Handbook of Refractory

HARBISON-WALKERHandbook of Refractory Practice 2005 Harbison-Walker Refractories Company 400 Fairway Drive Moon Township, PA 15108 © 2005 Harbison-Walker Refractories Co. 2005 Harbison-Walker Handbook of Refractory Practice Harbison-Walker Refractories Company 400 Fairway Drive Moon Township, PA 15108 Phone: (412) 375-6600 Fax: (412) 375-6783 www.hwr.com DISCLAIMER: The information presented in this book is for general education- al use only. It does not contain recommendations for any particular refractory for any particular use. It is not intended as, and should not be taken as, a war- ranty of any kind, including but not limited to a warranty of fitness. WARNING: Some materials which are present in refractory products are harm- ful. One such group is classified as substances known to cause cancer to humans. Other substances may be classified as probably or possibly carcino- genic. These materials include minerals used in or formed during the manufac- ture of these products. The primary threat presented by many of these materi- als comes from inhaling respirable dust. The use of proper respiratory equip- ment, as well as other personal protective equipment is mandatory where required by applicable law. Please refer to the applicable Material Safety Data Sheet for such product. Click Here to Enter © 2005 Harbison-Walker Refractories Company. All Rights Reserved. Handbook of Refractory Practice Table of Contents Section 1 Introduction I Section 2 Classes of Refractories CR Section 3 Properties of Refractories PR Section 4 Using Refractories UR Section 5 Monolithic and Ceramic Fiber Products MP Section 6 Brick Products BP Section 7 Installation References IR Section 8 Appendix A Section 9 Literature L Data Sheets www.hwr.com SECTION 1 Introduction History of Harbison-Walker 1 Technical Research Capabilities 3 Broad-Based Expertise 4 INTRODUCTION Out of the Fire The history of high heat manufacturing and refractory technology began with the discovery of fire. Nature provided the first refractories, crucibles of rock where metals were softened and shaped into primi- tive tools. Modern refractories are customized, high-temperature ceramics designed to withstand the destructive and extreme service conditions needed to manufacture metals, glass, cement, chemicals, petroleum and other essentials of contemporary life. The History of The company garnered acco- • In 1927, Harbison-Walker Harbison-Walker lades for the superior perfor- acquired majority ownership The refractories company known mance of the Lucy Furnace and of Northwest Magnesite, and as Harbison-Walker opened on began to expand rapidly, pushed following World War II, March 7, 1865, as the Star Fire in large measure by the explosive commissioned the company Brick Company. The firm was growth of the steel industry. In to build and operate a sea- founded by J.K. Lemon, a Pitts- 1910, a 10-company merger water magnesite facility at burgh entrepreneur who hoped to created Harbison-Walker Cape May, NJ. build a fortune on America’s Refractories Company, a 33- growing demand for refractory plant operation that was the • In 1945, the company pur- brick following the Civil War. largest of its kind in the world. chased Canadian Refractories In 1866, Lemon hired Samuel Harbison-Walker also thrived on Limited, makers of Pollock Harbison as a part-time its vertical structure, exerting MAGNECON, an outstand- bookkeeper. Within four years, control over every stage of its ing refractory for rotary the ambitious accountant had production process, through cement kilns. acquired enough stock and mining and raw materials refractory expertise to be named management to manufacturing, • In the 1950’s, Harbison- General Manager of Star Fire transportation and distribution. Walker built a high-quality Brick. In 1875, Harbison teamed In the decades that followed, magnesite facility at with another stockholder, Hay Harbison-Walker established and Ludington, Michigan. This Walker, to purchase the under- fortified its position of industry keyed the development of achieving company, and renamed leadership by building new several industry standard it Harbison-Walker. facilities and acquiring related products, including direct- Almost immediately, Harbison organizations. bonded magnesite-chrome and Walker realized a major brick, pitch-bonded and opportunity to grow their busi- • In 1916, Harbison-Walker pitch-impregnated magnesite ness and its reputation. Through organized the Northwest products, and magnesite- an on-going relationship with Magnesite Company near carbon refractories. Thomas Carnegie, the fledging Chewelah, WA. This gave company landed a contract from the company a secure domes- • In 1954, Harbison-Walker Kloman, Carnegie, and Company tic source of magnesite, a became the first U.S. com- to build the Lucy Furnace, the material of choice for indus- pany to produce refractories largest blast furnace ever de- trial furnaces in short supply for the basic oxygen furnace. signed. during World War I. Harbison-Walker I - 1 • In 1962, the company discov- • In 1998, Harbison-Walker Harbison-Walker Today ered massive deposits of high acquired A.P. Green Industries, Following World War II and the purity bauxitic kaolins at Inc. With 22 plants in six subsequent proliferation of techno- Eufaula, AL. This permitted the countries, A.P. Green, a major logical advances, Harbison-Walker company’s Bessemer and refractory producer in its own recognized the need for additional Fairfield, Alabama, plants to right, expanded considerably research capacity. In 1958, the manufacture significantly the global resources at company opened Garber Research improved high-alumina brick Harbison-Walker’s disposal. Center, now known as the Techni- that became a refractory of cal Center West Mifflin. The new choice for much of the refrac- • In 2000, RHI AG, an Aus- facility vastly enhanced Harbison- tory consuming industries. trian company with many Walker’s ability to test products holdings in the global refrac- under simulated service condi- • In 1967, Harbison-Walker tories industry, completed its tions and to conduct “post- was purchased by Dresser acquisition of Global Indus- mortem” analyses of used refrac- Industries, prompting an trial Technologies, Inc., the tory samples. accelerated diversification parent company of Harbison- Today, the Technical Center into non-steel related indus- Walker. RHI AG subse- West Mifflin, ranks among the tries. quently combined North world’s largest and most well- American Refractories equipped refractory research • In 1994, the company be- Company (NARCO) and facilities. A staff of outstanding came a part of Global Indus- Harbison-Walker, at the time physicists, chemists, metallur- trial Technologies, a major naming the resulting organi- gists and engineers work closely manufacturer of technologi- zation RHI Refractories with Harbison-Walker customers cally advanced industrial America. to develop new products and to products. This development solve process or production enabled Harbison-Walker to Today, the U.S. and export problems. strengthen its presence in operations have been reorganized In the mid-1990s, Harbison- several key markets through and operate independently under Walker completed a multi- alliances with other Global the name ANH Refractories. million-dollar investment in the Industrial Technologies Because of the strong reputations Technical Center West Mifflin companies. They included that Harbison-Walker and aimed at providing the Refractories Mexicanos NARCO established over their company’s engineers and scien- (REFMEX) and Refractorios long histories, the companies tists with the very latest testing Chileanos (RESCA), two of have retained their names and are and analytical equipment. This Latin America’s leading continuing to be the refractory commitment, made at a time refractory producers; and suppliers of choice in their when many refractory companies Magnesitwerk Aken, a respective market places. were diminishing their internal German refractory maker. Harbison-Walker continues to research capability, aggressively provide outstanding refractory positioned Harbison-Walker for materials to meet the needs of the the new century of refractory industrial markets, while NARCO industry leadership. serves the needs of the steel industry. I - 2 Harbison-Walker This enables customer service has yielded an combinations. this struc. the uniform quality of raw continuous dialogue between ing causes for deteriorating materials while insulating the Harbison-Walker and the indi. technical marketing support. tions. this studied. single product or single class of individualized approach to ries. Throughout each of customer’s furnace and why Harbison-Walker’s quality its markets. This pro. service conditions. Sales and technical represen- NARCO. This process can materials to the packaging and particular industry or series of be further aided through interac. type over another in a particular from the acquisition of raw each with specific training in a furnace zone. On a daily basis. Green and merger with With strong technical educations user. minerals refractory linings and configura. Test results may point to the facturing sites are dedicated to a Over the years. Individual tive CAD systems that allows rial. ceramic. the selection of Harbison-Walker to maintain a unending stream of innovative different refractory brands or the high degree of chemical purity. Harbison-Walker I . a reliable and ever present prob. of the raw materials it consumes. Harbison-Walker and the refractory A. resulting in uniform products. modes of refractory wear. permitting it to energy and chemicals markets. such as structure allows Harbison-Walker Most often. refractory performance resulting company from fluctuating sup- vidual industries the company from changing operating condi. market segments include glass. diagnoses are based chrome ore. land acquisition. industry-focused specific operating conditions in a Quality Control companies. Harbison-Walker those conditions suggest the control programs encompass employs application focused implementation of one refractory every facet of the organization. troubleshooting. and Harbison-Walker has adopted a life and improve process efficien. Follow-up technical support Technical Marketing and customers to identify and select can include orientation and training Sales Support refractories that can extend service programs. The capabilities and equipment at Broad Based Expertise Helping customers understand and the Technical Center West Mifflin Harbison-Walker’s sales and implement a proper refractory have been further enhanced by its technical support staff consists of management strategy is the first step additional staff and equipment chemical. these individu. ture is specifically designed to mance assessments. Imported minerals.P. refractory products and applica. Harbison-Walker offers is perfor. tion strategies for the entire range ries to better meet the altered free of contaminants and capable of heat-processing industries. and practical knowledge of the tatives are often on-site for refrac- industries they serve. adaptation of existing refracto. aggressive program of mineral processing and environmental. this tions within a customer’s plant. manu- lem-solving partner. This program also helps ensure promote innovation through a cess is usually aimed at identify. custom design of new refracto. At the processing stage. it to function more like a network Typical consultations explore of smaller. service and performance assess- marketing structure that enables cies. ments.3 . of tight dimensional tolerances. plies of key refractory minerals. customers to select and preview The company operates an industrial metals. tory installation and furnace start- Application Focused als are highly skilled at working with up. Another valuable service control a significant percentage Over the long term. shipment of the finished mate- related industries. applying refractories in new products. in an on-going relationship between acquired through its acquisition of industrial and mechanical engineers. serves. also are examined to respond more quickly to on post-mortem analyses of used and tested for quality by customer requests and to serve as refractories to determine the Harbison-Walker engineers. metallurgical. struction techniques. Harbison-Walker Department in West Mifflin. updates. the heat of industrial progress. PA. engineers offer refractory product which is responsible for monitor. centralized Quality Control In turn. This presents oppor- control engineers to measure tunities for installers to discuss their product characteristics against goals and expectations of refractory stated specifications.4 Harbison-Walker . as well as plant safety The company also operates a requirements. This mutual information exchange Industry Dialogue leaves participants more pre- Harbison-Walker encourages a pared to work cooperatively continuous dialogue among its throughout the year industry “partners” by communi. As the refractory industry cating continuously with contrac. Every year.. seeking feedback about all aspects of ways to better ways to contain refractory performance. tor/installers and soliciting Harbison-Walker pledges to regular customer input and maintain this dialogue. and a comprehensive ing quality standards for all review of installation and con- Harbison-Walker brands.In addition. each plant maintains a technical information in an educa- laboratory and a staff of quality tional forum. continues to evolve and expand. performance. the company brings together its engineers and select installers to disseminate I . SECTION 2 Classes of Refractories Basic Refractories CR-1 High-Alumina Refractories CR-7 Fireclay Refractories CR-10 Silica Refractories CR-12 Special Purpose Refractories CR-14 Mortar Materials CR-17 Monolithic Refractories CR-19 . fireclay and insulating. fused cast and several others. However. Most refractory materials are supplied as preformed shapes. This section reviews primary refractory classifications.1 . as well as several specially designed refractories. graphite. zircon. such as hydraulic setting castables. Harbison-Walker CR . Primarily. refractories are classified as basic. their typical properties and most common applications. and monolithics.CLASSES OF REFRACTORIES The broad variety of pyroprocessing applications across industry demands great diversity in the supply of refractory materials. ramming mixes and gunning mixes. many of these materials have been developed specifically to meet the service conditions of a particular process. zirconia. silica. plastic refractories. A variety of processed refractory grains and powders are also available for certain applications. The characteristic properties of each refractory class are a function of both their raw materials base and the methods used to manufacture the refractory products. In fact. bonding mortars. they also are manufactured in the form of special purpose clays. There are also classes of “special refractories” which include silicon carbide. high-alumina. combination with high firing temperatures made it possible to produce magnesium or silicon have been used to “direct bonded” brick. These compositions are Brick made with spinel and magnesite have better spalling resistance and used in special applications such as lower coefficients of thermal expansion than brick made solely with bottom blowing elements of basic oxygen furnaces. pitch bonded magnesite brick are an important category of basic containing about 5% carbon and magnesite-carbon brick which contain up to refractories. Magnesite brick are 30% carbon. special additives in the refractory 5. These additives generally One of the more important types of magnesite brick are those that have low constitute less than 6% of the total mix. It is anticipated that magnesite-carbon brick will continue to applications such as glass tank checkers. This has Broadly speaking. the acidic slags. deadburned magnesite. metallurgical and mineral processing 2. Dolomite brick offer a good application. elevated temperatures. either as the slide gate refractory or as a nozzle. where a ceramic bond between the chrome ore and improve hot strength and oxidation periclase particles exists. engineered basic refractories. metallic additives.Dolomitic products. Small boron carbide (B4C) resistance and strengths at elevated temperatures. MAGNESITE BRICK Basic brick containing carbon include pitch impregnated burned magnesite Brick made with dead-burned magnesite brick with carbon contents up to 2. As carbon good hot strengths and other features. basic oxygen furnaces.Products based on deadburned magnesite or magnesia in combination industries that use basic refractories.Deadburned magnesite or magnesia in combination with spinel. temperatures. Development of the more corrosion resistant magnesite-carbon characterized by good resistance to brick has resulted in decreased consumption of pitch impregnated and pitch basic slags as well as low vulnerability bonded magnesite brick. silicates in the has become an important constituent in the formulation of composite magnesite- groundmass or matrix formed the bond between the chrome ore and periclase carbon refractories. in the brick. However. subhearth brick for electric arc furnaces. include zirconia.BASIC REFRACTORIES Overview RAW MATERIALS Basic refractories were so named because they exhibit resistance to corrosive The principal raw materials used in the reactions with chemically basic slags. grow in importance as new products are developed and additional uses for and sometimes as backup linings in these products are found. These direct bonded brick exhibit superior slag resistance. the advent of high purity raw materials in such as powdered aluminum. such as trend has shifted to developing highly those used in primary copper applications. of liquid steel in continuous casting systems. They are often Dolomitic products are an important class of refractories that are used for impregnated with pitch in the latter example in rotary cement kilns and AOD’s. CR . Another category of magnesite brick contains a higher Examples of these special additives boron oxide content to improve hydration resistance. In recent years. chrome ore. brick have replaced magnesite-chrome brick in applications such as electric They are widely employed in arc furnaces.5%.Deadburned magnesite or magnesia in combination with carbon. Magnesite compositions balance between low cost and good refractoriness for certain uses. Historically. additions also can improve the oxidation Magnesite-spinel brick have increased in importance due to a desire to resistance of certain magnesite-carbon replace chrome-containing refractories because of environmental concerns. compositions. fall into this latter category. refractories have been developed that exhibit excellent resistance to rather spinel and carbon. One result of this effort has been the 3. They also are also widely used to control the flow offer good metallurgical characteristics for certain “clean steel” applications. boron oxide contents and dicalcium silicate bonds. hot strength and resistance to load at probably the most common.Products based on deadburned magnesite or magnesia. composition. In addition. basic refractories generally fall into one of five resulted from attempts to address the compositional areas: rapidly evolving needs of the 1. development of technology to address specific wear mechanisms by employing 4. These chemical features although levels at 3% and below are give the brick excellent refractoriness. with chrome-containing materials such as chrome ore. in many instances the magnesite-carbon to attack by iron oxide and alkalies. These features minimize the chance of the brick cracking during service. While this is still a useful definition. superior spalling resistance. of burned basic refractories. dusts and fumes at elevated production of basic refractories are dead-burned and fused magnesites.2 Harbison-Walker . which is sometimes Basic refractories containing chrome continue to be an important group of used to improve the spalling resistance materials due to their excellent slag resistance. some classes of basic dead-burned dolomite. Some types of direct bonded chrome-magnesite brick. Fe2O3 and Cr2O3. The first readily to Fe2O3. accessory silicate minerals of low melting points present in the groundmass of the ore. The term direct- they can be divided into two categories FeO that is present would oxidize bonded describes the direct attachment on the basis of chemistry. Sometimes. low boron magnesites. the makes it possible to choose products contents greater than 98% for better added magnesia also reacts with the best suited for an individual application. generally be regarded as having better B2O3) in order to impart good hydration The reaction of chrome ore with dead spalling resistance than one containing resistance. High brick is intentionally adjusted to a molar the excess R2O3 constituents strength at elevated temperatures is one ratio of two to one to create a dicalcium (Fe2O3. the RO constituent. a often determined by the amount and recognized that most of the iron content significant advance in the quality of type of impurity within the grain. serpentine and Silicate-bonded brick have a thin film of There are many types of magnesite talc. The new spinel will have containing 60% magnesia would boron oxide contents (greater than 0. Two solid phases would combining high purity chrome ores and to-silica ratios of two to one or greater.1% essentially the formula MgO•R2O3. RO constituent consists of MgO and While the reactions between chrome ore 5070°F (2800°C).Cr2O3 and Al2O3). or both. Cr2O3. when important better hot strength and high temperature less. interstitial gangue minerals. and the R2O3 constituent consists and magnesite outline the fundamental refractoriness of a magnesite brick is of Al2O3. The of properties of the brick is a function of brick generally has lime-to-silica ratios MgO also combines with the newly the magnesite-to-chrome ore ratio. a direct bonded brick These brick may contain relatively high structure. This would result in an of the magnesia to the chrome ore category consists of brick made with imbalance between the RO and R2O3. and firing them at Often. generally less the RO decreases and the R2O3 Direct-bonding was made possible by than 0.3 . be considered a better choice in a high- purity natural dead burned magnesites since spinels formed by MgO with alkali environment. 2MgO•SiO3.. most magnesite- adjusting the chemistry of the impurities generally olivine. resistance to “peel spalling” than of higher purity than the dicalcium When a chrome ore is heated with silicate-bonded brick. They A major advance in the technology of explain why magnesite-chrome and range from natural dead-burned basic refractories occurred during the chrome-magnesite refractories have materials.BASIC REFRACTORIES Various grades of dead-burned MAGNESITE-CHROME AND them to the highly refractory mineral magnesite are available for the CHROME-MAGNESITE BRICK forsterite. In of raw chrome ores is present as part of these products occurred in the late practice. the chrome ore particles. absence of dead-burned magnesite. although the latter might reasons. In addition. calcic chrome brick were silicate-bonded. and converts Harbison-Walker CR . that have lime. Since magnesia itself has the generic formula RO•R2O3. Brick with lime-to-silica the microscope as needle-like inclus. These are Prior to that time. This greater added magnesia. The balance The second category of magnesite the FeO as it oxidizes to Fe2O3. formed Fe2O3 to maintain the spinel example. for economic burned magnesite increases the 80% magnesia. For simplification. done to produce highly refractory Chrome ores are often represented by Direct-Bonded magnesites. combinations of chrome ore and dead. increases. the refractoriness of a dead. the ultimate FeO. as without intervening films of silicate. the lime-to-silica ratio of these MgO•R2O3 and (2) a solid solution of extremely high temperatures. Al2O3 and Fe2O3 have higher balance of properties as a function of At other times. orthopyroxene. from 100% chrome ore. plagioclase. This changing with magnesia contents of 95% or less. For between zero and one. the brick are made with melting points than the corresponding the ratio of magnesite-to-chrome ore very pure magnesites with MgO spinels formed by FeO. refractoriness. A large amount of work has been burned magnesite. silicate-bonded brick. MgO enters the chrome spinel to replace magnesite-to-chrome ore. with MgO contents of 90% or early 1930’s.02% boron oxide. of the single most important properties silicate bond that gives the brick high the solid solution is easily visible under of direct-bonded brick. brick are available with various ratios of desirable for certain applications. chlorites. These reactions production of magnesite brick.e. on a molar basis. as in a chrome. It should be chemistry of magnesite-chrome brick. to high purity synthetic magnesites discoveries were made regarding load resistance than refractories made containing 96% MgO or greater. silicate minerals that surrounds and refractories. They also have hot strength. these brick are made with lower refractoriness of the spinel minerals. Frequently. i. appear: (1) a spinel consisting mainly of magnesites. Direct-bonded magnesite-chrome chemical purity makes them more magnesite or magnesite-chrome brick. better slag resistance and better ratios greater than two to one are often ions. lowering the amount of impurities. both burned and If raw chrome ore were fired in the bonds together the magnesite and chemically-bonded. Chrome ores also 1950’s and early 1960’s with the burned magnesite is improved by contain siliceous impurities as introduction of “direct-bonded” brick. where the Magnesite-Chrome Brick an extremely high melting point. used. thermal expansion characteristics and Fused magnesite-chrome grain has chrome brick and chrome ores. The resulting ingots Magnesite-spinel brick have been more environments. good magnesite-chrome brick”. It principal functions of carbon is to compared to direct-bonded magnesite. magnesia. Spinel additions also oxidizes and forms a tight bond between is dense and exhibits a direct-bonded lower the thermal expansion coefficients the brick. solely with dead burned magnesite. the rebonded fused term “spinel” in this broader sense is from the observation that carbon is not magnesite-chrome brick have lower accepted practice. The direct-bonded The fused grain brick used in North ways.4 Harbison-Walker . brick family of minerals that crystallize in the made from this grain have a tendency to cubic system and have the general CARBON-CONTAINING shrink on burning rather than expand. constituent raw materials in various bonded variety. a constituents from the service steel casing. A family of magnesite-spinel brick has Burned chrome-magnesite brick may be degassers and sometimes in the more been developed by combining the of either the direct-bonded or silicate. grain. such as primary copper and be converted to the hexavalent state magnesite and chrome ore in an electric nickel production. These chemically-bonded brick do not One of the principal benefits of have the high temperature strength. FUSED MAGNESITE-CHROME certain classes of direct-bonded A desire to use chrome-free basic GRAIN BRICK magnesite-chrome brick. materials for better spalling resistance. Some magnesite-chrome brick are made spalling resistance than brick made usually as lower cost compositions to from coburned magnesite-chrome grain. chemically inert. and FeO and R2O3 may be Fe2O3. An alternative is to add Some magnesite-chrome brick are particular application in which they will be spinel grain to a composition containing chemically-bonded rather than burned. combining spinel and magnesia is that resistance or slag resistance of burned CHROME GRAIN BRICK the resulting compositions have better compositions. severe areas of nonferrous applications. The melted material is then earth constituents and other compounds poured from the furnace into ingots and MAGNESITE-SPINEL BRICK that are present in some service allowed to cool. the term have been shown to provide excellent extremely low porosity and is “spinel” is often used to refer to the service results in many rotary kilns. In addition. has become accepted usage to use the prevent liquid slag from entering the chrome brick. where RO may be BASIC BRICK is characteristic of many direct-bonded MgO. for example. brick made reduce thermal stresses that could in many applications.BASIC REFRACTORIES Chrome-Magnesite Brick This type of brick is used in AOD’s. as formula RO•R2O3. the mineral spinel has easily wetted by slag. They are widely used. with coburned grain shrink in burning contribute to cracking in certain and thus can have lower porosity than environments. mid 1970’s brick based on carbon in combination with magnesite were CR . While usage of the magnesite refractory originally stemmed these features. (Cr+6) by reaction with alkalies. They have grain. term magnesite-spinel brick to refer to brick and causing disruption. alkaline arc furnace. These factors have led to are crushed and graded into grain for broadly used in recent years. Fused steelmaking and in certain nonferrous present in magnesite-chrome brick can grain is made by melting deadburned industries. Thus. Brick made brick for environmental reasons has Products have been developed that with coburned grain find wide variety of increased the importance of magnesite- contain fused magnesite-chrome grain uses. In service. As a result of Al2O3 and Cr2O3. The resulting grain environment. the fine alumina Chemically-Bonded Magnesite. The technique of steel casing character. In discussing magnesite. MgO•AI2O3. The idea of adding carbon to a magnesite-chrome brick. load COBURNED MAGNESITE. Some magnesite-spinel brick are brands are used under more severe America typically contain 60% made by adding fine alumina to service conditions. Until the the products containing MgO•Al2O3. one of the porosity and superior slag resistance as the chemical formula MgO•Al2O3. such as in vacuum degassers in spinel brick. Some compositions contain a compositions composed mainly of combination of fused and unfused magnesia. reacts with the fine magnesia in the Chrome and Chrome-Magnesite to lower cost. combining fine magnesia and chrome temperature cycling and infiltration of chrome brick are sometimes used with ore and dead-burning in. are called “rebonded fused of brick refers to the mineral excellent spalling resistance. Trivalent chromium (Cr+3) to offer improved slag resistance. balance out wear profiles in various often referred to merely as coburned This feature results in the avoidance or applications. Like brick made with fused of magnesite compositions. the steel rotary cement kiln. Coburned grain is made by inhibition of peel spalling caused by Chemically bonded magnesite. or to achieve a balance of matrix of the brick to form an in situ Brick properties that is appropriate to the spinel bond. On firing. This can has accounted for improved service life magnesite-chrome grain. The term broad use of magnesite-spinel brick in brickmaking. Brick made from this “spinel” as used in describing this type rotary cement kilns. magnesia. hot face of a brick cracks and falls away adding flake graphite. Pitch-impregnated. the high thermal conductivities carbon contents ranging from 10% the furnace. The high Carbon-containing basic brick can be due to slag penetration in combination oxidation resistance of flake graphite categorized as follows: with temperature cycling. A high refractories in which the carbon phase potential for hydration to occur. Thus. used in charge pads. this type of brick is sometimes conductivities are a factor in the containing about 5% carbon. burned magnesite brick that have been graphite results in very high thermal magnesite brick containing about impregnated with pitch are used in a conductivities compared to most 2. melting point of about 3870°F (2130°C). degree of slag resistance and good high has a major influence on brick temperature stability have been found to properties. for example. but at the same time. In addition. Dicalcium silicate has an extremely high Pitch-bonded magnesite brick were there are impurities associated with it. the oxides in the brick brick are considered composite choice where it is judged that there is are reduced by the carbon). the principal working lining materials These may be minerals such as quartz. bonded. processes. These brick are also widely reduces the thermal stresses within the to 20% are most common). Harbison-Walker CR . product development typically used in the United States refers Not all pitch impregnated burned efforts have been directed towards to brick with carbon contents greater magnesite brick are dicalcium silicate producing magnesite-carbon brick with than 8%. Use of this bond in combination with for basic oxygen furnaces for many muscovites. result and adversely affect the physical carbon addition is too large to be in very good hydration resistance. Pitch-bonded magnesite brick furnaces. In cause the brick to have relatively low reactions that can reduce hot strength magnesite-carbon brick. These brick such as this are the products of temperatures (i. Although much purification is gives these brick excellent hot strength environments they have been replaced accomplished through flotation and an absence of fluxes at temperatures to a large extent by more erosion processes. Magnesite-carbon brick containing disruption caused by the impact of steel the temperature gradient through a 8% to 30% carbon (in this class. the are also used in subhearths of electric reduces potential for oxidation. mined material. scrap and liquid metal being added to brick. magnesite-carbon brick has been One category of burned pitch. but since that time they have The carbon also prevents the The high carbon contents of magnesite- been more broadly utilized in electric arc phenomenon of peel spalling. These high thermal 2. Burned Pitch-Impregnated in various applications.BASIC REFRACTORIES mainly used in basic oxygen steelmaking the hot strength and high refractoriness. Although in severe service feldspars. but mainly in The high temperature stability of Magnesite Brick basic oxygen furnaces and steel ladles. They carbon brick between heats and thus contain both magnesite and carbon. integrity of the brick at elevated considered merely a pore filler. Pitch-Bonded Magnesite Brick be advantageous in the hotter and more Pitch-bonded magnesite brick are used corrosive service environments. In recent years. number of applications. however. they continue to play an These mineral impurities are often The carbon derived from the important role in. the hot strength. the flake 1. Magnesite-Carbon Brick furnaces. High temperature magnesite brick can be thought of as lime to silica ratio and a high boron stability refers to the ability of the brick products containing just enough carbon oxide content. used as a tank lining material.e. term “magnesite-carbon brick” as arc furnaces. are easily reduced by constituents from chemically altering carbon and thus will result in a loss of the dicalcium silicate bond. In basic oxygen refractories.5 . the ash constituents. where the carbon brick are generally achieved by furnaces and steel ladle applications. and good slag resistance. iron oxides and tight chemical control of other oxides years. Since flake with a dicalcium silicate bond. carbon brick. i.5% carbon. most flake graphites contain commonly found in metallurgical resistant graphite-containing magnesite. however. strength. preserving carbon from the brick and a reduction in hot strength at elevated temperatures. graphite is a natural. where its high excellent spalling resistance of strength enables it to resist cracking and magnesite-carbon brick. a limited amount of these impurities. lower referred to as graphite “ash”. as a brick. These products have excellent thermal achieved by utilization of high purity impregnated magnesite brick is made shock resistance and high temperature graphites and magnesites. Some of impregnating pitch when the brick is wear areas of basic oxygen furnaces. One important class good slag resistance and high Pitch-impregnated and pitch-bonded of brick that deserves mention has a low temperature stability. High thermal conductivity also backup lining behind the main working results in faster cooling of a magnesite- While all brick in these categories lining of a basic oxygen furnace. These chemical features to resist internal oxidation-reduction to fill their pore structures.e. pyrite. By reducing 3. especially the silica heated in service prevents slag and iron oxide. contributes to the reduced erosion rates Dicalcium silicate bonded burned of these brick. to improve the hot strength of 1984. Silicon has been employed as an additive to inhibit the hydration of aluminum carbide that is formed in aluminum-containing magnesite-carbon brick. Carbon Bricks”.(1) Another way that metals may improve hot strength is simply by protecting the carbon bond in these brick from oxidation. Some brick to become finer after the brick is of the carbon-bonded products contain heated. high purity intermittent operations such as some magnesites are used. Tokyo. aluminum carbide (AI4C3) and silicon Dolomite brick are widely applied in carbide (SiC) by reaction between the applications as diverse as argon-oxygen metals and the carbon in the brick. The DOLOMITE BRICK metals consume oxygen that would Dolomite brick are available in burned otherwise oxidize carbon. Nov. This is illustrated by the following equation: Al4C3 + 12H2O • CH4 + 4Al(OH)3 CR . rotary finer pores result in decreased cement kilns and steel ladles.BASIC REFRACTORIES Magnesia can also be reduced by carbon This reaction represents a potential at high temperatures. permeability of the brick and inhibit (1) A. A applications such as tuyere elements in great deal of work has been done to bottom blown basic oxygen furnaces. magnesium and silicon. Japan. The decarburization vessels (AOD’s). magnesite-carbon brick. It is believed that the pores flake graphite and are somewhat become finer due to formation of analogous to magnesite-carbon brick.6 Harbison-Walker . The and carbon-bonded compositions. In develop special additives to improve the addition. Preprint of The First International Another reason for adding metals is Conference on Refractories. Magnesites with steel ladles or electric arc furnaces.. Aluminum carbide can react with atmospheric humidity or any other source of water to form an expansive reaction product that can disrupt the brick.al. magnesite-carbon brick are performance of carbon-containing brick sometimes impregnated with pitch in in these applications. One bonding in service. these carbon-containing basic brick are Boron-containing compounds such as used are very diverse due to process boron carbide (B4C) are used to improve changes in the steelmaking industry and oxidation resistance in certain critical due to broader use of the products. These additives order to improve oxidation resistance as include powdered metals such as well as to promote brick to brick aluminum. reason for adding these metals is to improve oxidation resistance. For best high problem for applications with temperature stability. very low boron oxide contents are Adding silicon to an aluminum- especially desirable. pp 125-134. “Effects of Metallic oxidation by making it more difficult for Elements Addition on the Properties of Magnesia- oxygen to enter the brick structure. containing brick greatly extends the The service environments in which time before which hydration will occur. It has been suggested that the improvement in hot strength is due to the formation of carbide “bridges” within the matrix of the magnesite-carbon brick. Watanabe et. The aluminum and silicon also cause the carbon-bonded varieties include both pore structure of a magnesite-carbon pitch and resin-bonded versions. Alumina has a specific gravity of 3.5% from the respective affected by composition. (alumina).high-alumina brick (usually bonded by effective in providing load resistance. such as alkalies. within any class of high- distinguishes them from brick made predominantly of clay or other alumina brick. those high in silica. The 85% and 90% alumina classes differ in that their allowable range is plus or minus 2% from nominal.predominantly contains the mineral phase particularly brick high in silica. The final class.5% to particularly in the fired refractory. in its various forms. free-silica and glass. mullite.. the silica to form a low melting glass when 52. • Mullite brick . chemical and content. a 70% alumina from both alumina and silica. The presence of certain impurities is critical TYPES OF HIGH-ALUMINA primary mineral phases present in fired in determining refractoriness.96 and silica. 60%. the raw materials and aluminosilicates which have an alumina content below 47. and High-alumina brick are resistant to acid slags. iron oxide (Fe2O3) and titania As previously mentioned. the the Al2O3-SiO2 phase diagram. such brick are Al2O3-SiO2 diagram cannot be strictly the brick are fired or reach high not greatly different from superduty Harbison-Walker CR . Most BRICK high-alumina brick are mullite and naturally occurring minerals contain corundum which have melting points of amounts of alkalies (Na2O. the brick could contain a range of within the following sections brick and progressively improves as phases which includes corundum concerning high-alumina brick. has a minimum alumina content rather than a range. alumina and chromia form a solid creep resistance. this value is 97%. alumina content increases up to 99+%. The 50%. etc. melting point and. several other properties are with an allowable range of plus or minus 2. nominal values.2% SiO2. K2O and 50% Alumina Class 3362°F (1850°C) and 3722°F (2050°). alumina (AI2O3) content of 47.usually phosphate-bonded brick in Creep or Load Resistance the 75% to 85% Al2O3 range. development is also particularly • Alumina-carbon brick .7 . At lime. Alkalies can be particularly classified as a 50% alumina product equilibrium is seldom reached.5%. CaO. is 71. Al2O3 and 28.5% or higher. a resin) containing a carbonaceous ingredient such as Density graphite. with various clay minerals Other physical. such as There are several other special classes of high-alumina products MgO. on a weight basis. is likely • Alumina-chrome brick . to form lower melting phases.typically formed from very high to be directly related to Al2O3 content. For example. is generally a function of alumina alumina. purity. since phase (TiO2). therefore. Slag Resistance 99% alumina. FeO. ranges in specific gravity from 2. An aluminum orthophosphate This property is most affected by (AlPO4) bond can be formed at relatively low temperatures. Basic components in slag. slag resistance generally improves. In addition to the melting behavior and 80% alumina classes contain their respective alumina contents of brick. Chemically. The refractoriness of 50% containing less than 45% Al2O3.26 to 2. • Chemically-bonded brick . bulk MINERALOGY product might contain a combination of density increases with alumina For alumina-silica brick. their associated impurities impact on High-alumina brick are classified by their alumina content the quality of the product and according to the following ASTM convention. Both Fe2O3 The term high-alumina brick refers to refractory brick having an and TiO2 will react with Al2O3 and SiO2. In refractories formulated CHEMISTRY AND PHASE applied. harmful since they ultimately react with has an alumina content of 47. This relationship is best described by In addition to Al2O3-SiO2 content. Mullite crystal solution which is highly refractory. As mullite (3Al2O3•2SiO2) which. When thermal properties will be discussed alumina brick is greater than fireclay fired. 70% performance in service. However. Li2O). This descriptive title Therefore. Fe2O3 and MnO2 worth noting: react with high-alumina brick. high-alumina materials and chromic oxide (Cr2O3).65. have a significant effect on high temperatures.5%. refractoriness a bauxite aggregate of about 90% content. that is.HIGH ALUMINA REFRACTORIES Overview temperature in service.8% Al2O3 content increases. a brick respectively. Impurities. reacts with available made from a variety of raw materials. They may these brick have low porosity. After the pressing Some are produced from calcined extensively in steel ladle applications. but typically they are made popular class of products. choice for preheater towers and and clay materials. e. These calcined bauxite with additions of typically fired to high temperature to qualities make such brick an excellent various amounts of other fine aluminas maximize mullite crystal development. hot versions of fireclay brick with the is advantageous in reducing the size of strength and load-bearing ability. such as are used in the steel industry. Properties Phosphate-bonded brick are widely excellent and cost-effective such as high hot strength. develop a combination chemical and good volume stability at high clay and fine silica. and fine materials such as calcined alumina. particularly in applications Applications include the steel-industry such as nose rings and discharge ends and cement and lime rotary kilns. These brick are resistance and low porosity. as well as relatively inexpensive. calcined bauxite and fireclay. This brick with exceptional cold strength. They are usually calcining zones of rotary kilns. excellent the base grain and may include various even be fired at higher temperatures to hot strength and creep resistance. brick are cured at bauxitic kaolin and high purity clay to temperatures between 600°F and 1000°F provide low levels of impurities. are characterized by low porosity and alumina and silica typically make up permeability and very high strength at 70% Alumina Class 99% of the chemical composition. Due to their more MULLITE BRICK to spalling. Many high-temperature homogeneous structure. giving a near monolithic temperature strength and refractoriness extreme cases of high temperature and lining at service temperature. they show In brick of this special category. These 50% alumina A higher cost and higher quality inert to a wide variety of slags. As these brick ceramic bond.HIGH ALUMINA REFRACTORIES fireclay brick which can contain up to bauxite to form mullite. provide 80% Alumina Class major portion of either sintered grain or exceptional load-bearing ability. perform well and phosphoric acid or various forms of rotary kilns. they are used alumina in the mix. the industries use them as backup brick. Based on a special fused (1600°C) . somewhat less expansion on reheating mineral phase mullite predominates. These brick shock resistance. A wide to prevent excessive expansion in range of products are available burning which causes problems in final depending upon Cr2O3 content. Because they are from bauxite. brick are also characterized by low typical products based on calcined thermal expansion and good resistance bauxite. As a 90% and 99% Alumina Classes (320°C and 540°C) which sets a chemical result of firing to high temperature. alkali These products are based primarily on fused mullite grain. alumina product class because of its are corundum and mullite. Most Phosphate-bonded brick can be 60% Alumina Class brick in this class have about 20% produced from a variety of high-alumina The 60% alumina class is a large. Brick within the 50% typically undergo large amounts of solution developed in firing results in alumina class are often upgraded secondary expansion when heated. good strength and thermal calcines.. industries. these applications since they minimize joints These brick have superior high products are selected for the most between brick. present in steel ladles. resistance benefit from this purity level. grain high in chromic oxide. ALUMINA-CHROME BRICK of rotary kilns where excellent abrasion Most brick in this class are based on Alumina-chrome brick consist of resistance is required. joints between brick and providing a addition.g. Usually. generally have low impurity levels. porosity. operation. The alumina content varies from about purity bauxitic kaolin. intermediate temperatures between This is the most frequently used high. The solid- 44% alumina. Brick are combinations of the two oxides fired to usually fired to fairly low temperatures develop a solid-solution bond. A P2O5 addition.desirable features for ladle high purity calcined bauxitic kaolin. class brick have low porosity and alternative to producing a 70% alumina Brick with higher Cr2O3 content are expand upon reheating to 2910°F brick is represented by brands based on also available. creep and slag used in the mineral processing performance in multiple environments. the solid-solution bond Compositions of this class are designed tight vessel structure. Expansion is caused by include a 90% Al2O3-10% Cr2O3 product reaction of the siliceous ingredients with based on high purity sintered alumina CR . fired at relatively low temperatures to PHOSPHATE-BONDED BRICK maintain consistent brick sizing. Brick in this class are are resistant to most slag conditions soluble phosphates. In addition of a high-alumina aggregate. These and significantly lower porosity than corrosiveness. the only mineral phases present 1500°F (815°C) and 2000°F (1090°C). 50% alumina products based on high than bauxite-based products. The brick and pure chromic oxide. These brick sizing. and other 70% to 78% and the brick can contain a ingredients in the matrix. These brick contain tabular alumina as bond of aluminum phosphate. Phosphate-bonded brick temperatures. between alumina and chromic oxide is primarily for ladles. a rotary kiln.8 Harbison-Walker . although silicon carbide is used.HIGH ALUMINA REFRACTORIES ALUMINA-CARBON BRICK In this class. A wide variety of compositions are possible based on the various high- alumina aggregates now available.9 . Graphite is the most common carbonaceous material. as well. brick are bonded by special thermosetting resins that yield a carbonaceous bond upon pyrolysis. Harbison-Walker CR . the and superduty fireclay brick. the superduty fireclay class. Flint clays and high-grade kaolin impart combined water is driven off. Some superduty usually some free silica. potassium. medium-duty. Maryland. The PCE of clays notable resistance to shrinkage. fracture. also known as “hard clay”. classes cover the range from approximately 18% to 44% alumina. Missouri. calcium. sodium. they have been ground and mixed with duty fireclay brick can often be used with better economy than medium-duty water. Colorado and several other states. are very low. Because of their greater resistance to thermal shock. or shell-like. Superduty fireclay brick have good strength and volume stability at high titanium. Their High-duty fireclay brick are used in large quantities and for a wide range plasticities and drying shrinkages. Ohio. lithium and temperatures and an alumina content of 40% to 44%. Ohio. including brick fired at temperatures several Flint clay. CR . Kaolinite is the most common member of A blend of clays is commonly used in the manufacture of high-duty this group. and kaolins. The best clays of this type are low in impurities and long periods of time but subject to frequent shutdowns.1% silica. and from Cone 26 to Cone 29 for many clays of high plasticity and excellent bonding power. for the most refractory varieties. plastic clays facilitate forming and impart bonding alumina and 54.9% shrinkages. hundred degrees higher than the usual product. clays”.FIRECLAY REFRACTORIES OVERVIEW FIRECLAY MATERIALS Refractory fireclay consists essentially of hydrated aluminum silicates with Refractory fire clays consist essentially of hydrated aluminum silicates with minor proportions of other minerals. their firing brick for the linings of furnaces operated at moderate temperatures over shrinkages are moderate. there are five standard classes of fireclay general formula for these aluminum brick: superduty. conchoidal.5% alumina (AI2O3). such as the relative proportions of clays used in a blend. even strength. Substantial deposits of plastic and semi-plastic refractory clays are found in Pennsylvania. Most flint clays break with a containing carbon monoxide gas. vary considerably in Semi-silica fireclay brick contain 18% to 25% alumina and 72% to refractoriness. high. can withstand abrasion limited areas of Pennsylvania. and from corresponding to 39. often called “soft clays” or “bond temperatures prevail. brick have superior resistance to cracking or spalling when subjected to Of greatest importance as refractories rapid changes of temperature. Cone 33. compounds of iron. after of applications. Low-duty fireclay brick find application as backing for brick with Plastic and semi-plastic refractory higher refractoriness. flint and semi-flint clays occur in rather within their serviceable temperature ranges. These silicates is Al2O3•2SiO2•2H2O. increases their resistance to fluxing. However. they also have excellent load-bearing of this type ranges from Cone 29 to strength and volume stability at relatively high temperatures. Medium-duty brick. plasticity and bonding 80% silica. with a low content of alkalies and other impurities. At high temperatures. and renders them of most superduty and high-duty practically inert to disintegration by carbon deposition in atmospheres fireclay brick made in the United States. low-duty and semi-silica. Deposits of exposed to conditions of moderate severity. better than many brick of the high-duty class. Kentucky. The character and quality of the brick to be made determines the purest clays contain small amounts of other constituents. There are several possible modifications in are flint and semi-flint clays.10 Harbison-Walker . have a Pyrometric Cone Equivalent Medium-duty brick are appropriate in applications where they are (PCE) of Cone 33 to 34-35. High firing enhances the high derives its name from its extreme temperature strength of the brick. magnesium. stabilizes their volume and mineral hardness. Kentucky. and for other service where relatively moderate clays. It is the principal component composition. The for Testing Materials (ASTM). about 50% to 80% silica. Drying and firing shrinkages are usually fairly high. With strength. high-duty. and the high refractoriness. plastic and semi-plastic clays.5% silica (SiO2) and 14% water (H2O). calcined clays control the drying and firing residue theoretically consists of 45. 46. As defined by the American Society minor proportions of other minerals. less pure varieties with machine are completely reshaped. harder. amount of water. Their refractoriness. the high-temperature strength of the As a consequence. chamber. several coal beds. Refractory kaolins generally have a PCE the range from 15 to 27-29. The PCE Many intricate special shapes are formed consist almost wholly of kaolinite. stabilizes their volume and resistant to impregnation and corrosion mineral composition. are made of a single clay. Usually.FIRECLAY REFRACTORIES Missouri. a large proportion of the mix is and sulfur compounds and organic Ozark region of Missouri. They usually are ordinarily varies from 311/2 to 321/2 -33. they are more brick. and with a small but closely controlled volume stability at high temperatures. stronger. of ground clay must include a range of clay are ceramically-bonded together graded sizes. Alabama and High-Duty stiff column. bodies of precalcined to control firing shrinkage matter are oxidized. in which blanks from the extrusion of Cone 33 to 35. The moistened batch Many superduty brick have good is then fed to a mechanically or resistance to cracking or spalling when hydraulically operated press in which subjected to rapid changes of the brick are formed under pressure. and finally. iron irregular form. kaolins shrink more than kaolins which have PCE values of 29 to 31. alumina the desired sizes and thoroughly mixed content of 40% to 44%. clays are ground containing carbon monoxide gas. in a dry pan. In carbon deposition in atmospheres making extruded brick. The batches are screened to fireclay brick are refractoriness. less porous and more The high firing temperature enhances dense than those made without vacuum. and system within the auger machine mineral kaolinite. The brick are then high drying and firing shrinkages. The kaolin composition of the product. including brick which are Brick made in this way typically have a fired at temperatures several hundred more homogeneous texture and are degrees higher than the usual product. In necessary ends are accomplished: free occurrences are relatively small and of making brick of kaolin and various other and combined water are driven off. The air is removed from the various other states. mixed wet or dry in a mixer. certain physical properties are less than 33. mineral isolated sink-hole deposits.” which is a rotating. FIRECLAY BRICK MANUFACTURE Brick formed by any of the processes Among the largest deposits of refractory Most fireclay brick are made from described above are dried in tunnel or kaolin are those which occur in Georgia blends of two or more clays. increases their by slags and to penetration by gases. In the class of superduty enhanced by the application of a high fireclay refractories are several vacuum during the forming of the brick. pan-shaped Superduty grinding mill having slotted openings in The outstanding properties of superduty the bottom. brick. a PCE of Cone 29 to 32 are common. In firing the brick. The temperatures of the clays. brought to the proper consistency in a pug mill. in In a modification of the power-press terms of their PCE values. and often plastic refractory clay occur in mixes for superduty and high-duty brick upon the service for which the brick are sedimentary strata in association with commonly contain raw flint and bond intended. strength. individual clays. In the north-central clays. especially those of the low-duty firing depends upon the maturing Most commercial deposits of flint and class. values of low-duty fireclay brick cover in vertical piercing-and-forming presses. Mississippi. The PCE value of high-duty fireclay clay before extrusion by a deairing Kaolins consist essentially of the brick may not be less than 311/2. Medium-Duty and Low-Duty typically repressed to give them sharp Siliceous kaolins shrink less and bauxitic Fireclay brick of the medium-duty class corners and edges and smooth surfaces. and extruded through the die of an auger machine in the form of a Harbison-Walker CR . may not be process.11 . with or without calcined clay. The column is cut into brick moderately plastic and have extremely by means of wires. The temperature of and Alabama. Some humidity driers. transformations and changes in volume deposits of Georgia and Alabama occur In making fireclay brick. the particles of in the form of lenslike bodies. and the gases refractory clay occur in the form of and stabilize the volume and mineral formed are eliminated. temperature. resistance to fluxing and renders them The extrusion process is sometimes practically inert to disintegration by used for making special shapes. modifications. the particles are affected. each in proper proportion. BRICK CLASSIFICATIONS The clays are typically ground in a “dry pan. into mechanically strong brick. these their high refractoriness. non.. CaO less than titania and alkalies.5% alumina. high resistance to acid slags. the action of dusts. as well as their ability to resist their effects on temperature of failure.12 Harbison-Walker .SILICA REFRACTORIES Overview alkalies present. When larger amounts of liquid critical temperature ranges. titania and alkalies is less than 0. the thermal conductivity otherwise crystalline silica. 4%. fumes and acid slags. As the temperature rises. constancy of volume at EFFECTS OF ALUMINAS MANUFACTURE OF SILICA temperatures above 1200°F (650°C). than of . than 1.50.2%. but their total concentration is the The American Society for Testing Materials (ASTM) divides silica significant factor. This system for classifying silica brick was preceded by a less exact CHARACTERISTIC PROPERTIES system which still is referenced today. as a whole retains its rigidity even under refractories must pass through several load. i. the modifications of silica. at first slowly and then more refractory product. Fe2O3. the consequently. the total amount of alumina. schedule during the firing process. the temperature of failure under a factor is determined by adding the alumina content and twice the total load of 25 pounds per square inch is alkali content. silicates melt and form a small amount to the high temperature crystal At temperatures below 1200°F (650°C).e. When relatively small amounts After being formed. the solid fired at a temperature high enough to crystalline portion of the brick forms a convert the quartz into forms of silica rigid skeleton. their ability classified as superduty silica brick could not contain more than a total to withstand pressure of 25 to 50 pounds of 0. titania and alkalies. and the brick the firing and cooling process. titania and CR . Individually. these the proper characteristics for conversion than that of fireclay brick. For this reason. and AND ALKALIES REFRACTORIES virtual freedom from thermal spalling After firing. temperatures in a reducing atmosphere. well-bonded brick which liquid formed at high temperatures attain their normal permanent expansion increases almost in direct proportion to of 12% to 15% by volume. especially above 2900°F washed to remove natural impurities. the percentage of of strong. Brick (1695°C) to 3110°F (1710°C).5% of lime. high mechanical strength and rigidity at oxides and alkalies vary appreciably in temperatures almost up to their melting points. Under the earlier system. A When silica brick contain the usual proper schedule assures the production 2% to 3. Among the important properties of silica insulating silica brick were either of conventional or superduty quality. TiO2 less than 0. The Type A class includes silica brick with a flux factor 50°F (28°C) to 90°F (50°C) higher. of liquid. with liquid merely present that are stable at high temperatures. When the sum of brick into Type A and Type B based on the brick’s flux factor. brick Both classes require that brick meet the following criteria: Al2O3 less classified as superduty must contain no more than a total of 0. the brick must be of silicate liquid are present. To assure the silica brick have less resistance to liquid increases because the silica also highest commercial quality in the thermal shock.5% alumina. it is necessary to maintain bond weakens and the brick may lose its a carefully planned time-temperature rigidity. Flux alumina. They are readily attacked melts. per square inch at temperatures within 50°F (28°C) to 100°F (56°C) of their ultimate melting points.50 or below. less than 2. brick are their relatively high melting temperatures. Type B includes all silica brick with a flux factor for brick containing a total of 1% of above . develop at higher temperatures. Upon being of quartz in finely crystalline form having of most silica brick is somewhat higher reheated to high temperatures. At high proportion of silicates in the body that is of silica refractories consists essentially temperatures.5%.5%.5%. In between the solid particles. silica brick contain a small The raw material used in the manufacture above 1200°F (650°C). and average modulus of rupture strengths not less than 500 psi. these oxides. the mineral must be by basic slags and iron oxide at high rapidly. (1600°C). approximately 3080°F Insulating silica brick were classified only as superduty. The temperature of Silica refractories are well adapted to high temperature service because of failure under load decreases correspondingly. A lightweight silica brick with a bulk density of 65 to 70 pounds per cubic foot (1. resistance to abrasion. Improved versions of conventional quality silica brick are available having better resistance to high temperature thermal shock. and their properties are conducive to arches having a wide span. especially the crowns of glass-tanks. Harbison-Walker CR . Superduty silica brick are used with excellent results in the superstructures of glass-tank furnaces. high mechanical strength. high resistance to spalling above 1200°F (650°C). The properties responsible for the excellent service record of this brick are rigidity under load at high temperatures.121 kg/m3) is suitable for use up to 3000°F (1650°C).SILICA REFRACTORIES SILICA BRICK PRODUCTS Certain superduty silica brick have been developed to meet the demand for a silica refractory that would permit higher furnace temperatures. give longer life and reduce maintenance costs. conventional quality silica brick have been regarded as the standard. its insulating value is excellent. At a mean temperature of 1200°F (650°C). These brick contain no more than 35% alumina plus alkalies and titania. resistance to corrosion by acid slags and uniformity of size. For many years.13 . They are also ideal for the construction of tunnel kiln crowns. Lightweight silica brick are used largely for the insulation of silica brick constructions.041 to 1. by alumina. zirconia.14 Harbison-Walker . such as boron carbide. made by blending beneficiated zircon Carbon is a desirable element for prone applications with temperatures sands. Nitride-bonded prevent appreciable combustion of Silicon carbide. fused silica and materials. or efforts should be made to situ formed silicon carbide. furnaces. This process uses a number of years as have clay-graphite CR . Their usefulness plasticizer or temporary binder. e. a producer can sell temperatures 3622°F to 4082°F (2000°C achieve a desired thermal conductivity. insulating brick are some of the refractories with extraordinary properties for alumina is typically added to the starting special applications. this refractory with a nitride phase or by self-bonding (1500° to 1650°C). The lower in wall of blast furnaces. a major component in SiC-shapes are typically used in carbon. silica. or by coating the nitrogen atmosphere to above 2200°F essentially of zircon are typically made shape with a protective glaze. Carbon and (typically silica) is added to the starting graphite. Generally.. is produced aluminum melting and refining production of carbon refractories are by reacting silica sand and coke at applications. carbon blocks have been silicon carbide using clay. Because of its susceptibility to achieved by bonding silicon carbide temperatures beneath 2732°F to 3000°F oxidation. Such shapes have a high heat transfer is required. The selection of an composed of the element carbon. Zircon refractories are from carbon. even at secondary phase. petroleum coke. CARBON AND GRAPHITE shapes. forming by most molten metals and slags. mixture. Fine carbon placed in the carbon yielding resins or pitch and SiC. various grades of silicon carbide grains to 2250°C) in an atmosphere of silicon These materials are combined with high ranging from 90% SiC content to 98% vapors. with the purity by first forming a shape using Naturally occurring flake graphite or level decreasing towards the outer zones conventional ceramic binders and then artificial graphites are sometimes of the mass. Under normal atmospheric vapors to form a silicon carbide shapes are well suited to places where conditions. Mg). forming a influenced by mineralizers. zircon. To form a sialon bond. The firing its strength increases when it becomes Higher strength bonds can be temperature of zircon is limited to heated. Gaseous nitrogen reacts with by a forming process called impact melting crucibles made of clay-graphite the dispersed silicon phase and forms pressing. By selectively cropping a firing the shape at very high blended with amorphous carbons to silicon carbide ingot. it will not selfbond. Self-bonded SiC Historically. for the most part. and firing to an excellent thermal shock resistance. the content of the atmosphere at a given sialon bond possesses the highest degree operating temperature is low enough to SILICON CARBIDE of oxidation resistance. such as stopper rods and relatively low thermal expansion and This type of refractory is essentially sleeves. Starting materials for the this special refractory class.g. structural supports. because within this should be used under reducing silicon carbide grains with secondary in temperature range zircon dis-sociates. conditions. fine shape and heating the shape in a alkalies and fluorides. Electrodes grain and firing the shape to sufficient Zircon is a silicate of zirconium having and anodes used in numerous industrial temperature to vitrify the clay and a composition of about 67% zirconia applications also are typically made produce a glassy bond. originally developed by have been used for a considerable silicon nitride crystals which readily Harbison-Walker. elevated temperature. Such inert. such as highly elevated temperatures. silicon carbide. heat center of the reacted mass is the area Self-bonded SiC refractories are made treated coal tar pitches and the like. such as shape. Clay-graphite shapes have been high strength. The various nitride phases all possess non-wetting properties. Nitride The actual temperature at which zircon minimize reaction with gaseous oxygen bonds are typically formed by adding dissociates into zirconia and silica is by adding oxidation inhibitors to the fine silicon powder to SiC. appropriate nitride bond is dependent is limited to applications which are either graphite shapes which provide longer upon the degree of oxidation in the strongly reducing or where the oxygen service life. service environment. metallurgical coke. are used with success in hot. having the highest purity. as well as in the bosh and typically the amorphous carbons.SPECIAL PURPOSE REFRACTORIES Overview bond to the surface of the silicon carbide Materials that surpass commonly used refractories in one or more of their aggregate. These shapes and 33% silica. an oxygen source essential properties are often required for industrial purposes. Metal (1205°C). milled zircon sands and a refractory use because it is not wetted under 2600°F (1427°C). abrasion. however. Its use replaced. To produce a silicon oxynitride bond. Carbon blocks have also been Clay bonded SiC refractories are made used to line the hearth and sidewalls of by adding crude clay to silicon carbide ZIRCON aluminum reduction pots. it has is limited by the refractoriness of the a desired shape. schemes have been developed to bond readily distinguishable. Silicon carbide by itself is extremely starting materials reacts with the silicon formed into blocks and slabs. and clay bond. Various “recrystallized” appearance and are areas using watercooled panels. Brick consisting metals (Al. temperatures above 3600°F (2000°C). Si. fused cast. metallic is typically used in heating elements and used to line the hearth and bosh of blast powders and molten silicon. control of the bore refractory compounds in a fusion spread use of zirconia has been limited. refractories to contain molten metal or phase is monoclinic which is stable to slag is their lack of interconnected about 2120°F to 2174°F (1160°C to FUSED SILICA REFRACTORIES porosity. because of two major zirconia is used to make crucibles for a simple shape. excellent resistance to fluid corrosive these oxides within the temperature shroud tubes. such as Zirconia can occur in three industry. Fused silica also has cast refractories. its tendency to thermally age. alumina-zirconia-silica. Because of these through a chemical process involving within the 1472°F to 2552°F (800°C to properties. Wide. fused cast is alumina-zirconia-silica. Beyond about 2000°F (1094°C) chemical inertness against acidic slags disadvantage of stabilized zirconia is amorphous silica devitrifies into and their good thermal shock resistance. Special drawbacks. diameter during casting is vital. Other. this material has excellent thermal prevent cracking or shattering of fused The fundamental cracking problem shock resistance. can be overcome using either of two excellent corrosion resistance in acidic Fused cast refractories are typically contrasting approaches. glass-tank refractories. considered volume or thermally stable an electric furnace. The rate of the melt to prevent cracking of heating. mix for casting into plaster molds. The cubic form of zirconia has linings for chemical reactors. polymorphs. such as metering nozzles FUSED CAST REFRACTORIES known to have excellent chemical used in continuous casting and inserts As the name implies. basic slags. These 40% to 50% chrome ore. such as a block. a refractory body so that destructive due to their excellent electrical zircon and spinel. A (1094°C). The absence of open the monoclinic-tetragonal transition heating quartzite (SiO2) with a purity of porosity enables this type of refractory causes a volume contraction. promise as an ideal refractory material refractories are only used in critical for many decades. Fused silica filled Fused cast alumina is primarily used is in dispersed phase works as a stress resins are used to encapsulate refining and superstructure areas of absorber as energy is absorbed by electronic components to protect them glass tanks. is as an additive to shrinkage cavities. micro-cracking is avoided. One is to mill media. 