistencies, so it can be used for dipped joints, troweled loints. as a surface coating for walls, or for patching. The mortar should not shrink excessively upon drying or heating, nor should it lose its strength at the maximum service temperature. Its thermal expansion should be approximate^ the same as that of the brick with which it is used: otherwise, temperature changes will lower bonding strength, and cause surface coatings to crack and peel. It stronc toints are needed, the mortar must sinter at the proper temperature to develop a strong ceramic bond. However the refractoriness must be sufficiently high so that the mortar will not melt or flow from joints at high temperatures. Two general classes of refractory mortars are air-setting and heat-setting. Air-setting mortars take a rigid set upon air drying while heat-setting mortars set at high tempera tures by sintering or developing a ceramic bond. To fulfill the many different sen-ice requirements. J-M provides several types of air-setting mortars, as well as heat-setting mortars. Air-Setting Mortars-Air-setting mortars are mixtures of finely ground aggregates plus binders, supplied in either a wet or a dry condition. The dry air-setting monars require tempering w-ith water to attain the desired consistency Upon air drying, they set to a good strength and form an almost monolithic structure with the brickwork. In somecases. the mortar joint is stronger than the surrounding brickwork. Air-setting mortars should always be applied in thin layers. If thick applications are made, the surface sets and forms a heavy skin which entraps the moisture in the unex posed material. This captive moisture becomes steam when heat is applied and in leaving the construction can damage the structure. This is particularly damaging in dense fire brick applications. It is good practice to keep the toints as thin as possible w-hen laying both insulating and dense fire brick. The thickness of the mortar should be approxi mately 1/32 in. for insulating fire brick and usually no greater than 1/16 in. for heavy brick. A mortar suitable for dense brick may not be suitable fur insulating fire brick. The shrinkage of a mortar whu.li develops a very strong bond may cause the relatively weal, insulating fire brick to crack at the joint. A mortar for laying insulating fire brick must have suffi cient water retention to allow the porous brick to be mot eii into position before it absorbs the water. Too much watci retention would cause dense brick to float before tin mortar sets. Heat-Setting Mortars-Heat-setting mortars arc com posed of ground raw or calcined refractory material mixed with water. Their distinguishing characteristic is. that they develop a ceramic set with a strong bond from a sintering reaction only at elevated temperatures Thvir composition and properties are similar to those of (hr brick with which they are to be used. Properly formulated heat-setting mortars are supplied to provide toints with minimum shrinkage A characteristi' of heat-setting mortars is that usually only a part of thentire mortar joint attains temperatures high enoueh t<> develop the ceramic bond. They are used where a strong bond through the entire wall thickness is not an essentia! requirement Heat-setting mortars are especially recommended fur irregular constructions in high temperature service such as domes, arches and walls with many openings As thev 1 co:.'.ons are heated the first time, they are free to mow : equalize internal stresses before the mortar re<< - setting temperature. They also provide some flev: , in expansion and contraction of the brick lining as '..mate temperature is raised and lowered. And. iht. ; to compensate for the high thermal expansion o! -'nek and for differences in thermal expansion br-. !>riLk of different types used in the same CO::'" i; WASH-COATINGS are utilized for coating surfaces to Der- ' ntk loints and to protect the wall from desir. onditions within the furnace. When insulating fin : : - are used at their maximum temperature, a hit:...... wash-coating will reduce opening of the hot fat- HELLJTE is expecialiv recommended for washcoot.:.^ M i 20 and NO. 32 are also used where a different air ::.:ic strength is desired. Th- wir.oce to be coated should be thoroughly cleaned do-.