Document gDNrorJ00jMNe9367yOwpDgRa

Johns-Manville's Modern Research Center and Manufacturing Plants Combine to Produce Insulating Fire Brick and Refractories of Highest Quality and Top Value JOHNS-MANVILLE SSUSSMSSSm *2&i T. are'nsBd by ceramic engineers in test ~ furnaces -phU of mamtammg up to 3000F. In iBustration below, an insulating fire brick dnignd to withstand very high heat is being tested under JONHS-MANVtLLE RESEARCH CENTER The Johns-ManviHe Research'Center (left), near M&nville, New Jersey, is one of the country's largest and most fuDy equipped groups of buildings of its kind, with a large staff of scientists, engineers and A special advanced testing equipment is located at the J-M Research Center. There; ceramic engineers regularly test the performance of all J-M refractories under conditions closely simulating those of high tempera ture service in the field. Chemical as well as physical tests are made, and individual raw mut^rinln are subjected to scientific analysis. Evaluations are also made to determine the optimum ha1rm. of refrac- tory properties. . . ' v - There, too7 comparisons of different formulations and blenda am continually checked for development of new refractories. Tests are also made to determine new uses far established J-M refractories in order to meet present production requirements. Special test ing furnaces are available for this research, as well as the most advanced apparatus for temperature measurements, microscopic studies and X-ray. The ceramic engineers also carry out research assignments related to specific awtomer problems. Hus broad research program plays a major part in Johna-ManviHe's ability to offer exactly the fight insulating fire brick and refractory--the most eco nomical and efficient castable, gunning mix, light weight aggregate, mortar or patching material--for ~- 3 -TWO MODERN PLANTS TO SERVE YOU ^ohna-Manville's modem refractories plant at Zelienople, Pa. (above ia one of the two plants that manufacture J-M inanlating fine brick. This plant, .and the one atLompoc, California, are geographically mtuated to supply industry with the most complete line of insulating fire brick to meet the diversified requirements of modem furnace construction. v . At Zelienople's control laboratory, trained cera mists continually conduct physical and chemiVal tests to insure product uniformity and high quality. This control is of paramount importance in these days of higher operating temperatures and mount ing operating expenses. It is important whether you use insulating fire brick, castable, gunning mix, bonding mortar, patching material orlightweight fill. At Lompoc, California (below), in an area once submerged beneath the sea, Johns-Manville owns and works the largest and most uniform deposit of diatomite--the fossilized remains of microscopic marine plants (diatoms) which died millions of years ago. From it, the Lompoc plant manufactures three types of Sil-O-Cel insulating brick used for back-up insulation behind refractory fire brick linings or behind insulating fire brick linings. TABLE OF CONTENTS Page INTRODUCTORY..................................... 2-5 INSULATING FIRE BRICK AND SIL-O-CEL INSULATING BRICK Insulating Fire Brick General Information Specification Data . . Method of Production Typical Uses Heat Losses Table Standard Shapes .....................................6-7 8-9 . . . . 10-11 . . . . . . 12-15 . . . 20-21 . . 22-23 Sil-O-Cel Insulating Brick General Information Specification Data Standard Shapes 16-17 . 18-19 ... 22-23 Special Shapes .. .. .. 24 Packaging and Palletizing ............................. 24-25 Construction Details Straight Walls 26-27 Curved Walls ... . . 28 Division Walls . . .29 Sprung Arches................................................ 30 Domes and Arches .... . . 31 Suspended Arches and Walls..........................31-32 Periodic Kiln Domes................................. 32-33 HYDRAULIC-SETTING REFRACTORIES (Castables and Gunning Mixes; Introduction ....................................................34-35 Firecrete General Information..................................... 36 Specification Data . 36-37 Application Instructions................................. 38-39 Elazecrete- General Information 40 Specification Data............................................ 40-41 Application Instructions................................. 42-43 REFRACTORY BONDING MORTARS Introduction............................................ 44 Ready-Mixed. Air-Setting Cements (Blakite, Super Blakite, Hellite andNo. 20) 44 Dry. Heat-Setting Cements (No. 31 and No. 32) . 44 Dry. Air-Setting Cements (No. 26) 44 Calculated Chemical Analysis, WetCements . 45 Packaging Information..................................... 45 LIGHTWEIGHT REFRACTORY AGGREGATES AND FILLS General Information......................................... 46 Available Types . 46-47 CERAFELT REFRACTORY FIBER FELT Genera! Information 48 Thermal Conductinty..................................... 48 Standard Densities and Thicknesses . . 48 GLOSSARY OF STANDARD TERMS 49-51 Insulating Fire Brick and Sil-O-Cel Insulating Brick JOHNS-MANVILLE INSULATING FIRE BRICK PROVIDE UNSURPASSED HEAT-CONTROL EFFECTIVENESS TO 3000F Johns-Manville provides industry with the most complete line of insulating fire brick and lightweight refractory aggregates, fills, and castables for tem peratures through 3000F. J-M INSULATING FIRE BRICK-Produced from high quality refractory clays. All six 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 six types of top-quality fire brick, JohnsManville offers operators and builders of'high tem perature equipment the opportunity to use the one 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 recommended use. In addition, J-M insulat ing fire brick has high purity (low reducible oxides), making them adaptable for use in prepared atmos phere furnaces and special ceramic kilns that use salt glazing processes. All six types have 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 lin ing or as back-up insulation behind other refractory protection. Their light weight and high insulating value make possible thinner furnace walls, improved efficiency and lower operating costs. Furnaces can be brought up to operating temperatures with un usual speed, thus resulting in increased production. COMPLETE LINE OF INSULATING FIRE BRICK The six types of J-M insulating fire brick with , their respective temperature limits are described below. The weights are approximate. JM-3000 (to 3000F) -- A high temperature insulating brick made for back-up or exposed use. This brick is especially adaptable for use in forge furnaces, ceramic 6 brick b ordinarily naad (&8 lb. per brick). JM-2S (to 280QF) --With its comparatively fight weight of 3.4 lb. per brick and high spalling re - airtance. this brick can be saad as insoleting fire brick or back-up insolation in enameling furnaces, forge furnaces, anaking-pit covers, ceramic kilns and other locations where it will not be subjected to temperatures above 2800F. JM-26 (to 2800F)--Combines high spalling resist ance and light weight (2.8 lb. per brick). It is suit able for use as an insulating fire brick or back-up insulation in calcmers, ceramic Hina, beat-treating furnaces and simiLar equipment where ft* tempera ture on the JM-26 brick does not **re**A 2600F. JM-23 (to 2300F) --A lightweight high purity brick (1.7 lb. per brick) wfth low iron content which pro vides high resistance to the deleterious effects of prepared atmospheres. It is designed for direct ex posure or back-up insulating in such equipment as oQ heaters, ceramic kiln domes,'drawing fumaoes, electric furnaces and hardening furnaces. - JM-20 (to 2000F) --This is & high purity brick (1.6 lb. per brick) with the perfect balance of chemi cal and physical properties for effective heat control in prepared atmospheres. It is made from carefully selected materials with an extremely low iron oxide content^ The brick has high cold-crushing and hotload bearing strength. It is used in annealing ovens and various other types of equipment such as car bonizing furnaces, lehrs, normalizing furnaces, oil stills and heaters, and far stack linings. - . JM-1620 (to 1600F exposed, to 2000F back-up) -- This iTvaiUtiwg fire brick (1.5 lb. per brick) is recom mended far use as a direct refractory lining far tem peratures not over 1600F, end far service behind fire brick or other insulating fire brick where the temperature on the JM-1620 brick will not exceed 2000F. It is used in such equipment as core evens, hot blast mams, producer gas mains, regenerators, recuperators, straw-relieving furnaces and similar equipment. ' \ . . .. -yvr;-- \ **V Sr^-V v *- -T- ? .if-  Phyi Temptrr. Apprci " . Transit';Coia Liner S" Reverse ; Expans. * Thf *.f..: <24 hr S - Typ, Maten. Comppsi' SlC: T.C. fe:: Al: 0 CaO MgC Na:: K;0 p:0 Al Wt The- Com  Physical Properties JM-3000 JM-28 JM-2B JM-23 JM-20 JM-1620 Temperature Limit 3000F** 2800F** 2600F** 2300F** 2000F** 2ooor*** 1600F** Approximate Density, pci Transverse Strength, psi 65 58 51 31 29 27 200 175 140 140 105 95 Cold Crushing Strength, psi 400 300 210 210 155 145 Linear Shrinkage, percent '0.8 at 3000F 1.4 at 2750F 1.0 at 2600F 0.1 at 2300F C O at 2000F 0.0 at 2000F Reversible Thermal Expansion, percent 0.65-0.75 0.65-0.75 0.65-0.75 0.5-0.6 0.5-0.6 0 5-0.6 at 2000F at 2000F at 2000F at 2000F at 2000F at 2000F "The figures given m this table are average values obtained m accoroance with accepted test methods. Back-up or esposed Backup only. '244ir Simulative Service Panel Test; all others 24-hr soaking period. Typical Chemical Analysis Material Campesition JM-1620 JM-20 and JM-23 JM 26 SiO, TiO, Fe,0, Al,0, CaO MgO Na,0 K,0 P30s Al Metal 43.0 1.3 0.5 36.9 17.6 .06 .03 .21 ,, -13 - 44.2 1.29 0.46 38.0 15.2 .06 .02 .27 0.16 - 57.4 1.7 .8 39.7 0.2 .1 .1 .1 - - JM-28 39.0 1.25 .5 59.0 - - .19 .06 - - JM-3000 29.4 1.0 .71 65.6 0.3 0.5 0.1 0.1 3.6 Thermal Conductivity: BTU IN. PER SQ FT PER F PER HR MEAN TEMPERATURE. F JM-3000 JM-28 JM-26 JM-23 JM-20 JM-1620 500 3.22 2.55 Z22 1j01 0.95 0.88 1000 3.30 2.80 2.44 1.18 Ml 1.05 1500 3.37 3.06 2.68 1.34 MS M3 2000 3.46 3.32 2.93 1.50 - Compliance with Government Specs JM-20 complies with MIL-B-16305A, Class A JM-28 complies with MIL-B-16305A, Class B Streamlined methods cut production time and speed delivery of J-M Insulating Fire Brick in standard and many sizes of special shapes In Johns-Manville's modem refractory plant at Zelienople, Pa., high quality insulating fire brick is made better and faster by an improved 'method dif ferent from the conventional process. With the J-M method, standard brick and a wide range of special shapes are cut out of fired slabs. The slabs are molded, fired rapidly through tunnel lfilng then cut into the desired shape. Handling of the slabs throughout the process is easier, a more stable load is possible on the kiln cars, with uniform temperatures and better spacing to permit bum-out. 