When laying refractory bricks, the brick joints should be staggered, and the brick joints should be filled with refractory mortar (dry refractory powder should be used for dry masonry). During the masonry process until production, it is necessary to prevent the masonry from being damp. To compensate for the volume expansion of masonry after heating, expansion joints should be left according to design and specification requirements during masonry.
Refractory brick masonry includes furnace wall, furnace bottom, furnace top, pipeline lining, brick grid, composite brick masonry, and expansion joint setting. The masonry furnace wall should be divided into two types according to its form: straight wall and curved wall. Before laying the straight wall, the base surface of the lower layer of the furnace wall should be leveled and laid out according to the construction drawing on the furnace foundation or steel structure. Measure the longitudinal and transverse centerlines and other reference lines of the furnace body, and accurately identify the wall dimension lines while ensuring the dimensions of each part of the furnace body.
The wall masonry should be flat and vertical, and each layer of bricks should be laid with lines. The levelness of the brick layer on the wall is checked using a ruler and a level ruler, while the verticality or inclination of the wall is checked using a template, plumb bob, and ruler. Within the same layer, brick joints should be staggered according to rules, and the mud inside the brick joints should be full, with the surface tightly pointed. After the wall corner masonry is heated, the expansion stress is relatively concentrated, which is the weak link of the wall. It should be carefully processed and assembled with refractory bricks to achieve tight jointing and pointing. When building the wall stack, the vertical joints of adjacent layers should be staggered. If there are holes with a width less than 450mm in a straight wall, bricks should be used to protrude layer by layer when laying bricks, and the protruding part of each layer of bricks should not exceed 75mm; If there are holes with a width of less than 250mm, processed bricks can be used to build them according to the drawing requirements. The upper layer of the wall should be kept horizontal, and if necessary, it can be leveled with processed bricks.
Circular arc wall masonry: Circular arc walls include two types: circular walls and curved walls, which are widely used in blast furnaces, hot blast furnaces, chemical furnaces, mixing furnaces, conversion furnaces, and rotary kilns. The horizontal and vertical joints of a curved wall are called radial joints, and the vertical and horizontal joints are called circumferential joints. Circular walls often use wedge-shaped bricks or irregular bricks, and the contact between the steel structure surface and the inverted arch surface should be carefully processed and constructed. The masonry brick joints should be built according to the inner furnace shell. Set up a central pipe at the center of the furnace when building the wall, and ensure that the mud is full during construction.
When building a furnace roof with curved roof, circular roof, or hanging roof, the vertical error of the shell center must comply with regulations. The masonry of the curved wall can be based on the inner shell of the furnace roof as the reference plane. When there is a spray coating on the furnace shell and the size is accurate, the masonry of the arc-shaped roof (arch top) should be done according to the arch axis arc, or the spray coating can be used as the reference surface. The staggered joints of arc-shaped walls should be based on parabolic arches and catenary arches. The industrial furnace arc furnace is at most circular in shape, and its masonry requires the same staggered joints as the straight wall.
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