-.: 11 hare brick Old settings, cleaned by scoring or scar,--.should have all dust particles thoroughly remo-, r. ti\ either carefully blowing them out with an air gui. cr b\ hosing out the crevices and washing the walls witr. nter Mix tbe mortar with sufficient water to bring n h. thin grout consistency. Thn rr.:v.iire is then applied to the face of the brickwork wit: a stiff brush or broom, and worked well into the era . and pores It is important to apply the mixture inn.to reduce a tendency to flaking. An egg shell thicknes- is normal. Insulating fire brick especially demand careful application as flaking can pull bits of the IFB out o' tin siirtace Anc'.ne: method of installation, ramming, is to form thick mortar into a ball or other handy sized chunk and hammer it ir.tu place with a mallet. This method is especially suitable for building out deeply erooeri spots, or for filling large cavities in dense refrac tories MIXING: 1-M air-setting mortars are supplied both wet in drums and dry in bags. Wet mortars are factory mixed with a proper amount of water for a stiff consistency. Prior to use. the mortar should be well mixed as the con tents settle in storage. For thinner consistencies, w'ater should be added in small quantities at a time, and thoroughly mixed after each addition until the desired mortar consistency is obtained. The use of a mechanical mixer is recommended. If one is not available the mortar can be mixed by hand with a trow el Only clean, fresh water suitable for drinking should be used Each mason has his preferences for consistency. We' mortars can be used immediately and additional water added at any time for retempering. When mixing dry mortar, it will speed the operation if water is added in controlled increments. A small mortar box is tne ideal container for mixing small quantities. The use of a mechanical mixer is necessary when larger amounts of mortar are to be prepared. Mortar which has been allowed to dry and become hard after mixing should not be used. Any wet mix. unused at the end of the working day. can be stored for use the next day by smoothing the surface of the wet mortar and cover ing the container with damp cloths to reduce evaporation. (Cloths should not touch the mortar.) The mortar can be easily retempered to the desired consistency the follow ing day. SHELF LIFE: The shelf life of wet air-setting mortars in well-sealed undamaged containers is about one year. If the unused contents of an opened container are covered with a thin layer of water and the container closed tightly, the mortar will remain satisfactory after days or weeks of storage. Wet air-setting mortar will not have deteriorated appre ciably if liquids have not hardened on the surface and if the contents of the container can be remixed thoroughly. The mortar should be stored in a cool, dry place. Although freezing does not harm its properties, it should be slowlythawed out and remixed thoroughly before use. Even if kept in storage for a long period of time. )-M BLAKITE will not have objectionable separation of liquids and solids. The bonding strength of wet-tvpe mortars is less likely to be affected adversely by ambient conditions in storage. For this reason, wet-type mortars are probably preferable for long distance (overseas) shipping. The shelf life of dry air-setting mortars stored in unopened bags at 75F and 50 percent relative humidity is approxi mately eight months. The shelf life will be appreciably less if the storage conditions are hot and humid or if the bag has been opened. Hard lumps m the dry mortar are evidence of deterioration of bonding strength. AVAILABLE TYPES Wef Air-Setting Mortars BLAKITE A highly refractory mortar which possesses high waterretention properties. It is expecially designed for laying insulating fire brick and is also used for fireclay, super duty and high alumina refractory brick. It is dark grayin color. Temperature to 3000F. It is furnished in a con sistency suitable for shallow patching or troweling. For a dipping consistency, add approximately 5 qts. of water to 100 lbs. of the as-received BLAKITE. BLAKITE is a good choice for a single mortar on jobs involving a majority of insulating fire brick and a few dense fire brick. NO. 2986 A highly refractory mortar very similar to BLAKITE. but gray to tan in color. Temperature to 3000F. SUPER BLAKITE An air-setting mortar for general purpose plant use. It has greater air-setting strength than BLAKITE or NO. 2986. It is used for dense fire brick and is also good for insulating fire brick where greater bonding strength is desired. SUPER BLAKITE is particularly good for deep patching. It is also used for coating over vertical industrial