50% to 60% dead-burned magnesite and cubic structure with lime. the crystalline nature of corrosive agents. cristobalite which undergoes a volume the stabilizer tends to migrate out of expansion when heated. Some furnace and casting the liquid melt into however. Fused cast magnesite -chrome effect. the dispersed Fused silica grains are classified into used in melting and superstructure phase is said to produce a “toughening” various sizes and formulated into a slip areas. applications are simply too rapid to disintegration of the refractory shape. Zirconia has held Due to its high cost. main use of zirconia in the refractories the shape and localized defects. than one micron) and disperse it within electronics industry as resin extenders alumina-silica. magnesite-chrome. fluctuations. It is another.SPECIAL PURPOSE REFRACTORIES rapid series of air hammer impacts to range 2750°F to 3100°F (1500°C to nonferrous troughs and spouts. Heating through Fused silica is produced by electrically refractories. its high cost and its refining special alloys where purity of attention must be paid to the cooling tendency to change crystal form upon the molten metal is of concern. Fused sold in the following compositions: monoclinic zirconia to a fine size (less silica powders are used in the alumina. The main expansion. however. to resist corrosion and infiltration of through the transition causes a volume In this process. and increase the thermal shock or slag The advantage of using fused cast cubic. The predominant type of zirconia to convert from one phase to from the environment. refractories are generally composed of The other approach is to stabilize the Using this technique. the insulating property. In fact. more intricate a uniform thermal expansion. their relatively Harbison-Walker CR . devitrified fused silica is not zircon or by fusing zircon with coke in 1400°C) range. The main advantages polymorphs reflect volume changes cyclical temperatures up to 2000°F of zircon refractories are their relative which occur upon heating. whereas silica shapes can be used in constant shapes are made by air ramming or thermal expansion of the other temperatures up to 3000°F (1650°C) and vibration casting. such as strong acids. In this way. The typical room temperature resistance of the refractory. That is. The phase change transition the silica is transformed into an disadvantage of fused cast refractories through cooling is instantaneous and amorphous structure by rapid is their great sensitivity to thermal results in spontaneous failure of the quenching from a molten condition. It has long been applications. many intricate. It has an extremely high in the bore area of slide gates. In these of refractories is formed by melting melting point of 4856°F (2680°C). The sudden temperature zirconia crystal. Fused such as rectangles. and as compress the mix into simple shapes. a feature inherent to sintered 1190°C) upon heating. magnesia or complex shapes can be made. this classification inertness.15 . displaying a ZIRCONIA the structure when the material is significantly higher thermal expansion Zirconia (ZrO2) is usually obtained exposed to long term temperatures than fused silica. This failure is Because of the extremely low thermal changes which occur in many expressed in the cracking and/or expansion of fused (amorphous) silica. 1700°C). They offer yttria by heating zirconia with one of shapes are used as coke oven doors. applications. monoclinic. tetragonal. however. zirconia when heated to elevated temperatures. cooling at least 98% silica in a fusion furnace. desired thermal profile. 2100°F to 2300°F (1150°C to 1261°C).16 Harbison-Walker . These numbers multiplied They are primarily used in rotary cement by 100 represent the nominal service kilns and glass tanks. etc. INSULATING BRICK • Faster heat-up of the lining Insulating brick are made from a variety due to the insulating effect and of oxides. creating internal A variety of insulating brick provide a porosity. Using this characteristics. used in the crowns of glass furnaces and insulating brick inherently have lower tunnel kilns. 26. such as refractory. insulating brick can be cast silica brick are similar to conventional instead of dry pressed. Additions of silica brick with the exception of density lightweight aggregates like diatomite. but they can also be used as working linings of furnaces where abrasion and wear by aggressive slag and molten metal are not a concern. service limit of 3000°F (1650°C) and are Because of their high porosity. the furnace lining and less heat loss to the refractory. which usually construction to obtain a results from a high degree of porosity. The high porosity of the brick is created • Less furnace weight due to the during manufacturing by adding a fine lower weight of the insulating organic material to the mix. insulating materials offer several distinct advantages: CR . By composition and property foaming agent to slip. Insulating brick based on thermal conductivity and lower heat fireclay aggregate are also available with capacity than other refractory materials. the organic addition burns out. Where they can be used. The desirable features of these insulating refractory. 23. These brick offer a alumina insulating refractories in the maximum service limit in the range of following sequence: 16. made from a high-alumina base. is another approach. During firing. lightweight. 20. and porosity. service. Products numbered from 16 to insulating 90% and 99% alumina brick 26 are made from a fireclay base and and alumina-chrome bricks are also products numbered from 28 to 33 are made.. They have a maximum haydite. sawdust.SPECIAL PURPOSE REFRACTORIES high cost and the development of • Savings in fuel cost due to suitable alternative refractories at lower decreased heat losses through cost has limited their wide-spread usage. 28. thermal conductivity. temperature in degrees Fahrenheit to For even higher temperature and which the refractory can be exposed in corrosive applications. Another way to accomplish range of thermal efficiencies and high porosity involves the addition of a strengths. a combination of high strength and low ASTM classifies fireclay and high. Typically. brick are their light weight and low • Thinner furnace wall thermal conductivity. insulating refractories are used as backup materials. lightweight insulating approach. most commonly fireclay or lower heat capacity of the silica. 30 and 33. masonry depends upon the strength of the individual brick. corrosion by volatile alkalies and slags extremely exacting and require a volatized fluxes or gases. They are carefully adjusted balance of properties. MORTAR CLASSES or trowelling consistency. a mortar should have good working otherwise contaminate the material Phosphate-bonded alumina-chrome properties when mixed to either dipping being processed in the furnace.MORTAR MATERIALS Overview which do not develop a strong bond are Masonry built of refractory brick consists of many relatively small units laid often desirable for use in laying brick walls which are alternately subjected to together to conform to a prescribed plan or design. there must be high-alumina brick in a variety of workability. specification C 178-47 superduty class mortar and are available in a wet or dry form. and excellent resistance to attack by Mortar materials and their methods of However.17 . and for certain in all types of furnaces. may greatly shorten the life of a range. fineness of grind. Phosphate-bonded at the maximum service temperature. it is essential that joint and load-bearing ability at high The conditions which a bonding material be highly resistant to chemical temperatures and are highly resistant to mortar must meet in service are often attack by the furnace charge. The mortar should not shrink High-Alumina Mortars ceramic set. Mortars of this kind meet ASTM refractory structure. as a smooth working properties. the manner in which they are laid together and the nature of the mortar material used in the TYPES OF MORTARS joints. used for dipped or trowelled joints. especially those where permit formation of more stable otherwise. vitrification temperature and sufficient to damage the brick. preparation have been developed for mortar must be high enough to resist Phosphate-bonded mortars with high particular combinations of properties melting or flowing from joints at high refractoriness and exceptionally smooth each bonding mortar should possess. temperatures. If strong joints are High-alumina air-setting mortars are these groups are materials of various needed. and upon drying. in contrast with air-setting excessively upon drying or heating. strengths. working properties are used for laying Among the factors included are In some cases. or high-alumina brick in the 50% to 70% joints filled with improper material. applications. Mortars mortars generate high bond strengths Harbison-Walker CR . phosphate bonds which are less affect the bond between brick and These mortars can be dipped or susceptible to rehydration in high mortar and cause surface coatings to trowelled. Temperatures in should be approximately the same as superduty fireclay brick in various excess of 700°F (370°C) are necessary to that of the brick with which it is used. cold and hot bonding should the chemical reaction be available for use up to 3400°F (1871°C). Most heat-setting mortars require surface coating for walls. but in no case purity tabular alumina calcines are refractoriness. as well as insulating brick. In many These mortars have exceptional stability resistance to chemical attack. chemical composition. drying and firing brick and mortar to develop a strong Heat-setting mortars based on high shrinkages. develop a strong ceramic bond. excellent into two classes: heat-setting mortars range of consistencies. the refractoriness of the corrosive slags. slag. a mortar can be intermediate temperature strength and and air-setting mortars. The strength of the soaking heat and cooling cycles. Included in each of crack or peel. volume stability. material should not discolor nor alumina class. the mortar material must be used in applications up to 3200°F compositions for use in specific affected sufficiently by the heat to (1760°C). dust. bond between them. calcines and smooth working plastic Mortar material should be selected as carefully as the brick with which it clays are recommended for use in laying is to be used. plasticity. With excellent Other air-setting mortars are available Refractory mortar materials are divided workability and water retention over a with high refractoriness. It should protect the joints from attack by slag and other Fireclay Mortars Air-setting mortars containing a mixture fluxes and provide resistance to infiltration by cold air and to the outward of high fired. water retention. temperature changes will resistance to ferrous slags is required. They have high refractoriness applications. or for relatively high temperatures to develop a patching. Users of refractories recognize that poorly made joints. resistance to attack by molten metal or mortars develop a chemical bond at The thermal expansion of the mortar slag are used in laying high-alumina and lower temperatures. fireclay and high-alumina flow of gases. nor Heat-setting mortars with very high mortars which take a rigid set merely should it overfire and become vesicular refractoriness. uses it is important that the mortar typically used for laying brick in the 90% For economy and convenience in laying. adequate chemical reaction between applications. types of service. moisture conditions. The purpose of the mortar is to fill the joints and bond the individual brick together. 18 Harbison-Walker . as well as some high-alumina compositions where slag attack and corrosion are especially damaging. They are used for laying basic brick of all types. Mortars of this kind are recommended for use when laying alumina-chrome brick. These are usually dry and may be used with other types of basic brick. brush coating over refractory walls. CR . Basic Mortars Dry. or other applications where strong bonded joints and resistance to slag or metal penetration are desired. These materials have exceptionally high resistance to corrosive slags and are used for laying all types of basic brick. Mortar brands are also available which contain high quantities of penetration and corrosion inhibitors. air-setting mortars with a chrome ore base have excellent resistance to a wide range of corrosive slags and fumes in chemical applications. but can be used as a neutral layer between basic and acid brick.MORTAR MATERIALS and show excellent resistance to corrosion by ferrous and nonferrous metals. Mortars based on high purity magnesite are also available and often used for refractories with high MgO content. on relatively high temperatures to Common usage divides monolithic trowelled. prepared in stiff plastic condition enough to develop a ceramic bond cement. However. refractory materials have led to new without further preparation. not infrequently. the best properties composition as firebrick provide better wall. monolithic refractory is most commonly tasks. with the use of a In more recent years. installed. develop a ceramic bond. however. They are usually poured or cast Heat-setting monolithic refractories TYPES OF MONOLITHIC in much the same manner as ordinary have very low cold strength and depend REFRACTORIES concrete. Gunning operations. they can be applied to form refractory aggregates combined with a somewhat lower through the monolithic or joint-free furnace linings suitable hydraulic-activated bonding intermediate temperature range. To use. improved resistance to the spalling predamped in a batch mixer. gunning mixes are are achieved when monolithic materials insulation. with a acceptance by all segments of the pyro- advantage over brick construction in semi-plastic bonding matrix which can be processing industries as an important various types of furnaces. Wet spraying is different than gunning since dry granular or cohesive plastic materials used to form virtually joint-free this is a wet castable pneumatically linings. They represent a wide range of mineral compositions and vary applied with a set activator added at the greatly in their physical and chemical properties. However. Water is activated monolithic refractories are Monolithic refractories are packaged added to the mix at the nozzle to reach used. they are are installed in their intended manner. Specially designed plastics are be made with a minimum loss of time refractory aggregate and a bonding sometimes gunned. water. technologies have been developed for refractory aggregates and cohesive the temperature of the lining can be high refractories that parallel that of Portland clays. • Ramming Mixes possessing combinations of properties the temperature in the cooler part is that make them ideal for many • Gunning Mixes usually not enough to develop a ceramic applications. delays for the manufacture of special construction site.19 . Under certain conditions. or to repair existing agent. at the nozzle creating the wet mixture as it is applied to the wall. Their use purchased ready-to-use or prepared by methods for the placement of refractory promotes quick installation. Castables are furnished dry and increases at higher temperatures with refractory masonry. as are many and. and ultra-low cement castables in a Harbison-Walker CR . in some cases. lower permeability and supplied dry. then When air-setting or hydraulic effects of thermal shock. Pumping low cement pounded into place with a mallet. and may contain plasticizing castables and ramming mixes. but in new construction. Ramming mixes are The discussion above suggests the brick shapes. becomes hard and strong at atmospheric handling and shipping. temperature drop across its thickness. weakness in construction. they are castables and pumping and wet spraying pneumatic hammers. new installation Plastic refractories are mixtures of suitable insulating material as backup. the entire thickness of a lining in suitable containers for convenience in the proper consistency. New equipment and improved at the proper consistency for use throughout its entire thickness. rammed or tamped into place. while others approach high purity brick compositions in their conveyed to the nozzle and water added ability to withstand severe environments. agents to increase their stickiness when mixes are often cast or trowelled. In the case of refractories into the following groups: or applied with air placement guns. Using monolithics placed with pneumatic hammers in 1-11/2 manner in which each class of frequently eliminates difficult bricklaying inch layers. The great upsurge in the use of these installation ADVANTAGES OF MONOLITHIC techniques is sufficient evidence of its REFRACTORIES Ramming mixes consist essentially of utility and effectiveness and its Monolithic refractories are used to ground refractory aggregates. form a strong cold set upon mixing with the development of a ceramic bond. Typically.MONOLITHIC REFRACTORIES Overview variety of applications is now an Monolithic or monolith-forming refractories are special mixes or blends of accepted installation practice. even during compound. They are When monolithic linings are used as installation techniques like self leveling generally rammed into place with the primary furnace lining. avoiding adding water in the mixer at the concretes. Some are relatively low in nozzle. which may be accompanied by stronger refractory body than plastics. The strength can be preparation. a furnace wall having the usual • Plastic Refractories They form strong monolithic linings. With little or no Castables consist of graded dry temperatures. continuously fed into a gun. but are sometimes vibrated. • Castables bond. monolithic linings of the same chemical pneumatically placed onto a furnace Typically. In gunning. dry material is refractoriness. but may also be usually held in place with either ceramic of refractory mixes. by a technique more common to another furnaces because substantial repairs can Gunning mixes consist of graded group. They are of but need some sort of form to restrain material of one group may be installed major importance in the maintenance of them when rammed. They supply a denser. They are easily temperature. Other phosphate-bonded alumina. these mixes are not usually as Superduty heat-setting plastics with temperatures which has extremely good strong in the low to intermediate graphite exhibit excellent resistance to resistance to high iron oxide slags of an temperature range as other types of wetting and corrosion by molten metal acid to neutral nature and to attack by castables. both ferrous and nonferrous metal gunned into place while maintaining its applications. but they tend to have higher and slags. adapted for many different operating often used in applications where Conventional castables have a conditions. Because of the low cement of the same features. applications between 2500°F (1370°C) depending upon furnace conditions and Application areas include cement kiln and 2900°F (1593°C). The bonding systems spalling. ultra-low alumina graphite and chrome types from 70% to 85% alumina content are cement and lime-free castables. combined with excellent used are often used to classify the types Plastics can include all the fireclay. These 1% to 3%. volume stability throughout their of castables into four categories: clay-graphite. The excellent abrasion a calcium-aluminate type of cement fills cartons. The certain chemical applications and where plastics offer higher refractoriness over presence of mullite grain allows for the highest possible hot strength and superduty plastics. Silicon-carbide based phosphate- Air-setting high-alumina plastics in bonded plastics with an aluminum Plastic Refractories the 80% alumina class are primarily phosphate bond are also available. packing. They have excellent high temperatures and are often used in and the use of additives to reduce the workability and very low shrinkage. and are especially offer good resistance to fluxing oxides wetting properties to many acid slags adaptable for making quick. Low cement castables are materials Heat-setting superduty fireclay plastics Plastics in the 90% alumina class are with lime contents of roughly between form a solid monolithic surface highly based on high purity aluminas. high. strengths. installation technique. These products aggregate. making them the ideal choice for rotary Phosphate-bonded alumina-chrome Ultra-low cement castables contain kiln hoods. These compositions. rammed to any shape or contour. Plastic refractories are used to form used where improved refractoriness over These have high conductivity and high refractory monolithic linings in various 60% alumina plastics is desired. Each strength and volume stability plastic refractory ideal for slagging method of anchoring has advantages. cement castables. plastics which have outstanding slag have desirable properties for use in Heat-setting 60% alumina class resistance to acid to neutral slags. compared to chemically similar mixes Plastics in the 50% alumina class chrome plastics with lower alumina with conventional or low cement bonds.8% lime. where slag and metal designed properties. high-alumina. coolers and bull noses. hot strength and refractoriness typically used in metal applications. These developed with bonding systems due to thermal shock and many types of include mullite based alumina-chrome containing no cement. incinerators and other plastics have very high strength at high from 0. Special gunning versions are resistance of 85% alumina plastics make in the spaces between aggregates. throughout their temperature range. they consist of sized Cold setting versions of superduty based on high purity alumina aggregates particles to achieve maximum particle fireclay plastics are available with many and chromic oxide. form an alumina. moisture proof required.2% to 0. Plastics ranging conventional. special purpose additives and often highly resistant to destructive typically have high density and a cement binder. ready to use. Like low general superduty plastic requirements.20 Harbison-Walker . Additional uses include can be poured. rammed or the proper consistency. easy to handle. This also available and are shipped in them suitable for use in high abrasion kind of castable is the most versatile for granulated form in moisture resistant conditions in petrochemical placement purposes in that normally it pallet packages. emergency repairs. and the ease with which from 70% to 90% are widely used in refractory concretes.MONOLITHIC REFRACTORIES or high temperature steel anchors. These are prepared at applications. low cement. the range of plastics ranging in alumina contents Castables are generally referred to as compositions. chrome solid solution bond at high content. They are resistant to spalling specific service conditions. typically serve as upgrades to superduty contents have been developed for Lime-free castables have been plastics. Phosphate-bonded high-alumina Castable Refractories The high refractoriness. with increased earlier reaction. They are available they can be rammed into place make many applications as primary lining in a wide variety of base materials and plastics suitable for many important materials and for patching existing typically consist of a refractory applications. Types of Plastic Refractories penetration are wear mechanisms. temperature range. This type of composition is coal slag. They are typically packaged resistance to slags and metal wash are cement-bonded matrix where. water needed to cast. making this type of high temperature load resistance is CR . economical and slags up to their maximum service and nonferrous metals. vibrated. They abrasion resistance as well as non- kinds of furnaces. in strong. temperatures. Plastic refractories are refractory linings. High densities and strength resistant to thermal shock and many products typically have high strengths at are achieved by careful particle packing acid slags. the foundry and steelmaking process. typically. These castables acid slags. plastics. they have outstanding be cast. castables based on low alkali. all-purpose castables for applications up 3100°F (1705°C). use up to 3200°F (1760°C). At high temperatures. materials can approach the properties of refractoriness than castables made from pressed and fired brick. a strong ceramic resistance up to 3300°F (1816°C). rammed or gunned and have High-alumina castables typically consist hot strength at elevated temperatures many uses. furnace tops. corrosive applications. These products Silica Castables have a wide range of uses up to 3100°F Silica-based castables include those Fireclay Castables (1705°C). density and porosity equivalent to high to 2800°F (1538°C). These castables are used in many could react with furnace constituents. stacks. They can High-Alumina Castables low silica content. conventional fireclay castables make purity aluminas with alumina contents Basic castables also come in the form them ideal for many applications. bonding systems which can give them cements. Other high strength. refractoriness. 85% alumina ultra-low operations and other high temperature super purity cements offer better high cement castables offer excellent hot furnace applications. Some of these temperature strengths and more total strength and thermal shock resistance. tunnel kiln car bottoms. temperature properties are another This type of composition has Use of higher purity aggregates and alternative in this category. are coke oven doors. cement kiln coolers. piers. glass forming dies and ash pits. Their uses outstanding strength and abrasion used where high strength and include rotary kiln lifters and cooler resistance and resist chemical attack and refractoriness are needed.MONOLITHIC REFRACTORIES required. providing good strength types are extremely low in silica content. made with vitreous silica as the raw Mixtures of high fired fireclay with a High purity alumina-bonded material with extremely low thermal refractory cement binder are designed to conventional castables with super high expansion. These Their maximum service temperature is bond forms. such as kiln floors. from 90% to 98% are also used. including boiler furnace This form of castable is used in many furnaces. such as metallurgical purity alumina-silica aggregate and Bauxite-based. zinc induction applications. When substantially lower density and thermal higher purity cements can create properly vibrated into place. castable with a lightweight castable include high purity conventional types Alumina contents of 60% to 70% are backup would otherwise be used. The lower curbs. linings for chain sections Low cement high-alumina castables high strength castables containing a in rotary kilns and subbottoms of with excellent intermediate to high fortified matrix and silica aggregate. Other silica-based castables include flues. This mixture provides good Ultra-low cement castables in the 70% extremely high hot strength. strength and castables with comparable strengths and Primary uses for these castables include excellent abrasion resistance. of chrome-magnesite mixes with Because of their high purity and very chemical air-setting bonds. have been developed. giving them excellent impart high initial strength and maintain purity cement typically have extremely resistance to cracking under repeated good intermediate temperature strength. hoppers. all-purpose castables with service alumina category exhibit excellent high temperature limits of 3000°F (1650°C). cartops. and quality fired silica brick are also and mineral processing industries. precast shapes. produced. but can develop greater binders. These are excellent and are used for applications up to castables with chemistry. Typical uses include lime content and porosity compared to Low cement castables based on high patching for rotary kiln linings. They are This class of castables includes chrome They have outstanding intermediate chemically similar to 85% phos-bonded ore base products with hydraulic cement strength and abrasion resistance. provide high density. temperature strength and thermal shock Upgraded high-alumina conventional resistance. air- of accurately sized high-alumina and are excellent for metal contact setting magnesite castables have aggregates with low iron refractory areas. lower purity cements. fireclay castables designed for extreme High-alumina castables also include abrasion applications in the intermediate 85% alumina low cement castables for Basic Refractory Castables temperature range. high refractoriness and chemical thermal cycling to 2000°F (1093°C). various types of furnaces. they conductivity than fireclay extra strength castables with additional refractoriness.21 . thermal spalling. These compositions have Low cement fireclay castables are intermediate strengths. annealing severe abrasion and chemically aluminum transfer ladles. 2400°F (1316°C) under continuous throughout their working temperature making them quite effective where silica service conditions. In the petrochemical doors. high Harbison-Walker CR . developed for high strength and typical of many low cement castables Ultra-low cement silica based abrasion resistance. chemical resistance to furnace single component lining where a dense Other types of fireclay castables atmospheres that can attack lime. The abrasion resistance. This combination rotary cement and lime kilns in sections lower lime content provides good of properties allows it to be used as a other than the burning zone. Primary applications range. depending on the binder made with little or no downtime. or gunning. A well balanced selection of ramming provides adequate strength at low ness. chemically refined rotary gun. The cement bond has the high purity. including coal ash slags. stacks. volume stability and a service materials includes compositions with temperatures until direct-bonding occurs temperature up to 3000°F (1650°C). Magnesite and hot gun outstanding thermal shock resistance high purity aluminas. Primary mixes are typically supplied in both wet lining. steelmaking. wet up well and Dry ramming mixes based on high severe service conditions experienced in stick to a hot furnace wall. Magnesite-chrome fused placing a cementless monolithic lining grain ramming mixes exist which High-Alumina Gunning Mixes at high density and relatively low provide exceptional density and These are high purity alumina mixes porosity. Gunning Mixes Ramming mixtures of 80% plus ramming mixes and specially designed A gun mix based on vitreous silica and a alumina content have excellent plastics can also be applied successfully special combination of calcined fireclay resistance to shrinkage and thermal with pneumatic guns. circumstances. incinerators. burner blocks. and dry forms. and provide cooler bull noses.MONOLITHIC REFRACTORIES Refractory Gunning Mixes excellent strength and chemical purity suited for forming dense monolithic.22 Harbison-Walker . installation and low rebounds. pneumatic convey-ing of developed specifically for hot gunning material. When properly coreless-type induction furnaces melting making. High-Alumina Ramming Mixes of choice. Other versions are have been designed for steelmaking. zircon and purity calcium-aluminate binder have others. or to Refractory ramming mixes consist of exceptional purity and stability are used provide excellent CO and load refractory aggregates and a semi-plastic primarily as lining materials for deformation resistance. homogeneous alumina content aggregates. mullite grain are also used in Gun mixes include siliceous. hot electric furnace maintenance. strength. designed for more feed in a batch gun. excellent resistance to thermal spalling in a batch pressure gun. Gun mixes Silicon carbide-based gunning mixes at high temperatures and remarkable should wet up well. ports and high-alumina. They typically feature very Fireclay Gunning Mixes advantage of forming a room high strength at high temperatures and Fireclay gunning mixes include multi. is often the method maintenance. These are based on high. turnaround which allow them to withstand severe lining construction and numerous other time and installation costs are the major environments with a maximum service monolithic constructions. installed. repairs need to be application areas are primarily chemical. at higher temperatures. breechings and a range in magnesia content from 60% to excellent slag resistance to acid to variety of other medium service areas. They are available in limit. Many castables. mixes which combine high fired alumina corundum. dead-burned magnesite Silica and Silicon Carbide similar applications. are normally predamped and fed cement binder gives excellent strength Other air-setting high-alumina mixes through a continuous dual chamber or and abrasion resistance coupled with employ stabilized. In both There are also gunning mixes system. dead-burned aggregate with a high strength. have a high purity calcium-aluminate ramming mixes can offer exceptionally cement bond. excellent coverage in a variety of a variety of silicon carbide levels and Phosphate-bonded. calcium-aluminate cement compositions Alumina-graphite ramming mixes are especially formulated for easy Basic Refractory Gunning Mixes designed for the steelmaking industry. purity magnesite and a sintering aid incinerators. high-alumina. They typically have good slag and High purity ramming mixes based on marked savings in time. alumina-chrome applications. corrosion resistance. have as wide a are designed for preheater buildups and volume stability up to their temperature water range as possible. without the use of forms and with a limit. In some industrial furnaces. Dense. providing a Alumina-silicon carbide ramming mixes monolithic linings can be gunned 3000°F (1650°C) service temperature are designed for non-ferrous industries. There are also fireclay gunning mixes phosphate bond. These have mixes are not predamped and are placed and low thermal conductivity. Ramming factors when choosing a refractory temperature of 3300°F (1820°C). for use in steel bonding phase. designed for high alkali applications Refractory Ramming Mixes Magnesite ramming mixtures of such as in cement kiln preheaters. These aggregate and slag inhibitors gives them process heaters. Gun base materials of silica. chrome ore. In other cases. The bond of this composition which provide exceptional refractori. ramming mixes offer a way of ferrous alloys. temperature set and a water insoluble extremely good resistance to acid to purpose hard-fired fireclay and standard bond at low temperatures. and chrome types. high magnesite. These A series of gun mixes are available for Their combination of high-alumina mixes are used in boilers. fireclay. Gunning mixes of this with high purity calcium-aluminate kind are designed to provide an even Basic Refractory Ramming Mixes bonding systems. neutral slags. Acid gun mixes and high purity calcium-aluminate spalling at high temperatures. These materials are particularly CR . 95% and are available with or without a slightly basic slags. mullite. SECTION 3 Properties of Refractories Physical Properties Room Temperature PR-2 Physical Properties Elevated Temperature PR-4 Changes in Dimension PR-5 Creep and Thermal Expansion PR-7 Heat Transmission PR-9 Spalling PR-11 Slag Reactions PR-12 Mineral Composition PR-13 . The systematic selection process starts with a careful evaluation of furnace operating conditions and performance demands. the methods used in their determination and their relationship to service conditions.e.PROPERTIES OF REFRACTORIES An understanding of the important properties of refractories is fundamental to the development.. i. Comparison of properties of used refractories against original properties often helps to identify wear mechanisms and actual operating conditions. metals and slags and provide thermal protection and mechanical stability to safeguard the furnace. Post-mortem analyses of the properties of refractories taken from service are useful in improving both refractory and furnace operating performance. quality control and selection of refractory linings for high temperature processes. improvement. Quality control and manufacturing engineers use property determinations throughout the manufacturing process to assure that products meet defined standards for the brand. Evaluation of refractory properties is also vital to the manufacture of superior refractory products. Refractory properties are equally important to the work of refractory research engineers who use them as product design criteria in the development of new and improved refractories.1 . Harbison-Walker PR . While properties of refractories alone cannot be used to predict lining performance. comparisons among properties of refractories are often used as screening tools by refractory engineers and users to select and upgrade refractory linings. the degree to which refractories must contain corrosive process atmospheres. Matching refractory lining requirements to service demands typically proceeds with a review of the hot physical and chemical properties of the lining materials under consideration. This section discusses important room temperature and hot properties of refractories. including operational upsets. 2 Harbison-Walker . other oxides. Hence. porosity and thought to be unimportant are now Table 3. is a measure porosity. This is temperature strength is an important analysis of a refractory alone does not particularly important in applications indicator of its ability to withstand permit evaluation of such properties as such as regenerator installations.1 shows typical has an effect upon its ability to resist temperatures may provide little or no chemical analyses for common industrial penetration by metals. The density of refractories is an compress but may be broken quite may differ widely in their behavior under indirect measurement of their heat readily in tension. silica). creep be low to obtain best performance behavior. moisture analysis to control of quality are: the will contain a small amount of SiO2 as a content at the time of pressing. the less the cannot be readily determined. Closed porosity refers to tures where the glassy phase may constitute the most serious impurity or porosity within the coarser grains. A product’s room the same furnace conditions. the higher the porosity.1b. CaO. true porosity represents a tures will typically exhibit significantly Of the three types shown in Table 3. Fe2O3. the shown in Table 3. category. dimensional changes of silica brick is an exception. accessory and. characteristics. with SiO2. Important properties determined at better.1c are essentially single- strengths of fired products are influ. oxide levels in chrome ores. recognized as controlling factors in the component systems. occurring zirconium silicate and is type and quality of the raw materials. particularly in the basic refractory. Bulk density is fireclay or 50% alumina product may refractory material may not be the most usually expressed in pounds per cubic contain glassy material in the bonding important selection criterion. pressure of determination of iron oxide and alkali result of oxidation during manufacture. the alumina and carbon brick are special refractories not The mechanical strength of refractory alkali content of silica refractories. brick is governed largely by the ground. alkalies closed pores. bulk density. Relatively few consist of and. in general. high-alumina. Table 3. However. This glassy material is difficult to almost identical chemical composition (kg/m3). generally. and Al2O3 are are chemical composition. operating temperatures. For example. and MgO. Other important properties spalling. a The chemical composition of a volume it occupies. However. Important properties of refractories For the basic refractories listed in which can be determined most readily Chemical Composition Table 3. the carbon Bulk Density (ASTM C134) At ambient temperatures. Minor components once The special refractory brick listed in refractories. For example. pressing. temperature and duration of firing. the compres. hot crushing strength. Another important applica. available differ considerably in chemical refractory.1a sample’s total porosity. serves as a basis for classification of products. Cr2O3. refractoriness under load. thus explaining many process. In contrast to apparent has good strength at ambient tempera. Chemical composition serves as a basis considered the primary refractory apparent porosity. permeability and pore size the various brands commercially of the open or interconnected pores in a distribution. The lime (CaO) content spalling resistance. (fireclay. referred to as open porosity. basic tures. are rather complex chemically. guide to their chemical properties and the accessory oxides. Silicon carbide size and “fit” of the particles. and the boron oxide The bulk density is a measure of the sive strength is typically much higher level in magnesites. MgO. These properties are often among refractories. The density.PROPERTIES OF REFRACTORIES PROPERTIES OF PHYSICAL PROPERTIES — and actually improves service perfor- REFRACTORIES ROOM TEMPERATURE mance. both open and reduced strength at elevated tempera. It is and thermal conductivity. slags and fluxes indication of their strength at furnace refractories. Chemical capacity or ability to store heat. refractories often have a spinel mineral those which are used as controls in the tion of chemical analysis. ratio of the weight of a refractory to the than the tensile strength. Among these are performance of many refractories. Fe2O3 and CaO gravity and strength at ambient tempera. the Among the applications of chemical refractory in that form. The apparent porosity. abrasion and impact in low temperature volume stability at high temperatures or applications and to withstand handling ability to withstand stresses. Zircon is naturally- enced by many factors. such as true porosity may be difficult to mea- elevated temperatures are hot modulus TiO2.1c. deliberately added during manufacture PR . slagging or Apparent Porosity (ASTM C830) and shipping. sometimes determined at ambient temperatures are In any given class of refractory brick. which become quite soft or even fluid. as related to structure which is tolerant of consider- manufacturing and quality control refractories. content of graphite. the alumina Alumina-carbon and magnesia- kiln atmosphere and the rate of cooling. a more than 90% of any single component the greater the insulating effect of the fireclay or 50% alumina material that and some. The chemical composition of both raw materials and finished of the high totals in the “others” column. porosity. The porosity of a refractory The strength of brick at ambient composition. as brick of foot (pcf) or kilograms per cubic meter phase. of rupture. chromic oxide content and accessory mass material between the larger grains. is in the control of quality able iron content. content of bauxites. should also sure. contents of some clays. apparent specific for classification of refractories and as a components. 0 0.1a Refractory Brick of the Alumina-Silica Types temperature. or where charge material Fireclay contacts refractory surfaces at lower Superduty 41.7 4. The where: generally show the highest resistance to cold crushing strength (CCS) and cold S = cold crushing abrasion.6 2.4 0.4 18. TiO2.7% temperatures.04 3.1 24.5 applications.1 19. may machine (see Figure 3. (TiO2.3 . fired 36.6 Harbison-Walker PR .1 Chemical Analysis of Common Industrial Refractories resistance of a material to erosion when impacted by fine silicon carbide at room 3. The crushing material charged into the furnace. thermal 3.9 Strength is one of the most widely used 70% class 69.7 9.2 0. This test is particularly Alumina Silica Alkalies Others appropriate to applications in which (Al2O3) (SiO2) (Na2O. Corundum class 99.2 26.2 4.1 3.5 26.2 0.4 predict service performance.1 4.5 95. resistance to abrasion.6 – 90. Fe2O3.1).4 provide a good tool for evaluating the 3. fired 98.1 Strength testing at elevated tempera.8% 3.0 5.5 0. unfired 72. the modulus of rupture or by ASTM Method C133.9 0.1c Special Refractory Brick shock and mechanical loading. psi (N/mm2) properties. As compared with other modulus of rupture tests are described strength. The load is In many types of service.0 62.3 16.0 3. For greatest resistance to these actions.5 11.2% 1. Both tests have a The equation for calculating is: brick should be mechanically strong and version for cold (ambient) temperatures S = W/A well-bonded. or direct impingement by (transverse) breaking strength and the over the surface area of the face which abrasive dusts and high velocity gases.0 38.3 temperature or at any temperature for which suitable test equipment exists.8 22. a sample 41/2” x A = cross-sectional area.1% 3. The strongest brick and high (service) temperatures.5 of a material to survive stresses caused by restrained thermal expansion. Room temperature testing Magnesia Chromia Alumina Others Types of brick (MgO) (Cr2O3) (Al2O3) (SiO2.7 4.4 30.2% 3. lbf (N) crushing test offers the best indication of crushing strength test.4 32.2% – 0. but do Superduty 0.PROPERTIES OF REFRACTORIES Abrasion Resistance slags.2 Room temperature (cold) strength Silica measurements cannot be used directly to Conventional 0. It is also Types of brick (SiO2) (ZrO2) (SiC) Fe2O3) common to use high temperature strength numbers to predict resistance to Zircon 32. MgO) refractories. Chrome. crushing strength test measures the receives the load.2% 1.5 Strength can be measured at room 90% class 88. Impact Others and abrasion resistance depend on Silica Zirconia Carbide (Al2O3.3 36. fired 55. In the cold W = maximum load. particulate laden gas streams impinge on Types of brick Li2O) CaO.7% erosion and corrosion by metals and Silicon carbide 5. The modulus of rupture strength is calculated by dividing the abrasion by metallic or nonmetallic (MOR) test measures the flexural maximum load supported by the sample solids. High-duty 41. fired 18.8 tures is valuable in assessing the ability Chrome-magnesite.3% 66.0% – 1.2 0.1b Basic Brick degree of bond formation during production.2 0. unburned 31.6% damage and to withstand abrasion and Magnesite-chrome.3 Modulus of Rupture of Refractory High-Alumina Brick and Shapes (ASTM C133) 60% class 58.2 96.3 Cold Crushing Strength and Low-duty 30.9% 53.1 3. Fe2O3) also indicates the ability of brick to withstand handling and shipping without Magnesite.5 8.9 0. although other properties. 41/2” x 21/2” or 3” is loaded at a standard in2 (mm2) The abrasion test determines the Table 3. K2O. refractories are be of equal or greater importance. applied vertically to the 41/2” x 41/2” face subjected to impact by heavy pieces of Two types of strength tests are of the sample until failure.0 51.6 23.8 9.0 0.4 parameters for evaluating refractories. common.9 impact in relatively low-temperature Magnesite-chrome. such as rate using a suitable mechanical testing (ASTM C704) mineral composition and porosity. Chrome-magnesite.1 8. as well. material strength. 85% class 86. compressive strength. lbf (N) rapid temperature change within critical L = span between supports. in (mm) refractories are those which enable them cylinders with the top and bottom (9” x to withstand the conditions to which 41/2”) faces oriented horizontally. The sample. liquids and gases. Heat energy flows into the refractory structure when the furnace is heated and a temperature differential develops between the inside and outside surfaces.PROPERTIES OF REFRACTORIES The setup for the cold modulus of b = breadth or width of PHYSICAL PROPERTIES — rupture test is shown in Figure 3. chemical and various combinations the following equation: ries are given in Table 3.2. abrasive action and penetration and corrosion by solids.2.4 Harbison-Walker . again a standard nine-inch d = depth or thickness of The most significant properties of straight. fumes and gases • Resistance to spalling • Thermal conductivity Thermal Effects The one condition obviously common to all furnace operations is high tempera- ture. They may be in (mm) required to withstand varying loads. and sizing of the aggregate. is placed on two bearing sample. These conditions may be flexure at a standard loading rate. Variables of the three. they psi (N/mm2) must be resistant to the stress effects of P = load at rupture. PR . High temperature properties of refractories which are relevant to service conditions include the following: • Refractoriness • Melting behavior • Mechanical strength and load bearing capacity • Changes in dimensions when heated Figure 3. A closely related combination of other thermal effects results from high temperatures and from the rate of temperature change. mechanical erosion and impact of solids • Resistance to corrosion and erosion at high temperatures by solids. The refractories of the same classification. firing refractory to withstand the maximum where: temperature. porosity. temperature intervals. The Strength values vary widely among they are exposed in service at elevated specimen is broken at mid-span in classes of refractories and even among temperatures. Part of the heat energy is stored in the refractory structure and part flows through the walls and other parts of the furnace Figure 3. mechani- modulus of rupture is calculated using Typical values for a number of refracto. exposed in service. and the strength temperatures to which they will be MOR = modulus of rupture.1 Cold Crushing Strength Test • Resistance to abrasion. Frequently. in (mm) ELEVATED TEMPERATURE test specimen.2 Modulus of Rupture Test structure and is lost to the outside air through radiation and convection. liquids. cal. classified broadly as thermal. which significantly affect cold strength Refractories must be sufficiently MOR = 3PL/2bd2 of refractories are bond chemistry. Chrome-magnesite.000-7. Therefore. differences in the amount In the high temperature portions of a same time as the tip of the test cone is of thermal expansion in various sections furnace.000-10.000 600-1.000 2.3. fired 189-194 19-22 3.400 individual brick from the mold size to the 90% class 181-185 14-18 9.300-3.000 800-1. but magnesite-chrome 205-245 1-15 900-1. generally will be increased by bonding mortar. course of refractory brick which will not The PCE does not indicate a definite tory structure.000 3. Basic However.000 changes in service are objectionable due Zircon 225-232 19.000-8. Furnace a fixed rate until the test cones soften ture drop of many hundreds of degrees fumes.000 1. Excessive dimensional Silicon carbide 160-166 13-17 9.000-2.000-10.000-6. abbreviated PCE when they are cold due to “reversible material is adequate to meet the various (ASTM C24).000 permanent. The plaque is heated at or arch. Dolomite 165-192 5-20 1.000-9. PCE values of Table 3. However.000 700-1. A reheat test Harbison-Walker PR . rupture.000 1. changes in dimensions and Magnesite.500 maintained for a sufficient period of time.” With some refracto.000-8.500 be completed in the firing step to prevent Silica (superduty) 111-115 20-24 4. fired 175-179 17-22 4.000-11.300 refractory brick. additional volume change. these reactions. if the furnace unburned 200-205 – 4.000-6. or by a joint of non-reactive test is not a measurement. altering the 85% class 176-181 18-22 8.500 This is also referred to asPermanent High-Alumina Linear Change or PLC.500 gradually diminishes.000 600-800 temperature for completion.000 2. cone whose tip touches the plaque at the Consequently.300-3.500 500-2.000 expansion or shrinkage later in service. dissimilar chemical compositions may cones having known high temperature Within a single brick in a furnace wall react chemically with each other if in softening values.000 1. usually a furnace. It is desirable that the changes Corundum class 185-190 18-22 7. In a refrac.000-6.400 volume require time as well as Magnesite-chrome.000-8.500 1.800-2. Types of brick lb/ft3 porosity lb/in2 lb/in2 CHANGES IN DIMENSION Fireclay Permanent Reheat Change Superduty 144-148 11-14% 1. conditions prevailing in different parts of A ground sample of the material to be ries. and slags can accelerate and bend.000 2.600-2. The number of the standard between the hot face and the cold end. As firing Magnesite-chrome.5-23.5 . such as arch operation. the rate of dimensional change unburned 185-191 – 3. comparison of the thermal behavior of thermal expansion of the brickwork.300 contraction during the firing process. dust. results from mineral refractories may be employed in the cones and mounted in a ceramic plaque inversions and transformations and construction.000-13. alumina-silica and fireclay compositions fireclay products. In the firing of 60% class 156-160 12-16 7.500-2.500 temperature is high enough and Magnesite-carbon 170-192 9-13 – 1.PROPERTIES OF REFRACTORIES When refractories are hot their linear Reactions Between Refractories is the determination of their Pyrometric dimensions and volumes are greater than When no single kind of refractory Cone Equivalent.000-5. proceeds. permanent changes in 70% class 157-161 15-19 6.000 2.700-2. as well as in the within the refractories than they are high temperature softening behavior of manufacture and quality control of capable of withstanding.000 2.2 Physical Properties of Refractory Brick alumina-silica refractories are given in Table 3.000 (ASTM C113) High-duty 132-136 15-19 4.000-12. Cold crushing Modulus of Density. it is good practice to separate reported as the PCE value of the test of the brick will cause internal stresses reactive refractories by an intermediate cone.400 feasible to attain complete expansion or Chrome-magnesite.500-4.000 1. refractories of with a series of standard pyrometric sometimes from other causes.400 dimensions generally occur.300 to their potentially harmful effect on the stability of the furnace.000-14.600-3. but merely a stresses.5 7.400 6.000 fired size.500-3. fired 195-200 15-19 5. The Unequal volume changes resulting from Pyrometric Cone Equivalent test is used in evaluating the refractory rapid fluctuations in temperature may (ASTM C24) quality of clays and the softening cause the development of higher stresses A standard method of evaluating the temperature of slags. there is commonly a tempera.800-3.900-2. the sample to that of standard cones.200 Low-duty 130-136 10-25 2. generally slight.000 800-1. in service.500-3.000-6.5-19 5.500-3.000 2. Yet. fired 177-181 15. pressure inherent in the react with either at the temperature of melting point or fusion point because the furnace construction. two or more different kinds of tested is molded into the form of test not reversible. it is rarely Chrome.500-3.500 there can be an additional change in Fused cast dimensions. contact at high temperatures.000-5. Apparent strength. to develop within the brick. thermal expansion. PROPERTIES OF REFRACTORIES Table 3. however.5 31. with the top results should be interpreted with 80% alumina classes.0% to 2. 60% Alumina Class 35 36 to 37 70% Alumina Class 36 37 to 38 Linear Thermal Expansion 80% Alumina Class 37 39 In common with essentially all other 90% Alumina Class – 40-41 structural materials. refractories will Mullite Class* – 38 expand when heated and contract when Corundum Class* – 42 Minus cooled. If the lining is con- In reporting PCE values. brick are placed in a “reversible thermal expansion. varying from a few tenths of a Medium-Duty 29 29 to 31 percent or less for some types of brick. and (4) whether a composition Some fireclay brick expand slightly in the has adequate refractoriness and volume heated uniformly at a constant rate.3 Typical Pyrometric Cone Equivalents of Refractory Brick Minimum gravity provides an adequate measure of PCE Typical the amount of permanent or residual Types of brick ASTM C24 PCE expansion. the temperature of caution. cause lining instability. shock occurs when severe temperature Reheat Change gradients in a material cause internal High temperature reheat tests may be of Fired Refractories used to reveal (1) whether a refractory stresses due to differential thermal In the reheat test at 2550°F (1400°C). the expansion does movement of the sample may be detected stability.0% in length. ways to estimate refractoriness. return to their original dimensions when range of minus 0.” Typically. the temperature sufficient basis for predicting the long If no changes of a permanent nature of the test may be 3140°F (1725°C) and occur during heating. however.5%. The results of a Thermal Expansion of of the 90% alumina class. After cooling. High fired chrome- Semi-Silica – 27 to 31 magnesite brick usually have little or no shrinkage in the reheat test at 2910°F High-Alumina (1600°C) and a shrinkage of only some 50% Alumina Class 34 35 tenths of a percent at 3000°F (1650°C). cooled. superduty fireclay brick whether it is made of volume stable usually made by determining the change usually shrink 0.5% for others. must not be so much as to which may occur at high temperatures. others. In such cases. An understand- This permanent reheat or linear change measurements are made to determine ing of thermal expansion characteristics is in addition to the reversible linear changes in linear dimensions and is also important in assessing the thermal thermal expansion that all refractories volume. temperature for five hours. in length of a bar-shaped specimen materials. or (2) at a high The measurement of the linear slight (up to 1. The amount of expansion allowance. and mullite brick. the lining must be designed to allow some free expansion. expansion. determines the amount of permanent furnace. destructive forces may result as the but shows that the material has a position as to softening approximately midway between lining expands during furnace heat-up. but dilatometer. rod. For high-alumina brick of the 50% to located above the furnace.5 to 33 shrinkage. or (3) if not fired. the higher value. corundum Fired Refractories short term reheat test may not be a brick. much as 2. This characteristic is known as In the standard ASTM reheat test. an also on the temperature and time of expansion up to 3. Fireclay In the reheat test at 2910°F (1600°C). It is generally impractical to obtain the expansion behavior of refractory PCE values of high-alumina brick above the 50% or 60% alumina class. At thermal expansion of a refractory is enough temperature. to silica brick. the word “to” is used between two standard cone numbers to indicate that different lots of the given material have a range of softening from the lower to strained by the furnace structure. The reheat test is not usually applied Method C113. fired refractories term volume changes which a refractory the linear change is usually within the may undergo in service. as the amount of of the specimen by means of a sapphire the reheat is usually 2910°F (1600°C).0% to 1. composition of a given quality has been high-duty fireclay brick generally show a fired long enough. materials is often crucial in designing furnace linings. The by connecting an electrical transducer. Knowledge of the thermal * Estimated and shown for convenience. The reheat test.6 Harbison-Walker . Low-Duty 15 15 to 27 up to 2. A device of this type is known as a shrinkage or expansion depends not only Some brick show a linear shrinkage of as on the refractory’s characteristics. Superduty 33 33 to 34 most basic brick will show a slight linear High-Duty 31.5%. change in dimensions of refractory brick mined temperature and maintained at that however. 2910°F (1600°C). The tests may be used in these not occur if the brick are in compression. shock resistance of a material.5% or more. gradually heated to a predeter. A dash (-) between two standard cone numbers does not indicate a range. Thermal exhibit when they are heated or cooled. For brick heating during the test. as the apparent specific PR .5% to plus 1.5%) linear contraction. the two pyrometric cone values. SILIC N SEM ZIRCO 0.00 densification and the materials contract. two 9- refractories have intermediate values. The thermal expansions of other The thermal expansion characteristics at high temperatures.60 1/16 A FIR I. it is important to under- refractories are given in Figures 3.00 determined by the quality and amount of Mg O ) 1.3 and Unfired Refractories stand the load-bearing capabilities of 3.PROPERTIES OF REFRACTORIES ated with thermal decomposition of the TEMPERATURE – DEGREES CENTIGRADE 0 100 200 300 400 500 600 700 800 900 1100 1300 1500 cement. fireclay.6. Notable age over the temperature range 400°F to dard procedure.7 . zircon brick. and most in bonding structure. at its minimum. mineralogical changes 0 100 200 300 400 500 600 700 800 900 1100 1300 1500 1/4 among the clay constituents result in 2. tures below their firing temperature show 800°F (about 425°C).20 Under Load HIGH-DUTY AND SUPERDUTY FIRECLAY 0 0 In service. an unfired material as a result of changes The standard laboratory tests for silicon-carbide.20 A determined by the characteristics of the 1/8 INA MIN ALU A 1. and sintering effects.20 (NOT PATCH) 1/8 Y SILICA SUPE RDUT 1. The expansions of different brands in In general. The linear thermal expan. inch straight brick are set on end in a most fired refractories. (ASTM C16).4 Approximate Reversible Thermal Expansion of Brick the reference point. At about 1900°F TEMPERATURE – DEGREES CENTIGRADE (1040°C). for applications in which the this behavior.6% LINEAR EXPANSION – INCHES PER FOOT 3/16 1. At temperatures above 1800°F to % 92 2000°F (980°C to 1090°C).5%. the thermal expansion candidate materials.40 The underlying thermal expansion is CONVENTIONAL SILICA 1.60 3/16 ES ITE LINEAR EXPANSION – PER CENT GN ST ER shrinkage occurs as a result of sintering. is TEMPERATURE – DEGREES FAHRENHEIT equal to the weight of the lining above FIGURE 3. 1. the exceptions are silica brick which undergo 600°F (205°C to 315°C) which is associ. MA R FO 1. and the data there.40 commonly are on the order of 0. these FIGURE 3.80 cement. dramatic refractories are heated relatively and forsterite brick have relatively high expansions or contractions may occur in uniformly to high temperatures. temperature is gradually raised in Harbison-Walker PR . In the stan- working range of temperature. entire lining component is at high sion characteristics of a number of fired Thermal Expansion of temperatures. Examples of such each class of refractory differ somewhat behaviors of unfired refractories are more applications include blast furnace stoves among themselves. refractory materials must 0 200 400 600 800 1200 1600 2000 2400 2800 support a load which.2% to 0. the greater part of their expansion below lining and the density of the material.5. however. These materials show shrink. The shrinkages which take A LUM 9 0% L U MIN O A 99% 80% T TO 70% 60% 0.80 EXPANSION UNDER LOAD Y ECLA 0. additional LINEAR EXPANSION – INCHES PER FOOT ITE( 1.80 Permanent shrinkages of 0. thermal expansion ries during initial heat-up are shown in furnace of specified design and a vertical increases at a fairly uniform rate over the Figure 3. nation of the behavior of brick under load rates.40 (1430°C). rates of thermal expansion.40 Changes in Dimensions 0.00 aggregate. Magnesite parts.60 are common after initial heating to 2600°F LINEAR EXPANSION – PER CENT SUPERDUTY SILICA 1.4. Therefore. load of 25 lb/in2 is applied. 1. and carbon bake furnaces in which the fore represent mean values. The pressure which is exerted depends on the height of the refractories that are heated to tempera. changes in refractories include one for the determi- insulating firebrick have relatively low minerology. complex than those of their fired counter. For of a number of cement-bonded refracto. During initial heating. The amount of shrinkage is 1/4 2.00 CREEP AND THERMAL E CHR OM 0.2% to ON C SILIC 0. Typically.20 1. In this test. 0 0 The thermal expansion curves for 0 200 400 600 800 1200 1600 2000 2400 2800 initial heat-up of several phosphate- TEMPERATURE – DEGREES FAHRENHEIT bonded plastics and clay-bonded plastics are shown in Figure 3.80 place during initial heat-up to 2600°F 0.60 (1430°C) are permanent in nature and 1/16 ARB IDE 0.3 Approximate Reversible Thermal Expansion of Brick materials show linear behavior below about 1900°F (1040°C). For most classes behavior is characterized by the amount brick. the temperature and expansion at this point characterize FIGURE 3. after which failure occurs abruptly rather then showing gradual 0. upper portion of Table 3.5 Thermal Expansion of Various Refractory Castables test. At very high-temperature strength of certain results are reported as “withstands load high temperatures. called steady state.20 subsidence over time as with fireclay 0 and high-alumina brick.20 dure.00 CASTABLE the preferred test is the ASTM method -1.4. basic. 3200°F (1760°C). The temperature of the sample is then held accordance with a definitely prescribed especially checker brick.20 measuring 11/2” x 11/2” x 41/2”. after which the furnace is of testing is 2640°F (1450°C).60 Load testing provides very significant LOW CEMENT data relative to maximum service -0. for The lower portion of Table 3. primary creep. the maximum temperature is held of high-alumina brick the top temperature of subsidence which occurs between the for 1½ hours. In the first stage. 1. to” rather “subsidence after heating to. allowed to cool by radiation to 1830°F the 90% alumina class and mullite and Like most structural materials. ASTM method C832. In the standard proce- PLASTIC 0.40 0 400 800 1200 1600 2000 2400 2800 3200 C832).8 Harbison-Walker . and “creep” during 0.” the test is more sophisti- cated than the conventional ASTM load FIGURE 3. the sample reaches a 0 400 800 1200 1600 2000 2400 2800 3200 point of peak expansion. a constant 0.” sometimes followed by a tertiary creep PR . secondary stage.00 0 vertical load.60 a constant rate. steady state creep is types of high-duty fireclay brick. and silicon. recent improvements in the carbide brick. results for silica.6 Thermal Expansion of Various Refractory Plastics the thermal expansion under load. -0. Test procedures 0.640°F.40 -1/16 failure occurs. is applied 70% MULLITE PLASTIC to the 11/2” x 11/2” faces of a specimen -0. it provides a continuous monitoring of this sample’s dimensional changes during the test. Most The amount of subsidence is reported Results of such testing on fireclay and refractories show two characteristic as percentage of the original length. Rather than measuring the subsid- ence of a sample after testing. usually 25 psi. For fireclay and high-alumina being tested at 2. the rate of subsidence duty fireclay brick is 2460°F (1350°C). 2640°F (1450°C). It will be seen that test rate of subsidence is constant.00 are different for those brick which are -0. They typically maintain their FIRECLAY CASTABLE 0.40 -1/16 heating to the prescribed temperature at -0. called the TEMPERATURE F maximum dilation point.60 under load (TEUL) for the heating 1/16 SUPERDUTY portion of the test. In the superduty fireclay brick. The high-alumina brick are shown in the stages of creep.40 FIRECLAY the hold portion.20 simply heated on a rising curve until -0.20 for measuring the thermal expansion and creep of refractories under load (ASTM -1. exposed to high temperatures.40 reached. (1000°C) or lower before the load is corundum brick it is 2900°F (1595°C) and refractories show creep behavior when removed.80 90% ALUMINA stress.00 The properties measured during this LINEAR EXPANSIONÐPER CENT 0. -1. More recently.80 FIRECLAY -1/8 temperatures in the field. have led to their for 50 hours or longer.80 test are known as thermal expansion 90% ALUMINA PLASTIC 0. the However.PROPERTIES OF REFRACTORIES This reflects a marked difference in the 1. Commonly referred to as a TEMPERATURE F “creep test. and the creep schedule. called normal temperature of the hold for high.60 integrity until a particular temperature is CASTABLE LINEAR EXPANSION-PERCENT 1/16 0.00 way the latter types behave under the combined forces of heat and mechanical 0. After -0.4 show declines gradually with time. for those of 20th and 50th hours. Measured thermal conductivites of various refractories are High-Alumina given in Table 3. of refractories.4 Typical Results of Load Test as Indicated by 25 lb/in2 Load Testing involved in the construction. Within the Magnesite-Chrome.0% subsidence after heating at 2640°F tures. thermal glass it may contain. either by an increase secondary creep can occur over a long in the amount of glass or liquid it term. In most types of vessels. and is lost to the outside air by desirable for heat conservation. approximately for several reasons: also affect creep behavior with larger tivity. For materials which have similar mineralogical compositions.0% subsidence after heating at 2640°F conductivity of a refractory material are 85% Class 0. surfaces of walls and roofs.5. fired Withstands load to 2800°F with increasing porosity. The conductivity of a refractory failure or creep rupture. as in retorts. or K-value.0% subsidence after heating at 2900°F which it contains. temperature range seen in most applica- unburned Withstands load to 2950°F tions. roofs. alumina refractories is illustrated by thermal energy is stored in the refractory byproduct coke oven walls and Figure 3. and part recuperators. Important hearths. the amount of 90% Class 0.0-3. However. the thermal fired Withstands load to 3020°F conductivity of glass is considerably Chrome-Magnesite. but is variables which affect creep behavior are radiation and convection. in Conversion Factor: °C = (°F . low thermal conductivity is based only on their chemistry. predict. while HEAT TRANSMISSION changed somewhat. but usually also for Fireclay the same material at different tempera- Superduty 1.9 . the conductivity of glasses tends to increase.4-1.PROPERTIES OF REFRACTORIES TABLE 3. muffles. region where the rate of subsidence aggregate and lower porosity giving the temperature effects are difficult to accelerates and leads to catastrophic better creep resistance. The creep behavior at develop between inside and outside requiring efficent transfer of heat 2600°F (1430°C) of a series of fired high. behaviors of brick cannot be predicted flows through the walls. use is made of a constructions can be calculated only behavior.0-0. lower than that of crystalline material of unburned Withstands load to 3020°F the same composition.8% subsidence after heating at 2900°F material tends to decrease. Aggregate sizing and porosity coefficent known as the thermal conduc. The thermal conductivity is High-duty Withstands load to <2640°F reported at the mean temperature of the Low-duty Withstands load to <2640°F test brick.1-0. amount of heat which will flow through fired Withstands load to 2700°F it at a given temperature. causing a temperature difference to for refractories used in constructions described above. secondary creep usually Thermal Conductivity contains. Part of this through brickwork. the Basic proportion of pore space is questionably Magnesite. The thermal conductivity value differs not only for Type of brick Results of load testing different materials. High thermal conductivity is desirable parameter determined by the method ture.5% subsidence after heating at 2640°F Major factors which affect the thermal 70% Class 0. At ambient temperatures. It is obvious that the creep structure and its foundation.1-0. whereas well-formed the quantities of heat flowing through The rate of heat flow in refractory crystalline bond phases give good creep the parts of a furnace. 60% Class 0. firing temperature. Therefore.2-0. while that of crystalline Zircon 0. and however.1-1. or by devitrification of any provides a more meaningful comparison When a furnace is heated.8 refractory bodies consisting of crystal aggregates with limited amount of glass. of each material Harbison-Walker PR . Formation of low often of considerable importance in the viscosity glassy phases results in poor economy of the process. With rising Silicon Carbide Withstands load to 2800°F temperatures. fired Withstands load to 3200°F the most important factor affecting the Magnesite-Chrome. In estimating Heat Flow creep behavior. Primary creep is in service at high temperature is often generally short in duration. its porosity and its Silica (superduty) Withstands load to 3060°F temperature. The amount of usually less important than other proper- chemistry of the bonding phase and heat which escapes in this manner is ties of the refractories. Chrome-Magnesite.4% subsidence after heating at 3200°F amorphous material (glass or liquid) Corundum Class 0.8% subsidence after heating at 2640°F the mineral composition. Secondary creep is the energy flows into the refractory struc.7.32)/1. thermal conductivity decreases Chrome. 3 14.5 11.6 17.9 18. SUBSIDENCE–PER -1 • The conductivity of a refratory -2 may be altered in service by -3 mineral changes in the refractory.) transmit more heat. Most protective atmospheres. 85% Cclass 18.0 97.9 Effects of Gases Chrome-Magnesite.9 17.9 character of the bonding mortar. 90% Class 21.6 22.2 16.4 16.6 22.5 8.2 15.4 16.5 19.1 13.8 9.2 external convection currents.3 12.8 Corundum Class 34.5 13. • The rate of heat flow is influenced by the pressure of the furnace Table 3.6 16.1 14.3 14.9 18.7 9.7 14.8 into the furnace.3 of gases within the furnace.5 32.9 if used.5 12.5 103.0 Chrome.5 16.9 15.9 This is especially true of atmospheres with a high content of hydrogen.6 14.3 8. or it may become thicker and transmit less FIGURE 3.0 100.7 16. LINEAR -5 85% Alumina or by absorption of slags. kilns).0 107.0 15.2 10.1 8.2 10.2 14.9 36.4 12.7 lining components and by the 70% Class 15.6 sphere can have a very appreciable effect on heat loss through the refractory walls.0 106. Magnesite-Chrome. -7 50% Alumina • The thickness of a furnace lining -8 may not remain constant during -9 operation. A positive Mean Temperature.5 17.7 16.1 31.1 refractory linings include the emissivity Basic of the refractory or metal shell.0 115.4 14.0 ing firebrick or other very porous refractories.PROPERTIES OF REFRACTORIES • The accuracy of the methods used 5 to measure thermal conductivity 4 is unconfirmed.7 Creep measurement of various high-alumina refractories heat because of the formation of a under 25 psi load at 2600°F for 0-100 hrs.5 16.2 43. Zircon 22. LINEAR -4 70% Alumina by vitrification of the refractory.0 94.0 90.7 14.4 17. fired 11. 