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. This streamlined operation provides the flexibility and basis for giving quick shipment of high quality standard and special insulating fire brick shapes to J-M customers. (1) Slinger machine throws selected mix from pug mill and forms continuous stiff column on pallets moving along molding conveyor. (2) Sharp blades first trim top and sides of column, then cut it into slabs so that each slab is on a pallet. CASTING METHOD (JM-1620, JM-20 and JM-23) (1) Blends of high purity refractory materials, setting agent and burn-out are thoroughly mixed with water in paddle-type mixer, then poured into a mold. (2) When mix hardens, the mold is moved to the stripping machine where slabs are removed from mold and put on kiln car. I 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 standard and special brick shapes by a sizing machine which slits the slabs to the proper width and length. The brick are then packed into cartons and stored until they are shipped by rail or truck. 10 delivery of oecial shapes * to permit bum-out. have to be molded :an now be produced so superior to shapes ck. >vides the flexibility ment of high quality : Are brick shapes to trim top and sides of column, o that each slab is on a pallet. $ 11 i mXTALS i fiaavll . r-t-- ,,-- *-S Insula ->>-- ;---: _r f '!^fe:4feShetj3SK -.-jc3T *rttir.r * --***:T-f -,'fli". -.'r-^'- 5<jSt- .--r - '? K*..-r si^-7.1 *-" - * vnumomr - f-`JciL^ .... . ; . JgjpsSyl? * ^^5*5' ' Bwlmlytir calk (mafnanzm) GslvsnUlIf --^ Umln| fixoMaas ~ "SMSW/^'i , pots (ahwnmnm) ^ 1 . : -.> (>>---*-. y-~sSr: -y:^-'~f t' rf-.` ' v 3iP\r?T:L- ~.~ UtSSiW^' Vi5j*^'-rife/0;^Wii-. 9W '?Vijt - I Insulating Fire Brick I Normalizing furnaces ] Open-hearth furnaces Plate-heating furnaces I Pusher furnaces Radiant tube annealing covers Recuperators I Rolldown furnaces Rotary hearth furnaces I Sintering furnaces Slab-heating furnaces Soaking pits 1 Soaking pit covers Spheroidizing furnaces I Stress-relieving furnaces Tempering furnaces Walking beam furnaces 13 I Typical uses for J-M THE PETROLEUM AMD CHEMICAL INDUSTRIES PETROLEUM INDUSTRY Hot air and gas mains Breechings Catalytic reformers Ducts Flues ,, Oil heaters or furnaces (walls, arch, door) Reactor chambers Regenerators Stacks Stills Vessel linings CHEMICAL INDUSTRY Ammonia reformers Calcining furnaces Carbon baking oven covers Driers High-temperature pressure vessels Hot gas mains Rotary calciners and dryers Special process furnaces Stacks and breechings Sulphur 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 Procelain enamel furnaces Flues and stacks Controlled atmosphere kilns Calcining furnaces GLASS INDUSTRY Bending furnaces Flattening ovens Gas mains Glass tanks, regenerators, dues and uptakes Lehrs Ports 14 i uses for J-M Core-drying ovens Heater* - Japanning oven* &*./:? Incinerators Rniiniolmj ftirngwn *' tfilrn Bake oveaa Burners * - - Ovens -"`v Retort benches Coke ovens - .' ~ CroaB-over flues ' Domestic oil burners Furnaces ' Gas producers and mniju Stacks *v . J Stoves c''* '' Gas generators Duct linings - T'v'---- ***+ .- * jat.. -: :*/'* v; . V. -rw; . . v...- * c* tfc.l Providing Good Insulating} Value and High S: Sil-O-Celinsulating brick ismade inJohns-ManvQle's Lompoc, California plant, mriwg selective KluHc of diatomaceous silica. This material ranem mminn. of microscopic cells that offer maximum resistance to the flow of heat. Consequently, these high load bearing brick are ideal for uae tahimi fir brick at temperatures through 2500F. - ' Three types of Sil-O-fVl inanlaHng hrirlr am aval]. ' able to meet the varying temperature requirements encountered in back-up insulation service: Si-0-Cel . Super, Sil-O-Cel C-22 and Sil-O-Cel 16L. All are used in boilers, stills, heat-treating furnaces, Hlnal _ lehrs, flues, retorts, stacks other types of high, temperature equipment. (Sil-O-Cel 16L maniating brick may also be used for mrpnaaH as well as back- up service.) ,.. -, ' - . Used as back-up insulation, Sil-O-Cel maniating ^ brick make it possible to reduce the necessary thick ""' ness of the exposed refractory as much as one-third. - - This results in a considerable saving in furnace " wall construction for all types of high-temperature equipment ._ SQ-O-Cel insulating brick are pressed, then dried - end fired in tunnel kilns. They are pressed to size, ' not sized after firing, as is the case with J-M insulat ing fire brick. ' \* -vr^,v.v.-4 * ' r THREE TYPES OF BRICK " - ^ - *----- The three types of Sil-O-Cel insulating brick are: ' . .. . ` SitO-Cel 18L --Made from diatomaceous silica, molded and calcined. They serve for temperatures to 1600F, back-up or exposed. This type ofSil-O-Cel brick is one of the most efficient insulating brick obtainable and is used in preference to other types of SQ-O-Cel brick except where severe temperatures are encountered. ` . . ^Theee brick have a cold crushing strength of ap proximately 350 psi, so they are amply strong far structural purposes. Owing to the extremely low reversible thermal expansion, less than 0.1 at 1600F, * SQ-O-Cel 16L brick are particularly advantageous in building long-lasting refractory masonry. Because of valuable property, 16L brick can also be ^ bonded for direct exposure. ; ;; ` - SQ-O-Cel 16L brick are finished so that accurate, ' month surfaces are assured. This enables the brick to be lid up with thin joints and permits bonding with the fire brick where required. .......... _ ib ~ I> ` Sil-O-Ce! C-22 - A: brick, pressed am! sulation behind ritv brick where the ten. not exceed 2000F. In preventing tr.i: are three to four inretarding heal flow i characteristic-, thrv gree. all those qua I; i < purpose insulating 1>i These brick have 700 psi. which is equ.They are therefore et ions where high load Sil-O-Cel Super -- A . designed for except, ice where subiecteii refractory. These brick have proximately 300 p-- tons per sq. ft. In many cases, it . thickness of first-qu. Super brick are used where Sil-O-Cel 16L fire brick. Sil-O-Cel > back of 9", or in some tory, thus making a i Value and High Strength Sil-O-Cel C-22 -- An efficient, diatomaceous silica brick, pressed and calcined for use as a back-up in sulation behind fire brick or behind insulating fire brick where the temperature on the insulation will not exceed 2000F. In preventing transmitted heat loss. C-22 brick are three to four times as effective as fire brick in retarding heat flow through furnace walls. In other characteristics, they combine, to a remarkable de gree, all those qualities desirable in an ideal, generalpurpose insulating brick. These brick have a cold crushing strength of about 700 psi. which is equivalent to over 50 tons per sq. ft. They are therefore especially recommended for loca tions where high load-bearing properties are essent ial. Sil-O-Cel Super --A calcined type of Sil-O-Cel brick designed for exceptionally severe insulating serv ice where subjected to temperatures behind the refractory. These brick have a cold crushing strength of ap proximately 300 psi, which is equivalent to over 21 tons per sq. ft. In many cases, it is possible to cut down on the thickness of first-quality fire brick when Sil-O-Cel Super brick are used. For instance, in equipment where Sil-O-Cel 16L would be used behind 13of fire brick, Sil-O-Cel Super brick could safely be used back of 9", or in some cases as low as 4 \A" of refrac tory, thus making a considerable saving. Johns-Manville Sil-O-Cel Insulating Brick SIL-O-CEL INSULATING BRICK Specification Data Physical Properties' Super C-22 m Temperature Limit Approximate Density Transverse Strength Cold Crushing Strength linear Shrinkage Reversible Thermal Expansion 2500F" 40 pel SO psi 300 psi 2.0% at 2500F 1.3% at 2000F 2000F'* 31 pel 115 psi 700 psi 0.1% at 2000F 0.7% at 2000F 1600F'** 34 pel SO psi 350 psi 0.7% at 1600F less than 0.1 % atlSOOF *Tht i|uret liven in Itiij table are averate values pbtamed in accordance mini accepted teat metnods ''Back-up only. ---Backup or exposed. Thermal Conductivity: BTU IN. PER SQ FT PER f PER HR MEAN TEMPERATURE. F 500 1000 1500 Super C-22 16L 1.70 1.95 2.19 1.67 1.88 2.08 0.92 1.07 122 2000 2.45  Compllmnc* with Bovmmmmnt Specs Sil-O-Cel Super complies with MIL-8-16182B ' '^ Standard Slaaa m SiMVCel Soper SU-O-Cel C-22 SMWellSL she Famished hi all stmlard 9-in. stupes of the 2tt and 3 in. series, well as special shapes. 19 . - '-ii -rrimirn-,--Storage and 3-M Insulating Fire Brick and HOT FACE TEM 'ip*: -v - .` U .- t : - r+if&gi&ji*-; ^ no .120 140 in in . Candndiaa Ja. * like . HL IT*-; ST MS HL JT ST MS HL IT ST HS HL JT ST HS HL IT I 'Vi j .jv~ -. *. .*: ' 4M'JM1620 4H'JM 4H'JMS ....7 4Vir JM26 ' ~ 4V4'J - . 4tt'JM3O0 ` 4K'fireclay brick 10 - . 155 1175 214 -- 176 1440 263 -- is 1740 314 216 2050 __ 173 - .153 1250 220 --' U3 150 269 -- 20 in 322 -- 222 220 379 ~m -- jn 1450 mi in 1650 293 _ 212 220 345 232 250 407 30 - 2 2500 479 274 310 a -- a 370 a 329 4400 n 432 --; no aso a -is SCO 657 -+ 322 4170 779 _ 349 510 906 515 330 a 3U 410 70 -- 347 5000 a -- 372 570 106 _ 74 -- 387 530 1272 -- 40 130 1596 -- a 940 19S -- 510 ion 220 - 4#*-- & " 4M' JM162D+ lVi'SX IS 411 141 1630 156 500 156 2070 191 585 171 2550 227 675 IK 290 _: 4H'JM0+IH'SX ' 125 03 142 170 10 50 J57 220 194 a 172 2740 231 a IS S40 'l 779 *S.--=T- \"r *'' 4HJMB+M'SX 134 m~ 145 ggjrtiP.; 'r^ 4H'fll+l'SX : 2B2 515 -175 2070 m a 162 300 "sT 735 10 250 <70 204 a 176 304 ~B55 S6 3U0 5770 242 a 712 18 975 235 300 670 2X2 05 416 lOK rr* . ..j. 4J4*JM28+1M'SX 214 545 UO 420 257 771 20 550 323 w 222 6600 a 1022 243 700 Ml UK 4M'JM 300+ IH'SX no m w 450 20 m 20 6250 341 '^w 229 760 40 T063 20 00 Kl UK jow^tairVJ3rtr.sfc*:--w^**1..... -m 5c . i r. *> '*- rjHisa . .. ' VJ --r 125 2220 UO * > 134 S40 IS. -- 10 3310 162 -- IS 3990 -- S'** .v`.. M ^125 2400 114 10 2940 10 141 3650 IS 10 4300 IS rmn-.y ^ . KJ ----UO 200 125 -- 142 300 152 *154 -.410 111 -- IS 490 211 -- . 