boiler tubes to level the surface and for shallow patching. The overall excellent properties of SUPER BLAKITE make it ideal for the one mortar to cam- in plant inventory. Temperature to 3000F. An excellent choice for the one mortar on a job involving many dense fire brick and a few insulating fire brick NO. 20 An air-setting cement, gray in color, for use where extra hard air-set strength is desired. It is not recommended for laying insulating fire brick. Used up to 2700F for setting hard brick with a rubbed joint, and for wash-coating. When desired to use old fire brick as a patching material or monolithic fill. NO. 20 is thinned with water and the crushed brick added. HELLITE A general-purpose, air-setting cement which is finely ground, very plastic and pink in color. Used for setting hard brick with troweled or dipped joints. It is expecially recommended for wash-coating dense fire brick and in sulating fire brick and also for shallow patching of hot or cold surfaces. Can be used up to 3000F. Dry Air-Setting Mortars Dry Air-Setting Mortars are mixed with water to suit the preferences of the application and the individual mason. After mixing with water, the mortar should be allowed to sir for at least two hours prior to using so the dry sodium silicate binder will properly combine with the water and develop maximum strength. No damage is done if the mixed mortar sits 12 hours. In fact, many masons mix their requirements the day before. For the mortar to be used immediately, the mixing water should be heated. Additional water may be added at any time. "ZELIE" Mortar: Because of its good water retention characteristics. "ZELIE" Mortar is used primarily for lav ing all types of insulating fire brick. It is recommended for temperatures to 3200F. For mixing "ZELIE" Mortar. 12 qts. of water are recommended for a troweling consist ent and 17 qts. of water for a dipping consistency. A major problem with most dry. air-setting mortars is low air-setting strength. This is not so with "ZELIE" Mortar. When in place, it gives a bond equal in strength to JM-23 and 1M-26 insulating fire brick, thus holding the brick together as well as the brick holds itself. When brick are being installed, air-setting strength is frequently important in holding the brick in place until job completion. No. 26 Mortar: No. 26 Mortar, used primarily for setting dense fire brick, is recommended for temperatures to 2900F Dry Heat-Setting Mortars Dry heat-setting mortars are prepared for use by mixing with clean, fresh water. The proper consistency for each application depends on the application and mason preference. The necessary amount depends upon the brick porosity and can be found by trial. The mortar must be thoroughly mixed and free from lumps. Maximum work ability plasticity is obtained by allowing the mortar to temper after mixture with water. Long periods of temper ing will not cause deterioration. Increased plasticity is obtained if the mortar is mixed the day before it is used. If this is not possible, mixing even a few hours before use will result in a mortar with decid edly improved plasticity. J-M supplies two dry. heat-setting mortars for laying dense fire brick. Both are recommended for temperatures to 3100F. NO. 31. a coarse material, is recommended lor thick joints. NO. 32. a fine material, is used for dipped joints. METHODS OF APPLICATION: Troweling and dipping are two methods for bonding brick with mortar. With either method, it is desirable to keep the joints as thin as possible. TROWELING: The mortar is mixed to a batter con sistency and the top of the exposed course of brickwork is spread using a trowel. The brick to be laid is given a troweled coating on the bottom and on one end and then tapped or pushed into place. A rubber mallet or the trowel handle can be used. Troweled joints result in a stronger bond more consistently. A mason experienced in laying of refractories is the best judge of suitable troweling consistency. DIPPING: The brick to be laid are dipped into a thin batter on the bottom and on one end and then pushed into place. Most insulating fire brick are laid by dipping. A suitable dipping consistency is that of thick cream and is more difficult to judge. Excess water plus settling in the mortar box can result in no bonding strength. A dipping consistency on the thick side usually results in better bonding strength than the cream consistency.. but increases the amount of material used. Dipping consistency usage is as