3 • The temperatures of the hotter 2 and cooler faces of the refractory CENT% 1 wall or roof are rarely known SUBSIDENCE 60% Alumina–Low Alkali 0 with exactness.5 14.2 14.6 In refractory structures built of insulat- Magnesite-Carbon 150.10 Harbison-Walker .7 17.3 Other important factors which affect the amount of heat flowing through Silica (superduty) 9.9 10.8 17.4 14.7 18.0 10.8 12.1 15.9 13. fired 73. High-duty 8.0 95. unburned 18.2 15.6 14.8 13.6 16. The lining may become -10 thinner because of wear and 0 10 20 30 40 50 60 70 80 90 100 TIME (Hrs. while a Types of brick 600 1200 1500 1800 2200 2600 negative pressure tends to draw Fireclay cold air from the surroundings Superduty 9.3 12. the type of furnace atmo- Silicon Carbide 121. exothermic PR .0 11.0 12. Btu • in/ft3 • hr • °F of the refractory. Note the excellent solid coating (as in rotary cement creep resistance of 60% alumina low alkali brick.9 18.5 K-Values for Refractory Brick at gases and by the permeability Various Mean Temperatures.0 • The rate of heat flow may be influenced by the thickness of High-Alumina the joints and gaps between 60% Class 13. and the Magnesite-Chrome. includ- ing dissociated ammonia. °F pressure tends to force hot gases out through the walls.6 20.1 11.5 13. fired 15. the kind Magnesite.2 112.4 12. metals -6 or other materials.6 17. fired 17.7 30. or pinching of hot ends of is almost directly proportional to the amount and character of the glass are brick. Thermal Spalling average density. The differential In various types of furnace operation. inadequate provision for thermal increase will be less and the relationship the size and “fit” of the particles. other conditions being equal. the presence of having the highest thermal conductivi. temperature. With in this context. Shattering or spalling of would be two to two and one-half times brick are generally dependent upon the brickwork may result from such influ- as great as in an atmosphere of air. changes which occur in service to the stresses resulting from unequal rates of Most silica brick are sensitive to rapid texture and composition of the hotter expansion or contraction between temperature changes at low temperatures portions of the brick through the action different parts of the brick and is usually due to the abrupt volume changes of heat. at of the brick expand more than the cold SPALLING temperatures high enough to cause the ends. resistant to spalling. contain having the lowest average rate of thermal rapidly as long as they remain above the appreciable percentages of hydrogen. brick are designed to generate a differential changes in the structure of furnace. excellent resistance to spalling. with proper choice of The thermal conductivity of hydrogen gradients and stresses which cause raw materials. pressure is known as mechanical or other refractory with similar porosity The spalling characteristics of fireclay spalling. silica These alterations may result in zones in resistance to thermal spalling are those brick may be heated or cooled quite the brick which differ in mineral content Harbison-Walker PR . while dense and hard ture gradient through a roof arch and inhibitors. A refractory of a given mineral refractory product increases the rate of composition will usually have maximum Mechanical Spalling heat flow through the refractory. the time and temperature of firing. basic brick with improved is approximately seven times as great as spalling are least destructive in brick thermal shock resistance can be manu- that of air. fireclay brick can be highly structure cannot rapidly adjust to the structure through cracking and rupture. However. hard-burned brick. high tensile strength and a inversion temperature of about 1200°F The conductivity of the hydrogen must texture conducive to flexibility and relief (650°C). fixed by the quantity and kind of which are strongest and toughest at As compared with the conductivity of accessory minerals in the clays and by operating temperatures have the greatest air. a high glass content is sprung brick arches because the hot ends conducive to spalling. the absorption of slags or fluxes associated with rapid changes in associated with the crystalline inversion and their reactions with the refractory. have high resistance to spalling tends to somewhat reduce pinch spalling. The spalling than denser. that of nitrogen is 100 percent. For a given refractory. spalling as fireclay and high-alumina treating furnaces. Structural Spalling control. The word “structural”. At amount of free silica present in the clays. shapes. In many caused by stresses resulting from construction. optimum sizing of grains. and operation of the cases. and endothermic gases. mechanical and structural. heat. as used Spalling of refractory bodies can be enhance their spalling resistance. However. be taken into consideration in calculating of stress. sion through narrow temperature ranges. ences as the rapid drying of wet brick- lower concentrations of hydrogen. higher furnace or the furnace lining assembly. Relatively porous. average porosity Contributing to structural spalling are This type of spalling is caused by compositions. density. carbon dioxide about 59 percent.PROPERTIES OF REFRACTORIES gases. bearing surfaces at the inner ends of the resistance of refractory brick to spalling Superduty fireclay brick of the spall brick. the strength to the modulus of elasticity is a by stresses resulting from impact or heat flow through an insulating firebrick maximum. does not refer to the divided into three general types: thermal. Consequently. The expansion. expansion forces. These compositions also do Burned basic brick. proper design of the brick burned. With an resistance to spalling when the ratio of The spalling of refractory brick caused atmosphere of 100 percent hydrogen. factured. Insulation decreases the tempera- is enhanced by the addition of spall resistant variety. the glass is rigid. do not the heat losses through the refractory not show a high rate of thermal expan. temperature brick. and Within the temperature range at which “Pinch spalling” is often observed in carbon monoxide about 97 percent. Brick percentage of hydrogen present. hydrogen gas in the pores of a porous ties.11 . especially in furnace arches. expansion. lower porosity compositions but to the texture or structure of the tend to have poorer spall resistance than individual brick units in the lining. Brick with the greatest of the mineral cristobalite. light-duty fireclay expansion may cause a concentration of service conditions necessarily expose the brick are usually more resistant to arch stresses upon relatively small brickwork to spalling influences. spalling Some high-alumina brick also have Structural spalling of a refractory unit is can also be minimized by proper design. in general. Other factors being equal. proper and retain this resistance upon exposure choice of grains and close manufacturing to high temperatures. resistance to mechanical spalling. This condition is aggravated by Spalling is the loss of fragments or spalls glassy bond to become somewhat rapid heating because the furnace from the face of a refractory brick or viscous. have as high a resistance to thermal walls of controlled atmosphere. However. the the composition of the glassy bond and work. system of stress-relieving microcracks to the unit. not having be preferred if the flux is only slightly been fired prior to installation. gradient slag test. rotary slag agents which have been absorbed. A chemical refractory compositions to spalling. High-alumina refractories may Monolithic refractories. at least typically give the best service. and fluxes high in silica are acidic. spalling. drip the molten slag. reaction rates and formation of brick. most metallurgical slags and metallic oxides are basic. resistant to thermal spalling than are chrome or a blend of these two materials their fired-brick counterparts. various slag of a refractory lining in service and tests have been developed. are more basic. An example is the washing be the actual material provided by the away of refractory grains after the bond customer or a synthetic material pre- between grains has been dissolved by pared to be chemically similar to the slag fluxing agents in the slag. For highly basic slags. If the ratio is less than 1. monolithic refractories protective glazes and coatings on the may be more subject to mechanical refractory surfaces. in the slag is commonly examined. or metal chemistry typical of the The composition of industrial slags. however. the ratio of lime-to-silica from the unaltered portions of the brick. magnesia. The slag used in the tests may corrosion. refractory and fluxing slag test. Slag Tests Spalling Tests In many industrial applications. the Several tests are commonly used to refractory is in contact with a slag or determine the relative resistance of metal during service. refractory and the slag or metal. Among the reactions which can take place between most common are the cup slag test. Some the prism spalling test and the loss of reaction products can be extremely strength test. detrimental to brick service life while other reactions result in little or no change in service life. including 1. the refractories which they contact in service. increased sensitivity to rapid temperature Fireclay. is acidic. and of the reaction products derived from them are exceedingly complex. The most advantageous selection of refractories frequently is governed by the chemical nature of fluxing agents present in the furnace. In order to SLAG REACTIONS determine the relative resistance of a Slag attack refers to chemical reactions refractory to the slag or metal present in and solutions which corrode the surface an industrial application. Alkaline materials are highly basic. the slag is usually considered to be differences in thermal expansion or basic. test. As a Following the development of a zoned general rule. based on operating and reaction tempera- Being lower in strength than fired tures. Excep- until they have become vitrified or tions to these general principles are slagged in service.PROPERTIES OF REFRACTORIES and chemical and physical properties acidic or basic.12 Harbison-Walker . high-alumina or silica brick are changes or the presence of shrinkage or generally used where the corrosive agent expansion cracks. dip and spin tests and aluminum Erosion of the refractory often follows boat test. if the CaO/SiO2 ratio (or CaO structure. The reaction often results between the most common are the panel spalling test. To determine whether a particular slag is PR . of customer’s operation. hot ends of the brick may spall + MgO/SiO2 + Al2O3 ratio) is greater than or fall off for various reasons. the slag is contraction between adjacent zones. considered to be acidic. physical properties of the fired refrac- brick and later given a ceramic bond by line structure. all refractory composition may vary continuously have very important effects upon the products which have been molded into over rather wide limits. largely state is likewise gradual and continuous. In the case of brick again assume the crystalline form. forming a have a diameter of ¼ inch or more. in Theoretically. the change from the constituents of a refractory which heated to high temperatures. The Ceramic Bond of Brick compositions.” changes described above in this glass. the viscosity has become so great that intentially added. especially at interfaces (2MgO•SiO2) and liquid. this rises above the temperature of dissocia. With rise in temperature. At room temperature. In the character of the minerals. The strength of the ceramic bond is particles bonded by glass or by smaller sively heated. and it has no specific tory brick. Alkali-silicate melts high in silica are forms of silica. the fines generally for the transport of material which it melts incongruently at 2835oF (1557oC) form a more or less vitrified ground. devitrification is an essential attribute tion of a strong ceramic bond between A mineral having a true or congruent to commercial glass compositions. After having been solution and thereby increases in amount. small amount of liquid can be expected completely liquid condition at a definite The coarser particles in some cases to form in the groundmass at a tempera- temperature. and for the formation and to form a mixture of forsterite mass. some of the solidify with an amorphous forming bond. which bonds together the growth of crystals. A temperature for a considerable length of diaspore dissociate. particles in contact. a glass is not a role in the development of the bond. When cooled slowly. When the temperature particles which will pass a 200-mesh occur. a change from a completely solid to a through intermediate to very fine sizes. the change from the dependent upon the character of the crystalline mineral particles. time before any crystals are formed. When a glass is progres. and will causing adjacent particles to adhere. line condition or “devitrify” if kept for about 1. As an example.5 percent of lime is A mineral may be defined as a a sufficient time within a critical added for bonding. pores. it lacks crystal. This type of melting point when heated will pass bonding is common in basic brick completely from the crystalline condi. the solid material dissolves percent of the total. particles of larger size. mixtures of particles of refractory the original heat treatment. proportions which depend upon the solid at all. a liquid phase develops. which may be regarded as the that at which complete fusion would liquid phase. fired.13 . or which varies Others must be maintained at a critical occurs. When a temperature of firing. and quartz is mineral usually has a definite crystal. Unfired or “green” brick consist of paragraph may have already occurred in A mineral is said to have an incongru. The ture some hundreds of degrees below different solid crystalline phase and a fines. the liquid may treatment is known as a “ceramic or dead-burned materials. the bond is formed by ties of a refractory at any given tem.” with a portion of the refractory. the borders of the larger particles The liquid becomes a medium suitable the mineral clino-enstatite (MgO•SiO2) are usually distinct. gradually in the liquid. During the firing of refractory brick. This immunity to the solid state. The physical proper. either definite in chemical composition lize even with very rapid cooling. as in the fluid state to the apparently solid occur in only small amounts (the so service. ent melting point when it does not material which usually vary from coarse In the firing of refractory brick. Its chemical its degree of adherence to the particles. often amount to as much as 30 liquid takes other materials present into tion. consist of crystalline mineral melting point. When such a brick is again molten glass is cooled. The character between liquid and solid particles. resulting in the forma- mineral. solid-state tion to the liquid state at a definite One of the most important purposes reactions are believed to have less temperature. mineral dissociation or transformation and physical properties. and Minerals and Glasses material in several respects. the for which brick are fired is to give them influence upon the bonding of silica- liquid formed will solidify or freeze at permanent mechanical strength. They apparently solid state to the fluid state brick mix as well as upon the time and contain a significant volume of small is gradual and continuous.PROPERTIES OF REFRACTORIES MINERAL COMPOSITION A glass differs from a crystalline and continuity of this groundmass.8 to 3. such minerals as kaolinite or in these respects within fixed limits. but dissociates. The bond developed by the heat molded wholly or in part from calcined With rapid cooling. and A glass will change into the crystal. by alumina brick than does the formation the same definite temperature. firing. transformed wholly or in part into other line structure. called impurities) play an important from the groundmass materials. at least. but is an under cooled liquid With some types of refractories small composition of the refractory and upon which has stiffened as it cooled. the body conforms to the generally chemical reaction of the material added perature are fixed by the amount and accepted concept of a “solid. screen. dissolves. Some melts crystal. of a liquid phase. Opal is an example of such a readily upon cooling. Harbison-Walker PR . Crystal growth and tively common minerals are amorphous extremely viscous and do not crystallize chemical reactions may occur also in in nature. until amounts of reactive materials are the temperature. In many cases. natural inorganic substance which is temperature range. although a few compara. However. manufacture of silica brick for example. glass. liquid of which it is composed. Aramaki and Roy revised the ing more than about 74. equilibria between the solids and the major nature have been made in the The brick mass is bonded together liquids formed by melting have engaged high-alumina side of the diagram. and by interlacing of crystals. and thus bonding groundmass will depend upon depend upon both the relative amounts conclusions based upon the earlier its composition. called “Phase Diagrams to change a little with rising without deformation. in “metastable. The alumina general. and 1987. The new diagram is in crystalline. Mineral Industries of The Pennsylvania about 2903oF (1595oC). century. obviously cannot Institution and by the College of is in equilibrium with silica up to interlace. a more aluminous. they have which the specimens were heated in limited stability. For a brick to equilibrium diagrams. Expanded volumes (4) There is a eutectic between refractory crystalline material.8 percent alumina. it contains changes in the body. 28.2 percent SiO2) periclase(MgO).” that is. an interpretation of has a true melting point of about incorporation in the brick mixes of diagrams. or both. or the viscosity of under the auspices of the American (1595oC). it may react chemically with the scale equilibrium diagrams of important cal 71. At this finely ground materials which affect glossary of terms. revisions of a formation of crystals. accelerate solid-state reactions. glass and transform it into highly ternary systems. “Phase Diagrams for content of the mullite at 3345oF fired under conditions which are Ceramists. can be prepared. The melting behavior of tions are not materially altered by this formation of glass. crystals having a Those published by the staff of the composition 3Al2O3• 2SiO2 (71.14 Harbison-Walker . sealed platinum-rhodium containers to PR . alumina.8 percent. The added bibliography. in Ceramic Society. for the with corundum. Their results are glass.4 percent operating temperatures. 1975. the such mixtures and the nature of the later work. than 71. published mullite forms solid solutions change which reduces the amount of by Bowen and Greig in 1924. experimental methods. Accordingly. and a selected temperature. it may were published by the ACS in 1964. or it Alumina-Silica System (5) In compositions containing more may cause improvement merely by The equilibrium diagram for mix. like those of mullite. becoming slightly the glass must be high. it may cause or alumina. including an explanation of ently as formerly believed. The tempera. instead of the theoreti- ways. A compilation of alumina-silica liquids was found withstand pressure at high temperatures these diagrams. like Geophysical Laboratory of the Carnegie percent Al2O3. Significant features of the new power of the glass. have contributed much mullite which occurs in fireclay glass will usually have high strength in fundamental information to the ceramic refractories therefore has the the cold condition. have appeared in scientific literature. the American approximately 73. the brick may deform form of drawings known as phase equilibrium with siliceous readily under pressure. Incorporated (ASC). molecular alumina: silica ratio of 3:2. by adherence of Since the early years of the twentieth diagram are the following: particles. However. 1959. close agreement with the older one up glass and crystalline material in the tures at which melting is complete to 55 percent alumina. the liquid formed at Equilibrium Diagrams prevent losses due to exposure to the high temperatures may become a rigid Melting of mixtures of two or more furnace atmosphere.1 percent. a 3362oF (1850oC). glass or liquid in the refractory would first time gave a clear picture of the solid solution mullites containing usually be more beneficial in service equilibrium conditions in alumina-silica as much as 78 percent alumina than a change which makes the glass compositions. low viscosity at furnace operating The data are presented mainly in the (2) The composition of mullite in temperatures.” was published in (1840oC) is apparently about favorable to the growth of crystals. Those contain- more viscous. 1981. its content of for Ceramists. In 1960.8 nearly equidimensional habit. The A brick containing a large amount of State University.PROPERTIES OF REFRACTORIES Upon cooling. or it may become partly or wholly minerals or oxides takes place over a shown in Fig 1. but temperatures materially increased by the phase rule. The first volume contains a 72. and upon the rate of of the materials present and their diagram for silica and fireclay composi- cooling. the brick should have been supplement. (1840oC) with 77. confirmed that mullite of the may tend to interlace. The relative proportions of range of temperatures. Certain types of refractories have section of general material on phase (3) Mullite does not melt incongru- their load carrying capabilities at high diagrams. slow cooling.2 percent alumina-silica diagram on the basis of alumina are believed to be standard quenching experiments. however.0 percent material may function in one of several Ceramic Society published ten large. corundum and mullite at 3344oF make the glass more viscous at furnace 1969. Rapid cooling favors the compositions. A tures of alumina and silica.” was published in 1956 temperatures above 2903oF glass must be low. many papers on the subject (1) The earlier conclusion is Elongated crystals. and given strength by the adhesive the attention of many investigators. Part II. but if the glass is of industries. 1983. reducing the proportion of the glass. 2% SiO2 — 1500 that all phase diagrams apply strictly 2678°F only (1) to completely pure materials.5% SiO2 71. and the second condition is seldom if ever Figure 1 Equilibrium Diagram of the System Alumina-Silica (Al2O3•SiO2) attained in furnace practice. 3133°F illustrate the application of phase Melting Point of Alumina (Corundum) 2050°C.5 silica above the eutectic ratio will composition being heated. will melt in part at the eutectic complete understanding of the melting and to heat them until the mullite. 3722°F diagrams in determining the behavior of 3800 2050 refractories at high temperatures. melting point is known as a “eutectic will increase through solution of the The mullite composition in equilibrium composition. when percent alumina and 94. The tempera- and then the melting temperature rises With further temperature rise above ture of complete melting is almost as the alumina content exceeds 5. alumina. 2600 TRIDYMITE PLUS MULLITE — 1400 and (2) to conditions of complete equilibrium.8% Al2O3 28. indicated by the heavy curved liquidus which have considerable effect on the tion of alumina and silica with less than line. and the tures of complete melting of all possible (2903oF or 1595oC). under conditions of complete entire mass will remain solid until the under these conditions has the chemical equilibrium. until the entire mass has melted.5 percent silica). forming an silica. with siliceous liquid changes with the Harbison-Walker PR . the achieve homogeneity in a reasonable silica which contains more than 5.8 percent need to be amplified by other data. alumina. remain in the solid form as cristobalite. and if equilibrium condi. ably at a temperature just below that at composition as the eutectic (5. the of the mineral mullite. 94. at a composition of 5.5 theoretical considerations outlined here time. which extends across the width of of the batch will melt. until the temperature reaches reaching a minimum of about 2903oF tions have been obtained. this liquid. Such a composition of lowest silica will decrease. With eutectic composition (5. The melting point of the exceedingly viscous liquid of the above 2903oF (1595oC) the liquid takes pure silica is 3133oF (1723oC).15 . 28. any excess the heavy curved line for the particular (1595oC). corresponding to by the heavy curved line (the “liquidus” reached.” melting occurs for any specific mixture is viscosity of the liquid phases. temperature 2903oF (1595oC). When the temperature rises the diagram. prefer.5 percent. complete melting occurs.PROPERTIES OF REFRACTORIES WEIGHT PERCENT SiO2 The new alumina-silica diagram is 100 90 80 70 60 50 40 30 20 10 0 used in the following paragraphs to Melting Point of Silica (Cristobalite) 1723°C.8 percent alumina. properties of refractories at high 5. CRISTOBALITE PLUS LIQUID — 2000 When conditions are favorable for the 3600 DEGREES CENTIGRADE volatization of silica. both of Consider any homogenous composi. All of the liquid thereby increases and its compo- 5.5 percent alumina (Al2O3). or a 3400 LIQUID 3362°F 3344°F temperature of about 3270oF(1800oC) — 1800 or above.5 percent SiO2).” and the temperature at solid. which a liquid could begin to form alumina. such as the MULLITE SOLID SOLUTION PLUS LIQUID CORUNDUM DEGREES FAHRENHEIT PLUS LIQUID— 1900 presence of a reducing atmosphere.5% Al2O3 CRISTOBALITE PLUS MULLITE SOLUTION 3Al2O3 • 2SiO2 (MULLITE) It cannot be emphasized too strongly 2800 94. To Any composition of alumina and temperatures. Moreover.2 percent line). 5. 94. for a divided and uniformly mixed particles. The amount of increasing amounts of alumina. complete melting occurs at alumina will enter into the formation of sition changes. up to Al2O3. are represented in Figure 1 temperature of 2903oF (1595oC) is formula 3Al2O3•2SiO2.5 2903oF (1595oC) the amount of solid constant from 60 to about 77 percent percent. phase diagrams give no information which it melts is known as a “eutectic The temperature at which complete concerning rates of reaction.5 percent silica. Mullite formed alumina. initial liquid phase will have the same alumina-silica materials. At this temperature a portion 71. it is necessary to start with finely percent and less than 71. The amount of liquid alumina. The behavior of refractory clays and other forming reaction is complete. caution must be exercised in 3200 the precise application of the phase rule 3133 MULLITE PLUS LIQUID MULLITE SOLID SOLUTION — 1700 data to predict or interpret reactions in 3000 compositions containing more than 2903°F CORUNDUM PLUS MULLITE SOLID — 1600 about 55 percent alumina. Practically the first 2400 0 10 20 30 40 50 60 70 80 90 100 condition is never met by commercially WEIGHT PERCENT Al2O3 fired refractory materials. becoming richer in successively lower temperatures.5 percent mullite into solution. or the temperature. As the temperature unmelted solid will consist of crystals mixtures of pure silica and pure of the material is further increased.5 percent Detailed Description: The tempera. Consequently. refractory plastic and liquidus line in Figure 1. Consider.8-0. and 14 percent mullites vary with heat treatment undergo the same changes as described water (H2O). Dissociation of these minerals 3345oF (1840oC).5 tion spacings of various solid-solution Upon cooling. mullite would crystallize from the 3245oF (1785oC).3% Mineral Changes During the and the eutectic contains 77. mullite previously described. PR . Equilibrium mullite and free silica at about 2785oF similar to that between silica and percentages are determined thus: (1530oC).8 percent alumina. The clays of greatest importance in the true glasses containing up to 77 percent 2903oF (1595oC). the solid percent silica. At all converted into a mixture consisting of about 73. as indicated by the curved Refractory clays consist mainly of the easily prepared and commonly found in liquidus line shown in Figure 1. a composition of 40 percent of the sillimanite minerals can be temperature has an alumina content of alumina.0 percent.4 heating. 39.0 percent mullite.PROPERTIES OF REFRACTORIES temperature. Index of refraction measurements on liquid. 37. and refractory kaolin.8 percent alumina will show the first do not follow as simple a pattern as that liquid development at 3344oF (1840oC). there is a mullite coexist in equilibrium and are Sillimanite begins to dissociate into eutectic between mullite and corundum. percent liquid. containing up to 78 percent alumina are changes. % Tridymite = (71. 94. completely melted. All of clay mineral kaolinite. At that point all size. instead of the temperatures included in Figure 1 about 88 percent mullite and 12 percent theoretical 71. as the temperature composition 5. Between P. and therefore appears a simple calculation. By such heat treatment. each component present at equilibrium long enough time to provide the Mullite has a true or congruent can be determined for any composition necessary energy to alter their crystal melting point of 3362oF (1850oC). In fact. corresponding chemical composition. becoming a mixture of and semi flint clays. forming a liquid with the The mineral compositions may vary corundum. up to 74.4 percent Heating of Fireclay alumina by weight. Again. andalusite all have the theoretical the line at the right-hand side of the field This has been confirmed by the authors composition Al2O3•SiO2. based upon the so. the solid phase in equilibrium the eutectic temperature of 2903oF to mineral composition or as to particle with the liquid will be mullite. per cent alumina. up to about Relative Amounts of Components: By silica. in reverse order. and at the eutectic temperature. At 2678oF (1470oC) the tridymite described on the preceding page.0 71.5 over a wide range and the grains may rises above 3344oF (1840oC). With further main reasons are that the ground clay 71.1 percent appears to be vertical.0- 71. At the eutectic tempera.0 In the commercial burning of fireclay brick.16 Harbison-Walker . The If the composition contains more than changes to cristobalite. hence they are 3265oF (1796oC) and 2903oF (1595oC) to a softening temperature of about not reliable indices of composition. Pure kaolinite has a almost as much as they vary with above. the difference is so slight that mullite under equilibrium conditions. kyanite at 2415oF (1325oC). the relative amounts of the more in diameter to particles much dissolve in the liquid until complete components as calculated are 48. but less than 77. The composition of the melt these are hydrous aluminum silicates. any However the mullite which melts at this example. As shown in Figure 1.5 percent alumina (Al2O3).0) 100 = 55. mullites occurs. the mineral changes which occur 71.C. can be affected by a heat treatment at a to represent a constant alumina-silica called “lever principle.8-40. vary all the way from pieces ¼ inch or phase (mullite or corundum) will ture. value of Cone 35. corresponding to alumina are metastable. With further rise in temperature Clays are composed essentially of mullite can take excess alumina into above 2903oF (1595oC) progressive one or more of a group of minerals solid solution in the crystal.” Typically. percent total alumina. and However.9 percent alumina. below 2678oF (1470oC). there is no solid solution of silica in minerals sillimanite.” the amount of sufficiently high temperature and for a ratio. tridymite and free silica.2 solution of the mullite in the liquid classified as “clay minerals. 46. if the (1595oC) is reached. in diameter. crystals of cristobalite and mullite. with some of the held long enough to attain equilibrium.7% 0. Thus any alumina- silica composition containing more than % Mullite = (40. and any temperature.0 smaller than one-thousandth of an inch melting occurs. eutectic temperature for the mullite- corundum range is 3344oF (1840oC).5 percent alumina. 60 percent silica. corresponding of “mullite plus liquid” in Figure 1 in another report. semi-plastic clays. for structure. which has the fusion-cast mullite. and firing temperatures are not composition contains more that 77. the only minerals present.E. 52.8-0.4 the cristobalite melts. the mass would percent silica (SiO2). the solid phase is mullite. Under equilibrium conditions. however it is the mullite is dissolved at about 3265oF approximate composition believed that the mullites richest in (1796oC) and the material is then Al2O3•2SiO2•2H2O. kyanite. becoming somewhat more The diagram (Figure 1) shows that The Sillimanite Minerals: The aluminous at the higher temperatures. the entire mass would refractories industry are refractory flint alumina were also used to locate the solidify abruptly.0 ) 100 = 44.8 percent. X-ray diffrac. no other changes occur until mixtures are not homogeneous either as percent. to 62. The and andalusite at 2460oF (1350oC). which kaolinite. and glass in amounts varying break down and to discard more silica. viscous liquid at temperatures several submicroscopic in size. 2910oF (1600oC). How. tion of the material. However. with the alumina content of the brick. the impurities tend to be concen- takes place. influenced by the raw materials from Harbison-Walker PR . some free silica At about 1920o to 2010oF (1050o to as the temperature becomes higher. 2Al2O3•4SiO2. Mullite is especially drated iron oxide) in clays which occur which have been heated to a tempera. The changes which take place in of the oxides present in the accessory heating a fireclay have been the subject minerals lower the temperature at Mineral Composition of Fireclay of extensive investigation for a great which liquid begins to form and and High-Alumina Brick many years. it is so poorly range of temperatures above 1805oF. The alkalies soda composed largely of mullite and free fireclay composed mainly of kaolinite and potash are especially potent in this silica (cristobalite. pyrite (FeS2). the viscosity gradually decreases and usually corundum. Nearly all Up to this point little has been said liquid. trated in the glass. Other minerals at high temperatures. cient to lower the temperature of initial usually contain less glass than do brick When metakaolin is heated to about liquid formation to 1805oF (985oC). and silica. they consist of mullite and amount is quartz (SiO2). greater fineness. In any fireclay 1700oF (925oC) an exothermic reaction the alkali-alumina-silica liquid. the time and with the formation of a semi-crystalline In clays which are otherwise pure. cooling. as it forms near the surface. there is which has more combined water and Above 2190oF (1200oC) cristobalite probably some concentration of less potash than is found in muscovite and mullite continue to develop. crystalline silica and at very high increase in size. but are identifi- Upon being heated. reacting to form a highly tridymite). may remain as residual quartz in bodies ence of crystals. defined X-ray diffraction pattern. migrates out of the metakaolin. Super duty fireclay brick This reaction is endothermic. to 3:2 in the final mullite. the mullite crystals approximately 2Al2O3•3SiO2 in compo. Many clays contain substan. However. The silica set free may be temperatures even mullite. cristobalite crystals and a viscous diaspore (Al2O3•H2O). and rarely are outlined in the following para. a temperature of firing. The discarded silica larger particles have nearly the same other than the alumina-silica mineral appears as cristobalite. the groundmass variable in composition. If the quartz strength. composition as the finer sizes. at which liquid would begin to form if patterns. respect. Quartz from the liquid. The crystals are mainly graphs. limonite (hy.PROPERTIES OF REFRACTORIES Even clays of highest quality contain containing more silica than the composi. brick. acces. and because of its hydrous mica in clays is somewhat above is believed to have the composi. Additional strength is than illite.17 . Heat form the groundmass of fired products tial amounts of illite. very small amount of potash is suffi. kaolinite loses hundred degrees below the temperature able by means of their X-ray diffraction most of its combined water (dehy. (K2O). the presence of crystallized that it cannot be identified the liquid is so viscous that it behaves mullite crystals is clearly indicated. A phase resembling mullite and of and upon the compositions and The mineral constitution is also uncertain composition forms. In photomicrographs sition. probably amounts of the accessory minerals. in others it is type phase. some additional refractory clays contain minor amounts regarding the effects of the accessory cristobalite and mullite may separate of titania-bearing minerals. depends upon the alumina-silica ratio. montmorillonite. The mullite formed at 2550oF (1400oC) or For this reason. through 2:3 in the spinel temperature. but apparently tion 3Al2O3•2SiO2 with no excess silica. as crystalline material by X-ray essentially as if it were a solid. giving a well. The accessory minerals in the groundmass. ture as high as 2700oF (1480oC). (generally cristobalite with occasional 1100oC) the spinel-type phase begins to The temperature of complete melting quartz). leaving sia. In many refractory clays the from 1:2 in the original kaolinite and in When fireclay brick are at the firing accessory mineral present in largest metakaolin. mineral begins to change to cristobalite bonds the mass together and gives it feldspars. effective as a ceramic bond. a form of mica is evolved in this temperature range. ever. High-alumina brick contain mullite diffraction. Some interlacing needle-like crystals. develops more liquid than the larger averages about 6 percent in potash Thus the alumina –silica ratio varies particles during firing of fireclay brick. (3Al2O3•6SiO2•K2O•2H2O). as do both amorphous and temperatures. at least. Over a wide of super duty fireclay brick reheated to amorphous. most of the significant amounts of constituents tion 3Al2O3•2SiO2. On cooling. in which some of the silica sory minerals containing lime. quartz. magne. In a single ground clay. and iron oxide dissolve wholly or in In fireclay brick exposed to high behind a cubic spinel type phase part. Glass also is present in drates) at about 750o to 980oF (400o to the body consisted wholly of alumina amounts depending upon the composi- 525oC) depending on the particle size. and micaceous minerals other at about 2280oF (1250oC). Some of the changes now increase the amount of liquid at any Burned fireclay refractories are believed to take place on heating a given temperature. Siderite (FeCO3) occurs in crystals are large the central portions imparted by the interlacing and adher- some deepmine clays. made from the clay. and the rate of compound metakaolin. much of the common accessory minerals are which is present as an accessory liquid cools to a rigid glass. In of the high-duty class. which chlorite. At about 2280oF 2600 than 71.9 percent on heating.3 percent. quartz does not corundum may be present even in change to trydimite.26. and free silica may be at which tridymite is the TRIDYMITE AND LIQUID “B” present even in compositions with more stable form. Cristobalite. has a and cristobalite.2 percent. and upper high-tridymite. tridymite. known as high-quartz and low-quartz. retarding or preventing an abrupt volume increase of approxi- In the presence of an appropriate further reaction between the corundum mately 0.2 percent. Cristobalite is formed 3200 placement with respect to grains and the in the absence of liquid.8 percent. Each of the three crystal forms of temperature is somewhat variable. cristobalite changes to tridymite on the interior of the grains and the free o corresponding shrinkage on cooling. The mullite o o Systems Lime-Silica and Ferrous Oxide-Silica rises. change to quartz. at ambient tempera- more than 71. alumina (artificial corundum) is added 1445oC). and 2 3000 than 71. yet it does not increases rapidly as the temperature Figure 2 Partial Equilibrium Diagram of the Binary proceed to completion. the temperature of formation. rapidly through the inversion range. any o o from 1598 F (870 C) to FeO+SiO pure alumina-silica refractory with less 2678oF (1470oC).8 percent alumina. which occurs at occur at ambient temperature. even 2700 compositions with less than 71. through the inversion range. in brick made wholly In the absence of a liquid or in part from bauxite or diaspore clay. protective film. when heated or cooled cations of silica are quartz. that of tridymite 2. found in nature is quartz. and from a high to low form on to crack or spall if heated or cooled ment. phase. The form generally tridymite. at temperatures between 2280 F silica formed from the fireclay between o o o (1250 C) and 2678 F (1470 C). the unaltered by the firing treatment. and low-tridymite. the mineral agent. and a liquid. 2800 dum. temperature of quartz is 2. that of tendency to crack. there is no 2900 CaO+SiO contain only mullite. with a small perceptible tendency for 2 amount of alumina dissolved in it. appears always to require the presence The change from low-quartz to high. A change volume change of about 2. 480 -392 F (249o-200oC). the reverse combining with free silica released by recrystallization of the fire clay. depends both on the material from The Minerals in Silica Refractories temperature modifications. AND LIQUID “B” than mullite and free silica. or cristobalite or tridymite to the mullite solid solution and corun. als: The three common crystal modifi.65.8 percent alumina would cristobalite is the stable form contain no crystalline material other CRISTOBALITE above 2678oF (1470oC). This mineral takes place rapidly from a low tempera. a protec- cristobalite. o change is very slow at 2280 F (1250 C) o which occurs between 600oF (316oC) and A similar condition exists when fused and is not rapid even at 2630oF (about 1100oF (593oC) is about 3. high cristobalite and low-cristobalite. The formation of tridymite cooling. of mullite during firing proceeds to an PERCENT OF SILICA (SiO ) 2 the rate of transformation advanced degree. The 14. At 2900 F (1593 C) transfor- formed at the surfaces of the grains of (CaO•SiO2 and FeO•SiO2) mation is complete in approximately bauxite or diaspore appears to act as a one hour. a change on cooling takes place at about o o interior of the corundum grains is volume increase of 17. of quartz to tridymite. When heated or cooled rapidly through to or is bonded by fire clay in the The specific gravity at room the inversion point quartz has a strong manufacture of high alumina brick. silica below 1598oF (870oC). Under (1250oC) quartz begins to 100 90 80 70 60 favorable conditions the development change slowly to cristobalite. the proportion of accessory Quartz is the stable form of 3133 CaO+SiO 3106° 2 oxides. which may be formed by quartz or the reverse. One with However. and the firing treatment. Two well-crystallized tridymites of a liquid. The However. 2.18 Harbison-Walker . and silica has high-temperature and low. 3100 TEMPERATURE-DEGREES FAHRENHEIT If complete equilibrium could be tridymite is the stable form FeO+SiO 2 3090° attained during the firing process. The low-high inversion of tive film of mullite forms at the Hence the transformation of quartz to cristobalite occurs at about 428o-513oF surfaces of the grains of corundum by o o cristobalite causes a volume increase of (220 -267 C) on heating.32. When the refractory is fired. These are which the cristobalite was formed and Stability relations of the silica miner. heating. is accompanied by nated as tridymite-M (for metastable) PR . the total reversible expansion the grains. desig- reaction of silica with a suitable fluxing o o about 1063 F (573 C). LIQUID “A” AND “B” matrix.8 percent alumina would ture and pressure. However.8 within the temperature range percent alumina.PROPERTIES OF REFRACTORIES which the brick were made. lower high. However. Refractory brick or other bodies may be converted to tridymite or ture to a high temperature form on consisting largely of this mineral tend cristobalite by appropriate heat treat. about 99. Behavior of Silica which solidifies largely to a The addition of up to 1 percent lime glass on cooling. 1. with titania. all a significant factor in the development mixtures of silica and ferrous oxide. Further additions of Plateau” upon the melting temperature The coarse grains in a silica brick lime. (113o.5 percent lime with 94. Within this range the mixtures bonding. and sum of the alumina.5 18 percent liquid.PROPERTIES OF REFRACTORIES and tridymite-S (for stable).5 percent lime and under equilibrium conditions will mass. In the manu- 2 TiO 2903 2900 a constant temperature of complete Na O facturing process. Highly PERCENT OF IMPURITY The lime combines with siliceous mixtures of silica with lime or silica and the impurities of with ferrous oxide exhibit this type of Figure 3 Effect of Certain Impurities Upon Melting the rock to form a liquid melting behavior.5 percent ture. and alkalies. under equilibrium The raw material used in the manu. & 3. Pseudo. and 138oC). titania. most 2800 melting. while at the same the lime and iron oxide. soda. a single liquid Apparently results from melting.3+ 1. as shown in Figure 2.5 percent of the alumina. contains almost all (1708oC). formation of only (2. can be seen by comparison of Figures 2 usually contain 99+ percent silica. a mixture of being well in excess of 99. form at a temperature as low as about conditions melt completely at 3090oF facture of silica refractories is a rock 2048oF (1120oC). or potash with silica will Thus the lime content of the ground- about 9 percent liquid at temperatures be completely melted. a small Conventional 40-54 28-41 <1 <1. Similarly. form two immiscible liquids upon 2822 During the firing. At 2920oF (1605oC). Under to silica results in a progressive percentage of alumina or alkalies some conditions.15 to 0.5 percent silica SiO2. liquid can ferrous oxide.2 percent and the volume changes through the inversion ferric oxide content about 3100 points are small. as well as much percent lime to silica would result in the temperature a mixture of 5. Instead. Noncrystalline Type Tridymite Cristobalite Quartz wollastonite Material * ture of complete melting drops rapidly Superduty 33-61 27-49 <1. and with the MINERAL COMPOSITION OF SILICA BRICK alkalies do not show the “Immiscibility Percent Plateau” effect. and the tempera.19 . mass is of the order of 8 to 10 percent. or alumina. The raw TiO 0. about 25 percent of the total having the same melting point 3106oF consist of 82 percent solid material with weight of the brick.5+ 5-24 * By difference. titania. but the formation of a second 5.3 to 1. The Mineral Changes Which of the liquid phase during firing.5 to 1. the mineral lowering of the temperature of com. Tridymite. 35-38 33-35 2.5+ 9-17 with even small additions of any one of Superduty. MELTING POINT 1358°F MELTING POINT 1460°F accompanying expansion 2 2 2750 but preserve their separate identitites. often tional lowering of the melting tempera. pseudowollastonite (CaO•SiO2) is plete melting from 3133oF (1723oC) to The effect of the “Immiscibility formed also.8 to 3. 3106oF (1708oC).35 percent.4 3 2O 2 2950 Al Refractories: Highly siliceous mixtures percent alumina. do not result in addi. Equilibrium Diagrams and Silica Na O with a total of 0. The two liquids do not blend. In alkalies may depress this temperature The equilibrium diagrams of silica Table I with alumina. of silica with certain other oxides have and alkalies. Small amounts of (1699oC). in lime-silica Spall Resistant or ferrous oxide-silica mixtures. The total 3133 0.113o. destroy the immiscibility. and and alkalies is usually about MELTING TEMPERATURE-DEGREES FAHRENHEIT 3150 280oF (64o.0 percent. titiania.0 percent silica.3+ 20-30 these oxides. believed to consist of “disordered” silica and 5 to 15 percent glass < = less than Harbison-Walker PR . 152oC) tridymite-S at 147o.3+ <2. percent of lime is added for 2850 tion. In the containing from 1 percent to 40 percent Occur Upon Firing Silica Brick system CaO-Al2O3-FeO-SiO2. instead of the usual single EUTECTIC MIXTURE 31% K O 69%SiO K O EUTECTIC MIXTURE of the quartz changes with 2 26% Na O 74%SiO 2 2 liquid. like mixtures of oil and water. consisting almost wholly of quartz. Hence the fine grained ground- liquid containing 27. however.5/27. 235o. just below 3106oF (1708oC).5 2 melting over a wide range of composi. no material used in the 2 3050 cracking occurs when tridymite is Al O manufacture of superduty 2 3 heated or cooled rapidly through the KO 2 silica refractories contains 3000 inversion points. PERCENT OF SILICA that used for making brick M passes through reversible inversion 100 98 96 94 92 90 of conventional quality the 88 86 3200 points at 235o and 306oF. Moreover. Thus the addition of 2. probably not exceeding 0. 0 2 4 6 8 10 12 14 into other forms of silica.5) x 100. So far as is known. 10 1 In a silica brick after firing. are most likely to and from the brine. or lime may be made to obtain Silica brick ordinarily are light in magnesium hydroxide. which is lumps resistant to atmospheric moisture (CaO•SiO2). due to the Raw magnesia-containing materials transformation of quartz to cristobalite The Mineral Composition of are “dead-burned” in rotary or shaft and tridymite. and often small quantities of a oxide magnesia (MgO) are (1) chemi. shown in Table I. The 50 EN 50 SIA transformation progresses into the RC interiors of the larger grains gradually. Magnesite Materials: The raw materi. small amounts of accessory minerals the process of dead-burning. Most of Figure 4 Composition Triangles in the Lime-Magnesia-Silica (CaO•MgO•SiO2) System the tridymite is in the groundmass. 30 •M gO gO •S During the firing. alumina. depending upon due to subtle changes in the ground. but often precipitated magnesium hydroxide. Such coloration is slaked calcined dolomite to react with (1540oC to 1845oC). The temperature of dead-burning are mottled or splotched in irregular prepared by causing slaked lime or varies from about 2800oF to 3350oF brownish patterns. such as dolomite. if any. naturally occurring silica. the larger grains are likely to consist predomi- nately of cristobalite. as now manufactured. remaining product into dense grains or been identified as pseudowollastonite ide. temperature heat treatment which cristobalite. dead-burning consists of a high- consist mainly of tridymite and als used in the manufacture of refracto. but increases as the temperature C ILI 40 rises. The Silica brick. is present in The permanent linear expansion of nounced. or magnesite contains small amounts of dissociates to form magnesia and in those containing more than about accessory minerals. PR . carbon dioxide gas. Magnesite Refractories kilns to prepare them for use. contains the type and purity of the product. and converts the finely crystalline mineral. Chemically desired compositions. hydroxide dissociates to form magnesia practical significance.2 percent. the liquid has a 10 marked influence on the rate at which 90 the mineral transformations occur. mineral brucite.4 : 2 = the stable form of silica at the firing . the Iron carbonate.86 O2 = 1 : SiO 2 : SiO 2= 2 5 :1 . (2) the mineral magnesite. many magnesites. color generally becomes less pro. magnesia These odd colorings. and quartz. converting it to tridymite. color with a yellowish cast. Besides its effect on SiO2 bonding strength. conver- 20 80 sion of quartz to cristobalite begins at PE about 2280oF (1250oC). is that in the interior of the 2CaO • SiO2 Ca 3C O aO •M 70 largest grains. The natural mineral and water vapor. and the carbon dioxide escape with the As the alumina content increases.20 Harbison-Walker . magnesium carbonate appear in brick of the highest purity. and with any remaining unconverted quartz in the PERCENT OF LIME centers of the largest grains.8 : 1 1 0. is about 4. serpentine. and carbon dioxide. The amounts of these naturally occurring magnesium carbon. magnesium-bearing brine. The water vapor three times as much lime as alumina.PROPERTIES OF REFRACTORIES still further. and to a minor extent (3) the additions such as iron oxide. residual ries consisting essentially of the basic drives off chemically combined water quartz. in solid solution with kiln gases. with some glass. In the firing of silica brick. and/or carbon dioxide. which has cally precipitated magnesium hydrox. talc. which are of no derived from the limestone or dolomite. together with the AG TO NE surfaces of the larger grains. with thin rims of CaO MgO 90 60 40 50 70 10 20 80 30 tridymite at their surfaces. silica brick during firing. The rate of RC 30 transformation is slow at this tempera- EN 70 A TO ture. with the glass from which it crystallized. phases which occur in silica brick are ate. 20 CaO =1 Si O . chalcedony.9 3: 90 temperature of about 2625oF (1440oC). the liquids formed 3CaO • SiO2 •S iO iO 2 2 in the groundmass begin to affect the CaO Ca 80 : SiO O: Ca cristobalite. 40 A 2MgO • SiO2 ing. PE 60 and ultimately the only quartz remain. The dead-burned product. the magnesium carbonate. In mass. In dead-burning. Small grains in the groundmass FM FS 60 are converted first. accompanying devitrification. usually composed of silicates of are shown in Figure 4.0 0. and microscopic examination 38. Silica (SiO2) 0.86 parts Merwinite 3CaO•MgO•2SiO2 temperatures during dead-burning. The area within a triangle either one or two magnesium-bearing dead-burned magnesias used in the represents all compositions in which the silicate minerals will invariable be United States lie within the ranges three minerals indicated by the apexes present at room temperatures. and component.86 parts Dicalcium Silicate 2CaO•SiO2 identified by painstaking research with 7 2-3 1. 8 3 2. TYPICAL COMPOSITIONS OF DEAD-BURNED MAGNESITE The particular minerals to be found in For Furnace Bottoms For Making Brick any stable blend of lime. which contains several percent of iron represents a composition of 35. compositions of most of the commercial equilibrium. and in which the lime-silica content of accessory constituents than represents all compositions in which the ratio is less that 1. relative proportions. The calcium and magnesium shows that the periclase crystals usually the composition of the mineral silicates which may coexist in equilib- contain dark moss-like inclusions. and their “composition triangles. 1 Under 1 Less than 0.80 parts Tricalcium Silicate 3CaO•SiO2 Lime CaO Harbison-Walker PR . For These have been identified as The large equilateral triangle is any given composition.6 percent MgO.5 percent SiO2.93 parts Forsterite 2MgO•SiO2 tion.93 parts Monticellite CaO• MgO•SiO2 Al2O3-FeO-Fe2O3-SiO2 are not avail. to the individual fine-grained crystalline groundmass The composition triangles in this system apexes.3-3.5-8. (More CaO than SiO2) Merwinite 3CaO•MgO•2SiO2 tions are not entirely reached in the 4 1½ 1.5 Under equilibrium conditions.” Each of the the lime-silica ratio.3-6. which is ex. 3 1-1 ½ 0. are fixed by accessory constituents. Dead-burned magnesia used in composition of a specific mineral.40 parts Monticellite CaO• MgO• SiO2 able.3-1. the body Ferric Oxide (Fe2O3) 0. For example. The two minerals indicated may coexist in (less than 2 to 1 on a molecular basis). 2 1 0.0 Alumina (Al2O3) 0. and this part of the system appear as full color. the composition.9 In Figure 4 the composition triangles of oxide is generally chocolate-brown in percent CaO.5 would consist of the three minerals represented by the apexes of the which is known commercially as “dead. In recent years. ultra high purity dead-burned magnesia Table III containing 99 percent MgO have gained MINERALS IN THE CaO-MgO-SiO2 SYSTEM WHICH COEXIST IN EQUILIBRIUM WITH PERICALSE wide spread use. which corresponds to lines. divided by heavy lines into triangles of silicates which may be present. rium with periclase are indicated. as shown shown in Table II. magnesia. 25. is of particular interest in buff or tan. because adequate data regarding (Less CaO than SiO2) Monticellite CaO•MgO•SiO2 the six component system MgO-CaO.86 to 1 by weight that used for making brick. Dicalcium Silicate 2CaO•SiO2 However.21 . periclase (MgO) is invariabley a low in iron oxide varies from white to consisting solely of CaO.0 1. in relative amounts fixed by the burned magnesia” consists mainly of starting point in studying the mineral distances from the point representing aggregates of periclase crystals. and The most desirable amounts of the unequal size. These are known as their relative proportions.40 – 1. MgO. A magnesia (MgO) is present in great furnace hearths in general has a higher line connecting any two apexes excess.3-1. Dead-burned magnesia SiO2. and because equilibrium condi. large equilateral triangle of Figure 4 in great excess. CaO-MgO-SiO2 serves as an excellent triangle. and in which therefore The color of dead-burned magnesia represents a definite composition.86 – 2. the particular magnesioferrite (MgO•Fe2O3).0-6.5 within which the composition lies.PROPERTIES OF REFRACTORIES Table II may coexist in equilibrium.80 parts Dicalcium Silicate 2CaO•SiO2 Tricalcium Silicate 3CaO•SiO2 X-ray diffraction. Molecules of CaO Parts By Weight Compatible Components The exact mineral composition of Case to 1 Molecule of SiO2 of CaO magnesia grains cannot be calculated to 1 part of SiO2 Minerals Compositions accurately from the chemical composi.80 parts Tricalcium Silicate 3CaO•SiO2 ation of the three component system 9 Over 3 Over 2. depend upon the three apexes of any composition In that part of the three component purposes for which the product is to be triangle represents the chemical system CaO-MgO-SiO2 in which used. with a composition of magnesia refractories.5 0. the point “A” connection with magnesia refractories.0-3.93 – 1.40 parts Merwinite 3CaO•MgO•2SiO2 brief period of exposure to high 5 1 ½-2 1. and Magnesia (MgO) 83-98% 88-98% silica may be predicted from the triangle Lime (CaO) 1.5-6. The CaO-MgO-SiO2 System: Consider. That part of the CaO-MgO-SiO2 magnesium and to a minor extent of plained as follows: Any point within the system in which the magnesia is present calcium.0 0. monticellite. the major components can be 6 2 1. alumina and liquid to disappear. below chemical analyses.PROPERTIES OF REFRACTORIES in Table III. would form liquid below 3254oF (1790oC). The lime reacts with silica o F o C to form dicalcium or tricalcium silicate. the more and if it is between 1.93 times dissolves in the magnesia. Monticellite CaO•MgO•SiO2 Melts incongruently at 2709oF (1487oC) to form Forsterite is a common bonding MgO and liquid. If completely 2500 homogenous mixtures could be obtained. and 3000 MAGNESIO WÜSTITE may develop liquid at a temperature as low as 2714oF (1490oC). exceeds 1. and important relationships are fairly well the amount of silica.86 or higher. no magnesium-bearing silicates 5070 TEMPERATURE . Lime CaO ~4660 ~2570 and with alumina and ferric oxide to Pericalse MgO ~5070 ~2800 form calcium aluminates and calcium Spinel MgO•Al2O3 ~3875 ~2135 Dicalcium Silicate 2CaO•SiO2 ~3865 ~2130 ferrites. and 1. Figure 5 Equilibrium Diagram of the system FeO•MgO lower lime-silica ratios. Al2O3-FeO-Fe2O3. However. In all these of particles. but often the 2280oF (1250oC) it tends to dissociate into 2CaO•SiO2 and CaO. In such mineral composi. of magnesia. magnesia.86 times the FeO WEIGHT PERCENT MgO amount of silica. If the lime-silica ratio of the 5500 high magnesia compositions is 1. even though diffusion at tions.86 times the amount of silica. if compositions. and the lime-silica ratio does Table IV MELTING POINTS OF COMPOUNDS WHICH MAY BE PRESENT not suffice to determine what minerals IN MAGNESITE REFRACTORIES are present. any ferrous oxide present higher temperatures should cause the the amount of lime is less than 0. the system applicable monticellite and merwinite will form. tions. would permit small quantities of liquid to form at tempera. and in which the amount of 3500 lime by weight is less than 1. low lime content. no combination of these 2000 0 oxides.93 If the amount of lime equals or component system CaO-MgO-SiO2. merwinite and would cause some coalescing together understood. available concerning the complex six. the amount of silica. in areas of even microscopic size.40 times the amount of silica. 4000 and silica alone. begins to melt at 3115oF (1713oC). will develop a liquid phase at 2867oF (1575oC). the to refractories which consist essentially mineral relationships are much more complex. in which the amount of lime is 10 20 30 40 50 60 70 80 90 100 equal to or more than 1. of microscopic and X-ray determina- Magnesioferrite MgO•Fe2O3 Dissociates slightly. Many attempts have been Forsterite 2MgO•SiO2 ~3450 ~1900 made to formulate rules whereby the Tricalcium Silicate 3CaO•SiO2 Stable only from 3452oF (1900oC) to 2880oF mineral compositions at room tempera- (1250oC). consisting mainly of periclase. Any combination of lime. it is little affected by the pres- PR .DEGREES FAHRENHEIT 5000 will be present. However.86 times tures lower than 3254oF (1790oC). the minerals ferric oxide combine with the magnesia.86 times the amount of silica. in the six-component system. At and above 3452oF (1900oC) it tures can be calculated from the dissociates into 2CaO•SiO2 and CaO. If the amount of lime is between 0. The Accessory Minerals in Magnesia forsterite and monticellite will form at forming the spinel minerals MgO•Al2O3 Refractories: Incomplete data are high temperatures in the groundmass. in which periclase is a component. MgO and liquid ~ = Approximately sions. calculated compositions are not in Dicalcium Ferrite 2CaO•Fe2O3 Melts incongruently at 2617oF(1436oC) forming satisfactory agreement with the results CaO and liquid.40 and 1. dicalcium silicate will form.22 Harbison-Walker . The lime-silica ratio has an important 4500 bearing upon the melting behavior of LIQUID lime-magnesia-silica compositions. It is highly refractory Merwinite 3CaO•MgO2•SiO2 Melts incongruently at 2871oF (1577oC) to form and has no undesirable mineral inver- 2CaO•SiO2. melting complete at approximately constituent of magnesia refractories of 3000oF (1650oC). and MgO•Fe2O3. this affect results from a atmosphere is strongly reducing. if the incongruent melting of FeO is development of the ceramic bond of Dicalcium ferrite is unstable above neglected. the groundmass in combination with However. melting temperature. in soluble in periclase at high tempera- The lime compounds tricalcium large measure. the refractoriness is still will be 1. and decomposes into and ferrous oxide (FeO) form a compositions having a lime:silica ratio free lime and a liquid high in iron continuous series of solid solutions favorable to the development of an oxide. amounts may have some value in the dicalcium silicate and free lime. It does not react with oxidation of the iron changes with the of incipient melting is even higher than magnesia (MgO). 3CaO•SiO2 and 2CaO•SiO2 ~3255 ~1790 cooling. If the mineral inversion at about 1340oF oxide will be in the form of FeO. free ferric in dead burned magnesia or in magnesia regarded as an undesirable component oxide loses oxygen at 2530oF (1368oC) brick may be present within the of basic refractories. or in solid solution with magnesium hydroxide.86 times as much lime as (MgO•Fe2O3). When this is done. Monticellite and merwinite melt at silicate is unstable below about 2280oF The equilibrium diagram for the relatively low temperatures. and that. and it is stable in the temperature. iron ferrite (MgO•Fe2O3) particles. it separates out upon cooling. 3CaO•MgO•2SiO2 and CaO•MgO•SiO2 2714 1490 brown surface portions the periclase MgO. merwinite. the temperature highly refractory. in the MgO. together with its very high While magnesioferrite is completely the inversion of the silicate on cooling. if the material high. Dead-burned magnesia 2617oF (1436oC). it contains 80 percent Fe2O3. might not re-form. In the greenish centers the MgO and 2CaO•SiO2 ~3270 ~1800 periclase crystals probably contain MgO. 2CaO•SiO2 and 3CaO•MgO•2SiO2 2867 1575 ferrous oxide in solid solution. notwithstanding the fact that (2CaO•SiO2). MgO. Tricalcium steel-encased basic brick. or forsterite.PROPERTIES OF REFRACTORIES ence of moderate amounts of ferric dicalcium silicate but do not coexist in reducing atmosphere. CaO•MgO•SiO2 and 2MgO•SiO2 2736 1502 MgO and 2MgO•SiO2 ~3380 ~1860 crystals contain inclusions of ~ = Approximately magnesioferrite particles. are compatible with iron oxides. Table V MELTING POINTS OF SOME CaO-MgO-SiO2 EUTECTICS Very dense grains of magnesia often are greenish in their interiors. it was sphere. Porous Harbison-Walker PR . This ferrite (2CaO•Fe2O3). silicate (3CaO•SiO2) and dicalcium refractory.86. by weight. for oxide. before dead refractoriness. and MgO and CaO ~ 4172 ~2300 chocolate-brown at their surfaces. means have been found to An important property of magnesium lime and alumina as brownmillerite prevent the dusting of dicalcium silicate oxide is its ability to absorb great (4CaO•Al2O3•Fe2O3). At one time. If the furnace solution. presence of moderate amounts of ferric oxygen pressure of the furnace atmo. At ordinary temperatures. It accounts for the fact that unless cooled very rapidly. which Melting Points of Eutectics Eutectics Between These Compounds o F o C were cooled out of contact with air. These added materials inhibit magnesia. some of the particular advantages of minerals monticellite and merwinite. With less Dicalcium silicate (2CaO•SiO2) is In basic refractories. Under these oxide (Fe2O3) to form magnesioferrite. in combination by adding small amounts of stabilizing amounts of iron oxide-either ferrous or with lime as dicalcium ferrite minerals to the raw magnesia or ferric-without undue decrease in (CaO•Fe2O3). the state of than 70 percent Fe2O3. When heated in air. Magnesium oxide (MgO) magnesia brick. for its value as a tures. in either an oxidizing or a frequently observed in microscopic examination. is cooled rapidly. silica. iron oxide oxide (Fe2O3). is responsible. free lime would be present which begins to melt only at 3115oF the compound dicalcium silicate in the dead-burned magnesite after (1713oC). and also. the dicalcium ferrite Magnesium oxide reacts with ferric magnesia is displaced from the silicates. It has been suggested that when which decrease in refractoriness with undesirable amount of monticellite or this occurs the iron oxide may leave the increasing proportions of ferrous oxide. cooling. oxide (Fe2O3). if lime-silica ratio by weight exceeds (725oC) which is accompanied by an strongly oxidizing. and the lime and silica combine to form conditions. burning. This property of silicates. CaO and 3CaO•SiO2 ~3360 ~1850 which were exposed to air during MgO. and in minor (1249oC) and tends to dissociate into MgO•FeO system is shown in Figure 5. iron oxide may be present also in abrupt volume increase of 10 percent. merwinite can be corrected by the liquid and combine with magnesia to However. even with more than 50 addition of sufficient lime so that there form the mineral magnesioferrite percent FeO. which may occur refractories high in magnesia can be accounts for the presence of the dark in magnesia refractories having high used advantageously in the presence of colored inclusions in periclase crystals lime-silica ratio. because of its and changes to the spinel mineral periclase grains as MgO•FeO solid tendency to turn completely into dust magnetite (FeO•Fe2O3). but reacts with lime to form the equilibrium with monticellite. and with changes in the 3115oF (1713oC). or as inclusions of magnesio- on cooling.23 . it will be ferric 1. 100% 100% in chrome ores are serpentine ___________________________________________________________________________ (3MgO•2SiO2•2H2O) and chlorite.3 4. and the R2O3 of ___________________________________________________________________________ The amount of accessory minerals in Cr2O3.2 spinel in chromite of one of the larger Marico Chrome Ore 48. aluminum. consisting mainly of be represented by the following Talc 3MgO•4SiO2•2H2O magnesium silicates in the form of formulas: Pyroxene interstitial material and veinlets. a Chrome Refractories This composition may be expressed complex hydrated silicate of magne- Ores: Chrome ores in general consist of more simply by the formula sium. minerals are soluble in each other over strictly to each individual spinel crystal.6 0.3 10. Frequently. brown m47f53 (c62a28f10) Feldspar all crystallize in the cubic system.2 0. However.PROPERTIES OF REFRACTORIES grains are less likely to have green deposits in the Camaguey district of individual spinels. but it is very active chemically _____ Fe2O3 5% minerals which occur most abundantly and slakes upon exposure to the air. and does not necessarily apply silicates which the ore contains. members of this group is of silicates in the matrix. For example. The free lime has no MgO 75% Cr2O3 40% spinel solid solution of chromite.0 27.5 14. Analyses and Melting Points: Typical a very wide range of compositions.4 15.2 15.2 15.9 26.4 28.3 22. + 10 mesh 32.2 0.8 PR . the RO Refractory Grade m71f29 (c42a55f3) ___________________________________________________________________________ consists of FeO and MgO (ferrous Metallurgical Grade m74f26 (c77a19f4) oxide and magnesia).6 0.6 0. calculated from its chemical chrome ore depend largely upon the solutions.Fe)O•SiO2 Chrome Spinel: The spinel minerals all Philippine m73f27 (c42a55f3) Hypersthene (Fe. melting points.0 15. as Olivine 2(Mg.3 0.8 0.6 0.2 3.3 11. the MN46 44.3 tures. disadvantage from the standpoint of FeO 25% Al2O3 55% Accessory Minerals: The accessory melting. The massive or granular aggregates of m75f25•(c40a55f5).4 0. There. Al2O3. Refractory sis =FeO. In Turkish Anorthite CaO•Al2O3•2SiO2 the spinels of chrome ores. R.8 26.2 9.4 1.1 11. The heat-resisting qualities of minerals is their habit of forming solid spinel. c= composition of clinochlore. Typical molecular compositions of _________________________________________________________________________ nent. Gov’t Stockpile 33. a highly refractory chrome.2 0. f within the parenthesis = 5(Mg.8 meteorites. iron. may components.7 12. all be of identical composition. The ores used for refractories is so great that some of the spinel Table VI minerals are not known to occur pure in TYPICAL ANALYSIS OF CHROME ORES nature.6 10. Other chrome ores may be regarded as Fe2O3.4 16.Fe)O•Al2O3•4H2O.3 15. Most of the and iron). Cuba is approximately the following: tained a series of spinels existing side Dead-burned magnesia sometimes ___________________________________________________________________________ by side.4 0.6 5. the molecular formula of a chrome 1650oC. For example.0 Transvaal Chrome Ore (excluding all accessory minerals) may Gov’t Stockpile 44.4 5. that the crystals of balanced spinel in a percent to 25 percent. These ___________________________________________________________________________ Diopside CaO•MgO•2SiO2 silicates are often of complex and Cuban (Moa Bay) m72f28 (c47a50f3) Enstatite MgO•SiO2 widely varying compositions.Mg)O•SiO2 have the general formula RO•R2O3 and Transvaal.3 15. ing: components: (1) the essential compo. one of the chromite crystals.7 26. the compositions of analyses of chrome ores are given in Their tendency to form mixed crystals chrome ore are reported in terms of Table VI. with minor amounts Cr2O3.4 19. the preponderance contain somewhat more free lime than RO RO of evidence is that the individual spinel _______________________________________________________2____3________________ would be anticipated from their minerals have no identity as such in the CaO:SiO2 ratio.9 17. well below 3000oF or An important property of the spinel fore.2 0.Fe)O•SiO2 containing spinel. and aluminum.4 16. all other natural chromites Phillipine Chrome Ore are believed to be isomorphous mix. as if the ore con- centers than dense grains. (2) accessory reported by J.8 RO and R2O3. is merely an average character and the amount of the with each other. and Fe2O3 (the There is evidence which indicates commercial chrome ores varies from 5 sesquioxides of chromium.5 9. Rait and others.2 The composition of a chrome spinel Fine Lump Ore 32. The proportion of Fe2O3 is given specimen of chrome ore may not accessory minerals have relatively low relatively small.3 Tiegaghi Chrome Ore 55.5 14.24 Harbison-Walker . The various spinel value.9 28. certain other chrome spinels.4 10.4 6. a= Al2O3.9 average molecular composition of the -48 mesh 45.7 0. The subscripts represent accessory minerals include the follow- naturally occurring mixtures of two molecular percentages. or isomorphous mixtures.2 2. f outside the parenthe. in which m=MgO.3 be stated in terms of molecular ratios of ERS Grade 44. Rhodesian m66f34 (c73a21f6) Bronzite (Mg. composition.5 6. chromite of the Source of Ore Cr2O3 Al2O3 FeO MgO CaO SiO2 formula FeO•Cr2O3 is known only in Pakistani Chrome Ore 54. react with as 26 percent ferrous oxide and as little MgO•R2O3 and (b) a solid MgO. and MgO with Cr2O3. Chrome ores high in point present in the groundmass balanced. renders it less likely to become atmosphere. 2MgO•SiO2. as it oxidizes to Fe2O3. 12 to 25 containing them.PROPERTIES OF REFRACTORIES usually fall within the ranges of 30 to 50 (3) The FeO in the spinel of most FeO. since spinels formed by Mineral Changes During Firing of an increase in porosity. ores Two solid phases appear: (a) a Fe2O3 may leave the spinel are being used which contain as much spinel consisting mainly of crystal as MgO enters. and chrome spinel crystal. as the RO de. compo. and percent chromic oxide (Cr2O3). at temperatures up to 2640oF ore in the presence of excess sition. expansion of about 5 to 10 grade. Cr2O3. as only on the composition and refractori. 14 to 20 into Fe2O3when the ores. and form a border of as 8 percent magnesia and 10 percent solution of the excess R2O3 MgO•Fe2O3 surrounding the alumina. part of the alumina. The Philippine chrome RO and R2O3. showing the melting apparently affected relatively conditions. in a spinel by oxidation of FeO and refractory chromites are those highest chrome ore which has been fired. concern. observed only when the oxidized formed by FeO. In amount of FeO oxidized. an oxidiz- ness of its major component chrome lesser tendency to oxidize in air ing heat treatment of a chrome spinel. 