307 --t 177 470 SI -- 10 570 30 2U 600 a -- 237 810 42 -- rjRa : 235 10 SU 293 -- SI 660 a ' --' 233 000 415 -- 254 9600 40 -- rjaaooo `r 2BS 200 on -- 2S 700 416 -- 255 9000 484 -- 276 ion 553 -- r FIRECLAY BRICK a -- as 1140 70 -- 323 1460 90 -- 366 1760 1017 - 30 2100 120 - i .;- ' 5 .. -- H* - rjuisa+rsK 9*JM0+3*SX rjua+rsx 9* JM 26 + 3' SX t*JM28+3'SX rjMaooo+rsx 63J 400 114 3sa 79.5 473 IS 400 97.3 si 131 4a 116 646 10 5900 -- -- su 403 113 340 06 40 121 4345 99L7 a 10 S33S 119 656 10 010 10 746 su 425 -115 010 Kl a 123 500 10 594 IS 620 125 a 141 7340 145 772 105 506 133 720 IS 713 144 130 IS a IS 1100 IK 948 10 1320 216 1K7 112 627 136 00 140 70 10 1060 10 873 161 U10 10 07 174 1540 229 1121 121 V 140 178 UO 792 a 1220 in 06 10 1470 20 1039 m 17600 240 1161 '"V - - ^. y . .* UK'jMlfia + JK'SX 13Vi'JM8+3H'SX ' 13H'JMB+'ST 13Vi'JM+3H'SX 13tt'JMa + 3H'SX 13U'JM3000 + 3K*SX 4U 345 105 463 350 104 903 30 MLS 536 in 05.4 S3 94.4 a is 420 490 550 000 UO0 1300 S6J 409 111 550 693 478 117 670 5U 411 110 600 713 489 116 7310 523 440 IS 710 762 a 1U 160 10 640 10 1200 10 745 10 1560 107 671 in 1530 129 70 143 1170 116 723 137 1740 10 a 10 2110 83J 552 IS 8060 653 564 IS 00 903 589 125 1020 10 01 149 1850 152 01 IS 21800 1C 947 158 24610 ---- 10 Ml 10 a IS 958 176 1013 IS 1058 H. - HmI Iab it Stndy SMM tomtom, BTU/5Q FT/ML JT -- Indian Tmpmm Mmn Brick aid takop InWaa, F. * Amtacnt - 0 F. Still Air. . >- . ST - Ontada Surface Tampnbn, F. HS - Had Stone*. BTU/5Q FT. ?:-r ...V, - v * >** ] . v.. - 'VU* '*! I Outside Surface Temperatures of Walls 4 Superex Compared to Fireclay Brick I PERATURE*--F wo I. ST MS 2000 HL JT ST HS 2200 HL JT ST HS 2400 HL JT ST HS 2600 HL JT ST HS 2n HL IT ST HS 242 2550 438 261 2900 I 2S2 2950 469 - 271 3350 533 - 290 3800 1 3S3 5000 917 -- 374 5700 1040 - 394 6400 1168 -- 411 7000 1300 -- 427 7600 -- __ 373 5850 1040 - 394 6600 1179 - 413 7400 1324 - 430 8200 1474 -- 447 8800 1627 -- 465 9600 394 6600 1175 - 414 7400 1317 - 431 8400 1462 - 448 9200 1607 -- 465 10000 1754 -- 482 11000 r 570 12700 2670 - 586 14100 3070 -- 619 15500 3510 - 642 17200 3990 - 658 18700 4450 - 703 20500 203 3790 312 873 219 4330 i 207 4350 324 899 223 5000 368 994 238 5550 254 7710 476 1216 273 8770 538 1336 291 9650 604 1455 308 10700 673 1574 325 11800 -- ' -- -- -- 263 9030 SOS 1273 282 10300 572 1398 300 11400 642 1522 318 12700 716 1645 335 13800 793 1766 350 14900 i- 2U 10300 523 1308 287 11600 588 1428 304 12700 656 1546 321 14200 726 1662 336 15300 798 1775 351 16400 4 172 4900 226 185 5600 179 5700 242 -- 192 6400 275 -- 205 7200 I 257 9400 482 275 10600 543 -- 292 12000 607 -- 309 13600 673 - 325 14600 - -- - 274 11000 547 -- 293 12600 617 -- 312 14000 689 -- 329 15600 764 -- 345 16800 841 - 360 18400 295 12400 623 -- 314 14000 694 -- 330 16000 767 -- 346 17600 840 -- 361 19200 915 - 374 21000 r 421 Z3400 1440 -- 445 26000 1653 - 469 29000 1871 - 497 33000 2090 - 533 35000 2305 - 584 39000 148 i 151 181 L 117 191 7400 8410 15300 17700 20200 160 838 157 8290 166 864 160 9920 246 1186 193 17200 262 1245 199 20100 272 1282 203 23100 189 957 170 ion 278 1305 206 19300 296 1369 212 22200 304 1401 216 25200 311 1424 218 21300 331 1493 225 24300 338 1518 228 27400 345 1543 231 23400 368 1616 238 26500 373 1634 240 30500 - -- 406 1738 251 29700 409 1749 252 32600 I 130 10100 116 720 137 11700 132 11600 121 746 139 13200 137 826 147 15100 1 159 21600 164 25000 168 187 1065 169 24400 200 1126 174 28100 209 1167 178 32600 210 1173 179 27500 226 1239 185 31200 234 1276 188 35800 235 1281 189 30100 252 1352 196 35000 259 1383 198 39500 261 1389 199 32900 280 1465 206 38100 285 1489 208 - -- -- 308 1578 217 41200 312 1593 218 46600 I i I 21  Standard Shapes of J-M Insulating 22 , / ' r'. -1 333U,^'.,.: ire Brick and Sll-O-Cel Insulating Brick 'J * f > ' !.# ` \T ^ 1 4V4' J. .. PX-v! -- . - m Special Shapes - --, ;.,: - -- .- -r- In addition to the production of all standard brick Jahne-Manvihe alao mamrfartnres many .. specialshapes direct from 9'x24'alabs. Theseshapes normally would have to be molded and proremcd as . specialty items. -- .- Below, special shape is cut from standard slab and timn mtanlrad on pallet with m'Tnilar pieces. Illustra tion at bottom of page shows how 20 of these pieces are aurmhlnd to make a particular product. ------ Information on Packaging CARTONS Johns-ManviDe TMilny Fire Brick and SQ-O-Cel Insulating Brick are packed in standard mumw which contain either 20 or 25 brick per carton. Ship ping weights, per carton are: JM-3000 . 76 lbs. (20 brick) JM-28. . 67 lbs. (20 brick) JM-26. 76H lbs. (25 brick) JM-23. . 48 lbs. (25 brick) JM-20. . 46 lbs. (25 brick) JM-1620.................................. . 41 lbs. (25 brick) Sil-O-Cel Super....................... . 63 lbs. (25 brick) Sfl-O-Cel C-22 ....... . 62 lbs. (25 brick) Sfl-O-Cel 16L ....... . 54 lbs. (25 brick) Each J-M brick is clearly marked with the brick type designation far quick, correct selection on the job. PALLETS - Carload shipments of standard sizes and shapes of Johns-ManviUe Insulating fire Brick and Sil-O-Cel Insulating Brick should be ordered in pallet-load units: Palletizing, is done according to the basic rec ommendations on packaging lnudinp standards of the Refractories Institute Palletizing Committee. Standard Pallets measure 48' z 36' will take 48 cartons totaling 1200 brick, except for JM-28 and -JM-3000 which total 960 brick per pallet. fra a 40-foot rail car there are usually 24 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 30 pallets, with the doorway filled with approximately the same niimlw of loose cartons as in the 40-foot car. If there is a large quantity of JM-28 and JM-3000 brick in the car, there will be about 2 less pallets than with other brick, because the JM-28 and JM-3000 pallets are slightly larger than those used far other brick. There are 8 cartons on a course of JM-28 and JM-3000 of 6 as in the other brick. (The 48' x 36' size referred to above is the dimension of the pallet only and does not allow for any overhang of the cartons.) Special pUpswing is available to our customers if the standard method is not suitable for their partic ular requirements. ' yyy*** - --:^a. -  Types of Straight Wall Construction RECOMMENDED CONSTRUCTIONS-The most common constructions where J-M Insulating Fire Brick is used are those consisting of all headers or of alternate header and stretcher courses. These con structions are recommended unless other factors in fluence the type of wall used. PERMISSIBLE UNSUPPORTED HEIGHT-Unsup ported wall 4 H' 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 W walls under same conditions are suitable up to 12-ft. heights. HEADER COURSES ALL HEADERS--Many 9*-thick Insulating Fire Brick walls are built of all-header courses. This is especially true of bell-type annealing furnaces. Ad vantages are a reasonably stable wall with the back side of all brick under comparatively low tempera tures. Hence, a preferred construction for walls operating near their temperature 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. m STRETCHER COURSES ALL STRETCHERS--Not very rigid and is not rec ommended except for walls under 3 ft. in height, or walls having other means of support, such as sus pended walls or veneer courses between a heavier wall and exterior casing. Even for walls under 3 ft. high other types of construction are preferable. MAINLY OF STRETCHERS - This type of wall is ex tensively used where the brick are subjected 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 both 9' and 13V$' thicknesses constructed ofalternate headers and stretchersmake 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. 26 II I C unrad Wall d alack* a <V fat t r|> fvifn* a* \r. *vrr< * v m werw< jr- Mkaaund at Ifc *V wait* eg fun**** macW u- i*v fom rf rtrn lu (It* ptalar Mabti.: t than . ar. tv with Hufti'. *. lOVAVTAOCS A pn^cth nnim tnl rurtwf a i Buh n*c lUbtr thar. * tln^t;'. a a'. th in> (nr ttuckam Theevfuev m*h wall* ran . t- nntnirwd higher than straight wall* Whan wall* of miff* mt curvature arr er* !<** :r a rawH nHi a* in a stark lining . Ihr wedging *> *< of thr bnrk presents them front falling timani tlw madr and thr caamg prrvrnu them from falling outward, so thr only limiting factor on hrtfht i* tl*abilitv of thr bnck to carry- thr weigh: of thr nsrr head material undrr operating condition* MICK SHAPES -Curved wall section.* arr usually constructed by using circle brick and kr> bnrk either alonr or in combination When necesemry arch and wedge bnck can also be used, but are much Ian damrablr W*hm uamg insulating fire brick to make curved walla or roofs, it is always preferable to use specially cut bnrk to fit the curvature rather than a combina tion of straight bnck and standard shapes as i* customary practice with dense fire brick CONSTRUCTION GUIDE Mfbdau lacasmM Inti Otter Hssrbtt trek luf iNvd' C'* In *#, trch buck are sometimes used b.' ere not recommended Combination o' circle end key bnc auy be laid up uun( any combina tans used lo< stingM mils Same as for ?* buck !' necesu-t eed(t bid can be used or lc* lit but thee mi is no' iecc" MAXIMUM HEIGHT-On walls where the curvature sufficient to make the wall seif-suppontng. the hrtghl is limited only by the ability of the bnck in thr lowest course to carry the weight of thr cour~~ above Since thr crushing strength of all refmctone* vanes with temperature, thr safe bright of au> I. linings will depend upon thr typr of bnck used and operating ternprrslure Jr ~ - ! Division Walls JL. r^,;-- ' -OcraaionaTlv.fignacsBiue designed having heating l" chambers side by side, with a common wall between. -This construction is usually more expensive than I two separate walls and is subject to the 1 outlined below. irg) I I I I I.i 4. , b:: i i 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 approaching their point. " _ - - v.ftr- .