1. Basic procedures for masonry

The selection of the starting point should be carried out from the hot end to the cold end or from the low end to the high end. The construction site should be cleaned, marked, and bricks should be selected. Different materials of refractory bricks should be used according to the needs of the cold and hot sections, and qualified bricks should be selected. If there are anchoring nails or supporting brick plates, welding of anchoring nails or supporting brick plates should be carried out. If there is a thermal insulation layer (such as silicon calcium plate), the installation of the insulation layer should be carried out first, and the mortar should be prepared and used. The mortar should match the refractory bricks, and the expansion gaps of the brick should be reserved and filled.

2. Refractory bricks are generally divided into two types, namely unshaped refractory materials and fixed refractory materials. Unshaped refractory material, also known as castable, is a mixed powder particle composed of multiple aggregates or aggregates and one or more binders. When used, it must be mixed evenly with one or more liquids, and has strong fluidity. Shaped refractory materials are generally refractory bricks, with standard rules in shape, and can also be temporarily processed during construction and cutting as needed.

3. The production of refractory bricks is time-consuming and labor-intensive, mainly used in chimney linings, stoves, and other parts, with the advantage of easy construction. The fire resistance of refractory bricks is not as good as that of concrete.

4. Construction requirements for refractory bricks

(1) Requirements for masonry fire mud: Different types of mud should be used with different tools, and clean water should be used to accurately weigh and mix the fire mud evenly. The prepared mud should not be diluted with water arbitrarily, and the mortar should have a fullness of more than 95% to ensure that the brick joints are dense. The surface brick joints should be pointed with the original mortar. The parts of the shell that cannot be corrected should be aligned with mud.

(2) The refractory bricks of the wall should be built in staggered joints. When the bricks are joined to the silicon calcium board, they should be constructed in a distributed manner: different silicon calcium through joints should be left, and expansion joints should be left according to the design requirements; The masonry shall not exhibit any skewness, and the mortar fullness shall reach more than 95%. The excess mortar on the brick surface shall be scraped flat; The wall of brick concrete structure should have a smooth and even pouring material, and the bricks on the pouring material should wait for the pouring material to have a certain strength before being laid.

(3) When laying bricks, refractory brick requirements: the top of the brick lining should be fully adhered to the surface of the cylinder without leaving any gaps, and adjacent single brick surfaces should be in complete contact. The length of the processed brick must be less than 50% of the original brick, and the thickness must not be less than 80% of the original brick.

(4) Precautions during construction: Hammers should not be used during construction to prevent the following phenomena of refractory bricks: inverted large and small heads, drawing lots, mixing slurry, and misalignment.

(5) Slanting, uneven mortar joints, climbing, deviation from center, middle seam, opening, void, rough seam, serpentine bend, brick bulging, missing edges and corners, etc.

(6) Requirements for joint steel plates for bricklaying: The thickness is generally 1-2mm, and it is required to be flat, not curled, not twisted, and without burrs. The board width is about 10mm smaller than the brick width. During masonry, the steel plate shall not exceed the edge of the brick, and there shall be no insertion or bridging phenomenon. A maximum of one steel plate is allowed to be used in each seam.

(7) There are a large number of process voids in the preheater, decomposition furnace, and ascending flue, which need to be carefully inspected and constructed one by one. The vertebral body part needs to be constructed in sections, the slope of the inclined wall surface needs to be accurate, and the lining surface needs to be smooth to ensure smooth feeding and no material storage during production operation.

(8) Before construction inside the kiln, a comprehensive inspection of the kiln shell should be carried out to align the centerline of the kiln barrel. Uneven surfaces on the shell (such as welds and welding slag) should be polished, and debris inside the kiln barrel should be cleaned thoroughly.

(9) Measurement inside the kiln requires setting out lines: the longitudinal reference line of the kiln should be placed every 1.5m along the circumference, and each line should be parallel to the kiln axis. The circumferential reference line should be placed every 10m, and the construction control line should be placed every 2m. The circumferential lines should be parallel to each other and perpendicular to the kiln axis.

(10) The basic requirements for bricklaying inside the kiln are: the brick lining should be tightly attached to the shell brick, the brick joint should be straight, the intersection should be accurate, the brick should be locked firmly, not misaligned, and not sagging or hollowing out. To ensure reliable concentricity between the brick lining and the kiln body during operation.

(11) After the completion of the refractory brick masonry in the entire kiln, a comprehensive cleaning and necessary fastening of the brick lining must be carried out before ignition. It is necessary to conduct a circular inspection, and it is not advisable to rotate the kiln after fastening.

5. Construction rules for pouring materials in various environments

(1) Winter construction refers to construction when the ambient temperature is within ± 5 ℃. Construction can only be carried out when reliable cold protection measures are taken when the temperature is below -5 ℃.

(2) During winter construction, winter construction techniques must be adopted, and the working environment should be well sealed, windproof, heated, and kept warm. The temperature of the lining after masonry should be maintained above+5 ℃.

(3) When pouring materials for winter construction, dry materials should be stored in a heating room and stirred with hot water. The temperature of the mixed materials should be kept above 10 ℃, and it is not advisable to add chemical accelerators or antifreeze agents.

(4) When constructing in the furnace in winter, the insulation layer should be built first to improve the frost resistance of the refractory layer. After construction, the masonry should be covered with plastic cloth, and then covered tightly with hay. For newly built kilns, the insulation time should not be less than 10 days. It is strictly prohibited to expose the already built masonry to the cold atmosphere.

(5) During rainy days, indoor operations should be carried out, and all materials, transportation vehicles, work sites, and masonry should be protected from rain. Unfinished buildings should be covered with roofs, holes plugged, and leaks plugged. The upper openings of completed furnaces should be closed, and prefabricated ground components should be raised and covered. It is strictly prohibited to soak them in water.

(6) When the ambient temperature is ≥ 30 ℃, it can be considered as summer construction. During summer construction, the water temperature and material temperature should be controlled below 30 ℃. Materials exposed to scorching sun should be cooled down before use.

(7) When pouring materials during summer construction, it should be arranged as much as possible in the morning or evening. After pouring, it should be covered with curtains in a timely manner and water should be sprinkled frequently to cool down.

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