follows for insulating fire brick: 1. Using "BLAKITE" Refractory Cemenl -- 220-270 lbs. per 1000 brick for -t'.i-in. walls 270-330 lbs. per 1000 brick (or 9-in. walls 2. Using "ZELIE" Mortar175-250 lbs. per 1000 brick for -t'j-in. walls 215-300 lbs. per 1000 brick for 9-in. walls A combination method sometimes used consists of pour ing a batter onto the exposed top course and then placing a dipped brick on the batter layer. This results in more completely filled joints than the straight dipping method. Quantities necessary to lay dense fire brick are approxi mately within the range of (hat required to lay insulat ing fire brick. j-M superex 2000 Block insulation # provides exceptional heat resistance and excellent insulating value tor high temperature uses. For over a quarter of a century. Johns-Manville Superex has been the leading high temperature block insulation for service to 1900F. and more recently 2000F. Its unique combination of low conductivity and high stability at high temperatures provides greater operating efficiency and longer maintenance-free service. Asbestos-free Superex is made from calcined diatomaceous silica blended with other insulating materials. It is so strong it easily withstands the daily punishment encoun tered in normal service. Under 6 tons' pressure per square foot, it only compresses V inch. Ever since its introduction. Superex block insulation has demonstrated its versatility as a high temperature insu lation. Today, for example, it is used both as back-up and exposed insulation, depending upon service condi tions. to provide economical, efficient protection for a variety of uses. Some of these are as an insulation in annealing and all types of heat-treating furnaces and equipment, heated combustion air piping, hot gas flues, bustle pipes, soaking pits, and blast furnace hot blast stoves. < J-M Refractory Fib Products lightweight therma insulation tor use with insula ing tire brick J-M Pure White Cerafiber -- A lightweight bulk refrac tory fiber suitable for continuous exposure to 2300F. This unusual material can be used anywhere a lightweight fibrous and resilient insulation or fill is needed. It is ex cellent as a fill on heated equipment or for packing voids and expansion ioints. It can be used as a loose insulating fill for crowns and walls of kilns, sulphur-burning, anneal ing. heat-treating and hold ing furnaces. Good for insulating kiln car tops, as a packing in furnace ioints. fire boxes, burner openings, furnace door seams and brickwork voids. Pure White Cerafiber is available in loose bulk form, packed in 25-pound boxes J-M RF Expansion Joint Board -- a refractory fiber ex pansion joint board for service up to 2300F. Its resiliency and uniform density make it excellent for use as an ex pansion joint in industries ranging from petrochemical to metals --wherever heat is used with brick. In one simple operation. RF Expansion joint Board provides the neces sary spacing in the refractory' construction plus the fiber to fill the joint. It fits tight, makes construction easy, and is rigid enough to build against. RF Expansion )oint Board is available in B pcf and 14 pcf densities, in sizes up to 4' x B' sheets. Thicknesses are from V to 1". Ask for Refractory Fiber Products brochure IN'D-3021 with complete physical properties data. 27 Glossary of terms relating to refractories Abrasion of Refractories. -- Wearing away of refractorysurfaces by the scouring action of moving solids. Air-Setting Refractory Mortar. - A composition of finely ground materials, marketed in either a wet or dry condition, which may require tempering with water to attain the desired consistency and which is suitable for laying refractory brick and bonding them strongly upon drying and upon subsequent heating at furnace temper atures. Bloating of Refractories. - Substantial swelling pro duced by a heat treatment that causes the formation of a vesicular structure. Bond Fire Clay. - See Fire Clay. Plastic or Bond. Bum (n). -- The heat treatment to which refractory ma terials are subjected m the firing process. Burning (Firing) of Refractories. -- The final heat treat ment in a kiln to yvhich refractory brick and shapes are subjected in the process of manufacture for the purpose of developing bond and other necessary physical and chemical properties. Calcine or Calcines (n). -- Refractory material, often fireclay , that has been heated to eliminate volatile con stituents and to produce desired physical changes. Calcining