3 to 6 percent oxidizing atmosphere. chrome brick. in the presence ores are noted for their high content of creases and the R2O3 increases. little by heating in a reducing (10) The stabilization of the chrome it may be inferred that the most atmosphere. To an increasing extent. However. of the iron is present as FeO. are fired in an spinel structures. and melting points of the (1449oC) than those in chromic MgO to stabilize the spinel silicates present. This (1260oC). extreme cases. As the temperature rises. MgO enters the probably much greater than that chrome spinel to replace the which enters into the formation Harbison-Walker PR . and Chrome Ore sometimes by cracking. the highly refractory mineral R2O3 constituents. R2O3 solid solution is usually refractoriness of the spinel accompanied by expansion and grains. ing the behavior of various chrome ores ore is exposed to reducing gases. points of the individual spinel minerals. and Green and others. depending on the begins at temperatures as low as 2300oF in a reducing atmosphere. alumina content appear to have a well as Fe2O3. How- (2) Most of the iron content of with added magnesia. Al2O3. but melting of these (6) In a chrome ore which has as accessory minerals. This will have essentially the formula silica (SiO2) and less than 1 percent results in an unbalance between MgO•R2O3. melting of the silicate impurities and is readily reduced by heating percent. (8) During oxidation. The melting behavior of inclusions.25 . the iron is present largely as accompanied by a volume In most chrome ores of refractory Fe2O3 in an R2O3 solid solution. The new spinel percent alumina (Al2O3). constituents (Fe2O3. as in a ever. 14 to 20 chrome ores is readily oxidized also combines with the newly percent ferrous oxide (FeO). As might be expected from its Al2O3). a chrome ore does not solution is easily visible under MgO•Fe2O3 is easily reduced. of the ore. it may be reduced effect may be partially offset by some solution of the spinels in the to metallic iron. appear Repeated oxidation and reduc. Frequently the solid (9) While Fe2O3 in the simple spinel constitution. it have a true melting point. or brick formed Fe2O3 to maintain the percent magnesia (MgO). lime(CaO). (7) When a chrome ore is heated forsterite. (12) The added magnesia also reacts and synthetic spinels on firing. absorption of MgO may be in magnesia and chromic oxide. spinels is not complete until a much become oxidized on firing. are ing oxidizing and reducing From Table IV. Thus. (11) The stabilization of the chrome higher temperature is reached-possibly reduction of the Fe2O3 in the spinel by MgO increases the as high as 3900oF (2150oC). and on the furnace oxide. expansion and cracking are than the corresponding spinels Lovell. in which most friable when exposed to alternat- reducing. when the R2O3 a particular chrome ore depends not (4) Chrome spinels of relatively high consists of Al2O3 and Cr2O3. with the accessory magnesium to have established the following facts: tion may cause an ore to become silicate minerals of low melting (1) Chrome spinels in general are friable. containing equal alumina show much less ten. absorbed by the spinel is the RO constituent. whether oxidizing or (5) Raw chrome ores. shrinkage of the silicates present liquid occurs. but rather a the microscope as needle like is much more stable in the spinel melting range. The Fe2O3 have higher melting points The thorough investigations of Rigby. and converts them to molecular percentages of RO and dency to become friable. the amount of magnesia chrome ores is present as part of chrome-magnesite or magnesite. but also on the amount. of excess magnesia. MgO•R2O3. Forsterite Refractories melting point of 3450oF (1900oC). is various proportions and in numerous refractoriness. Usually. tion with fayalite (2FeO•SiO2). weight. 2MgO•SiO2. periclase absorbs iron oxides from the Forsterite is a magnesium silicate Later. resistance to brick consisting mainly of Serpentine has the composition in which dead-burned magnesia. The ferric oxide Composite Chrome-Magnesia in the broader system containing Cr2O3 produced reacts with additional Refractories also are similar. Any groundmass. consists of a complete providing stress relief in an otherwise amounts of magnesia and silica by range of sizes. Therefore the FeO of the spinel is oxidized at high refractory may react with basic slags to a fired chrome magnesite brick temperatures to Fe2O3. forsterite. the addition of chrome ore the production of refractories corre- which chrome ore predominates.7 These discoveries provided great 1. occasionally dicalcium silicate consisting only of chrome ore. usually constitutes all the larger grains. will normally not be as strong at magnesia remains in the brick as free merwinite (3CaO•MgO•2SiO2). tions as manufactured. coarsely ground. may decrease maintain the RO: R2O3 balance when (CaO•MgO•SiO2) present in the the bonding strength. important discover. and (2) magnesia-chrome brick. mass. (2CaO•SiO2). with sesquioxides will occur. to silica of 1.86 or less. and the oxide formed diffuses into of chrome ore and dead-burned same as those shown in Table III. and part of the produce secondary periclase (MgO). Part of the excess magnesia magnesia and chrome refractories. and room temperature as a brick periclase. apparently by 3MgO•2SiO2•2H2O. to the refractory mineral solutions. and consist of spinel solid surface of the chrome spinel crystals. While the addition of magnesia to ing of Mg-Fe olivine.” Commonly the iron modifications. since the improvements condition rarely if ever exists in always occurs in homogenous combina- led to the production of brick of greater commercial chrome-magnesia composi. a large proportion of all the service as the result of exposure to forsterite and fayalite is called “olivine” basic refractories used commercially basic slags. and may also magnesia refractories. and forsterite (2MgO•SiO2). and has an important known as “dunite. With CaO:SiO2 ratios greater than percent magnesia (MgO) and 42. At high temperatures. plates. and contains equal main component. Forsterite almost ing refractories. grains to shatter. dead-burned magnesia serves a differ. in mineralogy. The utility. it was discovered that the spinel grains to form solid solutions of with the theoretical formula addition of the magnesia resulted also MgO with FeO and MgO•Fe2O3. steel plates frequently show growth of ground dead-burned magnesia were Chrome-magnesia brick usually have a magnetite (FeO•Fe2O3) or added to chrome refractories. weight. The addition of coarse the olivine used for making forsterite confined to the fine-grained ground. Its melting point is impetus to the use of chrome-contain. corresponding to 57. which has a monticellite. However. or “chrysolite. There are two main effect on their high-temperature content of magnesium olivines used for groups: (1) chrome-magnesia brick. and form additional magnesioferrite. considerably The mineral changes occurring in weaken the natural bond between more magnesia is customarily added magnesia-chrome refractories in service grains. This 3450oF (1900oC).26 Harbison-Walker . The accessory minerals occurring in while the dead-burned magnesia is ent purpose. stabilization with MgO may of the particles. chrome ore imparts improved spalling brick are largely serpentine and talc. the lime-silica ratio less than 0. during firing. The mineral relationships in the six.PROPERTIES OF REFRACTORIES of forsterite in the matrix. but may occur in series of mixed crystals consisting of Today. compounds of CaO percent silica (SiO2). with minor burned magnesia and chrome ore in chrome refractories increases their amounts of accessory minerals. chrome ores have relatively low melting Fe2O3 are combined with FeO and MgO Chrome grains adjacent to the oxidized points. resulting from the enters the chrome-spinel grains to forsterite (2MgO•SiO2) or monticellite addition of MgO. Most of the silicates in the sesquioxides Cr2O3. while the chrome ore is relatively rigid structure.” while the rock consist- consist essentially of blends of dead. Al2O3. The ferrous oxide (FeO) but is usually stronger at high component system CaO•MgO•SiO2• in the chrome ore oxides to ferric oxide temperature.3 in stabilization of the chrome spinel.93 by magnesioferrite (MgO•Fe2O3) on the silicates would be largely converted. periclase. The steel plates oxidize ies were made concerning combinations containing lime and magnesia are the also. and to refractories consisting mainly of sponds to about 15 percent of fayalite. In addition the increase than is required for reaction with the are similar to those which occur in in refractoriness of the silicate silicates. It was learned that if finely to form spinel solids solutions.86 by weight. With the ratio of lime magnesia to form magnesioferrite In the early 1930’s. They are also made with internal steel cause the edges of the spinel In the manufacture of chrome. the dead-burned magnesia. the phases (MgO•Fe2O3). The relationships structure by magnesia. Al2O3•FeO•Fe2O3 have been described (Fe2O3) and is replaced in the spinel on preceding pages. The composition of talc is PR . and the magnesia adjacent to the plates to magnesia. there are magnesia-chrome brick are chemically (13) The volume expansion of various other modifications of the sizing bonded and encased in steel sheets. For from cyclic oxidation and reduction.6 percent liquid. In forsterite brick is made by the addition either case.4 percent An important modification of burned cristobalite and 95. The forsterite is stable.27 . Fireclay brick contains large proportions of liquid at temperatures within their working range. Forsterite brick are fired products consisting essentially of olivine with added magnesia. The ferrous oxide (FeO) of the fayalite oxidizes to form ferric oxide (Fe2O3). oxide from the olivine to form a solid- The development of a considerable solution spinel. Harbison-Walker PR . and to combine with the iron oxide present to form magnesioferrite (MgO•Fe2O3).5 percent secondary forsterite by reacting with a of a siliceous liquid. important changes take place in the forsterite fayalite solid solution of the olivine. (1559oC) pure serpentine would form The latter forms additional amounts of 60. brick containing magnesium silicate melts behave quite differently. the presence of these of alumina which during the firing natural impurities in olivine lowers the reacts with free magnesia and iron temperature at which liquid forms. The silica liberated by the decomposition of the fayalite unites with part of the added magnesia to form secondary forsterite. How- ever. At 2838oF form secondary forsterite and silica. Yet the liquid is so very viscous that there can be no drainage from the pores. when heated to 2640oF (1450oC) developed a melt of such high fluidity that liquid drained freely from the pores. Any weight. They also found that this drainage could be prevented by the addition of sufficient magnesia to convert the magnesium silicates serpentine and talc into forsterite upon firing. both these serpentine present in fissures or in the minerals develop large amounts of liquid groundmass decomposes upon firing to at relatively low temperatures.5 percent forsterite and 39. pure talc would become 4. and the silica of the fayalite is liberated. During the firing under oxidizing conditions. Birch and Harvey found that a brick made of Mg-Fe olivine relatively high in accessory minerals. Upon heating. and persists as such in the finished brick. This stabilized spinel is amount of liquid in a refractory body is highly resistant to growth resulting not of itself a serious matter. corresponding to A comparable transformation occurs only half as much magnesia as silica by in the accessory silicate minerals.PROPERTIES OF REFRACTORIES 3MgO•4SiO2•2H2O. at 2811oF (1544oC) portion of the added magnesia. example. The ferric oxide then combines with a part of the added magnesia to form magnesioferrite (MgO•Fe2O3). These materials include minerals used in or formed during the manufacture of these products. SECTION 4 Using Refractories Selection of Refractories UR-1 Ordering Refractories UR-3 Thermal Expansion UR-4 Thermal Conductivity UR-6 Heat Flow Calculations UR-7 Installing Castables UR-9 Installing Gun Mixes UR-13 Installing Rammed and Gun Plastics UR-15 Installing Ramming Mixes UR-17 Furnace Refractory Lining and Construction UR-19 Arch Construction UR-22 WARNING: Some materials which are present in refractory products are harmful. Please refer to the applicable Material Safety Data Sheet for such product . One such group is classified as substances known to cause cancer to humans. as well as other personal protective equipment is mandatory where required by applicable law. Other substances may be classified as probably or possibly carcinogenic. . The use of proper respiratory equipment. The primary threat presented by many of these materials comes from inhaling respirable dust. A comprehensive treatment of refractory design and construction issues is beyond the scope of this section. heat transfer and the installation of monolithic refractories including anchoring and the construction of refractory furnace linings and arches. abrasive raw materials. Slag. A substantial investment in products intended to handle these conditions can be lost through inadequate design and careless construction of refractory structures.1 . Discussions involve thermal expansion of refractories.USING REFRACTORIES Using Refractories Just as the design and construction of masonry and concrete structure must meet exacting load-bearing and curing demands. corrosive gases or any combination of these elements can contact and threaten the integrity of refractories. This section addresses problems inherent to refractory design and construction and describes workable solutions to many of them. thermal conductivity. Calculations are also provided for a variety of arch and ring combinations. molten metal. Harbison-Walker UR . If your specific refractory lining problem is not addressed in the following pages. please contact your Harbison-Walker representative for assistance. so must refractory materials stand up to the demands of high temperature and otherwise destructive environments. porosity. However. monoliths) • Chemical attack by metals. • Conditions of heating (one or Special shapes or forming required slags.2 Harbison-Walker .e. the following major factors must be Permeability to gases or liquids identified. Moreover.or water-cooling • Abrasion from contained solids or • Type of refractory construction gases (brick or monoliths) • Impact from charging • Methods of bonding or support • Erosion by molten furnace contents • Provision for thermal expansion • Impinging flames or hot spots • Mechanics of any moving furnace parts UR . it may appear that the Density. Volume stability (bloating or shrinkage) Resistance to gases and fumes OPERATING FACTORS FURNACE DESIGN AND Thermal conductivity Heat capacity • Function of the furnace CONSTRUCTION • Nature of material being processed Electrical resistance • Type of furnace • Rate and continuity of operation • Economic factors • Design and dimensions of walls • Range and rapidity of temperature and arches Delivered cost changes • Loads imposed on the lining Cost of installation (brick vs. more sides) Service life • Fluidity of molten metal or slag • Amount of insulation • Velocity of furnace gases • Air. resistance Resistance to thermal shock to metals. Resistance to abrasion or erosion When selecting refractories. In some cases. the best refractory selection Size and design often depends on a few requirements so important that other • Properties at high temperatures – factors play a minor role. permeability choice of most suitable material would be exceedingly difficult. alone will be the deciding factor. Sometimes high insulating value is desirable. or disintegration by reducing gases may be the Resistance to chemical attack governing factors. etc. Chemical and mineral composition Sometimes this is true. i.SELECTION OF REFRACTORIES Optimum use of refractories is achieved by careful study of REFRACTORY-RELATED furnace design and evaluation of operating conditions prior to FACTORS selection of refractory products which meet the design and • Properties at room temperature – operating requirements. temperature and in others high refractoriness will have to be coupled with Reversible thermal expansion resistance to thermal shock. Refractoriness or maximum service maximum service temperature. Under other circumstances. Workmanship and physical strength From the multiple factors listed below. refractoriness. Resistance to mechanical impact or stress but in other situations high thermal conductivity may be needed. there are usually data on hand from previous experience Uniformity under similar conditions. slags. ash.. necessary to send drawings. send limited quantity of extra pieces in Refractory technology is becoming a drawing of the shape and the assembly accordance with the following table. When filling orders for special shapes. When you cases. one complete set. and 4. combination of refractories and design breakage during transit and handling.2 *Not less than one shape.000 3% Number of brick per cubic foot 14. Square Foot of Wall or Floor NOTE: Minimum figures are used ordinarily for estimating. year after year. ‘SAIRBOND® 250 .000 lb. Non standard palletizing for States.6 OVERAGE 41/2 5.000-5.9 Specified Overage Specified Overage 9 10. On subsequent tives have been trained to do this work orders the Harbison-Walker drawing Standard Packaging and are ready as an accommodation to number or your drawing and shape Standard packaging for monolithic discuss your application with you. H-W number will ensure that the order is refractories are 55 lb. but provide a complete description and correct dimensions for the shapes that you need. provide Brick Laid with both the inside and outside diameter of Brick Laid Dipped or Thinly the lining. it is not from the kilns in perfect condition. 3.300 350 .. This standard procedure also oughly understand an application area evaluate the design and verify that the helps avoid shortages resulting from before making refractory selections. brick or monoliths and non standard In most cases.4 1-100 10% 5.450 * This is for 9-inch straights.1 1. Mortar Materials Dry and Grouted Trowelled Joints Orders for brick should include Heat-Setting Mortars enough mortar material of the right kind SATANITE® 250 . all of the extra pieces will come order various shapes and sizes. increasingly specialized.000 7% Over 10.ORDERING REFRACTORIES ORDERING Special Shapes Then.000 2% 18 21. Harbison-Walker Marketing Representa. Harbison-Walker will ship a REFRACTORIES On initial orders for special shapes. will help Harbison-Walker engineers the order.3 6 7.300 350 . Information required to specify the number.3 . for larger sizes the quantities required are reduced in porportion to the decrease in surface area covered by the mortar Number of Refractory Straights Required Per per 1000 9-inch equivalent.300 350 .600 Handbook. The assembly drawing unless special instructions are entered on so that it is often necessary to thor. Refer to the previous cartons.450 to lay the brick.450 Brick Sizes and Shapes Section of the H-W® PERIBONDTM 300 .10. careful specification of Harbison-Walker makes a slightly larger packaging options including export your requirements and operation will number of shapes than specified to cover palletizing are available for additional help Harbison-Walker fill your order possible breakage in firing. major cities throughout the United order by number and date. Harbison-Walker UR . Normally.2 Quantity Quantity 71/2 8.000 1% 27 32.450 appears in the following tables and in the ‘SAIRSET® 250 .7 131/2 21. into which it fits. In some charges. produces the best results. If in sets. Wall or Floor 9 X 41/2 X 3 Inch Thickness. 2.000 . offices are listed in phone books in properly filled. bulk bags.4 100-1.000 lb.300 350 . correctly and without delay. pails.400 500 . sacks. Approximate Pounds of Mortar per 1000 9-Inch Brick If you order circle brick or other shapes (9 X 41/2 X 21/2 Inch)* designed to fit a circular lining.000 lb. Inches Brick 3 3.. shape and size of Air Setting Mortars brick as well as the quantity of mortar HARWACO BOND® 250 . fired /4 2. Thermal expansion data can be tion. temperature drop between hot and cold face. and. expansion allowances must be determined with reasonable type of refractories involved.30 each vertical joint. Basic brick also can Basic be laid dry with a heavy paper or 1 Magnesite. will differ somewhat with air-setting mortar. The thickness sion will occur depends on several factors. furnace the amount of permanent linear insulating firebrick have relatively low builders customarily stagger vertical expansion to be expected.08 3/ Magnesite-chrome. fired /4 2.THERMAL EXPANSION Overview EXPANSION ALLOWANCES Like virtually every construction material. Thermal Expansion of Refractory Brick in High Temperature Service tunnel kiln construction usually calls for expansion joints 10 to 15 feet apart Approximate Expansion in the high temperature section and 15 Per foot. expansion joints may fall expansion values for refractory brick in sion while other refractories fall somewhat farther apart than in other high temperature service. Results of reheat testing. within a class. “Permanent” thermal sion graphs are available from your setting mortar. Fireclay In silica brick walls.com UR .76 program or go to 3/ Zircon 32 0.4 Harbison-Walker . fired 1/ 8 1.30 or wider intervals. sion may be substantial. In fireclay boiler settings with walls other properties of each brand. fireclay. spaced 10 to 16 feet apart. “Reversible” thermal expansion our webpage at www.55 1/ Chrome.hwr. and operating conditions. Too little will cause pinch spalling. types of construction.04 Chrome-magnesite. and joints must permit the horizontal dimensions. Walls must be differ considerably. Brands even refractory expands should not be laid during operation. indicate silicon carbide. as well as the Further.04 are laid in a number of ways to allow for expansion. However. or at about 18-inch Silica 5/ 32 1. Refractory thermal expansion occurs in brick classes shown in thermal expan- When construction calls for a heat- two forms. 1 Magnesite-chrome.08 cardboard filler in each vertical joint. refractories expand or Brick Refractories Methods of making allowance for contract at high temperatures.76 extend from bottom to top.hwr. and how expan. For example.76 1.04 Click here to go to Harbison- Chrome-magnesite. How much expansion allowance to long walls where total thermal expan- calculate depends largely on the refractory material. unburned 5/ 32 1. Generally. thermal expansion must be thermal expansion in refractory brick considered in the design of most refractory structures. expansion high temperatures for long periods of HEATransferTM 2003 program found on joints must be lined up vertically from time. unburned 16 1. thus. Basic brick-magnesite and chrome- 60%Class 70%Class 85%Class 90% Class } 3 1 /8 /32 0. Per meter. rates of expansion. including the type of and insulation of a wall determine the refractory. If the The table below lists approximate relatively high rates of thermal expan- walls are low. to 20 feet apart in the low temperature Type of Brick inches cm section. Thus.30 Walker HEATransferTM 2003 3/ Silicon Carbide 32 0. Reversible between the two. fired 8 1.76 www. Basic brick show expansion joints 4 to 6 feet apart. insulation. where brick are laid refractory brick when they remain at found in the Harbison-Walker with an air-setting mortar. depending on wall allowed to expand freely upward. zircon brick and most 15 feet or more in length. too much may weaken becomes especially important in high or the wall or roof unnecessarily. Adequate provision for expansion accuracy. the amount of thermal THERMAL EXPANSION TYPES thermal expansion for certain refractory expansion at both faces. vertical expan- Super Duty sion joints typically are placed to High-Duty Low-Duty High-Alumina } 3/32 0. Some furnace builders lay the brick dry with sufficient space at Corundum Class 5/32 1. vertical expansion joints expansion takes place as the result of Harbison-Walker Marketing representa- can be staggered to tighten construc- mineralogical changes within the tive. Brick required to occurs as the brick expand and shrink The thermal expansion data repre- move with respect to each other as the when the temperature rises and falls sents average values. shown with among themselves. the mortar used expansion required by the refractories. course to course.com. 5 . castables show required to control shrinkage. same manner as construction joints During initial heat-up. castable refractories differ those which will be used in metal considerably from brick. tracts as it sinters and mineralogi. Lining – 5” or Less Lining – 5” or More Castables of this type may require an expansion allowance in massive installations. always cut or form the joint midway between anchors. assume the reversible expansion and Expansion joints in refractory contraction characteristics found in fired castables are typically designed in the ceramic bodies. some types of compressible • The fired aggregate expands material should be incorporated in the according to its chemical composi. How- the results of complex forces at work: ever. and that knowledge is difficult to transfer to castables. there are two practical rules of thumb: • Fireclay castables do not normally require an expansion allowance. Expansion joint construction is the same.THERMAL EXPANSION Castable Refractories Construction joints are suggested for In any consideration of thermal most castable installations except for expansion. please call your Harbison-Walker cal reactions occur. except that the joint is thicker to permit insertion of the required expansion material. The figure below tion. expansion joint. Only after shrinkage and cracks that can form on prolonged exposure to heat do they drying. Anchor tines should be 2 to 3 inches from the joint. illustrates typical configurations for • The cement phase shrinks as it joint construction. anchors should remain halfway between them. If joint position is not fixed in the drawing. highly refractory castables have substantial revers- ible thermal expansion up to Thin Single Component Thick Single Component 2000oF (993oC) or more. Double Lining Double Lining Hot Face or Backup – 5” or Less Hot Face or Backup – 5” or More When construction joints are required. and If you have specific questions about • The body itself expands or con. thermal expansion in refractories. No anchors should be located at any joint. Marketing Representative. But. Most background material concern- ing thermal expansion of refractories is based on brick. Construction joints control not fired before installation. Harbison-Walker UR . and Typical Joint Construction • Certain dense. in the field. Castables are contact. loses the water of hydration. T. Proposal P142. surface.com. it is often necessary to calculate the heat flow and temperature refractory components and the furnace profile of the refractory lining. zones. RT = total thermal resistance of (5. Lj = thickness of gram which can be access on our website at www.67 x 10-8 W/m2-K4) “Proposed Procedure for Calculating wall. and escapes to the surroundings at The inside and outside surfaces are surface. heat by: acceptable to assume that all heat enters the inside surface of the lining. To = temperature of outside typically requires use of a computer. The hot face thickness and the lining materials must condition for flow through a flat wall or temperature is usually assumed to be be uniform in all directions parallel roof may be expressed mathematically equal to the gas temperature within the with the hot face. °F (°C) F = 1. A user name component j.THERMAL CONDUCTIVITY Overview The total thermal resistance of the In selecting refractory lining configurations for high temperature wall is calculated by summing the individual thermal resistances of all vessels. (m) and password is required to secure this data and perform on-line heat Kj = thermal conductivity of component j. °F (K) UR .S. radiation and convection. the lining must be of uniform convection. one-dimensional flow may Ti = temperature of inside Qr = heat loss by radiation. it is usually lining. The portion on relative conductivity.Ta4) In areas which are well removed from BTU/ft2-hr(W/m2) where edge effects. Ta = temperature of surrounding the rate of heat flow into the lining is air. heat flows along different QL = (Ti-To)/ RT quantified by using the following paths having different lengths.hwr. the steady state of the furnace wall. upward or downward.74 x 10-9 BTU/ft2-hr-°R4 is presented in A. these are where equation: commonly referred to as edge effects. RT = (L1/K1)+(L2/K2)+(L3/K3) entering the hot face of the lining flows passes through the lining via conduc- in one direction. The heat flux at the cold face. for practical reasons. Temperature profiles n are important in choosing combinations of materials which prevent Σ RT = Lj/Kj overheating of refractories and support structures. QL = heat flux in the wall. °F (°C) ft2-hr (W/m2) A widely used method for calculating To = temperature of one-dimensional steady state heat flow outside surface. In order for this assumption to the outside surface via radiation and commonly called the hot and cold faces be valid. flow calculations. depending determined using the following expres. Qs. and in determining the solidification and condensation of where furnace process components in the lining. For example. perpendicular to its tion. some heat may flow between The heat flux in the lining may be determined by two mechanisms. BTU/ be assumed. In conventional furnaces.6 Harbison-Walker . In the case of sion: which is lost by radiation may be a corner. Qr = Fg(To4 . zones. With certain limitations. steady-state heat flow rates and BTU-in/ft2-hr-°F temperature profiles in walls and roofs can be calculated with sufficient (W/m-K) accuracy for most engineering purposes. ft2-hr-oF/BTU g = total emissivity of outside Heat Losses Through Furnace Walls. surface. in. Therefore. difference is typically too small to regions of transition between material and QS is the heat flux at the outside warrant the complex calculation. Thermal conductivity data n = number of components for many of our products are available on our HEATransferTM 2003 pro. Actually. dimensionless This method uses an interactive approach which. °F (K) When a furnace lining is under steady state (or equilibrium) conditions. the hot face tem- a vessel in which one-dimensional flow QL = QS perature is somewhat cooler. Examples of areas of as: furnace. but the cannot be assumed are corners and where QL is the heat flux in the lining. such as the shell j=1 and anchors. is vertically. a wall consisting of two ONE DIMENSIONAL STEADY refractory components and a shell STATE FLOW equal to the rate of heat flow out of the would have a thermal resistance given For most furnace designs.M.” (m2-K/W) surface. In the case of a wall zoned surface. Heat flow rates are important in shell: assessing the economics of furnace operation. The total temperature of the lightweight castable. By decreasing the emissivity of must be realized that only one convec. Outside air temperature: 100°F C = 1. °R Example 1: Estimate the steady state inches in ½ inches increments.. the air accurate. wind and fan-blown air. the thermal resistance value of Example 3: The shell of the furnace Ta = surrounding air temperature. this was The appropriate equation here is: rounding air temperature is 70°F (21°C). e. Hot face temperature: 2500oF Qnc = heat loss by natural (1370°C) convection.9. (i.g. 0. ft/sec calculations searching for heat balance To = outside surface temperature. V = air speed. Emissivity of shell: 0. The design criteria j=1 Qnc = 0.18(To-Ta)1. and the proper equation is: Tn = Ti –QL E Rj the insulating layer. and a ¼“ second table on the following page. essentially equal to the maximum service Qfc = (1 + 0. The Ta = surrounding air heat flux and interface temperatures in temperature at the first interface. each component was re-evaluated based wall described in Example 1 is coated o F on the newly chosen value of the with aluminum paint (emissivity = The convection equations were outside surface (cold face) temperature. BTU/ft2-hr shows the sequence of computer 2½ to 3inch thickness would be chosen. °R a furnace wall consisting of 6“ of 60% shell temperature. a tion. and since more heat condition. 2 ½ “ of 2300°F each lining thickness are shown in the Forced convection occurs when (1260°C) insulating firebrick. including hot face gradient through it. For each o F iteration. It W/m2). Therefore. and total emissivity of nent is given its own thermal conductiv- the outside surface (g). The first table on the following page 100°F (38°C) safety factor.7 . a straight line over the range of the temperature would increase. temperature of 2196°F (1202°C). or QL = Qr + Qfc Harbison-Walker UR . The computer solution indicated determined empirically and apply only since thermal conductivity changes with that the heat flux would decrease from for the units given.27 are: where j=1 1.53C(1/Tavg)0. No forced air at outside surface Tavg = average of outside surface For the second interface: 4. ture is 2700°F (1482°C). The 4-inch thickness gave an interface surface. set of conditions. °R And so on. forced air moves across the outside steel shell. the component temperature (Ti). The thickness of the insulating To = outside surface component was varied from 2 to 5 temperature. 286°C). In this case. since its temperature gradient speed (V) must also be known. must be given. the motion components may be calculated in engineer must determine the maximum of the air at the outside surface is accordance with the following relation: amount of 2200°F (1204°C) lightweight caused by differences in density (hot air castable which can be safely used for n rises).. surrounding air should be subdivided.30). Each subcompo- temperature (Ta). and the sur. The motion occurs.THERMAL CONDUCTIVITY The convection mechanism may be After the correct outside surface Example 2: A 6-inch layer of tabular either natural or forced.225V)(To-Ta) There is no forced air motion. the interface alumina castable has been chosen as a convection occurs when no forced air temperature between any two lining working lining of a furnace wall. heat flux values in temperature. heat in equals heat out).39 for a vertical wall or inside surface): (38°C) 1. Natural temperature is determined. it is a good practice since satisfies the heat balance criterion: calculation time is typically of no QL = Qr + Qnc concern. A cold face temperature of 1099 to 1055 BTU/ft2-hr (3465 to 3326 W/ metric units can be obtained by 402°F (206°C) resulted in heat balance m2) and the shell temperature would multiplying Qnc or Qfc in BTU/ft2-hr by with a heat flux of 1099 BTU/ hr-ft2 (3465 increase from 402°F to 547°F (206°C to 3. the temperature. The is smaller. BTU/ft2-hr For the first interface (closest to the 2. ity characteristic which should be more If forced convection is in effect. necessary. less heat would be radiated to tion equation is applicable to a given component has a thermal conductivity the surroundings. Subdivision is usually not approach is to determine the tempera.79 for a crown T1 = Ti -QLR1 3.153 to convert to units of W/m2. where emissivity of the shell is 0.e. curve which does not approximate a would be retained (stored). The inside surface tempera. the shell To find the steady state solution. but with the use of a com- ture of the outside surface which puter. but it is common practice to allow a Qfc = heat loss by forced convec. and the heat flux for ® alumina brick (UFALA ).85 and surrounding air T2 =Ti-QL (R1 + R2) temperatures. If the material used for a lining the shell. 8 Harbison-Walker . values the shell temperature would decrease. the values forced air flow would draw heat away as the distance from the inside surface approach those for a flat wall of the from the outside surface at a faster rate.062 1275 0 0 surface caused by conduction is: 170 2.0 500 1630 4. Many vessels various effects. the inside surface area may be significantly diameters but identical linings.THERMAL CONDUCTIVITY Heat Balance Calculations For this case (Ti > To). same construction. heat flows inches of fused silica castable and a ¼ ft2-hr and the shell temperature would radially outward.173 1118 321 193 QL = (Ti-To)/ro E (Lj/Kj)(ln (rjo/rji) j=1 370 2. have a cylindrical geometry which may no more than three significant digits are appropriate. Realistically.100 1062 1048 453 where 460 2. having as many as four significant In Examples 1 through 4. increases. in (m) rji = inside radius of jth Determinants of Insulation Thickness component. the heat flux decreases inside diameter grows. in (m) Insulation Interface Shell Heat Flux Kj = thermal conductivity of jth Thickness (in) Temperature (oF) Temperature (oF) (BTU/ft2-hr) component. 450 2. BTU-in/ft2-hr-oF 2 1980 460 1310 (W/m-K) 2½ 2050 428 1130 lj = thickness of jth 3 2110 403 992 component. Effect of Wall Diameter on Heat Flow Inside Diameter (ft) Shell Temperature (oF) Heat Flux (BTU/hr-oF) 0.089 1101 733 358 ro = radius of outside surface.074 1090 904 412 Ti = temperature of inside 430 2.0 531 1850 16. oF (K) 420 2.0 538 1900 ∞* 545 1950 * flat wall UR .092 1099 737 660 in (m) 402 2.5 435 1240 1. In the sample calculations.081 1095 816 385 To = temperature of outside 410 2. The less than the outside surface area. and even under steady inch steel shell. Notice that as the decrease from 402oF to 297oF. it is assumed digits were used to precisely illustrate that the walls are flat.071 1087 950 426 BTU/ft2-hr (W/m2) 440 2.078 1093 859 399 surface. in (m) 3½ 2160 382 886 n = number of components 4 2200 364 802 The effect of wall curvature is 4½ 2230 348 732 indicated in the following example: 5 2250 334 674 Example 4: The shell of the furnace wall described in Example 1 is cooled using Example 5: The table below gives the shell temperatures and heat fluxes of forced air. In wall is heated at the inside surface to solution predicts that the heat flux the case of a cylindrical vessel which is 2000oF (1093oC) and consists of 6 would increase from 1099 to 1128 BTU/ heated at the inside surface. oF (K) 400 2. 401 2.137 1090 620 319 470 2. the air speed is constant at require special treatment because the cylindrical walls having different inside 10 ft/ sec (3.0 519 1760 8. Here.05m/sec). The state conditions.091 1099 741 361 rjo = outside radius of jth component. however.235 1132 123 81 n 270 2.064 1085 998 440 QL = heat flux at outside surface.0 471 1450 2. and since less heat would be retained.085 1098 774 372 surface. the equation To(oF) RT(ft2-hr-oF/BTU) QL(BTU/ft2-hr) QR(BTU/ft2-hr) QNC(BTU/ft2-hr) for steady state heat flux at the outside 70 2. Each convection mechanism is forced. pour one-half to The “ball-in-hand” test for cast three-quarters of the total amount of installations provides a useful guide to water required for a batch into the mixer proper consistency. used to raise the temperature of the mix reduce strength and break down the to between 60°F and 80°F (16°C and aggregate. thorough mix. is reached). Water contents are listed on clean themselves from batch to batch. Excessive mixing will In cold weather. do not over mix (i. temperature does not exceed 80°F reached proper consistency should be (27°C) at the mixer.e. MIXING Conventional Castables All castable refractories should be For mechanical mixing a clean paddle. Do not use more than conditions. warm water can be generate heat. anchors. dry mixed beforehand. between mixing and casting exceed 30 using a wide variety of pouring or Decreased castable strength results from minutes. Tossed 6 to 12 with the paddles turning. Harbison-Walker UR . purity calcium-aluminate cements vibration to fill the mold or surround Specific mixing instructions follow should be placed within 15 minutes. a ball of properly mixed castable castable in units of full bags. the water somewhat after leaving the mixer. lining cavities and molds without forming air pockets. EXPRESS® castables allow for Harbison-Walker’s wide range of quick installation into the most intricate castables. speed up setting time. placement. mechanically mixed in a paddle mixer type mixer is recommended. These potable water to material and mix mixers assure a rapid. used. past the castable. product data sheets. Add the dry inches. These instructions cover the basic principles of castable installations with specific reference to mixing. They can be installed the recommended amount of water. Dense castables The mixer must be clean. If a partial bag is to be Breaking may indicate insufficient water air and caught. thoroughly to desired casting discharge the full batch and virtually consistency. They are shipped dry and develop strength when tempered with water. In hot weather. the contents should be carefully in the mix. Lightweight castables should combine with the cement in castables be mixed for 2 to 3 minutes. Add the balance Castables should be poured into EXPRESS® Free Flowing of water required to bring the mix to forms immediately after they are mixed. To begin a mix. forms and curing.INSTALLING CASTABLES Overview Castables are defined as the large group of refractory concretes containing a hydraulic setting binder. or castable should be cooled so that the Judgment on whether the mix has This ball is too dry for casting. it should never exceed Castable refractories tend to stiffen 100°F (38°C). Castables casting consistency in small increments particularly when being installed under EXPRESS® castables are available in after the castable in the mixer comes to high temperature and/or humidity conventional and ultra-low cement a uniform color. 27°C). consistency. Castables containing high pumping systems and require no excess moisture.. Add of 4 to 12 cubic foot capacity. made at the point of placement. Individual product data sheets and package instructions provide information relevant to each product. The water used in mixing point where proper casting consistency castable refractories must be fit to drink. should adapt to the shape of the hand Segregation of castable components when it is caught. of fingers when tossed 6 to 12 inches in the transportation. The ball should not A properly mixed ball shows the impression may occasionally occur during flow through the fingers or break apart. however. lower the ultimate strength of the in the mix. In no case should the time formulations.9 . Some should never be mixed for less than 2 to substances found in dirty mixers 3 minutes. To avoid and can cause flash setting or otherwise breaking down the lightweight aggregate This ball shows too much water in the mix. A paddle mixer is used for castables. GREEN® ultra-low cement castables are shrinkage to take place prior to similar to those for VERSAFLOW®. hydration of the cement. an alternate bay system should be used in Guidelines for placing ULTRA- construction. installation of the adjacent section. Steel forms are water additions for these products. hydration reaction takes place with the All high strength castables should be calcium aluminate cement. Mixing and vibrated into place. For VERSAFLOW® castables and Cement Castables ULTRA-GREEN® ultra-low cement For mixing EXPRESS® and castables form vibration is the preferred VERSAFLOW® castables. This is because castable so it does not leave holes or NOTES the heat released from the exothermic channels behind. joints shown on the drawings of the continuous mixes and transit trucks. as well as close-fitting UR . construction in-hand” consistency is desired. installation. paddle or installation method. Whenever possible. the masonry must also be an amount that can be cast within 30 This mix is right for vibration casting. At proper consistency. safety helmets. Most conventional castables are not typically installed using pump casting methods due to segregation of mixes at INSTALLATION high water contents. preferable to wood forms. a withdrawing the vibrator from the handful of material should begin to level castable. A respirator mask should of the refractory will be reduced by For large installations where pumping be worn over the mouth and nose to premature loss of water required for the castable is the desired method of protect the respiratory tract from dust. At one time. physical properties. Casting should placement. The mix is too stiff if All persons performing castable reaction tends to increase the material the vibrator leaves holes (see installations should wear protective temperature into the temperature range accompanying photographs). wood conservatively and mixing continued for forming should be treated to prevent a minimum of five minutes. Generally speaking. When used. forms or molds used for EXPRESS® and VERSAFLOW® castables can be installed using pump There is not enough water in this batch. The ultimate strength casting methods. This permits initial This contains too much water for vibration. waterproofed beforehand. tempering water contents in be carried out quickly enough to assure the upper end of the recommended range will be necessary. Mixing joints will coincide with the expansion often is done in large paddle mixers. For pump cast the castable. casting refractories must be thoroughly oiled or greased. which tend to Tempering water should be added dampen vibration. Extended long-sleeved clothing. This can be turbine mixers are recommended to accomplished with a clamp-on or bolt- obtain effective distribution of the low on style vibrator. The longer absorption of water from the mix and if mixing time will help distribute the low the castable is placed against existing water additions. An immersion vibrator IMPORTANT SAFETY ambient temperatures between 60°F and should be drawn slowly up through the 80°F (16°C and 27°C). used for this type of installation. Large multiple paddle CURING that the exposed surface of the castable mixers or Redi-Mix trucks have been Upon mixing with water. with extreme care in placement Pumping Installations and vibration. an exothermic does not dry out. Immersion minutes. installations with EXPRESS® and VERSAFLOW® castables. and Water contents for these products are reduces total linear shrinkage within the critical in order to obtain maximum lining. To prevent premature loss of moisture from the mix.INSTALLING CASTABLES VERSAFLOW® Castables and vibration will segregate components and ULTRA-GREEN® Ultra-Low weaken the castable. only mix masonry.10 Harbison-Walker . safety goggles. Specific water contents are vibration must be used with care to published on the castable bag and should prevent holes being left when be followed. gloves and plastic for optimum development of strength. a wet “ball. Extended vibration will and consolidate when shaken vigorously segregate the components and weaken back and forth. These materials should be placed immediately after mixing. especially coarse casting should always take place in aggregate mixes. 11 . hydration reaction may partially dry out Curing at low temperatures also the refractory surface. the refractory plastic sheeting. Harbison-Walker castables (10°C). New products and should also fall within this range. The curing material must be kept completely dry. Consult Harbison-Walker for Temporary exterior shell insulation can the current shelf life of these materials. Do not set bags on damp ground or concrete. be sure there is may be air dried indefinitely before heat sufficient ventilation under the plastic is applied. the lining See Heat-Up information on page UR-14 should be heated to at least 250°F to 300°F (121°C to 149°C). Loss of water increases the risk of steam spalling from the surface before the cement is during initial heat-up. The lower the become unsuitable for use. the gun mixes have a finite shelf life. the compound onto the surface. If bags are protected by under ideal conditions.e. This temperature range is sufficient to drive off excess casting water and prevent ice crystal formation within the refractory. but will burn off at relatively low preferably indoors. shelf lives. be used to retain heat on the steel shell generated by the heat of hydration. Refractory damage will occur if the cement freezes before it has developed full strength. and avoid storing in Curing Temperatures areas of high humidity. curing. less than 50°F manufacture. The preferred and common method to prevent surface STORAGE moisture loss is to spray a generous To obtain maximum storage life for coating of resin-based concrete curing castable and gun mix refractories. the slower the good storage conditions. i. but Harbison-Walker UR . Space low cement castables may have shorter heaters can be used to accomplish this. Typically. the temperatures. The temperature in the area rotating inventory to use the oldest code where the castable is being installed dated materials first. If stored outside. sheet to prevent water from condensing on the bags. compound will form an impermeable Castables and gun mixes should be membrane or vapor barrier during stored away from weather elements. castable or gun mix will eventually temperature dependent. Seventy to eighty percent of the cement’s strength should be developed after the 24-hour cure. releasing steam into the unit is an ideal way to heat the lining. even under atmospheric temperatures. and gun mixes is one year from date of In cold weather. the cement-containing monolith are stamped with a code date when should be mixed and installed within the manufactured to aid in determining the temperature range of 50°F to 80°F (10°C age of the material. This also aids in to 27°C). fully hydrated promotes dusting when the furnace is heated. Less Than 70°F (21°C) All Harbison-Walker castables and As with all chemical reactions.INSTALLING CASTABLES The heat released during the this takes longer in very cold weather. In long periods of cold weather. increased storage life for conventional castables curing time is required. bags must be protected from rain or After the initial 24-hour air cure and dripping water.. Any cement hydration reaction is time. If the unit is to be idle for long HEAT-UP periods in very cold weather. hydration reaction therefore. Harbison-Walker’s Gunning Mixes can help achieve up to 150 psi water breaks into pieces. For KAST-O-LITE® were designed to have a wider water pressure and should be used with H-W Gun Mixes pre-dampening to high range and therefore less sensitivity to the gun mixes.INSTALLING GUN MIXES Overview Harbison-Walker Gun Mixes are specifically designed to provide the highest quality gunned linings at the lowest possible installed cost. The amount of plugging. If one of these variables is below 15% or more by weight of water. Water control is not as signals or radio. The installation procedures review the steps to control predampening. 100 psi air compressor is suggested for narrow. being used. Gunning installation. air pressure. When gunning starts. Wide Water Adjustment Range Dusty Old-Style H-W Gun Mixes Water Addition Gun Mixes UR . and the coarse aggregate makes craters for sufficient material flow and at least Lightweight and medium-weight on the surface upon impact. when tapped. Water booster pumps into a column which. A sandy. they control air and critical and product slumping and water pressures and material feed rates Harbison-Walker gun mixes require high dusting is minimized. There should be plenty of air paddle or similar mixer is typical. In Figure 1. With old style gun so that proper flow occurs and the air pressures and high material feed rates mixes (castables shot through a gun). Following the installation steps as outlined is most important to assure the quality of Harbison-Walker’s Gun Mixes. single gun operation. Predampening Nozzle Water Control Equipment Preparations Proper predampening is required to The appearance of the gunned refractory Prior to start-up. material feed. by means of hand Feed adhesive quality. pre-dampening water should be controlled so that a liner must be clean and in good with 4% to 6% by weight of water in a gunned surface has a wet. proper sticky consistency range is very from the nozzle. 80 psi water via a 3/4-inch diameter gunning mixes could require 10% to gritty surface indicates too little water is hose. “sticky” material condition. check to insure that the control hose flow and limit rebounds and surface is the best indicator of the hoses are laid with no loops to prevent dust at the point of application. Refer to specific product materials have optimum adhesion in the Controlling the Flow data sheets for recommended levels. Larger compressors are recommended when several guns are used concurrently. moisture levels is the key to successful amount of water added. Slumping. For correct water/mix ratio. This tends to widen the water range because the more Material Consistency material that passes the water ring per Sticky given amount of time the less sensitive the material is to slight changes in the amount of water added. The water ring and nozzle dense gunning mixes. the correct consistency of material emerges for optimum installation. silky sheen condition. A 600 CFM. Figure 1 High air pressures and material feed rates speed the gun mix through the Castable nozzle water ring. nozzle water and flow technique. quality of the job.12 Harbison-Walker . ripples or a par it can adversely affect the flow Material consistency should allow a washboard effect on the surface emerging from the gun and ruin the handful of the gun mix to be squeezed indicates too much water is being used. the nozzle it is clear that the water adjustment operator and gun operator are Air Pressures and Material range is much wider for optimum teammates. Together. High pressures Damp also help reduce laminations within the refractory mass. INSTALLING GUN MIXES Illustration 1 Direct nozzle spray to form loops. the new HEAT-UP material can be gunned into place. especially for irregular patches. most gun installation depends at least as much on proceed to build upward. provides somewhat better adhesion than material feed rates. to the surface. See Illustration 1. bounce clear of the target and are not Corners should be shot first in order to At the same time. to-surface distance of three to four feet. lam-inations spacing. Entrapment of rebounds by prevent trapping rebounds. immediately before placement. while increasing the existing refractory should be wetted the insulating value of the lining. See Heat-Up information on page UR-14 Harbison-Walker UR . labor the patch area clean. High predamp of oval loops six to nine inches high and should be pointed at an angle 90 degrees and high gun pressure reverse the rules. Aiming the Nozzle General Gunning Installing Medium-weight and Once proper flow is achieved. 18 to 24 inches wide. Material is deposited as the might dust off at the nozzle. the nozzle rebounds are expected. Maintain the nozzle- casting. The nozzle mixes should be predampened before the gunning technique as on the should be kept perpendicular to and gunning. The edges should be square and and density. and installation costs. Anchors should be welded on the shell Following these procedures will in the appropriate anchor pattern significantly cut rebounds. Typically. specified densities and relatively high nozzle is moved rhythmically in a series During actual gunning. Limit the also increase production rates. and work should begin at reducing rebounds and significantly Be careful that rebounds fall or the lowest point of the installation. lowering the density of the installation. With about three to four feet from the surface nozzle easier and traps cement that traditional techniques. Harbison-Walker recommends the use to laminations or spots of low density in Gunning to repair existing linings of high predampening and high pressure the lining. This makes flow through the characteristics of the gun mix.13 . Following standard procedures. For better adhesion. as well as material. the nozzle Preparations Lightweight Gunning Mixes operator should direct the stream of Most of the water is added at the nozzle A quality medium-weight or lightweight material at the base of the wall and during placement. these techniques can entrapped. higher than of the work. the fresh stream from the nozzle can lead work to an area which can be kept moist. With increasing temperature. Normally. THE HOLD PERIOD SHOULD BE MAINTAINED UNTIL STEAMING SUBSIDES.DRYING AND HEAT UP OF CASTABLES AND GUN MIXES HEAT-UP After curing for a minimum of 24 hours. THERMOCOUPLES MAY BE PLACED ½” AWAY FROM THE LINING SURFACE FOR AN ACCURATE MEASURE OF TEMPERATURE DURING HEAT-UP. high purity binders. castable and gun mix linings must Thicker linings contain a larger volume normally undergo a controlled heat-up of material and thus. with increasing temperature). THE TEMPERATURES REFERRED TO IN SCHEDULES ARE THE TEMPERATURES OF THE HOT GASES IN CONTACT WITH THE CASTABLE OR GUN MIX AND NOT THE LINING IT- SELF. use cement binders.hwr. a larger volume of schedule to remove the moisture. INCREASED HEATING DURING STEAMING CAN RESULT IN SIGNIFICANT STEAM PRES- SURE BUILD UP AND POSSIBLE STEAM SPALLING. the temperature should be held binder). STEAMING OF THE LINING IS OBSERVED. Consult your installation incorporated at 250°F (121°C). for specific products. Steam dissipation should be especially true for those containing high slower for thicker linings to prevent strength. This is water. APPLICATION AND HEAT-UP OF CASTABLES ARE NOT OBSERVED SPALLING DURING HEAT-UP MAY OCCUR. the rate is 30°F (17°C) this link to the Mixing and no one dry-out schedule can be advised per hour. As a rule of thumb to determine the time period. Steep sintering takes place between the cement thermal gradients can cause stresses and the refractory aggregate in the within the lining and spalling. FLAME IMPINGEMENT ON THE REFRACTORY MUST BE AVOIDED. SEE INSTRUCTIONS ON PRODUCT PACKAGE. steaming is range (depending on the aggregate and noticed. If. steam at around 212°F (100°C). at any 1. while The hold period helps dissipate steam the water of hydration will be driven off and allows heat to penetrate the lining between 400°F (204°C) and 1200°F (this avoids a steep thermal gradient (649°C). For the proper schedule hour. high purity Because each installation is unique. holds are Use section of our web to fit all uses. site. use one hour Heat will remove the free water as per inch of thickness for dense linings.14 Harbison-Walker . For high strength. PROPER VENTILATION AND AIR CIRCULATION WITHIN THE FURNACE MUST BE PRO- VIDED FOR THE REMOVAL OF STEAM AND EXHAUST GASES. 500°F (260°C) and 1000°F (538°C). UR . dependent on refractory thickness.com period for the temperature hold is CAUTION: IF PROPER PROCEDURES FOR PREPARATION. THIS WILL CAUSE LOCALIZED OVERHEATING AND POSSIBLE SPALLING.600°F to 2500°F (871°C to 1371°C) point during the heat-up. until steaming subsides. IF AT ANY TIME DURING THE HEAT-UP OR HOLD TIME. Direct flame Initial firing rates typically raise the impingement on the refractory should be temperature at about 50°F (28°C) per avoided. The time representative for specific guidance. steam spalling. www. As an When ramming around burner ports or be lightly rammed up and around the intermediate step. Here are some basic guidelines for the proper installation of each. of the rammer should always be parallel to the hot face of the material and vessel Roof Finishing.15 . The entire mass of plastics.. requires special attention. When ramming plastics. As installation progresses. they require support forms to best anchor system to use with rammed prevent slumping during installation. The direction surface of the hot face. the refractory mass will strip as much as can be finished in a installed on 8 or 12-inch centers and retain its full specified thickness. the hot face of the plastic ramming force should be directed into must be trimmed (or shaved) back to the Venting the main refractory mass in a manner face of the refractory anchors. the plastic adjacent to refractory anchors.INSTALLING RAMMED AND GUNNED PLASTICS Overview H-W manufactures plastics for both rammed and gunned installations. Pennsylvania for installation surface is necessary for uniform drying. it may be desirable Procedure to cut “construction joints” in the refractory hot face. the completed. anchors or ports. After scoring the joints with a slabs. e. During trimming. using a that forces the plastic to seal against the trowel or trimming spade. Shave toward the /16-inch diameter rod to provide escape be installed. RAMMED PLASTICS massive installations. Care should Immediately after finishing is complete. so that when forms are anchor to press the plastic tight against vents for steam which develops during stripped and the surface of the hot face the anchor. please contact Harbison- taken not to smooth the exposed surface Walker's Technical Support Group in of the refractory hot face. After ramming is seal. A lining thickness be taken not to peel the plastic away pierce the finished plastic with a 1/8 or 3 overage of 1/8 – 1/4-inch of plastic should from the anchor. area adjacent to the form one extra time installation. This technique is called peening.g. they should be patted shut so knitting is accomplished by breaking the that only a thin line remains on the slabs into smaller pieces. If forms were needed. Plastic adjacent to anchors should spalling of the refractory surface. two or three hours. roof or floor. ram the 3-inch will save material and make a better the refractory lining thickness. three times to secure its integrity. a coarse Pittsburgh. special care must be thick walls. When After ramming. Peening. 2 inches deep on 36-inch centers. these forms need to be seating anchors into the plastic. This should penetrate to about two-thirds of ramming next to forms. To minimize and control cracking on all Harbison-Walker UR . particularly phosphate-bonded should be rammed thoroughly two or types. only heat-up. the best trowel. These steam vents should be is finished. The Generally. Overhead installation walls. plastics are ceramic anchors. anchors should be lightly rammed up be broken up to facilitate installation and around the anchors to give a tighter in these tight areas. slabs of plastic must anchors to give a tighter seal. When short time. num head is strongly recommended for horizontally and vertically between positive knitting of plastic refractory anchors. These joints should A pneumatic ramming tool with be scored approximately a minimum 2 1/2 – 3-inch convex alumi. Wall Finishing. guidelines. tap progressively removed and replaced them into the mass with a leather mallet with expanded metal since the ignition to be certain that they set properly and of wood forms during heat-up can cause that there are no voids around them. For special conditions such as very to minimize laminations. The installation time of Procedure. electric power purposes. material falls into the feed wheel Other required key hardware pockets. Next. material hose. for best results. The key to a successful cut into a “V” shaped opening. Loose particles must be bulk carton. For estimating • a 440 volt. or plastic refractory structure. a thin coat Gunning Advantages of PHOXBOND® high-alumina phos. two material strong and resistant to penetration and GREENGUN® Plastics are widely handlers. Then the installation is the GREENGUN® BSM material is raked into the feed hopper of Gun. two erosion.INSTALLING RAMMED AND GUNNED PLASTICS Patching with Plastics GUNNED PLASTICS Refractory plastics provide a simple way to repair almost any worn brick. Here you can see the BSM Gun. high pressure. typical rebound rates with source required to operate the GREENGUN® are 15-20%. plus extra wear phate-bonded mortar should nology was developed in 1986 in pads and drive belts. shields and hard hats. Model GL 404-50. chip back the worn refractory area until a sound. unpenetrated and unaltered surface is the “V” Shaped opening in the exposed. Trim off any were looking for a more efficient and distributor for the BSM Gun in the excess plastic in the patch so that its faster method to install plastic refrac. rebound can be recycled. Today. The patch anchors. and the GREENGUN® plastic being raked into the hopper. To make a lasting repair patch. two way radios. In any but the smallest patches. The typical crew size on any will develop a phosphate bond at GREENGUN® can be as much as 50% GREENGUN® project is 4 to 6 people. with a 15 the BSM Gun. The installation process is very simple. The GREENGUN® bulk Installation containers are placed above the BSM Gun. trimming tools. market place. 3 phase. and for larger jobs. The GREENGUN® pocket feed wheel. H-W’s operator. which is available GREENGUN® Plastics gunning in 33' lengths. The best anchor system to use rent or purchase. Roughen the surface of the patch with gunned plastics are ceramic to facilitate moisture removal. face UR . shovels. phosphate-bonded plastics are espe- cially suited for repairs. When using phosphate- bonded plastics. be applied to the entire void after response to refractory contractors who Harbison-Walker is the exclusive the surface is prepared. one nozzle man. the GREENGUN® carton is Equipment. GREENGUN® Plastic Gunning Tech. • a 750 CFM air compressor needed to transport the gunned material through the hoses. Common job tools needed for installation are a fork lift. BSM Gun. BSM to the refractory surface. the void should have steeply angled sides to provide a grip for the repair patch. castable. it is advisable to cut away the worn refrac- tory in a V-shape toward the cold face. Air pressure transfers the includes: material into the hose and is then applied • 13/8" ID. This helps tie in the patch with the refractory mass. removed and. accepted throughout the refractory trimmers and rebound reclaimers. approximately 500°F (260°C) during less than the installation time of air The crew includes: one BSM Gun heat-up and will become extremely rammed plastic. tory. Strong. United States and the gun is available to surface is flush with the hot face.16 Harbison-Walker . This can be important when thick walls. or als. of the lining. If plastics must be 4. use Schedule II: out. contact your Harbison. 5. This lowers the freezing point per inch plastic thickness. Hold at 1000°F (538°C) for one hour more quickly. From ambient temperature. If forms cannot be removed. Hold at 500°F (260°C) for one hour cracks. These 4. Hold at 250°F (121°C) for one hour Plastics that include the word PLUS® in workability. specific conditions they can be heated Harbison-Walker offers a winterized 6. Hold for steaming (see note). Harbison-Walker packages rammed Phosphate-bonded plastics already have Note: If steaming of the lining is evident at any plastic refractories in 55-lb (25 kg) or a similar freezing point and do not time during heat-up. Harbison-Walker will manufac- ture to individual customer requirements as needed. All plastic materi. especially 500°F (260°C) at the hot face of the refractory surfaces should be covered lining at a rate not exceeding 50°F with a resin-based curing compound to in warm places. resulting in improper per inch plastic thickness. even those winterized. PLUS® DESIGNATION opened plastic may lose moisture and 2.) Remove winter. From ambient temperature.INSTALLING RAMMED AND GUNNED PLASTICS HEAT-UP STORAGE Schedule I: It is necessary to begin heat-up as soon Even though Harbison-Walker plastic as possible after completion of the refractories are carefully packaged to Heat-Setting and Air-Setting Plastics structure. PACKAGING has no effect on refractory properties. Plastic is sealed in polyethylene to minimize moisture loss and preserve the plastic's workability. to below 15°F (. Please discuss your special workability needs with your H-W representative. compound is helpful when performing a from sources of heat. equally important. then plastics as soon after receipt as possible. Heat to operating temperature at Walker Sales Representative. During 1. Hold for steaming (see note). overhead installation. after installation specified workability and moisture until heat-up. heat at a installation. although they a rate not exceeding 100°F (38°C) normally close during heat-up. visual inspection of surface coverage. the packages should hour per inch plastic thickness. The optimum 3. kept above freezing before installation tomer preference. desired. In use an air-setting mortar. plastics have passed a very severe For heat-set and air-set plastics. first-out basis. In hot outdoor areas. should be more. For specific heat-up version. slow drying and reduce shrinkage plastic materials should be stored in 2. If covering. Heat to operating temperature at from getting larger. with curing compound to keep them be covered with a tarpaulin or similar 5. bulk containers. Storage Harbison-Walker UR . or immediate installation is anticipated. Heat to 1000°F (538°C) at a rate of temperature for storage of plastics 50°F–75°F (10°C–24°C) per hour. Shrinkage cracks should be resprayed is 55-60°F (13-16°C) . Heat to 500°F (260°C) at a rate of satisfactory installation. (Do not an 8–12 inch space for air circulation. the product name contain non-metallic knitting of slabs and a less than 3. If this cannot be done. plastics should be prevented forms. do not permit wood forms to burn from freezing. The use of a colored curing cool. on a first-in. Plastics are made to and. heat to plastics are stored too long. Heat to 1000°F (538°C) at a rate of spalling test indicating that under 50°F–75°F (10°C–24°C) per hour. Unopened packages of (10°C) per hour. slurry of PHOXBOND® mortar. steaming subsides. The winterizing process per hour. Hold at 1000°F (538°C) for one stored outdoors. 50°F (10°C) per hour. depending on product or cus. Check all Phosphate-Bonded Plastics expanded metal forms are often a better choice because they allow the heat to plastic carefully before use. storage of the products at lower a rate not exceeding 100°F (38°C) temperatures. and 3000-lb. 8. dry-out is possible if 1. fiber additions to facilitate moisture removal during the dry-out. hold the temperature until 100-lb (44 kg) cartons. hour to 250°F (121°C) at the hot face plastic as is immediately needed.17 . Hold at 500°F (260°C) for one hour WINTERIZING per inch plastic thickness. the tarp per hour. unwrap only as much rate not exceeding 50°F (10°C) per penetrate the plastic better. levels. requirements. all retain moisture.9°C) and permits 7. shaded areas under roof and away per inch plastic thickness. cracks can be sealed with a or covering should be raised to provide 6. 2500. Gunned plastics are packaged in 1500. Pre. mass is divided into four to six slabs. As a rule of thumb. The refractory require winterizing. then be scored and additional material The type of installation involved rammed.INSTALLING RAMMING MIXES Overview Rigid forms are required when ramming vertical walls. lamination-free structure. RAMMING An anvil-type or reciprocating air indication that the material has been rammer having a metal ramming head rammed sufficiently. or arches and care must be taken to prevent deflection of the forms during the ramming operation. if Serrated ramming heads have been used possible. is when the rammer should be used to install Harbison. roofs. Score each layer to no more than 75oF (40oC) per hour and approximately ¼-inch depth to assure hold at 500oF (260oC) for at least one knitting of the subsequent layer. UR . finished in one continuous operation. a damp cloth so that the face will remain When batch feeding the material. should be roughened with a small trowel or small rake to eliminate laminations HEAT-UP and provide a continuous bond from Bring temperature up slowly. The surface should heads are of various shapes and sizes. reached. the ramming operation for more than Continuous feeding of the mix during one hour. The installation should be determines which is appropriate. Proper installation of Harbison- Walker ramming mixes will provide a dense. at a rate of batch to batch. head leaves noticeable tracks in the top Walker ramming mixes. Metal ramming face of the layer.18 Harbison-Walker . If it is necessary to interrupt for some installations. blows of the rammer should be directed Temperatures then can be increased at a in such a manner that lamination planes rate of no more than 100oF (55oC) per are not parallel to the hot face of the hour until operating temperatures are ramming mix. Ram at the most acute angle possible to the hot face. cover the unfinished area with ramming is preferable to batch feeding. The hour for every inch of thickness. A good Installing ramming mix in top cap of coreless induction furnace. the moist and new material will bond to it smooth surface formed by the rammer properly. produce satisfactory performance. tures. Wall thickness must bear some branch of masonry. the brick spalling conditions are severe. a return consisting of a crushed stone aggregate. heavy loads and slag attack. depending on wall on plates. hotter portion loses its ability to provide the brick count. girders or low brick piers. determine the top of the concrete foundation. the need for gas-tight construc. Walls must be designed to simple rectangular shapes. Three or pebbles. Courses consisting mostly of headers other furnace details should be de- For many industrial furnaces. so to the cooler part of the wall when the thickness. For temperatures above in applications where joints tend to more refractory brick go into the 700°F (371°C). wall because they expose a smaller area In composite wall construction Limestone or dolomite rock in an to high temperature. stretcher consisting of two or more kinds of brick aggregate will calcine at somewhat courses expose fewer joints than in inner and outer courses. When the tempera.21. it expand sufficiently at temperatures up Header courses tend to spall less than should not be used where stretcher to 1000°F (538°C) to set up stresses in stretchers at the hot face of a furnace courses may fall into the furnace. volume in cubic feet from the appropri- others. dehydration Courses of brick laid in a wall so that Courses consisting mainly or entirely of the cement reaches a point where the the lengths parallel the face of the wall of headers on the inner face and mainly concrete retains little mechanical are called stretchers. Usually. This on your refractory investment may not sand and binder of hydrated Portland construction is usually preferred for be realized. An they lie on one edge (See illustration. are embedded in the foundation. ture reaches 900°F (483°C). Otherwise. determined from the chart on UR . Calcined fireclay. For walls not of Sometimes. 