-r-- . * TYPE OF BRICK--Because of the high operating temperature, a higher quality brick may be required far a division wall than on the remainder of the furnace. In addition, the brick in the interior of the division wall will be subjected to the same tempera ture 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 akewbacka are sqH^vi parted by a solid course of refractory brick. Fig. 2 * illustrates the akewbacka supported by channels- resting an brick spacers. This construction, either ~_i\ with or without flues, permits one arch to be repaired 7^* without disturbing the other. However, it is necea - sary to space out the brick between the channels to dissipate the heat. . _. The air flues in the center of the division walls (Fig. 3) allow the beat to escape to the outside air. They are formed when laying the brick, providing openings that are either vertical or horizontal, or both. Where horizontal flues are used alone, air is - : BRICK SPACER AT INTERVALS BETWEEN FLUES HORIZONTAL CONNECTING . FLUE AT BOTTOM i i i i >: i %*s*ag?A$~~. Sprung Aruhiu^r^^-^Z - rS^-' ' "~r~-~~'r' -. " Sprang arches an the most common type of area ' i1imarmiShey me fsiriy easy ta erect and require the least elaborate nwhwniml means of V; support. ; ' . -**&&&&** j - - 'These arches rest at both ends on akewbacks which . tiniumit the arch etrmneo to the supporting parts of furnace. The "built-up" akewback of cut stand- ~ ard 9-inch brick is the most accepted form, but the por-iol one-piece akewback is also widely used. Since --- movement of the akewbaclm may cause failure of the JVjv arch, furnaces must be rigidly constructed. . , : Sprung arches for direct exposure can be made from *> rrenilnfiny fin brick or dense fire brick. The same practices governing proper arch construction apply \ to both types ofbrick. Although insulating fin brick feu.-. may have lesa strength per unit of weight than some types of fin brick, they serve for as wide a span, &r' Wni any deficiency in strength is overcome by Iww --tight and more uniform sizing of the insulat- - . ing fin hr** This uniformity results in an even j*1-''. distribution of the load over all the brick in the arch. BRICK SHAPES USED-Since dense fin brick an jfr^fooulded to size and burned and cannot be machined Jl- ' readily, standard wen adopted for arch, wedge jj3fc*--and key brick; designating them No. 1, No. 2, and No. 3 arch. Arches an built using s combination of No. 1, 2, and 3 brick and straights in quantities suffi- * cient to turn a given circle. - * s - J-M Insulating Fin Brick, however, an machined to size after firing and an furnished with the correct taper for any specific arch. This results in a sturdier construction and simplifies the laying operation, as BE only one brick size is involved, although, when nec essary, the standard shapes can be used. The stand ard shapes used for various arch thicknamea an: . * - M tests mi CraUatim . 4Vt* I An* bfK* or a combttution o< trch nd strrfht Mi* lUrjt 9* cb or esmbinatioa of tarje 9* adi aid la|t 9* stnifM.. -. .--.* -- ^ --- Wod| brick or a eowbinitoi a w*d*e md rtniftrt. (Coo- rtiuction of toy brick or conbinttion of kny and straight ao oot cowmen m Of tad-b siaetd on Of narmr face of tSa brick. This construction Is anijr toad where special conditions nuka k desintiiaJ .. . 0*v9* ICanstnidad, nacassartly, of apodal wad(a brick. However, 13 Vk* wad|t brick aa trashed as staidad by soma saa> facturere. ..... *C .. RISE OF ARCHES--The minimum rise for an arch should be 1H' per foot of span. Arches with a rise of 1.608* per foot of span an common, aa this rise results in an included angle of 60 degrees with the aside radius equal to the span. Wherever possible, however, for wide spans, it is recommended that the rise be made at least l$r per foot of span. "The maximum rise of an arch has generally set as 3' per ft A rise of 3' per ft will be sturdier than one with less rise. Therefore, as gnat a rise as -patebie ffteoammanded within tl limits of 1^' minimum to 3' mnrimum per foot of span. TYPES OF SPRUNG ARCHES-The "bonded" arch is the most commonly used arch and the best for most conditions, because the entire construction is tied together. If one or several bricks fail in the banded arch, the load will be talrn by the brick on either side and the arch will remain in pipTM 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 thin type arch is ease in laying, especially when a combination of standard shapes is used. .- . The "ribbed" arch is used chiefly for open hearth furnaces. The ribs strengthen the arch and give it stability after the intermediate brick have eroded away. ^ -. "Jack" arches are very seldom used except over openings, since they are costly and possess few advantages over the other types. - ' ' I0L - -*- V. \ .-'--A-*- 30 ... m H n H H H i  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 combination with 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 accommodate the difference between the inside and outside arch lengths of the dome. In addition, some brick also have a wedge taper and others an arch taper. The brick are laid up in 4H' rings until the dome is closed except for the hole in the center. During con struction, a template is frequently used. This con sists 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 inside surface of the dome, acts as a guide for each brick course. TYPICAL DOME SKEWBACK The drawings fat 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. umsentwLOhcfkocrutthtiso m gap MARK NUMBER REQUIRED DIMENSION 1 DIMENSION Y A SAC 2U* 2.19* MB 2-20* 2IS* C IBS 2-22* tsr 0 m 2.19* 2.or E M 2.10* IRC* r S7 2.01* 1JR* G 45 IM* 177* H S3 ICR* 1JT* i 24 1JI* ur 10 STRAIGHT MICK f * 4*a l 2H# REQUIRED FOR CENTER PLUG-MARK'S APPROXIMATELY 900 LB- OF 1M CEMENT REQUIRED OCTAIL Of MARK 149 REQUIRED NOTTS- AIL 0**C* TO 9F MARKED WITH MQUAAAN*TLITEITETSERGIVEN . INCLUDE NO allowance roe WASTE Suspended Arches and Walls A suspended arch or wall is one which is not self supporting, 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 for 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, Special Formed Member, and Ceramic Hanger. 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 in sulation 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 fiat arches and thin, lightweight walls with high thermal effi ciency and structural stability. The height of the wall or width of the arch is limited only by 31 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 radia tion. With self-supporting walls and sprung arches or domes, the variation in furnace shapes is quite limited, while with suspended construction, a shell ofany 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 sections. (5) To act as occasional anchorage in otherwise self-supporting walls. 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 advantage 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 rela tively 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 vertically, to avoid stresses which can cause breaking. Provision can easily be made for ventilation or for water-cooling as conditions may require. Ifthe weight of the roofis supported by suspended construction, the top courses of the walls may neces sarily be tied to the furnace binding by metal hangers or clips to keep the walls from bowing inward. DISADVANTAGES The chief disadvantage to suspended construction is its cost. For equal thickness, the cost of most sus pended construction will be higher than the cost of self-supporting 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 constructions also are unable to stand as much mechanical abuse as self supporting brickwork. THICKNESS The thickness of suspended-arch and wall construc tion is limited only by the manufacturing limits of the brick shapes. Most common thicknesses in in sulating refractories are 4^' and 9*. Very few sus pended arches or walls are constructed with a thick ness less than 4^' or more than 9'. 32 SIZE OF UNITS Brick shapes for suspended arches and walls require absolute uniformity of size to assure close fitting and to eliminate the possibility of air infiltration and gas leakage. The most common insulating fire brick unit for this construction is the 2H' 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 over all cost of steel, labor and refractories than when the 2l/$r size is used. NOTE: Where suspended construction is used, only one insulating fire brick of sufficient thickness to obtain the desired- insulating effect should be used. Do not use a combination of insulating refractories and back-up insulation, as such construction will dam up the heat on the hangers and cause trouble. TmcAL coNsniuentm of wsknocd kcmcs and mus 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 in diameter from 15 to 40 feet, typically constructed as shown in figure 2. The rise is usually 2}-2" 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. 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 Lo from the i of the dome to the base of the dome. ,Lo (inches), = 2--i-r--R--<-,--x--^- ggDgoo-m---e---A--n-gle 3. Since the brick are laid the 4Yf way, the total number of courses is The center hole will re duce the number of courses just calculated by H its diameter in inches divided by 4.5. n w Ml M *1 It It II V is* I 1 1 I I 1 'foie- I * m S'. 1 I I I I i I m Determine the angle * Conned by a aingle brick (projected to the dome center). See Figure 1. - ct 4* "880 TTf# * 3620r(4^Ji) :i..a.. i r~.*...w.s.: ., 5. At this point, the total number of counee aa de termined in etep 3 may be checked by Dome Angle Total numb'er of couiaee (leas center hole). t 6. All brick in tbe dome are key cut, and the key taper ie determined by X._Ri x 4.5 m* - (4.5' -i- X') Key cut on all brick. - 7. Set up a table of eleven columns across and of'a length equal to the number of counee. The first wiliimn tbe couree number. 8. In Column 2 list the angle between the vertical l of the dome the farthest edge of each couree Xsee Figure 1). This angle is H of the Dome Angle minus tbe sum of 's to each couree. For example, for a 120* Dome, couree No. 1 is 60.000* -- 0* -- 60.000*; Course No. 2is 60.000*minus ; Couree No. 3 is 60.000* -- 2 ; etc. ' 9. Convert the decimal portion ofeach angle to minutee . . of a degree to facilitate determining its sire or use decitrig tables. '**' 10. In Column 3 list Po, the horizontal distance from the L to the lowre edge of each couree on the outer arc (Point C on Fig. 1) Po " Ro sin Col 2 angle. Use R plana farigMMmwfaric tshl-- . . , 11. In 4 list the drcum&renoe (in a horizontal plane) of the loci of point C about the . This circumference Co K 2 r P. -- 12. In Hnlmun 6 list the difference (Co -- B0 between theoutsidecircumference ofeach course, Co (Column 4) and tbe inside circumference (Point B -- Fig. 1) ..4'. m.t of the inside edge of the -This mode < - hi^Co--"|l - couree about the - This is derived as follows: . o G R gj -- ; Bj gj Co (similar triangles) Therefore Co -Bj - Co -gJCo - Co(l-j^) (-) *is a constant. 13. In Column 6 list the total number of brick per couree. This is Co (Column 4) divided by 21?'