of Refractory Materials. -- The heat treat ment to which raw refractory materials are subjected, preparatory to further processing or use. for the purpose of eluninating'Volatile chemically combined constituents and producing volume changes. Corrosion of Refractories. - Destruction of refractory surfaces by the chemical action of external agencies. Diaspore Clay. -- A rock consisting essentially of diaspore bonded by fire clay. Dolomite, Calcined Refractory. -- Raw refractory dolo mite that has been heated to a temperature sufficiently high and for a long enough time to decompose the car bonate structure and remove volatile constituents. Dolomite, Dead-Burned Refractory. - Raw refractory dolomite that has been heated with or without additives to a temperature sufficiently high and for a long enough time to decompose the carbonate structure so as to furm calcium oxide and periclase in a matrix that provides resistance to subsequent hydration and recombination with carbon dioxide. Double-Screened Ground Refractory Material. - A rei rat ion material that contains its original gradation of particle sizes resulting from crushing, grinding, or both, and from which particles coarser and finer than two specified sizes have been removed by screening. Erosion of Refractories. -- Wearing away of refractorysurfaces by the washing action of moving liquids. Firebrick. -- A broad term covering any type of refrac tory brick used more narrowly to mean fireclay brick. Firebrick, Insulating. -- A refractory brick characterized by low thermal conductivity and low heat capacity. Fire Clay. -- An earthy or stony mineral aggregate which has as the essential constituent hydrous silicates of aluminum with or without free silica, plastic when suf ficiently pulverized and wetted, rigid when subse quently dried, and of suitable refractoriness for use in commercial refractory products. Fire Clay, Nodular. -- A rock containing aluminous or ferruginous nodules, or both, bonded by fire clay. NOTE. -- Jn some districts such cloys ore called "burley" or "hurley flint" cloy. Fire Clay, Plastic or Bond. - A fire clay of sufficient natural plasticity to bond nonplastic materials. Fireclay Plastic Refractory. - A fireclay material tem pered with water and suitable for ramming into place to form a monolithic furnace lining that will attain satis factory physical properties when subjected to the heat of furnace operation. Flint Fire Clay. -- A hard or flint-like fire clay occurring as an unstratified massive rock, practically devoid of natural plasticity and showing a conchoidal fracture. Grog.-- A granular material produced from calcined or burned refractories, usually alumina-silica. Grog Fireclay Mortar. -- Raw fire clay mixed with cal cined fire clay, or with broken fireclay brick, or both, all ground to suitable fineness. Ground Fire Clay. -- Fire clay or a mixture of fire clays that have been subjected to no treatment other than grinding or weathering, or both. Ground Fireclay Mortar. -- A refractory mortar consist ing of finely ground raw fireclay. Molten Cast Refractory. -- A solidified material made by melting refractory ingredients and pouring into molds. Mortar, Heat Setting. -- A refractory mortar of finely ground materials whose potential strength is dependent on use at furnace or process temperatures. Mortar, Refractory. -- A finely ground preparation which becomes plastic and trowelable when tempered with water and is suitable for laying and bonding re fractory brick. Mullite Refractories. - Refractory products consisting predominately of mullite (3Al-0:i *2510;) crystals L:rr.ed either by conversion of one or more of the sillimanite group of minerals or by synthesis from appro priate materials employing either melting or sintering processes. Permanent Linear Change. - The per cent dimensional change in length (based on original length) of a refractorv specimen free of externally applied stresses, after being subjected to a prescribed heat treatment. Plastic Refractory. -- A refractory material, tempered with water, that can be extruded and that has suitable workability to be pounded into place to form a mono lithic structure. Porosity. - The percentage of the total volume of a material occupied by both open and closed pores. Pyrometric Cone Equivalent (PCE). - The number of that Standard Pyrometric Cone whose tip would touch the supporting plaqne simultaneously with a cone of the refractory material being investigated when tested m accordance with the Method of Test for Pyrometric Cone Equivalent (PCE) of Refractory Materials (ASTM Designation: C 24). Quartzite (Ganister). -- For refractories, a rock consist ing predominantly of the mineral quartz suitable for the manufacture of silica brick and characterized by a high SiO.. content and a low percentage of impurities. .VOTE. -- Confusion sometimes results from the use of the term ganister because it is also applied in some parts of the United Stales to crushed firebrick or to a mixture of crushed firebrick or silica rock with clay for use in temped 1; nines. Ramming Mix.