3 inches in diameter or tures. pipes. the backup courses should not be conventional aggregate. UR . the courses higher temperatures and weaken headers. can be substituted for stretchers and off-setting vertical joints. wall can be tied for repairs. and it will not shrink walls. and in row-lock courses. of the foundation. Brick with lengths stretchers on the cold face are some- strength. and this provides an advantage are sometimes tied together. best placed in the tural stability. The type of bond selected for any especially true when the temperature at the highest temperature to which particular furnace will depend upon the gradient through the wall makes a concrete can be subjected. ate formula on this page and multiply by larger. Walls. thickness of the significant difference in total expansion. This is expansion is low. Its thermal strengthens and stabilizes furnace tied to the inner courses. the considerably. At carry structural loads at high tempera. when brick have marked the foundation. silica gravel. by the area of the wall to that air circulates under the vessel. crushed silica stand on end. furnace construction. in through combinations of headers and differences in rates of thermal expan- sizes up to 1 inch. design of the furnace.FURNACE REFRACTORY LINING & CONSTRUCTION Overview used in smaller furnaces and in furnaces Sound furnace refractory lining and construction — whether carried out by where heat must pass through the walls.provide a wall to which a 4½-inch skin aggregate of silica rock in any form will 20). cement. WALL CONSTRUCTION inch walls.19 . start ends of walls and turn hands of bricklayers experienced in The foundation must function at the corners. the concrete and weaken the foundation. or tightening construction However. the choice of a castable refractory for Bonding. However. basic brick walls. arches and temperature produced by the furnace. 13½-inch walls subject to high tempera- structural stability. Good furnace design In any case. inner. In soldier courses. cross flues are formed in the carry them. are often used advantageously in 9 and signed and constructed to assure tors build foundations of concrete. Alternate header and stretcher courses probably provide the most common arrangement for standard industrial furnaces. sion. experienced masonry specialists working on a high production furnace or a contractor Double tongue and groove brick provide building a municipal incinerator — begins with a few fundamental ideas required to stability for thin walls. Large 9-inch brick break FOUNDATION joints. good practice points to wear more rapidly than brick. However. running at right angles to the face are times considered desirable when Ordinary aggregates include quartz headers. Stretcher walls — one brick the number of brick per cubic foot. the wall should be Multiply brick per square foot from the often requires placement of the furnace bonded so that loads will be transferred appropriate row. severity of operating conditions required to build a simple wall can be courses of brickwork or the upper part and the need for easy maintenance. but most safely used for furnace foundations up expansion joints pass entirely through 9- to 700°F (371°C). Building furnaces is a specialized thick — usually have the least struc. four stretcher courses to one header rock and/or crushed limestone. interlocking courses. The bond provides Portland cement concrete has been stability and easy replacement. Under normal conditions. contrac. High temperature furnace operation walls. The number of refractory straights also calls for ventilation in the lower tion. but they are sometimes relation to height and unsupported Harbison-Walker UR . FURNACE REFRACTORY LINING & CONSTRUCTION BONDING OF WALLS BUILT WITH RECTANGULAR BRICK Wall 9 inches thick Wall 13½ inches thick Alternate header and stretcher courses Three stretcher courses to one header course on exposed or hot face Wall 13½ inches thick Wall 18 inches thick Alternate header and stretcher courses Only header course on hot face Wall 13½ inches thick Mainly stretcher course on cold face Three header courses to Wall 22½ inches thick one stretcher course on exposed or hot face Only header course on hot face Alternate header and Wall 18 inches thick stretcher course on cold face Alternate header and Wall 13½ inches thick stretcher courses Five header courses to one stretcher course on hot face Only stretcher course on cold face Back-up brick not tied to inner courses UR .20 Harbison-Walker . FURNACE REFRACTORY LINING & CONSTRUCTION length. A number of engineering firms Harbison-Walker UR . Thickness. 8 to 12 feet. On many Construction details. Number of Refractory Straights are built with brick tapered to turn Joints made with an air-setting mortar Required Per Square Foot of Wall circles. specialize in high temperature process 4½-inch thickness will carry heights up When there is no need for an especially design. Furnace hearths. contact with these organizations. such as dead-burned toe of the skewback (See discussion of magnesite or a ramming mix.9 wedge shape makes a 9-inch lining. the Sophisticated applications for refracto- mortar. Others where brick would be cut to fit. ramming mixes or dry refrac. the brick are laid without organizations concentrate on refractory to 8 feet. 27 32. In furnace construction. The brick should be given height than straight walls. In unsupported straight walls. Usually. 13½ inches. Arch brick slope from edge to generally can be somewhat thicker.2 taper along the edges. Some furnace the type of bond will be chosen to bottoms must withstand impact and minimize the number of joints in the abrasion from a charge of scrap metal. Generally. 18 21.2 makes a 4½-inch lining. and the design. the fusion that construction. furnaces and stacks. but or Floor edge so that the length of the brick such joints should be completely filled. In many cases.1 Rammed plastic refractories used for HEARTHS arch construction minimize the JOINT CONSIDERATIONS The construction of furnace hearths number of joints. as well as the installations. 9 x 4½ x 3” Brick parallels the furnace wall like a stretcher.21 . Even different furnaces ports is filled with ramming mix or within the same application area may castable refractories. For have sub-bottoms built of brick with example. metal or slag accompanied by corrosion ties for penetration by metal. with adequate mortars should have thin joints. may be somewhat thinner for a dipped or poured. while the same upward and horizontal expansion 7½ 8.3 header.6 so that it faces into the furnace like a expansion.7 basic brick. A 9 x 4½ x 2½-inch arch brick allowances permit walls to move freely 6 7. rubbed or tapped into place to produce as Cylindrical walls. arches and domes much brick-to-brick contact as possible. lining. walls higher than 12 feet. and thermal courses and to provide smooth bedding know-how to the search for solutions to spalling conditions may indicate addi. the irregular space between refractories themselves. furnace gases. any problem involving the use of tional thickness. lending than one and one half times their heights the use of mortar is desirable to level its engineering skills and applications should be somewhat thicker. In some cases. Combinations of the discussion of thermal expansion 13½ 16. vertical expansion 4½ 5. inches. depend on electric furnace roof brick and electrode applications. Arch Construction. usually seated materials are often used to fill places on a monolithic refractory bed. refractory brick depends on the brick. takes place on the hot face will provide Harbison-Walker maintains close Walls with unsupported length more the bond required. working hearths composed of monolithic tory materials can be used to protect the refractories.4 turn domes. either backing. 9 inches will carry heights of 3 strong bond. slag or or erosion. a requirements for thermal expansion. perform more efficiently with a different The thickness of joints between refractory design. Monoliths — not without Liquid pressure may tend to float brick. the need for preventing gas ries call for specialists in refractories leakage or slag penetration. UR . in many cases. however.0 these shapes taper in two dimensions to which begins on UR-4. and many contractor/installer to 3 feet. proper Inches while the wedge tapers from end to end allowance must be made for thermal 3 3. and 18 mortar. Walls of cylindrical Brickwork laid with heat-setting refractories. brick sizes and shapes or presents special problems. construction or thermal expansion joints Many hearths must resist penetration by – present the fewest joints and opportuni.22). 9 10. are Ramming mixes or castable refractory built of refractory brick. In allowances appear at joints in the brick. for the brick. key brick shapes may also The subject is covered in some detail in 12 14. From the viewpoint of longer brick in every third or fourth force may be carried by steel beams or arch design. a steel super- furnace. heavy basic brick. the center of the roof at midspan. The vertical characteristics. but design considerations remain supported until the final. link one side of the furnace to to the span and cutting the inside arc to structure helps carry the weight of the the other. the outside and inside arcs. center shapes In bonded construction. the binding consists of: LINE OF THRUST 1. like those required for brick arches–have of the arch rests on a skewback. Horizontal tie rods. buckstays. furnace designers force on the skewbacks. Each end better resistance to spalling. are gaining popularity throughout the industry.ARCH CONSTRUCTION Overview arch to the walls and binding. arch becomes self-supporting after all of the furnace to forestall outward Skews may be eliminated in monolithic the pieces go into place. suffer less deformation at high temperatures than they otherwise might. combustion chambers and Suspended arches are often used with dense. A the keys go into place. The concentric circles separated by the when the thinner parts of the roof wear horizontal thrust of a roof arch travels thickness of the roof. Ring arches require somewhat structural unit. This construction creates ribs by the furnace walls or a combination of or surfaces of the roof. essentially a Arch geometry determines all design strengthen ring arch roofs by using a distribution of its weight. 2 spaced at intervals along the -F F r concrete. but monolithic materials In suspended construction. arches a method for attaching the brick to an span wall openings. Bonded roofs are better adapted for hot including reduced cost and downtime. Harbison- flues. which remain strong walls and steel buttresses. and its angular value when roofs must be patched. vertical force and an outward horizontal ARCH GEOMETRY Sometimes. and balance opposing forces. the arch springs from the another in a stronger construction. Cold Monolithic Arches is a small piece of the radius of the circle repairs are easier to make and they offer Monolithic arches–cast over forms much of which the arch is a segment. sloping faces of the skewback shapes. or 2 2 2 channels extending across the S furnace above the roof to connect the upper ends of opposite Hypothetical position of thurst in a simple sprung arch. TYPES OF ARCHES Ring Arches Using suspended construction. ring. Vertical beams. each joint less labor for initial construction. However. The skewback away. and W 3. and sometimes they carry the weight of walls or overhead steel superstructure. refractories carry smaller loads and therefore. it is also In ring arches. when the bricks are in full contact at joints. W H h 2. Arches form the roofs of most furnaces. In traditional furnace design. determines the shape of each block or the roof. I-beams. The rise of the arch measures Suspended Arches rods. all joints are the same as those for brick arches. In some application. each course of brick easier to make allowance for thermal Sprung Arches forms a separate ring running across the expansion to avoid thermal stresses and In a true arch. arches. Most arches are built of brick. When it is broken and the rings help bond one monolithic arch provides all of the complete. Horizontal buttress beams CENTER OF GRAVITY running lengthwise to the furnace CENTER OF PRESSURE T -H in contact with the skewbacks F -F where possible. or backstays. The tie rods. Providing the standard solution to the problem of spanning the Walker has basic brick brands to provide high temperature process with refractories. UR . The skewbacks cut off the arc of the repairs but they demand more skill of circle on the outside radii of the arc. the design of the whole roof and the joints are continuous across pinch spalling.22 Harbison-Walker . are segments of across the roof. supporting system known as the binding equals half the included central angle of which is composed of beams and tie the arch. advantages monolithic construction.equal In suspended arches. but it must be displacement. usually above the the distance from the inner chord . the brick masons and more uniformity in The sprung arch exerts a downward the brick. otherwise distributed through the one against the other. checkerwork. Theoretically. The ring arches require support at the end of replaced brick in some applications. The strength of the ribs also helps through the skewbacks to a steel slope cuts the arc. roof. 23 .ARCH CONSTRUCTION Ribbed arch roof Ring arch roof Typical castable construction for sprung arch Bonded arch roof Harbison-Walker UR . the line Top of of thrust. Basic expansion are particularly important. which give up hot strength in Rise is normally expressed in inches cycling and the refractories used. thermal expansion of the brick will limit Special Skew Special Shapes upward movement of the arch. heat-up.608 inch refractories. Paperboard placed between brick will burn out and make room for expansion. or in terms of the Typically. On the other hand. span. rods arc spring loaded or manually Line of adjusted to permit thermal expansion of Thrust the refractories. shortening the radius of the arc and increasing the rise. As the line of thrust approaches a horizontal position in the Bulk Insulation arch. The 60° central angle equals one sixth of a circle and the span equals the inside radius. Without adequate provision for thermal expansion. Hot strength and thermal nor more than three inches per foot of per rise per foot of span. the line of force along which Approx. foot of span. 60-9 temperatures may become permanently Skew Buckstay deformed. It should be easy to visualize a larger High temperatures and soaking heat call For many applications. Insulating into consideration. Mortar Mixture Ground Brick and number of brick required to build the Mortar Mixture roof is easy to calculate. a 1. is a logical standard Special Standard in that it meets normal requirements for Skew Skew strength and stability. Built-up skewback A 60° skewback with In some furnaces allowance for A construction to be avoided. opening Special skewback Built-up skewback joints at the top and pinching brick at the A recommened construction A recommened construction bottom. Steel casings can provide an allowance for expansion. buttress block. thermal firebrick. thickness and weight. smaller included central angle and a point. from 11/2 to three inches per foot of span. inches per foot. the rise refractories need 21/4 to three inches of Good arch design must take these factors selected should depend on operating rise in sprung arches. the horizontal force approaches its maximum value. horizontal tie Approx.. so the Ground Brick and Approx. Thrust establishes the practical limit for roof rise. thickness and rise are angle including a higher rise and a for higher values. Brick that soften at operating Standard Buttress Block Skewback No. per foot of span. as well Experiences suggests that a simple High-alumina refractories used in arch as the thermal properties of the roof arch should rise not less than one construction call for at least 1. Skewback the arch distributes the vertical and Buttress Line of Thrust Angle horizontal elements of its weight. i.ARCH CONSTRUCTION When span. on its rise. conditions. exchange for low thermal conductivity. the relationship between arch thickness and rise* of the Special skewback Arch with skewbacks cold arch must be such that the line of A construction occasionaly used supported outside of walls thrust does not drop out of the arch Note: A stretcher course should never be used immediately below the skewback. They are directly related.24 Harbison-Walker . As the arch rises on heat-up. Silica roofs made with established. stable fireclay arches rise call for two to three inches of rise per central angle. In some cases. shifts downward. Operation and thermal expansion tend to push the brick upward. about 15/8-inch. the brick that maintain dimensional stability calculated using the formulas in this flatter roof with a smaller rise indicates a and hot strength almost to their melting section.e. all other dimensions can be shorter radius. chiefly temperature. The reaction of refractory brick to Header Course Line of furnace operation. Line of Header Course Thrust Approx. UR .608 inch rise. For any particular furnace. normally rise from one to two The stability of any arch will depend longer radius. column 5. If it does. twice shapes.70417S 90° 28.29517 1.62500S 106° 15. That means h-1/48S the arch is a segment of a circle with an If the design specifies 13½ x 6 x 3 inch 18 foot.13519T 0. No. Arch Constants for Given Rises per Foot of Span Rise Central Angle 0 Difference Skewback Inches Inside Inside Between Per Foot Radius Degress Part of Arc Outside & H V F of Span (r) Circle (aa) Inside Arc (d) (Aa . Ø divided by 360°.66004S 98° 29.4’. 1 Wedge 9. and the an arch with a 12 foot span.16667 1. then: exceed thickness (T) times the of the provides data to develop the required 0.83333S 73° 44.43507T 0.76042S 82° 13. with or without steel supports. circle.5’ 0. September 1939.25133 1.63757Q 2 0.70414T 1.7’ 0. cosine of the central angle (0)plus 1/48 design values.640 pieces. selecting the proper combinations for rings.20483 1. 1 Wedge * Assuming that the absolute lower limit a minimum rise of 21/4 inches per foot of for the rise of the line of thrust is 1/4 inch span.05579S 1.88235T 0.43557Q 11/2 1. equal to 2.82157T 0.4’ 0. but thrust where it belongs.84320T 0. 11 / 2 inches.4’ 0.57735Q 13/4 0.11200S 1.74329T 0.80000T 0.aa) (1) (2) (3) (4) (5) (6) (7) (8) (9) 1 1.01840S 0.04720T 0.4’ 0.160444Q 3 0.71906T 0. exceed: determine the inside radius.13464S 1.87273Q 2. the For a more complete discussion of arch central angle for this arch will be 82° design calls for 40 times 19. three inch inside diameter. running foot on the 20 foot roof.75000Q 21/4 0. especially when carried out In practical construction problems.125 or 9 feet.73 or 19 pieces. Equations vertical and horizontal components are required to produce the necessary values On page IR .53760T 0.50000T 0.284 ten thousandths of a pieces. This implies that T should not multiply the span by 0.85459T 0.333334Q NOTE: The factors in the above tables are the following functions of 0: Column 2. total of 1.75753T 0.ARCH CONSTRUCTION when it is heated. No.71006T 0. No. a total of 760 stresses see: J. 2 Wedge span (S).28701T 0.65280T 1. not difficult. 2 Wedge and force.9’ 0.608 1. combinations for rings for 13½ inch The walls. is sometimes lengthy. the rise (h) must The table of Arch Constants below thousandths of a ring. 3 inch ring must carry the vertical force.65753T 0.15912S 1. requires 176 pieces.13076 1.2284 x 82 = 18. on a furnace 20 feet long. the with a pocket calculator. column 4. 1/2 cosecant 1/2 0 Harbison-Walker UR .2 or 41 pieces. in this case.60000T 1. a Roots for High Temperature furnaces.39933T 0. then two rings will cover a Cosine 0/2 the inside radius. 1 Wedge.8’ 0. If this design calls for 2.09544S 1.22840 1.10514 1. the arch will ARCH CONSTRUCTION not be stable.32432T 0.04720S 1.54167S 37° 50.75342T 0. not flush with professional job to assure face-to-face flush with Calculation of arch parameters.90000Q 21/2 0.00000S 60° 0.07251S 1. 2 Wedge. NARMAG® 60DB basic brick. and 40 The table also indicates that the rings will roof the furnace.0’ 0.94595T 0.06250S 56° 8.45 the tables of brick more important than the resultant force. No.76042 to 0.284 ten (1/48) per foot of span.7’ 0.80000T 0.2284 x 176 = 40. Suppose that a furnace design calls for linings show that an 18 foot.02868S 0.5’ 0. “Sprung-Arch 13.46563T 0. are included in this section.60000T 0.302 0.6’ 0. Spotts Mcdowell. 82 pieces. No.53333Q 1.25 .93006S 65° 2.97992T 0.27360 1.66059T 0. Generally.86603T 0. including buckstays thick built of NARMAG® 60DB brand and tie rods. must contain the horizontal brick.47059T 0.18067 1.15596 1.91681T 0. and 40 times 41. CALCULATIONS The line of thrust in a cold arch The brick count for many sizes can be should lie within the middle third of the calculated from the tables of brick brick.57918T 0.66896T 0.34286Q 11/4 1. For a 21/4 inch rise. since simple combination of brick shapes and doing a Skewback Skewback sprung arches are segments of circles.” Blast Furnace and Steel Plant.25208S 47° 4. Thus. 1/2 cosecant 1/2 0.23326 1. No.09125S 1.04117S 0. the arch at top arch at top contact between brick will keep the arch numbers. 131/2 inches can be built with: horizontal binding.74742S 83° 58.00840Q 23/4 0. 68 W D= Density of brick in pounds per cubic foot.25 ft span. or slightly above. In this example above.4'.75342 times the However.89 pounds per foot of arch length.57 W 0.5’ 1.64 pounds per be calculated from constants in the same F= H2+(W/2)2 foot of arch length. UR .302 83° 58.17 DST 0. weight (W). to the center of arch thickness at the skewbacks. by the weight of material adhering to.17 DST. the weight of the Outside radius (R+T) = 10.8’ 1. The horizontal force depends on the on the assumption that the line of thrust Skewback dimensions can be weight of the arch and on the span and passes from the center of arch thickness determined from the table of Arch rise.6’ 1.98 W 1. and conditions in the furnace.17 times 192 times 12 in this example.80 W 21/2 90° 28.125 ft the one-piece skewback generally can settle.125 ft provides greater strength and better and (5) arch stresses can be increased Density of support at the buttress. the angle of 82° 13. W=Weight of brick per foot of arch length. even when the Maximum Values on the following page. Other dimensions can times 1.18 W 1. workmanship in construction of the arch design described earlier in this as previously illustrated.5’ 1.71 W 3 106° 15. The thrust of cold arch with a 2¼ inch rise Other skewback dimensions can be limiting value which the horizontal per foot of span equals 0.7’ 1.72 W 0.10 DST 0. 1516.25 ft channel or angle. rise and span=12 x 2.11 DST 0.4’ 1. position of the line of thrust will Span (S) = 12 ft Built-up skews satisfy the requirements change when the furnace is heated.25 DST 0. determined from the table below. four feet or less. the line of thrust brick.04 W 13/4 65° 2. or one-piece arch may be less than perfect. Inside Radius (r) = 9.46 W 0. S=Span in feet.0’ 1.09 DST 0. that is: is. The constants given in this table are based on the assumption that the line of thrust passes from the center of the arch thickness at the point of midspan.26 Harbison-Walker . The force acting against the skewbacks depends Rise (h) = 2. above.91 W 1.64 equals be only approximated because of the from the constants in the table of 1940. 0. for this arch.25 = 27 inches=2.608 60° 0.75342 times full contact.97 W 2 73° 44.07 DST 1. T=Thickness of arch in feet. 1. NARMAG® 60DB (D) = 192 lb/ft3 The slope of the skewback must be or absorbed by the bricks. in which all adjoining brick are in 1516. The following calculations are based the corner of the supporting steel.7’ 1.4’ 1. at midspan to the center of arch Constants below. the horizontal 13.4’ 1.64 W 0. The slope equals half sum of the squares of horizontal (H) weight of the arch equals 1. the stresses of a cold and buttresses must carry amounts to thickness of an arch with a 2¼ inch rise.83 W 0.19 DST 0. can be approximately From the same table. following variables: (1) the exact position Constants for Calculation of Stresses in Unheated Arches Forces Per Foot of Arch Length Rise in Inches H F Per Foot Central W Horizonal Resultant Thrust at of Span Angle (0) Weight Thrust Skewback 1 37° 50.125 equals 3032. For the arch under The amount of stress in a furnace can Hmax. (2) Consider the NARMAG® 60DB brick combinations of rectangular brick sizes.14 DST 0.81 W 2. the vertical force that the walls The V dimension is 0.32. (4) of narrow spans. When the skewback is carried on a thickness of the arch.9’ 1.17 DST 0.5 equals approximately 10. changing arch parameters. Vertical force equals one half the weight of the arch per running foot.62 W 0. is not known. thrust approaches in a heated arch. but tie rods can stretch and the furnace Thickness (T)= 1.22 DST 0.64 time its determined in the same way. can be calculated approximately consideration.28 W 11/2 56° 8.25 inches per foot of designed to match the central angle of the arch.76 W 23/4 98° 29.6' and vertical (W) forces.ARCH CONSTRUCTION SKEWBACK DESIGN of the line of thrust. 0. determined by the rise and primarily on the span. Its design parameters are: special skews designed to fit the arch. Since W/2 equals table.88 W 21/4 82° 13. amounting to 41° 6.64 times 3032. From the example The resultant thrust (F) acting at the thickness at the skewbacks.57 W 11/4 47° 4. arch. (3) the chapter.10 W 1. That the central angle.17 inches. a 2¼ inch rise produces a central skewback equals the square root of the As shown in the table below.4' should pass through. Skewbacks may be built-up arch is cold.51 W 0.05 DST 1. Central Angle (0) = 82°13.32 pounds per foot of arch length.49 W 1. 80 H 3.73 H 3 106° 15.63 H 1. In the parameters in a few minutes. depending on the size of designers limit tensile stress to 12. that is. is 0. For ordinary temperature not over 250°F(121°C) for 24 structural steel bindings. or Walker representative. it is often pounds per foot of arch length. many furnace hours or longer.27 .52 H 1. Maximum Value Approached by Horizonal Thrust in Heated Arch Free to Rise Hmax Per Foot of Arch Length Inches Thickness of Arch in Precent of Span Per Foot Central of Span Angle (O) 4% 5% 6% 7% 8% 9% 10% 1 37° 50. For a 2¼ inch rise. This furnace design.46 H 1.24 H 1.69 H 1. Careful drying of linings built indicate that the maximum value involving refractory applications. refractory structures often tap Harbison.37 H 1.29 H 2.79 H 1.38 H 1.86 H 2.17 H 2.28 H 1.93 H 2.94 H 2.42 H 1. of magnesia and some of its compounds approached by horizontal thrust for a Harbison.41 H 1.608 60° 0.000 the vessel and the refractories in use.22 H 21/4 82°13.26 H 1. circulating over the walls to remove preliminary heat-up develops the The safety factor used in furnace moisture.82 H 23/4 98° 29.63 H * H = Horizonal thrust.86 H 2.48 H 1. that used in conventional steel structural brickwork.14 H 2.39 H 1.09.45 H 1.41 H 3. that can hydration of the magnesia. tend to equals 0. This Initial Heat-Up Considerations good practice to heat the refractories to a value is an approximation.0’ 1.29 H 1.04 H 2.88 H* 2. 1.84 times 1940..81 H 1.7’ 1.51 H 1. rapid changes in temperature. Harbison-Walker UR .33 H 1. ** Stress excessive. but it lies In most cases.69 H 1. Good practice permits a design because the furnace binding may furnace to dry out thoroughly at a become overheated.4’ 1.95 H 21/2 90° 28. Furnace builders and refractory Maximum values approached by Walker resources.67 H 1.72 H 1.9’ 1.47 H 1.7’ 1.37 H 1. often during heat-up can cause rapid.89 equals 3571.30 H 13/4 65° 2.57 H 1.26 H 1. e.47 H 1.4’ 1.84H.57 H 1.84 H 2. 1.ARCH CONSTRUCTION The resultant force. especially. pounds per square inch. requirements of the brands that line their the factors listed in the table. which steam under pressure can cause determined by multiplying the cold arch are used with customers.29 H 5.24 In low temperature furnaces.8’ 1.81 times 3032. as determined from the previous table.43 H 1.302 83° 58. Water vapor or heated arch free to rise can be developed computer programs.88 H 1.6’ 1. length.00 H 2.43 H 1.98 H 2. also determined from COMPLEX REFRACTORY Temperatures above 400°F to 600°F the table above.75 H 3. spall when subjected to excessively maximum thrust approaches 1.59 H 1.33 H 1.33 H 1. problems.77 H 2 73° 44.41 H 2. Steam trapped in the pores of ceramic bond in mortared joints and binding design is ordinarily higher than brick or mortar may damage the increases their mechanical strength.5’ 1.31 H 2.22 H 1. engineering skills consumers should understand the horizontal thrust can be determined from and advanced refractories technology. please call your Harbison.g.61 H 1.53 H 1. expansion with consequent spalling. localized example considered earlier.58 H 1. horizontal thrust by a factor dependent produce complex arch or dome design Flame impingement on brickwork on the ratio of thickness to span.29 H 1. a new furnace should be higher temperature than that required for well within the requirements of practical heated slowly with enough air operation for a short period of time. These data for solutions to complex problems furnaces.73 H 5.0 H ** ** ** 11/4 47° 4.4’ 1.60 H 1.56 H 1.5’ 1. equals 9% of span. thickness saving many man-hours of calculation.55 H 3.70 H 1.64 DESIGN PROBLEMS (205°C to 316°C) should be avoided until equals 2546.06 H 3.34 H ** 11/2 56° 8.Walker engineers have is especially important.44 pounds per foot of arch Customers who design or build all steaming ceases.125/12 For assistance with your difficult design Silica and basic brick.63 H 1. V=T Cos½0 13. Sines. quick and easy. i. Tan ¼ 0 = d/6 That allows you to go from number to calculator. d = 6 Tan ¼0 cosines or tangents are found in tables of = 0. but the The following symbols and variables multiplication. all the algebra you need to know is that parentheses tell you to perform the arithmetic operation Arches Arch Formulas inside before carrying out the other Many pocket calculators will make operations. cosine or dimensions. aa = 6. Q = Skewback dimensions indicated in the Arch Constants table. P. aa = Length of inside arc A a = Length of outside arc R = Outside radius of arch r = Inside radius of arch S = Span of arch d = Rise in inches per foot of span h = Total rise of arch T = Thickness of arch 0 = Central Angle (Theta) H. Solutions to 4. 1.125) 9. = ½ The Central Angle 11. fingertips on many models. Tan ¼ 0 = 2h/S associated with a particular number. r = S2/8h + h/2 All you have to know about numerical characteristics such as trigonometry is that each sine.r2-(S/2)2 associated with one particular angle. Sine ½ 0 = S/2r and that an arcsine. Remember. H = T Sine ½0 requirements of the problem. formulas and pushing buttons on the 6. arccosine or arch problems involve nothing more arctangent is a particular angle than substituting numbers into the 5. UR .2832r (0/360°) trigonometric functions or in pocket Arcsine 0. or back previously specified: and forth. and (3) perform the arithmetic operations required by the formula.2832R (6/360°) The Central Angle = 82. division and reference to are used in the arch formulas: the table take more time. once the span and rise of an arch are decided. they involve three steps: (1) pick out the formula that produces the dimension or other number that you Skewback Skewback need. or from angle to number.6575 10. Aa= 6. calculation of arch parameters. depending on the 8. h = r . For example in the design 7. all other dimensions follow.6575 = 41. Sine ½0 =S/2r = 12 (2 x 9. V.ARCH CONSTRUCTION REFRACTORY CONSTRUCTION CALCULATIONS Calculations to determine the dimensions or numerical characteristics of refractory structures are not difficult. cosine 2.11° calculators. Part of circle = 0/360° angle.28 Harbison-Walker . pencil and a table of Arch Symbols trigonometric functions.e. (2) substitute the numbers in your not flush with flush with problem that fit the letter-variables in arch to top arch to top the formula. P=QTan ½0 The problem is no more difficult with paper. To use these formulas. R = r+T tangent is a particular number and tangent values are literally at your 3.22° = 82° 13' 12. Generally. Sine. and 2-c. ce-cf brick E. 2-b. dg = A given inside diameter. is a radial. E. and 4-c for a series of combinations. if brick E is radial Dg must lie Nx=Number of pieces of brick E required between De and Df. when Nx latter case. brick F turns a smaller used in combination with brick F. F used in combination to form a ring having a given outside diameter Dg. (3-b) Nece+Nfcf =
dg Df = Outside diameter of ring formed by Nt=Total number of pieces of brick E and brick F. use Formulas 2-a. to
Dg-Nfcf De = Outside diameter of ring formed by form a ring having a given out side (2-b) Ne = diameter Dg.29 . (4-c) Nt = Ne+Nf Harbison-Walker UR . E and F. Ring Formulas Ring Symbols 2
T Cf = Outside chord dimension of (1-a) Nf = E = Either a straight brick or a radial Cf-cf brick used with a companion brick brick F. are radial and the inside and outside Inside Chord Dimensions Inside Chord Dimensions chord dimensions of E differ from those Combination of a Straight Brick (E) Combination of Two Radial Brick of F. and 4-a. used with a cf= Inside chord dimension of brick F. are radial with outside Ring chord dimensions and inside chord Calculations dimensions unequal.ARCH CONSTRUCTION Rings The number of brick of two sizes to form Outside Cord Dimensions Outside Cord Dimensions a ring can be calculated from formulas listed below. when brick E is radial it turns a brick E. use Formulas 3-a. outside diameter Df. is a straight. When both brick. form a ring having a given outside De-Df diameter Dg. Ce Cf F = A radial brick. in the Ne=Number of pieces of brick E. When both brick. when Ce used in combination with brick E. to form a complete ring having an (1-c) Nt = Ne+Nf outside diameter De. E and F. to (4-a) Ne = (Dg-Df) diameter than brick E. (2-c) Nf = Nt-Ne Ny=Number of pieces of brick F required Ce= Outside chord dimension of to form a complete ring having an (3-c) Nt = Ne+Nf brick E. 1-b and 1-c. Ny (4-b) Nf = (De-Dg) Dg = A given outside diameter larger than De-Df Df. and the other. 3-b and 3-c for a and a Radial Brick (F) (E and F) to Form a Ring. Nf=Number of pieces of brick F. F. use Formulas 1-a. 4-b.
Dg-NfCf T = Radial dimension common to both (1-b) Ne = brick E and F. ce= Inside chord dimension of
Dg
Dg F. (2-a) Nt = = larger diameter than brick F. (3-a) Nece+NfCf =
Dg companion brick E which may be either straight or radial. When one brick. Brick E to Form a Ring Turns a Large Diameter than Brick F single combination. .com *In order to provide current data to the users on this handbook. we have chosen to use an on-line link to our website. www. SECTION 5 Monolithic and Ceramic Fiber Products Mortar Materials MP-1 Plastic Refractories MP-4 Gunning Mixes MP-8 Castable Refractories MP-11 Ramming Refractories MP-20 Ceramic Fiber Products MP-22 Data Sheets* www.com.hwr.hwr. If you are not able to access the website. please contact your local sales representative to secure the required data sheets. com Harbison-Walker MP . bonds individual brick together. The wall is bonded throughout. and maintain the strength of the bond up to the temperature at which the ceramic bond takes effect. which may require an adjusted balance of properties. Prepared from suitable refractory materials by proper selection and combination.MORTAR MATERIALS Overview Since masonry built of refractory brick consists of many relatively small units. Air-setting mortars take a rigid set when dried. brick and mortar should develop a strong bond. However. and the nature of the mortar materials used in the joints. or where a very strong bond through the entire wall thickness is not an essential requirement. Mortar material should be selected as carefully as the brick with which it is to be used. strong joints are desired. for laying brick walls that are subjected alternately to soaking heat and cooling cycles. temperature changes will affect the bond between brick and cause surface coatings to crack or peel. heat-setting mortars are supplied for laying refractory brick in applications where full or solid joints with minimum shrinkage are especially desirable. the manner in which they are laid together. Mortar should not shrink excessively upon drying or heating. Click here for Technical Data Sheets or go to www. A bonding mortar often must meet extremely exacting conditions while in service. Consequently. Air-setting mortars form mechanically strong joints with high resistance to abrasion and erosion. A mortar should have good working properties for both economy and convenience in laying when mixed to either dipping or trowelling consistency. Thermal expansion of the mortar should be approximately the same as that of the brick with which it is used. mortars that do not develop a strong bond are often desirable.hwr. These mortars provide flexibility in expansion and contraction as furnace temperature rises and falls. Refractory mortar materials are generally divided into two classes: heat-setting mor- tars and air-setting mortars. chemical binders impart air-setting properties. otherwise. Heat-setting mortars develop a ceramic set with a strong bond only at furnace tem- peratures. Heat-setting mortars may also compensate for the high thermal expansion of certain brick. nor should it overfire and become vesicular at the maximum service temperature. In some applications. Mortar fills the joints. and protects the joints from attack by slag and other fluxes. The following product descriptions of Harbison-Walaker’s mortar materials refracto- ries are categorized by their classification. from the hot to the cold surface. and for differences in thermal expansion between brick of different types used in the same furnace. This listing represents the major brands supplied for a wide variety of furnaces and applications. the strength of the masonry depends on the strength of the individual brick. Available in various compositions.1 . and it must be chosen for compatibility with the composition of the brick. Refractoriness must be sufficiently high so that mortar will not melt or flow from the joints at high temperatures. and smooth trowelling A wet. very low silica contents. It cautiously. It can be used for all types of high-alumina brick where Click here for extra bond strength is needed in the Technical Data Sheets joints for structural stability. THERMOLITH® possesses provides high bonding strength and suitable for use at temperatures up to excellent resistance to corrosive slags excellent resistance to corrosion and 3200°F (1760°C). 36 REFRACTORY CEMENT® is a wet. and then very temperatures up to 3400°F (1873°C). ability without peeling. Heating to a and is very resistant to corrosion by BOND® refractory mortar consists of minimum of 500°F (260°C) is necessary volatile alkalies and slags in all types high fired.MORTAR MATERIALS BASIC MORTARS PHOSPHATE-BONDED HIGH. CORALITE® BOND his high refractori- ness and excellent resistance to attack by corrosive slags No. volume GREENSET® -85-P TUFLINE® MORTAR stability. A phosphate-bonded. air-setting version of ’SAIRSET®. wet mortar on high purity alumina aggregate. high DM and TUFLINE® 98 DM in temperature mortar. Formulated to minimize A dry high-alumina based air-setting shrinkage.2 Harbison-Walker . Develops high strength and to a higher workability is also available. resistance to slag attack. It is especially repairing fiber lined furnaces. GREENSET®-94-P has excellent GREENPATCH 421 ’SAIRBOND® resistance to aluminum reaction. tempered mortar. air-setting. intended for use with TUFLINE® 95 A wet. HIGH-ALUMINA MORTARS Con’t ALUMINA MORTARS THERMOLITH® KORUNDAL® BOND ® An air-setting. It is ’SAIRSET® slag attack. high temperature PHOXBOND High-Alumina air-setting mortar based bonding material with a chrome ore This phosphate-bonded. It is used to lay basic mortar can be sprayed or brush coated KORUNDAL® MORTAR brick of all types or as a neutral layer over refractory walls to reduce perme. and fumes through a wide range of erosion. of furnaces. brick and as a coating in a variety of GREFPATCH® 85 & WET applications.hwr. air-setting. PHOXBOND® refractory temperatures. alumina mortar. ’SAIRBOND® has excellent trowelling effective in laying extra high-alumina characteristics. It combines high refractoriness. qualities. phosphate bonded. high-alumina calcines and to develop full strength. KORUNDAL® mortar should not be thinned unless MORTAR provides excellent service at FIRECLAY MORTARS absolutely necessary. has excellent working properties. smooth working plastic clays. and good resistance to trowelling characteristics. and plaster.com MP . PHOXBOND® high refractoriness. It is used primarily for for use at temperatures up to 3000°F. with smooth working TUFLINE® MORTAR has very good characteristics. but can A wet. A WET version. 36 REFRACTORY CEMENT® No. Rolling the drums prior to also has exceptional stability and load- HARWACO BOND® opening will help bring the mortar to bearing ability at high temperatures Shipped wet or dry. high strength. 84% alumina patching plaster. phosphate. high temperature cement with good bonding strength and refractoriness. or go to www. This mortar is GREENSET®-94-P applications requiring materials with formulated for trowelled joint. 94% alumina. It is base. GREFPATCH® 85 can HIGH-ALUMINA MORTARS be applied by trowelling or hand packing of areas that have spalled or CORALITE® BOND eroded. be thinned for dipping by adding water. HARWACO working consistency. An air setting high-alumina patching A dry. bonded mortar with excellent refractori- ness. high purity 95% alumina mortar. A heat-setting mortar with extremely between brick of any type. smooth working characteristics. high A dry. 3 . Available dry with a separate liquid component.hwr.MORTAR MATERIALS ALUMINA-CHROME MORTARS AUREX® BOND A 75% chromic oxide containing. excellent resistance to corrosion by non-ferrous and ferrous metals. For varying consis- tency. phosphated bonded mortar . High bond strength. a special liquid thinner is available.com Harbison-Walker MP . RUBY® BOND A unique air set alumina-chrome mortar with excellent corrosion resistance and high temperature strength SILICA MORTARS FUSIL® MORTAR A high purity. AUREX® BOND is used in highly corrosive applications such as slagging gasifiers. Click here for Technical Data Sheets or go to www. air-setting fused silica mortar. RUBY® MORTAR Phosphate-bonded mortar with 10% chromic oxide. cupolas. “Heat-setting” refractories stable at high furnace operating conditions. annealing ovens. shock from rapid heating or cooling In the group of plastic refractories. Typically. aluminum furnaces. moisture content. Its special bonding system provides additional strength at lower also be pounded with a mallet.PLASTIC REFRACTORIES FIRECLAY PLASTICS (Air-Set) Overview Plastic refractories are mixtures of refractory materials prepared in SUPER HYBOND® PLUS stiff. plastic refractory. SUPER HYBOND® 80 brands supplied for a wide variety of furnaces and applications. It has excellent adhesion refractories are especially adaptable for making quick. economical. HIGH-ALUMINA PLASTICS (Air- Harbison-Walker’s ramming plastic refractories are precut into slabs for Set) easy use. super-duty fireclay generally rammed into place with pneumatic hammers. boilers. It exhibits sacks for easy handling on the job site. these include soaking pits. as most clay-bonded materials do until heated. SUPER HYBOND® 80 tories are categorized by their classification. Plastic temperatures. those that are “air-setting” take a furnace conditions. A 50% alumina. eliminating the need to cut special shapes. This listing represents the major An air-setting. emergency repairs and are easily installed to any shape or contour. but has no effect on refractory properties. After heating. Exceptional purity provides maximum For shipment during cold weather. 80% alumina. gunned or vibrated into place.4 Harbison-Walker . but they can plastic. Click here for Technical Data Sheets or go to www. The following product descriptions of Harbison-Walker’s plastic refrac. Vibratable plastics are packaged in 55 pound on high purity bauxite. 3200°F (1761°C). 60% alumina plastic based aged in 3000 pound boxes. It is very volume firm set as they dry out at ambient temperatures. SUPER HYBOND® 60 PLUS An air-set. Harbison-Walker “winterizes” its non. exhibits excellent resistance to thermal ladles. and many other industrial applications. FIRECLAY PLASTICS (Heat-Set) The ease with which plastic refractory materials can be installed qualifies SUPER G them for many applications. Also develops freezing point a few degrees and permits storage of the refractory at lower moderate strength upon drying. resistance to slag attack and outstand- ing ability to withstand load at operat- phosphate bonded plastic refractories. properties and low shrinkage. Each of these types of plastic increased strength and volume stability refractories is enclosed in polyethylene prior to packaging to preserve its throughout its temperature range. They are An air-setting. extruded condition for application without mixing.com MP . Gunning plastics are granulated to accommodate charging the BSM gun. remains refractory at high tempera- tures. incinerators. It offers excellent resistance to fluxing oxides and slags and good volume stability up to its maximum service temperature.hwr. and packaged in 55 or 100 pound cartons for shipping. Winterizing the mix suppresses the ing temperatures. It forging furnaces. bake ovens. temperatures. both types take the strong ceramic set typical of refractories. heat-set plastic. and pack. remain relatively soft. and rotary kiln resistance. phosphate bonded plastic. making it where excellent resistance to tempera. alumina-chrome ture range. This product is used allows for earlier sintering. boiler bottoms. proved strength at intermediate include iron and steel troughs. resistance to erosion from slag and severe abrasion and erosion. RUBY® PLASTIC stability throughout its entire tempera. plastic. Its high kaolin. NARPHOS™ 85P PLASTIC industrial incinerators. metal wash. attack by coal slag. phosphate bonded plastic with RUBY® PLASTIC S treating furnaces. good workability. Applications include foundry troughs. trowelling plastic. A 70% alumina. high strength. industrial NARPHOS™ 85 TP KORUNDAL® PLASTIC incinerators. At high temperatures. phosphate-bonded. troughs and tap-out areas. phos- A 50% alumina. high strength. resistance to erosion from slag and slags.PLASTIC REFRACTORIES HIGH-ALUMINA PLASTICS CORAL PLASTIC® (28-82) ALUMINA-CHROME PLASTICS (Phosphate Bonded) An 85% alumina. and to attack by coal slag. and An 85% alumina. operating temperature. and catalyst lines. Technical Data Sheets or go to www.hwr. H-W® BULL RAM PLASTIC GREENPAK 85-P PLUS recovery boilers. phosphate-bonded.com Harbison-Walker MP . cyclones. excellent strength. phosphate over tubes. A phosphate-bonded. phosphate bonded combined with excellent volume phate-bonded. boilers. CORAL PLASTIC® (28-82) RUBY® PLASTIC AMC GREENPAK 50-P PLUS provides high strength and density An economical. 85% alumina. A highly workable and cohesive 70% is required. NARPHOSTM 85P PLASTIC A fine grind. Applications include dams. tabular alumina slagging areas over tubes. The presence of mullite grain tional. chrome solid solution bond which has excellent resistance to temperatures. GREENPAK 90-P PLUS GREENPAK 90-P PLUS is an extra high alumina. alumina-chrome plastic. and chromic oxide containing plastic firing hoods. NARPHOS 85 TP is high strength at high temperature is ideal for patching and veneering thin needed. and tap holes. linings. impact areas. It is of an acid to neutral nature and to also has high density and good hot phosphate-bonded and shows im. It exhibits high density and Click here for excellent strength. GREENPAK 85-PF PLUS and lower side walls in slagging areas plastic. volume stability at high temperatures. It displays non-wetting low shrinkage. heat alumina. induction furnaces and pulp mill plastic. alumina/mullite phosphate bonded ladles.5 . is used in a wide range of applications. It is used in applications where characteristics. thermal shock. slag. resistance while retaining high hot NARMUL® P PLASTIC strengths and low open porosity. mullite plastic. spouts. boiler bottoms. Typical RUBY PLASTIC forms an alumina- metal wash. Typical uses strength. slag resistance and A phosphate-bonded. It exhibits higher strengths to ture range. It has excellent based plastic with exceptional refracto- physical properties. dams. oxide slags of an acid to neutral nature required. phosphate-bonded. outstanding slag A phosphate-bonded. It has GREENPAK 85-MP PLUS RUBY PLASTIC S has extremely high purity for outstanding corrosion This is an economical version of good resistance to high iron oxide slags resistance. It displays non-wetting chromic oxide content gives it out- withstand mechanical abuse and has characteristics to provide outstanding standing resistance to acid and neutral better alkali resistance than conven. excellent workabil. It features combined with excellent volume high refractoriness. heat-setting plastics. corrosion resistant plastic based on high purity bauxitic stability throughout its entire tempera. GREENPAK 85-P PLUS is a high including incinerators. thermal shock. spouts. impact areas. ferrous and non. tundish and foundry extremely good resistance to high iron slag. ity. naces. This product is used where applications include induction fur. and abrasion 2500°F (1371°C) and 2900°F (1593°C). provides high strength and density bonded plastic refractory. NARMUL® P PLASTIC GREENPAK 85-P PLUS. formulated to optimize slag erosion It demonstrates good resistance to resistance and iron oxide penetration alkali attack. ideal for slagging applications between H-W® BULL RAM PLASTIC tures. An 85% alumina. and workability riness. and abrasion is ladles. It was developed for plastic with very high strength at high characteristics to provide outstanding use as a patching material in areas of temperatures. high-alumina ferrous metals furnaces. troughs. and brass reverberatory content provides high thermal conduc- SHAMROCK® 885 PLASTIC furnace upper sidewalls. boilers. furnace upper cases and special shapes. high density and is resistant to ECLIPSE® 60-P ADTECH® ferrous and non-ferrous metal penetra- A phosphate-bonded silicon carbide tion. containing approximately 73% silicon VIBRATABLE PLASTICS TIC utilizes a fused chrome-alumina carbide. It is especially RUBY® PLASTIC 20 to thermal shock from rapid heating or formulated for ramming on studded High strength. Typical applications include excellent thermal shock resistance. It is phosphate free. on water-wall alumina-chrome plastic with 20% volume stable under high temperature tubes in waste-to-energy units. It is an excellent choice for improved aluminum resistance. With its high (370-650°C). boiler tube protec. corrosive slags and abrasion. Its 30% chromic GREENGUN 85-P PLUS oxide content. on water-wall tubes in waste. air/heat set vibratable non-wetting properties to many acid plastic. channel Technical Data Sheets tion and high abrasion. TASIL® 570 LM VIBRATABLE ity and abrasion resistance as well as A 70% alumina. AUREX 65 PLAS. runners. Typical applications are other heat recovery units. forge ECLIPSE® 80-P ADTECH® oxide and coal slag. air-setting gunning A phosphate-bonded 70% silicon plastic. pre- slags and nonferrous metals. It has high conductiv. cement plant including reheat furnaces. alkali resistance. It is applications include municipal incin. beyond standard furnace sidewalls and roofs. good fired boilers. plastic has enhanced resistance to iron combustion chambers. phosphate low temperature bonding at 700-1200°F TM GREENGUN 70-P PLUS bonded. boilers. plastic that forms an aluminum phosphate bond. been developed so that it can be quickly vibrated into place behind steel TM GUNNING PLASTICS GREENGUN JADE PLUS forms. It is very tubes in cyclone boilers. and excellent abrasion containing a penetration inhibitor for of wool insulation furnaces. coal. 70% alumina Applications include coal gasifiers and to-energy units. Typical applications slags. alumina-chrome abrasion resistance.PLASTIC REFRACTORIES TM ALUMINA-CHROME PLASTICS GREENGUN 80 ECLIPSE® 70-P ADTECH® con’t An 80% alumina. and resistance. reheat furnace carbide plastic. tivity and outstanding strength and A phosphate-bonded. With this characteristic and the An alumina-chrome. temperature dryers. It is used in many applications are incinerator linings. both hot and cold repairs. With high conditions.hwr. and good abrasion and resistance to acidic and slightly basic quickly with minimum labor cost. and very high density A high density. phosphate bonded cyclones.6 Harbison-Walker . and recovery A high alumina. phosphate bonded purity alumina and chromic oxide. recovery units. or go to www. thermal shock resistance. fluid-beds. A phosphate-bonded. has extremely high refractoriness and foundry ladles which must be lined low porosity. It exhibits excellent resistance carbide plastic. phos- tance. excellent TM GREENGUN ECLIPSE® 73-P penetration resistance and good AUREX 65 PLASTIC PLUS abrasion resistance. arc furnaces. gunning plastic. this rotary kiln feed and discharge hoods. incinerators. vibratable plastic which features very fast installation and turn-around time. and on other heat plastic refractory. SILICON CARBIDE PLASTICS GREFVIBE 850 has high refractori- ness. high HARBIDE PLASTIC 70 AL provide outstanding corrosion resis. It extreme-service areas in wet-slag. it suited for lining iron foundry and steel plastic gunning mix with high strength. high A phosphate-bonded 80% silicon phosphate-bonded plastics. strength at elevated temperatures.com MP . tundishes. GREFVIBE 700 has chemical incinerators. phosphate-bonded cooling furnace conditions. GREFVIBE 700 is specially A high alumina. and chromic oxide content. Its high silicon carbide soak zones. phosphate bonded. used in iron and steel ladles. TM refractory plastic. phate bonded refractory plastic patching glass contact and stack areas high strength. A phosphate-bonded. Click here for erators. It is specially formulated to grain to achieve the maximum possible gun on studded tubes in cyclone GREFVIBE 700 resistance to highly corrosive slags. shows excellent strengths. waste heat GREFVIBE 850 firing hoods and fluid bed combustor boilers. alumina gunning plastic that exhibits A high purity silicon carbide. Principal densified and ready to install. chrome-alumina A phosphate bonded gunning plastic plastic refractory. boilers. hwr. This plastic possesses good resistance to hot metal and slag erosion and represents an economical alternative to NARCARB ZP and SUPER NARCARB in less severe conditions.com Harbison-Walker MP . SUPER GRAPHPAK-85 This air-setting. This yields very low porosity for enhanced corrosion resistance to cupola slags. SUPER NARCARB PLASTIC is intended for extended cupola campaigns and the most severe service conditions. It contains SiC with oxidation inhibitors. It exhibits good resistance to molten iron or iron slag penetration. Click here for Technical Data Sheets or go to www. GRAPHPAK-85 & PLUS A high alumina plastic containing graphite. GRAPHPAK-45 & PLUS A super-duty fireclay plastic refractory containing graphite. It exhibits better resistance to molten iron or iron slag penetration than conventional super- duty plastics. it does not give off polluting emissions. SiC and graphite containing.PLASTIC REFRACTORIES SiC & CARBON CONTAINING PLASTICS SUPER NARCARB PLASTIC Based on fused alumina with SiC and oxidation inhibitors. As a result. It is ideally suited for high temperature molten iron up to 2850°F (1566°C) metal temperature. oxidation resistant plastic contains no pitch or resins. NARCARB ZP provides excellent performance in extended cupola campaigns under severe conditions. and a more environmentally friendly bond system than the phenolic resin bonded materials. It offers the highest level of carbon containing.7 . non-wetting components. NARCARB ZP PLASTIC This phenolic resin bonded plastic provides high strengths at iron produc- ing temperatures. aluminum furnace upper sidewall sitions combine relatively low heat losses with good strength. high brands supplied for a wide variety of furnaces and applications. essentially free from lamination and cracks. overhead or irregular structures CONVENTIONAL HIGH. breech- KRUZITE® GR PLUS NARCO® GUNCRETE ings and other medium service areas. It is CO resistant and An extra strength. Gunning also makes it possible to line horizontal. tics. 3200°F (1760°C) displays excellent gunning characteris. alumina. they represent the most economical choice for a refractory erosion. dense. soaking pit linings and Although gunning requires more skill than pouring castables. KRUZITE® GR PLUS is a 70% A high strength. encompass a wide range of applications. Used in boilers. Good for thinner linings in large areas. rebounds. low cement. low moisture gun ing severe abrasion at temperatures up TUFSHOT® LI/OT ADTECH® mix.8 Harbison-Walker . This product shows excellent to 1200°F. corrosion and abrasion resistance. It can be gunned to thickness to repairs to refractory furnace linings without greatly reducing the furnace maintain the original contour of the temperature. The following product descriptions of Harbison-Walker’s gunning mixes GREENCAST® 94 GR PLUS are categorized by their classification.com MP . process heaters. The mixes perform very A fireclay based. purity gun mix with good abrasion resistance. It has low rebound and good setting characteristics. compact nance of refractory linings. It exhibits temperature range of 1600°F (872°C) to 3300°F (1817°C). thus. stacks. and roof areas.ALUMINA without forms.GUNNING MIXES Overview Gunning mixes are granular refractory mixtures designed for applica. GUN MIXES The properties of Harbison-Walker’s gunning mixes vary considerably LO-ABRADE® GR PLUS and.hwr. gunning mix characterized by very low average rebound loss. . A variety of air guns are used to spray GREFCOTE® 50 PLUS is a 50% alumina. 94% alumina. refractory lining. Excellent strength and chemical purity allow it to withstand severe environments with a maximum service temperature of 3400°F (1820°C). GREFCOTE® 50 PLUS tion with air-placement guns. A specially formulated fireclay castable. Typical applications are: hot gunning of iron torpedo ladle while denser mixes are used in the more severe applications. Lightweight gunning mixes normally are used for insulation. cold or hot gunning mix for mainte- the mixes at high velocity and pressure to form homogeneous. dense abrasion well in both original linings and maintenance applications within a service resistant gunning mix. lining. it can place reheat furnace sidewalls. low iron fireclay gunning characteristics with below displays excellent gunning characteris. Click here for Technical Data Sheets or go to www. high-energy impact. This listing represents the major A high strength. applications. Some compo- lips. KS-4® GR PLUS maximum service temperature gunning tics. It exhibits excellent strengths gunning mix with good strength and and high densities. and temperature. FIRECLAY GUNNING MIXES NARCO® GUNCRETE AR Abrasion resistant version of NARCO® NARCOGUN® LC-95 GREENCAST® 12 GR PLUS GUNCRETE. NARCOGUN® LC-95 is a high A high strength castable for withstand. fireclay gun mix that alumina. In many exceptional resistance to abrasion. vertical. good adhesion to walls that are hot or Gunning mixes are either air-setting or heat-setting and some allow cold. It displays linings. incinera- tors. a higher volume of material in less time than any other method. It has a requiring resistance to abrasion and VERSAGUN® 70 ADTECH® special fortified matrix to provide reducing environments. improved refracto. and HPVTM GUN MIX excellent volume stability. An insulating gun mix designed for a A high strength gun mix based on high. Used in applications with reduced cement content. mix based on hard fired calcined DENSE MAGNESITE GUN MIXES kaolins and a reduced lime content. gunning refractory. resistance. very good low cement gun mix based on selected abrasion resistance. It is based on a (1650°C). A high strength. thermal shock resistance. resistance. VERSAGUN® THERMAX® A high strength. NARCOGUN® SiC 80 AR superduty fireclays and a lower cement riness & hot strengths. VERSAGUN® PH is a high strength. fireclay strength and thermal shock resistance. low cement gun mix Excellent abrasion resistance. containing an aluminum penetration inhibitor that installs with conventional INSULATING GUNNING MIXES LOW CEMENT HIGH.GUNNING MIXES LOW CEMENT FIRECLAY VERSAGUN® 60Z ADTECH® SPECIAL PURPOSE GUNNING MIXES A 60% alumina low cement gunning GUNNING MIXES mix based on Alabama bauxitic calcines VERSAGUN® BF and with the addition of zircon. insulating especially for gun placement to allow MAGNAMIX 85G is a basic gun mix gunning mix with exceptionally high quick installations and/or repairs with of the 85% MgO class. very good abrasion MAGSHOT® is a magnesite based maximun service temperatures of 3000°F resistance. designed for a maximum service A 60% alumina low cement gunning temperature of 2600°F (1427°C). It has excellent strengths. maximum service temperature of 2200°F fired fireclay aggregate and a reduced NARCOGUN® BSC-DS (1205°C).ALUMINA gunning equipment. Primary use in strength and abrasion resistance. low cement gun mix.com Harbison-Walker MP . low cement gunning excellent strength and abrasion mix having a reduced lime content.hwr. A strong. repairing and maintaining electric furnace linings in the small to medium sized foundries. hot ADTECHTM based on a high-fired. Developed MAGNAMIX 85G A high strength. KAST-O-LITE® 30 LI G PLUS VERSAGUN® 60 ADTECH® features MAGSHOT® A low iron. It has excellent abrasion gunning mix. low-iron.9 . dicalcium silicate natural magnesite MIZZOU® GR® PLUS that has good resistance to molten GREENLITE 45 L GR 60% alumina gunning castable. A 70% alumina. silicon carbide content. lightweight. medium density gun mix VERSAGUN® 60 ADTECH® containing material. content of high purity cement. suppressed to eliminate any dusting at (Formerly H-W® LT WT GUN MIX 26) the nozzle or gun. low cement. and improved refractoriness. Click here for Technical Data Sheets or go to www. smelt and soda. gun mix designed for a excellent strengths. This is a SiC A low iron. minimum downtime. A 70% alumina. along with unmatched VERSAGUN® PH based on hard fired calcined kaolins. This unique formula. good slag resistance. Used in NARCOGUN® BSC-DS is a bauxite applications requiring high strength and based trough mix that is totally dust KAST-O-LITE® 26 LI G PLUS abrasion resistance. The reduced cement resistance and high refractoriness to VERSAGUN® 70/AL content yields improved abrasion 2800°F (1538°C). Excellent GUNNING MIXES physical properties in the 1500°F KAST-O-LITE® 22 G PLUS (816°C) range and permits fast and (Formerly CASTABLE INSULATION #22 GR) VERSAGUN® 50 ADTECH® effective repairs to metal line areas. (1650°C) gunning refractory with low or slow heat-up schedules. iron content. vitreous silica gun mix aggregate. A 2500°F insulating gunning mix with MIZZOU® GR® PLUS is a 3000°F tion does not require lengthy cure time high strength and low density. Lower density minimal rebounds. PNEUCRETE® A 55% alumina low cement spray mix 45 ADTECH® can be used for minerals for use in high alkali and abrasion processing. Nearly dust free installation with shotcreting methods. environments.com MP . low-cement spray mix combined with an activator at the for use in a wide variety of applica- nozzle it can be applied by standard tions. shotcreting methods. mix for use in abrasion environments Used primarily to replace conventional and carbon monoxide environments. cement spray mix. It has the unique property that when combined with an activator at the PNEUCRETE® THERMAX® nozzle it can be applied by standard Unique vitreous silica based low shotcreting methods. It gunning mixes as insulation for has the unique property that when petroleum heaters or as insulation combined with an activator at the backup lining in two component linings nozzle it can be applied by standard for many applications. used in cement and lime plant mainte- nance and other applications requiring high strength. low cement composi- tions. PNECRETE® BF ADTECH® can be used for blast PNEULITE® SPRAY 26 ADTECH® furnace repairs. combined with an activator at the nozzle it can be applied by standard PNEUCRETE® 55/AR ADTECH® shotcreting methods. naphtha reform- for use in abrasion environments. Used PNEUCRETE® 45 ADTECH ® primarily to replace conventional PNEUCRETE® 45 ADTECH® is a gunning mixes applied in FCCU fireclay based low cement spray mix regenerating vessels. chemical industry applica.Gunning Mixes SPRAY MIXES PNEULITE® SPRAY 22 PNEULITE® SPRAY 22 ADTECH® is a PNEUCRETE® BF ADTECH® uniquely formulated refractory specifi- PNEUCRETE® BF ADTECH® is a super cally for spray application that lowers duty fireclay based low cement spray dust and permits virtually no rebounds. and incineration and aluminum free installation with minimal re- furnace backup linings. It ers and other process furnaces requir- has the unique property that when ing semi-insulating. coefficient of thermal expansion and PNEUCRETE® 60 ADTECH® can be good abrasion resistance. bounds. PNEULITE® SPRAY 26 is a uniquely and other applications requiring high formulated refractory specifically for strength.hwr. spray application that lowers dust and permits virtually no rebounds. one spray linings. Features nearly dust tions. low by standard shotcreting methods. outstanding thermal shock activator at the nozzle it can be applied resistance in cycling applications. Nearly dust free installation with minimal rebounds. . Click here for Technical Data Sheets or go to www. minerals processing. It has the unique than conventional extra strength property that when combined with an castables. low cement compositions.10 Harbison-Walker . It PNEUCRETE® 60 ADTECH® has the unique property that when A 60% alumina. and high strength. The growing use of castables stems directly from their economic and handling advantages. They are less permeable. Click here for Technical Data Sheets or go to www. Some special castables use sodium silicate or portland cement binders.CASTABLE REFRACTORIES Overview Often called refractory concretes. castables offer several performance advantages. castable refractories are furnished dry to be mixed with water before installation.e. high purity cements. Castables reduce installation costs. castables often provide the best lining for vessels or chambers at other than atmospheric pressures. The service capability of any refractory is determined by its major ingredients – fireclay. Many castable refractories have good resistance to impact and mechanical abuse. low iron oxide cements. castables can also be in- stalled by trowelling. conveying and placement can be mechanized. and most castables offer good volume stability within the specified temperature range. high purity cements. i. The following product descriptions of Harbison-Walker’s castable refractories are categorized by their classification. go into place quickly and easily. Along with ease of installation. Usually cast or vibrated in the same manner as ordinary concrete. silica or basic materials such as mag- nesite and chrome ore. This listing repre- sents the major brands supplied for a wide variety of furnaces and applications. Thus. and mixing. are designed to match those of the refractory base materials. They also save time formerly spent cutting brick to fit and eliminate inventories of special shapes.hwr. pneumatic gunning or occasionally ramming. roofs and floors have fewer joints. They include standard calcium-aluminate cements. partly because of the nature of the hydraulic bond and partly because cast walls. Properties of the binders. hydraulic ce- ments that give castables an air-set.com Harbison-Walker MP .. alumina.11 . furnace covers. EXPRESS®-27 PLUS is a 2700oF. NARCOCAST® LM95 G has age. MP . SHAC also chambers. Also flowing consistency. It is used for lithic lining. displaying high refractoriness and strength with abrasion resistance. SPECIAL HIGH ALUMINA CASTABLE ADTECH MIZZOU CASTABLE® PLUS SHAC is a high purity.com foundry ladles. designed for quick turnaround. low temperature incinera. conventional A 3000°F (1647°C). refractory castables. KS-4V A 2800°F general purpose castable. EXPRESS® 30 QS is a quick setting mechanical abuse. hydraulic setting castable the with excellent resistance to slag forms a dense. Its density low iron content makes it particularly ideal for thin walled castings requiring together with very good abrasion good for use in specialized atmosphere improved properties. It can tion versus conventional brick linings.CASTABLE REFRACTORIES CONVENTIONAL FIRECLAY EXPRESS® 27 C PLUS EXPRESS®-30 PLUS CASTABLES A coarse. It is recommended for shells to increase the speed of installa. fireclay based. energy loss through the refractory riness. and minimal shrink. alumina. extremely high strength at tempera- tures up to 3000°F. possesses good volume stability and is tors. burner blocks. air heaters. features improved impact resistance makes it an ideal hot face lining MC-25® possesses two-to-three times over conventional extra-strength material. high purity calcium use in relatively thin sections. resistance makes it an ideal hot face furnaces. It has dense. KS-4V PLUS A general purpose castable for use to SUPER KAST-SET® PLUS NARCOCAST® LM95 G temperatures to 2600°F. It is ideal for precast shapes. Its well suited as a grout material. stable linings for long service. cast vibrated properties are has excellent resistance to thermal to install by pumping. It is recommended for use lining material. boilers. use as a plastering material to repair It easily conforms to irregular furnace GREENCAST®-94 & PLUS boiler baffles. even when used in large patches. vibcasting and superior to free-flowing properties. dense. resistant to carbon monoxide disinte- Click here for aluminum furnace upper sidewalls and gration. installed at a self leveling consistency. A high strength. It with very good abrasion resistance castable for temperatures to 2250°F. Excellent for applications up to 2800°F. CONVENTIONAL HIGH-ALUMINA abrasion and mechanical abuse. Used in conditions requiring lining. high abrasion and chemical resistance. and withstands heavy loads and conventional casting techniques. aluminate bonded 94% alumina also be used for overhead gunning Its moderate density allows for reduced castable with extremely high refracto- repairs where thickness is required. castables or fireclay plastics. shock. strong general purpose HARCAST® ES ADTECH KRUZITE® CASTABLE PLUS castable refractory for use at tempera. forge furnaces. vibrated product with properties A 2600°F castable with excellent NARCOCAST® LM95 G is especially superior to those attained at self resistance to abrasion and erosion.hwr. It is easy used. super-duty A general purpose 3200°F castable. tures up to 2550°F. It can either be MC-25® PLUS strength and high impact resistance are cast or pumped. where abrasion is encountered. conventional cement features good resistance to abrasion. and induction A more plastic material than most A 2200°F maximum service tempera. KS-4T HYDROCRETE® high temperature boilers. istics and high strength to produce design. burner blocks. It A high purity. a has good permanent volume character.12 Harbison-Walker . It has excellent EXPRESS®-27 PLUS resistance to molten metal erosion. Technical Data Sheets roof regions. KS-4® PLUS A dense. high strength mono- penetration and spalling. It is preferred for ture. dense free flowing cement castable for use where high refractory castable. Its density together A high strength. It has excellent abrasion many applications such as combustion and erosion resistance. coarse aggregate required up to 2700°F (1482°C). castable employing a low moisture low iron content. and iron or go to www. EXPRESS® 27 C PLUS can also be version. moderate strength. A very high strength. If reduced water content is the strength of regular dense castables. general purpose castable. reduced water levels to provide LO-ABRADE® PLUS Due to its fine grained design. extra high A high strength 60% alumina castable. Applications include foundry ladles. free-flowing refractory castable CASTABLES significantly higher density and lower that can also be vibration cast using porosity than conventional castables. It combines high castable with high purity binder. tors and aluminum furnace upper A 70% alumina. strengths to withstand the erosive VERSAFLOW® 45 PLUS effects of hot dust laden gases. superior corrosion resistance. VERSAFLOW® 70 C ADTECH® A 45% alumina. sizing make TAYCOR® 414-FH NARCON 65 CASTABLE HYDROCAST especially well suited A low moisture mullite castable for use for thin walled castings.hwr. casting techniques.CASTABLE REFRACTORIES CONVENTIONAL HIGH-ALUMINA ULTRA-EXPRESS 45 VERSAFLOW® 57A CASTABLES con’t. High hot A low moisture mullite castable for use strengths at elevated temperatures. to repair grain castable based on bauxitic and lifters. from vibcast consistency to pump impact resistance. self- flowing. Excellent LOW CEMENT HIGH-ALUMINA to 3200°F (1760°C). improves thermal shock. impact and abrasion resistance in high cement kilns. rotary kiln nose rings used as original linings. boilers alkali environments. extra-high is not required to remove air voids. low cement. to 3250°F (1788°C). high hot strengths at 2500°F. flint-based. thermal shock damage than conven- tures up to 3400°F (1870°C). coarse grain castable vibratable castable. The low cement choice for coil grouting in coreless CASTABLES content provides extremely high induction furnaces melting steel alloys. castables. It flowing castable with excellent thermal TAYCOR® 414-FH HYDROCAST has the unique property that vibration shock and alkali resistance. based on very high purity ingredients. versatile product can be either cast or pumped.com Harbison-Walker MP . with high strength. This product has excellent abrasion resis. self. This versatile product can be cast or alumina. which has less susceptible to thermal shock An excellent utility castable for use in versatile installation capability . Typical uses and in the chemical processing include incinerators and aluminum industry. tance to alkali attack and abrasion. Specifically designed for and precast tundish furniture. ULTRA-GREEN 45 Typical applications include incinera. vib-casting to pump casting. An A 70 % Alumina low cement castable A coarse aggregate. andalusite based. Typical uses include low porosity and high density. high refractoriness strength. This High purity. furnace roofs. non-ferrous furnaces and ladles. based on bauxite calcines. refractoriness. ultra-low cement. and alkalies. high hot A unique castable refractory of 60% strengths at 2500°F (1371°C). exceptional resistance to alkali attack. ultra-low cement castable. Its ® GREENCAST 97 PLUS A 60% alumina casting mix. existing linings. A 60% alumina. and high ULTRA LOW CEMENT FIRECLAY alumina class with exceptional resis. It features excel- VERSAFLOW® 55/AR ADTECH® lent abrasion resistance. coolers and rings. The low cement LOW CEMENT FIRECLAY Designed to replace brick and plastic content provides extremely high where joints are undesirable. fireclay based low excellent all purpose castable for based on Alabama bauxitic calcines cement castable. conventional cement castable. Its A fireclay based low cement castable. Its coarse aggregate applications such as incinerator charge which can be installed in several ways. High refractoriness. incinerator charge zones. A 60% alumina low cement castable grain sizing makes NARCON 70 much This product features good strengths. high abrasion areas. Features excellent sidewalls and roofs. burners. VERSAFLOW® 70 ADTECH® ® ® VERSAFLOW 45C ADTECH tance. calcines. VERSAFLOW® 55/AR C ADTECH® resistance. and rotary kilns. Can be A 55% alumina. and phosphate-bonded NARCON 70 CASTABLE plastics after curing.13 . strengths to withstand the erosive KALAKAST AR® ADTECH® effects of hot dust laden gases. dense.from damage than conventional castables. It is Other benefits include better abrasion tional castables. resistance than 60% alumina fired low in silica. homogeneity of structure makes GREENCAST® 97 PLUS is a 97% KALAKAST AR® ADTECH® has NARCON 65 much less susceptible to alumina dense castable for tempera. abrasion and zones. VERSAFLOW® 60 PLUS homogeneity of structure and coarse with versatile installation capability. and as pre-cast shapes. fine grained. coarse foundry ladles. strength and grain pumped. iron oxide. brick. Click here for Technical Data Sheets or go to www. outstanding hot load bearing and excellent abrasion and impact ability. A 50% alumina. andalusite based.14 Harbison-Walker . low castables in this class. with a higher purity matrix than other An extra-high alumina. D-CAST 85 TM-CC ULTRA-GREEN 57A is a 57% containing a special penetration CASTABLE does not employ the gas alumina. exhibits excellent slag corrosion and designed for placement by ramming. VERSAFLOW® 80 C ADTECH is a high alumina castable offers high ULTRA-GREEN 60 & PLUS coarse. It runners. ultra-low 85 can be installed by ramming. cement castable. alumina. ultra low inhibitor for increased resistance to channel technology but relies on an cement castable with outstanding metal penetration. or FASKAST 80 in longer campaign life and easier pumping by varying the amount of An 80% alumina. It can either be or go to www. together with very good abrasion D-CAST 85 TM CASTABLE resistance makes it an ideal hot face An 85% alumina low cement castable GREFCON® 98 SP lining material. MP . ultra-low cement slag resistance. high density. It has the unique Click here for property that vibration is not required Technical Data Sheets to remove air voids. characterized by its high unique property that vibration is not pumping by varying the amount of density. This coarse grained structure ing hot load bearing ability. It can be water. ULTRA-GREEN 57A A 70% alumina low cement castable However. low copper and iron foundry applications. low poros. Designed specifically for controlled dry out can be conducted. low moisture castable charac- terized by its high density. D-CAST GREFCON® 98 T cyclones. low cement castable cleaning of ladles. cement. abrasion and hot foundry ladles.hwr. It has the vibration cast. Based ULTRA-GREEN 60 is a 60% alumina castable based on calcined bauxite. and excellent abrasion either cast or pumped. tion. resistance to hot load. ULTRA EXPRESS 80 easier drying. also features high hot strength. ultra low choice for many metal-contact areas. metal penetration resistance resulting vibration cast. and is an ideal alumina. low porosity and high It has excellent impact resistance and castables. 