. the width of the outside end of each brick regardless of shape. To speed calculation by avoiding a division for each course, remember that Co = 2 r P0. so that Total Number of brick per couree = (if* * ooMt"t' 2*1328). 14. In Column 7 list the number of wedge keys required per course. The difference in circumferences, Co -- * * Bj (CoL 5) must be satisfied by inserting a number of wedge-cot brick in each couree. For example, if a . "(2J$# " 2*) wedge cut is selected, each wedge key ... tapers )$', so if Co -- B1 is 10' for a course. 20 wedge keys must be used to turn tbe circle of that oocae,Therefore Column 7, Number of Wed**v^ " 15. In Figurel, note that for any course. Point C swings -- a larger ends about the i than Point A, the upper outer edge of die aame couree. Point A is, however, tbe asme as Point C for tbe next higher course. So, to determine the difference in circumference be tween the loci of points A and C, uae C0 course No. 1 minus Co course No. 2, Co course No. 2 -- Co course No. 3, etc. This difference is listed for each course Iff. In Column 9 list die numbs of arch key required per course. The difference in circumferences shown . in 8 between Point C and Point A must be satisfied by in--rtiny a number of arch cut brick in aach coarea. For example, if a (214' -- 2') arch cut ' is selected, it tapers )$'. So. if the difference in fJii uiiifrmnw in Column 8 is 10' for a course, 20 arch keys must be used. Therefore, CoL 9, number oxr m'e-!n:z!s.ays -vA.rchC-oCluu. mt Tna8per. or more degrees of arch taper on the arch key brick. Tbe key taper remains the same, but on courses approaching the top of tbe dome, the arch taper is increased so that the JHfa--v in i^wmifwwmi (Column 8) can be satisfied with fewer arch key brick. This is im portant in tbe upper now we because there are so few brick peri 17. In CohmmTO fist the total number of arch key and wedge key for aach course. This figure is tbe sum of - 7 {"IrtliTwiTl 9, ..t m In Column 11 list the number of key brick required per ouurea. After tbe arch and wedge requirements have been met, all tbe remaining brick in a couree amkeys. Therefore, Column 11 Column 6 minus CohmmlO. 33 V. -- v- ... .jsvhf**# . ju**- - ' ` ^ _ .' 9. .. . . ? 57' >4*r.\ .' c-~ ; '* J ^^asr.: '^c-. _ H Johns-Manville offers a wide range of refractories for forming monolithic linings. All of these materials of the highest quality and each performs a ~ specific service to industry. Castable Refractories m Gunning or "Slap-Troweling" Mixes.................................................. This classification refers to castable refractories that, when tempered with water, will develop struc tural strength by reason of a hydraulic set. These refractories are composed principally of alumina or aluminum-silica aggregates, using hydraulic-setting cement. Castables are furnished in dry form, are mixed with water on the job, and poured or cast in place like portland cement concrete. When casting or pour ing. certain rules must be observed. It is essential to use water suitable for drinking, in the correct ratio, with a short mixing time and quick installation. For best results, a vibrator should be used when the castable is placed in the form. Care should be taken to limit the vibration, as excessive agitation will force the binder and fines to the surface. . Where the castable is poured in contact with por ous surfaces, such as insulating fire brick or block insulation, it is necessary to coat the surface to pre vent the water escaping from the mix. This can be done by using oil, grease or waxpaper as a coating. Depending upon atmospheric conditions, installed castables will harden in less than 8 hours, but they should have approximately 24 hours of water curing to assure proper hydration of the binder and to re move heat generated by the chemical reaction. High ambient temperatures lessen curing time, while low temperatures prolong it. Castables should not be installed at freezing temperatures or allowed to freeze until thoroughly cured. In many industrial furnace operations, it is often de sirable to build or repairsections ofrefractory furnace linings by gunning or "slap-troweling" applications. GUNNING is done with a pneumatic gun that ap plies gunning mixes which are hydraulic-setting re fractories. These are applied at high velocity and pressure to form dense, homogeneous linings. Gunning mixes are used to advantage in vessels, stacks, ash pits, tanks, slab-heating furnaces and individual boilers. Densely-compacted linings can be gunned quickly, and easily with the use of forms. There are two types of guns available: dry and wet. With the dry type, the mix is forced through the hose and the right amount of water is added at the nozzle. The wet type combines water and mix in the hopper to produce a wet mix which is then forced through the hose and ejected from the nozzle. "SLAP-TROWELING" is used in locations where it is not suitable or economical to employ gunning pro cedures. "Slap-troweling" means the cement is thrown or forced into place with the use of a largesize trowel. The cement is mixed with water to a stiff consistency for easy application. The proper consistency can quickly be found by trial and error.  J-M Firecrete castable refractories DESCRIPTION: Johns-ManviUe produces nine types of castable refractories to meet practically every requirement for temperatures through 3000F. Each of these refractories is economical and effi cient in the service range for which it is recom mended. All harden rapidly and are highly resistant to spalling. AVAILABLE TYPES: 3X Firecrete--A high alumina refractory for service to 3000F. It is used extensively in ceramic kilns for casting cartops, doors and special shapes of all description. Suitable for casting shapes and linings 2-inch thick or more. * H. T. Firecrete--An economical, high alumina re fractory for service to 2800F. Suitable for casting shapes and linings 2-inch thick or more. JM-20 Firecrete--A lightweight, economical, alu minum silicate refractory for service to 2000F. This castable combines unusually light weight, high in sulating value and strength. Recommended for cast ing shapes and linings 2-inch thick or more. 2200 CA Insulating Firecrete--A high purity, light weight refractory for service to 2200F in controlled atmosphere applications. This castable supplements CA Insulating Firecrete or JM-20 Firecrete. Recom mended for casting shapes and linings 2 inches thick or more. Lo-D Firecrete --Designed primarily for use as a back-up insulating refractory in naval boilers. Service to 2500F. C-31 M Refractory Cement--A chrome base cast able refractory for service to 3000F. Used in boilers. Standard Firecrete--An economical, aluminum sili cate refractory for service to 2500F. It is a generalpurpose castable, developing high strength on air curing. Suitable for casting shapes and linings 1inch thick or more. L. W. Firecrete--A lightweight, aluminum silicate refractory for service to 2400F. This castable com bines unusually high insulating value with excep tional strength. Recommended for casting shapes and linings 2-inch thick or more. , CA Insulating Firecrete--A high purity, lightweight refractory for service to 2600F. Developed especially for use in controlled atmosphere applications. Rec ommended for casting shapes and linings 2-inch thick or more. ADVANTAGES: Hardens Rapidly Firecrete permits casting and use of any desired shape within 24 hours. Resists Spalling All nine types are highly resistant to spalling. Negligible Shrinkage Firecrete has no drying shrink age and only negligible fire shrinkage at recom mended temperatures. Easy and Economical to Use The adaptability of Firecrete makes possible the easy construction of monolithic furnaces, linings and the like which would otherwise require the use of special shapes or in volve costly cutting and fitting of brick. Specification Data | Physical Properties* Highest Recommended Service Temperature 3X 3000F H.T. 2800F Pyrometric Cone Equivalent 33 (3173F) 30 (3002F1 Weight As Placed Oven Dried at 220F After 5-Hr Firing at 1750F 148 pcf 134 pcf 130 pcf 131 pcf 113 pcf 110 pcf STD. L.W. CA insulating 2500F 2400F 2600F 16I2669F) 15126150 32 Vi I3135F) 130 pcf 116 pcf 110 pcf 109 pcf 80 pcf 75 pcf 109 pcf 80 pcf 75 pel IM-20 C-31 M Refractory 2000F 14 (2552F1 3000F 3613290F) 96 pcf 62 pcf 58 pcf 193 pcf 183 pel 177 pcf 2200 CA Insulating Firecrete 2200F 16-1712740F) 97 pcf 66 pcf 57 pcf Crushing Strengths After 5-Hr Firing at: 220F 1200F 1750F 2200F 2400F 3500 psi 2680 psi 2350 psi 2490 psi 2950 psi 700 psi 560 psi 300 psi 580 psi 1500 psi 1310 psi 1190 psi 780 psi 1190 psi 2130 psi 630 psr 595 psi 490 psi 690 psi 1690 psi 580 psi 475 psi 595 psi 650 psi 840 psi 500 psi 490 psi 410 psi 365 psi IB) 2920 psi 1780 psi 1300 psi 1690 psi 3850 psi 310 psi 320 psi 375 psi 380 psi IB) linear Change After 5-Hr Firing at: 1200F 1750F 2200F 2400F 2800F 0.2% 0.1% 0.2% 0.7% 0.9% 0.1% 0.2% 0.1% -0.6%(A) -0.9%(A) 0.0% 0.2% 0.6% -1.6%(A> (B) 0.2% 0.3% 0.5% 1.2% IB) 0.1% 0.2% 0.3% 0.8% IB) 0 4% 04% IB) IB) (B) 0.2% 0.2% 0.3% 0.5% 1.9% 0.1% 0.1% 0.7% 18) IB) The figure* given n this table are average values obtained m accordance with accepted test methods (A) Minus sign denotes eipansion. (B) Above recommenoed temperature limit. 36 LoO 2500F 100 pcf 48 pcf 44 pcf 80 psi 60 psi 80 psi 110 psi 260 psi 0 7% 10% 2 6% 4.2% IBJ or-s U J c m CD . aluThis \h in cast- lightrolled nents scornthick as a .rvice castailers. use of istant lrinkecom- ty of Lon of rou]d or in- )-D OOF } pel 3 pci 1 pci 0 psi 0 psi 0 psi 0 psi Opsi i`r'- >\iS~ 3 ff 1 Calculatad Chamlcal Anatfmla jf.- Material S E.T. LW. MM 2288~ Eilat. Cempo- FJrt- Fire- Standard Ffte- Fbe- C-J1M Fire- CA tae. sitlaa creta cnta Fncrete crata creta CaaMat creta Fncrata SiO, Al,0, TO,FajOj CaO MgO M Na,0 FtO Cr^Oi Mac. If. Loss 39.9 393 535 503 0.6 45 15 25 2.7 45 0.1 -- -- ---- ---- ---- -- 0.4 0.2 - 40.6 435 4.7 23 75 0.1 0.4 -- -- 0.1 03 463 313 365 38.4 5.6 45 15 15 8.9 21.4 -- 05 - [ 03 -- ---- --- 05 -- 13 05 4.7 40.1 317 515 05 05 03 l 13 4.7 4.7 15.4 0.1 - 11 01 123 285 -- -- -- -- 0.7 - lJ 275 535 0.4 05 155 03 \ 0.4 -- - -. 15 323 415 25 05 175 15 tu -- -- trace 25 . - , . | Thermal Conductivity comucTnrm: 8Tum ra sa ft ra f pa w MUM TmPOATWL F , 800 1000 1200 1400 1600 1800 2000 3X Firecrete -- 75 72 75 75 85 -- 5 H.T. Firecrete Standard Firecrete -- 4.45 4.76 558 5.41 574 436 434 459 458 539 552 LW. Firecrete 159 259 231 236 256 212 CA Insulating Firecrete -- 257 2.70 250 3.12 333 355 JM-20 Firecrete 1.43 150 157 155 135 157 -- C-31M Refractory Cement -- 65 61 63 65 67 65 2200 CA Insulating Firecrete -- 150 157 1.65 1.75 157 156 Lo5 Firecrete ' - 56 136 136 136 156 156 | Compliance with Qovmmmmnt Space Lo-0 Firecrete complies witii MIL-C-19794A - yi,- \TV Packaging Information 3X Firecrete.............................. H.T. Fncrete............................. Standard Firecrets..................... LW. Fncrete............................ CA Insulating Fncrete.............. JM-20 Firecrete.......................... C41 M Refractory Cement........ tot) Firecrete............................ 2200 CA Iraulating Firecrete ... 1004 bap 1004 bap 50 or 1004 bap 1004 bap . 1004 bap " 004 bap 1004 bap 504 bap 804 bap - t -- * - rr?. . ...... '37 ,V. I JmM Firecrete application instructions Mixing: Firecrete hardens rapidly, therefore water should not be added until the job is ready far applica tion. Only clean, fresh water should be --f The amount of water will vary depending upon the shape and type of installation. Mix thoroughly after addition of water and adjust to proper percentage. Avoid an excesH ofwater in order to obtain mariminw structural strength in the refractory concrete. If cast against a porous material it is necessary to waterproof, or thoroughly wet, the surface to pre vent water being taken from the refractory mixture. -'Casting: Forms for casting shapes can be of -eitherwood or metaL Wooden formashould be coated -with shellac to prevent the absorption of water. If necessary, wooden forma can be burned away with- =out damage to the refractory. If more one shape is to be cast, heavy metal forma are man satisfactory. Hey should be smooth and coated with oil or grease to permit the easy removal of shapes. He refractory mixture should be "rodded" with a blunt-end tool until all comers are filled and air pockets eliminated. He use of vibrating equip ment is recommended. Curing and Firing: Firecrete air-hardena sufficiently . in six hours to permit the removal of forms if necee- sary. For linings or large shapes, it is preferable to air cure for 12 hours or longer before firing. In firing, . apply heat slowly and without interruption until temperature is brought above service-operating conditions. Preparation of Door Frames: A door which is leas than 4 sq ft in area generally requires no reinforcing to hold the refractory in place. On larger doors, how ever, it is necessary to provide the refractory with some mn of anchorage. Rods with bent ends or bolts with washers and nuts are generally uaed. Although such anchorage is necessary, best practice suggests that it be kept at a minimum, both in thick- iwi and number. .. . AH bolts or rods, spaced on about 24' centers, pbnnld extend through approximately one-half the tbirlnuw of the refractory and, where poesible, be placed in a staggered construction. Use maximum diameter of the bolts or rods generally used is H'. Anchors should not be placed at the comet of the door. Wrap rods with friction tape to allow for expansion. . ... .. Storage: Firecrete should be stored in a cod, dry as exposure to moisture will cause the matet 1 I ESTIMATED POUNDS OF DRY MATERIAL REQUIRED PER CU FT OF CONSTRUCTION (no allowance made lor waste) Type ol Firecrete Lbs/cutt 3X Firecrete H. T. Firecrete Standard Firecrete L. W. Firecrete CA Insulating Firecrete JM-20 Firecrete 1 2200 CA Insulating Firecrete Lo-0 Firecrete C-31 M Refractory Cement _ 130 no no 75 75 58 57 44 175 ESTIMATED POUNDS OF WATER REQUIRED PER 100 LBS OF CEMENT Type of Firecrete Lbs water/ 100 lbs of Cement 3X Firecrete H. T. Firecrete Std. Firecrete L. W. Firecrete CA Insulating Firecrete JM-20 Firecrete Lo-D Firecrete C-31 M Refractory Cement 2200 CA Insulating Firecrete 12 18 17 45 44 66 110 8 64  J-M Blazecrete (for gunning and slap-troweling applications) DESCRIPTION: Four types of dry monolithic, hy draulic-setting refractories have been developed and produced by Johns-Manville for gunning and slaptroweling applications. These four refractories are especially adaptable for gun application in building new refractory lin ings and repairing old ones. They adhere readily with a minimum of loss when "shot" in place. Mixed with water at the gun nozzle, they are pneu matically projected with great force, resulting in a dense, homogeneous lining. Blazecrete is equally effective for heavy patching by troweling, especially where brickwork has eroded deeply. It eliminates the laborious ramming or tamping required with "plastics", and patches need not be prefired. AVAILABLE TYPES: 3X Blazecrete--High alumina refractory for serv ice to 3000F. Particularly adaptable for gun appli cations and for heavy patching by slap-troweling. Standard Blazecrete--Aluminum silicate refractory for service to 2400F. L. W. Blazecrete--Lightweight aluminum silicate refractory for service to 2000F. Used extensively for stack linings, heaters and other applications where gunning mix with low rebound loss is required. C-2 Refractory Cement--High strength aluminum silicate refractory for service to 2300F. Used to ad vantage in making a protective abrasion-resistant refractory surface over L. W. Blazecrete. USES: Recommended for lining or patching forge furnaces, ashpits, cyclones, heaters, boilers, oil refin ing equipment, furnace bottoms, ladles and similar applications. L. W. Blazecrete is extensively used on tanks, structural steel and skirts for fire protection purposes. Specification Data Physical Properties Higbest Recommended Senrice Temperature Pyrometric Cent Equivalent Weight Slap Troweled: As Placed Oven Dried at 220F After 5-Hr Firing at 1750F Weight Gunned: As Placed Oven Dried at 220F After 5-Hr Firing at 1750F Crashing Strengths After 5 Hants Firing at: 220F 1200F 1750F 2200F 2400F linear Shrinkage After 5 Honrs Firing at: 1200F 1750F 2200F 2400F 3X 3000F 3313173F) 148 pcf 133 pcf 130 pcf 153 pcf 142 pcf 140 pcf 570 psi 700 psi 790 psi 1040 psi 2390 psi 0.0% 0X1% 02% 02% STD. 2400F 16 (2669F) 132 pcf 116 pcf 110 pcf 134 pcf 124 pcf 118 pcf 1350 psi 1070 psi 1130 psi 1480 psi 2870 psi 0.1% 0.4% 0.6% 0.4% The i|wn |tan in Wit table ere iwip mints obtaince in accordance with icctpttO tail metbodt. (A) Atom recommended Umperature limit. 40 LW. 2000F 14 (2552F) 104 pcf 69 pcf 65 pcf 117 pcf 76 pcf 73 pcf 500 psi 500 psi 600 psi (A) (A) 0.3% 0.6% (A) (A) C-2 Cement 2300F 15 I2608F1 140 pcf 126 pcf 120 pcf 142 pcf 134 pcf 128 pcf 6200 psi 4700 psi 2600 psi 2700 psi (A) 0.2% 02% 0.1% (A) | cateulatmd Chemical Anafyala a. gt Blsaotti OtaMrrti CaMt sto. 41,0, Fe,0, no. CaO M<0 K,0 IU,0 Mac. I(.laa 380 533 1J 23 20 tract tract 13 410 *3.1 40 20 (0 0.1 [u 330 380 40 U 190 0.4 [ 00 J OJ L5 20 ' .--r 1.1. * ->\ 400 33.4 70 130 U . 03 OJ 03 . Thmrmaf Conductivity ' coNDuenvm: itu m. pa m rr ra f ram Taaperatan s F Blazacnta Staadad Blaacrata LW. Btaacntt M tefractary Caanat BOO 1000 1200 1400 1600 1100 2000 309 136 T . -v- _____ 4J0 305 1.43 3.40 400 405 109 300 40B 404 : 1J6 300 5.40 407 .102 400 605 509 208 5.10 701 - . .< . 500 'C ~ * 'a. .. . I Packaging Information 3X Blancrat*......................................................... 100*tap Standard Blancrate............................................... 100*tap LW. Blaracrat*......................................................... 104btap C-2 Refractory Cement...........................................100*tap , fc-f a AmjMT^^MsnmucTKMs Preparation of Siifaet All -- r i | AmK Ka clna free <ff looas ftdfc or other ft--ign malarial. When BlazecRte is applied to won brickwork or other refractories, the surface should be chipped to expon raw solid material. Metal should be rUanad by wire brushing, steam, or aandhlaaHny to provide a satisfactory surface. . Reinforcement As a general rule, reinforcement is not required when Blasecrete is gunned on a sloping or flat surface because gravity will hold it in place. However, on vertical walls or overhead areas, ex cept far patching, reinforcement should be ^ to hold the refractory in place. Where continuous reinforcing is unnecessary, rods with bent ends or bolts with washers and nuts should be used. All bolts or rods, spaced on about 24' cen- ten, should extend through approximately one-half the thirlmem of the refractory and where possible be placed in a staggered arrangement. Use bolts or rods with a maximum diameter of Yi . Friction tape wrapped around the bolts or rods win permit expan - skm of the metal under heal ~ . For continuous reinforcement, welded wire fabric or heregunal steel grating is recommended. A wire fabric should be spaced midway in the refractory and held in place with suitable studs, lag bolts, at other means. When more than one type material is to be applied, include a reinforcing mesh in each layer. For thin linings, hexagonal steel grating %' or 1' thick with openings approximately 1^' x 1*1' x 14 gauge should be tack welded to the equipment and lie refractory applied flush to the surface of the hoTngfinal maah ------ .42 Gunning Fallow the standard methods of gunning as recommended by gun manufacturers. It is helpful to pre-moisten Blazecrete before placing it in the gun hopper. This can be done by flirt putting the Blaze crete in a concrete *n*r adding a wnnll amount of water. After thorough mixing, the Blazecrete hnnld be just slightly damp, but not enough to bell up. Pre-moistened Blazecrete tends to take an addi tional water at the gun "**1* more readily end the amount of dust and rebound is kept to e minimum. Some guns premix water with the cement before reaching the gun nozzle. -- : . Do not apply refractory through grating at mesh with openings of less than 4* ifthe shell of the vessel or tha fnanlating surface is more than 1* from the underside oftha maah or grating. Agiven area should be finiahad if there is to be a lapse of time before the entire job is completed. When work is resumed, the - vl:-***: contact surface of the material which has already been applied should be roughened, cleaned and wet. When Blazecrete is used in double layers, the first layer should still be wet when applying the second layer. Do not use rebound material. Troweling Mix Blazecrete thoroughly with clean, fresh water until a stiff consistency is obtained so that it can be readily placed by slap-troweling. Curing and Firing It is preferable to air cure Blaze crete for 12 hours or longer before firing. Heat slowly and without interruption, bringing temperature above the service operating conditions. Product type Estimated Pounds of Refractory Required for 1 Cubic Foot Estimated Pounds of Water (No allowance Required tor 100 lbs. made for waste) of Cement 3X Blazecrete 130 (slap-troweling) 140 (gunning) Standard Blazecrete 110 (slap-troweling) 118 (gunning) l.W. Blazecrete 65 (slap-troweling) 73 (gunning) C2 Refractory Cement 120 (slap-troweling) 140 (gunning) 14 18 53 15 i J-M Refractory Cements (Mortars) . purpose of J-M Refractory Cement in laying brick is to bond together many relatively small nits into a stable, strong and gas-tight structure, lie nature of the cement or mortar used, and the lanner applied largely determine the strength and fficiency of the refractory masonry. Use of the proper mortar for the particular condi;ion involved assures correct bonding, protection of joints against slag, resistance against passage of gases, and reduction in spalling difficulties. To fulfill the many different service requirements. J-M provides several different types of mortars 'or cements which are classified under "Ready-Mixed, Air-Setting" and "Dry, Heat-Setting." Ready-Mixed, Air-Setting Cements (Mortars) BLAKITE REFRACTORY CEMENT A highly refractory, ready-mixed, air-setting cement which possesses high water-retention properties, making it adaptable for laying insulating fire brick. Furnished in a consistency suitable for shallow patching, Blakite can also be used for laying fireclay, super duty and high alumina refractory brick. It is dark gray in color. Temperature to 3200F. SUPER BLAKITE Used for coating over vertical industrial boiler tubes, shallow patching, and laying brick. Temperature to 3000F. HELLITE REFRACTORY CEMENT A general purpose, air-setting cement which is finely ground, ready-mixed, plastic and pink in color. Used for setting hard brick with troweled or dipped joints, for wash-coating and especially for shallow patching, either hot or cold surfaces. Can be used up to 3000F. 4 NO. 20 REFRACTORY CEMENT An air-setting cement, gray in color, for use where an extra hard air set is desired. 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. Bonding brick: All types of air-setting cements re tain easy workability even though kept in storage for long periods. These mortars can be thinned with water to suit the porosity of the brick to be bonded. Full directions are furnished with each cement shipment. To obtain maximum workability and best results, the mortars should be thoroughly mixed before us ing. If a thinner consistency is desired, small quanti ties of water are slowly added -re-mixing thoroughly after each addition until desired consistency is ob tained. An excess of water should be avoided. Wash-coating brick: When Hellite, No. 20 and No. 32 (see below) are used for wash-coating, the setting should be thoroughly cleaned and the cement mixed with sufficient water to bring it to a thin grout con sistency. The mixture is applied to the face of the brickwork with a stiff brush or broom, working it well into,the cracks and pores in the brick. It is im portant to apply the mixture thinly in order to prevent flaking. When old settings have to be scarified in cleaning, it is necessary to thoroughly remove all dust particles before wash-coating. This can be accomplished by carefully blowing out dust with an air gun or by hos ing out the crevices and washing the walls with water. Dry, Heat-Setting Cements (Mortars) NO. 31 A NO. 32 REFRACTORY CEMENT The above mortars are heat-setting used for laying hard brick. No. 31 is recommended for thick joints and is a coarse material. No. 32 is similar to No. 31 Cement, but has a finer grind. It is recommended for dipped joints. Recommended up to 3100F. When preparing No. 31 and No. 32 cements, water is mixed with the cement to provide the proper con sistency. Clean, fresh water is required; the quantity depending upon the porosity of the brick which can best be found by trial. The mortar should be thor oughly mixed and free from lumps. Maximum work ability isobtained by allowing the mortar to "temper" after mixture with water. Long periods of tempering will not cause deterioration. Dry, Air-Setting Cements (Mortars) NO. 26 REFRACTORY CEMENT A coarse, dry cement which takes a medium air set. Used for setting fire brick with a medium bond joint. In special cases also recommended for hot or cold shallow patching, cement gun work and rammed linings. For temperatures to 2900F. 44 Calculated CAwn/ca/ Analysis - - -Mfmt CtnMte* ----- IWH *20 CwsstiUM Ctatit HellIts FinIts BUfcHt ttaUi ` S, 903 49.6 85.4 418 413 ' Al0> t 5.1 37.8 6.4 433 433 F0j f - 23 03 13 1.6 TO, - 23 - 18 13 CjO - 0.6 - 03 03 ' 0 - (U - - - . .. M - 1.4 - 03 03 N*,0 13 13 63 2.4 2.7 Mac. 03 0.4 - -- If. Ian - 3.6 23 13 L7 . *lyi> It m *t kali. | Packaging Information Blakite and No. 20 Refractory Cement--200, 100, 50, 25, 15, 10 and 5-lb containers _ ... ,, . Super Blaldte and Heflite--200,100 and 50-lb con tainers. * No. 26, 31 and 32-100-Ib bags. . ^^1 J-M Lightweight Refractory - .. . Aggregates and Fills Jahu-ManviDe lightweight aggregstm and AH* aerve for nuking manlating refrictoiy concretes end as granular eii-r--nr |M|| Hi,, inamesiTih n>m to provide on high-temperature equipment. Tlteae lightweight aggregates and fills indude the following products: JM-Zelie, JM-2400, SQ-O-Cai C-3, SQ-O-Cel Insulating Powderand SD-O-Cel Coarse Grade. Sil-O-Cd Insulating Powder and Coarse Grade an uaad aa fills only. '. < ... -. _ When used as fills, roe products an worked into place jd their anginal dry twin When need as an insulating < refractory concrete for various operating conditions, the aggregates (JM-Zelie and 2400) an mixed with cakium aluminatenment MATri C-tcan hsnaad wlwm with either lnm<i ilnwiTM** nwnt or portland ce ment. The insulating refractory ooncrete is used for con structing foundations and bases of bested equipment, furnace doors, and many special shapes such as bailies Wfj fbwi|lw \ i -----* - --* - AD of these products an invaluable for the coneerva- tion of heat where other forms of insulation cannot be ' economically because of surface irregularitiee or lack ofspace. They are also excellent for the many in dustrial requirements which demand satisfactory insu lating refractory cements. - . Spmctflcatlon Data - 'v CeapetMes Appier. deaslty t stick feepsistsia is an eemSty PKfcsgiaf IWtF pecked he peree It JM-2400 LW.Agfrtpte al.eflictts JMJtlis LW. Aggregate si. silicate SiWWslC-3 calcined conegraded dietoreeceous silica . JlWWal lasuiiting feeder finely ground silica SB-OOel Cane Grade sinular to SIMVCaI lesuletmg Reader, but coarsely ground 2400 ' 2400 2000 1600 1600 50 Mb begs 31 S04bbsgs 31 504b begs 17 50-lb begs 22 504b bap 7 ", | J-H hmutmttng Rmfrmclory Concrmtma The lightweight aggregates (JM-Zelie and 2400) and SD-O-Cei C-3, in the form of insulating refractory con cretes, wm be formed into any shape desired. The tables following give typical mixtures beand upon average values obtained from uniform, well-tamped or cast insu lating concrete. In every case, excessive water is detri mental to the strength of the concrete and hnnM be avoided. . 4fi ,efct.s< Sil-O-Cel C-3 Insulating Concrete amping Consistency* Sil-O-Cel C-3 mixed 4 to 1 by Volume with with Calcium Portland Cement JUuminate Cement Loose Density, Sil-O-Cel C-3. lb per cu ft................ Approx. Ratio by Weight (Sil-O-Cel C-3 to cement).. Mixing Water by Weight, percent............................ Yield. Dry Mix per cu ft, lb...................................... Maximum Service Temperature. F............................ 23 to 28 50-50 86 50.5 1800 Avoid excessive water. 23 to 28 50-50 80 54 1800 JM-Zelie L W. Concrete JM-Zelie mited 3 to 1 by Volume with Calcium Aluminate Cement Tamping Consistency* Casting Consistency* Loose Density, JM-Zelie, lb per cu ft............ Approx. Ratio by Weight (JM-Zelie to cement). Mixing Water by Weight, percent.................. Yield. Dry Mix per cu ft. lb............................ Maximum Service Temperature, F................ 41 5743 65 62 2000 41 5743 68.5 58 2000 Avoid excessive water. Sil-O-Cel C-3 Insulating Concrete: First thoroughly mix Sil-O-Cel C-3 with water (16 gallons of water per 100 lb of Sil-O-Cel C-3), then add Portland or calcium aluminate cement and thoroughly mix with the wetted Sil-OCel C-3 to the desired working consistency. The homogeneous mixture is then placed in the re quired form, reinforced if necessary, and tamped with a heavy metal tamper until the required thickness is ob tained. Sufficient force must be used in tamping to \ i provide a uniform, coherent mass, free from voids. The form is then covered with a damp cloth and kept wet for not less than 48 hours, then dried slowly in a warm, well- ventilated place, and finally subjected to a slow initial heat until all the water has been eliminated. When a mechanical mixer is used, part of the water should be poured into the mixer before the dry Sil-O-Cel C-3 is added, and the inside of the drum thoroughly flushed. (This prevents the Sil-O-Cel C-3 from balling-up in lumps and sticking to the walls.) The dry Sil-O-Cel C-3 and remaining water should then be put in the mixer and thoroughly mixed. From this point, the procedure is the same as described above. With a mechanical mixer, each batch of Sil-O-Cel C-3 Insulating Concrete should be completed in from four to five minutes. JM-Zelie L W. Concrete: The aggregate and calcium aluminate cement are first thoroughly mixed. Then water is added slowly to obtain the desired tamping or casting consistency. Forhighertemperature conditions, JM-2400 L. W. Aggregate can be used. This aggregate is generally handled in the same manner as JM-Zelie Aggregate. 