-- A refractory material, usually tem pered with water, that cannot be extruded but that has suitable properties to permit ramming into place to form a monolithic structure. Refractories |n). -- Materials, usually non-metallic, used to withstand high temperature. Refractories, Acid. -- Refractories containing a substan tia! amount of silica that may react chemically with basic refractories, basic slags, or basic fluxes at high temperatures. Refractories, Basic. -- Refractories whose major con stituent is lime, magnesia, or both, and which may react chemically with acid refractories, acid slags, or acid fluxes at high temperatures. NOTE -- Commercial use of this term also includes refractories made of chrome ore or combinations of chrome ore and dead-burned magnesite. Refractories, Neutral. -- Refractories that are resistant to chemical attack by both acid and basic slags, refrac tories. or fluxes at high temperatures. Refractoriness. -- In refractories, the property of being resistant to softening or deformation. Refractory (adj). -- Resistant to high temperature. Reheat Behavior. -- The changes in length or volume taking place in a fired refractory when subjected to a reheat test. Reheat Test. -- The prescribed heat treatment of a fired refractory free of externally applied stresses to deter mine its linear or volume stability by measurements before and after the heating. Shrinkage. -- The decrease in dimension of a refractory material during manufacture or service. Silica Fire Clay. -- A refractory mortar consisting of a finely ground mixture of quartzite, silica brick, and fire clay of various proportions. NOTE. -- Sometimes called silica cement by the trade. Silicon Carbide Refractories. -- Refractory products consisting predominantly of silicon carbide. Slagging of Refractories. -- Destructive chemical reac tion between refractories and external agencies at high temperatures resulting in the formation of a liquid. Spalling of Refractories. -- The cracking or rupturing of a refractory unit, which usually results in the detach ment of a portion of the unit. Spalling of Refractories, Mechanical. - The spalling of a refractory unit caused by stresses resulting from im pact or pressure. Spalling of Refractories, Structural. - The spalling of a refractory unit caused by stresses resulting from dif ferential changes in the structure of the unit. Spalling of Refractories, Thermal. - The spalling of a refractory unit caused by stresses resulting from nonuniform changes of the unit produced by a difference in temperature. Stopper Head. -- A rounded refractory shape, usually made from clay and graphite, providing a valve head seating into a nozzle brick, this assembly forming a metal flow control for bottom-pouring ladles. Thermal Expansion. -- The reversible change in size of materials due to te Unburned Brick. -- Brick manufactured by processes that do not involve firing of the finished product. Zircon Refractory -- Refractory products consisting sub stantially or entirely of zirconium orlhosilicale (ZrSiO*). Zirconium Oxide Refractory. - Refractory products consisting substantially of zirconium dioxide. 29 ;T> jOuNS-MANVILLE warrants its title and Products sc;: r.e'eunae' are manufactured it> tee vif. the aoo'caD'e Specifications and are detects m materia: and workmanship using our t.o"? as a stanca-i Tne nmit oi ojr liability lor a" . c` cu' Products to meet the foregoing war- fcr o-earn c' an, ome' warrant, epress or sna be rc sudp-. an eoj.,a>ent amount of proda". P-od_:ts returnee to us and tojnd to be defective by us. Due to tne widely va',ing cone: " unoer which our Products are used and instated we ofceno warranty, express O' implied, as to me" /e'g-- service hte or suitability for any parti:u,ar purpose ievent shall we be liable for incidenta o- conseaje't.a damages. No person is authorized to Pme us ic- a', further warranty obligation beyono lhat stated ir. ;r.; paragraph.  