85 TM uses special gas forming A tabular alumina based castable with technology to create gas channels for high purity and high refractoriness. vibratable castable. strengths. free-flowing. superior GREFCON® 85 provides for very good thermal shock corrosion resistance. dense self-flowing. An equivalent product compared with ALUMINA D-CAST 85 TM in regards to base VERSAFLOW® 70/CU ADTECH® aggregate and matrix additions. with a high purity mullite matrix. or pumped and is suited for The ‘CC’ is designed for custom tions having extreme cyclic tempera- service temperatures up to 2850°F casting applications where a more ture conditions.CASTABLE REFRACTORIES LOW CEMENT HIGH-ALUMINA D-CAST 85 TM-CC CASTABLE ULTRA LOW CEMENT HIGH- CASTABLES con’t. system than the other D-CAST its high density. Typical applications tance and excellent high temperature castable with high hot strength for include kiln car tops. Its density resistance. high purity. ULTRA-GREEN 57A (1566°C). High density moisture castable that contains spinel ULTRA-GREEN 80 and low porosity result in increased additions for slag penetration resis. low cement. ladle lip rings. Typical applications are alumina kiln burning zones. ULTRA-GREEN 60 is outstanding thermal shock resistance. coke calcining and metal erosion. and low porosity- GREFCON® 85 is a high-alumina low resistance. castable with intermediate cement Features excellent strength. D-CAST 85 HS CASTABLE hot strength. burners. organic fiber addition to aid in drying. An 80% alumina. and high density superior or D-CAST 85 HS CASTABLE equal to fired brick of similar composi- VERSAFLOW® 80 C ADTECH® This specially designed low-cement. on a higher purity aggregate and matrix low cement castable characterized by which can be pumped or vibration cast. 80% alumina low cement density and high hot strengths. or castable. and nose rings. high hot and cold required to remove air voids.com cast or pumped. troughs. It can be vibcast. GREFCON® 98 ULTRA-EXPRESS 70 ADTECH® ity. hand casting. low-moisture cement refractory castable. hand casting. TAYCOR 414-C HYDROCAST ULTRA-GREEN 70 is a 70% alumina. and high hot strength. porosity. low porosity. This product has exceptional strength ULTRA EXPRESS 80 is an 80% and abrasion resistance. thermal shock resistance in applica- poured. outstand- content. and water. strength. has a relatively fast set time and good ULTRA-GREEN 70 ADTECH® ® hot strengths and outstanding flow. Ideal for field casting in areas such as This is a coarse grained 96% alumina ultra-low cement. kiln nose rings. GREFCON® GREFCON® 98 is a volume stable 98% A dense. vibrating castable. Maximum operating temperature is 3400°F (1870°C). burner blocks allows the dry out to begin sooner than resistance to hot load deformation and and channel induction furnace linings. Ideally suited for impact volume stability. cast shapes and burner blocks. CASTABLES CASTABLES tional ultra-low cement tabular alumina castables. lime free monolith EXCELERATE ABR PLUS is a HP-CAST ULTRA with excellent creep resistance. glass tank crown and burner blocks. or gunned hot and cold. based on vitreous silica aggregate with oven maintenance. A high purity. With a monolith has superior hot strengths at hand packed. The cement free alumina based. Low moisture. refractoriness. It has high castable with an alumina rich spinel ULTRA-GREEN SR hot strength. It bine to provide improved slag and between 2000 and 2700°F compared to features volume stability. matrix.CASTABLE REFRACTORIES ULTRA LOW CEMENT HIGH. low-cement 92% A 97% silica cement-free monolith Typical uses include glass tanks. 3400°F service temperature and high temperatures. spinel additions for optimum slag This product has high hot strength and resistance. Coarse grain with exceptional refractoriness and A vitreous silica based casting mix technology provides excellent thermal purity. and is ideal for hot repair work and manufacture of HP-CAST MAXIMA NOVACON® S large and/or complicated shapes. Low moisture. Typical applications steel and iron slags. HP-CAST 93S applications. low cement castable incinerators. chloride attack. for cement containing castables. Its spinel addition with exceptional refractoriness load ATM-2000 and outstanding hot properties com. HP-CAST 93Z3 FASTDRY 8 CASTABLE ALUMINA con’t. lime free monolith DESCON® S97 ADTECH® optimum slag resistance. well blocks and other high wear resistance to alkali and chlorine attack. low-cement. and precast shapes. This product has excellent hot with outstanding thermal shock shock resistance. coke alumina castable with patented bond. NOVACON® 85 CASTABLES Excellent hot strengths and thermal An 85% alumina. vib-cast. ATM-2000 is designed in addition to resistance to chlorine for easy placement in inaccessible HP-CAST 94MA-C environments. The lime free shock resistance. castable displays outstanding strengths solving capabilities in numerous and abrasion resistance. and porosity equivalent to high processing temperatures. DESCON® S97 ADTECH® porosity and high hot strengths help good chemical resistance. lime free monolith shock resistance.hwr. This precast shapes. phosphate bonded. low hot load deformation. ultra-low include ammonia plant secondary formulation provides exceptional cement. fused silica castable. as well as excellent pads.15 . thermal metal erosion resistance in ladle impact conventional castables. 86% alumina. spinel VITREOUS/FUSED SILICA containing 94% alumina castable. resistance. binder allows for reduced dry-out time. This monolith heated within 4 hours of installation to is ideally suited for steel contact and provides resistance to alkali and minimize furnace downtime. chemical setting Low moisture. spinel Relative to conventional castables. methods. It offers good resistance to ULTRA-GREEN SR is a tabular and low porosity.FREE HIGH-ALUMINA CHEMICALLY BONDED shock resistance superior to conven. This reformers and transfer lines. resist metal and slag attack at steel problem solving capabilities for pre density.com Harbison-Walker MP . carbon strength at high temperatures and product displays high hot strength for black reactors. quality fired silica brick. conductivity. this castable that can be rammed. For use in hearths. areas. forming 96% alumina castable. It has problem . in addition to It develops a quick set and can be outstanding hot strengths this castable reduced dry-out time. This is a high alumina. places and for shapes that are difficult Coarse grained. NOVACON® 65 ADTECH® EXCELERATE™ ABR PLUS A 65% alumina. hot abrasion. HP-CAST 94MA-C contains NOVACON® 95 preformed magnesia-alumina spinel for A 95% alumina. thermal shock resistant. Click here for Technical Data Sheets or go to www. cement free ultra low cement castable. nozzles. low strengths at high temperatures and resistance. gates. High density. and superior hot strengths A high purity. and low thermal pads and other precast shape. to manufacture by conventional based on high purity alumina aggre. hot patching of Contains both preformed and in-situ outstanding thermal shock resistance. low-cement. It has features chemistry. Its addition of andalusite gives it thermal CEMENT . GR-FG® CASTABLE HPV ESX CASTABLE A chemically bonded basic castable A high purity. abrasion high refractoriness. low thermal end of the recommended water range. This refractory is 820 I has exceptional volume stability. ture does not exceed 2000°F (1093°C). A refractory castable employing a successful in furnaces prone to blended mixture of carefully sized corundum formation. hoods or covers. A unique low cement refractory A chrome-alumina castable based on containing a fortified matrix and AUREX® and NOVACON® technology. It features outstand- lent resistance to cracking due to zirconia-mullite castable with a silicon ing strength and abrasion resistance. as well as volume stability. VERSAFLOW® FUSECRETE® C6 which does not contain a calcium THERMAX® AL ADTECH® offers FUSECRETE® C6 is a high alumina aluminate binder. vides excellent resistance to slag HPV ESX is an excellent choice for NARCON ZRAL penetration in both ferrous and non- burner blocks and other thermally A 60% zirconia castable with excellent ferrous applications. It thermal shock. hydraulic setting ways-from vibcast consistency to pump improved resistance to thermal shock. chromic oxide content for resistance to fluxes and slags due to purity of raw corrosion by ferrous and non-ferrous materials. This product has excellent abrasion resistance.16 Harbison-Walker . It has excellent corrosion resistance A fine grained. fused silica castable. vitreous silica castable with a high FUSECRETE® C is a high alumina volume stable refractory and can be purity binder and reinforced matrix. It features outstand- exceptional thermal shock and abrasion castable refractory that has high ing resistance to chemical attack by resistance. MP . low-moisture fused hydraulic binder. H-W CHROMEPAK is a strong. ADTECH® resistance to corrosion by ferrous and A vitreous silica based low-cement non-ferrous slags. Magnesia-Chrome single component lining where a dense erosion. HARCHROME® CASTABLE vitreous silica aggregate and hydraulic A chrome ore base castable refractory binder. Zoning alumi. erosion by basic slags. FUSECRETE® C10 CASTABLE has high density and low A high alumina castable refractory with permeability to help prevent penetra- VERSAFLOW® THERMAX® AL high chromic oxide content for tion by molten metals. gunning. GR-FG® cyclical applications. and light weight. Primary applications include has exceptional resistance to alkalis.com nozzles. ramming. A pumpable. NOVUS® CASTABLE castable with an aluminum penetration A magnesia chrome spinel castable. inhibitor. FUSIL® CASTABLE casting techniques. NARMAG® FG tion may be used. cement binder. self leveling when tempered at the high thermal shock resistance. trowelling or air placement with the mullite and will not reduce. fused silica castable Ideally suited for installation in several and contains a spall inhibitor for utilizing a high purity.hwr. ALUMINA-CHROME CASTABLES H-W® CHROMEPAK® ® ® VERSAFLOW THERMAX PLUS A chrome magnesite mix with a silicate A unique. gun. lightweight castable combina. low cement FUSECRETE® C bond. steel or ductile iron Technical Data Sheets ladle linings. lance sections. The zircon is tied up also has high resistance to chemical casting. It features extremely low THOR AZSP ADTECH® using a standard calcium aluminate thermal expansion resulting in excel. and copper applications. It has excellent installed by casting. or conditions exist and maximum tempera. extra-strength. CASTABLE has the ability to be num furnace belly bands with applied by both casting and pneumatic VISIL® ES CASTABLE ADTECH® NARCON ZRAL has proven to be very gunning techniques. It that employs fused magnesium- has volume stability which leads to ZIRCON CASTABLES chromate spinel aggregate that pro- outstanding thermal shock resistance. corundum resistance. It attack and thermal spalling. FUSIL® CASTABLE 820I unique vitreous silica aggregate. low density and thermal conductivity high cold compressive strength. castable with excellent resistance to castable. HARCHROME® CASTABLE can be furnaces in which severe cycling chlorides and sulfates.CASTABLE REFRACTORIES VITREOUS/FUSED SILICA EXPRESS® THERMAX® ADTECH® AUREX® 70 CASTABLE CASTABLES con’t. Its castable refractory characterized by cast or gunned. slags and gases. Typical uses include AOD Click here for slags. Easily installed by carbide addition. along with high strength and abrasion erosion resistance and containing 3% NARMAG® FG CASTABLE resistance allow it to be used as a chromic oxide for resistance to slag Fused grain. DENSE MAGNESITE CASTABLES conductivity. collector or go to www. A reduced cement carbide and carbon containing castable A low cement. silicon MAGSHOT® CASTABLE D-CAST XZR-OR and XZR-OR-CC carbide and carbon containing castable MAGSHOT® CASTABLE is based on CASTABLE developed for improved oxidation a dicalcium silicate natural magnesite A low cement.com Harbison-Walker MP . Typical applications OR PLUS the most slag resistant D- helps improve alkali resistance. A reduced cement composition resistant to corrosive and PLUS additions make D-CAST TRC- content with a special additive package dust laden gases. D-CAST XZR-OR has D-CAST TRC-OR features good or slow heat up schedules. A low cement.hwr. Can be applied using tions include cupola wells and tapholes THOR 60 ABR ADTECH® SHOTKAST technology. to abrasion by hot flowing molten and carbon additions from oxidation. carbide and carbon containing castable. thermal shock resistance. high alumina. containing castable that can be D-CAST TRC-SR installed by vibration casting. To aid organic fiber addition while the in drying.CASTABLE REFRACTORIES DENSE MAGNESITE CASTABLES SILICON CARBIDE CONTAINING D-CAST TRC-OR and TRC-OR-CC cont. for negligible sintering cracks during NARMAG® 95LS CASTABLE Typical applications include copper service. CASTABLES CASTABLE A low cement. high alumina. Can be applied using very high strength and abrasion SHOTKAST technology. The THOR 60 ADTECH® make D-CAST TRC-SR extremely PLUS designation is a separate A low cement. silicon content with a special additive package developed for optimum slag resistance. technology. Used primarily in the aluminum industry. the ‘CC’ version contains an liquid metals. high alumina. Typical applica- runners. An anti-oxidant addition is that has good resistance to molten carbide containing castable. tion does not require lengthy cure time metals. and volume stability and excellent oxidation resistance. It offers excellent thermal shock resistance. Click here for Technical Data Sheets or go to www. shotgun. resistance.17 . and gases. 60% silicon carbide resistant to hot flowing molten metals addition for improved slag resistance. The combination and sizing of the Contains the same oxidation resistant silicon carbide and carbon additions technology as D-CAST TRC-OR. foundry ladles and slag runners. and permeability. To aid limit corrosion and penetration of in drying. it is a proven problem solver in hearths. This unique formula. silicon D-CAST TRC-OR PLUS ning. and low permeability also make the combined with the non-wetting and ning. It is intended for cupola front slaggers and holders. the ‘CC’ version contains an DENSE SILICON CARBIDE standard version employs gas forming organic fiber addition while the technology. high alumina. silicon resistance. and casthouse applications in A 60% silicon carbide castable with ironmaking. containing castable that can be and slags. slags. or shotcreting. Can be applied using standard version employs gas forming THOR 30 ADTECH® SHOTKAST technology. include cupola wells. provide resistance to abrasion by hot density and strength. Resistant provided to protect the silicon carbide smelt and soda. 30% silicon carbide SHOTKAST technology. high density. ramps and sills. shotgun. Can be applied using A low cement. low porosity excellent casting characteristics. and flowing molten metals and slags and to basic steel and iron operations. helps improve alkali resistance. These properties combine to A 96% magnesia castable with high and brass furnace linings and launders. Outstanding hot properties Low porosity and permeability installed by vibration casting. troughs and slag CAST TRC material. low hot load deformation. or shotcreting. controlled atmosphere furnace linings. good strengths. KAST-O-LITE® 19L PLUS conductivity. controlled atmosphere furnaces. stacks. hydraulic VERSAFLOW® 45/AL ADTECH® behind stainless steel shroud and waste setting castable with high strength. low- heat boilers. A 2500°F insulating castable. traditional mineral wool block insula. GREENLITE-45-L PLUS temperature insulating castable.hwr. insulating KAST-O-LITE® 20 PLUS A 2800°F insulating castable combin. furnace safety linings. A 45% alumina. lightweight. for such a lightweight material. It has high strength. catalytic reformer linings A lightweight. gate castable with excellent impact and ings. KAST-O-LITE® 22 PLUS KAST-O-LITE® 97L PLUS HYDROCRETE® AL A lightweight castable for temperatures A 3300°F (1815°C) maximum service An aluminum resistant version of the to 2200°F (1205°C). A 2500°F (1370°C) insulating castable permanent linear change after heating with good strength and low thermal to 1500°F (816°C). strength and moderate density. CASTABLES efficiency. insulating refractory castable. H-W® ES reducing furnace conditions. GREENLITE 75-28 is rated to 2800°F. (1649°C). to reduce shell temperatures. GREENLITE EXPRESS 24 PLUS A 2400°F. Typical waste heat boiler tube sheets. back-up lining behind hot face linings 2600°F (1427°C). It has high thermal conductivity and good strength contains bubble alumina for high strength and a moderate density. It has the unique property that vibration is not required Click here for to remove air voids. usable in direct contact with hot gases castable in a lightweight. self-flowing. and low iron. KAST-O-LITE® 30 LI PLUS GREENLITE-45-L AL ® ® KAST-O-LITE 20 LI ADTECH A lightweight insulating castable with This lightweight castable has a very A low iron insulating castable with a high purity cement and a maximum high strength to weight ratio. cement castable with improved strength versus conventional castables.18 Harbison-Walker . pumping. It standard HYDROCRETE®. It is maximum service temperature of service temperature of 3000°F ideally suited for insulating Aluminum 2000°F (1093°C). sub-hearths and crucibles. and CASTABLE C AL is a coarse aggre- applications are: flues. It features low temperature insulating castable. MP . insulating under continuous or intermittent material. pumpable. very low silica content to resist economical choice for aluminum KAST-O-LITE® 23LI PLUS detrimental hydrogen atmospheres. It is used ideally as a maximum service temperature of pump.CASTABLE REFRACTORIES INSULATING CASTABLES KAST-O-LITE® 23 ES ADTECH® GREENLITE CASTABLE 22 PLUS An intermediate strength insulating GREENLITE CASTABLE 22 PLUS is KAST-O-LITE® 16 PLUS castable with a maximum service a 2200°F (1203°C) maximum service A 1600°F insulating castable with temperature of 2300°F (1260°C). breech. petroleum transfer and riser back-up GREENLITE 75-28 PLUS linings. or pumped using a or go to www. castable with exceptionally high A 2000°F (1095°C) insulating castable ing the features of an extra strength strength and abrasion resistance. It can be conven- Technical Data Sheets tionally cast. An industry standard for aluminum contains low iron to resist detrimental very high temperature back-up linings. It carbon black reactor back up linings. HPV™ CASTABLE MC-28L PLUS A high strength. super-duty. low ALUMINUM RESISTANT operation without loss of thermal shrinkage. It or gunning. KAST-O-LITE® 23LI PLUS is a Typical applications are secondary 2300°F (1260°C) maximum service ammonia reformer back-up linings. H-W® ES CASTABLE C AL temperature insulating castable. with exhibits greater crushing strengths than high strength and low density. temperature insulating castable that outstanding low density and very low can be cast or gunned. It has moderate thermal conductivity that can be KAST-O-LITE® 50-25 density.com Putzmeister pneumatic pump. and a low applied by casting or gunning. thermal shock resistance. KAST-O-LITE® 26 LI PLUS GREENLITE-45-L can be pumped tion and can conform to irregular shell A low iron insulating castable with a using a Putzmeister pneumatic configurations. KAST-O-LITE 50-25 A 1900°F (1037°C) maximum service can be installed by pouring. furnace sub-hearths. It has a HYDROCRETE® AL is an attractive. contains an aluminum penetration With a minor zircon addition. aluminum resistant. thermal shock resistance. VERSAFLOW® 65/AL PLUS ALSTOP GREFCON® 80 A Its fused alumina coarse aggregate has A 65% alumina. It has sills. 70% alumina. troughs. ramps. tabular alumina based. It is well suited for melting and ARMORKAST™ 65AL holding furnaces where pure metal A very high purity low cement chemistry is of extreme importance. Its This tabular alumina based castable is 2-TOUGH® AL ADTECH® coarse aggregate improves its thermal also silica-free. This makes it very resistant NARCOTUFF SUPER AL is an HP-CASTTM 96AL to aluminum corrosion. high hot strength and very low poros- ity. high strength. 2-TOUGH® HP ADTECH® GREENKLEEN 60 PLUS and self-leveling characteristics. Click here for Technical Data Sheets or go to www. non-wetting in contact with aluminum. An ultra-low cement. belly bands. Typical used excellent choice for the lower sidewall A high purity. low cement. with slight corundum growth. It is essentially silica free. wear areas in aluminum contact such ADTECH® as ramps. and is designed combat 2-TOUGH® AL ADTECH® is specifi- shock and impact resistance. and electric furnace deltas. than traditional 90% alumina castables. applications. aluminum resistant castable. 2-TOUGH® HP ADTECH® has set a and resistance to aluminum penetra. GREENKLEEN strong and is ideal for pumping over alumina matrix gives this high purity 60 PLUS displays outstanding abrasion long distances and for casting into mix outstanding corrosion resistance. tance.com Harbison-Walker MP . GREENKLEEN This high purity. It has exceptional strength including well blocks. A 65% alumina. It is and aluminum resistance. sill and cruce bottoms. ARMORKAST™ 70 AL An economical. resistance.CASTABLE REFRACTORIES ALUMINUM RESISTANT ULTRA-EXPRESS 70 AL HIGH TOUGHNESS CASTABLES CASTABLES con’t.19 . include precast hearths. high corrosion resis. low cement castable ULTRA-EXPRESS 70 AL is very alumina aggregate and a fine tabular containing andalusite. and NARCOTUFFTM SUPER AL resistance. It can be vibration cast or ARMORKAST™ 80AL ADTECH® almost 70 impacts!! This unique pumped as required. inhibitor. For use in high ARMORKAST™ XPUR/AL and rotary kiln lifters. coarse grain castable. pumpable. aluminum furnace jambs and lintels. and cruces. ARMORKASTTM 80AL is designed for and slag resistant in waste-to-energy the most severe aluminum contact 2-TOUGH® FA ADTECH® boilers. Exceptionally high strength and impact resistance characterize this product. surviving tion. 70% alumina castable designed with enhanced flow. Its unique bonding matrix provides exceptionally high strength and ultimate corrosion resistance. with high strength and versatile years. ladle bottoms quickly than regular castables. It has good strength and resistance to molten aluminum alloys. low cement castable An industry standard for more than 15 a higher density than tabular alumina. castable. 80% product has solved severe wear 60 PLUS contains special additives alumina castable is built for corrosion problems in several steel applications which enable it to be fired more resistance.hwr. 80% alumina low cement Typical uses for 2-TOUGH® FA VERSAFLOW® 65/AL C ADTECH® castable. It shows very cally designed for use in aluminum high strength and excellent aluminum contact. record in the impact test. The combination of a coarse tabular Is a 60% alumina. ALSTOP GREFCON® 80A is a resulting in significantly lower porosity installation characteristics. and or bellyband in an aluminum furnace aluminum resistant castable. intricate form patterns. corundum formation. ADTECH® include ladle bottoms. wet form. exceptional intermediate and high Most ramming mixes are supplied dry. Dry mixes are prepared for use by adding water and by acid and neutral slags and is mixing. magnesia based. carefully graded as to RUBY® RAMMING MIX relative proportions of different particle sizes. dried and heated.RAMMING MIXES ALUMINA-CHROME Overview RAMMING MIXES Ramming mixes typically consist of ground refractory grog materials in a wide range of chemical composition. HARMIX AL is NARPHOS 90R RAM H-W® C MIX ideally suited for inductor blocks. and steel ladles. It exhibits high density hearths. thermal shock. and excellent resistance to deformation volume stability throughout its entire bottoms and working linings of Electric under load. NARPHOS 85R rammed to the highest density. phosphate bonded. strong monolithic structures. ramming mix. or go to www.com metal resistance and volume stability at elevated temperatures. wetting characteristics to provide HARMIX® AL outstanding resistance to erosion from HARMIX FE® An air-setting. phosphate bonded ramming mix for electric furnace NARPHOS 55R (FINE) RAM ramming mix.20 Harbison-Walker . linear and volume stability up to its temperature limit. are specifically designed to refractory is exposed to coal ash and coal slag. MAGNESITE & MAG-CHROME ticularly suitable for forming dense monolithic hearths.hwr. and ladle linings for ferrous and nonferrous industries GR-FG RAMMING MIX An organic bonded. A high alumina air-setting ramming A versatile. Typical uses and maintenance of electric furnace include burner rings. For new to shrinkage and thermal spalling at construction of electric furnace hearths high temperatures. It has high strength and excellent installation RAMAL® 80 MAGNAMIX® 95 characteristics. ramming mixes form dense. brands supplied for a wide variety of furnaces and applications. When mixed HIGH-ALUMINA RAMMING MIXES NARPHOS 85R RAM with water. It features A dry ramming mix based on high exceptionally high density and strength Click here for purity sintered alumina. slag. It features excellent resistance gunning. Once rammed. In-situ spinel and volume stability throughout Technical Data Sheets formation provides improved slag and temperature range. with minor amounts of A phosphate-bonded. high purity alumina-chrome ramming mix with other materials added to make the mixes workable and self-bonding. purposes in process vessels. chemically bonded extra high alumina. It displays non. gunned or vibrated into place. GREFMAG® 95R develops An 85% alumina class. good plastic workability so it can be BRIKRAM® 57 RB bonded. roofs. phosphate. Ramming mixes are par. Others. magnesite-chrome. high alumina RAM provides high strength and applications include the working ramming mix with high hot strength density combined with excellent linings of coreless induction furnaces. This listing represents the major A high quality. and coreless induction furnaces melting Resists spalling and has remarkable abrasion is required. MP . Resists attack use. Arc furnaces. high purity periclase mix mixture furnished in wet form. electric furnace and BOF tapholes. Some ramming mixes can be applied successfully with air-place. vibrated into place. or vibration casting. ready which can be installed by ramming. especially suited for use where the ment guns. temperature strengths. A high purity. RAMMING MIXES The following product descriptions of Harbison-Walker’s ramming mixes GREFMAG® 95R are categorized by their classification. This product is A high purity magnesite ramming mix ramming mix with excellent strengths used where excellent resistance to with exceptional stability for use in at all temperatures within its use range. Typical A phosphate-bonded. temperature range. and excellent strength. steel and alloys. but some are shipped in ready-to. for use. subhearths and other leveling An economical. temperatures. known as dry-vibratibles. NARPHOS 90 R RAM is a high purity. chemically bonded ramming mix available in the dry form. high-alumina ramming mix. high purity alumina slag and metal wash. TAYCOR® 245-D RAM MIX fused grain ramming mix. This mix is ideally erosion created by high temperatures SiC & CARBON CONTAINING suited for cupola taphole applications. This melting steel alloys. It offers excellent NARCARB RAM is intended for dimensional stability and has a NARCOVIBE XL extended cupola campaigns and the combination of physical and chemical An alumina-magnesia spinel dry most severe service conditions.com Harbison-Walker MP . during ladle tearouts. It is also suitable to provide intermediate sintering for bonded materials. it is engineered bond system than the phenolic resin induction furnaces. Designed for PLASTICS & RAMMING MIXES smaller furnaces with installations of GREFITE R less than 5-inches of sidewall thick- RAMAL 85 G GREFITE R is a damp fireclay based. molten copper and copper alloys. Designed for deep excellent performance in maintenance material will not sinter in service sintering at 1000°F or greater to situations or as the original lining in providing for easier lining removal protect against damage from charging Cupola bottoms and troughs. low A bauxite-based. its high bond penetration by ferrous metals. NARCOVIBE 82A FINE An alumina-magnesia spinel dry This mix offers high density. RAM. penetration and corrosion by coreless induction melting of steel containing. The high purity molten iron.RAMMING MIXES MAGNESITE & MAG-CHROME NARCARBTM XZR-HS RAM NARCOVIBE S RAMMING MIXES con’t. It has non-wetting An alumina-magnesia spinel dry aggregate and graphite addition characteristics that permit easy vibratable refractory designed for the combine to provide resistance to slag removal of skulls which results in coreless induction melting of steel and metal erosion. runners.hwr. RAMAL 85 G is cleaner linings and metal. This phenolic resin-bonded ramming An alumina-magnesia spinel dry mix is a high strength. Based on fused alumina with SiC and HARMIX CU® Designed for larger furnaces with oxidation inhibitors. The improved properties. it is engineered bottoms. Based on sintered alumina and ming mix for increased resistance to combined with its high amount of non. non-wetting components. resistance to cupola slags. alloys. for deeper sintering and higher strength blast furnace troughs and runners. troughs. oxidation vibratable refractory designed for the OXIMIX® resistant upgrade to NARCARBTM XZR coreless induction melting of steel A carbon containing magnesia ram. high alumina based installations of greater than 5-inches of low porosity for enhanced corrosion ramming mix with a penetration and sidewall thickness. Contains a spinel addition for improved corro- NARCARBTM XZR RAM sion resistance. the furnace. large or small size furnaces. as a fill material between brick working cap of coreless induction furnaces NARCARBTM XZR RAM provides and backup linings of steel ladles. This yields very A mullite bonded. and corrosive alloys. gray and malleable iron ladles. make this mix strength and high purity raw materials extremely resistante to metal erosion provide extreme resistance to the and slag attack. It properties particularly adapted to resist vibratable refractory designed for the offers the highest level of carbon wetting. Engineered to sinter and bond with the hot face lining. and high purity magnesia. development to protect against lining SUPER NARCARB RAM fracture during the charging procedure. dry vibratable for use vibratable refractory designed for top porosity and high hot strengths. alloys. wells. Based on sintered alumina and especially well suited for cupola include cupola breasts. and runners. ness. This is a phenolic resin-bonded DRY VIBRATABLES ramming mix with the second highest NARCOVIBE TOP CAP amount of non-wetting components. high purity magnesia. Typical uses alloys. Click here for Technical Data Sheets or go to www. wetting components. high high quality graphitic ramming mix alumina wet ramming mix with a high possessing good resistance to slag and NARCOVIBE SD amount of graphite. for some high carbon steels. Based on sintered alumina and and a more environmentally friendly Typical uses include linings for copper high purity magnesia. SUPER corrosion inhibitor.21 . This is a fused grain containing. packing and sealing Applications include petro-chemical. high velocity applications.hwr. boards are required. It completely restored upon drying. If wet by water or with excellent insulating characteristics steam. machinability where special shaped include gasketing.com MP . Applications include petro-chemical. where high quality back up insulation chemical stability. and Typical applications for these products hot face or back up insulation material. INSBOARD is available in 2300. and 3000 degree board. low heat storage. lightweight and excellent sound absorption. These products also offer excellent chemical stability and resistance to chemical attack from most corrosive agents. The INSWOOL® Ceramic Fiber Product line has a wide temperature range for applications from 1500° F to 3000° F. the field. as well as with excellent insulating temperatures up to 2300°F (1260°C). Click here for Technical Data Sheets or go to www. ceramics. high temperature stability. excellent thermal shock resistance. steel. thermal stability. 2800.CERAMIC FIBER PRODUCTS Overview INSWOOL® Ceramic Fibers are a family of products that are manufactured from alumina-silica materials into several product forms. and 3000 degree board. aluminum. Produced from ceramic incineration. and waste incineration. ropes and braids also resist oxidation vacuum formed ceramic fiber board and reduction.22 Harbison-Walker . These fiber INSBOARD HD is a high density. waste enables easy cutting and machining in equipment. and the glass industry. thermal stability. resisting attack from 2600. No is often used as a hot face insulation in water of hydration is present. Applications include areas fibers. Its lightweight in and around high-temperature heating ceramics. most corrosive agents. is required. 2600. The exceptions are phosphoric acid. glass. It can be used as a characteristics. thermal properties are and increased mechanical strength. these products exhibit excellent INSBOARD is available in 2300. Those products are made from spun fibers that provide low thermal conductivity. hydrofluoric acid and strong alkalies. steel. Exceptions are hydrofluoric and phosphoric acids and INSBOARD® HD concentrated alkalies. INSWOOL® Ceramic Fibers come in various product forms which include: • Blankets • Paper • Modules • Moldable and Pumpable • Bulk • Rope and Braids • Board INSBOARD® INSBOARD® 2300 LW INSWOOL® Ropes and Braids INSBOARD is a vacuum formed INSBOARD 2300 LW is a lightweight H-W provides a family of ropes and ceramic fiber board with excellent vacuum formed ceramic fiber board braids for industrial use in insulating characteristics. aluminum. It both hot and cold. low heat storage. INSWOOL HP MODULES will reduce INSWOOL HTZ MODULES will high purity ceramic fiber blanket energy losses through the lining more reduce energy losses through the lining developed especially for use in highly effectively than insulating firebrick. steam. and has relatively low shot content and on the furnace anchors even at high good sound absorption. reformer sidewalls heaters. high INSWOOL HTZ BULK is an alumina- purity alumina-silica bulk ceramic fiber silica-zirconia bulk ceramic spun fiber which can be used at temperatures to which can be used at temperatures to 2400°F. flexible and suitable for applications include oil heaters.23 . as well as outstanding low thermal well as outstanding low thermal conductivity and low heat storage. INSWOOL HP BULK 2700°F. These modules will most furnace applications. Typical excellent conductivity. INSWOOL HP BLANKET is a low iron. lightweight. DO NOT use maximum usage temperature. alkali laden. The thermal and concentrated alkalis.com Harbison-Walker MP . thermal conductivity. upon drying if it becomes wet by water.CERAMIC FIBER PRODUCTS INSWOOL® CG BLANKET INSWOOL® HP MODULES INSWOOL® HTZ MODULES INSWOOL CG is an alumina silica INSWOOL HP MODULES are a family INSWOOL HTZ MODULES are a blanket used in applications up to of 12" x 12" modules up to 12" thick. It is conductivity and low heat storage. and high will not affect its ability to insulate and conditions. flexible INSWOOL HTZ BLANKET is a 2700°F INSWOOL UTILITY BLANKET is a blanket insulation with a low iron related alumina-silica-zirconia ceramic Kaolin based ceramic fiber blanket. and homogenizing sidewalls and end walls. INSWOOL® HP BULK INSWOOL® HTZ BULK INSWOOL HP BULK is a low iron. positive pressure conditions. furnace doors and shields. thermal temperature resistance. and soft fibrous structure right up to its furnaces. expansion joint seals. annealing furnaces. characteristics. reformer INSWOOL HP BLANKET retains a and end walls. Special shapes are available can be used as back up insulation for request. thermal stability and resistance to vibration. stay in place. The thermal and physical properties of INSWOOL and physical properties of INSWOOL HP BULK are completely restored HTZ BULK are completely restored upon drying if it becomes wet by water. Typical applications include oil operating temperatures to 2400°F. or oil. tensile strength and handling mistreatment in shipment and handling. It remains in place shock resistance. 2450°F (1345°C) for continuous use. It is a high quality product that Special shapes are available upon thick. It is attacked by acids atmospheres. It content of less than 1%. abrasive. INSWOOL HP BLANKET was developed to meet the INSWOOL® HTZ BLANKET INSWOOL® UTILITY BLANKET demand for a high temperature. and insulating castables. family of 12" x 12" modules up to 12" 2000°F. steam. or oil. INSWOOL HTZ BULK demonstrates excellent high demonstrates excellent high temperature resistance. It is and insulating castables. and even contact with molten metal. more effectively than insulating reducing atmospheres. Click here for Technical Data Sheets or go to www. It displays very low is lightweight. These modules will resist upon request. flexible and suitable for HP BLANKET has excellent strength. as stability and resistance to vibration. INSWOOL fiber blanket. for linings in contact with molten the most extreme temperature changes alkali laden. Typical firebrick. It is resistant to attack under reducing resistant to attack under reducing atmospheres. temperatures up to 2400°F (1315°C) for resist temperatures up to 2700°F intermittent use and up to 2250°F (1480°C) for intermittent use and up to INSWOOL® HP BLANKET (1230°C) for continuous use. excellent thermal operating temperatures to 2300°F. It is attacked by acids and concentrated alkalis. abrasive.hwr. annealing furnaces. DO NOT use for linings in homogenizing furnaces. INSWOOL temperatures and can resist damage applications are glass furnace crown UTILITY BLANKET exhibits moderate even when subjected to normal insulation. and high positive pressure metal. It is grade of ceramic paper. and can be dried or 12". This box or shell. board-like consistency. even fill thin cracks. When exposed to existing hot face linings for insulating thermal conductivity and good temperatures above 1562°F (850°C) it purposes. thermal shock resistance. compared to conventional ceramic refractory material processed from fiber products. and can be used in contact with conductivity throughout and its clean. Excellent INSWOOL PUMPABLE is a 2300°F recommended for continuous use at chemical resistance and resistance to ceramic fiber.com MP . It is binder based compound. putty-like consistency material. and easy cutting. to pack large voids. INSWOOL PUMPABLE is a light conductivity throughout and its clean. INSWOOL wetting by most non-ferrous metals. and therefore a good contact. INSWOOL smooth surface makes it ideal as a 12". INSFORM’s module shell is a MOLDABLE an excellent material for efficient. It is especially noted for having box. Its highly uniform undergoes an increase in strength due small voids and thin cracks. for good sturdy integrity. when service temperature lightweight mineral material. seal. put into service immediately with no INSWOOL® UTILITY PAPER pre-heat required. and as a INSFORM PREFIRED MODULE is a general purpose patching product. INSWOOL MOLDABLE is with no pre-heat required. the wool block insulation. with the binder gives INSBLOK-19 excellent light weight. and can be good moisture resistance. It is especially thermal reflectance and dielectric usually used for pumping behind noted for having exceptional low strength properties. Its organic place. putty like consistency temperatures to 2300°F. or INSWOOL PUMPABLE has excellent exhibits very low thermal conductivity. pumping with special equipment. application is as a backup lining to abuse and high air velocities as lower furnace shell temperatures. 475°F. It dries to a firm. used for linings up to three used as a hot face material. seal and spacer material. structure assures equal thermal to formation of the ceramic bond. INSBLOK-19 meets the ASTM insulator. INSBLOK-19 INSWOOL MOLDABLE is a 2300°F Although normally used as a back up INSBLOK-19 is a 1900°F maximum ceramic fiber. Normal box size is 18" x molten aluminum. conditions. with the exception of INSWOOL UTILITY PAPER is a INSFORM ADHESIVE GRADE 2 direct molten metal contact. and therefore a good gasket. and for filling contraction cracks. It is also an ideal exceptional low thermal conductivity back. refractory material INSFORM ADHESIVE GRADE 2 is a processed from alumina-silica ceramic finely ground alumino-silicate and inert INSWOOL® PUMPABLE fibers formed into a flexible sheet. INSBLOK-19 inches thick. yet it develops a strong hot C612 Class 5 specification. lightweight. and spacer material. INSWOOL PAPER is clean and module.CERAMIC FIBER PRODUCTS INSWOOL® MOLDABLE used in contact with molten metal. Its principal face surface to withstand physical INSWOOL® PAPER INSWOOL PAPER is a lightweight. Its continuous use at temperatures to vacuum formed. Thickness range from 4" to shock resistance. material. easy It can be troweled or hand packed into dried or put into service immediately handling.hwr. Its ability to compress makes it ideal for expansion joints. containing no unfiberized pre-fired vacuum formed five sided expansion joints and for filling shot. It is also used as a high alumina-silica ceramic fibers formed in a flexible sheet. is manufactured from a wide material to fill ceramic cuplock and good handling strength. as mentioned above. Its highly range of ceramic fiber mixes designed anchors for ceramic fiber blanket uniform structure assures equal thermal to withstand specified service linings. insulator. weight material with very low thermal smooth surface makes it ideal as a conductivity.24 Harbison-Walker . however it can be used to fill handling strength. with very low thermal exception of direct molten metal cold strength but will dissipate above conductivity. available. In addition it is Click here for Technical Data Sheets or go to www. It is recommended for INSFORM PREFIRED MODULE temperature gasket material. open at the contraction cracks. but special sizes as required are MOLDABLE has excellent thermal gasket. especially formulated for UTILTITY PAPER is a commercial Excellent thermal shock resistance. pre-fired ceramic fiber ability to compress makes INSWOOL 2300°F. hwr. . If you are not able to access the website. www.com *In order to provide current data to the users on this handbook. please contact your local sales representative to secure the required data sheets. SECTION 6 Brick Products Basic Refractories BP-1 High-Alumina Refractories BP-3 Fireclay Refractories BP-6 Insulating Refractories BP-7 Special Purpose Refractories BP-9 Data Sheets* www.com.hwr. we have chosen to use an on-line link to our website. solid NARMAG® 142 features excellent hot or liquid oxides. SUPER NARMAG® 145 High fired. The term NARMAG® 142 basic refractory refers to refractory materials composed primarily of High-fired. At high temperatures. the application for these products has broadened to include non-basic NARMAG® 60 DB High-fired. hot strength and good corrosion and logical changes occurring in the industries they serve. Its coatability makes it a product is for normal basic iron and good performer in the burning zone. and fumes. This listing repre- beneficiated chrome ore. (acidic) slags are present. furnaces in the copper industry where siliceous approximately 60% magnesia content. Outstanding hot strength and good SUPER NARMAG® FG resistance to alkali attack are features TOMAHAWK® This is a burned 100% fused MG-Cr of SUPER NARMAG® B a 98% High-fired. direct bonded. rebonded. As the technology of basic refractories has advanced. Consequently. SUPER NARMAG® 145 BRICK MAGNESITE-CHROME offers improved resistance to slag and load at high temperatures as well as BRICK SUPER NARMAG® B higher hot strength. This yields excellent ture. NOKROME 87 LK NOKROME 87 LK has very low NARMAG® FG thermal conductivity and lends itself to This is a burned 100% fused Mg-Cr applications to reduce shell tempera. NARMAG® 60 DB brick are made from high purity periclase and refractories are categorized by their classification. density. dusts. magnesite- chrome brick based on high purity magnesite and chrome ore with 50% BURNED MAGNESITE DIRECT-BONDED fused grain. SUPER NARMAG® FG is reduction reactions as well as slag direct-bonding for improved thermal intended for the most basic iron and attack.1 . basic refractories are chrome brick based on high purity magnesite and chrome ore. NARMAGr B brand brick provide fused magnesia-chrome spinel grain. porosity. It is standard product for applica.BASIC BRICK Overview Basic refractories are those based on magnesite (MgO). TOMAHAWK® also has secondary strength. It offers very good well in all zones of kilns under normal porosity. steel containing conditions. tions in upper and lower transition NARMAG® FG is intended for extreme zones of cement kilns under normal basic iron and steel containing condi- operations. This operations. and excellent unusual resistance to oxidation. density. highly resistant to the corrosive action of chemically basic slags. magnesite- basic (non-acidic) oxides. sents the major brands supplied for a wide variety of furnaces and applications. spalling resistance elevated tempera- The following product descriptions of Harbison-Walker’s basic brick tures. grain brick. direct-bonded basic brick of conditions. and strength. tions.com Harbison-Walker BP . NOKROME 92 LK SUPER NARMAG® 142 NOKROME 92 LK has good This is a burned 20% fused Mg-Cr coatability characteristics and performs grain brick. very high density.hwr. present.g. they are the refrac. strength and good corrosion resistance tory materials of choice when one or more of these conditions are at steel-melting temperatures. SUPER chrome brick based on high purity This yields extremely low porosity. shock resistance. magnesia refractory brick. Development of new and improved basic NARMAG® 60 DB features excellent refractories continues at a rapid pace driven by equally rapid techno.. steel containing conditions with regards to slag corrosiveness and temperature. magnesite- grain brick with chrome enhancement. and strength. direct-bonded. e. Click here for Technical Data Sheets or go to www. metal antioxidants and fused refractory grains. fused spinel and a matrix of the brick to resist internal oxidation- reinforced spinel gives MAGNEL® reduction reactions that can reduce hot RSV its excellent physical properties at strength and otherwise adversely affect a cost effective price. premium carbon bonded refractory brick based on high MAGNEL® N/XT purity magnesite.hwr. The moderate the physical integrity of the brick at amount of spinel yields a product that high temperature. MAGNEL® HF MAGNEL® HF is composed of crystalline magnesia with a bond of magnesium-aluminate spinel. brick joints throughout the entire ladle containing refractory is based on high campaign without the need for mortar. but is best suited for lower transition and burning zone areas. has excellent ressitance to clinker liquids while maintaining lower thermal conductivity and thermal expansion than similar products of the same class.2 Harbison-Walker .e. Specialized MAGNEL® N/XT its excellent physical products contain high purity graphites.e brick are designed to have MAGNEL® RSV good slag resistance and retain high A combination of high purity synthetic temperature stability. Click here for Technical Data Sheets or go to www. This broad product A combination of high purity synthetic offering makes it possible to design magnesite and fused spinel give zoned refractory linings. This brick is typically used for vacuum induction furnace melting. COMANCHE® undergoes a well as a great mechanical flexibility.com BP . ries are high density. Ladles lined with MAGNEL® RS COMANCHE® will maintain tight ® This magnesia aluminate spinel. as bottoms. as well EAF series magnesite carbon refracto- as excellent spalling resistance. It has low thermal expansion and thermal EAF conductivity for a basic brick. properties. It has great resistance designed for steel ladle barrels and against alkali and sulphur attack.BASIC BRICK MAGNESITE-SPINEL MAGNESITE-CARBON BRICK BRICK ANKRAL R17 COMANCHE® This is a burnt magnesia aluminate An alumina-magnesia-carbon brick spinel brick. gradual permanent expansion at the hot face during service. MAGNEL® RSV can be used in all basic zones. i. It offers improved spalling resistance and good hot strength. purity magnesite with a reinforced spinel bond for higher hot strength. the ability of magnesite. meets the requirements of a great variety of service conditions in many UFALA® XCR offers improved load resistance and thermal shock resistance different types of furnaces. blast furnace stoves and pentoxide addition to yield increased incinerators. exhibiting good properties for continuous temperatures up to 2650oF The following product descriptions of Harbison-Walker’s high- (1450oC).hwr. UFALA® XCR Harbison-Walker manufactures high-alumina brick of all classes. along with incinerators and and excellent corrosion resistance to acid and neutral slags at high rotary kilns. temperatures.3 . This listing represents the major brands supplied for a wide variety of incinerator UFALA® UCR and industrial furnace applications. Click here for Technical Data Sheets or go to www. glass tank regenerators rider 60% alumina brick with a phosphorus arches. abrasion. over conventional 60% alumina Harbison-Walker’s continually improving manufacturing techniques. has led to the manufacture of high-alumina refractories unequaled in ARCO® 60 A 60% alumina firebrick economic service life. RESISTAL® S 65 W A An andalusite containing chemically bonded 65% alumina brick with very high strength and alkali resistance. thermal shock resistance and alkali resistance. alumina refractories are categorized by their classification. These multi-purpose refractories are available with alumina This product manufactured from high contents of up to 99+% and are useful for service extending to about purity bauxitic kaolin displays low porosity. including mullite. and 3300°F (1817°C). with an- dalusite to enhance load and thermal dalusite. This 60% alumina brick. impact.com Harbison-Walker BP . and alkali attack. KALA SR provides excellent resistance to alkali attack. Major applications are Often chosen for their resistance to spalling. 50% ALUMINA CLASS KALA® SR NIKETM 60 AR KALA® A 50% alumina refractory with an. Their refractoriness is generally in proportion to their superior resistance to thermal shock alumina content. high-alumina brick’s broadest appeal lies in its high refractoriness stoves. with low porosity and exceptional resistance to alkali attack and creep improved service in applications where under sustained loads. 50% alumina refractory shock resistance. The product this high-alumina brick is based on high line covers a wide range in refractoriness and other properties.5% alumina. corundum and alumina-chrome brick. Primary temperature swings are common RESISTAL SM 60C applications include carbon baking An andalusite containing. This brick is the premium quality member of the UFALA® family of andalusite containing refractories. products. coupled with the company’s use of high purity domestic raw materials. low porosity flues. Ultimate creep resistance and excellent thermal shock resistance make UFALA® BURNED HIGH ALUMINA UCR an ideal choice for applications involving high loading and temperature BRICK cycling. very good hot strength. An upgraded version of UFALA® CR. or in checker settings of blast furnace load.HIGH-ALUMINA BRICK Overview 60% AND 65% ALUMINA CLASS High-alumina brick belong to the alumina-silica group containing more than UFALA® 47. shows good strength and High purity. and purity bauxitic kaolins and andalusite. ALADIN® 85 offers improved perfor. Based on calcined non-ferrous melting furnaces. Matrix (DM). Features are high of handling very difficult applications. about 3700°F (2040°C) and brick in this class. It is used and thermal shock resistance along prevail. Successful applications ALADIN® 85 A dense 90% alumina refractory with include cement kilns. ladles.hwr. bauxite with very low alkali levels. ALADIN 80 is an economical corundum refractory with Densified refractory. mullite bonded. Withstands the penetration of fluid slags. phosphate High purity ingredients and a high High purity corundum bonded extra bonded brick that exhibits low porosity purity mullite bond make KORUNDAL high-alumina brick with Densified and high hot strengths. Click here for Technical Data Sheets or go to www. cant thermal shock resistance. This is a mullite-bonded high purity required. KORUNDAL and hot strengths. 90% . brick with excellent spalling resistance. capable Matrix (DM). higher strengths than most 80% shock resistance and low porosity. Resistant to most KORUNDAL XD® DM stability and inertness of alumina are slag conditions in steel ladles. exceptional thermal roofs. electric furnace This brick features high density and high hot strength. life in channel induction furnaces for burned phosphate-bonded brick the foundry industry. served successfully in many applica. hot load strength and the ability to (1650oC) withstand attack by corrosive slags TUFLINE® 90 and metals.99% ALUMINA CLASS shock. reheat furnaces and many ferrous and alumina brick. It exhibits excellent alkali. It has content in its class. temperatures in excess of 3000oF slag. A 90% alumina refractory with a tional products typically used for steel Densified Matrix (DM) and mullite bond VALORTM P70 ladle applications.. resistance to penetration and corrosion brick with the lowest porosity and silica Excellent alkali rating from 2200°F to by molten slags and other fluxes. and fluxes.com BP . TUFLINE® 95 DM has 80% AND 85% ALUMINA CLASS for 90% alumina brick since the mid. tions. ALADIN® tion by slag and in constructions where A high-alumina brick product consist- 80 has good strength. reheat expansion heavy loads and high temperatures ing of high purity corundum. (1650°C). XD a premium refractory brick. ALTEX® 75B KORUNDAL XD® TUFLINE® 95 DM A 75% alumina. ALADIN® 80 where it resists corrosion and penetra.4 Harbison-Walker . such as slagging rotary kilns. incinerators. H-W® CORUNDUM DM Based on calcined bauxites. 90% alumina brick KRUZITE® 70 containing premium bauxite. This containing phosphorous pentoxide A dense. high alumina. i. excellent thermal shock resistance. characterized by exceptional slag A 70% alumina phosphate containing resistance and resistance to thermal burned alumina brick. featuring excellent alkali resistance. along with signifi- 2500°F. low porosity and improved It has been the acknowledged standard refractoriness. DV-38 is an extra high strength. DV-38 is an excellent choice for abrasive environments at low temperatures. metals. and good A 90% alumina brick with high density DV-38 resistance to acid slags.HIGH-ALUMINA BRICK 70% ALUMINA CLASS GREENAL-80 GREENAL-90 An 80% alumina burned brick A mullite bonded.e. Good thermal shock resistance. high hot strength. soaking pits. and also offer excellent A 98% high purity corundum bonded burned brick containing phosphate. These brick carry a substantial GREENAL-80-P load at temperatures above 3000°F TUFLINE® 98 DM An 80% alumina. low-porosity 70% alumina bauxite results in less vitrification at additions. strength. low XD DM has provided longer campaign apparent porosity. in applications where the high melting with lower porosity than any other point. burned. Characterized by low ALADIN® 90 porosity. TUFLINE® 90 DM 70% AND 75% ALUMINA CLASS mance potential over other conven. 1960’s. and abrasion resistance. Click here for Technical Data Sheets or go to www. penetration and reaction by molten metals. fused applications include slag pools of grain refractory contains 75% chromic- rotary incinerators.5 . available in custom brick shapes as AUREX® 75/C.HIGH-ALUMINA BRICK . AUREX® 30 SR ® RUBY SR A high purity. outstanding resistance to iron-silica slags and excellent stability at very CORAL® BP RUBY® DM high temperatures. Typical AUREX® 90 An extremely dense. wetting. Also extremely high temperature service available in custom brick shapes as ALTEX® 75B where it provides extraordinary AUREX 75SR/C. high purity. Also available in oxide with a solid solution bond Also custom brick shapes as RUBY® SR/C. This brick has strength. these burned. of AUREX® 75 with improved chromic oxide brick designed for resistance to thermal spalling. where it provides extraordinary resistance to chemical attack. It is well suited for use in applications include the slag lines of fused-grain refractory containing 90% alkali environments needing resistance induction furnaces and carbon black chromic oxide. reactors. alumina. containing 30% chromic oxide and alumina-chromic-oxide brick. The chromic oxide addition exceptional resistance to thermal provides enhanced resistance to spalling. This brick features to mechanical abuse. Featuring low porosity. fused grain refractory This is a solid solution bonded. brick provide good resistance to . resistance to chemical attack. porosity. corrosive incinerator slags.hwr. This 75% alumina. corrosion AUREX® 75 and thermal shock. PHOSPHATE BONDED HIGH RUBY® AUREX® 75SR An upgraded version ALUMINA BRICK A solid-solution bonded. refractory with 20% chromic oxide and chemically bonded brick has very high solid-solution bond. BURNED CHROME-ALUMINA BRICK BURNED ALUMINA-CHROME BRICK AUREX® 20 SR RESISTAL® KR 85 C A high purity. densified matrix and a solid-solution tures. phosphate-bonded bond. phosphate bonded. resistance. corundum-based This 85% alumina. high strength An alumina-chrome refractory with a and volume stability at high tempera. Typical This very dense.com Harbison-Walker BP . corrosion burned brick has high strength and low and severe slag attack. 5% chromic oxide. designed solid-solution bond with good spall for extremely high temperature service. resistance to thermal shock. coarse grain. Some fireclay brick. and resistance to carbon monoxide combustion chambers. charcoal furnaces. and cyclones. type classification. calcined clays control drying and firing shrinkages. dry pressed good strength. Fireclay brick in these classes cover the approximate range of about 18% to 44% alumina.com BP . furnace stacks. The relative proportions of these used in a blend depend upon the character and quality of the ware to be made. plastic clays facilitate forming and impart bonding strength. It is suitable for general service conditions. air is available in 9” x 4½” x 3”and 2½” and good resistance to carbon monox- heaters. medium-duty. super. semi- silica. ALAMO® high strength. low shrinkage. Click here for Technical Data Sheets or go to www. ide disintegration. dry-pressed. Typical high strength. and good firebrick that exhibits low porosity.hwr. zinc galvanizing pots. are made of a single clay. Flint clays and high-grade kaolins impart high refractoriness. good alkali resistance. dense brick back-up linings. high-duty. good alkali resistance. HIGH-DUTY FIRECLAY SUPER-DUTY FIRECLAY EMPIRE® S ALAMO® KX-99®-BF An economical. and from 50% to 80% silica. boilers. It is intended for super-duty brick with low porosity. and other areas encountering sizes. rotary kilns and include glass tank lower checkers. fireclay brick meeting ASTM regular duty fireclay brick. applications included air heaters. Not suggested for abrasive conditions. High-duty and super-duty fireclay brick are commonly made of a blend of clays. especially those of the medium and low-duty class. dry-pressed. A high fired dry pressed.FIRECLAY BRICK Overview The five standard classes of fireclay brick are super-duty. super-duty. The following product descriptions of Harbison-Walker’s fireclay refractories are categorized by their classification.6 Harbison-Walker . high-duty An economical. CLIPPER® DP KX-99® A dry pressed super-duty brick with Is a high fired. boilers. flue and duct disintegration. and low-duty. moderate operating temperatures. stacks. graphitizing furnaces. This listing represents the major brands supplied to a wide variety of applications. Typical applications linings. It is not sug- insulating brick is intended for service gested for rotary kiln service.com Harbison-Walker BP . and ceramic fiber products to provide additional insulating lining options. GREENLITE HS is appropriate for other applications requiring higher strength than standard insulating firebrick. thermal conductivity. G-Series Insulating Firebrick Harbison-Walker’s low iron insulating GREENLITE® HS firebrick are available at five service This is a 2600oF rated. multiplied by 100 represents the nominal maximum temperature to which the refractory can be exposed in service at the hot face. porous materials with much lower density. 23. gunning mixes. Harbison-Walker also manufacturers a full range of insulating castable. high strength insulating brick. zone. 20.INSULATING BRICK Overview Insulating refractory brick are lightweight. The following product descriptions of Harbison-Walker insulating refractory brick are categorized by their classification. and 28. high strength temperature ratings between 2000oF and insulating brick that is used back up in 3000oF. These products can be used in high temperature ceramic kiln application and some high corro- sive applications as either hot face or back up lining materials. conditions involving hydrogen and fluorine containing atmospheres.7 . Another type of insulating brick are those based on high purity hollow sphere alumina. brick intended for very severe service semi-insulating brick for rotary kiln in both hot face and back up applica. It offers lower density TUFLINE® LW and better insulating value than the HS This 99% alumina. It is available in RKB as well as ® standard sizes. refractoriness than GREENLITE® HS. INSULATING ALUMINA-CHROME INSULATING FIRECLAY REFRACTORIES REFRACTORIES ® RUBY® LW LOTHERM RK A unique lightweight alumina-chrome This brick is the original high strength. Click here for Technical Data Sheets or go to www. IFB’s with temperature rating of 3000oF are also available. Special insulating refractories offering significantly higher strength than standard IFB’s are also available. They offer excellent insulating two layer paper kiln burning zones and value along with traditional chemical as full thickness liners in intermediate and physical properties. corundum-bonded version listed above. These can be used in applications requiring load bearing ability. Typically a 150 to 200oF safety factor is used in selecting the appropriate brick. service. 