47 I J-M CerateIt refractory fiber felt DESCRIPTION: J-M Cerafelt is a lightweight, re fractory-fiber insulation notable for its excellent thermal and chemical stability. Made predominantly of alumina and silica, it combines lightness, heat resistance, low conductivity and high sound-absorp tion qualities. AVAILABLE FORMS: Furnished in densities ranging from 3 to 24 lbs. per cu. ft. Also available in loose form (J-M CERAFIBER) in 25-lb. bags. USES: Recommended for a great variety of high temperature industrial applications such as insula tion protection in repairing open hearth roofs; on cover-type annealers to fill openings for electrical access; expansion joints in kilns, furnaces and boiler walls. ADVANTAGES High Heat Resistance Will withstand continuous exposure to a full 2000F. Low Thermal Conductivity Unusually low conductivity at high temperatures due to opacity of basic fibers to infra-red radiation. Light Weight Weighs as little as 1/40 equal volume of hard fire brick. Chemically Stable Non-alkaline and chemically stable. Contains no corrosionpromoting agents. Thermal Conductivity CONDUCTIVITY: ITU IN. PER SQ FT PER F PER HR Density MEAN TEMPERATURE F lbs *er cn tt 300 400 500 600 700 800 900 moo 3 .40 .48 57 .68 .80 .93 158 155 4 .38 .44 52 .61 .71 .82 .94 1.07 6 .36 .41 .47 54 .62 .70 .79 .89 8 .34 .39 .45 51 57 .64 .72 .81 10 53 .38 .43 .49 .55 .61 .68 .76 12 .33 .37 .42 .47 53 59 .65 .72 14 .33 .37 .41 .46 51 57 .63 .69 18 .32 56 .40 .45 50 .55 .60 .65 24 .31 55 59 .44 .48 53 58 .62 Standard Densities A Thicknesses Type Density* lbs per ca tt Available Thicknesses,* Inches K V. % a V. 1 VA 2 CRF-300 3 0 00 0XX CRF-400 CRF600 4 6 0000 0X 0000XX CRF-800 8 000000X CRF-1000 10 XX X X X X X CRF-1200 12 XXXXXXX CRF-1400 14 XXXXXX CRF-1800 18 XXXXX CRF-2400 24 XXXXX 'Otter thicknesses and oensities available on request 0 denotes avsilatility of 4' and I' sheets and 28' rolls X denotes mailability of 4' and t' sheets only Standard width is 42 inches Glossary of terms relating to refractories Abrasion of Refractories--Wearing away of refractory surfaces by the scouring action of moving Air-Setting Refractory Mortar.--A compositioa of finely ground materials, marketed in either a wet or dry condi tion, which may require tempering with water to attain the desired consistency and which is soitahla for laying refractory brick and bonding them strongly upon drying and upon subsequent heating at furnace temperatures. Bloating of Refractories.--Substantialswellingproduced by a beat treatment that causes the formation of a vesicular structure. Bond fire Cloy.--See Fire Clay, Plasticor Bond.. Bum (n).--The heat treatment to which refractory materials are subjected in the fixing preieem ^t^ssK^ Burning (Firing) of Refractories.--The final heartreat ment in a kiln to which refractory brick andchapes are*' subjected in the procam of manufacture for the pnrpoan of developing bond and other nrirrreerr physical and dsmril properties. .. Calcine or Calcines (n).--Refractory material,.,---^ fireclay, that has been heeted to volatile^, - -. constituents and to produce desired, physical Calcining of Refractory Materials.--IWbesttreatmentto which raw refractory materials are subjected,! story to further processing or use, for toe purpose of' ____ eliminating volatile rhemirally mmhiiMiri constitaerrts^ and producing volume changes...... Corrosion of Refractories. --Destruction of refractory surfaces by the chwmical action of external agencies. Diaspora Clay.--A rock consistins nmentisHv ofdiaspcatt _ik bonded by fire day. . I l! ;-" tC. Dolomite, Calcined Refractory.--Raw refractory dolo-- mitu that has been heated to a tmnswature suffidentiy -- Mgti ud for a long enough time to decompose the carbonate structure and remove volatile constituents. . ` . Dolomite, Daad-Bumed Refractory.--Raw refractory dolomite that has been bested with or without additives - to a temperature sufficiently high and for a long enough 7 - ^ _ time to decompose the carbonate structure so as to form _ calcium oxide end prririser in a matrix that provides * - resistance to subsequent hydration and recombination . _7a-., with carbon dioxide. .^ ^ - - r r. Double Screanad Ground Refractory Material-- if'-rs - -*;;., fractory material that contains its original gradation of . V.: particle sizea resulting from crushing, griruimg, or both, and from which particles saw wt twr tlum taro spocifind sizee have been removed by screening. Erosion of Rafractorias__ Wearing away of refractory surfaces by the washing of moving liqrata. tv^-Vc >-> - *-. *-* ---4 * . * *-* A -"!% V*** J. -v; y i^jP f. '^VZj <*" " " 'Erosion of Rafractoriaa. --Wearing away of refractory . soifaces by the washing action of moving liquids. Firebrick.--A broad term covering any type of refractory 1 brick used more narrowly to mean fireclay brick. '-/' '-`^'^TVofaHck, Insulating.--A refractory brick characterized j-** by low thermal conductivity and low heat capacity. #>---1 .i--.-n.-- .. . '-- ^,--5reCly.p-An earthy or stony mineral aggregate which ~ r lin u fhu merntill constituent hydrous silicates of aluminum. with or without free silica, plastic when sufficiently pulverised and wetted, rigid when subee- ^Ivjpustlgjliied, and of suitable refractarineas for use in ^^.-."cnnmarcial refractory products. .- -`iASsstrfc , -- tt?CSa:.Fire Clay,"Nodular. --A tool containing alun ous or " nodiulea.br bot'hT, b"ondV' e--d by fire cuy. _ X.XHacmedistricts sucA days are called "buriey" isgrr*. --'iyvy'''gW^,ife>.v 'ptst. .. . Clay. Wasfic or Bond. --A fire day of sufficient nat- i ural to bond nonjplastic materials; FbocUf Flastieltefrartory.-A fireclay material tem- jg**;- patad with water knd editable for ramming into place to ifjPT r-. fie 111 a furnaceJmmg.that will attain satis- 14".'. trw..rfoctcry physical propertias.when subjected to the heat 0f furnace operation. ^ - .. if-v: 'V FIM Fire Clay.--A hud or flmtJike fire clay occurring u an nrwbratified maaeive rock, practically devoid of ml 1 ml plasticity and showing a ranchoirial fracture. - . - TW ' - * - * . Greg. --A granular material produced from calcined or * burned refractories, usually alumina-ailica. .!'. firofl' frtday Mortar. -- Raw fire day mixed with -. calcined fire day, or with broken fireclay brick, or both, all ground to auitable finenewa. '' \ LGround Fba Clay.--Fire day 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 consisting "... of finely ground raw fireday. ; ^ Molton Cast Refractory.--'A solidified material made by melting refractory ingredients and pouring into molds. Mortar, Host Sotting.--A refractory mortar of finely " * ground materials whose potential strength is dependent _ on use at furnace or process temperatures. - Tt * .. ' Mortar, Refractory.--A finely ground preparation which h^nrrvii piuntie and tiowdable when tempered with ~ water and is suitable for laying and bonding refractory .. brick. r.v- - rN ...... . -*'-*wK* - % 4-:-rS; <r,-V Mullite Refractories. -- Refractory products consisting predominately of mullite i3AL>0.t*2Si0j) crystals formed either by conversion of one or more of the sillimanite group of minerals or by synthesis from appropriate materials employing either melting or sintering processes. Refractories, Neutral.--Refractories that are resistant to chemical attack by both acid and basic slags, refrac tories, or fluxes at high terrpieratures. Refractoriness.--In refractories, the pro|)erty of being resistant to softening or deformation. Permanent Linear Change.--The per cent dimensional , Refractory tarf/i.-- Resistant to high temperature change in length (based on original length) of a refractory specimen free of externally applied stresses, after being subjected to a prescribed heat treatment. Reheat Behavior.--The changes in length or volume taking place in a fired refractory when subjected to a reheat test. Plastic Refractory. -- A refractory material, tempered with water, that can be extruded and that has suitable work ability to be pounded into place to form a monolithic structure. 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. Porosity.--The percentage of the total volume of a material occupied by both open and closed pores. Shrinkage.--The decrease in dimension of a refractorv material during manufacture or service. Pyrometric Cone Equivalent [PCE) --The number of Silica Fire Clay.--A refractory mortar consisting of a that Standard Pyrometric Cone whose tip would touch finely ground mixture of quartzite, silica brick, and fire the supporting plaque simultaneously with a cone of the clay of various proportions. I f refractory material being investigated when tested in accordance with the Method of Test for Pyrometric Cone Equivalent (PCE) of Refractory Materials (ASTM Designation: C 24). NOTE.--Sometimes called silica cement by the trade. Silicon Carbide Refractories. --Refractory products con sisting predominantly of silicon carbide. Quartzite (Ganister).--For refractories, a rock consisting Slagging of Refractories.--Destructive chemical reac II predominantly of the mineral quartz suitable for the manufacture of silica brick and characterized by a high Si02 content and a low percentage of impurities. 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 NOTE.--Confusion sometimes results from the use of ment of a portion of the unit. the term ganister because it is also applied in some parts of the United States to crushed firebrick or to a mixture of crushed firebrick or silica rock with clay for use in tamped linings. . Ramming Mix.--A refractory material, usually tempered with water, that cannot be extruded but that has suit able properties to permit ramming into place to form a monolithic structure. Refractories in). --Materials, usually non-metallic, used toevithstand high temperature. Refractories, Acid. --Refractories containing a substan tial amount of silica that may react chemically with basic refractories, basic slags, or basic fluxes at high temperatures. Refractories, Basic.--Refractories whose major constitu ent 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 re fractories made of chrome ore or combinations of chrome ore and dead-burned magnesite. Spalling of Refractories, Mechanical.--The spalling of a refractory unit caused by stresses resulting from impact or pressure. Spalling of Refractories. Structural. --The spalling of a refractory unit caused by stresses resulting from differ ential changes in the structure of the unit. Spalling of Refractories, Thermal.--The spalling ol a re fractory unit caused by stresses resulting from nonuni form changes of the unit produced bv 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 termperature changes. Unbumed Brick. --Brick manufactured by pro<-esses that do not involve firing of the finished product. Zircon Refractory--Refractory products consisting sub stantially or entirely of zirconium orthosilicate ZrSiOi'. Zirconium Oxide Refractory.--Refractory products con sisting substantially of zirconium dioxide. 51 `' *' T1 COLOR-TEMPERATURE CONVERSION The cower of this catalog illus trates graphically the approm mare relationship between co cr and temperature in the com men turnace operating ranges 1 .. - .* ri- '* **> * -4 - -'**jMi; : . rjias*-' , - - "V'V : 7'V,-S^?r ---v" -.Sh--.- -;- jy{| Johns-Manville llTj I General Headquarters: 22 East 40th Street. New York 16, N. Y. 'p.! Offices in all Large Cities IN-4S1A 12*43 UTMO IN U.SX