T. z. Insulating Fire Brick Facts How to Calculate Quantifies of J-M Insulating Fire Brick for Periodic Kiln Domes - Description of Round Periodic Kilns Round periodic kilns are widely used in struc tural clay plants which manufacture such products as ceramic tile, brick, pipe and other clay ware. These kilns vary in diameter from ]5 to JO feet, typically constructed as shown in Figure No. 3. The rise is usually 2V' to 3" per foot of span. The sidewalls are normally constructed of dense fire brick although a layer ol insulating fire brick is recommended to ef fectively reduce heat transfer through this area. The kilns are either coal. gas. or oil fired. Advantages of J-M insulating Fire Brick The use of J-M Insulating Fire Brick instead of dense fire brick in the construction of pe riodic kiln crowns offers the following impor tant advantages: 1. Substantial fuel savings --the thermal conductivity of J-M Insulating Fire Brick is about one-quarter that of dense fire brick. 2. Shorter firing cycles with faster heating and cooling-having a lower density. J-M Insulating Fire Brick absorbs about onethird as much heat as dense fire brick. 3. Improved product quality with fewer rejects-more rapid and uniform heat transmission together with greater ease and accuracy in controlling operating temperatures. Dome Construction A dome differs from a sprung arch in that a sprung arch describes a portion of a cylinder, whereas a dome describes a portion of a sphere. The recommended thickness of a J-M Insulat ing Fire Brick dome is 9", made up of key brick used in combination with brick tapered both in width and thickness, or in other words, wedge key and arch key brick. Each brick is color coded at the factory on the large end of the shape for quick identification on the job. All brick have the same key cut to accommo date the difference between the inside and out side arch lengths of the dome. In addition, some brick also have a wedge taper and others an arch taper. The quantities of each type of brick shape and the amount of the tapers are calculated in accordance with the method de scribed below. The rings of brick are laid up using J-M IFB mortar mixed to a stiff dipping consistency (without form-work or temporary supports) until the dome is closed except for the hole in the center. Frequently a template is used during construction consisting of wood frame attached to a pipe positioned ver tically directly below the top of the dome. T-i template is free to rotate around the vertical pipe, and having a shape similar to the fir.. ' inside surface of the dome, acts as a guide each brick course. J-M Superex M Block is recommended a- . back-up insulation over the insulating tm brick cut to fit on the job. where necessan. and adhered with J-M Fibrous Adhesive. Ththickness of J-M Superex M selected should, be sufficient to insure a cold face temperatur* of less than 225: F and. at the same time, pro vide that the mean temperature of the 9" of insulating fire brick will not exceed 2000 F. General practice is to apply a layer of dense brick over the insulation as a wearing surface. Weatherproofing consists of J-M No. 50 A>phalt Saturated Asbestos Felt embedded in J-M Insulkote ST. Surfaces should be primed with J-M Insulkote Primer S before the appli cation of weatherproofing. See Figure No. 2 Colculation of Brick Quantities and Shapes 1. Refer to Figure 1. "Kiln Dome Layout For Calculation Data." The following calculations are based on the tr; - metric relationships shown inthi- o Determine the length of the outL.. from the _ of the dome to of the dome. L,, (inches) = 2 a R. x 1; Dome Aiu 3G0 3. Since the brick are laid the 41 /' way. the total number of courses is-4r.o^. The ccnter hole will reduce the number of courses just calculated by 1its diameter in inches divided by 4.5. 4. Determine the angle - formed by a sin gle brick (projected to the dome center). See Figure 1. a _ 4.5 _3(><> f 4.5) 3G0 " 2 a R..: ~ 2 a R 5. At this point, the total number of curseas determined in stepS may be checked b\ -'--j---D--o--m--e----A--n--g--l-e- = T--otal* numb. er <: courses (less center hole i. G. AH brick in the dome are key cut. and the key taper is determined by X R, 4.5 " R : 4.5R R ( 4.5" -- X" ) Key cut on all brick. 