26. These materials are covered in other sections. The American Society for Testing Materials (ASTM) classifies insulating fireclay brick (IFB) into groups 16. and heat storage capacity than other refractories.hwr. ® INSULATING HIGH-ALUMINA GREENLITE 27 REFRACTORIES This is a 2700oF rated. The group number. It offers slightly higher tions. SPECIAL PURPOSE REFRACTORIES Overview Materials that surpass commonly used refractories in one or more of their essential properties are often required in industrial processes. Chemical- resistant brick and tile, silicon carbide, and zircon refractories are examples of products with extraordinary properties for special applications. The following product descriptions of Harbison-Walker’s special purpose refractories are categorized by their classification. This listing represents the major brands supplied for a wide variety of furnaces and applications. VIB-TECH SHAPES ZIRCON REFRACTORIES SILICON CARBIDE ® Harbison-Walker manufactures This family of brick, mortars, and HARBIDE is a clay bonded silicon VIB-TECH shapes for application patching mixes, designated by the TZB carbide brick that offers excellent requiring high-performance, complex name, have been the standard of the resistance to abrasion and high thermal shapes. They are thixotropic cast, industry for many years. They are conductivity. ceramic bonded, high-fired shapes that suited for applications involving provide the unique characteristics of siliceous fluxes including glass. several of our premium brick brands. They are designated by the /C suffix. These brands include VITREOUS SILICA KORUNDAL® XD/C, TUFLINE® 90 DM/C, TUFLINE® 98 DM/C, TUFLINE® VISIL® is a vitreous silica brick that DM/C AL, H-W® CORUNDUM DM/C, provides exceptional resistance to RUBY® SR /C, and AUREX® 75 /C. In thermal cycling at temperatures below addition to these alumina and alumina- 2000oF. It also offer excellent resistance chrome products, we also manufacture to many acidic slags and chemicals. vitreous silica, VISIL /C® , and silicon carbide, HARBIDE® /C, shapes. Click here for Technical Data Sheets or go to www.hwr.com Harbison-Walker BP - 9 SECTION 7 Installation References Brick, Sizes, Shapes IR-1 EAF Door Jambs/Blast Furnace IR-6 Blast Furnace Keys IR-7 Electric Furnace Roof Shapes IR-8 Semi-Universal Ladle Brick IR-10 Skewback Shapes IR-11 Combination Linings for Rotary KIlns IR-16 ISO and VDZ Combination Linings IR-20 Ring Combinations IR-25 Arch Combinations IR-52 Anchoring Refractories IR-63 BRICK SIZES AND SHAPES Wherever furnace construction and operating conditions permit, refractory linings are typically constructed with brick of standard sizes and shapes. Standard materials cost less than larger, more intricate shapes and frequently are more serviceable. They are also more accessible, in that they are likely to be routinely stocked by the manufacturer. The most widely used standard size for all types of refractory brick is 9 x 41/2 by 3 inches. Most brands offer larger sizes, as well. Special shapes, such as skewback brick, are important in the construction of numerous kinds of furnaces having sprung arches. This section provides a comprehensive listing of standard brick sizes and shapes for a variety of furnace applications, as well as ring and arch combinations for standard size refractory brick. Additional sections address special shapes such as semi-universal ladle brick, brick counts for rotary kilns and rotary kiln brick shapes, including ISO, VDZ and CR two-shape systems for combination linings. Together, offer refractory users a ready reference of information governing furnace refractory lining and construction. If you require a special shape which is not included in this booklet, please contact your Harbison-Walker representative. Harbison-Walker manufactures special shapes based on customer designs showing shape details and assembly in the furnace lining. Harbison-Walker IR - 1 BRICK SIZES AND SHAPES OVERVIEW Refractory brick are classified on the basis of their form as Rectangular Shapes or Special Shapes. Rectangular Sizes are brick of relatively simple design, with certain definite shapes, that are marketed in sufficient amounts to permit quanti- ty production. Rectangular sizes are preferred wherever furnace con- struction and operating conditions permit. These brick cost less than longer and more intricate shapes. Special Shapes are refractory brick of special design of either sim- ple or intricate form. Some special shapes may be considered as mod- ifications of rectangular tile having the same overall dimensions. For initial orders of special shapes, drawings showing complete details of the shapes, as well as their assembly in the furnace, should be included. The drawing and shape numbers should be provided on all subsequent orders. Nine-Inch Sizes ( 9 X 41/2 X 3 ) 3" 4 1/2" 4 1/2" 4 1/2" 9" 9" 9" 3" 2" 2 3/4" 9 Inch Straight 9 – 2 Inch Split 9 Inch No. 1 Wedge 9 X 41/2 X 3 9 X 41/2 X 2 9 X 41/2 X (3 – 23/4) 3" 4 1/2" 3 1/2" 4 1/2" 9" 9" 3" 9" 2 1/2" 1 1/2" Small 9 Inch Straight 9 Inch Split 9 Inch No. 2 Wedge 9 X 31/2 X 3 9 X 41/2 X 11/2 9 X 41/2 X (3 – 21/2) 3" 3" 4 1/2" 4 1/2" 2 1/4" 9" 9" 9" 3" 2 7/8" 2" 9 Inch Soap 9 Inch No. 1-X Wedge 9 Inch No. 3 Wedge 9 X 21/4 X 3 9 X 41/2 X (3 – 27/8) 9 X 41/2 X (3 – 2) IR - 2 Harbison-Walker BRICK SIZES AND SHAPES Nine-Inch Sizes ( 9 X 41/2 X 3 ) 1 13/16" 3" 4 1/2" 3" 4 1/2" 3" 9" 9" 3" 9" /2" 41 2 3/4" 9 Inch No. 1 Arch 9 Inch No. 3 Key 9 Inch – 48° Side Skew 9 X 41/2 X (3 – 23/4) 9 X (41/2 – 3) X 3 9 X (41/2 – 113/16) X 3 3" 2 3/4" 4 1/2" 4 1/2 " 3" 3" 9" 9" /4 " 9" /2" 21 41 2 1/2" 9 Inch No. 2 Arch 9 Inch No. 4 Key 9 Inch – 60° Side Skew 9 X 41/2 X (3 – 21/2) 9 X (41/2 – 21/4) X 3 9 X (41/2 – 23/4) X 3 3" 6 5/16" 4 1/2 1/8" 3" 3" " 9" 9" /2" 9" /2" 41 41 2" 9 Inch No. 3 Arch 9 Inch – 48° End Skew 9 Inch Featheredge 9 X 41/2 X (3 – 2) (9 – 65/16) X 41/2 X 3 9 X 41/2 X (3 – 1/8) 4 1/2" 4 1/2" 3" 3" 1 1/2" 5/8" 9" 9" 9" /2" 4" 41 3" 9 Inch No. 1 Key 9 Inch Edge Skew 9 Inch Neck 9 X (41/2 – 4) X 3 9 X (41/2 – 11/2) X 3 9 X 41/2 X (3 – 5/8) 4 1/2" 7 1/4" 3" 4 1/2" 3" 9" 2" 9" /2" 4 1/ 31 9" 3" 9 Inch No. 2 Key 9 Inch – 60° End Skew 9 Inch Jamb 9 X (41/2 – 31/2) X 3 (9 – 71/4) X 41/2 X 3 9 X 41/2 X 3 Harbison-Walker IR - 3 BRICK SIZES AND SHAPES High-Alumina, Basic and Silica Brick TYPICAL STRAIGHT, ARCH, WEDGE AND KEY BRICK Sizes Name Dimensions (In.) Equivalent 9x6x3 Straight 9x6x3 1.60 No. 1 Arch 9 x 6 x (3-23/4) 1.53 Straight Arch Wedge Key No. 2 Arch 9 x 6 x (3-21/2) 1.47 No. 3 Arch 9 x 6 x (3-2) 1.33 Sizes Name Dimensions (In.) Equivalent No. 1-X Wedge 9 x 6 x (3-27/8) 1.57 9x 41/2x 21/2 Straight 9x 41/2 x 21/2 1.00 No. 1 Wedge 9 x 6 x (3-23/4) 1.53 9 x 31/2 x 21/2 Soap 9 x 21/4 x 21/2 0.50 No. 2 Wedge 9 x 6 x (3-21/2) 1.47 9 x 21/4 x 21/2 2" Split 9 x 41/2 x 21/2 0.80 No. 3 Wedge 9 x 6 x (3-2) 1.33 9 x 41/2 x 21/2 Split 9 x 41/2 x 11/4 0.50 No. 1 Key 9 x (6-53/8) x 3 1.52 9x 41/2 x 21/2 No. 1-X Wedge 9x 41/2 x (21/2-21/4) 0.95 No. 2 Key 9 x (6-413/16) x 3 1.44 No. 1 Wedge 9 x 41/2 x (21/2-17/8) 0.88 No. 3 Key 9 x (6-3) x 3 1.20 No. 2 Wedge 9 x 41/2 x (21/2-11/2) 0.80 No. 1 Arch 9 x 41/2 x (21/2-21/8) 0.93 9 x 63/4 x 3 Straight 9 x 63/4 x 3 1.80 No. 2 Arch 9 x 41/2 x (21/2-13/4) 0.85 No. 1-X Wedge 9 x 63/4 x (3-27/8) 1.76 No. 3 Arch 9 x 41/2 x (21/2-1) 0.70 No. 1 Wedge 9 x 63/4 x (3-23/4) 1.72 No. 1 Key 9 x (41/2-4) x 21/2 0.94 No. 2 Wedge 9 x 63/4 x (3-21/2) 1.65 No. 2 Key 9 x (41/2-31/2) x 21/2 0.89 No. 3 Wedge 9 x 63/4 x (3-2) 1.50 No. 3 Key 9 x (41/2-3) x 21/2 0.83 No. 4 Key 9 x (41/2-21/4) x 21/2 0.75 9x9x3 Straight 9x9x3 2.40 No. 1-X Wedge 9 x 9 x (3-27/8) 2.35 9 x 41/2 x 21/2 48° End Skew (9-63/4) x 41/2 x 21/2 0.88 No. 1 Wedge 9 x 9 x (3-23/4) 2.30 60° End Skew (9-79/16) x 41/2 x 21/2 0.92 No. 2 Wedge 9 x 9 x (3-21/2) 2.20 48° Side Skew 9 x (41/2-21/4) x 21/2 0.75 No. 3 Wedge 9 x 9 x (3-2) 2.00 60° Side Skew 9 x (41/2-31/16) x 21/2 0.84 Edge Skew 9 x (41/2-11/2) x 21/2 0.67 12 x 41/2 x 3 Straight 12 x 41/2 x 3 1.60 Featheredge 9 x 41/2 x (21/2-1/8) 0.53 No. 1 Arch 12 x 41/2 x (3-23/4) 1.53 Neck 9 x 41/2 x (21/2-5/8) 0.63 No. 2 Arch 12 x 41/2 x (3-21/2) 1.47 Jamb 9 x 41/2 x 21/2 0.89 No. 3 Arch 12 x 41/2 x (3-2) 1.33 9 x 41/2 x 3 Straight 9 x 41/2 x 3 1.20 No. 1-X Wedge 12 x 41/2 x (3-27/8) 1.57 9 x 31/2 x 3 Sm. Straight 9 x 31/2 x 3 0.93 No. 1 Wedge 12 x 41/2 x (3-23/4) 1.53 9 x 21/4 x 3 Soap 9 x 21/4 x 3 0.60 No. 2 Wedge 12 x 41/2 x (3-21/2) 1.47 9 x 41/2 x 11/2 Split 9 x 41/2 x 11/2 0.60 No. 3 Wedge 12 x 41/2 x (3-2) 1.33 9 x 41/2 x 3 No. 1 Arch 9 x 41/2 x (3-23/4) 1.15 12 x 6 x 3 Straight 12 x 6 x 3 2.13 No. 2 Arch 9 x 41/2 x (3-21/2) 1.10 No. 1 Arch 12 x 6 x (3-23/4) 2.04 No. 3 Arch 9 x 41/2 x (3-2) 1.00 No. 2 Arch 12 x 6 x (3-21/2) 1.96 No. 4 Arch 9 x 41/2 x (3-1) 0.80 No. 3 Arch 12 x 6 x (3-2) 1.78 No. 1-X Wedge 9 x 41/2 x (3-27/8) 1.17 No. 1-X Wedge 12 x 6 x (3-27/8) 2.09 No. 1 Wedge 9 x 41/2 x (3-23/4) 1.15 No. 1 Wedge 12 x 6 x (3-23/4) 2.04 No. 2 Wedge 9 x 41/2 x (3-21/2) 1.10 No. 2 Wedge 12 x 6 x (3-21/2) 1.96 No. 3 Wedge 9 x 41/2 x (3-2) 1.00 No. 3 Wedge 12 x 6 x (3-2) 1.78 No. 1 Key 9 x (41/2-4) x 3 1.13 No. 1 Key 12 x (6-51/2) x 3 2.04 No. 2 Key 9 x (41/2-31/2) x 3 1.07 No. 2 Key 12 x (6-5) x 3 1.96 No. 3 Key 9 x (41/2-3) x 3 1.00 No. 3 Key 12 x (6-3) x 3 1.87 No. 4 Key 9 x (41/2-21/4) x 3 0.90 12 x 63/4 x 3 Straight 12 x 63/4 x 3 2.40 9x 41/2 x3 48° End Skew (9-65/16) x 41/2x3 1.02 No. 1-X Wedge 12 x 63/4 x (3-27/8) 2.35 60° End Skew (9-71/4) x 41/2 x 3 1.08 No. 1 Wedge 12 x 63/4 x (3-23/4) 2.30 48° Side Skew 9 x (41/2-113/16) x 3 0.84 No. 2 Wedge 12 x 63/4 x (3-21/2) 2.20 60° Side Skew 9 x (41/2-23/4) x 3 0.97 No. 3 Wedge 12 x 63/4 x (3-2) 2.00 Edge Skew 9 x (41/2-11/2) x 3 0.80 12 x 9 x 3 No. 1 Arch 12 x 9 x (3-23/4) 3.07 Featheredge 9 x 41/2 x (3-1/8) 0.63 No. 2 Arch 12 x 9 x (3-21/2) 2.93 Neck 9 x 41/2 x (3-5/8) 0.73 No. 3 Arch 12 x 9 x (3-2) 2.67 Jamb 9 x 41/2 x 3 1.07 Straight 12 x 9 x 3 3.20 9x6 Straight 9 x 6 x 21/2 1.33 No. 1-X Wedge 12 x 9 x (3-27/8) 3.13 Flat Back Split 9 x 6 x 11/4 0.67 No. 1 Wedge 12 x 9 x (3-23/4) 3.07 No. 1 Arch 9 x 6 x (31/2-21/2) 1.60 No. 2 Wedge 12 x 9 x (3-21/2) 2.93 No. 2 Arch 9 x 6 x (31/2-2) 1.47 No. 3 Wedge 12 x 9 x (3-2) 2.67 IR - 4 Harbison-Walker BRICK SIZES AND SHAPES Sizes Name Dimensions (In.) Equivalent Sizes Name Dimensions (In.) Equivalent 131/2 x 41/2 x 3 Straight 131/2 x 41/2 x 3 1.80 18 x 41/2 x 3 Straight 18 x 41/2 x 3 2.40 No. 1 Arch 131/2 x 41/2 x (3-23/4) 1.72 No. 1-X Wedge 18 x 41/2 x (3-27/8) 2.35 No. 2 Arch 131/2 x 41/2 x (3-21/2) 1.65 No. 1 Wedge 18 x 41/2 x (3-23/4) 2.30 No. 3 Arch 131/2 x 41/2 x (3-2) 1.50 No. 2 Wedge 18 x 41/2 x (3-21/2) 2.20 No. 3 Wedge 18 x 41/2 x (3-2) 2.00 No. 1 Key 131/2 x (41/2-4) x 3 1.70 No. 2 Key 131/2 x (41/2-31/2) x 3 1.60 18 x 6 x 3 Straight 18 x 6 x 3 3.20 No. 3 Key 131/2 x (41/2-3) x 3 1.50 No. 1-X Wedge 18 x 6 x (3-27/8) 3.13 No. 4 Key 131/2 x (41/2-21/4) x 3 1.35 No. 1 Wedge 18 x 6 x (3-23/4) 3.07 No. 2 Wedge 18 x 6 x (3-21/2) 2.93 131/2 x 6 x 3 Straight 131/2 x 6 x 3 2.40 No. 3 Wedge 18 x 6 x (3-2) 2.67 No. 1 Arch 131/2 x 6 x (3-23/4) 2.30 No. 2 Arch 131/2 x 6 x (3-21/2) 2.20 18 x 9 x 3 Straight 18 x 9 x 3 4.80 No. 3 Arch 131/2 x 6 x (3-2) 2.00 No. 1-X Wedge 18 x 9 x (3-27/8) 4.70 No. 1 Wedge 18 x 9 x (3-23/4) 4.60 No. 1-X Wedge 131/2 x 6 x (3-27/8) 2.35 No. 2 Wedge 18 x 9 x (3-21/2) 4.40 No. 1 Wedge 131/2 x 6 x (3-23/4) 2.30 No. 3 Wedge 18 x 9 x (3-2) 4.00 No. 2 Wedge 131/2 x 6 x (3-21/2) 2.20 No. 3 Wedge 131/2 x 6 x (3-2) 2.00 21 x 6 x 3 Straight 21 x 6 x 3 3.73 No. 1-X Wedge 21 x 6 x (3-27/8) 3.65 No. 1 Key 131/2 x (6-5) x 3 2.20 No. 1 Wedge 21 x 6 x (3-23/4) 3.58 No. 2 Key 131/2 x (6-43/8) x 3 2.07 No. 2 Wedge 21 x 6 x (3-21/2) 3.42 No. 3 Key 131/2 x (6-3) x 3 1.80 No. 3 Wedge 21 x 6 x (3-2) 3.11 131/2 x 63/4 x 3 Straight 131/2 x 63/4 x 3 2.70 21 x 9 x 3 Straight 21 x 9 x 3 5.60 No. 1-X Wedge 131/2 x 63/4 x (3-27/8) 2.64 No. 1-X Wedge 21 x 9 x (3-27/8) 5.48 No. 1 Wedge 131/2 x 63/4 x (3-23/4) 2.59 No. 1 Wedge 21 x 9 x (3-23/4) 5.37 No. 2 Wedge 131/2 x 63/4 x (3-21/2) 2.47 No. 2 Wedge 21 x 9 x (3-21/2) 5.13 No. 3 Wedge 131/2 x 63/4 x (3-2) 2.25 No. 3 Wedge 21 x 9 x (3-2) 4.67 131/2 x 9 x 3 Straight 131/2 x 9 x 3 3.60 Misc. Straight 9x6x2 1.07 No. 1 Arch 131/2 x 9 x (3-23/4) 3.45 Straights Straight 9x7x2 1.24 No. 2 Arch 131/2 x 9 x (3-21/2) 3.30 Straight 9 x 71/2 x 2 1.33 No. 3 Arch 131/2 x 9 x (3-2) 3.00 Straight 101/2 x 41/2 x 3 1.39 Straight 101/2 x 41/2 x 41/2 2.10 No. 1-X Wedge 131/2 x 9 x (3-27/8) 3.52 Straight 131/2 x 41/2 x 41/2 2.70 No. 1 Wedge 131/2 x 9 x (3-23/4) 3.45 Straight 18 x 63/4 x 3 3.60 No. 2 Wedge 131/2 x 9 x (3-21/2) 3.30 Straight 18 x 9 x 41/2 7.20 No. 3 Wedge 131/2 x 9 x (3-2) 3.00 15 x 41/2 x 3 Straight 15 x 41/2 x 3 2.00 No. 1 Arch 15 x 41/2 x (3-23/4) 1.92 No. 2 Arch 15 x 41/2 x (3-21/2) 1.83 No. 3 Arch 15 x 41/2 x (3-2) 1.67 No. 1-X Wedge 15 x 41/2 x (3-27/8) 1.96 No. 1 Wedge 15 x 41/2 x (3-23/4) 1.92 No. 2 Wedge 15 x 41/2 x (3-21/2) 1.83 No. 3 Wedge 15 x 41/2 x (3-2) 1.67 15 x 6 x 3 Straight 15 x 6 x 3 2.67 No. 1-X Wedge 15 x 6 x (3-27/8) 2.61 No. 1 Wedge 15 x 6 x (3-23/4) 2.56 No. 2 Wedge 15 x 6 x (3-21/2) 2.44 No. 3 Wedge 15 x 6 x (3-2) 2.22 No. 1 Key 15 x (6-5) x 3 2.56 No. 2 Key 15 x (6-43/8) x 3 2.31 No. 3 Key 15 x (6-3) x 3 2.00 15 x 9 x 3 Straight 15 x 9 x 3 4.00 No. 1-X Wedge 15 x 9 x (3-27/8) 3.92 No. 1 Wedge 15 x 9 x (3-23/4) 3.83 No. 2 Wedge 15 x 9 x (3-21/2) 3.67 No. 3 Wedge 15 x 9 x (3-2) 3.33 Harbison-Walker IR - 5 EAF DOOR JAMBS/ BLAST FURNACE BLAST-FURNACE BOTTOM BLOCKS METALKASE DOOR JAMB BRICK (18 X 9 X 4 1/2 Inches) Number per course for blocks laid on end Diameter of Diameter of No. of No. of Hearth Jacket Hearth Jacket B Blocks Blocks (Ft In) (Ft In) C 17 6 897 27 6 2176 18 0 947 28 0 2255 A D 18 6 999 28 6 2335 19 0 1053 29 0 2417 19 6 1108 29 6 2500 A B C D Name (In) (In) (In) (In) 20 0 1164 30 0 2584 20 6 1222 30 6 2669 21 0 1281 31 0 2756 DJ-1-3 9 4 1/2 11/2 3 21 6 1342 31 6 2845 22 0 1403 32 0 2935 DJ-2-3 9 6 3/4 3 3/4 3 22 6 1467 32 6 3026 DJ-3-3 9 9 6 3 23 0 1531 33 0 3119 23 6 1598 33 6 3213 BS-115-3 13 1/2 6 3/4 2 3/4 3 24 0 1665 34 0 3308 24 6 1734 34 6 3405 BS-116-3 13 1/2 9 5 3 25 0 1804 35 0 3503 25 6 1876 35 6 3603 DJ-18-1-3 18 6 3/4 2 3/4 3 26 0 1949 36 0 3704 26 6 2023 36 6 3806 DJ-18-2-3 18 9 5 3 27 0 2099 37 0 3909 High-Alumina Circle Brick Circle Brick Number Nine-Inch Sizes Number* Chord Per (9 X 4 1/2 X 3) (3 Inch) (Inch) Ring * The first two numbers of the 24 - 33 - 3 6 17/32 12 Circle Number indicate the 9" 36 - 45 - 3 7 3/16 16 inside and outside diameters, respectively, of the ring produced 48 - 57 - 3 7 19/32 20 by each shape. For example, 60 - 69 - 3 7 13/16 24 24 - 33 - 3 Circle Brick will 41 produce a ring with a 24-inch /2" 72 - 81 - 3 8 29 3" inside diameter and 33-inch 84 - 93 - 3 8 1/8 33 outside diameter for a 4 1/2 96 - 105 - 3 8 7/32 37 inch lining. 108 - 117 - 3 8 5/16 41 120 - 129 - 3 8 3/8 45 IR - 6 Harbison-Walker BLAST FURNACE KEYS SHAPES FOR ALL-KEY BLAST FURNACE LININGS 6" 6" 2" 2" 5 29/3 5 29/3 3" 3" 3" 3" 13 1/2 " " /16 13 1/2 " 5 11 9" /16 " " " 9" /16 5 11 /16 5 11 5 11 13 1/2-Inch – X-1 9-Inch – X-1 13 1/2-Inch – X-2 9-Inch – X-2 NOTE: Blast Furnace keys X-1 and X-2 are also regulary manufactured in 6, 101/2 and 15-inch lengths. The brick com- binations for rings (see Brick Combinations for All-Key Linings table) are applicable for X-1 and X-2 keys of all lengths. BRICK COMBINATIONS FOR ALL-KEY LININGS Diameter Inside Number Required Per Ring Diameter Inside Number Required Per Ring Brickwork Brickwork (Ft In) X-2 X-1 Total (Ft In) X-2 X-1 Total 13 3 98 — 98 27 0 49 135 t84 13 6 96 3 99 27 6 47 140 187 13 9 95 6 101 28 0 45 145 190 14 0 95 8 103 28 6 44 150 194 14 6 93 13 106 29 0 42 155 197 15 0 91 18 109 29 6 40 160 200 15 6 89 23 112 30 0 38 165 203 16 0 87 28 115 30 6 37 169 206 16 6 85 33 118 31 0 35 174 209 17 0 84 37 121 31 6 33 179 212 17 6 82 42 124 32 0 32 184 216 18 0 80 48 128 32 6 30 189 219 18 6 79 52 131 33 0 28 194 222 19 0 77 57 134 33 6 26 199 225 19 6 75 62 137 34 0 24 204 228 20 0 73 67 140 34 6 23 208 231 20 6 71 72 143 35 0 21 213 234 21 0 70 76 146 35 6 19 219 238 21 6 68 82 150 36 0 18 223 241 22 0 66 87 153 36 6 16 228 244 22 6 65 91 156 37 0 14 233 247 23 0 63 96 159 37 6 12 238 250 23 6 61 101 162 38 0 10 243 253 24 0 59 106 165 38 6 9 247 256 24 6 57 111 168 39 0 7 253 260 25 0 56 116 172 39 6 5 258 263 25 6 54 121 175 40 0 4 262 266 26 0 52 126 178 40 6 2 267 269 26 6 51 130 181 41 0 — 272 272 Harbison-Walker IR - 7 ELECTRIC FURNACE ROOF SHAPES OVERVIEW Electric furnace roofs may be constructed using many different shapes and combinations. The combination of standard size key-arch and key-wedge shapes with standard shapes design, and the two-shape (arch-key-wedge) brick design are the most common in electric fur- nace roof construction. Annular rings are laid from the The chart below displays two-shape available in 131/2-inch sizes for larger combinations for your specific roof electric furnace roof brick combina- electric furnace roofs. design. Consideration must be tions for 9-inch roof thicknesses. By Providing your Harbison-Walker given to the best design to provide combining both shapes, all annular representatives with the dimensions of cost-effective service life. The two- rings for a given diameter can be cal- your electric furnace roof or a current shape, triple taper brick uses two culated. The center of the range indi- drawing of your roof enables them to bricks that conform to the roof contour. cates the ideal spherical radius for the produce an accurate ring count and Bricklaying is simplified using only given system. Shape identification is assembly detail. two shapes, in that inventory levels done by a notching system at the cold may be reduced and faster installation is end of the brick shape, as illustrated on possible. p. IR-9. The two-shape system is also ELECTRIC FURNACE ROOF-SHAPES 9 X 41/2 X 3-Inch Arch-Key-Wedge Shapes Spherical Radius Range H-W Shape Designations HW-2721-B 6’6” to 7’9” HW-2721-S HW-2746-B 7’9” to 9’6” HW-2746-A HW-2745-B 9’6” to 12’6” HW-2745-A HW-2592-B 12’6” to 16’0” HW-2592-A HW-2704-B 16’0” to 22’4” HW-2704-A IR - 8 Harbison-Walker ELECTRIC FURNACE ROOF SHAPES A A A B B A A A A B B A A B A B Two-Shape Electric Furnace Roof Construction Two-Shape (arch-key-wedge) roof brick designs are available in a variety of 9-inch sizes to fit EAF roof contours and spherical radii. “A” and “B” Arch-Key-Wedge Brick Harbison-Walker IR - 9 ing.831 IR .60 140 and Up In all four series. The height in inches of the ladle and 100 mm.20 45 to 70 46 x 32 = 1472 SULB brick per lining SU .1416 x 120 = 46 pieces per ring one or more starter sets to start the upward spiral. A universal starter set that wall divided by 3 equals the number of suits all series and wall thicknesses up rings.25 selecting the proper series for any ladle. . .45 100 to 140 SU .414 One tilt back course (to close ring-cut the ends square SU 4-45 7. For guidance in 8. the calculations follow: linings 3 to 9 inches thick. SULB’s are also available (length of brick) to find the number per in two additional thicknesses — 4-inch ring. The 12-piece times the number of rings equals the UL-7-SS12 set is illustrated below. regular 18-piece starter set for 9-inch equivalent to the thickness of the lin. the following chart identifies 96 = 32 rings Series Ladle Diameter (Inch) 3 SU . A SULB lining usually includes a tilt back course to lay the rings square against the sloping sides of a ladle and 3. .690 of two bricks) SU 4-60 7. then dividing by 8.983 SU 4-30 7. . thick walls is also available.30 70 to 100 SU . For example. All series can be produced in widths to construct 96 inches. (All series for a 4-inch thick wall) 8. high-alumina and basic refractories in four series of brick to diameter of 120 inches (outside line sidewalls of iron and steel teeming ladles of various diameters diameter of SULB lining) and a height of and configurations. The number of pieces per ring to 7 inches is available.10 Harbison-Walker .1416.25 series brick.250" 11 12 10 4" Half brick to bond course 8 9 7 6 5 4 3" A 3 2 A 1 Regular Semi-Universal Name Size (to close the first course-cut the ends square of two bricks) SU 4-20 6. a 5-inch required for a lining can be calculated by thick lining in a ladle about 120 inches multiplying the average diameter of the in diameter would require an SU 5-45 ladle by 3.SEMI-UNIVERSAL LADLE BRICK (SULB) OVERVIEW Harbison-Walker manufactures Semi-Universal Ladle Brick (SULB) in For a ladle with an average fireclay. the width of the brick. A total number of SULB shapes required. is positioned in the rectangular The number of SULB shapes frame . 4’ Skewback Consists of 2–9 Inch – 48° End Skew 1–9 Inch – 48° Side Skew 12" 1–9 Inch Soap 3 19/32" 1 19/32" 12" 4 1/2" 2 1/4" 9" 13/16" Shape No.7’ 1 13/16 " 4 1/2" 9" 17/32" 4 1/2" 4 1/2 " 9" 4 1/2" 9" 29/32" 9" 9" 4 1/2" Shape No. 60-12 7 1/2" for Arch 12 9" 4 1/2" 9" 6 3/4" 9" Shape 74-9 For Arch 9 Inches Thick Rise 2 Inches Per Foot of Span For Arch 9 Inches Thick Central Angle 73° 44.11 .7’ Shape 56-9 for Arch 4 1/2 Inches Thick For Arch 9 Inches Thick Skewback Consists of Rise 1 1/2 Inches Per Foot of Span 1–9 Inch – 2 Inch Split 4 1/2" 1–9 Inch Featheredge Central Angle 56° 8.5’ Skewback Consists of 13 1/2" 2 – 9 Inch – 48° End Skew 4 1/2" 2 – 9 Inch – 48° Side Skew 1 – 9 Inch Soap Shape No.5’ Rise 2 Inches Per Foot of Span 6" Central Angle 73° 44.SKEWBACK SHAPES FOR ARCHES WITH NINE-INCH SIZES ADDITIONAL SIZES 60° CENTRAL ANGLE 2 1/8" Rise 1. 60-9 for Arch 9 Inches Thick For Arch 4 1/2 Inches ThickRise 2.608 (119/32) Inches 4 3/4 " Per Foot of Span 2 1/4 " 4 1/2" 4 1/2 " 4 3/4 " 9" 11/16" 9 1/2" 19/32" 9" 4 1/2" 9" 4 1/2 " For Arch 4 1/2 Inches Thick Rise 1 1/2 Inches Per Foot of Span Shape No.4’ 13 1/2" Rise 2. 60-13 1/2 for Arch 13 1/2 Inches Thick Harbison-Walker IR . Central Angle 83° 58. Central Angle 83° 58.302 (2 5/16) Inches Per Foot 1 13/18" of Span.302 Shape 74-4 1/2 (2 5/16) Inches Per Foot For Arch 4 1/2 Inches Thick of Span. 60-40 1/2 Central Angle 56° 8. 60-13 1/2-C tables are useful for estimating the For Arch 13 1/2 Inches Thick For Arch 13 1/2 Inches Thick quantities of brick required for the construction of arches. 60-9-C For Arch 9 Inches Thick For Arch 9 Inches Thick 5" 2 1/4" 2 1/2" 9" 12" 17/32 " 1 19/32" 8 1/4 " 4 1/2 " 11 1/4" 4 1/2" Shape No. 60-12-C For Arch 12 Inches Thick For Arch 12 Inches Thick 2 15/16" 3" 5 5/8" 13 1/2" 13 1/2" 1 13/16" 1 13/16" Note: 12 3/8" 12 11/16" 4 1/2" Brick Combinations required for arch 4 1/2" construction are detailed in the tables starting on pages IR .SKEWBACK SHAPES SKEWBACK BRICK WITH CUTOUTS FOR STEEL ANGLE AND CHANNEL SUPPORTING FRAMEWORK For Arches with 60° Central Angle Rise 1. 60-9-A Shape No. These Shape No. IR . 60-13 1/2-A Shape No.608 (1 19/32) Inches Per Foot of Span STEEL ANGLE STEEL CHANNEL Maximum Dimensions Maximum Dimensions Shorter Thickness Channel Flange Web Skewback Leg Skewback Size Width Thickness (in) (in) (in) (in) (in) 60-9-A 4 3/4 60-9-C 12 3 13/32 3/4 60-12-A 6 1 60-12-C 12 3 13/32 3/4 60-13 1/2-A 8 11/8 60-13 1/2-C 15 3 13/16 13/16 1 1/4" 2 1/2" 3 3/4 " 9" 9" 17/32 " 17/32" 4 1/2" 8 1/4 " 8 1/4" 4 1/2 " Shape No. 60-12-A Shape No.12 Harbison-Walker .52. are made. of the ring produced by the shape. RKA-2/3.13 . 5’-6” 54-A-66 2 7/8 58 respectively. RKA-3/4. For example. Two of each keying brick should be ordered for each ring. Dia. RKB 162-A-174 will 6’-0” 60-A-72 2 29/32 63 produce a ring with a 162-inch inside 6’-6” 66-A-78 2 31/32 68 diameter and 174-inch outside diameter.BRICK COUNTS FOR ROTARY KILNS HIGH-ALUMINA BRICK Ins. keying bricks of two-thirds thickness. and of three-quarters thickness. 7’-0” 72-A-84 3 74 7’-6” 78-A-90 3 1/32 79 8’-0” 84-A-96 3 1/16 84 8’-6” 90-A-102 3 3/32 89 9’-0” 96-A-108 3 1/8 95 9’-6” 102-A-114 3 1/8 100 10’-0” 108-A-120 3 5/32 105 10’-6” 114-A-126 3 5/32 111 11’-0” 120-A-132 3 3/16 116 11’-3” 123-A-135 3 3/16 119 11’-6” 126-A-138 3 3/16 121 12’-0” 132-A-144 3 7/32 126 12’-6” 138-A-150 3 7/32 132 13’-0” 144-A-156 3 7/32 137 13’-6” 150-A-162 3 1/4 142 14’-0” 156-A-168 3 1/4 148 14’-6” 162-A-174 3 1/4 153 15’-0” 168-A-180 3 9/32 158 15’-6” 174-A-186 3 9/32 164 16’-0” 180-A-192 3 9/32 169 16’-6” 186-A-198 3 9/32 174 17’-0” 192-A-204 3 9/32 179 17’-6” 198-A-210 3 5/16 185 18’-0” 204-A-216 3 5/16 190 To facilitate the keying of arch-type rotary kiln blocks. Harbison-Walker IR .) Per Ring ROTARY KILN BLOCKS Arch-Type (9 x 6 x 31/2) 3’-6” 30-A-42 2 1/2 37 4’-0” 36-A-48 2 5/8 42 The numbers in the RKB column indi. * All brick quantities per ring have been calculated from theoretical diameter turned by the brick to which a steel plate (1. RKB Inside Number Kiln Shell Number Chord (In.5 mm thickness) has been attached. 4’-6” 42-A-54 2 23/32 47 5’-0” 48-A-600 2 13/16 52 cate the inside and outside diameters. 14 Harbison-Walker .) Per Ring ROTARY KILN BLOCKS Nine-Inch Size (9 x 9 x 4) 5’-6” 48-66 6 17/32 23 6’-0” 54-72 6 3/4 26 6’-6” 60-78 6 17/16 28 The numbers in the RKB column indi- 7’-0” 66-84 7 1/16 30 cate the inside and outside diameters. For example. 7’-6” 72-90 7 3/16 32 respectively. 48-66 RKB will 8’-0” 78-96 7 5/16 34 produce a ring with a 48-inch inside 8’-6” 84-102 7 13/32 36 diameter and 66-inch outside diameter 9’-0” 90-108 7 1/2 38 for a 9-inch lining. of the ring produced by the shape. Dia.BRICK COUNTS FOR ROTARY KILNS HIGH-ALUMINA BRICK Ins. RKB Inside Number Kiln Shell Number Chord (In. 9’-6” 96-114 7 19/32 40 10’-0” 102-120 7 21/32 42 10’-6” 108-126 7 23/32 44 11’-0” 114-132 7 25/32 46 11’-3” 117-135 7 13/16 48 11’-6” 120-138 7 13/16 49 12’-0” 126-144 7 7/8 51 12’-6” 132-150 7 29/32 53 13’-0” 138-156 7 31/32 55 13’-6” 144-162 8 57 14’-0” 150-168 8 1/32 59 14’-6” 156-174 8 1/16 61 15’-0” 162-180 8 3/32 63 15’-6” 168-186 8 1/8 65 16’-0” 174-192 8 5/32 67 16’-6” 180-198 8 3/16 70 17’-0” 186-204 8 7/32 72 17’-6” 192-210 8 7/32 74 18’-0” 198-216 8 1/4 76 18’-6” 204-222 8 9/32 78 19’-0” 210-228 8 9/32 80 19’-6” 216-234 8 5/16 82 20’-0” 222-240 8 5/16 84 20’-6” 228-246 8 11/32 86 21’-0” 234-252 8 11/32 88 21’-6” 240-258 8 3/8 90 IR . For example. Dia. 4’-6” 42-54 7 19 5’-0” 48-60 7 3/16 21 cate the inside and outside diameters. 7’-6” 78-90 7 13/16 32 8’-0” 84-96 7 7/8 34 8’-6” 90-102 7 15/16 36 9’-0” 96-108 8 38 9’-6” 102-114 8 1/16 40 10’-0” 108-120 8 3/32 42 10’-6” 114-126 8 5/32 44 11’-0” 120-132 8 3/16 46 11’-3” 123-135 8 3/16 48 11’-6” 126-138 8 7/32 49 12’-0” 132-144 8 1/4 51 12’-6” 138-150 8 9/32 53 13’-0” 144-156 8 5/16 55 13’-6” 150-162 8 11/32 57 14’-0” 156-168 8 11/32 59 14’-6” 162-174 8 3/8 61 15’-0” 168-180 8 13/32 63 15’-6” 174-186 8 13/32 65 16’-0” 180-192 8 7/16 67 16’-6” 186-198 8 15/32 70 17’-0” 192-204 8 15/32 72 17’-6” 198-210 8 1/2 74 18’-0” 204-216 8 1/2 76 18’-6” 210-222 8 1/2 78 19’-0” 216-228 8 17/32 80 19’-6” 222-234 8 17/32 82 20’-0” 228-240 8 9/16 84 20’-6” 234-246 8 9/16 86 21’-0” 240-252 8 9/16 88 Harbison-Walker IR .15 . of the ring produced by each shape. 144-156 RKB 6’-0” 60-72 7 1/2 26 will produce a ring with a 144-inch 6’-6” 66-78 7 5/8 28 inside diameter and 156-inch outside 7’-0” 72-84 7 23/32 30 diameter for a 6-inch lining. 5’-6” 54-66 7 3/8 23 respectively.) Per Ring ROTARY KILN BLOCKS Six-Inch Size (9 x 6 x 4) 3’-6” 30-42 6 7/16 15 4’-0” 36-48 6 3/4 17 The numbers under the RKB column indi.BRICK COUNTS FOR ROTARY KILNS HIGH-ALUMINA BRICK Ins. RKB Inside Number Kiln Shell Number Chord (In. operators with kilns of dif- nished in four sizes. inventories. KW-2 KW-2. KA-lX Linings 9 inches thick KW-3. KA-2 KA-2. Kiln Diameter Combinations 6 to 8 feet 8 to 13 feet 13 to 21 feet Linings 6 inches thick KA-3. KA and KW ming. thereby producing a tighter lining blocks are 9 x 6 x 4-inch kiln liners with less chance of dropout or spiral- made in the arch or wedge shape for ing. two thirds and three ROTARY KILNS quarter splits are designed to work with all KA and KW linings to eliminate the Harbison-Walker developed the KA need for cutting keys. Because these shapes fit kilns of high-alumina brick. KW-lX KA-1 KA-2 KA-3 KA-1X 6" 9" 9" 9" 9" KW-1 KW-2 KW-3 KW-1X 9" 6" 6" 6" 6" IR . Each shape is fur. two of which will ferent sizes can reduce their in-plant line any kiln (see chart below). KW-l KW-l.COMBINATION LININGS FOR ROTARY KILNS KA AND KW BLOCKS FOR In addition. KA-l KA-l. and KW system to simplify and Using the proper combination of KA eliminate problems associated with the and KW blocks also can reduce shim- linings of rotary kilns.16 Harbison-Walker . many sizes. 2/3 x and KW .COMBINATION LININGS FOR ROTARY KILNS Number of KA Blocks Required for Kilns Diameters Inside Inside Number Required Per Ring Number Required Per Linear Ft Lining Shell Ft In Ft In KA-3 KA-2 KA-1 KA-1X Total KA-3 KA-2 KA-1 KA-1X Total 5 0 6 0 50 7 — — 57 67 10 — — 77 5 3 6 3 44 15 — — 59 59 20 — — 79 5 6 6 6 38 24 — — 62 51 32 — — 83 5 9 6 9 32 32 — — 64 43 43 — — 86 6 0 7 0 25 41 — — 66 34 55 — — 89 6 3 7 3 19 50 — — 69 26 67 — — 93 6 6 7 6 13 58 — — 71 18 78 — — 96 6 9 7 9 6 67 — — 73 8 90 — — 98 7 0 8 0 — 76 — — 76 — 102 — — 102 7 3 8 3 — 72 6 — 78 — 96 8 — 104 7 6 8 6 — 68 13 — 81 — 91 18 — 109 7 9 8 9 — 64 19 — 83 — 86 26 — 112 8 0 9 0 — 60 25 — 85 — 80 34 — 114 8 3 9 3 — 56 32 — 88 — 75 43 — 118 8 6 9 6 — 52 38 — 90 — 70 51 — 121 8 9 9 9 — 48 44 — 92 — 64 59 — 123 9 0 10 0 — 44 51 — 95 — 59 68 — 127 9 3 10 3 — 40 57 — 97 — 54 76 — 130 9 6 10 6 — 36 63 — 99 — 48 84 — 132 9 9 10 9 — 33 69 — 102 — 44 92 — 136 10 0 11 0 — 28 76 — 104 — 38 102 — 140 10 3 11 3 — 24 82 — 106 — 32 110 — 142 10 6 11 6 — 21 88 — 109 — 28 118 — 146 10 9 11 9 — 17 94 — 111 — 23 126 — 149 11 0 12 0 — 13 100 — 113 — 18 134 — 152 11 3 12 3 — 9 107 — 116 — 12 143 — 155 11 6 12 6 — 5 113 — 118 — 7 151 — 158 11 9 12 9 — 1 119 — 120 — 1 159 — 160 12 0 13 0 — — 118 5 123 — — 157 7 164 12 3 13 3 — — 114 11 125 — — 152 15 167 12 6 13 6 — — 111 17 128 — — 148 23 171 12 9 13 9 — — 107 23 130 — — 143 31 174 13 0 14 0 — — 104 28 132 — — 139 37 176 13 3 14 3 — — 100 35 135 — — 133 47 180 13 6 14 6 — — 97 40 137 — — 130 53 183 13 9 14 9 — — 93 46 139 — — 124 62 186 14 0 15 0 — — 90 52 142 — — 120 70 190 14 3 15 3 — — 86 58 144 — — 115 77 192 14 6 15 6 — — 82 64 146 — — 110 85 195 14 9 15 9 — — 79 70 149 — — 106 93 199 15 0 16 0 — — 76 75 151 — — 102 100 202 15 3 16 3 — — 72 82 154 — — 96 110 206 15 6 16 6 — — 69 87 156 — — 92 116 208 15 9 16 9 — — 65 93 158 — — 87 124 211 16 0 17 0 — — 62 99 161 — — 83 132 215 16 3 17 3 — — 58 105 163 — — 78 140 218 16 6 17 6 — — 54 111 165 — — 72 148 220 16 9 17 9 — — 51 117 168 — — 68 156 224 17 0 18 0 — — 47 123 170 — — 63 164 227 17 3 18 3 — — 44 128 172 — — 59 171 230 17 6 18 6 — — 40 135 175 — — 54 180 234 17 9 18 9 — — 37 140 177 — — 49 187 236 18 0 19 0 — — 33 146 179 — — 44 195 239 18 3 19 3 — — 30 152 182 — — 40 203 243 18 6 19 6 — — 26 158 184 — — 35 211 246 18 9 19 9 — — 23 164 187 — — 31 219 250 19 0 20 0 — — 19 170 189 — — 25 227 252 19 3 20 3 — — 15 176 191 — — 20 235 255 19 6 20 6 — — 12 182 194 — — 16 243 259 19 9 20 9 — — 8 188 196 — — 11 251 262 20 0 21 0 — — 5 193 198 — — 7 257 264 20 3 21 3 — — 2 199 201 — — 3 265 268 NOTE: When using KA .1x shape.17 .3/4 x to facilitate keying. order two pieces each ring KW . Harbison-Walker IR . order two pieces each ring KW . IR .COMBINATION LININGS FOR ROTARY KILNS Number of KW Blocks Required for Kilns Diameters Inside Inside Number Required Per Ring Number Required Per Linear Ft Lining Shell Ft In Ft In KW-3 KW-2 KW-1 KW-1X Total KW-3 KW-2 KW-1 KW-1X Total 4 6 6 0 50 7 — — 57 100 14 — — 114 4 9 6 3 44 15 — — 59 88 30 — — 118 5 0 6 6 38 24 — — 62 76 48 — — 124 5 3 6 9 32 32 — — 64 64 64 — — 128 5 6 7 0 25 41 — — 66 50 82 — — 132 5 9 7 3 19 50 — — 69 38 100 — — 138 6 0 7 6 13 58 — — 71 26 116 — — 142 6 3 7 9 6 67 — — 73 12 134 — — 146 6 6 8 0 — 76 — — 76 — 152 — — 152 6 9 8 3 — 72 6 — 78 — 144 12 — 156 7 0 8 6 — 68 13 — 81 — 136 26 — 162 7 3 8 9 — 64 19 — 83 — 128 38 — 166 7 6 9 0 — 60 25 — 85 — 120 50 — 170 7 9 9 3 — 56 32 — 88 — 112 64 — 176 8 0 9 6 — 52 38 — 90 — 104 76 — 180 8 3 9 9 — 48 44 — 92 — 96 88 — 184 8 6 10 0 — 44 51 — 95 — 88 102 — 190 8 9 10 3 — 40 57 — 97 — 80 114 — 194 9 0 10 6 — 36 63 — 99 — 72 126 — 198 9 3 10 9 — 33 69 — 102 — 66 138 — 204 9 6 11 0 — 28 76 — 104 — 56 152 — 208 9 9 11 3 — 24 82 — 106 — 48 164 — 212 10 0 11 6 — 21 88 — 109 — 42 176 — 218 10 3 11 9 — 17 94 — 111 — 34 188 — 222 10 6 12 0 — 13 100 — 113 — 26 200 — 226 10 9 12 3 — 9 107 — 116 — 18 214 — 232 11 0 12 6 — 5 113 — 118 — 10 226 — 236 11 3 12 9 — 1 119 — 120 — 2 238 — 240 11 6 13 0 — — 117 6 123 — — 234 12 246 11 9 13 3 — — 112 13 125 — — 224 26 250 12 0 13 6 — — 108 20 128 — — 216 40 256 12 3 13 9 — — 103 27 130 — — 206 54 260 12 6 14 0 — — 98 34 132 — — 196 68 264 12 9 14 3 — — 94 41 135 — — 188 82 270 13 0 14 6 — — 89 48 137 — — 178 96 274 13 3 14 9 — — 84 55 139 — — 168 110 278 13 6 15 0 — — 79 63 142 — — 158 126 284 13 9 15 3 — — 75 69 144 — — 150 138 288 14 0 15 6 — — 70 76 146 — — 140 152 292 14 3 15 9 — — 65 84 149 — — 130 168 298 14 6 16 0 — — 60 91 151 — — 120 182 302 14 9 16 3 — — 56 98 154 — — 112 196 308 15 0 16 6 — — 51 105 156 — — 102 210 312 15 3 16 9 — — 46 112 158 — — 92 224 316 15 6 17 0 — — 42 119 161 — — 84 238 322 15 9 17 3 — — 37 126 163 — — 74 252 326 16 0 17 6 — — 32 133 165 — — 64 266 330 16 3 17 9 — — 28 140 168 — — 56 280 336 16 6 18 0 — — 23 147 170 — — 46 294 340 16 9 18 3 — — 18 154 172 — — 36 308 344 17 0 18 6 — — 14 161 175 — — 28 322 350 17 3 18 9 — — 9 168 177 — — 18 336 354 17 6 19 0 — — 4 175 179 — — 8 350 358 17 9 19 3 — — — 182 182 — — — 364 364 NOTE: When using KA .1x shape.18 Harbison-Walker .2/3 x and KW .3/4 x to facilitate keying. 26 51 99 14’.0” 4.COMBINATION LININGS FOR ROTARY KILNS CR COMBINATION Combination Linings – CR Series LININGS Kiln Diameter CR (Combination Ring) rotary kiln Feet Meters CR-89 CR-249 brick are designed to line kilns from 8 to 24 feet in diameter for a 9-inch 9’-10” 3.3” 4.6” 3.9” 5.4” 5.6” 3. RKW-3/4.0” 5.0” 4.0” 4.70 29 169 19’.0” 3.1” 5.1” 4.9” 4.48 32 159 18’.20 53 94 14’.9” 5.36 67 50 11’. keying bricks of two-thirds thickness.40 66 53 11’.80 27 175 To facilitate the keying of wedge-type rotary kiln blocks.10 38 140 17’.18 37 143 17’.6” 3.40 33 155 18’.80 43 124 CR-89 31/2 213/16 6 9 16’.20 69 43 given diameter.1” 4.2” 3.10 54 89 13’.0” 5.34 34 152 17’.0” 5.00 56 83 13’.04 71 35 10’.02 39 136 16’.66 61 66 12’.30 35 150 17’.8” 5. The appropriate combinations of the two kiln liners 10’.5” 4.50 64 58 11’-10” 3.60 46 114 15’.10 71 37 are calculated for the best fit for the 10’.50 32 160 18’.9” 4.72 44 121 SHAPE A B L H 15’.2” 3.00 72 33 lining thickness.2” 3.42 49 105 14’. Harbison-Walker IR .6” 5. RKW-2/3.0” 3.6” 4.80 59 74 12’-10” 3.70 61 66 12’.6” 5. and of three-quarters thickness.34 50 102 14’.5” 5. are made.6” 5.64 29 167 18’. 10’-10” 3.1” 4.58 47 112 Dimensions (Inches) 15’.00 40 134 16’.5” 4. Two of each keying brick should be ordered for each ring.6” 4.5” 4.50 48 109 CR Series 15’.9” 4.1” 4.90 57 79 13’.30 67 48 11’.5” 5.19 .40 50 103 14’.30 51 99 14’.90 41 130 CR-249 31/2 39/32 6 9 16’.96 57 81 13’.88 42 128 16’.1” 5.20 36 145 17’.0” 3.60 63 63 12’.12 54 90 13’.6” 4.60 30 165 18’.0” 3.70 45 119 15’. in any lining thickness from 160 mm to 250 mm. liner options – ISO (International Stan- Harbison-Walker suggests brick blend.ISO AND VDZ COMBINATION LININGS ISO and VDZ • In plants which have several kiln Combination Linings sizes. allowing for a better fit. dards Organization) metric linings. one of which fits a kiln of larger diameter and the The charts for combination linings other a kiln of smaller diameter. On the other hand. in kiln shells.20 Harbison-Walker . small amount of stepping which can occur.0 meters diameter outside brickwork. correcting shims. on the following pages provide several As good engineering practice.INSIDE Chord (hot face) VARIABLE EXAMPLE: Designation 320 ISO The first digit (3) denotes tapered brick which turn a circle of 3. and ing ratios between 3:1 and 1:3 for the VDZ (Verein Deutscher Zementwerke) two-shapes.running LENGTH 198 H .BACK Chord (cold face) 103 B . This helps to minimize the combination linings. combinations are made using outside diameter brickwork dimensions. The principal advantages of combination linings are: ISO Series .0 meters to 6. • Liner to liner contact is maintained. since two American minerals processing plants shapes in appropriate combintions is to use one brick of a size manufac. will fit many kilns. tured to fit a specific rotary kiln diam.0 meters.Dimensions (mm) L . any rotary kiln lining and minimizes the need for can be lined with an appropriate com. the number of kiln liner Standard practice in many North shapes can be reduced. eter.lining THICKNESS 160 180 200 220 250 A . bination of two kiln liners. IR . This results in a tight Within practical limits. A chart showing a 2M. international while following minor deformations practice is to use combination linings. The last two digits (20) denote a lining thickness of 200 mm. Using ISO series combination lining charts. 6M brick combination is for tapered brick which turn a diameter between 2. 5 LENGTH (L) 198 198 HEIGHT (H) 160 160 180 180 H 200 200 C 220 220 250 250 L B BASIC LINING X NON-BASIC LINING X Schematic diagram showing critical dimensions of ISO and VDZ shapes A A H H C L L B B ISO brick outside chord (A) VDZ brick mean chord (C) dimension is constant at dimension is constant at 103mm (4.81”) Harbison-Walker IR .21 .05”) 71.5mm (2.ISO AND VDZ COMBINATION LININGS INTERNATIONAL SYSTEM International System ISO VDZ BACK CHORD (A) 103 VARIABLE A INSIDE CHORD (B) VARIABLE VARIABLE MIDDLE CHORD (C) VARIABLE 71. 19 4.33 19 180 718 103 97.2 222 103 80 3.66" 8. DIMENSIONS VOL.0mm DRY LAYED THICK = 198 mm KILN 6.3 3.33 11.99 23 322 103 88 4.3 320 103 89 3.66" 8. TAPER A A B H L dm3 216 103 86 2.36 5.5 822 103 97.5 4.8 3.ISO AND VDZ COMBINATION LININGS ISO SHAPES ISO Shapes SHAPE No.22 Harbison-Walker .80 21 H 200 198 820 103 97.7 3.7 218 103 84 3.99 17 160 716 103 98.7 MIXING RATIO FOR ISO SHAPES ALUMINA LINING JOINT THICKNESS .66" DIAMETER 160mm 180mm 200mm 220mm 220mm 220mm 216 716 218 718 320 820 322 622 322 822 222 622 SHAPE No: 06085 05807 06088 05808 06091 06093 05810 06095 05810 06096 06552 06095 6'-6" 60 1 7'-0" 57 8 58 8 58 7 7'-6" 55 14 56 14 56 14 8'-0" 54 21 54 21 53 21 8'-6" 52 28 52 27 51 28 9'-0" 50 34 50 34 49 35 9'-6" 48 40 49 40 47 42 10'-0" 46 47 47 46 88 5 92 2 92 1 44 49 10'-6" 45 53 45 53 85 13 87 11 89 9 42 56 11'-0" 43 60 43 59 83 20 82 20 86 16 40 63 11'-6" 41 66 41 66 80 27 78 30 83 24 38 70 12'-0" 39 73 40 72 77 35 73 39 80 31 35 76 12'-6" 38 79 38 79 74 42 68 48 78 39 33 83 13'-0" 36 85 36 85 72 50 64 57 75 46 31 90 13'-6" 34 92 34 92 69 57 59 67 72 54 29 97 14'-0" 32 98 32 98 66 64 54 76 69 61 26 104 14'-6" 30 105 31 104 63 72 50 85 66 69 24 111 15'-0" 29 111 29 111 61 79 45 95 63 76 22 118 15'-6" 27 118 27 117 58 87 40 104 61 84 20 125 16'-0" 25 124 25 124 55 94 36 113 58 91 17 132 16'-6" 23 130 23 130 52 101 31 123 55 99 15 139 17'-0" 22 137 22 137 50 109 26 132 52 106 13 145 17'-6" 47 116 49 114 11 152 18'-0" 44 124 46 121 8 159 18'-6" 41 131 43 129 6 166 19'-0" 39 138 41 136 4 173 P-160 P-180 P-200 P-220 P-250 KEY BRICKS P-161 P-181 P-201 P-221 P-251 P-162 P-182 P-202 P-222 IR .3 4.87" 8.16 15 L 220 B 622 103 95.58 5.09" 7.30" 7.98 5. 87" 8.27 13 160 B-416 75 68 2.66" DIAMETER 160mm 180mm 200mm 220mm 220mm B-216 B-716 B-218 B-618 B-220 B-620 B-322 B-622 B-222 B-622 SHAPE No: 02474 05807 02476 02478 02479 02481 16484 06080 06078 06080 6'-6" 77 4 7'-0" 75 12 7'-6" 73 21 84 9 8'-0" 71 30 80 20 8'-6" 69 38 75 31 92 14 9'-0" 67 47 71 42 87 25 9'-6" 65 56 67 53 83 35 100 18 10'-0" 63 65 63 63 79 46 95 29 10'-6" 61 73 59 74 75 57 91 40 11'-0" 59 82 54 85 71 68 87 51 11'-6" 57 91 50 96 67 79 83 62 12'-0" 55 99 46 107 62 90 126 26 79 73 12'-6" 53 108 42 118 58 101 119 39 74 84 13'-0" 51 117 38 129 54 112 112 52 70 95 13'-6" 49 125 34 140 50 123 106 66 66 105 14'-0" 47 134 29 151 46 133 99 79 62 116 14'-6" 45 143 25 161 41 144 92 93 58 127 15'-0" 43 152 21 172 37 155 85 106 53 138 15'-6" 41 160 17 183 33 166 79 119 49 149 16'-0" 39 169 13 194 29 177 72 133 45 160 16'-6" 25 188 65 146 41 171 17'-0" 20 199 59 160 37 182 17'-6" 52 173 33 192 18'-0" 45 186 28 203 18'-6" 39 200 19'-0" 32 213 P-160 P-180 P-200 P-220 P-250 KEY BRICKS P-161 P-181 P-201 P-221 P-251 P-162 P-182 P-202 P-222 Harbison-Walker IR .11 13 B-322 76.83 5 B-222 78 65 3.83 13 H 200 B-620 74 69 2.0mm DRY LAYED THICK = 198 mm + 1mm (cardboard) = 199mm KILN 6.66" 8.11 5 MIXING RATIO FOR VDZ SHAPES BASIC LINING JOINT THICKNESS .55 7 198 B-220 78 65 2. DIMENSIONS VOL.09" 7.5 220 3.ISO AND VDZ COMBINATION LININGS VDZ SHAPES VDZ Shapes SHAPE No.55 13 180 B-418 75 68 2.11 10 L B B-622 74 69 3.27 7 B-218 78 65 2.23 . TAPER A A B H L dm3 B-216 78 65 2.5 66.30" 7. 200 mm Up to 5.24 Harbison-Walker .8M (19’-0”) I.RECOMMENDED LINING THICKNESS RECOMMENDED LINING THICKNESS ROTARY KILN DIAMETER *RECOMMENDED BRICK THICK <3. 180 mm Up to 4.5M (16’-6”) I. 250mm *Recommendations are based on kiln diameter only.D.D. 220 mm Over 5. not taking operating data into consideration. 160 mm Up to 4M (13’-6”) I.8M (19’-0”) I. IR .6M (12’-0”) I.D.D.D. the brick combinations shown may lay up to diameters which differ slightly from the theoretical diameters. or to calculate the ring combinations for brick of two different sizes. refer to the formulas found on page UR . roofs and arches. For these reasons.RING COMBINATIONS BRICK COMBINATIONS REQUIRED FOR RINGS The tables on the following pages are useful in estimating the quantities of brick required for the construction of circular linings. These tables give the combinations of brick sizes required for rings of given diameters. Fractional parts equal to or greater than one tenth of a brick were counted as an entire brick. For brick combinations required for rings not shown in the following tables. In calculating the tables. no allowance was made for mortar or expansion joints or for size deviations of the brick. may be slightly in excess of the number actually required. and in some instances several pieces. Harbison-Walker IR. The num- ber of brick required for a ring. to complete the ring. it is often necessary to cut one or two pieces.25 .29 which covers ring calculations. as given in the tables. In laying a ring course of brick. 1 Ft.21/2 Inch Arch Brick 41/2 Inch Lining . In.2 No. In.3 No.RING COMBINATIONS 41/2 Inch Lining . Arch Arch Arch Straight Total Ft.21/2 Inch Arch Brick 9 x 41/2 x 21/2 or 131/2 x 41/2 x 21/2 Inch 9 x 41/2 x 21/2 or 131/2 x 41/2 x 21/2 Inch Diam. Inside Number Required per Ring Brickwork No.2 No. Arch Arch Arch Straight Total 0 6 19 — — — 19 6 0 — — 76 26 102 0 7 18 3 — — 21 6 2 — — 76 29 105 0 8 17 5 — — 22 6 4 — — 76 31 107 0 9 15 8 — — 23 6 6 — — 76 34 110 0 10 14 10 — — 24 6 8 — — 76 36 112 0 11 13 13 — — 26 6 10 — — 76 39 115 1 0 12 15 — — 27 7 0 — — 76 41 117 1 1 10 18 — — 28 7 2 — — 76 44 120 1 2 9 20 — — 29 7 4 — — 76 46 122 1 3 8 23 — — 31 7 6 — — 76 49 125 1 4 7 25 — — 32 7 8 — — 76 51 127 1 5 5 28 — — 33 7 10 — — 76 54 130 1 6 4 30 — — 34 8 0 — — 76 56 132 1 7 3 33 — — 36 8 2 — — 76 59 135 1 8 2 35 — — 37 8 4 — — 76 61 137 1 9 — 38 — — 38 8 6 — — 76 64 140 1 10 — 36 3 — 39 8 8 — — 76 66 142 1 11 — 36 5 — 41 8 10 — — 76 69 145 2 0 — 34 8 — 42 9 0 — — 76 71 147 2 1 — 33 10 — 43 9 2 — — 76 74 150 2 2 — 31 13 — 44 9 4 — — 76 76 152 2 3 — 31 15 — 46 9 6 — — 76 79 155 2 4 — 29 18 — 47 9 8 — — 76 81 157 2 5 — 28 20 — 48 9 10 — — 76 84 160 2 6 — 26 23 — 49 10 0 — — 76 87 163 2 7 — 26 25 — 51 10 2 — — 76 89 165 2 8 — 24 28 — 52 10 4 — — 76 92 168 2 9 — 23 30 — 53 10 6 — — 76 94 170 2 10 — 21 33 — 54 10 8 — — 76 97 173 2 11 — 20 36 — 56 10 10 — — 76 99 175 3 0 — 19 38 — 57 11 0 — — 76 102 178 3 1 — 18 40 — 58 11 2 — — 76 104 180 3 2 — 16 43 — 59 11 4 — — 76 107 183 3 3 — 15 46 — 61 11 6 — — 76 109 185 3 4 — 14 48 — 62 11 8 — — 76 112 188 3 5 — 13 50 — 63 11 10 — — 76 114 190 3 6 — 11 53 — 64 12 0 — — 76 117 193 3 7 — 10 56 — 66 12 2 — — 76 119 195 3 8 — 9 58 — 67 12 4 — — 76 122 198 3 9 — 8 60 — 68 12 6 — — 76 124 200 3 10 — 7 63 — 70 12 8 — — 76 127 203 3 11 — 5 66 — 71 12 10 — — 76 129 205 4 0 — 4 68 — 72 13 0 — — 76 132 208 4 1 — 3 70 — 73 13 2 — — 76 134 210 4 2 — 2 73 — 75 13 4 — — 76 137 213 4 3 — — 76 — 76 13 6 — — 76 139 215 4 4 — — 76 1 77 13 8 — — 76 142 218 4 6 — — 76 4 80 13 10 — — 76 144 220 4 8 — — 76 6 82 14 0 — — 76 147 223 4 10 — — 76 9 85 14 2 — — 76 149 225 5 0 — — 76 11 87 14 4 — — 76 152 228 5 2 — — 76 14 90 14 6 — — 76 154 230 5 4 — — 76 16 92 14 8 — — 76 157 233 5 6 — — 76 19 95 14 10 — — 76 159 235 5 8 — — 76 21 97 15 0 — — 76 162 238 5 10 — — 76 24 100 IR .26 Harbison-Walker .1 Brickwork No.3 No. Inside Number Required per Ring Diam. 1-X Brickwork No. Wedge Wedge Wedge Straight Total Ft. 9 x 63/4 x 21/2 or 9 x 9 x 21/2 Inch Diam.1 No.1 No. 9 x 63/4 x 21/2 or 9 x 9 x 21/2 Inch 9 x 41/2 x 21/2. In.21/2 Inch Wedge Brick 9 Inch Lining . Wedge Wedge Wedge Straight Total 2 3 57 — — — 57 7 0 — 66 63 — 129 2 4 55 3 — — 58 7 1 — 65 65 — 130 2 5 52 7 — — 59 7 2 — 64 67 — 131 2 6 51 10 — — 61 7 3 — 63 69 — 132 2 7 48 14 — — 62 7 4 — 62 72 — 134 2 8 46 17 — — 63 7 5 — 61 74 — 135 2 9 44 20 — — 64 7 6 — 60 76 — 136 2 10 42 24 — — 66 7 7 — 59 78 — 137 2 11 40 27 — — 67 7 8 — 59 80 — 139 3 0 38 30 — — 68 7 9 — 58 82 — 140 3 1 36 34 — — 70 7 10 — 57 84 — 141 3 2 34 37 — — 71 7 11 — 56 86 — 142 3 3 32 40 — — 72 8 0 — 56 88 — 144 3 4 29 44 — — 73 8 1 — 55 90 — 145 3 5 28 47 — — 75 8 2 — 54 92 — 146 3 6 25 51 — — 76 8 3 — 53 94 — 147 3 7 23 54 — — 77 8 4 — 52 97 — 149 3 8 21 57 — — 78 8 5 — 51 99 — 150 3 9 19 61 — — 80 8 6 — 50 101 — 151 3 10 17 64 — — 81 8 7 — 49 103 — 152 3 11 15 67 — — 82 8 8 — 49 105 — 154 4 0 13 70 — — 83 8 9 — 48 107 — 155 4 1 11 74 — — 85 8 10 — 47 109 — 156 4 2 9 77 — — 86 8 11 — 46 111 — 157 4 3 6 81 — — 87 9 0 — 46 113 — 159 4 4 4 84 — — 88 9 1 — 45 115 — 160 4 5 2 88 — — 90 9 2 — 44 117 — 161 4 6 — 91 — — 91 9 3 — 43 120 — 163 4 7 — 90 2 — 92 9 4 — 42 122 — 164 4 8 — 89 4 — 93 9 5 — 41 124 — 165 4 9 — 88 7 — 95 9 6 — 40 126 — 166 4 10 — 87 9 — 96 9 7 — 40 128 — 168 4 11 — 86 11 — 97 9 8 — 39 130 — 169 5 0 — 85 13 — 98 9 9 — 38 132 — 170 5 1 — 85 15 — 100 9 10 — 37 134 — 171 5 2 — 84 17 — 101 9 11 — 36 137 — 173 5 3 — 83 19 — 102 10 0 — 35 139 — 174 5 4 — 82 21 — 103 10 1 — 35 140 — 175 5 5 — 82 23 — 105 10 2 — 34 142 — 176 5 6 — 81 25 — 106 10 3 — 33 145 — 178 5 7 — 80 27 — 107 10 4 — 32 147 — 179 5 8 — 79 29 — 108 10 5 — 31 149 — 180 5 9 — 78 32 — 110 10 6 — 30 151 — 181 5 10 — 77 34 — 111 10 7 — 30 153 — 183 5 11 — 76 36 — 112 10 8 — 29 155 — 184 6 0 — 75 38 — 113 10 9 — 28 157 — 185 6 1 — 75 40 — 115 10 10 — 27 159 — 186 6 2 — 74 42 — 116 10 11 — 26 162 — 188 6 3 — 73 44 — 117 11 0 — 25 164 — 189 6 4 — 72 47 — 119 11 1 — 24 166 — 190 6 5 — 72 48 — 120 11 2 — 23 168 — 191 6 6 — 71 50 — 121 11 3 — 23 170 — 193 6 7 — 70 52 — 122 11 4 — 22 172 — 194 6 8 — 69 55 — 124 11 5 — 21 174 — 195 6 9 — 68 57 — 125 6 10 — 67 59 — 126 Harbison-Walker IR .RING COMBINATIONS 9 Inch Lining . Inside Number Required per Ring Diam. In. Inside Number Required per Ring Brickwork No.21/2 Inch Wedge Brick 9 x 41/2 x 21/2.2 No.2 No.27 .1-X Ft. RING COMBINATIONS 9 Inch Lining .1-X Ft.21/2 Inch Wedge Brick 9 x 41/2 x 21/2. Wedge Wedge Wedge Straight Total Ft.21/2 Inch Wedge Brick 9 Inch Lining . Inside Number Required per Ring Brickwork No.1 No.1 No. Inside Number Required per Ring Diam.1-X Brickwork No. In.28 Harbison-Walker . In. 9 x 63/4 x 21/2 or 9 x 9 x 21/2 Inch Diam.2 No.2 No. 9 x 63/4 x 21/2 or 9 x 9 x 21/2 Inch 9 x 41/2 x 23/4. Wedge Wedge Wedge Straight Total 11 6 — 20 176 — 196 20 0 — — 227 98 325 11 7 — 20 178 — 198 20 6 — — 227 105 332 11 8 — 19 180 — 199 21 0 — — 227 113 340 11 9 — 18 182 — 200 21 6 — — 227 120 347 11 10 — 17 184 — 201 22 0 — — 227 128 355 11 11 — 16 187 — 203 22 6 — — 227 135 362 12 0 — 15 189 — 204 23 0 — — 227 143 370 12 1 — 14 191 — 205 23 6 — — 227 150 377 12 2 — 13 193 — 206 24 0 — — 227 158 385 12 3 — 13 195 — 208 24 6 — — 227 165 392 12 4 — 12 197 — 209 25 0 — — 227 173 400 12 5 — 11 199 — 210 25 6 — — 227 181 408 12 6 — 10 202 — 212 26 0 — — 227 188 415 12 7 — 10 203 — 213 26 6 — — 227 196 423 12 8 — 9 205 — 214 27 0 — — 227 203 430 12 9 — 8 207 — 215 27 6 — — 227 211 438 12 10 — 7 210 — 217 28 0 — — 227 218 445 12 11 — 6 212 — 218 28 6 — — 227 226 453 13 0 — 5 214 — 219 29 0 — — 227 233 460 13 1 — 4 216 — 220 29 6 — — 227 241 468 13 2 — 4 218 — 222 30 0 — — 227 248 475 13 3 — 3 220 — 223 30 6 — — 227 256 483 13 4 — 2 222 — 224 31 0 — — 227 263 490 13 5 — 1 224 — 225 31 6 — — 227 271 498 13 6 — — 227 — 227 32 0 — — 227 279 506 13 7 — — 227 1 228 32 6 — — 227 286 513 13 8 — — 227 2 229 33 0 — — 227 294 521 13 9 — — 227 3 230 33 6 — — 227 301 528 13 10 — — 227 5 232 34 0 — — 227 309 536 13 11 — — 227 6 233 34 6 — — 227 316 543 14 0 — — 227 7 234 35 0 — — 227 324 551 14 6 — — 227 15 242 35 6 — — 227 331 558 15 0 — — 227 22 249 36 0 — — 227 339 566 15 6 — — 227 30 257 36 6 — — 227 346 573 16 0 — — 227 37 264 37 0 — — 227 354 581 16 6 — — 227 45 272 37 6 — — 227 362 589 17 0 — — 227 52 279 38 0 — — 227 369 596 17 6 — — 227 60 287 38 6 — — 227 377 604 18 0 — — 227 67 294 39 0 — — 227 384 611 18 6 — — 227 75 302 39 6 — — 227 392 619 19 0 — — 227 83 310 40 0 — — 227 399 626 19 6 — — 227 90 317 40 6 — — 227 407 634 41 0 — — 227 414 641 41 6 — — 227 422 649 42 0 — — 227 429 656 42 6 — — 227 437 664 43 0 — — 227 444 671 43 6 — — 227 452 679 44 0 — — 227 460 687 44 6 — — 227 467 694 45 0 — — 227 475 702 IR . 1 Straight Total Ft In Straight Total Ft In Arch Arch Arch Arch Arch Arch Arch Arch 0 4 1/2 15 — — — — 15 4 6 — — 47 19 — 66 0 5 14 1 — — — 15 4 7 — — 46 21 — 67 0 6 13 3 — — — 16 4 8 — — 45 23 — 68 0 7 12 5 — — — 17 4 9 — — 44 26 — 70 0 8 11 7 — — — 18 4 10 — — 43 28 — 71 0 9 10 9 — — — 19 4 11 — — 42 30 — 72 0 10 8 12 — — — 20 0 11 7 14 — — — 21 5 0 — — 41 32 — 73 5 1 — — 40 34 — 74 1 0 6 16 — — — 22 5 2 — — 39 36 — 75 1 1 5 18 — — — 23 5 3 — — 38 38 — 76 1 2 4 20 — — — 24 5 4 — — 37 40 — 77 1 3 4 22 — — — 26 5 5 — — 36 42 — 78 1 4 3 24 — — — 27 5 6 — — 35 44 — 79 1 5 1 27 — — — 28 5 7 — — 34 46 — 80 1 6 — 29 — — — 29 5 8 — — 33 48 — 81 1 7 — 28 2 — — 30 5 9 — — 32 50 — 82 1 8 — 26 5 — — 31 5 10 — — 31 52 — 83 1 9 — 25 7 — — 32 5 11 — — 29 55 — 84 1 10 — 24 9 — — 33 1 11 — 23 11 — — 34 6 0 — — 28 57 — 85 6 1 — — 27 59 — 86 2 0 — 22 13 — — 35 6 2 — — 26 61 — 87 2 1 — 21 15 — — 36 6 3 — — 25 63 — 88 2 2 — 20 17 — — 37 6 4 — — 24 65 — 89 2 3 — 19 19 — — 38 6 5 — — 23 67 — 90 2 4 — 18 21 — — 39 6 6 — — 22 70 — 92 2 5 — 17 23 — — 40 6 7 — — 21 72 — 93 2 6 — 16 25 — — 41 6 8 — — 20 74 — 94 2 7 — 15 27 — — 42 6 9 — — 19 76 — 95 2 8 — 14 29 — — 43 6 10 — — 18 78 — 96 2 9 — 13 31 — — 44 6 11 — — 17 80 — 97 2 10 — 12 33 — — 45 2 11 — 10 36 — — 46 7 0 — — 16 82 — 98 7 1 — — 15 84 — 99 3 0 — 10 38 — — 48 7 2 — — 14 86 — 100 3 1 — 9 40 — — 49 7 3 — — 13 88 — 101 3 2 — 8 42 — — 50 7 4 — — 12 90 — 102 3 3 — 7 44 — — 51 7 5 — — 11 92 — 103 3 4 — 6 46 — — 52 7 6 — — 10 94 — 104 3 5 — 5 48 — — 53 7 7 — — 9 96 — 105 3 6 — 3 51 — — 54 7 8 — — 7 99 — 106 3 7 — 2 53 — — 55 7 9 — — 6 101 — 107 3 8 — 1 55 — — 56 7 10 — — 5 103 — 108 3 9 — — 57 — — 57 7 11 — — 4 105 — 109 3 10 — — 56 2 — 58 3 11 — — 55 4 — 59 8 0 — — 3 107 — 110 8 1 — — 2 109 — 111 4 0 — — 54 6 — 60 8 2 — — 1 111 — 112 4 1 — — 52 9 — 61 8 3 — — — 113 — 113 4 2 — — 51 11 — 62 8 6 — — — 113 4 117 4 3 — — 50 13 — 63 4 4 — — 49 15 — 64 9 0 — — — 113 10 123 4 5 — — 48 17 — 65 10 0 — — — 113 22 135 11 0 — — — 113 35 148 12 0 — — — 113 48 161 13 0 — — — 113 60 173 14 0 — — — 113 73 186 15 0 — — — 113 85 198 Harbison-Walker IR. 2 No.RING COMBINATIONS 41/2 Inch Lining — 3 Inch Arch Brick 41/2 Inch Lining — 3 Inch Arch Brick 9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch 9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch — Continued Diam. 4 No. Inside Number Required Per Ring Brickwork No. 3 No. 2 No. 1 Brickwork No. Inside Number Required Per Ring Diam. 3 No.29 . 4 No. RING COMBINATIONS 41/2 Inch Lining — 3 Inch Circle Brick 41/2 Inch Lining — 3 Inch Circle Brick 9 x 41/2 x 3 Inch 9 x 41/2 x 3 Inch — Continued Diam. Inside Number Required Per Ring Brickwork 24-33-3 36-45-3 48-57-3 60-69-3 72-81-3 Brickwork 72-81-3 84-93-3 96-105-3 108-117-3 120-129-3 Ft In Total Ft In Total Circle Circle Circle Circle Circle Circle Circle Circle Circle Circle 2 0 12 — — — — 12 6 0 29 — — — — 29 2 1 11 1 — — — 12 6 1 26 3 — — — 29 2 2 10 3 — — — 13 6 2 24 5 — — — 29 2 3 9 4 — — — 13 6 3 22 8 — — — 30 2 4 8 5 — — — 13 6 4 19 11 — — — 30 2 5 7 7 — — — 14 6 5 16 14 — — — 30 2 6 6 8 — — — 14 6 6 14 17 — — — 31 2 7 5 9 — — — 14 6 7 12 19 — — — 31 2 8 4 11 — — — 15 6 8 9 22 — — — 31 2 9 3 12 — — — 15 6 9 7 25 — — — 32 2 10 2 13 — — — 15 6 10 5 27 — — — 32 2 11 1 15 6 11 3 30 — — — 33 — — — 16 7 0 — 33 — — — 33 3 0 — 16 — — — 16 7 1 — 30 3 — — 33 3 1 — 14 2 — — 16 7 2 — 27 7 — — 34 3 2 — 13 4 — — 17 7 3 — 25 9 — — 34 3 3 — 12 5 — — 17 7 4 — 22 12 — — 34 3 4 — 11 7 — — 18 7 5 — 19 16 — — 35 3 5 — 9 9 — — 18 7 6 — 16 19 — — 35 3 6 — 8 10 — — 18 7 7 — 14 21 — — 35 3 7 — 7 12 — — 19 7 8 — 11 25 — — 36 3 8 — 5 14 — — 19 7 9 — 8 28 — — 36 3 9 — 4 15 — — 19 7 10 — 5 31 — — 36 3 10 — 3 17 — — 20 7 11 — 3 34 — — 37 3 11 — 2 18 — — 20 8 0 — — 37 — — 37 4 0 — — 20 — — 20 8 1 — — 34 3 — 37 4 1 — — 19 2 — 21 8 2 — — 31 7 — 38 4 2 — — 17 4 — 21 8 3 — — 28 10 — 38 4 3 — — 15 6 — 21 8 4 — — 24 14 — 38 4 4 — — 14 8 — 22 8 5 — — 22 17 — 39 4 5 — — 12 10 — 22 8 6 — — 18 21 — 39 4 6 — — 10 12 — 22 8 7 — — 15 24 — 39 4 7 — — 9 14 — 23 8 8 — — 12 28 — 40 4 8 — — 7 16 — 23 8 9 — — 9 31 — 40 4 9 — — 5 18 — 23 8 10 — — 7 34 — 41 4 10 — — 4 20 — 24 8 11 — — 3 38 — 41 4 11 — — 2 22 — 24 9 0 — — — 41 — 41 5 0 — — — 24 — 24 9 1 — — — 38 4 42 5 1 — — — 22 3 25 9 2 — — — 34 8 42 5 2 — — — 20 5 25 9 3 — — — 31 11 42 5 3 — — — 18 8 26 9 4 — — — 28 15 43 5 4 — — — 16 10 26 9 5 — — — 24 19 43 5 5 — — — 14 12 26 9 6 — — — 20 23 43 5 6 — — — 12 15 27 9 7 — — — 17 27 44 5 7 — — — 10 17 27 9 8 — — — 14 30 44 5 8 — — — 8 19 27 9 9 — — — 10 34 44 5 9 — — — 6 22 28 9 10 — — — 7 38 45 5 10 — — — 4 24 28 9 11 — — — 4 41 45 5 11 — — — 2 26 28 10 0 — — — — 45 45 IR .30 Harbison-Walker . Inside Number Required Per Ring Diam. 1 Ft In Straight Total Ft In Straight Total Arch Arch Arch Arch Arch Arch 2 0 38 — — — 38 6 8 — 55 42 — 97 2 1 37 2 — — 39 6 9 — 54 44 — 98 2 2 36 4 — — 40 6 10 — 53 46 — 99 2 3 35 6 — — 41 6 11 — 52 48 — 100 2 4 34 8 — — 42 2 5 32 11 — — 43 7 0 — 51 50 — 101 2 6 31 13 — — 44 7 1 — 49 53 — 102 2 7 30 15 — — 45 7 2 — 48 55 — 103 2 8 29 17 — — 46 7 3 — 47 57 — 104 2 9 29 19 — — 48 7 4 — 46 59 — 105 2 10 28 21 — — 49 7 5 — 45 61 — 106 2 11 27 23 — — 50 7 6 — 44 63 — 107 7 7 — 43 65 — 108 3 0 26 25 — — 51 7 8 — 42 67 — 109 3 1 24 28 — — 52 7 9 — 41 69 — 110 3 2 23 30 — — 53 7 10 — 40 71 — 111 3 3 22 32 — — 54 7 11 — 39 73 — 112 3 4 21 34 — — 55 3 5 20 36 — — 56 8 0 — 38 75 — 113 3 6 19 38 — — 57 8 1 — 37 78 — 115 3 7 18 40 — — 58 8 2 — 36 80 — 116 3 8 17 42 — — 59 8 3 — 35 82 — 117 3 9 16 44 — — 60 8 4 — 34 84 — 118 3 10 15 46 — — 61 8 5 — 33 86 — 119 3 11 14 48 — — 62 8 6 — 32 88 — 120 8 7 — 31 90 — 121 4 0 13 50 — — 63 8 8 — 30 92 — 122 4 1 12 52 — — 64 8 9 — 29 94 — 123 4 2 11 54 — — 65 8 10 — 27 97 — 124 4 3 9 57 — — 66 8 11 — 26 99 — 125 4 4 8 59 — — 67 4 5 7 61 — — 68 9 0 — 25 101 — 126 4 6 7 63 — — 70 9 1 — 24 103 — 127 4 7 6 65 — — 71 9 2 — 23 105 — 128 4 8 5 67 — — 72 9 3 — 22 107 — 129 4 9 4 69 — — 73 9 4 — 21 109 — 130 4 10 2 72 — — 74 9 5 — 20 111 — 131 4 11 1 74 — — 75 9 6 — 19 113 — 132 9 7 — 18 115 — 133 5 0 — 76 — — 76 9 8 — 17 117 — 134 5 1 — 75 2 — 77 9 9 — 16 119 — 135 5 2 — 74 4 — 78 9 10 — 15 122 — 137 5 3 — 72 7 — 79 9 11 — 14 124 — 138 5 4 — 71 9 — 80 5 5 — 70 11 — 81 10 0 — 13 126 — 139 5 6 — 69 13 — 82 10 1 — 12 128 — 140 5 7 — 68 15 — 83 10 2 — 11 130 — 141 5 8 — 67 17 — 84 10 3 — 10 132 — 142 5 9 — 66 19 — 85 10 4 — 9 134 — 143 5 10 — 65 21 — 86 10 5 — 8 136 — 144 5 11 — 64 23 — 87 10 6 — 7 138 — 145 10 7 — 5 141 — 146 6 0 — 63 25 — 88 10 8 — 4 143 — 147 6 1 — 62 27 — 89 10 9 — 3 145 — 148 6 2 — 61 29 — 90 10 10 — 2 147 — 149 6 3 — 60 32 — 92 10 11 — 1 149 — 150 6 4 — 59 34 — 93 6 5 — 58 36 — 94 11 0 — — 151 — 151 6 6 — 57 38 — 95 12 0 — — 151 13 164 6 7 — 56 40 — 96 13 0 — — 151 25 176 14 0 — — 151 38 189 Harbison-Walker IR. Inside Number Required Per Ring Diam. 3 No. Inside Number Required Per Ring Brickwork Brickwork No. 2 No. 3 No. 2 No.RING COMBINATIONS 6 Inch Lining — 3 Inch Arch Brick 6 Inch Lining — 3 Inch Arch Brick 12 x 6 x 3 or 131/2 x 6 x 3 Inch 12 x 6 x 3 or 131/2 x 6 x 3 Inch — Continued Diam. 1 No.31 . 32 Harbison-Walker . Inside Number Required Per Ring Brickwork Brickwork Ft In Total Ft In Total 54-66 60-72 102-114 108-120 4 6 23 — 23 8 6 40 — 40 4 7 20 4 24 8 7 34 7 41 4 8 15 9 24 8 8 27 14 41 4 9 11 13 24 8 9 20 21 41 4 10 8 17 25 4 11 4 21 25 8 10 14 28 42 8 11 7 35 42 60-72 66-78 5 0 26 — 26 108-120 114-126 5 1 21 5 26 9 0 42 — 42 5 2 17 9 26 9 1 35 8 43 5 3 13 14 27 9 2 28 15 43 5 4 9 18 27 5 5 4 23 27 9 3 21 22 43 9 4 14 30 44 66-78 72-84 9 5 7 37 44 5 6 28 — 28 5 7 23 5 28 114-126 120-132 5 8 18 10 28 9 6 44 — 44 5 9 14 15 29 9 7 37 8 45 5 10 9 20 29 9 8 29 16 45 5 11 5 24 29 9 9 22 23 45 72-84 78-90 9 10 15 31 46 6 0 30 — 30 9 11 7 39 46 6 1 25 5 30 6 2 20 10 30 120-132 123-135 6 3 15 16 31 10 0 46 — 46 6 4 10 21 31 10 1 31 16 47 6 5 5 26 31 10 2 15 32 47 78-90 84-96 6 6 32 — 32 123-135 126-138 6 7 26 6 32 10 3 48 — 48 6 8 21 12 33 10 4 32 16 48 6 9 16 17 33 10 5 16 32 48 6 10 11 22 33 6 11 6 28 34 126-138 132-144 84-96 90-102 10 6 49 — 49 7 0 34 — 34 10 7 40 9 49 7 1 28 6 34 10 8 32 17 49 7 2 23 12 35 10 9 24 26 50 7 3 17 18 35 10 10 16 34 50 7 4 11 24 35 10 11 8 42 50 7 5 6 30 36 90-102 96-108 132-144 138-150 7 6 36 — 36 11 0 51 — 51 7 7 30 6 36 11 1 42 9 51 7 8 24 13 37 11 2 34 17 51 7 9 18 19 37 11 3 25 27 52 7 10 12 25 37 11 4 17 35 52 7 11 6 32 38 11 5 8 44 52 96-108 102-114 8 0 38 — 38 NOTE: In orders.” IR .RING COMBINATIONS 6 Inch Lining — Rotary Kiln or Cupola Blocks 6 Inch Lining — Rotary Kiln or Cupola Blocks 9 x 6 x 4 Inch 9 x 6 x 4 Inch — Continued Diam. the complete names of the blocks desired should be given. as for example “54-66 RKB” or “60-72 Cupola. Inside Number Required Per Ring Diam.” 8 2 25 14 39 8 3 19 20 39 8 4 13 26 39 8 5 7 33 40 NOTE: In orders. as 8 1 31 7 38 for example “102-114 RKB” or “102-114 Cupola. the complete names of the blocks desired should be given. Inside Number Required Per Ring Diam.” 14 4 21 44 65 14 5 11 54 65 NOTE: In orders. the complete names of the blocks desired should be given. as for example “138-150 RKB” or “138-150 Cupola. Inside Number Required Per Ring Brickwork Brickwork Ft In Total Ft In Total 138-150 144-156 174-186 180-192 11 6 53 — 53 14 6 65 — 65 11 7 44 9 53 14 7 54 12 66 11 8 35 18 53 14 8 43 23 66 11 9 26 28 54 14 9 32 34 66 11 10 18 36 54 14 10 22 45 67 11 11 9 46 55 14 11 11 56 67 144-156 150-162 180-192 186-198 12 0 55 — 55 15 0 67 — 67 12 1 45 10 55 15 1 56 12 68 12 2 37 19 56 15 2 45 23 68 12 3 27 29 56 15 3 33 35 68 12 4 18 38 56 15 4 23 46 69 12 5 9 48 57 15 5 11 58 69 150-162 156-168 186-198 192-204 12 6 57 — 57 15 6 70 — 70 12 7 47 10 57 15 7 58 12 70 12 8 38 20 58 15 8 46 24 70 12 9 28 30 58 15 9 35 36 71 12 10 19 39 58 15 10 23 48 71 12 11 10 49 59 15 11 12 59 71 156-168 162-174 192-204 198-210 13 0 59 — 59 16 0 72 — 72 13 1 49 10 59 16 1 60 12 72 13 2 39 21 60 16 2 48 24 72 13 3 29 31 60 16 3 36 37 73 13 4 20 40 60 16 4 24 49 73 13 5 10 51 61 16 5 12 61 73 162-174 168-180 198-210 204-216 13 6 61 — 61 16 6 74 — 74 13 7 51 10 61 16 7 61 13 74 13 8 41 21 62 16 8 49 25 74 13 9 30 32 62 16 9 37 38 75 13 10 21 42 63 16 10 25 50 75 13 11 10 53 63 16 11 12 63 75 168-180 174-186 204-216 210-222 14 0 63 — 63 17 0 76 — 76 14 1 53 11 64 14 2 42 22 64 NOTE: In orders.33 .” Harbison-Walker IR. as 14 3 31 33 64 for example “174-186 RKB” or “174-186 Cupola.RING COMBINATIONS 6 Inch Lining — Rotary Kiln or Cupola Blocks 6 Inch Lining — Rotary Kiln or Cupola Blocks 9 x 6 x 4 Inch — Continued 9 x 6 x 4 Inch — Continued Diam. the complete names of the blocks desired should be given. 1.RING COMBINATIONS 6 Inch Lining — Rotary Kiln Blocks 9 Inch Lining — 3 Inch Wedge Brick 9 x 6 x 4 Inch Arch Type —Two Shape System 9 x 4 1/2 x 3. 2 and 3 arch brick for the corresponding wedge brick. IR . Inside Lining Shell Brickwork No. 3 No.34 Harbison-Walker . order two (2) pieces each KA-2/3 and KA-3/4 to facilitate keying. NOTE: For each ring. 2 No. For additional information. 1 Ft In Ft In KW-3 KW-2 KW-1 KW-1X Total Straight Total Ft In Wedge Wedge Wedge 5 0 6 0 50 7 — — 57 3 0 57 — — — 57 5 3 6 3 44 15 — — 59 3 1 56 2 — — 58 5 6 6 6 38 24 — — 62 3 2 55 4 — — 59 5 9 6 9 32 32 — — 64 3 3 54 6 — — 60 6 0 7 0 25 41 — — 66 3 4 52 9 — — 61 6 3 7 3 19 50 — — 69 3 5 51 11 — — 62 6 6 7 6 13 58 — — 71 3 6 50 13 — — 63 6 9 7 9 6 67 — — 73 3 7 49 15 — — 64 7 0 8 0 — 76 — — 76 3 8 48 17 — — 65 7 3 8 3 — 72 6 — 78 3 9 47 19 — — 66 7 6 8 6 — 68 13 — 81 3 10 46 21 — — 67 7 9 8 9 — 64 19 — 83 3 11 45 23 — — 68 8 0 9 0 — 60 25 — 85 8 3 9 3 — 56 32 — 88 4 0 44 26 — — 70 8 6 9 6 — 52 38 — 90 4 1 43 28 — — 71 8 9 9 9 — 48 44 — 92 4 2 42 30 — — 72 9 0 10 0 — 44 51 — 95 4 3 41 32 — — 73 9 3 10 3 — 40 57 — 97 4 4 40 34 — — 74 9 6 10 6 — 36 63 — 99 4 5 39 36 — — 75 9 9 10 9 — 33 69 — 102 4 6 38 38 — — 76 10 0 11 0 — 28 76 — 104 4 7 37 40 — — 77 10 3 11 3 — 24 82 — 106 4 8 36 42 — — 78 10 6 11 6 — 21 88 — 109 4 9 35 44 — — 79 10 9 11 9 — 17 94 — 111 4 10 34 46 — — 80 11 0 12 0 — 13 100 — 113 4 11 33 48 — — 81 11 3 12 3 — 9 107 — 116 11 6 12 6 — 5 113 — 118 5 0 32 50 — — 82 11 9 12 9 — 1 119 — 120 5 1 31 52 — — 83 12 0 13 0 — — 118 5 123 5 2 29 55 — — 84 12 3 13 3 — — 114 11 125 5 3 28 57 — — 85 12 6 13 6 — — 111 17 128 12 9 13 9 — — 107 23 130 5 4 27 59 — — 86 5 5 26 61 — — 87 13 0 14 0 — — 104 28 132 5 6 25 63 — — 88 13 3 14 3 — — 100 35 135 5 7 24 65 — — 89 13 6 14 6 — — 97 40 137 5 8 23 67 — — 90 13 9 14 9 — — 93 46 139 5 9 22 70 — — 92 14 0 15 0 — — 90 52 142 5 10 21 72 — — 93 14 3 15 3 — — 86 58 144 5 11 20 74 — — 94 14 6 15 6 — — 82 64 146 14 9 15 9 — — 79 70 149 6 0 19 76 — — 95 15 0 16 0 — — 76 75 151 6 1 18 78 — — 96 15 3 16 3 — — 72 82 154 6 2 17 80 — — 97 15 6 16 6 — — 69 87 156 15 9 16 9 — — 65 93 158 6 3 16 82 — — 98 6 4 15 84 — — 99 16 0 17 0 — — 62 99 161 6 5 14 86 — — 100 16 3 17 3 — — 58 105 163 6 6 13 88 — — 101 16 6 17 6 — — 54 111 165 6 7 12 90 — — 102 16 9 17 9 — — 51 117 168 6 8 11 92 — — 103 17 0 18 0 — — 47 123 170 6 9 10 94 — — 104 17 3 18 3 — — 44 128 172 6 10 9 96 — — 105 17 6 18 6 — — 40 135 175 6 11 7 99 — — 106 17 9 18 9 — — 37 140 177 18 0 19 0 — — 33 146 179 NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting 18 3 19 3 — — 30 152 182 Nos. see discussion of KA and KW Blocks for Rotary Kilns. 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch Inside Inside Number Required Per Ring Number Required Per Ring Diam. 3 No. 1 No. 2 No. Harbison-Walker IR . 3 No. 1 Ft In Straight Total Ft In Straight Total Wedge Wedge Wedge Wedge Wedge Wedge 7 0 6 101 — — 107 11 0 — 69 88 — 157 7 1 5 103 — — 108 11 1 — 69 90 — 159 7 2 4 105 — — 109 11 2 — 67 93 — 160 7 3 3 107 — — 110 11 3 — 66 95 — 161 7 4 2 109 — — 111 11 4 — 65 97 — 162 7 5 1 111 — — 112 11 5 — 64 99 — 163 7 6 — 113 — — 113 11 6 — 63 101 — 164 7 7 — 112 3 — 115 11 7 — 62 103 — 165 11 8 — 61 105 — 166 7 8 — 111 5 — 116 11 9 — 60 107 — 167 7 9 — 110 7 — 117 11 10 — 59 109 — 168 7 10 — 109 9 — 118 11 11 — 58 111 — 169 7 11 — 108 11 — 119 12 0 — 57 113 — 170 8 0 — 107 13 — 120 12 1 — 56 115 — 171 8 1 — 106 15 — 121 12 2 — 55 117 — 172 8 2 — 105 17 — 122 12 3 — 54 119 — 173 8 3 — 104 19 — 123 12 4 — 52 122 — 174 8 4 — 103 21 — 124 12 5 — 51 124 — 175 8 5 — 102 23 — 125 12 6 — 50 126 — 176 8 6 — 101 25 — 126 12 7 — 49 128 — 177 8 7 — 100 27 — 127 12 8 — 48 130 — 178 8 8 — 99 29 — 128 12 9 — 47 132 — 179 8 9 — 97 32 — 129 12 10 — 47 134 — 181 8 10 — 96 34 — 130 12 11 — 45 137 — 182 8 11 — 95 36 — 131 13 0 — 44 139 — 183 9 0 — 94 38 — 132 13 1 — 43 141 — 184 9 1 — 93 40 — 133 13 2 — 42 143 — 185 9 2 — 92 42 — 134 13 3 — 41 145 — 186 9 3 — 91 44 — 135 13 4 — 40 147 — 187 9 4 — 90 47 — 137 13 5 — 39 149 — 188 9 5 — 89 49 — 138 13 6 — 38 151 — 189 13 7 — 37 153 — 190 9 6 — 88 51 — 139 13 8 — 36 155 — 191 9 7 — 87 53 — 140 13 9 — 35 157 — 192 9 8 — 86 55 — 141 13 10 — 34 159 — 193 9 9 — 85 57 — 142 13 11 — 33 161 — 194 9 10 — 84 59 — 143 9 11 — 83 61 — 144 14 0 — 32 163 — 195 14 1 — 30 166 — 196 10 0 — 82 63 — 145 14 2 — 29 168 — 197 10 1 — 81 65 — 146 14 3 — 28 170 — 198 10 2 — 80 67 — 147 14 4 — 27 172 — 199 10 3 — 79 69 — 148 14 5 — 26 174 — 200 10 4 — 78 71 — 149 14 6 — 25 176 — 201 10 5 — 77 73 — 150 14 7 — 25 178 — 203 10 6 — 76 75 — 151 14 8 — 23 181 — 204 10 7 — 74 78 — 152 14 9 — 22 183 — 205 10 8 — 73 80 — 153 14 10 — 21 185 — 206 10 9 — 72 82 — 154 14 11 — 20 187 — 207 10 10 — 71 84 — 155 10 11 — 70 86 — 156 15 0 — 19 189 — 208 15 1 — 18 191 — 209 NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting 15 2 — 17 193 — 210 Nos. 15 3 — 16 195 — 211 15 4 — 15 197 — 212 15 5 — 14 199 — 213 NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting Nos. 2 and 3 arch brick for the corresponding wedge brick. 9 x 4 1/2 x 3. 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.35 .RING COMBINATIONS 9 Inch Lining — 3 Inch Wedge Brick 9 Inch Lining — 3 Inch Wedge Brick 9 x 4 1/2 x 3. Diam. 1. Inside Number Required Per Ring Diam. 1. Inside Number Required Per Ring Brickwork Brickwork No. 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d. 2 No. 2 and 3 arch brick for the corresponding wedge brick. RING COMBINATIONS 9 Inch Lining — 3 Inch Wedge Brick 9 Inch Lining — 3 Inch Key Brick 9 x 4 1/2 x 3, 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d. 9 x 4 1/2 x 3 Inch Number Required Per Ring Diam. Inside Number Required Per Ring Diam. Inside Brickwork No. 3 No. 2 No. 1 Brickwork No. 4 No. 3 No. 2 No. 1 Straight Total Ft In Straight Total Ft In Wedge Wedge Wedge Key Key Key Key 15 6 — 13 201 — 214 1 6 26 — — — — 26 15 7 — 12 203 — 215 1 8 23 4 — — — 27 15 8 — 11 205 — 216 1 10 20 8 — — — 28 15 9 — 10 207 — 217 — — — 15 10 — 8 210 — 218 2 0 17 13 — — — 30 2 2 14 17 — — — 31 15 11 — 7 212 — 219 2 4 12 21 — — — 33 2 6 9 25 — — — 34 16 0 — 6 214 — 220 2 8 6 29 — — — 35 16 1 — 5 216 — 221 2 10 3 34 — — — 37 16 2 — 4 218 — 222 16 3 — 3 220 — 223 3 0 — 38 — — — 38 16 4 — 3 222 — 225 3 2 — 35 4 — — 39 16 5 — 1 225 — 226 3 4 — 32 9 — — 41 16 6 — — 227 — 227 3 6 — 29 13 — — 42 17 0 — — 227 6 233 3 8 — 27 17 — — 44 3 10 — 24 21 — — 45 17 6 — — 227 12 239 18 0 — — 227 18 245 4 0 — 21 25 — — 46 18 6 — — 227 25 252 4 2 — 18 30 — — 48 19 0 — — 227 31 258 4 4 — 15 34 — — 49 19 6 — — 227 37 264 4 6 — 13 38 — — 51 4 8 — 10 42 — — 52 20 0 — — 227 44 271 4 10 — 7 46 — — 53 20 6 — — 227 50 277 21 0 — — 227 56 283 5 0 — 4 51 — — 55 21 6 — — 227 62 289 5 2 — 1 55 — — 56 5 3 — — 57 — — 57 22 0 — — 227 69 296 5 4 — — 56 2 — 58 22 6 — — 227 75 302 5 6 — — 55 4 — 59 23 0 — — 227 81 308 5 8 — — 53 7 — 60 23 6 — — 227 88 315 5 10 — — 52 10 — 62 24 0 — — 227 94 321 24 6 — — 227 100 327 6 0 — — 50 13 — 63 25 0 — — 227 106 333 6 2 — — 49 16 — 65 25 6 — — 227 113 340 6 4 — — 48 18 — 66 26 0 — — 227 119 346 6 6 — — 46 21 — 67 26 6 — — 227 125 352 6 8 — — 45 24 — 69 6 10 — — 43 27 — 70 27 0 — — 227 132 359 27 6 — — 227 138 365 7 0 — — 42 30 — 72 28 0 — — 227 144 371 7 2 — — 41 32 — 73 28 6 — — 227 150 377 7 4 — — 39 35 — 74 29 0 — — 227 157 384 7 6 — — 38 38 — 76 29 6 — — 227 163 390 7 8 — — 36 41 — 77 7 10 — — 35 44 — 79 30 0 — — 227 169 396 30 6 — — 227 176 403 8 0 — — 34 46 — 80 31 0 — — 227 182 409 8 2 — — 32 49 — 81 8 4 — — 31 52 — 83 31 6 — — 227 188 415 8 6 — — 29 55 — 84 32 0 — — 227 194 421 8 8 — — 28 58 — 86 32 6 — — 227 201 428 8 10 — — 27 60 — 87 33 0 — — 227 207 434 33 6 — — 227 213 440 9 0 — — 25 63 — 88 34 0 — — 227 220 447 9 2 — — 24 66 — 90 34 6 — — 227 226 453 9 4 — — 22 69 — 91 35 0 — — 227 232 459 9 6 — — 21 72 — 93 35 6 — — 227 238 465 9 8 — — 20 74 — 94 36 0 — — 227 245 472 9 10 — — 18 77 — 95 36 6 — — 227 251 478 10 0 — — 17 80 — 97 10 2 — — 15 83 — 98 NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting 10 4 — — 14 86 — 100 Nos. 1, 2 and 3 arch brick for the corresponding wedge brick. IR - 36 Harbison-Walker RING COMBINATIONS 9 Inch Lining — 3 Inch Key Brick 9 Inch Lining — 3 Inch Key Brick 9 x 4 1/2 x 3 Inch — Continued 9 x 6 x 3 Inch Diam. Inside Number Required Per Ring Number Required Per Ring Diam. Inside Brickwork No. 4 No. 3 No. 2 No. 1 Brickwork No. 3 No. 2 No. 1 Ft In Straight Total Straight Total Key Key Key Key Ft In Key Key Key 10 6 — — 13 88 — 101 1 6 19 — — — 19 10 8 — — 11 91 — 102 1 8 18 2 — — 20 10 10 — — 10 94 — 104 1 10 18 3 — — 21 — — — 11 0 — — 9 96 — 105 2 0 17 5 — — 22 11 2 — — 7 100 — 107 2 2 16 7 — — 23 11 4 — — 6 102 — 108 2 4 15 9 — — 24 11 6 — — 4 105 — 109 2 6 15 11 — — 26 11 8 — — 3 108 — 111 2 8 14 13 — — 27 11 10 — — 2 110 — 112 2 10 14 14 — — 28 12 0 — — — 113 — 113 3 0 13 16 — — 29 12 6 — — — 113 5 118 3 2 12 18 — — 30 13 0 — — — 113 9 122 3 4 12 19 — — 31 13 6 — — — 113 13 126 3 6 11 21 — — 32 14 0 — — — 113 17 130 3 8 10 23 — — 33 14 6 — — — 113 21 134 3 10 9 25 — — 34 15 0 — — — 113 26 139 4 0 9 26 — — 35 15 6 — — — 113 30 143 4 2 8 28 — — 36 16 0 — — — 113 34 147 4 4 7 30 — — 37 16 6 — — — 113 38 151 4 6 7 31 — — 38 17 0 — — — 113 42 155 4 8 6 33 — — 39 17 6 — — — 113 47 160 4 10 5 35 — — 40 18 0 — — — 113 51 164 5 0 5 36 — — 41 18 6 — — — 113 55 168 5 2 4 38 — — 42 19 0 — — — 113 59 172 5 4 3 40 — — 43 19 6 — — — 113 63 176 20 0 — — — 113 68 181 5 6 2 42 — — 44 20 6 — — — 113 72 185 5 8 2 43 — — 45 — — — 5 10 1 45 — — 46 21 0 — — — 113 76 189 21 6 — — — 113 80 193 6 0 — 48 — — 48 22 0 — — — 113 84 197 6 2 — 47 2 — 49 22 6 — — — 113 88 201 6 4 — 46 4 — 50 23 0 — — — 113 93 206 6 6 — 45 6 — 51 23 6 — — — 113 97 210 6 8 — 44 8 — 52 6 10 — 43 10 — 53 24 0 — — — 113 101 214 24 6 — — — 113 105 218 7 0 — 41 13 — 54 25 0 — — — 113 109 222 7 2 — 40 15 — 55 25 6 — — — 113 114 227 7 4 — 39 17 — 56 26 0 — — — 113 118 231 7 6 — 38 19 — 57 26 6 — — — 113 122 235 7 8 — 37 21 — 58 7 10 — 36 23 — 59 27 0 — — — 113 126 239 27 6 — — — 113 130 243 8 0 — 34 26 — 60 28 0 — — — 113 135 248 8 2 — 33 28 — 61 28 6 — — — 113 139 252 8 4 — 32 30 — 62 29 0 — — — 113 143 256 8 6 — 31 32 — 63 29 6 — — — 113 147 260 8 8 — 30 34 — 64 8 10 — 28 37 — 65 30 0 — — — 113 151 264 30 6 — — — 113 155 268 9 0 — 27 39 — 66 31 0 — — — 113 160 273 9 2 — 26 41 — 67 31 6 — — — 113 164 277 9 4 — 25 43 — 68 32 0 — — — 113 168 281 9 6 — 24 46 — 70 32 6 — — — 113 172 285 9 8 — 23 48 — 71 9 10 — 22 50 — 72 33 0 — — — 113 176 289 33 6 — — — 113 181 294 *NOTE: For brickwork of inside diameters less than 6 feet, involving the use of 34 0 — — — 113 185 298 9 x 6 inch No. 3 Keys which have a very sharp taper, a better bricklaying fit 35 0 — — — 113 193 306 can be obtained by the use of the 9 x 41/2 inch Key-brick combinations. Harbison-Walker IR - 37 RING COMBINATIONS 9 Inch Lining — 3 Inch Key Brick 9 Inch Lining — Rotary Kiln Blocks 9 x 6 x 3 Inch — Continued 9 x 9 x 4 Inch Diam. Inside Number Required Per Ring Diam. Inside Number Required Per Ring Brickwork No. 3 No. 2 No. 1 Brickwork Ft In Straight Total Ft In Total Key Key Key 10 0 — 21 52 — 73 60-78 66-84 10 2 — 19 55 — 74 5 0 28 — 28 10 4 — 18 57 — 75 5 1 23 5 28 10 6 — 17 59 — 76 5 2 18 10 28 10 8 — 16 61 — 77 5 3 14 15 29 10 10 — 15 63 — 78 5 4 9 20 29 5 5 5 24 29 11 0 — 13 66 — 79 11 2 — 12 68 — 80 66-84 72-90 11 4 — 11 70 — 81 5 6 30 — 30 11 6 — 10 72 — 82 5 7 25 5 30 11 8 — 9 74 — 83 5 8 20 10 30 11 10 — 8 76 — 84 5 9 15 16 31 12 0 — 6 79 — 85 5 10 10 21 31 12 2 — 5 81 — 86 5 11 5 26 31 12 4 — 4 83 — 87 12 6 — 3 85 — 88 72-90 78-96 12 8 — 2 87 — 89 6 0 32 — 32 12 10 — — 90 — 90 6 1 26 6 32 6 2 21 12 33 13 0 — — 91 — 91 6 3 16 17 33 13 6 — — 91 4 95 6 4 11 22 33 14 0 — — 91 7 98 6 5 6 28 34 14 6 — — 91 10 101 15 0 — — 91 13 104 78-96 84-102 15 6 — — 91 16 107 6 6 34 — 34 6 7 28 6 34 16 0 — — 91 19 110 6 8 23 12 35 16 6 — — 91 22 113 6 9 17 18 35 17 0 — — 91 26 117 6 10 11 24 35 17 6 — — 91 29 120 6 11 6 30 36 18 0 — — 91 32 123 — 18 6 — — 91 35 126 82-102 90-108 19 0 — — 91 38 129 7 0 36 — 36 20 0 — — 91 44 135 7 1 30 6 36 21 0 — — 91 51 142 7 2 24 13 37 22 0 — — 91 57 148 7 3 18 19 37 23 0 — — 91 63 154 7 4 12 25 37 24 0 — — 91 70 161 7 5 6 32 38 — 25 0 — — 91 76 167 90-108 96-114 26 0 — — 91 82 173 7 6 38 — 38 27 0 — — 91 88 179 7 7 31 7 38 28 0 — — 91 95 186 7 8 25 14 39 29 0 — — 91 101 192 7 9 19 20 39 30 0 — — 91 107 198 7 10 13 26 39 7 11 7 33 40 31 0 — — 91 114 205 32 0 — — 91 120 211 NOTE: In orders, the complete names of the blocks should be given, as for example 33 0 — — 91 126 217 “60-78 RKB.” 34 0 — — 91 132 223 35 0 — — 91 139 230 36 0 — — 91 145 236 37 0 — — 91 151 242 38 0 — — 91 158 249 39 0 — — 91 164 255 40 0 — — 91 170 261 41 0 — — 91 176 267 IR - 38 Harbison-Walker RING COMBINATIONS 9 Inch Lining — Rotary Kiln Blocks 9 Inch Lining — Rotary Kiln Blocks 9 x 9 x 4 Inch — Continued 9 x 9 x 4 Inch — Continued Diam. Inside Number Required Per Ring Diam. Inside Number Required Per Ring Brickwork Brickwork Ft In Total Ft In Total 96-114 102-120 123-141 126-144 8 0 40 — 40 10 3 50 — 50 8 1 34 7 41 10 4 33 17 50 8 2 27 14 41 10 5 16 34 50 8 3 20 21 41 8 4 14 28 42 126-144 132-150 8 5 7 35 42 10 6 51 — 51 10 7 42 9 51 102-120 108-126 10 8 34 17 51 8 6 42 — 42 10 9 25 27 52 8 7 35 8 43 10 10 17 35 52 8 8 28 15 43 10 11 8 44 52 8 9 21 22 43 8 10 14 30 44 132-150 138-156 8 11 7 37 44 11 0 53 — 53 11 1 44 9 53 108-126 114-132 11 2 35 18 53 9 0 44 — 44 11 3 26 28 54 9 1 37 8 45 11 4 18 36 54 9 2 29 16 45 11 5 9 46 55 9 3 22 23 45 9 4 15 31 46 138-156 144-162 9 5 7 39 46 11 6 55 — 55 11 7 45 10 55 114-132 117-135 11 8 37 19 56 9 6 46 — 46 11 9 27 29 56 9 7 31 16 47 11 10 18 38 56 9 8 15 32 47 11 11 9 48 57 117-135 120-138 144-162 150-168 9 9 48 — 48 12 0 57 — 57 9 10 32 16 48 12 1 47 10 57 9 11 16 32 48 12 2 38 20 58 12 3 28 30 58 120-138 123-141 12 4 19 39 58 10 0 49 — 49 12 5 10 49 59 10 1 32 17 49 10 2 16 13 49 150-168 156-174 12 6 59 — 59 NOTE: In orders, the complete names of the blocks should be given, as for example 12 7 49 10 59 “84-102 RKB.” 12 8 39 21 60 12 9 29 31 60 12 10 20 40 60 12 11 10 51 61 156-174 162-180 13 0 61 — 61 13 1 51 10 61 13 2 41 21 62 13 3 30 32 62 13 4 21 42 63 13 5 10 53 63 NOTE: In orders, the complete names of the blocks should be given, as for example “123-141 RKB.” Harbison-Walker IR - 39 RING COMBINATIONS 9 Inch Lining — Rotary Kiln Blocks 9 Inch Lining — Rotary Kiln Blocks 9 x 9 x 4 Inch — Continued 9 x 9 x 4 Inch — Continued Diam. Inside Number Required Per Ring Diam. Inside Number Required Per Ring Brickwork Brickwork Ft In Total Ft In Total 162-180 168-186 204-222 210-228 13 6 63 — 63 17 0 78 — 78 13 7 53 11 64 17 1 65 13 78 13 8 42 22 64 17 2 52 27 79 13 9 31 33 64 17 3 39 40 79 13 10 21 44 65 17 4 26 53 79 13 11 11 54 65 17 5 13 67 80 — 168-186 174-192 210-228 216-234 14 0 65 — 65 17 6 80 — 80 14 1 54 12 66 17 7 66 14 80 14 2 43 23 66 17 8 53 28 81 14 3 32 34 66 17 9 40 41 81 14 4 22 45 67 17 10 27 54 81 14 5 11 56 67 17 11 14 68 82 — 174-192 180-198 216-234 222-240 14 6 67 — 67 18 0 82 — 82 14 7 56 12 68 18 1 68 14 82 14 8 45 23 68 18 2 55 28 83 14 9 33 35 68 18 3 41 42 83 14 10 23 46 69 18 4 27 56 83 14 11 11 58 69 18 5 14 70 84 180-198 186-204 222-240 228-246 15 0 70 — 70 18 6 84 — 84 15 1 58 12 70 18 7 70 15 85 15 2 46 24 70 18 8 56 29 85 15 3 35 36 71 18 9 42 43 85 15 4 23 48 71 18 10 28 58 86 15 5 12 59 71 18 11 14 72 86 186-204 192-210 228-246 234-252 15 6 72 — 72 19 0 86 — 86 15 7 60 12 72 19 1 72 15 87 15 8 48 24 72 19 2 57 30 87 15 9 36 37 73 19 3 43 44 87 15 10 24 49 73 19 4 29 59 88 15 11 12 61 73 19 5 14 74 88 192-210 198-216 234-252 240-258 16 0 74 — 74 19 6 88 — 88 16 1 61 13 74 19 7 74 15 89 16 2 49 25 74 19 8 59 30 89 16 3 37 38 75 19 9 44 45 89 16 4 25 50 75 19 10 30 60 90 16 5 12 63 75 19 11 15 75 90 198-216 204-222 240-258 — 16 6 76 — 76 20 0 90 — 90 16 7 63 13 76 — 16 8 50 26 76 16 9 38 39 77 NOTE: In orders, the complete names of the blocks should be given, as for example 16 10 25 52 77 “204-222 RKB.” 16 11 13 65 78 NOTE: In orders, the complete names of the blocks should be given, as for example “162-180 RKB.” IR - 40 Harbison-Walker RING COMBINATIONS 9 Inch Lining — Rotary Kiln Blocks 12 Inch Lining — 3 Inch Wedge Brick 9 x 6 x 4 Inch Wedge Type —Two Shape System 12 x 4 1/2 x 3, 12 x 6 x 3 or 12 x 9 x 3 Inch Inside Inside Number Required Per Ring Diam. Inside Number Required Per Ring Lining Shell Brickwork No. 3 No. 2 No. 1 No. 1-X Ft In Ft In KW-3 KW-2 KW-1 KW-1X Total Ft In Straight Total Wedge Wedge Wedge Wedge 4 6 6 0 50 7 — — 57 4 0 76 — — — — 76 4 9 6 3 44 15 — — 59 4 3 72 7 — — — 79 5 0 6 6 38 24 — — 62 4 6 69 13 — — — 82 5 3 6 9 32 32 — — 64 4 9 66 19 — — — 85 5 6 7 0 25 41 — — 66 5 9 7 3 19 50 — — 69 5 0 63 25 — — — 88 5 3 60 32 — — — 92 6 0 7 6 13 58 — — 71 5 6 57 38 — — — 95 6 3 7 9 6 67 — — 73 5 9 54 44 — — — 98 6 6 8 0 — 76 — — 76 6 9 8 3 — 72 6 — 78 7 0 8 6 — 68 13 — 81 6 0 51 50 — — — 101 7 3 8 9 — 64 19 — 83 6 3 47 57 — — — 104 7 6 9 0 — 60 25 — 85 6 6 44 63 — — — 107 7 9 9 3 — 56 32 — 88 6 9 41 69 — — — 110 8 0 9 6 — 52 38 — 90 8 3 9 9 — 48 44 — 92 7 0 38 75 — — — 113 8 6 10 0 — 44 51 — 95 7 3 35 82 — — — 117 8 9 10 3 — 40 57 — 97 7 6 32 88 — — — 120 7 9 29 94 — — — 123 9 0 10 6 — 36 63 — 99 9 3 10 9 — 33 69 — 102 8 0 25 101 — — — 126 9 6 11 0 — 28 76 — 104 8 3 22 107 — — — 129 9 9 11 3 — 24 82 — 106 10 0 11 6 — 21 88 — 109 8 6 19 113 — — — 132 10 3 11 9 — 17 94 — 111 8 9 16 119 — — — 135 10 6 12 0 — 13 100 — 113 10 9 12 3 — 9 107 — 116 9 0 13 126 — — — 139 11 0 12 6 — 5 113 — 118 9 3 10 132 — — — 142 11 3 12 9 — 1 119 — 120 9 6 7 138 — — — 145 11 6 13 0 — — 117 6 123 9 9 3 145 — — — 148 11 9 13 3 — — 112 13 125 10 0 — 151 — — — 151 12 0 13 6 — — 108 20 128 10 3 — 148 6 — — 154 12 3 13 9 — — 103 27 130 10 6 — 144 13 — — 157 12 6 14 0 — — 98 34 132 10 9 — 142 19 — — 161 12 9 14 3 — — 94 41 135 13 0 14 6 — — 89 48 137 13 3 14 9 — — 84 55 139 11 0 — 139 25 — — 164 13 6 15 0 — — 79 63 142 11 3 — 135 32 — — 167 13 9 15 3 — — 75 69 144 11 6 — 132 38 — — 170 14 0 15 6 — — 70 76 146 11 9 — 129 44 — — 173 14 3 15 9 — — 65 84 149 14 6 16 0 — — 60 91 151 12 0 — 126 50 — — 176 14 9 16 3 — — 56 98 154 12 3 — 122 57 — — 179 12 6 — 120 63 — — 183 15 0 16 6 — — 51 105 156 12 9 — 117 69 — — 186 15 3 16 9 — — 46 112 158 15 6 17 0 — — 42 119 161 13 0 — 113 76 — — 189 15 9 17 3 — — 37 126 163 13 3 — 110 82 — — 192 16 0 17 6 — — 32 133 165 13 6 — 107 88 — — 195 16 3 17 9 — — 28 140 168 16 6 18 0 — — 23 147 170 13 9 — 104 94 — — 198 16 9 18 3 — — 18 154 172 17 0 18 6 — — 14 161 175 14 0 — 101 100 — — 201 17 3 18 9 — — 9 168 177 14 3 — 98 107 — — 205 17 6 19 0 — — 4 175 179 14 6 — 95 113 — — 208 17 9 19 3 — — — 182 182 14 9 — 91 120 — — 211 NOTE: For each ring, order two (2) pieces each KW-2/3 and KW-3/4 to facilitate 15 0 — 88 126 — — 214 keying. For additional information, see discussion of KA and KW blocks for 15 3 — 85 132 — — 217 Rotary Kilns. 15 6 — 82 138 — — 220 15 9 — 79 144 — — 223 Harbison-Walker IR - 41 Inside Number Required Per Ring Brickwork No. 1-X Ft In Straight Total Ft In Straight Total Wedge Wedge Wedge Wedge Wedge Wedge Wedge Wedge 16 0 — 76 151 — — 227 28 0 — — 226 151 — 377 16 3 — 73 157 — — 230 28 3 — — 223 158 — 381 16 6 — 69 164 — — 233 28 6 — — 220 164 — 384 16 9 — 66 170 — — 236 28 9 — — 217 170 — 387 17 0 — 63 176 — — 239 29 0 — — 214 176 — 390 17 3 — 60 182 — — 242 29 3 — — 211 182 — 393 17 6 — 57 188 — — 245 29 6 — — 207 189 — 396 17 9 — 54 195 — — 249 29 9 — — 204 195 — 399 18 0 — 51 201 — — 252 30 0 — — 202 201 — 403 18 3 — 47 208 — — 255 30 3 — — 198 208 — 406 18 6 — 44 214 — — 258 30 6 — — 195 214 — 409 18 9 — 41 220 — — 261 30 9 — — 192 220 — 412 19 0 — 38 226 — — 264 31 0 — — 189 226 — 415 19 3 — 35 232 — — 267 31 3 — — 185 233 — 418 19 6 — 32 239 — — 271 31 6 — — 182 239 — 421 19 9 — 29 245 — — 274 31 9 — — 180 245 — 425 20 0 — 25 252 — — 277 32 0 — — 176 252 — 428 20 3 — 22 258 — — 280 32 3 — — 173 258 — 431 20 6 — 19 264 — — 283 32 6 — — 170 264 — 434 20 9 — 16 270 — — 286 32 9 — — 167 270 — 437 21 0 — 13 276 — — 289 33 0 — — 163 277 — 440 21 3 — 10 283 — — 293 33 3 — — 160 283 — 443 21 6 — 7 289 — — 296 33 6 — — 158 289 — 447 21 9 — 3 296 — — 299 33 9 — — 154 296 — 450 22 0 — — 302 — — 302 34 0 — — 151 302 — 453 22 3 — — 299 6 — 305 34 3 — — 148 308 — 456 22 6 — — 295 13 — 308 34 6 — — 145 314 — 459 22 9 — — 292 19 — 311 34 9 — — 141 321 — 462 23 0 — — 289 26 — 315 35 0 — — 138 327 — 465 23 3 — — 286 32 — 318 35 3 — — 135 333 — 468 23 6 — — 283 38 — 321 35 6 — — 132 340 — 472 23 9 — — 280 44 — 324 35 9 — — 129 346 — 475 24 0 — — 277 50 — 327 36 0 — — 126 352 — 478 24 3 — — 273 57 — 330 36 3 — — 123 358 — 481 24 6 — — 270 63 — 333 36 6 — — 119 365 — 484 24 9 — — 267 70 — 337 36 9 — — 116 371 — 487 25 0 — — 264 76 — 340 37 0 — — 113 377 — 490 25 3 — — 261 82 — 343 37 3 — — 110 384 — 494 25 6 — — 258 88 — 346 37 6 — — 107 390 — 497 25 9 — — 255 94 — 349 37 9 — — 104 396 — 500 26 0 — — 251 101 — 352 38 0 — — 101 402 — 503 26 3 — — 248 107 — 355 38 3 — — 97 409 — 506 26 6 — — 245 114 — 359 38 6 — — 94 415 — 509 26 9 — — 242 120 — 362 38 9 — — 91 421 — 512 27 0 — — 239 126 — 365 39 0 — — 88 428 — 516 27 3 — — 236 132 — 368 39 3 — — 85 434 — 519 27 6 — — 233 138 — 371 39 6 — — 82 440 — 522 27 9 — — 229 145 — 374 39 9 — — 79 446 — 525 IR .RING COMBINATIONS 12 Inch Lining — 3 Inch Wedge Brick 12 Inch Lining — 3 Inch Wedge Brick 12 x 4 1/2 x 3. 