7 Sr: up :i table of eleven column? aero?? and of a lenjrth equal to the number of course?. The first column indicate? the course number. - lr, Column 2 list the anple between the vertical _ the dome anti the farthest eil'-e of each course t see Fijrure ] 1. This ancle is of the Dome Ancle minus the -um of '? to each course. For exam ple. for 120 Dome, course No. 1 i,,u cum -- 0 = GO.000 : Course No. 2 iilO.iiun minus = : Course No. 3 is G0.0O0 -2 : : etc. ci. Convert the decimal portion of each anule to minute? of a decree to facilitate determinin': its size or use decitri" tables. lb. In Column 3 list P... the horizontal dis tance from the _ to the lower edjre of each course,on the outer arc (Point C on Fit:. 1 > P. = R. sin Co] 2 anyde. L'se a calculator ami 5 place trigonometric tables. 11. In Column 4 list the circumference (in a horizontal plane) of the loci of point C about the . This circumference C = 2 P... 12. In Column 5 list the difference <C. -- F, l between, the outside circumference of *ach course. C (Column 4 1 anti the in side circumference (Point P. -- Fie. It of the inside edtre of the same course about the . This inside circumference B . C.-B.=(l-|)c. This is derived a- follow-: : B = S- C. (similar triansrles ) KK K ThereforeC -P -C -^-C =C. (l--^) |l - is a constant. Id. In Column f> list the total number of brick per course. This is C (Column 4 ) divided by 2' the width of the outside end of each brick regardless of shape. To speed calculation by avoiding a division l'..r each course, remember that C. = 2 .7 P.. so that Total Number of brick per course = (-j; * constant. 2.5132?). 14. In Column 7 li-t the number of wedyokeys required per course. The difference in circumferences. C. -- B, (Col. 5> nui.-t be satisfied by inserting a number wedpe-cut brick in each course. For ex ample. if a (2V' - 2") wedpe cm is se lected. each wedpe key tapers >> if C. -- B is 10" for a course. 2" wedpe k-\ must be used to turn the circle of :h..course. Therefore Column 7. Nunvu-i C -F Wedye Kevs =-w--e--drpe-c'ut t-a--p--e-r- l-i. In Fitrure 1. note that for any com--. Point C swinp a larper circle about tr,-. than Point A. the upper outer edue <! the same course. Point A is. however, in.same as Point C for the next hi'.lur course. So. to determine the difference it circumference between the loci of p..nnA and C. use C.. course No. 1 minus i course No. 2. C. course No. 2 -- C. cour~v No. 3. etc. Thi- difference is listed, for each course in Column S. K> In Column 9 list the number of arch k<-\ required per course. The difference in circumferences shown in Column S be tween Point C and Point A must be sat isfied by insertinp a number of arch cut 1-rick in each course. For example, it a (2 - 2"t arch cut is selected, it taper- V. So. if the difference in circumfer ences in Column S is lb" for a course. 2" arch keys must be used. Therefore. (''. P. number of arch key C olumn S Arch-Cut Taper. It is necessary, sometimes, to u-e two or more decree- of arch taper on the arch key brick. The key taper remain- the same, but on cour-es approachinc the top of the dome, the arch taper i- i'1- creased so that the difference in circum ference (Column 81 can be satisfied wiih fewer arch key brick. This is important in the upper course- because there are few brick per course. 17. In Column 10 list the total number of arch key and wedye key for each course. This fipure is the sum of Column 7 and Column 9. 1?. In Column 11 list the number of kov brick required percotir-r After the arch and wedpe requirements have been met. all the remaininp brick in a course are keys. Therefore. Column 11 - Column ( rnimi- Column 10. 19. It is recommended that for oj-derinyand c-on-t ruction use. the brick quantitie- per course be tabulated as shown on Figure 4. *- DENSE FIRE BRICK WEARING SURFACE. TYPICAL SECTION THROUGH CIRCULAR PERIODIC KILN WITH INSULATING FIRE BRICK DOME FIGURE No. 4 SHAPE DETAIL AND S/M INSULATING FIRE BRICK C3 ARCH KfT TYPE'A' COlOR-GREEN REO________ ED ARCH KEY -TTPE*B' color-yellow REO_________ m3 ARCH ACT -TTPf *C* color-black REA COURSE ,, WEDGE ! ARCH KEY NO KEY TYPE A TYPE B TYPE C 2 ':1 47 ! e BRICK FIGURE No. I KILN DOME LAYOUT FOR CALCULATION DATA DETERMINATION OF ANGLE CX LENGTH - STRIPS AS LONG AS CAN BE APPLIED WITHOUT WRINKLES MUST BE SHORTER TOWARD CROWN TOP. ~ STAGGER ALL VERTlCAL_ JOINTS AT LEAST 6' 1 1_____ l *-2' LAP OVER CENTERLINE FIRST LAYER AROUND BASE 8' WIDE ('/* WIDTH OF OTHERS I EACH LAYER OF FELT 'BEDDED IN INSULKOTE ST METHOD OF APPLYING J M NO SO ASPHALT - SATURATED PELT AND INSULKOTE ST AS WEATHERPROOFING FOR INSULATED CIRCULAR KILN CROWN FIGURE No 2 PERIODIC KILN CROWN WEATHERPROOFING