1 No. Diam. 12 x 6 x 3 or 12 x 9 x 3 Inch–Cont’d. 2 No. 1 No. 2 No. 12 x 6 x 3 or 12 x 9 x 3 Inch–Cont’d. 3 No. 12 x 4 1/2 x 3. Inside Number Required Per Ring Diam. 1-X Brickwork No. 3 No.42 Harbison-Walker . RING COMBINATIONS 12 Inch Lining — 3 Inch Wedge Brick 12 Inch Lining — 3 Inch Key Brick 12 x 4 1/2 x 3. 1 No.2 No. 3 No. 1-X Brickwork No. 12 x 6 x 3 or 12 x 9 x 3 Inch–Cont’d. 2 No. Inside Number Required Per Ring Brickwork No. 1 Ft In Straight Total Ft In Straight Total Wedge Wedge Wedge Wedge Key Key 40 0 — — 76 452 — 528 10 0 76 — — 76 40 3 — — 72 459 — 531 10 2 75 2 — 77 40 6 — — 69 465 — 534 10 4 74 4 — 78 40 9 — — 66 472 — 538 10 6 72 7 — 79 10 8 71 9 — 80 41 0 — — 63 478 — 541 10 10 70 11 — 81 41 3 — — 60 484 — 544 11 0 69 13 — 82 41 6 — — 57 490 — 547 11 2 68 15 — 83 41 9 — — 54 496 — 550 11 4 67 17 — 84 11 6 66 19 — 85 42 0 — — 50 503 — 553 11 8 65 21 — 86 42 3 — — 47 509 — 556 11 10 64 23 — 87 42 6 — — 44 516 — 560 42 9 — — 41 522 — 563 12 0 63 25 — 88 12 2 62 27 — 89 43 0 — — 38 528 — 566 12 4 61 29 — 90 43 3 — — 35 534 — 569 12 6 60 32 — 92 43 6 — — 32 540 — 572 12 8 59 34 — 93 43 9 — — 28 547 — 575 12 10 58 36 — 94 44 0 — — 25 553 — 578 13 0 57 38 — 95 44 3 — — 22 560 — 582 13 2 56 40 — 96 44 6 — — 19 566 — 585 13 4 55 42 — 97 13 6 54 44 — 98 44 9 — — 16 572 — 588 13 8 53 46 — 99 13 10 52 48 — 100 45 0 — — 13 578 — 591 45 3 — — 10 584 — 594 14 0 51 50 — 101 45 6 — — 6 591 — 597 14 2 49 53 — 102 45 9 — — 3 597 — 600 14 4 48 55 — 103 14 6 47 57 — 104 46 0 — — — 604 — 604 14 8 46 59 — 105 46 3 — — — 604 3 607 14 10 45 61 — 106 46 6 — — — 604 6 610 46 9 — — — 604 9 613 15 0 44 63 — 107 15 2 43 65 — 108 47 0 — — — 604 12 616 15 4 42 67 — 109 47 3 — — — 604 15 619 15 6 41 69 — 110 47 6 — — — 604 18 622 15 8 40 71 — 111 15 10 39 73 — 112 47 9 — — — 604 22 626 16 0 38 75 — 113 48 0 — — — 604 25 629 16 2 37 78 — 115 48 3 — — — 604 28 632 16 4 36 80 — 116 48 6 — — — 604 31 635 16 6 35 82 — 117 48 9 — — — 604 34 638 16 8 34 84 — 118 16 10 33 86 — 119 49 0 — — — 604 37 641 49 6 — — — 604 44 648 17 0 32 88 — 120 50 0 — — — 604 50 654 17 2 31 90 — 121 50 6 — — — 604 56 660 17 4 30 92 — 122 17 6 29 94 — 123 51 0 — — — 604 62 666 17 8 27 97 — 124 51 6 — — — 604 69 673 17 10 26 99 — 125 52 0 — — — 604 75 679 52 6 — — — 604 81 685 18 0 25 101 — 126 18 2 24 103 — 127 18 4 23 105 — 128 53 0 — — — 604 88 692 18 6 22 107 — 129 53 6 — — — 604 94 698 18 8 21 109 — 130 54 0 — — — 604 100 704 18 10 20 111 — 131 54 6 — — — 604 106 710 Harbison-Walker IR .43 . Inside Number Required Per Ring Diam. 12 x 6 x 3 Inch Diam. Inside Brickwork No. 2 No. Inside Number Required Per Ring Diam.RING COMBINATIONS 12 Inch Lining — 3 Inch Key Brick 13 1/2 Inch Lining — 3 Inch Wedge Brick 12 x 6 x 3 Inch — Continued 13 1/2 x 4 1/2 x 3. 1-X Straight Total Straight Total Ft In Key Key Ft In Wedge Wedge Wedge Wedge 19 0 19 113 — 132 4 6 85 — — — — 85 19 2 18 115 — 133 4 9 82 6 — — — 88 19 4 17 117 — 134 19 6 16 119 — 135 5 0 79 13 — — — 92 19 8 15 122 — 137 5 3 76 19 — — — 95 19 10 14 124 — 138 5 6 73 25 — — — 98 5 9 69 32 — — — 101 20 0 13 126 — 139 20 2 12 128 — 140 6 0 66 38 — — — 104 20 4 11 130 — 141 6 3 63 44 — — — 107 20 6 10 132 — 142 6 6 60 50 — — — 110 20 8 9 134 — 143 6 9 57 56 — — — 113 20 10 8 136 — 144 21 0 7 138 — 145 7 0 54 63 — — — 117 21 2 5 141 — 146 7 3 51 69 — — — 120 21 4 4 143 — 147 7 6 47 76 — — — 123 21 6 3 145 — 148 7 9 44 82 — — — 126 21 8 2 147 — 149 21 10 1 149 — 150 8 0 41 88 — — — 129 8 3 38 94 — — — 132 22 0 — 151 — 151 8 6 35 100 — — — 135 22 2 — 151 1 152 8 9 32 107 — — — 139 22 4 — 151 2 153 22 6 — 151 3 154 9 0 29 113 — — — 142 23 0 — 151 6 157 9 3 25 120 — — — 145 23 6 — 151 10 161 9 6 22 126 — — — 148 9 9 19 132 — — — 151 24 0 — 151 13 164 24 6 — 151 16 167 25 0 — 151 19 170 10 0 16 138 — — — 154 25 6 — 151 22 173 10 3 13 144 — — — 157 26 0 — 151 25 176 10 6 10 151 — — — 161 26 6 — 151 28 179 10 9 7 157 — — — 164 27 0 — 151 32 183 11 0 3 164 — — — 167 27 6 — 151 35 186 11 3 — 170 — — — 170 28 0 — 151 38 189 11 6 — 167 6 — — 173 28 6 — 151 41 192 11 9 — 163 13 — — 176 29 0 — 151 44 195 29 6 — 151 47 198 12 0 — 160 19 — — 179 12 3 — 157 26 — — 183 30 0 — 151 50 201 12 6 — 154 32 — — 186 30 6 — 151 54 205 12 9 — 151 38 — — 189 31 0 — 151 57 208 31 6 — 151 60 211 32 0 — 151 63 214 13 0 — 148 44 — — 192 32 6 — 151 66 217 13 3 — 145 50 — — 195 13 6 — 141 57 — — 198 33 0 — 151 69 220 13 9 — 138 63 — — 201 33 6 — 151 72 223 34 0 — 151 76 227 14 0 — 135 70 — — 205 34 6 — 151 79 230 14 3 — 132 76 — — 208 35 0 — 151 82 233 14 6 — 129 82 — — 211 35 6 — 151 85 236 14 9 — 126 88 — — 214 36 0 — 151 88 239 15 0 — 123 94 — — 217 36 6 — 151 91 242 15 3 — 119 101 — — 220 37 0 — 151 94 245 15 6 — 116 107 — — 223 37 6 — 151 98 249 15 9 — 113 114 — — 227 38 0 — 151 101 252 38 6 — 151 104 255 IR . 1 No. 13 1/2 x 6 x 3 or 13 1/2 x 9 x 3 Inch Number Required Per Ring Diam. 2 No.44 Harbison-Walker . 3 No. 1 Brickwork No. Inside Number Required Per Ring Brickwork No. 1-X Ft In Straight Total Ft In Straight Total Wedge Wedge Wedge Wedge Wedge Wedge Wedge Wedge 16 0 — 110 120 — — 230 28 0 — — 299 82 — 381 16 3 — 107 126 — — 233 28 3 — — 296 88 — 384 16 6 — 104 132 — — 236 28 6 — — 292 95 — 387 16 9 — 101 138 — — 239 28 9 — — 289 101 — 390 17 0 — 97 145 — — 242 29 0 — — 286 107 — 393 17 3 — 94 151 — — 245 29 3 — — 283 113 — 396 17 6 — 92 157 — — 249 29 6 — — 280 119 — 399 17 9 — 88 164 — — 252 29 9 — — 277 126 — 403 18 0 — 85 170 — — 255 30 0 — — 274 132 — 406 18 3 — 82 176 — — 258 30 3 — — 270 139 — 409 18 6 — 79 182 — — 261 30 6 — — 267 145 — 412 18 9 — 75 189 — — 264 30 9 — — 264 151 — 415 19 0 — 72 195 — — 267 31 0 — — 261 157 — 418 19 3 — 70 201 — — 271 31 3 — — 258 163 — 421 19 6 — 66 208 — — 274 31 6 — — 255 170 — 425 19 9 — 63 214 — — 277 31 9 — — 252 176 — 428 20 0 — 60 220 — — 280 32 0 — — 248 183 — 431 20 3 — 57 226 — — 283 32 3 — — 245 189 — 434 20 6 — 53 233 — — 286 32 6 — — 242 195 — 437 20 9 — 50 239 — — 289 32 9 — — 239 201 — 440 21 0 — 48 245 — — 293 33 0 — — 236 207 — 443 21 3 — 44 252 — — 296 33 3 — — 233 214 — 447 21 6 — 41 258 — — 299 33 6 — — 230 220 — 450 21 9 — 38 264 — — 302 33 9 — — 227 226 — 453 22 0 — 35 270 — — 305 34 0 — — 223 233 — 456 22 3 — 31 277 — — 308 34 3 — — 220 239 — 459 22 6 — 28 283 — — 311 34 6 — — 217 245 — 462 22 9 — 26 289 — — 315 34 9 — — 214 251 — 465 23 0 — 22 296 — — 318 35 0 — — 210 258 — 468 23 3 — 19 302 — — 321 35 3 — — 208 264 — 472 23 6 — 16 308 — — 324 35 6 — — 205 270 — 475 23 9 — 13 314 — — 327 35 9 — — 201 277 — 478 24 0 — 9 321 — — 330 36 0 — — 198 283 — 481 24 3 — 6 327 — — 333 36 3 — — 195 289 — 484 24 6 — 4 333 — — 337 36 6 — — 192 295 — 487 24 9 — — 340 — — 340 36 9 — — 188 302 — 490 25 0 — — 336 7 — 343 37 0 — — 186 308 — 494 25 3 — — 333 13 — 346 37 3 — — 183 314 — 497 25 6 — — 330 19 — 349 37 6 — — 179 321 — 500 25 9 — — 327 25 — 352 37 9 — — 176 327 — 503 26 0 — — 324 31 — 355 38 0 — — 173 333 — 506 26 3 — — 321 38 — 359 38 3 — — 170 339 — 509 26 6 — — 318 44 — 362 38 6 — — 166 346 — 512 26 9 — — 314 51 — 365 38 9 — — 164 352 — 516 27 0 — — 311 57 — 368 39 0 — — 161 358 — 519 27 3 — — 308 63 — 371 39 3 — — 157 365 — 522 27 6 — — 305 69 — 374 39 6 — — 154 371 — 525 27 9 — — 302 75 — 377 39 9 — — 151 377 — 528 Harbison-Walker IR . 2 No. 13 1/2 x 6 x 3 or 13 1/2 x 9 x 3 Inch – Continued 13 1/2 x 9 x 3 Inch – Continued Diam. 2 No. Inside Number Required Per Ring Diam. 13 1/2 x 6 x 3 or 13 1/2 x 4 1/2 x 3. 1 No. 3 No. 1-X Brickwork No.45 .RING COMBINATIONS 131/2 Inch Lining — 3 Inch Wedge Brick 131/2 Inch Lining — 3 Inch Wedge Brick 13 1/2 x 4 1/2 x 3. 3 No. 1 No. 1 No. 2 No. Inside Number Required Per Ring Diam. 3 Keys which have a very sharp taper. Inside Number Required Per Ring Brickwork No.RING COMBINATIONS 131/2 Inch Lining — 3 Inch Wedge Brick 131/2 Inch Lining — 3 Inch Key Brick 13 1/2 x 4 1/2 x 3. involving the use of 51 6 — — 3 673 — 676 131/2 x 6 inch No.46 Harbison-Walker . 1-X Brickwork No. 13 1/2 x 6 x 3 or 131/2 x 6 x 3 Inch 13 1/2 x 9 x 3 Inch – Continued Diam. 3 No. 1 Ft In Straight Total Ft In Straight Total Wedge Wedge Wedge Wedge Key Key Key 40 0 — — 148 383 — 531 2 3 29 — — — 29 40 3 — — 144 390 — 534 2 4 28 1 — — 29 40 6 — — 142 396 — 538 2 6 26 4 — — 30 40 9 — — 139 402 — 541 2 8 25 6 — — 31 2 10 24 8 — — 32 41 0 — — 135 409 — 544 3 0 23 10 — — 33 41 3 — — 132 415 — 547 3 2 21 13 — — 34 41 6 — — 129 421 — 550 3 4 20 15 — — 35 41 9 — — 126 427 — 553 3 6 19 18 — — 37 3 8 18 20 — — 38 42 0 — — 122 434 — 556 3 10 17 22 — — 39 42 3 — — 120 440 — 560 42 6 — — 117 446 — 563 4 0 16 24 — — 40 42 9 — — 113 453 — 566 4 2 14 27 — — 41 4 4 13 29 — — 42 4 6 12 31 — — 43 43 0 — — 110 459 — 569 4 8 11 33 — — 44 43 3 — — 107 465 — 572 4 10 9 36 — — 45 43 6 — — 104 471 — 575 43 9 — — 101 477 — 578 5 0 8 38 — — 46 5 2 7 40 — — 47 44 0 — — 98 484 — 582 5 4 6 42 — — 48 44 3 — — 95 490 — 585 5 6 4 45 — — 49 44 6 — — 91 497 — 588 5 8 3 47 — — 50 44 9 — — 88 503 — 591 5 10 2 49 — — 51 6 0 — 52 — — 52 45 0 — — 85 509 — 594 6 2 — 51 2 — 53 45 3 — — 82 515 — 597 6 4 — 49 5 — 54 45 6 — — 79 521 — 600 6 6 — 48 7 — 55 45 9 — — 76 528 — 604 6 8 — 46 10 — 56 6 10 — 44 13 — 57 46 0 — — 73 534 — 607 46 3 — — 69 541 — 610 7 0 — 43 16 — 59 46 6 — — 66 547 — 613 7 2 — 41 19 — 60 46 9 — — 63 553 — 616 7 4 — 40 21 — 61 7 6 — 38 24 — 62 7 8 — 36 27 — 63 47 0 — — 60 559 — 619 7 10 — 35 29 — 64 47 3 — — 57 565 — 622 47 6 — — 54 572 — 626 8 0 — 33 32 — 65 47 9 — — 51 578 — 629 8 2 — 31 35 — 66 8 4 — 30 37 — 67 48 0 — — 47 585 — 632 8 6 — 28 40 — 68 48 3 — — 44 591 — 635 8 8 — 26 43 — 69 48 6 — — 41 597 — 638 8 10 — 24 46 — 70 48 9 — — 38 603 — 641 9 0 — 23 48 — 71 9 2 — 21 51 — 72 49 0 — — 35 609 — 644 9 4 — 19 54 — 73 49 3 — — 32 616 — 648 9 6 — 18 56 — 74 49 6 — — 29 622 — 651 9 8 — 16 59 — 75 49 9 — — 25 629 — 654 9 10 — 14 62 — 76 50 0 — — 22 635 — 657 10 0 — 13 64 — 77 50 3 — — 19 641 — 660 10 2 — 11 67 — 78 50 6 — — 16 647 — 663 10 4 — 9 70 — 79 50 9 — — 13 653 — 666 10 6 — 8 73 — 81 10 8 — 6 76 — 82 10 10 — 5 78 — 83 51 0 — — 10 660 — 670 51 3 — — 7 666 — 673 *NOTE: For brickwork of inside diameters less than 6 feet. appreciable cut- 51 9 — — — 679 — 679 ting may be necessary in some cases to secure the best bricklaying fit. IR . 2 No. 3 No. Inside Diam.1 Straight Total Total Ft In Key Key Key Ft In Wedge Wedge Wedge 11 0 — 3 81 — 84 5 0 95 — — 95 11 2 — 1 84 — 85 5 1 94 2 — 96 11 3 — — 85 — 85 5 3 91 7 — 98 11 6 — — 85 2 87 5 6 88 13 — 101 5 9 85 19 — 104 12 0 — — 85 5 90 12 6 — — 85 8 93 6 0 82 25 — 107 13 0 — — 85 11 96 6 3 79 31 — 110 13 6 — — 85 14 99 6 6 75 38 — 113 14 0 — — 85 18 103 6 9 73 44 — 117 14 6 — — 85 21 106 7 0 69 51 — 120 15 0 — — 85 24 109 7 3 66 57 — 123 15 6 — — 85 27 112 7 6 63 63 — 126 16 0 — — 85 30 115 7 9 60 69 — 129 16 6 — — 85 33 118 17 0 — — 85 36 121 8 0 57 75 — 132 17 6 — — 85 39 124 8 3 53 82 — 135 8 6 51 88 — 139 18 0 — — 85 43 128 8 9 47 95 — 142 18 6 — — 85 46 131 19 0 — — 85 49 134 9 0 44 101 — 145 19 6 — — 85 52 137 9 3 41 107 — 148 20 0 — — 85 55 140 9 6 38 113 — 151 20 6 — — 85 58 143 9 9 35 119 — 154 21 0 — — 85 61 146 10 0 31 126 — 157 21 6 — — 85 65 150 10 3 29 132 — 161 22 0 — — 85 68 153 10 6 25 139 — 164 22 6 — — 85 71 156 10 9 22 145 — 167 23 0 — — 85 74 159 23 6 — — 85 77 162 11 0 19 151 — 170 11 3 16 157 — 173 24 0 — — 85 80 165 11 6 13 163 — 176 24 6 — — 85 83 168 11 9 9 170 — 179 25 0 — — 85 87 172 25 6 — — 85 90 175 12 0 7 176 — 183 26 0 — — 85 93 178 12 3 3 183 — 186 26 6 — — 85 96 181 12 6 — 189 — 189 12 9 — 186 6 192 27 0 — — 85 99 184 27 6 — — 85 102 187 13 0 — 182 13 195 28 0 — — 85 105 190 13 3 — 179 19 198 28 6 — — 85 109 194 13 6 — 176 25 201 29 0 — — 85 112 197 13 9 — 173 32 205 29 6 — — 85 115 200 14 0 — 170 38 208 30 0 — — 85 118 203 14 3 — 167 44 211 30 6 — — 85 121 206 14 6 — 164 50 214 31 0 — — 85 124 209 14 9 — 160 57 217 31 6 — — 85 127 212 32 0 — — 85 131 216 15 0 — 157 63 220 15 3 — 154 69 223 33 0 — — 85 137 222 15 6 — 151 76 227 34 0 — — 85 143 228 15 9 — 148 82 230 35 0 — — 85 149 234 36 0 — — 85 156 241 16 0 — 145 88 233 16 3 — 142 94 236 37 0 — — 85 162 247 16 6 — 138 101 239 38 0 — — 85 168 253 16 9 — 135 107 242 39 0 — — 85 175 260 40 0 — — 85 181 266 Harbison-Walker IR . Inside Brickwork No. 3 No. 3 No. 2 No.RING COMBINATIONS 131/2 Inch Lining — 3 Inch Key Brick 15 Inch Lining — 3 Inch Wedge Brick 131/2 x 6 x 3 Inch — Continued 15 x 6 x 3 or 15 x 9 x 3 Inch Number Required Per Ring Number Required Per Ring Diam.2 No. 1 Brickwork No.47 . 1 No. Inside Number Required Per Ring Brickwork No. Inside Number Required Per Ring Diam.RING COMBINATIONS 15 Inch Lining — 3 Inch Wedge Brick 15 Inch Lining — 3 Inch Wedge Brick 15 x 6 x 3 or 15 x 9 x 3 Inch — Continued 15 x 6 x 3 or 15 x 9 x 3 Inch — Continued Diam. 1-X Ft In Total Ft In Total Wedge Wedge Wedge Wedge Wedge 17 0 132 113 — 245 29 0 358 38 396 17 3 129 120 — 249 29 3 355 44 399 17 6 126 126 — 252 29 6 352 51 403 17 9 123 132 — 255 29 9 349 57 406 18 0 120 138 — 258 30 0 346 63 409 18 3 116 145 — 261 30 3 343 69 412 30 6 339 76 415 18 6 113 151 — 264 30 9 336 82 418 18 9 110 157 — 267 31 0 333 88 421 19 0 107 164 — 271 31 3 330 95 425 19 3 104 170 — 274 31 6 327 101 428 19 6 101 176 — 277 31 9 324 107 431 19 9 98 182 — 280 32 0 321 113 434 20 0 94 189 — 283 32 3 317 120 437 20 3 91 195 — 286 32 6 314 126 440 20 6 88 201 — 289 32 9 311 132 443 20 9 85 208 — 293 33 0 308 139 447 21 0 82 214 — 296 33 3 305 145 450 21 3 79 220 — 299 33 6 302 151 453 21 6 76 226 — 302 33 9 299 157 456 21 9 72 233 — 305 34 0 295 164 459 34 3 292 170 462 22 0 69 239 — 308 34 6 289 176 465 22 3 66 245 — 311 34 9 286 182 468 22 6 63 252 — 315 22 9 60 258 — 318 35 0 283 189 472 35 3 280 195 475 23 0 57 264 — 321 35 6 277 201 478 23 3 54 270 — 324 35 9 273 208 481 23 6 50 277 — 327 23 9 47 283 — 330 36 0 270 214 484 36 3 267 220 487 24 0 44 289 — 333 36 6 264 226 490 24 3 41 296 — 337 36 9 261 233 494 24 6 38 302 — 340 24 9 35 308 — 343 37 0 258 239 497 37 3 255 245 500 25 0 32 314 — 346 37 6 252 251 503 25 3 28 321 — 349 37 9 248 258 506 25 6 25 327 — 352 25 9 22 333 — 355 38 0 245 264 509 38 3 242 270 512 38 6 239 277 516 26 0 19 340 — 359 38 9 236 283 519 26 3 16 346 — 362 26 6 13 352 — 365 39 0 233 289 522 26 9 10 358 — 368 39 3 230 295 525 39 6 226 302 528 27 0 6 365 — 371 39 9 223 308 531 27 3 3 371 — 374 27 6 — 377 — 377 40 0 220 314 534 27 9 — 374 7 381 40 3 217 321 538 40 6 214 327 541 28 0 — 371 13 384 40 9 211 333 544 28 3 — 368 19 387 28 6 — 365 25 390 41 0 208 339 547 28 9 — 361 32 393 41 3 204 346 550 41 6 201 352 553 41 9 198 358 556 IR . 1 No. 1-X Brickwork No.48 Harbison-Walker . 2 No. Inside Number Required Per Ring Brickwork No. 3 No. 1 Ft In Straight Total Ft In Total Wedge Wedge Wedge Wedge Wedge 42 0 195 365 — 560 6 0 113 — — 113 42 3 192 371 — 563 6 1 112 3 — 115 42 6 189 377 — 566 6 2 111 5 — 116 42 9 186 383 — 569 6 3 110 7 — 117 6 6 107 13 — 120 43 0 182 390 — 572 6 9 104 19 — 123 43 3 179 396 — 575 43 6 176 402 — 578 7 0 101 25 — 126 43 9 173 409 — 582 7 3 97 32 — 129 7 6 94 38 — 132 44 0 170 415 — 585 7 9 91 44 — 135 44 3 167 421 — 588 44 6 164 427 — 591 8 0 88 51 — 139 44 9 160 434 — 594 8 3 85 57 — 142 45 0 157 440 — 597 8 6 82 63 — 145 45 3 154 446 — 600 8 9 79 69 — 148 45 6 151 453 — 604 45 9 148 459 — 607 9 0 76 75 — 151 9 3 72 82 — 154 46 0 145 465 — 610 9 6 69 88 — 157 46 3 142 471 — 613 9 9 66 95 — 161 46 6 138 478 — 616 46 9 135 484 — 619 10 0 63 101 — 164 10 3 60 107 — 167 47 0 132 490 — 622 10 6 57 113 — 170 47 3 129 497 — 626 10 9 54 119 — 173 47 6 126 503 — 629 47 9 123 509 — 632 11 0 50 126 — 176 11 3 47 132 — 179 48 0 120 515 — 635 11 6 44 139 — 183 48 3 116 522 — 638 11 9 41 145 — 186 48 6 113 528 — 641 48 9 110 534 — 644 12 0 38 151 — 189 12 3 35 157 — 192 49 0 107 541 — 648 12 6 32 163 — 195 49 3 104 547 — 651 12 9 28 170 — 198 49 6 101 553 — 654 49 9 98 559 — 657 13 0 25 176 — 201 50 0 94 566 — 660 13 3 22 183 — 205 50 3 91 572 — 663 13 6 19 189 — 208 50 6 88 578 — 666 13 9 16 195 — 211 50 9 85 585 — 670 14 0 13 201 — 214 51 0 82 591 — 673 14 3 10 207 — 217 51 6 76 603 — 679 14 6 6 214 — 220 52 0 69 616 — 685 14 9 3 220 — 223 52 6 63 629 — 692 15 0 — 227 — 227 53 0 57 641 — 698 15 3 — 223 7 230 53 6 50 654 — 704 15 6 — 220 13 233 54 0 44 666 — 710 15 9 — 217 19 236 54 6 38 679 — 717 16 0 — 214 25 239 55 0 32 691 — 723 16 3 — 211 31 242 55 6 25 704 — 729 16 6 — 207 38 245 56 0 19 717 — 736 16 9 — 205 44 249 56 6 13 729 — 742 17 0 — 201 51 252 57 0 6 742 — 748 17 3 — 198 57 255 57 6 — 754 — 754 17 6 — 195 63 258 58 0 — 754 7 761 58 6 — 754 13 767 17 9 — 192 69 261 Harbison-Walker IR .RING COMBINATIONS 15 Inch Lining — 3 Inch Wedge Brick 18 Inch Lining — 3 Inch Wedge Brick 15 x 6 x 3 or 15 x 9 x 3 Inch — Continued 18 x 6 x 3 or 18 x 9 x 3 Inch Diam. Inside Number Required Per Ring Diam.49 . 2 No. 1 No. 1-X Brickwork No. Inside Number Required Per Ring Brickwork No. 2 No. 1-X Ft In Total Ft In Total Wedge Wedge Wedge Wedge Wedge Wedge 18 0 189 75 — 264 30 0 38 377 — 415 18 3 185 82 — 267 30 3 35 383 — 418 18 6 183 88 — 271 30 6 31 390 — 421 18 9 179 95 — 274 30 9 29 396 — 425 19 0 176 101 — 277 31 0 26 402 — 428 19 3 173 107 — 280 31 3 22 409 — 431 19 6 170 113 — 283 31 6 19 415 — 434 19 9 167 119 — 286 31 9 16 421 — 437 32 0 13 427 — 440 20 0 163 126 — 289 32 3 9 434 — 443 20 3 161 132 — 293 32 6 7 440 — 447 20 6 157 139 — 296 32 9 4 446 — 450 20 9 154 145 — 299 33 0 — 453 — 453 21 0 151 151 — 302 33 3 — 449 7 456 21 3 148 157 — 305 33 6 — 446 13 459 21 6 145 163 — 308 33 9 — 443 19 462 21 9 141 170 — 311 34 0 — 440 25 465 22 0 139 176 — 315 34 3 — 437 31 468 22 3 135 183 — 318 34 6 — 434 38 472 22 6 132 189 — 321 34 9 — 431 44 475 22 9 129 195 — 324 35 0 — 427 51 478 23 0 126 201 — 327 35 3 — 424 57 481 23 3 123 207 — 330 35 6 — 421 63 484 23 6 119 214 — 333 35 9 — 418 69 487 23 9 117 220 — 337 36 0 — 415 75 490 24 0 113 227 — 340 36 3 — 412 82 494 24 3 110 233 — 343 36 6 — 409 88 497 36 9 — 406 94 500 24 6 107 239 — 346 24 9 104 245 — 349 37 0 — 402 101 503 37 3 — 399 107 506 25 0 101 251 — 352 37 6 — 396 113 509 25 3 97 258 — 355 37 9 — 393 119 512 25 6 95 264 — 359 25 9 91 271 — 362 38 0 — 390 126 516 38 3 — 387 132 519 26 0 88 277 — 365 38 6 — 384 138 522 26 3 85 283 — 368 38 9 — 380 145 525 26 6 82 289 — 371 26 9 79 295 — 374 39 0 — 377 151 528 39 3 — 374 157 531 27 0 75 302 — 377 39 6 — 371 163 534 27 3 73 308 — 381 39 9 — 368 170 538 27 6 69 315 — 384 27 9 66 321 — 387 40 0 — 365 176 541 40 3 — 362 182 544 28 0 63 327 — 390 40 6 — 358 189 547 28 3 60 333 — 393 40 9 — 355 195 550 28 6 57 339 — 396 28 9 53 346 — 399 41 0 — 352 201 553 41 3 — 349 207 556 41 6 — 346 214 560 29 0 51 352 — 403 41 9 — 343 220 563 29 3 47 359 — 406 29 6 44 365 — 409 42 0 — 340 226 566 29 9 41 371 — 412 42 3 — 336 233 569 42 6 — 333 239 572 42 9 — 330 245 575 IR .50 Harbison-Walker . 1-X Brickwork No. 1 No. 1 No. Inside Number Required Per Ring Diam.RING COMBINATIONS 18 Inch Lining — 3 Inch Wedge Brick 18 Inch Lining — 3 Inch Wedge Brick 18 x 6 x 3 or 18 x 9 x 3 Inch — Continued 18 x 6 x 3 or 18 x 9 x 3 Inch — Continued Diam. 2 No. no allowance was made for mortar or expansion joints or for size deviations of the brick. as given in the tables. These tables give the combina- tions of brick sizes required for arches of given spans and rises. to complete the course. IR . it is often necessary to cut one or two pieces. which detail arch calculations. the number of brick required for an arch. In laying an arch course of brick. For these reasons. For the brick combinations required for arches not included in the following tables. refer to the arch formulas found on page UR . may be slightly in excess of the number actually required. In calculating the tables. and in some instances several pieces. or to determine the dimensions or other numerical characteristics of arches. Fractional parts equal to or greater than one tenth of a brick were counted as an entire brick.52 Harbison-Walker .28.ARCH COMBINATIONS BRICK COMBINATIONS REQUIRED FOR ARCHES The following tables are useful in estimating the quantities of brick required for the construction of arches. 3 No. 3 No. 2 No.53 . 2 No.608 Inch (119/32 Inch) Rise Per Foot of Span (60° Central Angle) Number Required Per Course Number Required Per Course Inside Inside Span Rise Span Rise Radius No. 1 Ft In Ft In Straight Total Ft In Ft In Straight Total Ft In Arch Arch Arch Ft In Arch Arch Arch 1 0 2 10 6 1 — — 7 1 0 119/32 1 0 4 2 — — 6 1 1 2 5/32 1027/32 5 2 — — 7 1 1 1 3/4 1 1 4 3 — — 7 1 2 211/32 1121/32 5 2 — — 7 1 2 1 7/8 1 2 3 4 — — 7 1 3 2 1/2 1 0 1/2 5 3 — — 8 1 3 2 1 3 3 4 — — 7 1 4 221/32 1 111/32 4 4 — — 8 1 4 2 5/32 1 4 3 5 — — 8 1 5 227/32 1 2 5/32 4 4 — — 8 1 5 2 9/32 1 5 2 6 — — 8 1 6 3 1 3 4 5 — — 9 1 6 213/32 1 6 2 6 — — 8 1 7 3 5/32 1 327/32 3 6 — — 9 1 7 217/32 1 7 2 7 — — 9 1 8 311/32 1 421/32 2 7 — — 9 1 8 211/16 1 8 1 8 — — 9 1 9 3 1/2 1 5 1/2 2 8 — — 10 1 9 213/16 1 9 1 8 — — 9 1 10 321/32 1 611/32 2 8 — — 10 1 10 215/16 1 10 1 9 — — 10 1 11 327/32 1 7 5/32 2 9 — — 11 1 11 3 3/32 1 11 — 9 1 — 10 2 0 4 1 8 1 10 — — 11 2 0 3 7/32 2 0 — 9 1 — 10 2 1 4 5/32 1 827/32 1 10 — — 11 2 1 311/32 2 1 — 9 2 — 11 2 2 411/32 1 921/32 1 11 — — 12 2 2 315/32 2 2 — 8 3 — 11 2 3 4 1/2 1 10 1/2 — 12 — — 12 2 3 3 5/8 2 3 — 8 3 — 11 2 4 421/32 1 1111/32 — 11 1 — 12 2 4 3 3/4 2 4 — 8 4 — 12 2 5 427/32 2 0 5/32 — 11 2 — 13 2 5 3 7/8 2 5 — 7 5 — 12 2 6 5 2 1 — 11 2 — 13 2 6 4 1/32 2 6 — 7 5 — 12 2 7 5 5/32 2 127/32 — 10 3 — 13 2 7 4 5/32 2 7 — 7 6 — 13 2 8 511/32 2 221/32 — 10 4 — 14 2 8 4 9/32 2 8 — 6 7 — 13 2 9 5 1/2 2 3 1/2 — 10 4 — 14 2 9 4 7/16 2 9 — 6 7 — 13 2 10 521/32 2 411/32 — 9 5 — 14 2 10 4 9/16 2 10 — 6 8 — 14 2 11 527/32 2 5 5/32 — 9 6 — 15 2 11 411/16 2 11 — 5 9 — 14 3 0 6 2 6 — 8 7 — 15 3 0 413/16 3 0 — 5 10 — 15 3 2 611/32 2 721/32 — 8 8 — 16 3 1 431/32 3 1 — 5 10 — 15 3 4 621/32 2 911/32 — 7 10 — 17 3 2 5 3/32 3 2 — 4 11 — 15 3 6 7 2 11 — 6 11 — 17 3 3 5 7/32 3 3 — 4 12 — 16 3 8 711/32 3 021/32 — 6 12 — 18 3 4 511/32 3 4 — 4 12 — 16 3 10 721/32 3 211/32 — 5 14 — 19 3 5 5 1/2 3 5 — 3 13 — 16 3 6 5 5/8 3 6 — 3 14 — 17 4 0 8 3 4 — 4 15 — 19 3 7 5 3/4 3 7 — 2 15 — 17 4 2 811/32 3 521/32 — 3 17 — 20 3 8 529/32 3 8 — 2 15 — 17 4 4 821/32 3 711/32 — 3 18 — 21 3 9 6 1/32 3 9 — 2 16 — 18 4 6 9 3 9 — 2 20 — 22 3 10 6 5/32 3 10 — 1 17 — 18 4 8 911/32 3 1021/32 — 1 21 — 22 3 11 6 9/32 3 11 — 1 17 — 18 4 10 921/32 4 011/32 — 1 22 — 23 4 11 927/32 4 1 5/32 — — 23 — 23 4 0 6 7/16 4 0 — 1 18 — 19 4 1 6 9/16 4 1 — — 19 — 19 5 0 10 4 2 — — 23 1 24 4 2 611/16 4 2 — — 19 — 19 5 6 11 4 7 — — 23 3 26 4 3 627/32 4 3 — — 19 1 20 6 0 1 0 5 0 — — 23 5 28 4 6 7 1/4 4 6 — — 19 2 21 6 6 1 1 5 5 — — 23 7 30 5 0 8 1/32 5 0 — — 19 4 23 5 6 827/32 5 6 — — 19 6 25 6 0 921/32 6 0 — — 19 8 27 6 6 10 7/16 6 6 — — 19 10 29 Harbison-Walker IR .ARCH COMBINATIONS 41/2 Inch Arch Thickness — 3 Inch Arch Brick 41/2 Inch Arch Thickness — 3 Inch Arch Brick 9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch 9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch 2 Inch Rise Per Foot of Span 1. 1 Radius No. 54 Harbison-Walker . 3 No.302 Inch (2 5/16 Inch) Rise Per Foot of Span Number Required Per Course Number Required Per Course Inside Inside Span Rise Span Rise Radius No. 1 Radius No. 2 No.ARCH COMBINATIONS 41/2 Inch Arch Thickness — 3 Inch Arch Brick 41/2 Inch Arch Thickness — 3 Inch Arch Brick 9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch 9 x 41/2 x 3 or 131/2 x 41/2 x 3 Inch 11/2 Inch Rise Per Foot of Span 2. 3 No. 2 No. 1 Ft In Ft In Ft In Ft In Ft In Arch Arch Arch Straight Total Ft In Arch Arch Arch Straight Total 1 0 1 1/2 1 0 3/4 3 3 — — 6 1 0 2 5/16 831/32 7 — — — 7 1 1 1 5/8 1 113/16 3 3 — — 6 1 1 2 1/2 923/32 6 1 — — 7 1 2 1 3/4 1 2 7/8 3 4 — — 7 1 2 211/16 1015/32 6 2 — — 8 1 3 1 7/8 1 315/16 2 5 — — 7 1 3 2 7/8 11 7/32 6 2 — — 8 1 4 2 1 5 2 5 — — 7 1 4 3 1/16 1131/32 5 3 — — 8 1 5 2 1/8 1 6 1/16 2 6 — — 8 1 5 3 1/4 1 023/32 5 4 — — 9 1 6 2 1/4 1 7 1/8 1 7 — — 8 1 6 315/32 1 115/32 5 4 — — 9 1 7 2 3/8 1 8 3/16 1 7 — — 8 1 7 321/32 1 2 3/16 4 6 — — 10 1 8 2 1/2 1 9 1/4 1 8 — — 9 1 8 327/32 1 215/16 4 6 — — 10 1 9 2 5/8 1 10 5/16 — 9 — — 9 1 9 4 1/32 1 311/16 3 7 — — 10 1 10 2 3/4 1 11 3/8 — 9 1 — 10 1 10 4 7/32 1 4 7/16 3 8 — — 11 1 11 2 7/8 2 0 7/16 — 8 2 — 10 1 11 413/32 1 5 3/16 3 8 — — 11 2 0 3 2 1 1/2 — 8 2 — 10 2 0 419/32 1 515/16 2 9 — — 11 2 1 3 1/8 2 2 9/16 — 8 3 — 11 2 1 425/32 1 611/16 2 10 — — 12 2 2 3 1/4 2 3 5/8 — 7 4 — 11 2 2 5 1 7 7/16 2 10 — — 12 2 3 3 3/8 2 411/16 — 7 4 — 11 2 3 5 3/16 1 8 3/16 1 11 — — 12 2 4 3 1/2 2 5 3/4 — 7 5 — 12 2 4 5 3/8 1 815/16 1 12 — — 13 2 5 3 5/8 2 6 3/16 — 6 6 — 12 2 6 5 3/4 1 10 7/16 — 14 — — 14 2 6 3 3/4 2 7 7/8 — 6 6 — 12 2 8 6 1/8 1 1129/32 — 13 1 — 14 2 7 3 7/8 2 815/16 — 6 7 — 13 2 10 617/32 2 113/32 — 12 3 — 15 2 8 4 2 10 — 5 8 — 13 2 9 4 1/8 2 11 1/16 — 5 8 — 13 3 0 629/32 2 229/32 — 11 5 — 16 2 10 4 1/4 3 0 1/8 — 5 9 — 14 3 2 7 9/32 2 413/32 — 10 6 — 16 2 11 4 3/8 3 1 3/16 — 4 10 — 14 3 4 711/16 2 529/32 — 10 7 — 17 3 6 8 1/16 2 713/32 — 9 9 — 18 3 0 4 1/2 3 2 1/4 — 4 10 — 14 3 8 8 7/16 2 8 7/8 — 8 11 — 19 3 1 4 5/8 3 3 5/16 — 4 11 — 15 3 10 813/16 2 10 3/8 — 7 12 — 19 3 2 4 3/4 3 4 3/8 — 3 12 — 15 3 3 4 7/8 3 5 7/16 — 3 12 — 15 4 0 9 7/32 2 11 7/8 — 7 13 — 20 3 4 5 3 6 1/2 — 3 13 — 16 4 2 919/32 3 1 3/8 — 6 15 — 21 3 5 5 1/8 3 7 9/16 — 2 14 — 16 4 4 931/32 3 2 7/8 — 6 16 — 22 3 6 5 1/4 3 8 5/8 — 2 14 — 16 4 6 10 3/8 3 4 3/8 — 5 17 — 22 3 7 5 3/8 3 911/16 — 2 15 — 17 4 8 10 3/4 3 527/32 — 4 19 — 23 3 8 5 1/2 3 10 3/4 — 1 16 — 17 4 10 11 1/8 3 711/32 — 3 21 — 24 3 9 5 5/8 3 1113/16 — — 17 — 17 3 10 5 3/4 4 0 7/8 — — 18 — 18 5 0 11 1/2 3 827/32 — 3 22 — 25 3 11 5 7/8 4 115/16 — — 18 — 18 5 2 1129/32 3 1011/32 — 2 23 — 25 5 4 1 0 9/32 3 1127/32 — 1 25 — 26 4 0 6 4 3 — — 18 1 19 5 6 1 021/32 4 111/32 — — 27 — 27 4 3 6 3/8 4 6 3/16 — — 18 2 20 5 8 1 1 1/16 4 213/16 — — 27 — 27 4 6 6 3/4 4 9 3/8 — — 18 3 21 5 10 1 1 7/16 4 4 5/16 — — 27 1 28 4 9 7 1/8 5 0 9/16 — — 18 4 22 6 0 1 113/16 4 513/16 — — 27 2 29 5 0 7 1/2 5 3 3/4 — — 18 5 23 6 6 1 231/32 4 10 5/16 — — 27 4 31 5 3 7 7/8 5 615/16 — — 18 6 24 5 6 8 1/4 5 10 1/8 — — 18 7 25 5 9 8 5/8 6 1 5/16 — — 18 8 26 6 0 9 6 4 1/2 — — 18 9 27 6 6 9 3/4 6 10 7/8 — — 18 11 29 IR . 11/2 Inch Rise Per Foot of Span 11/2 Inch Rise Per Foot of Span Number Required Per Course Number Required Per Course Inside Inside Span Rise Span Rise Radius No. 2. 1 and 2 arch brick for the corresponding wedge brick. 2 No. 1. 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.ARCH COMBINATIONS 9 Inch Arch Thickness — 3 Inch Wedge Brick 9 Inch Arch Thickness — 3 Inch Wedge Brick 9 x 4 1/2 x 3. and 3 arch brick for the corresponding wedge brick. 2 No. 1 Radius No. 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch 9 x 4 1/2 x 3. 3 No. 1 Ft In Ft In Total Ft In Ft In Straight Total Ft In Wedge Wedge Wedge Ft In Wedge Wedge 1 6 2 1/4 1 7 1/8 9 1 — 10 5 6 8 1/4 5 10 1/8 10 16 — 26 1 7 2 3/8 1 8 3/16 8 2 — 10 5 7 8 3/8 5 11 3/16 9 18 — 27 1 8 2 1/2 1 9 1/4 8 2 — 10 5 8 8 1/2 6 0 1/4 9 18 — 27 1 9 2 5/8 1 10 5/16 8 3 — 11 5 9 8 5/8 6 1 5/16 8 19 — 27 1 10 2 3/4 1 11 3/8 7 4 — 11 5 10 8 3/4 6 2 3/8 8 20 — 28 1 11 2 7/8 2 0 7/16 7 4 — 11 5 11 8 7/8 6 3 7/16 8 20 — 28 2 0 3 2 1 1/2 7 5 — 12 6 0 9 6 4 1/2 7 21 — 28 2 1 3 1/8 2 2 9/16 6 6 — 12 6 1 9 1/8 6 5 9/16 7 22 — 29 2 2 3 1/4 2 3 5/8 6 6 — 12 6 2 9 1/4 6 6 5/8 7 22 — 29 2 3 3 3/8 2 411/16 6 7 — 13 6 3 9 3/8 6 711/16 6 23 — 29 2 4 3 1/2 2 5 3/4 5 8 — 13 6 4 9 1/2 6 8 3/4 6 24 — 30 2 5 3 5/8 2 613/16 5 8 — 13 6 5 9 5/8 6 913/16 6 24 — 30 2 6 3 3/4 2 7 7/8 5 9 — 14 6 6 9 3/4 6 10 7/8 5 25 — 30 2 7 3 7/8 2 815/16 4 10 — 14 6 7 9 7/8 6 1115/16 5 26 — 31 2 8 4 2 10 4 10 — 14 6 8 10 7 1 5 26 — 31 2 9 4 1/8 2 11 1/16 4 11 — 15 6 9 10 1/8 7 2 1/16 4 27 — 31 2 10 4 1/4 3 0 1/8 3 12 — 15 6 10 10 1/4 7 3 1/8 4 28 — 32 2 11 4 3/8 3 1 3/16 3 12 — 15 6 11 10 3/8 7 4 3/16 4 28 — 32 3 0 4 1/2 3 2 1/4 3 13 — 16 7 0 10 1/2 7 5 1/4 3 29 — 32 3 1 4 5/8 3 3 5/16 2 14 — 16 7 1 10 5/8 7 6 5/16 3 30 — 33 3 2 4 3/4 3 4 3/8 2 15 — 17 7 2 10 3/4 7 7 3/8 3 30 — 33 3 3 4 7/8 3 5 7/16 1 16 — 17 7 3 10 7/8 7 8 7/16 3 31 — 34 3 4 5 3 6 1/2 1 16 — 17 7 4 11 7 9 1/2 2 32 — 34 3 5 5 1/8 3 7 9/16 1 17 — 18 7 5 11 1/8 7 10 9/16 2 32 — 34 3 6 5 1/4 3 8 5/8 — 18 — 18 7 6 11 1/4 7 11 5/8 2 33 — 35 3 7 5 3/8 3 911/16 — 18 — 18 7 7 11 3/8 8 011/16 1 34 — 35 3 8 5 1/2 3 10 3/4 — 17 2 19 7 8 11 1/2 8 1 3/4 1 34 — 35 3 9 5 5/8 3 1113/16 — 17 2 19 7 9 11 5/8 8 213/16 — 36 — 36 3 10 5 3/4 4 0 7/8 — 16 3 19 7 10 11 3/4 8 3 7/8 — 36 — 36 3 11 5 7/8 4 115/16 — 16 4 20 7 11 11 7/8 8 415/16 — 36 — 36 4 0 6 4 3 — 16 4 20 8 0 1 0 8 6 — 36 1 37 4 1 6 1/8 4 4 1/16 — 15 5 20 8 6 1 0 3/4 9 0 3/8 — 36 3 39 4 2 6 1/4 4 5 1/8 — 15 6 21 9 0 1 1 1/2 9 6 3/4 — 36 5 41 4 3 6 3/8 4 6 3/16 — 15 6 21 9 6 1 2 1/4 10 1 1/8 — 36 7 43 4 4 6 1/2 4 7 1/4 — 14 7 21 10 0 1 3 10 7 1/2 — 36 9 45 4 5 6 5/8 4 8 5/16 — 14 8 22 10 6 1 3 3/4 11 1 7/8 — 36 11 47 4 6 6 3/4 4 9 3/8 — 14 8 22 4 7 6 7/8 4 10 7/16 — 13 9 22 11 0 1 4 1/2 11 8 1/4 — 36 13 49 4 8 7 4 11 1/2 — 13 10 23 11 6 1 5 1/4 12 2 5/8 — 36 15 51 4 9 7 1/8 5 0 9/16 — 13 10 23 12 0 1 6 12 9 — 36 17 53 4 10 7 1/4 5 1 5/8 — 12 11 23 12 6 1 6 3/4 13 3 3/8 — 36 19 55 4 11 7 3/8 5 211/16 — 12 12 24 13 0 1 7 1/2 13 9 3/4 — 36 21 57 13 6 1 8 1/4 14 4 1/8 — 36 24 60 5 0 7 1/2 5 3 3/4 — 12 12 24 5 1 7 5/8 5 413/16 — 12 13 25 14 0 1 9 14 10 1/2 — 36 26 62 5 2 7 3/4 5 5 7/8 — 11 14 25 14 6 1 9 3/4 15 4 7/8 — 36 28 64 5 3 7 7/8 5 615/16 — 11 14 25 15 0 1 10 1/2 15 11 1/4 — 36 30 66 5 4 8 5 8 — 11 15 26 5 5 8 1/8 5 9 1/16 — 10 16 26 NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No. Harbison-Walker IR . NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No.55 . 608 Inch (119/32 Inch)Rise Per Foot of Span 1.ARCH COMBINATIONS 9 Inch Arch Thickness — 3 Inch Wedge Brick 9 Inch Arch Thickness — 3 Inch Wedge Brick 9 x 4 1/2 x 3. 1 Radius No. 3 No. 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch 9 x 4 1/2 x 3.608 Inch (119/32 Inch)Rise Per Foot of Span (60o Center Angle) (60o Center Angle) Number Required Per Course Number Required Per Course Inside Inside Span Rise Span Rise Radius No. NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No. and 3 arch brick for the corresponding wedge brick. 2. IR . 1. 2 No. 1 Ft In Ft In Total Ft In Ft In Straight Total Ft In Wedge Wedge Wedge Ft In Wedge Wedge 1 6 2 13/32 1 6 10 — — 10 5 6 8 27/32 5 6 12 15 — 27 1 7 2 17/32 1 7 9 1 — 10 5 7 8 31/32 5 7 11 16 — 27 1 8 2 11/16 1 8 9 2 — 11 5 8 9 1/8 6 8 11 16 — 27 1 9 2 13/16 1 9 9 2 — 11 5 9 9 1/4 6 9 11 17 — 28 1 10 2 15/16 1 10 8 3 — 11 5 10 9 3/8 6 10 10 18 — 28 1 11 3 3/32 2 11 8 4 — 12 5 11 9 1/2 6 11 10 18 — 28 2 0 3 7/32 2 0 8 4 — 12 6 0 9 21/32 6 0 10 19 — 29 2 1 3 11/32 2 1 7 5 — 12 6 1 9 25/32 6 1 9 20 — 29 2 2 3 15/32 2 2 7 6 — 13 6 2 9 29/32 6 2 9 20 — 29 2 3 3 5/8 2 3 7 6 — 13 6 3 10 1/16 6 3 9 21 — 30 2 4 3 3/4 2 4 6 7 — 13 6 4 10 3/16 6 4 8 22 — 30 2 5 3 7/8 2 5 6 8 — 14 6 5 10 5/16 6 5 8 22 — 30 2 6 3 1/32 2 6 5 9 — 14 6 6 10 7/16 6 6 8 23 — 31 2 7 3 5/32 2 7 5 9 — 14 6 7 10 19/32 6 7 7 24 — 31 2 8 4 9/32 2 8 5 10 — 15 6 8 10 23/32 7 8 7 24 — 31 2 9 4 7/16 2 9 4 11 — 15 6 9 10 27/32 7 9 7 25 — 32 2 10 4 9/16 3 10 4 11 — 15 6 10 11 7 10 6 26 — 32 2 11 4 11/16 3 11 4 12 — 16 6 11 11 1/8 7 11 6 27 — 33 3 0 4 13/16 3 0 3 13 — 16 7 0 11 1/4 7 0 6 27 — 33 3 1 4 31/32 3 1 3 13 — 16 7 1 11 3/8 7 1 5 28 — 33 3 2 5 3/32 3 2 3 14 — 17 7 2 11 17/32 7 2 5 29 — 34 3 3 5 7/32 3 3 2 15 — 17 7 3 11 21/32 7 3 4 30 — 34 3 4 5 11/32 3 4 2 16 — 18 7 4 11 25/32 7 4 4 30 — 34 3 5 5 1/2 3 5 2 16 — 18 7 5 11 15/16 7 5 4 31 — 35 3 6 5 5/8 3 6 1 17 — 18 7 6 1 0 1/16 7 6 3 32 — 35 3 7 5 3/4 3 7 1 18 — 19 7 7 1 0 3/16 7 7 3 32 — 35 3 8 5 29/32 3 8 1 18 — 19 7 8 1 0 5/16 7 8 3 33 — 36 3 9 6 1/8 3 9 — 19 — 19 7 9 1 0 15/32 7 9 2 34 — 36 3 10 6 5/32 4 10 — 19 1 20 7 10 1 0 19/32 7 10 2 34 — 36 3 11 6 9/32 3 11 — 18 2 20 7 11 1 0 23/32 7 11 2 35 — 37 4 0 6 7/16 4 0 — 18 2 20 8 0 1 0 7/8 8 0 1 36 — 37 4 1 6 9/16 4 1 — 18 3 21 8 1 1 1 8 1 1 36 — 37 4 2 6 11/16 4 2 — 17 4 21 8 2 1 1 1/8 8 2 1 37 — 38 4 3 6 27/32 4 3 — 17 4 21 8 3 1 1 1/4 8 3 — 38 — 38 4 4 6 31/32 4 4 — 17 5 22 8 6 1 1 21/32 8 6 — 38 1 39 4 5 7 3/32 4 5 — 16 6 22 4 6 7 1/4 4 6 — 16 6 22 9 0 1 2 15/32 9 0 — 38 3 41 4 7 7 3/8 4 7 — 16 7 23 9 6 1 3 9/16 9 6 — 38 5 43 4 8 7 1/2 4 8 — 15 8 23 10 0 1 4 1/16 10 0 — 38 7 45 4 9 7 5/8 5 9 — 15 8 23 10 6 1 4 7/8 10 6 — 38 10 48 4 10 7 25/32 5 10 — 15 9 24 11 0 1 5 11/16 11 0 — 38 12 50 4 11 7 29/32 5 11 — 14 10 24 11 6 1 6 1/2 11 6 — 38 14 52 5 0 8 1/32 5 0 — 14 10 24 12 0 1 7 9/32 12 0 — 38 16 54 5 1 8 3/16 5 1 — 14 11 25 12 6 1 8 3/32 12 6 — 38 18 56 5 2 8 5/16 5 2 — 13 12 25 13 0 1 8 29/32 13 0 — 38 20 58 5 3 8 7/16 5 3 — 13 13 26 13 6 1 9 11/16 13 6 — 38 22 60 5 4 8 9/16 5 4 — 12 14 26 14 0 1 10 1/2 14 0 — 38 24 62 5 5 8 23/32 5 5 — 12 14 26 14 6 1 11 5/16 14 6 — 38 26 64 NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting 15 0 2 0 1/8 15 0 — 38 28 66 No.56 Harbison-Walker . 2 No. 1 and 2 arch brick for the corresponding wedge brick. 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d. 1. 1 Ft In Ft In Total Ft In Ft In Straight Total Ft In Wedge Wedge Wedge Ft In Wedge Wedge 1 10 321/32 1 611/32 12 — — 12 6 0 1 0 5 0 17 13 — 30 1 11 327/32 1 7 5/32 11 1 — 12 6 1 1 0 5/32 5 027/32 16 14 — 30 6 2 1 011/32 5 121/32 16 15 — 31 2 0 4 1 8 11 2 — 13 6 3 1 0 1/2 5 2 1/2 16 15 — 31 2 1 4 5/32 1 827/32 10 3 — 13 6 4 1 021/32 5 311/32 15 16 — 31 2 2 411/32 1 921/32 10 4 — 14 6 5 1 027/32 5 4 5/32 15 17 — 32 2 3 4 1/2 1 10 1/2 10 4 — 14 6 6 1 1 5 5 15 17 — 32 2 4 421/32 1 1111/32 9 5 — 14 6 7 1 1 5/32 5 527/32 15 18 — 33 2 5 427/32 2 0 5/32 9 6 — 15 6 8 1 111/32 5 621/32 14 19 — 33 2 6 5 2 1 9 6 — 15 6 9 1 1 1/2 5 7 1/2 14 19 — 33 2 7 5 5/32 2 127/32 8 7 — 15 6 10 1 121/32 5 811/32 14 20 — 34 2 8 511/32 2 221/32 8 8 — 16 6 11 1 127/32 5 9 5/32 13 21 — 34 2 9 5 1/2 2 3 1/2 8 8 — 16 2 10 521/32 2 411/32 7 9 — 16 7 0 1 2 5 10 13 21 — 34 2 11 527/32 2 5 5/32 7 10 — 17 7 1 1 2 5/32 5 1027/32 12 23 — 35 7 2 1 211/32 5 1121/32 12 23 — 35 3 0 6 2 6 7 10 — 17 7 3 1 2 1/2 6 0 1/2 11 24 — 35 3 1 6 5/32 2 627/32 6 11 — 17 7 4 1 221/32 6 111/32 11 25 — 36 3 2 611/32 2 721/32 6 12 — 18 7 5 1 227/32 6 2 5/32 11 25 — 36 3 3 6 1/2 2 8 1/2 5 13 — 18 7 6 1 3 6 3 10 26 — 36 3 4 621/32 2 911/32 5 14 — 19 7 7 1 3 5/32 6 327/32 10 27 — 37 3 5 627/32 2 10 5/32 5 14 — 19 7 8 1 311/32 6 421/32 10 27 — 37 3 6 7 2 11 4 15 — 19 7 9 1 3 1/2 6 5 1/2 10 28 — 38 3 7 7 5/32 2 1127/32 4 16 — 20 7 10 1 321/32 6 611/32 9 29 — 38 3 8 711/32 3 021/32 4 16 — 20 7 11 1 327/32 6 7 5/32 9 29 — 38 3 9 7 1/2 3 1 1/2 3 17 — 20 3 10 721/32 3 211/32 3 18 — 21 8 0 1 4 6 8 9 30 — 39 3 11 727/32 3 3 5/32 3 18 — 21 8 1 1 4 5/32 6 827/32 8 31 — 39 8 2 1 411/32 6 921/32 8 31 — 39 4 0 8 3 4 2 19 — 21 8 3 1 4 1/2 6 10 1/2 7 33 — 40 4 1 8 5/32 3 427/32 2 20 — 22 8 4 1 421/32 6 1111/32 7 33 — 40 4 2 811/32 3 521/32 2 20 — 22 8 5 1 427/32 7 0 5/32 6 34 — 40 4 3 8 1/2 3 6 1/2 1 21 — 22 8 6 1 5 7 1 6 35 — 41 4 4 821/32 3 711/32 1 22 — 23 8 7 1 5 5/32 7 127/32 6 35 — 41 4 5 827/32 3 8 5/32 1 22 — 23 8 8 1 511/32 7 221/32 5 36 — 41 4 6 9 3 9 — 24 — 24 8 9 1 5 1/2 7 3 1/2 5 37 — 42 4 7 9 5/32 3 927/32 — 23 1 24 8 10 1 521/32 7 411/32 5 37 — 42 4 8 911/32 3 1021/32 — 23 1 24 8 11 1 527/32 7 5 5/32 5 38 — 43 4 9 9 1/2 3 11 1/2 — 22 3 25 4 10 921/32 4 011/32 — 22 3 25 9 0 1 6 7 6 4 39 — 43 4 11 927/32 4 1 5/32 — 21 4 25 9 2 1 611/32 7 721/32 4 40 — 44 9 4 1 621/32 7 911/32 3 41 — 44 5 0 10 4 2 — 21 5 26 9 6 1 7 7 11 2 43 — 45 5 1 10 5/32 4 227/32 — 21 5 26 9 8 1 711/32 8 021/32 1 45 — 46 5 2 1011/32 4 321/32 — 20 6 26 9 10 1 721/32 8 211/32 — 46 — 46 5 3 10 1/2 4 4 1/2 — 20 7 27 5 4 1021/32 4 511/32 — 20 7 27 10 0 1 8 8 4 — 47 — 47 5 5 1027/32 4 6 5/32 — 19 8 27 10 6 1 9 8 9 — 47 2 49 5 6 11 4 7 — 19 9 28 11 0 1 10 9 2 — 47 4 51 5 7 11 5/32 4 727/32 — 19 9 28 12 0 2 0 10 0 — 47 9 56 5 8 1111/32 4 821/32 — 19 10 29 13 0 2 2 10 10 — 47 13 60 5 9 11 1/2 4 9 1/2 — 18 11 29 14 0 2 4 11 8 — 47 17 64 5 10 1121/32 4 1011/32 — 18 11 29 15 0 2 6 12 6 — 47 22 69 5 11 1127/32 4 11 5/32 — 17 13 30 NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No. and 3 arch brick for the corresponding wedge brick. 3 No. 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch 9 x 4 1/2 x 3. 1 Radius No. 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d.ARCH COMBINATIONS 9 Inch Arch Thickness — 3 Inch Wedge Brick 9 Inch Arch Thickness — 3 Inch Wedge Brick 9 x 4 1/2 x 3.57 . 2 No. Harbison-Walker IR . 1. 2. 1 and 2 arch brick for the corresponding wedge brick. 2 No. No. 2 Inch Rise Per Foot of Span 2 Inch Rise Per Foot of Span Number Required Per Course Number Required Per Course Inside Inside Span Rise Span Rise Radius No. 302 Inch (2 5/16 Inch) Rise Per Foot of Span Number Required Per Course Number Required Per Course Inside Inside Span Rise Span Rise Radius No. 15 0 2 1017/32 11 217/32 — 53 18 71 NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting No. 1. 2 No.58 Harbison-Walker . 1 Ft In Ft In Total Ft In Ft In Straight Total Ft In Wedge Wedge Wedge Ft In Wedge Wedge 2 0 419/32 1 515/16 14 — — 14 6 0 1 113/16 4 513/16 22 9 — 31 2 1 425/32 1 611/16 13 1 — 14 6 1 1 2 4 6 9/16 22 9 — 31 2 2 5 1 7 7/16 13 1 — 14 6 2 1 2 3/16 4 7 5/16 22 10 — 32 2 3 5 3/16 1 8 3/16 12 3 — 15 6 3 1 2 3 /8 4 8 1/16 21 11 — 32 2 4 5 3/8 1 815/16 12 3 — 15 6 4 1 219/32 4 813/16 21 12 — 33 2 5 5 9/16 1 911/16 11 4 — 15 6 5 1 225/32 4 9 9/16 20 13 — 33 2 6 5 3/4 1 10 7/16 11 5 — 16 6 6 1 231/32 4 10 5/16 20 13 — 33 2 7 515/16 1 11 5/32 11 5 — 16 6 7 1 3 5/32 4 11 1/32 20 14 — 34 2 8 6 1/8 1 1129/32 10 6 — 16 6 8 1 311/32 4 1125/32 19 15 — 34 2 9 611/32 2 021/32 10 7 — 17 6 9 1 317/32 5 017/32 19 15 — 34 2 10 617/32 2 113/32 10 7 — 17 6 10 1 323/32 5 1 9/32 19 16 — 35 2 11 623/32 2 2 5/32 10 8 — 18 6 11 1 315/16 5 2 1/32 18 17 — 35 3 0 629/32 2 229/32 9 9 — 18 7 0 1 4 1 /8 5 225/32 18 17 — 35 3 1 7 3/32 2 321/32 9 9 — 18 7 1 1 4 5/16 5 317/32 18 18 — 36 3 2 7 9/32 2 413/32 8 11 — 19 7 2 1 4 1 /2 5 4 9/32 17 19 — 36 3 3 715/32 2 5 5/32 8 11 — 19 7 3 1 411/16 5 5 1/32 17 20 — 37 3 4 711/16 2 529/32 7 12 — 19 7 4 1 4 7 /8 5 525/32 16 21 — 37 3 5 7 7/8 2 621/32 7 13 — 20 7 5 1 5 1/16 5 617/32 16 21 — 37 3 6 8 1/16 2 713/32 7 13 — 20 7 6 1 5 9/32 5 7 9/32 16 22 — 38 3 7 8 1/4 2 8 1/8 6 14 — 20 7 7 1 515/32 5 8 1/32 15 23 — 38 3 8 8 7/16 2 8 7/8 6 15 — 21 7 8 1 521/32 5 8 3 /4 15 23 — 38 3 9 8 5/8 2 9 5/8 6 15 — 21 7 9 1 527/32 5 9 1 /2 15 24 — 39 3 10 813/16 2 10 3/8 6 16 — 22 7 10 1 6 1/32 5 10 1/4 14 25 — 39 3 11 9 1/32 2 11 1/8 5 17 — 22 7 11 1 6 7/32 5 11 14 25 — 39 4 0 9 7/32 2 11 7/8 4 18 — 22 8 0 1 613/32 5 11 3/4 14 26 — 40 4 1 913/32 3 0 5/8 4 19 — 23 8 2 1 613/16 6 1 1 /4 13 28 — 41 4 2 919/32 3 1 3/8 4 19 — 23 4 3 925/32 3 2 1/8 3 20 — 23 8 4 1 7 3/16 6 2 3 /4 12 29 — 41 4 4 931/32 3 2 7/8 3 21 — 24 8 6 1 7 9/16 6 4 1 /4 11 31 — 42 4 5 10 5/32 3 3 5/8 3 21 — 24 8 8 1 731/32 6 523/32 11 32 — 43 4 6 10 3/8 3 4 3/8 3 22 — 25 8 10 1 811/32 6 7 7/32 10 34 — 44 4 7 10 9/16 3 5 3/32 2 23 — 25 4 8 10 3/4 3 527/32 2 23 — 25 9 0 1 823/32 6 823/32 9 35 — 44 4 9 1015/16 3 619/32 2 24 — 26 9 2 1 9 3/32 6 10 7/32 8 37 — 45 4 10 11 1/8 3 711/32 1 25 — 26 9 4 1 9 1 /2 6 1123/32 8 38 — 46 4 11 11 5/16 3 8 3/32 — 26 — 26 9 6 1 9 7 /8 7 1 7/32 7 39 — 46 9 8 1 10 1/4 7 211/16 6 41 — 47 5 0 11 1/2 3 827/32 — 27 — 27 9 10 1 10 5/8 7 4 3/16 6 42 — 48 5 1 1123/32 3 919/32 — 26 1 27 5 2 1129/32 3 1011/32 — 26 1 27 10 0 1 11 1/32 7 511/16 5 44 — 49 5 3 1 0 3/32 3 11 3/32 — 26 2 28 10 2 1 1113/32 7 7 3/16 4 45 — 49 5 4 1 0 9/32 3 1127/32 — 25 3 28 10 4 1 1125/32 7 811/16 3 47 — 50 5 5 1 015/32 4 019/32 — 25 4 29 10 6 2 0 3/16 7 10 3/16 3 48 — 51 5 6 1 021/32 4 111/32 — 25 4 29 10 8 2 0 9/16 7 1121/32 2 50 — 52 5 7 1 027/32 4 2 1/16 — 24 5 29 10 10 2 015/16 8 1 5/32 1 51 — 52 5 8 1 1 1/16 4 213/16 — 24 6 30 5 9 1 1 1/4 4 3 9/16 — 23 7 30 11 0 2 1 5/16 8 221/32 — 53 — 53 5 10 1 1 7/16 4 4 5/16 — 23 7 30 11 6 2 215/32 8 7 5/32 — 53 2 55 5 11 1 1 5/8 4 5 1/16 — 23 8 31 12 0 2 3 5 /8 8 11 5/8 — 53 4 57 13 0 2 515/16 9 819/32 — 53 9 62 NOTE: This table can be used also for 131/2 x 9 x 3 inch arch brick by substituting 14 0 2 8 1 /4 10 5 9/16 — 53 13 66 No. 1 and 2 arch brick for the corresponding wedge brick.302 Inch (2 5/16 Inch) Rise Per Foot of Span 2. 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch 9 x 4 1/2 x 3. 2. 3 No. 2 No. IR . 9 x 6 3/4 x 3 or 9 x 9 x 3 Inch–Cont’d. 1 Radius No. 2 and 3 arch brick for the corresponding wedge brick.ARCH COMBINATIONS 9 Inch Arch Thickness — 3 Inch Wedge Brick 9 Inch Arch Thickness — 3 Inch Wedge Brick 9 x 4 1/2 x 3. 1.ARCH COMBINATIONS 12 Inch Arch Thickness — 3 Inch Wedge Brick 12 Inch Arch Thickness — 3 Inch Wedge Brick 12 x 41/2 x 3.608 Inch (119/32 Inch) Rise Per Foot of Span (60° Central Angle) (60° Central Angle) Number Required Per Course Number Required Per Course Inside Inside Span Rise Span Rise Radius No.59 . 1 No. 12 x 6 x 3 or 12 x 9 x 3 Inch 12 x 41/2 x 3. 2 No. 1 No. 1-X Radius No.608 Inch (119/32 Inch) Rise Per Foot of Span 1. 12 x 6 x 3 or 12 x 9 x 3 Inch–Cont’d. 1-X Ft In Ft In Total Ft In Ft In Straight Total Ft In Wedge Wedge Wedge Ft In Wedge Wedge 6 0 921/32 6 0 21 9 — 30 16 0 2 123/32 16 0 30 42 — 72 6 3 10 1/16 6 3 20 11 — 31 16 3 2 2 1/8 16 3 29 44 — 73 6 6 10 7/16 6 6 19 13 — 32 16 6 2 217/32 16 6 28 46 — 74 6 9 1027/32 6 9 18 15 — 33 16 9 2 215/16 16 9 27 48 — 75 7 0 11 1/4 7 0 17 17 — 34 17 0 2 311/32 17 0 25 51 — 76 7 3 1121/32 7 3 16 19 — 35 17 3 2 323/32 17 3 24 53 — 77 7 6 1 0 1/16 7 6 15 21 — 36 17 6 2 4 1/8 17 6 23 55 — 78 7 9 1 015/32 7 9 14 23 — 37 17 9 2 417/32 17 9 22 57 — 79 8 0 1 0 7 /8 8 0 13 25 — 38 18 0 2 415/16 18 0 21 59 — 80 18 3 2 511/32 18 3 20 61 — 81 8 3 1 1 1 /4 8 3 12 27 — 39 18 6 2 5 3/4 18 6 19 63 — 82 8 6 1 121/32 8 6 11 29 — 40 18 9 2 6 5/32 18 9 18 65 — 83 8 9 1 2 1/16 8 9 10 31 — 41 19 0 2 617/32 19 0 17 67 — 84 9 0 1 215/32 9 0 8 34 — 42 19 3 2 615/16 19 3 16 69 — 85 9 3 1 2 7 /8 9 3 7 36 — 43 19 6 2 711/32 19 6 15 71 — 86 9 6 1 3 9/32 9 6 6 38 — 44 19 9 2 7 3/4 19 9 14 73 — 87 9 9 1 311/16 9 9 5 40 — 45 20 0 2 8 5/32 20 0 13 75 — 88 10 0 1 4 1/16 10 0 4 42 — 46 20 3 2 8 9/16 20 3 12 77 — 89 10 3 1 415/32 10 3 4 44 — 48 20 6 2 831/32 20 6 10 80 — 90 10 6 1 4 7 /8 10 6 3 46 — 49 20 9 2 911/32 20 9 10 82 — 92 10 9 1 5 9/32 10 9 1 49 — 50 21 0 2 9 3/4 21 0 9 84 — 93 11 0 1 511/16 11 0 — 51 — 51 21 3 2 10 5/32 21 3 8 86 — 94 11 3 1 6 3/32 11 3 — 50 2 52 21 6 2 10 9/16 21 6 7 88 — 95 11 6 1 6 1 /2 11 6 — 48 5 53 21 9 2 1031/32 21 9 6 90 — 96 11 9 1 6 7 /8 11 9 — 47 7 54 22 0 2 11 3/8 22 0 5 92 — 97 12 0 1 7 9/32 12 0 — 46 9 55 22 3 2 1125/32 22 3 3 95 — 98 12 3 1 711/16 12 3 — 45 11 56 22 6 3 0 3/16 22 6 2 97 — 99 12 6 1 8 3/32 12 6 — 44 13 57 22 9 3 0 9/16 22 9 1 99 — 100 12 9 1 8 1 /2 12 9 — 43 15 58 23 0 3 031/32 23 0 — 101 — 101 13 0 1 829/32 13 0 — 42 17 59 23 3 3 1 3/8 23 3 — 101 1 102 13 3 1 9 5/16 13 3 — 41 19 60 23 6 3 125/32 23 6 — 101 2 103 13 6 1 911/16 13 6 — 40 21 61 23 9 3 2 3/16 23 9 — 101 3 104 13 9 1 10 3/32 13 9 — 39 23 62 24 0 3 219/32 24 0 — 101 4 105 14 0 1 10 1/2 14 0 — 38 25 63 24 3 3 3 24 3 — 101 5 106 14 3 1 1029/32 14 3 — 37 27 64 24 6 3 3 3/8 24 6 — 101 6 107 14 6 1 11 5/16 14 6 — 36 29 65 24 9 3 325/32 24 9 — 101 7 108 14 9 1 1123/32 14 9 — 35 31 66 25 0 3 4 3/16 25 0 — 101 8 109 15 0 2 0 1 /8 15 0 — 34 33 67 25 3 3 419/32 25 3 — 101 9 110 15 3 2 017/32 15 3 — 32 36 68 25 6 3 5 25 6 — 101 10 111 15 6 2 029/32 15 6 — 32 38 70 25 9 3 513/32 25 9 — 101 11 112 15 9 2 1 5/16 15 9 — 31 40 71 Harbison-Walker IR . 1 No. 1-X Ft In Ft In Total Ft In Ft In Straight Total Ft In Wedge Wedge Wedge Ft In Wedge Wedge 6 0 921/32 6 0 27 3 — 30 17 0 2 311/32 17 0 37 39 — 76 6 3 10 1/16 6 3 26 5 — 31 17 3 2 323/32 17 3 36 41 — 77 6 6 10 7/16 6 6 25 7 — 32 17 6 2 4 1/8 17 6 35 43 — 78 6 9 1027/32 6 9 24 9 — 33 17 9 2 417/32 17 9 34 45 — 79 7 0 11 1/4 7 0 22 12 — 34 18 0 2 415/16 18 0 33 48 — 81 7 3 1121/32 7 3 21 14 — 35 18 3 2 511/32 18 3 32 50 — 82 7 6 1 0 1/16 7 6 21 16 — 37 18 6 2 5 3/4 18 6 31 52 — 83 7 9 1 015/32 7 9 20 18 — 38 18 9 2 6 5/32 18 9 30 54 — 84 8 0 1 0 7/8 8 0 19 20 — 39 19 0 2 617/32 19 0 29 56 — 85 8 3 1 1 1/4 8 3 18 22 — 40 19 3 2 615/16 19 3 28 58 — 86 8 6 1 121/32 8 6 17 24 — 41 19 6 2 711/32 19 6 27 60 — 87 8 9 1 2 1/16 8 9 16 26 — 42 19 9 2 7 3/4 19 9 26 62 — 88 9 0 1 215/32 9 0 14 29 — 43 20 0 2 8 5/32 20 0 25 64 — 89 9 3 1 2 7/8 9 3 13 31 — 44 20 3 2 8 9/16 20 3 24 66 — 90 9 6 1 3 9/32 9 6 12 33 — 45 20 6 2 831/32 20 6 23 68 — 91 9 9 1 311/16 9 9 11 35 — 46 20 9 2 911/32 20 9 22 70 — 92 10 0 1 4 1/16 10 0 10 37 — 47 21 0 2 9 3/4 21 0 21 72 — 93 10 3 1 415/32 10 3 9 39 — 48 21 3 2 10 5/32 21 3 19 75 — 94 10 6 1 4 7/8 10 6 8 41 — 49 21 6 2 10 9/16 21 6 18 77 — 95 10 9 1 5 9/32 10 9 7 43 — 50 21 9 2 1031/32 21 9 17 79 — 96 11 0 1 511/16 11 0 6 45 — 51 22 0 2 11 3/8 22 0 16 81 — 97 11 3 1 6 3/32 11 3 5 47 — 52 22 3 2 1125/32 22 3 15 83 — 98 11 6 1 6 1/2 11 6 4 49 — 53 22 6 3 0 3/16 22 6 14 85 — 99 11 9 1 6 7/8 11 9 3 51 — 54 22 9 3 0 9/16 22 9 13 87 — 100 12 0 1 7 9/32 12 0 2 53 — 55 23 0 3 031/32 23 0 12 89 — 101 12 3 1 711/16 12 3 1 55 — 56 23 3 3 1 3/8 23 3 12 91 — 103 12 4 1/2 1 7 29/32 12 4 1/2 — 57 — 57 23 6 3 125/32 23 6 10 94 — 104 12 6 1 8 3/32 12 6 — 56 1 57 23 9 3 2 3/16 23 9 9 96 — 105 12 9 1 8 1/2 12 9 — 55 4 59 24 0 3 219/32 24 0 8 98 — 106 13 0 1 829/32 13 0 — 54 6 60 24 3 3 3 24 3 7 100 — 107 13 3 1 9 5/16 13 3 — 53 8 61 24 6 3 3 3/8 24 6 6 102 — 108 13 6 1 911/16 13 6 — 52 10 62 24 9 3 325/32 24 9 5 104 — 109 13 9 1 10 3/32 13 9 — 51 12 63 25 0 3 4 3/16 25 0 4 106 — 110 14 0 1 10 1/2 14 0 — 50 14 64 25 6 3 5 25 6 2 110 — 112 14 3 1 1029/32 14 3 — 49 16 65 26 0 3 513/16 26 0 — 113 1 114 14 6 1 11 5/16 14 6 — 48 18 66 26 6 3 619/32 26 6 — 113 3 116 14 9 1 1123/32 14 9 — 47 20 67 27 0 3 713/32 27 0 — 113 5 118 15 0 2 0 1/8 15 0 — 46 22 68 27 6 3 8 7/32 27 6 — 113 7 120 15 3 2 017/32 15 3 — 45 24 69 28 0 3 9 28 0 — 113 9 122 15 6 2 029/32 15 6 — 44 26 70 28 6 3 913/16 28 6 — 113 11 124 15 9 2 1 5/16 15 9 — 43 28 71 29 0 3 10 5/8 29 0 — 113 14 127 16 0 2 123/32 16 0 — 41 31 72 29 6 3 11 7/16 29 6 — 113 16 129 16 3 2 2 1/8 16 3 — 40 33 73 30 0 4 0 7/32 30 0 — 113 18 131 16 6 2 217/32 16 6 — 39 35 74 30 6 4 1 1/32 30 6 — 113 20 133 16 9 2 2 15/16 16 9 — 38 37 75 IR . 1-X Radius No.608 Inch (119/32 Inch) Rise Per Foot of Span (60° Central Angle) (60° Central Angle) Number Required Per Course Number Required Per Course Inside Inside Span Rise Span Rise Radius No. 2 No. 13 1/2 x 6 x 3 or 13 1/2 x 9 x 3 Inch 13 1/2 x 9 x 3 Inch – Continued 1.60 Harbison-Walker . 1 No.ARCH COMBINATIONS 13 1/2 Inch Arch Thickness — 3 Inch Wedge Brick 13 1/2 Inch Arch Thickness — 3 Inch Wedge Brick 13 1/2 x 4 1/2 x 3.608 Inch (119/32 Inch) Rise Per Foot of Span 1. 13 1/2 x 6 x 3 or 13 1/2 x 4 1/2 x 3. 2 No.61 .608 Inch (119/32 Inch) Rise Per Foot of Span 1. 1-X Radius No. 1-X Ft In Ft In Total Ft In Ft In Straight Total Ft In Wedge Wedge Wedge Ft In Wedge Wedge 6 3 10 1/16 6 3 32 — — 32 18 0 2 415/16 18 0 45 36 — 81 6 6 10 7/16 6 6 31 2 — 33 18 3 2 511/32 18 3 44 38 — 82 6 9 1027/32 6 9 30 4 — 34 18 6 2 5 3/4 18 6 43 40 — 83 18 9 2 6 5/32 18 9 42 42 — 84 7 0 11 1/4 7 0 28 7 — 35 7 3 1121/32 7 3 27 9 — 36 19 0 2 617/32 19 0 41 44 — 85 7 6 1 0 1/16 7 6 26 11 — 37 19 3 2 615/16 19 3 40 46 — 86 7 9 1 015/32 7 9 25 13 — 38 19 6 2 711/32 19 6 39 48 — 87 19 9 2 7 3/4 19 9 38 50 — 88 8 0 1 0 7/8 8 0 24 15 — 39 8 3 1 1 1/4 8 3 23 17 — 40 20 0 2 8 5/32 20 0 37 52 — 89 8 6 1 121/32 8 6 22 19 — 41 20 3 2 8 9/16 20 3 36 54 — 90 8 9 1 2 1/16 8 9 21 21 — 42 20 6 2 831/32 20 6 35 57 — 92 20 9 2 911/32 20 9 34 59 — 93 9 0 1 215/32 9 0 20 23 — 43 9 3 1 2 7/8 9 3 19 25 — 44 21 0 2 9 3/4 21 0 33 61 — 94 9 6 1 3 9/32 9 6 18 27 — 45 21 3 2 10 5/32 21 3 32 63 — 95 9 9 1 311/16 9 9 17 29 — 46 21 6 2 10 9/16 21 6 31 65 — 96 21 9 2 1031/32 21 9 30 67 — 97 10 0 1 4 1/16 10 0 16 32 — 48 10 3 1 415/32 10 3 15 34 — 49 22 0 2 11 3/8 22 0 29 69 — 98 10 6 1 4 7/8 10 6 14 36 — 50 22 3 2 1125/32 22 3 28 71 — 99 10 9 1 5 9/32 10 9 13 38 — 51 22 6 3 0 3/16 22 6 26 74 — 100 22 9 3 0 9/16 22 9 25 76 — 101 11 0 1 511/16 11 0 12 40 — 52 11 3 1 6 3/32 11 3 11 42 — 53 23 0 3 031/32 23 0 24 78 — 102 11 6 1 6 1/2 11 6 10 44 — 54 23 3 3 1 3/8 23 3 23 80 — 103 11 9 1 6 7/8 11 9 9 46 — 55 23 6 3 125/32 23 6 22 82 — 104 23 9 3 2 3/16 23 9 21 84 — 105 12 0 1 7 9/32 12 0 8 48 — 56 12 3 1 711/16 12 3 7 50 — 57 24 0 3 219/32 24 0 20 86 — 106 12 6 1 8 3/32 12 6 5 53 — 58 24 3 3 3 24 3 19 88 — 107 12 9 1 8 1/2 12 9 4 55 — 59 24 6 3 3 3/8 24 6 18 90 — 108 24 9 3 325/32 24 9 17 92 — 109 13 0 1 829/32 13 0 3 57 — 60 13 3 1 9 5/16 13 3 2 59 — 61 25 0 3 4 3/16 25 0 16 94 — 110 13 6 1 911/16 13 6 1 61 — 62 25 3 3 419/32 25 3 15 96 — 111 13 9 1 10 3/32 13 9 — 63 — 63 25 6 3 5 25 6 14 98 — 112 25 9 3 513/32 25 9 13 100 — 113 14 0 1 10 1/2 14 0 — 62 2 64 14 3 1 1029/32 14 3 — 61 4 65 26 0 3 513/16 26 0 12 103 — 115 14 6 1 11 5/16 14 6 — 60 6 66 26 3 3 6 3/16 26 3 11 105 — 116 14 9 1 1123/32 14 9 — 59 8 67 26 6 3 619/32 26 6 10 107 — 117 26 9 3 7 26 9 9 109 — 118 15 0 2 0 1/8 15 0 — 58 10 68 15 3 2 017/32 15 3 — 57 13 70 27 0 3 713/32 27 0 8 111 — 119 15 6 2 029/32 15 6 — 56 15 71 27 3 3 713/16 27 3 7 113 — 120 15 9 2 1 5/16 15 9 — 55 17 72 27 6 3 8 7/32 27 6 6 115 — 121 27 9 3 8 5/8 27 9 4 118 — 122 16 0 2 123/32 16 0 — 54 19 73 16 3 2 2 1/8 16 3 — 53 21 74 28 0 3 9 28 0 3 120 — 123 16 6 2 217/32 16 6 — 52 23 75 28 3 3 913/32 28 3 2 122 — 124 16 9 2 215/16 16 9 — 51 25 76 28 6 3 913/16 28 6 1 124 — 125 28 9 3 10 7/32 28 9 — 126 — 126 17 0 2 311/32 17 0 — 49 28 77 17 3 2 323/32 17 3 — 48 30 78 29 0 3 10 5/8 29 0 — 126 1 127 17 6 2 4 1/8 17 6 — 47 32 79 29 6 3 11 7/16 29 6 — 126 3 129 17 9 2 417/32 17 9 — 46 34 80 30 0 4 0 7/32 30 0 — 126 5 131 31 0 4 127/32 31 0 — 126 9 135 Harbison-Walker IR .608 Inch (119/32 Inch) Rise Per Foot of Span (60° Central Angle) (60° Central Angle) Number Required Per Course Number Required Per Course Inside Inside Span Rise Span Rise Radius No. 1 No. 1 No.ARCH COMBINATIONS 15 Inch Arch Thickness — 3 Inch Wedge Brick 15 Inch Arch Thickness — 3 Inch Wedge Brick 15 x 6 x 3 or 15 x 9 x 3 Inch 15 x 6 x 3 or 15 x 9 x 3 Inch — Continued 1. 1 No. 2 No. 2 No.608 Inch (119/32 Inch) Rise Per Foot of Span 1. 1-X Radius No. 1-X Ft In Ft In Total Ft In Ft In Total Ft In Wedge Wedge Wedge Ft In Wedge Wedge Wedge 8 0 1 0 7/8 8 0 36 4 — 40 20 0 2 8 5/32 20 0 — 61 29 90 8 3 1 1 1/4 8 3 35 6 — 41 20 3 2 8 9/16 20 3 — 60 32 92 8 6 1 121/32 8 6 34 8 — 42 20 6 2 831/32 20 6 — 59 34 93 8 9 1 2 1/16 8 9 32 11 — 43 20 9 2 911/32 20 9 — 58 36 94 9 0 1 215/32 9 0 31 13 — 44 21 0 2 9 3/4 21 0 — 57 38 95 9 3 1 2 7/8 9 3 30 15 — 45 21 3 2 10 5/32 21 3 — 56 40 96 9 6 1 3 9/32 9 6 29 17 — 46 21 6 2 10 9/16 21 6 — 55 42 97 9 9 1 311/16 9 9 29 19 — 48 21 9 2 1031/32 21 9 — 54 44 98 10 0 1 4 1/16 10 0 28 21 — 49 22 0 2 11 3/8 22 0 — 53 46 99 10 3 1 415/32 10 3 27 23 — 50 22 3 2 1125/32 22 3 — 52 48 100 10 6 1 4 7/8 10 6 25 26 — 51 22 6 3 0 3/16 22 6 — 50 51 101 10 9 1 5 9/32 10 9 24 28 — 52 22 9 3 0 9/16 22 9 — 49 53 102 11 0 1 511/16 11 0 23 30 — 53 23 0 3 031/32 23 0 — 48 55 103 11 3 1 6 3/32 11 3 22 32 — 54 23 3 3 1 3/8 23 3 — 47 57 104 11 6 1 6 1/2 11 6 21 34 — 55 23 6 3 125/32 23 6 — 46 59 105 11 9 1 6 7/8 11 9 20 36 — 56 23 9 3 2 3/16 23 9 — 45 61 106 12 0 1 7 9/32 12 0 19 38 — 57 24 0 3 219/32 24 0 — 44 63 107 12 3 1 711/16 12 3 18 40 — 58 24 3 3 3 24 3 — 43 65 108 12 6 1 8 3/32 12 6 17 42 — 59 24 6 3 3 3/8 24 6 — 42 67 109 12 9 1 8 1/2 12 9 16 44 — 60 24 9 3 325/32 24 9 — 41 69 110 13 0 1 829/32 13 0 15 46 — 61 25 0 3 4 3/16 25 0 — 40 71 111 13 3 1 9 5/16 13 3 14 48 — 62 25 3 3 419/32 25 3 — 39 73 112 13 6 1 911/16 13 6 13 50 — 63 25 6 3 5 25 6 — 38 75 113 13 9 1 10 3/32 13 9 12 52 — 64 25 9 3 513/32 25 9 — 37 78 115 14 0 1 10 1/2 14 0 11 54 — 65 26 0 3 513/16 26 0 — 36 80 116 14 3 1 1029/32 14 3 9 57 — 66 26 3 3 6 3/16 26 3 — 35 82 117 14 6 1 11 5/16 14 6 8 59 — 67 26 6 3 619/32 26 6 — 34 84 118 14 9 1 1123/32 14 9 7 61 — 68 26 9 3 7 26 9 — 33 86 119 15 0 2 0 1/8 15 0 7 63 — 70 27 0 3 713/32 27 0 — 32 88 120 15 3 2 017/32 15 3 6 65 — 71 27 3 3 713/16 27 3 — 31 90 121 15 6 2 029/32 15 6 5 67 — 72 27 6 3 8 7/32 27 6 — 30 92 122 15 9 2 1 5/16 15 9 4 69 — 73 27 9 3 8 5/8 27 9 — 29 94 123 16 0 2 123/32 16 0 2 72 — 74 28 0 3 9 28 0 — 27 97 124 16 3 2 2 1/8 16 3 1 74 — 75 28 3 3 913/32 28 3 — 26 99 125 16 6 2 217/32 16 6 — 76 — 76 28 6 3 913/16 28 6 — 25 101 126 16 9 2 215/16 16 9 — 75 2 77 28 9 3 10 7/32 28 9 — 24 103 127 17 0 2 311/32 17 0 — 74 4 78 29 0 3 10 5/8 29 0 — 23 105 128 17 3 2 323/32 17 3 — 72 7 79 29 3 3 11 1/32 29 3 — 22 107 129 17 6 2 4 1/8 17 6 — 71 9 80 29 6 3 11 7/16 29 6 — 21 109 130 17 9 2 417/32 17 9 — 70 11 81 29 9 3 1113/16 29 9 — 20 111 131 18 0 2 415/16 18 0 — 69 13 82 30 0 4 0 7/32 30 0 — 19 113 132 18 3 2 511/32 18 3 — 68 15 83 30 3 4 0 5/8 30 3 — 18 115 133 18 6 2 5 3/4 18 6 — 67 17 84 30 6 4 1 1/32 30 6 — 17 117 134 18 9 2 6 5/32 18 9 — 66 19 85 30 9 4 1 7/16 30 9 — 16 119 135 19 0 2 617/32 19 0 — 65 21 86 31 0 4 127/32 31 0 — 15 122 137 19 3 2 615/16 19 3 — 64 23 87 31 3 4 2 1/4 31 3 — 14 124 138 19 6 2 711/32 19 6 — 63 25 88 31 6 4 221/32 31 6 — 13 126 139 19 9 2 7 3/4 19 9 — 62 27 89 31 9 4 3 1/32 31 9 — 12 128 140 32 0 4 3 7/16 32 0 — 11 130 141 IR .ARCH COMBINATIONS 18 Inch Arch Thickness — 3 Inch Wedge Brick 18 Inch Arch Thickness — 3 Inch Wedge Brick 18 x 6 x 3 or 18 x 9 x 3 Inch 18 x 6 x 3 or 18 x 9 x 3 Inch — Continued 1. 1 No.608 Inch (119/32 Inch) Rise Per Foot of Span (60° Central Angle) (60° Central Angle) Number Required Per Course Number Required Per Course Inside Inside Span Rise Span Rise Radius No.62 Harbison-Walker . however. Over the years. Installation parameters will differ however. there has been a system is to retain the refractory mass in constant search for improved methods of place. • Type of refractory being installed plastics. Harbison-Walker has compiled the following information as an • Method of refractory installation overview of this complex and important (gunning. systems must be selected and installed to At first. and each operation is subject to unique service conditions. In order to perform this holding these extremely useful products requirement successfully.63 . damaged brickwork. Today. This section provides a partial listing of • Maximum and continuous vessel Harbison-Walker’s anchor products. anchoring in place under varying service conditions. Please contact your Harbison-Walker Marketing Representative at any time for more specific information on the use of ceramic and metallic anchors in your application. Since refractory installations shotcreting) vary. this • Process vessel geometry material is provided only as a guideline.ANCHORING REFRACTORIES Overview This information is presented as a general guide to selection and installation of Harbison-Walker anchors and anchoring systems. bindings or support structure • Exterior insulation • Operating atmosphere or process • Whether or not portions of existing lining remain or brick lining exist Harbison-Walker IR . INTRODUCTION SELECTION GUIDELINES Since castable and plastic refractories The primary function of any anchoring were introduced. or subject. entire installations are lined with castables. • Lining thickness and number of lining As a recognized leader in refractory components technology. • Structural stability of vessel shell. and anchoring has emerged as a technology of its own. operating temperatures Please contact your Harbison-Walker Marketing Representative if you need • Vibration and/or severity of vessel operation additional information. monolithic refractory according to a number of variables technology has expanded far beyond including: simple patchwork. monoliths were typically used for match the service conditions under which the temporary repair of small areas of the process vessels will operate. casting. ramming. 8 or 5 refractory.) 1A 2 to 7 3 ” 16 Walls.8 equals 4. The wire anchors 9x9 1. Wire and Rod Anchor Spacing Wire Anchor Dimensions ¼” AWAY ¾” FROM BEND Locations Lining Anchor Anchor Available Lengths. Then bend movement or gravity impose loads on the flat one of every 100 anchors to insure lining. roofs.44 include color coding anchor by metal 12 x 12 1 type. The inset illustration come in mild steel. through simple installation. Estimating Anchor Quantities Harbison-Walker supplies wire anchors for a broad range of monolithic anchoring Anchor Spacing Anchors/Sq Ft The majority of wire anchor installation linings situations.8 metal washer allows the anchor tines to be presented represent the most commonly spread to retain the block insulation. gunned linings utilize the V-type alloy This figure is generally rounded up wire anchors they provide adequate to the nearest half-inch. require more anchors. stamping Anchor Welding 12 x 18 0. indicates a good weld. A dull thud and areas where vibration.3 details the installation of a 4A wire anchor. 304. Anchor Spacing Welds can be tested by striking half of Distance between anchors should be them with a hammer. The stainless steels. support and holding power for the a 6-inch lining times 0. 4-7 9 2L 1 to 7 Bullnoses 7-9 12 * Lengths vary in ½-inch increments Floors 2-5 9 5-9 15 9+ 24 IR 64 . ¼” 1” Thickness Centers (in)* 1¼” (in. If the test shows poor spacing for various areas is suggested in welds. 2-4 6 1L 1 to 7 Roofs. mechanical indicates a potential failure. Tack welding is Walker also supplies custom made not enough for wire anchors. A ringing sound considered carefully. which will allow heat dissipation by conduction and/or circulation.WIRE ANCHORS Anchor Length Wire Anchors Length of wire anchors should be 0. Metallic components the lining. Typical Spacing Pattern anchors also may require more fillet weld on both sides of the leg. Anchor quantities based on should be based on the temperatures of typical anchor centers are shown in the the lining and should be installed in ways table.Harbison-Walker . nose. 2-4 6 2A 3 to 9 Cylinders. rotating the anchor tines 90° from neighboring anchors. 309 or 310 8x8 2. Edges.) (in. For example. Harbison-Walker wire anchors 6x6 4 are 9 inches thick or less.8 Many anchoring systems for castable and times the thickness of the lining. accompanying illustration. Anchors should be welded in a square pattern.33 used types.67 metal type and supply in special Wire anchors require at least a half inch of packaging upon request. 4-6 9 3A 5 to 15 NOTE: KEEP WELD ¼” AWAY FROM VERTICAL BEND Slopes 6-13½ 12 4A 5 to 11 Overhead. Standard weld does not fail. which also offers economy inches of anchor length. Harbison. Heavier rod anchors to meet special requirements. Other available options 10 x 10 1. multiply the anchors per square temperatures do need exceed foot by the total number of square feet in 2000°F(1904°C). using color plastic tips. weld fillet on both sides. check all the anchors and replace the table below and indicated in the those that fail. Estimating Anchor Quantities Wire anchors are used for most anchor To determine the total number of anchors applications where the service required. 9 x 12 1. The foot provides additional weld strength. the clip permits the first component to be installed before the 3A or 2A anchors are attached and the hot face lining is installed. 310 SS Yellow 1700 Harbison-Walker IR . Also incorporating a foot for added weld strength. An anchor configuration designed for holding power and a foot designed for added weld strength give the 2A the versatility needed for use with high density materials.WIRE ANCHORS Wire Anchors 1A 2A & 3A 1A – This ¼ inch diameter anchor is designed for economical use with linings 5 inches or less. It may also be used with lightweight materials where loads are not high. The plate Maximum Temp of supplied with the anchor is welded to the shell. Expansion 304 SS No Color 1600 and contraction in the lining is assured while the 309 SS Red 1650 lining is retained in place. heavy overhead loads areas subject to movement and vibration. 4A 5A & 6A 3A – This 5/16-inch diameter anchor is a larger version of the 2A. 2L clips have a 1/4. KL – This 3/8 inch diameter anchor is for use in Grades of Steel Required for High Temperature Service rotary kiln linings 4 ½ to 9 inches thick. In lengths from 3 to 10 inches. they are typically used for anchoring in door framings.. pockets and small voids. 1L & 2L Clips – These metal clips are used with the 3A and 2A anchors respectively. A anchors can be used 1L & 2L CLIPS in high density linings 7 inches thick or less and FOR 2A & 3A ANCHORS for lightweight linings. Examples include rotary kiln dams and lifters. 5A & 6A – These ¼ inch and 5/16 inch anchors are typically used for light duty monolithic linings.inch notch for incorporating the 2A anchors. 2A – This ¼ inch diameter anchor can be used for thicker linings where additional holding power is needed. Type of Steel Color Code The tack weld between the plate and the anchor Metallic Components °F can break during operation and thus allow limited Carbon Steel Blue 1000 movement between lining and shell. A washer is furnished with the anchor which permits the anchor tines to be spread after the insulation is in place.65 . available in heights from 13 to 40 inches are typically used in specific applications where massive installations of refractories occur. heavy overhead loads and areas subject to movement or vibration. 7A – The “Christmas Tree” anchor. 1L clips have a 5/16-inch notch for use with the 3A anchor. In the 2 component lining application. The 4A is typically used in KL linings with a total thickness of 4 to 12 inches. corners. for installing 7A 3R 2 component linings. 4A – This ¼ inch diameter anchor is intended for use with monolithic linings with backup insulation. the 3A handles thick dense linings up to 9 inches. 3A-3/8 – This 3/8 inch 3A anchor is designed for dense thick linings from 6 to 16 inches thick. 3A. 7A.Harbison-Walker . 3A-3/8.40" 8" 6 ½" 8 ½" 7" SUGGESTED USE FOR 4A ANCHOR 9" 7" TOTAL TOTAL LENGTH OF UNBENT ANCHOR WITH 9 ½" 7 ½" LINING 1" 1½“ 2” 2½“ 3” 3 ½" 4" 10" 8" THICKNESS Block Block Block Block Block Block Block 10 ½" 8 ½" 4" 4" 4" 11" 9" 4 ½" 4" 4" 4" 12" 9" 5" 4 ½" 4 ½" 4 ½" 4 ½" 12 ½" 10" 5 ½" 5" 5" 5" 4 ½" 4 ½" 13 ½" 10 ½" 6" 5 ½" 5 ½" 5" 5" 5" 6 ½" 6" 6" 5 ½" 5 1½" 5 ½" 5 ½" 7" 6 1/2" 6" 6" 6" 6" 6" 7 ½" 7" 7" 6 ½" 6 ½" 6 ½" 6 ½" 6 ½" 8" 7" 7" 7" 7" 7" 7" 7" 8 ½" 7 ½" 7 ½" 7 ½" 7 ½" 7 ½" 7 ½" 7 ½" 9" 8" 8" 8" 8" 8" 8" 8" 9 ½" 8 ½" 8 ½" 8 ½" 8 ½" 8 ½" 8 ½" 8 ½" 10" 9" 9" 9" 8 ½" 8 ½" 8 ½" 8 ½" 10 ½" 9 ½" 9 ½" 9" 9" 9" 9" 9" 11" 10" 10" 10" 9 ½" 9 ½" 9 ½" 9 ½" 11 ½" 10 ½" 10 ½" 10 ½" 10" 10" 10" 10" 12" 11" 11" 11" 10 ½" 10 ½" 10 ½" 10 ½" 12 ½" 11 ½" 11 ½" 11 ½" 11" 11" 11" 11" 13" 11 ½" 11 ½" 11 ½" 11 ½" 11 ½" 11 ½" 11 ½" 13 ½" 12" 12" 12" 12" 12" 12" 12" IR 66 .48" >13". THICKNESS 5A.WIRE ANCHORS STANDARD WIRE ANCHORS STANDARD WIRE ANCHORS TOTAL TOTAL LINING LINING THICKNESS 1A. 2A. 6A- 2" 1 ½" 3 ½" 3" 3" 2 ½" 2" 4" 3 ½" 3 ½" 3" 2 ½" 4 1/2" 4" 4" 3 ½" 3" 5" 4" 4" 4" 3" 5 ½" 4 ½" 4 ½" 4 ½" 3 ½" 3 ½" 6" 5" 5" 5" 4" 4" 6 ½" 5 ½" 5 ½" 5 ½" 4½" 7" 6" 6" 6" 5" 5" 7 ½" 6" 6" 6 ½" 5" 5" 8" 6 ½" 6 ½" 7" 5 ½" 5 ½" 8 ½" 7" 7" 7 ½" 6" 6" 9" 7 ½" 7" 8" 6 ½" 6 ½" 9 ½" 8" 8" 8 ½" 7" 7" 10" 8" 8" 9" 7” 7" 10 ½" 8 ½" 8 ½" 9 ½" 7½" 7½" 11" 9" 9" 10" 8" 8" 11 ½" 9" 9" 10 ½" 8½" 12" 10" 10" 11" 9" 12 ½" 10" 10" 11 ½" 9" 12" 9½" 12 ½" 10" KL ANCHORS 13" 10 ½" TOTAL 13½" 11" LINING 14" 11" THICKNESS KL- 14½" 11½" 5 ½" 4 ½" 15" 12" 6" 5" 15½" 12½" 13" 7" 5 ½" 16" 13" 7 ½" 6" >16". 1” Min. Working Working Lining Lining Anchor Anchor ½” Form 7/8” Ø Std ½” Form 7/8” Ø Std ½” ½” Board Washer Board Washer 1-L Backup 2-L Backup Anchor Clip Lining Anchor Clip Lining Casing R L 7” Max.67 . 1” Min.WIRE ANCHORS 3A Anchor and 1-L Clip Arrangement 2A Anchor and 2-L Clip Arrangement For 2 Component Cast Lining For 2 Component Cast Lining Hot Face Hot Face 2-A 15½” Max. 5½” Min. 7/8” 7/8 Dim “B” Dim D Dim “A” 1-L CLIP 2-L CLIP Dim C 1-L CLIPS 2-L CLIPS Anchor Dim A Dim B Anchor Dim C Dim D 1-L-1 1 1 11/16 2-L-1 1 1 5/8 1-L-1 1/2 1 1/2 2 3/16 2-L-1 1/2 1 1/2 2 1/8 1-L-2 2 2 11/16 2-L-2 2 2 5/8 1-L-2 1/2 2 1/2 3 3/16 2-L-2 1/2 2 1/2 3 1/8 1-L-3 3 3 11/16 2-L-3 3 3 5/8 1-L-3 1/2 3 1/2 4 3/16 2-L-3 1/2 3 1/2 4 1/8 1-L-4 4 4 11/16 2-L-4 4 4 5/8 1-L-4 1/2 4 1/2 5 3/16 2-L-4 1/2 4 1/2 5 1/8 1-L-5 5 5 11/16 2-L-5 5 5 5/8 1-L-5 1/2 5 1/2 6 3/16 2-L-5 1/2 5 1/2 6 1/8 1-L-6 6 6 11/16 2-L-6 6 6 5/8 1-L-6 1/2 6 1/2 7 3/16 2-L-6 1/2 6 1/2 7 1/8 1-L-7 7 7 11/16 2-L-7 7 7 5/8 1-L-7 1/2 7 1/2 8 3/16 Harbison-Walker IR . 3-A 9½” Max. 3½” Min. Casing R L 6 ½” Max. 50 1-R-3 3. Dim C Shape No.50 1-R-T-4 4.00 1-R-T-3.00 2.5 3.50 1-R-T-5 5.5 11.50 1-R-T-7 7.5 12.50 1-R-6 6.00 5.00 1-R-T-6.50 1-R-5 5.00 1-R or 1-R-T Clip Assembly 3-R-7 7.50 3-R-9 9.00 Dim A 1-R-4.5 3.50 1-R-2 2.5 7.50 1-R-T CLIP Shape No.50 3-R-12 12.00 1-R Clip 1-R-7.00 3.5 2.5 7.00 1-R-6.00 3-R-4 4.5 4.00 3-R-12.5 13.50 3-R-10 10.50 6.5 6.WIRE ANCHORS 3-R Anchor assembly to be used with two component lining (Gunned) 3-R ANCHOR Shape No.5 3.50 3-R-5.5 6.00 3-R-13.5 5.00 1-R CLIP Shape No.00 1-R-5.50 3-R-7.5 7.00 6.5 9.00 3-R-10.50 5.50 Detail of 3-R Anchor and 3-R-6.50 2.5 5.50 3.50 3-R-11 11.5 5.5 1.5 6.00 4.00 Dim C 1-R-T-5.50 3-R-2.50 1-R-4 4.5 10.00 1-R-1.5 8.50 1-R-7 7.00 1-R-3.Harbison-Walker .50 1-R-T-6 6.5 2. Dim D 1-R-1 1.00 1-R-T Clip 1-R-T-7.00 3-R-6 6.00 Dim A 1-R-T-4.00 3-R-3 3. Dim A Dim C 1-R-T-3 3.00 3-R-8 8.00 1-R-2.50 3-R-3.50 3-R-4.50 3-R-14 14.00 3-R-15 15.00 3-R-5 5.00 3-R-8.00 3-R-11.00 3-R-9.5 4.5 4.50 3-R-13 13.50 IR 68 . Dim C Dim C 3-R-2 2.50 4. ) Anchoring Spacing (in. show the combinations of the longest anchor and the shortest metallics for the Ceramic Anchor Systems The portion of the metal hanger which lining thickness shown. power than most metal anchors. require refractory mass for greater holding ceramic anchors directly to the steel shell. They allow for some of stock H-W ceramic anchors are Anchor Brackets and Clips movement of the anchor system during Refractory Anchor Solid (RAS). fired H-W certain amount of movement can occur ceramic anchors are recommended. Harbison-Walker ceramic anchors should be used in all designed to accept C-Clips which are IT-3 Series Beam Hanger installations where temperatures in the welded or bolted to the shell. roof and nose. more anchors. and areas ceramic anchors also provides more CC-Series Anchor Clips (see page IR-72) where vibration. for overhead attachment to standard 3 or 4 being installed. Some 310 Alloy: 1700°F (926°C) 330 Alloy: 1800°F (981°C) Generally. When the Vertical and circular units 9-12 15 ceramic anchor is attached in this 12-15 18 15+ 24 manner. Refractory anchors are normally used in heat-up and subsequent operation. will then be exposed to lower temperatures.7 furnace will routinely exceed 2000°F castings and Ice-Tong Clips for overhead Drop Temperature Limit at this Point 304 Alloy: 1600°F (870°C) (1094°C). H-W ceramic anchors for be IT-3-1. Insulation placed Ice tong anchor clips are designed to selecting anchors made of refractory over the cold face of the roof should not support RAS refractory ceramic anchors materials compatible with the refractory cover the anchor clip. The design of H-W stock carefully. These specs are called of special H-W custom produced castable and plastic refractories are out in the anchor charts. welded to steel shell wall or bolt and nut Lining Thickness "A" duty service range between assembly positioned within Rotary Kiln RAS-Series Refractory Anchor approximately 9 and 19 inches. castable and plastic installations may use U-Series Rod with nut 113/16” refractory lining thicknesses for heavy. it is necessary to specify the size Rotary Kiln Anchor (RKA) and a choice operating temperatures routinely exceed and alloy to be used. ceramic anchors. Slip-On (2 Required per Anchor) 3" I @ 5.) shell or supporting steelwork. the metallic hanger bracket. between the refractory anchor and its metal Refractory Anchor Length and Anchor attachment to accommodate expansion and Spacing Ceramic anchors have several The length of refractory anchors usually advantages over other types contraction of the lining.STANDARD STOCK ANCHORS Harbison-Walker Standard Stock Anchors for Castable and Plastic Refractories REFRACTORY ANCHORS Refractory Anchor Solid (RAS) are ceramic anchors for flat suspended They are available in several metal types roof and wall applications. between anchors should be considered retention. to accommodate a range of service conditions. mechanical movement or surface area in contact with the These are used to attach the RAS refractory gravity impose loads on the lining. When installed.69 . An example would 2000F (1094C). They applications. they are Refractory Anchor with Hole (RAH) are ceramic anchors for wall typically welded to the vessel shell. Edges. Included in the selection –inch I beams. For Anchor that is welded to steel wall. Suggested of anchoring components. primarily for roof the Anchor spacing chart. Harbison-Walker IR . are available in three standard lengths to handle the many lining thicknesses with Rotary Kiln Anchor (RKA) are ceramic anchors for rotary kiln applications standard anchors. monolithic refractory installations where ordering. Roofs. When Refractory Anchor with Hole (RAH). or suspension installations operating at temperatures rod. attachment to a standard I-beam.5-304. The RAS anchor charts and wall applications. Distance face. A these types of constructions. They extend pages illustrate a variety of anchor spacing for ceramic anchors is covered in through the refractory mass to the hot arrangements. providing an extra measure of construction and sidewall installations. The overall length of ceramic anchors Suggested Spacing for Ceramic Refractory Anchors should place the cold face end of the anchor as close as possible to the vessel Locations Lining Thickness (In. The following equals the lining thickness. should remain exposed to ambient air Ice Tong Anchor Clips (see page IR-73) above 2000°F are best served by to permit heat dissipation. noses and arches 6+ 12 which secures it. Most castable and refractory engages the overhead I-beam. 13½ 15 18 Arches 6 .) RAH-7. Horiz.5 105/16 "A" RAS-12 RAH-12 1113/16 RAS-13. Other brands available on a made-to-order basis.5 RAS-10. Anchor 7/8” Diameter (In.5 16 5/16 4" RAS-18 17 13/16 RAS-20 19 13/16 Side View Anchor Spacing Chart Castable Linings RAH Centers Refractory Thickness Location Vert.) Hole Hole (In. Side View (Cut-away) IR 70 .13½ 12 15 & Bullnoses Plastic Linings Top View Walls & Slopes 6 .5 RAS-7.5 13 5/16 RAS-15 1413/16 RAS-16.REFRACTORY ANCHORS RAH & RAS SERIES Refractory Anchor with Hole Series (RAH) for Wall Applications and Refractory Anchor Solid Series (RAS) for Flat Suspended Roof and Wall Applications RAH & RAS-Series Anchor Lengths and Anchor Spacing Selection Charts RAS Refractory Anchor Solid RAH & RAS Series Anchors in 9 Lengths RAH-Series RAS-Series “A” 4 ½" Anchor Anchor (In.Harbison-Walker .13½ 15 18 "A" Arches All Thicknesses 12 12 & Bullnoses Note: Anchors will be stocked in CORAL® BP brands.5 79/16 RAH-9 RAS-9 815/16 Top View RAH-10.) (In.) Walls & Slopes 6 . RAH-Series Refractory Anchor Z-Series ½” Anchor Rod (Comes with Square Nut) Steel Shell ½” (Approx.5 U-2.5 RAH-12 U-1.) 14 RAH-12 U-2 or Z-2 14.5 or Z-1.5 U-2 or Z-2 Steel Shell 13 RAH-10.5 U-3 or Z-3 Refractory Anchor U-Series 13 RAH-12 U-1 or Z-1 ½” Anchor Rod (Comes with 13. Harbison-Walker IR .5 RAH-10.) Anchor Rod 8.5 or Z-1.5 U-3 or Z-3 for RAH & U-Series 10 RAH-9 U-1 or Z-1 Anchor Rod Temperature Limit 10.5 U-1.REFRACTORY ANCHORS RAH-U SERIES RAH & U-Series / Z-Series Anchor Rods Lining Thickness Refractory Anchor (In.71 .5 RAH-9 U-1. Other RAH refractory anchors lengths are available but not for standard stock.5 9.5 C\v" Square Nut Welded to 12.5 U-2 or Z-2 10 RAH-7.5 or Z-2.5 RAH-10.5 or Z-2. (Cut-away) Other sizes of U-Series and Z-Series Rods are available.5 330 Alloy: 1800°F (981°C) 12 RAH-9 U-3 or Z-3 11.5 Square Nut) ½” (Approx.5 RAH-Series 13.5 at this Point 11 RAH-9 U-2 or Z-2 304 Alloy: 1600°F (870°C) 310 Alloy: 1700°F (926°C) 11.5 or Z-1.5 or Z-1.5 or Z-2.5 RAH-10.5 U-2.5 RAH-12 U-2.5 U-1 or Z-1 Lining Thickness 12 RAH-10. and are available on a made to order basis.5 U-1 or Z-1 9 RAH-7.5 RAH-7.5 RAH-9 U-2.5 15 RAH-12 U-3 or Z-3 Steel Shell Note: The combinations above provide the longest anchor Side View and the shortest metallics for the lining thickness shown.5 U-1.5 RAH-7.) Side View (Cut-away) C\v" Square Nut Welded to Steel Shell Ordering Information When ordering U-Series or Z-Series Rods the alloy must be specified (Example U-2-304).5 or Z-2.5 RAH-7.5 Top View 10. 5 CC-0.5 11 RAS-10.5 12.5 RAS-16.5 RAS-15 CC-0.5 14 RAS-13.REFRACTORY ANCHORS RAS & H-W 3184 SERIES 9/16 ” Diameter Hole (Weld or Bolt) Steel Shell Weld Along Both Sides CC-Series Anchor Clip Lining Thickness RAS-Series Refractory Anchor C-Clip Temperature Limit at this Point Front View Side View Front View 304 Alloy: 1600°F (870°C) 310 Alloy: 1700°F (926°C) 330 Alloy: 1800°F (981°C) Lining Refractory Anchor Thickness (In.) Anchor Clip 6 HW-3184 CC-A 6.5 10 RAS-9 CC-1 10.5 CC-0.5 RAS-10.5 (Example CC-1-304).5 14.5 CC-1.5 RAS-18 CC-1.5 18.5 17.5 When ordering CC-Series Anchor Clips the alloy must be specified 15.5 RAS-12 CC-1.5 CC-0.5 RAS-9 CC-1.5 RAS-7.5 CC-1 18 RAS-16.5 RAS-9 CC-0.5 CC-1 12 RAS-10.5 HW-3184 CC-C 7 HW-3184 CC-E 8 RAS-7.5 RAS-15 CC-1.5 RAS-18 CC-0.5 RAS-13.5 Note: The combinations above provide the longest anchor and the shortest metallics for the lining thickness shown.5 9.5 13 RAS-12 CC-1 13.5 CC-1 Ordering Information 15 RAS-13.5 CC-1.5 8. 16 RAS-15 CC-1 16.5 CC-1.5 11.5 RAS-12 CC-0.Harbison-Walker .5 17 RAS-16.5 CC-1 9 RAS-7.5 19 RAS-18 CC-1 19.5 CC-0. IR 72 .5 CC-1. 5 111/16 Hangers 18.5 IT-3-0.5 IT-3-0.5 111/16 11 8.5 11 /16 14.5 111/16 Harbison-Walker IR .5 11 RAS-10.5 111/16 11.7 Temperature Limit at this Point Drop 304 304 Alloy: Alloy: 1600°F 1600°F (870°C) (870°C) 309 310 Alloy: Alloy: 1650°F 1700°F (899°C) (926°C) 310 330 Alloy: Alloy: 1700°F 1800°F (926°C) (981°C) 113/16” Lining Thickness "A" RAS-Series Refractory Anchor Maximum “A” Refractory Anchor Lining Drop (In.REFRACTORY ANCHORS RAS SERIES Refractory Anchor Solid Series (RAS) for Flat Suspended Roof Applications RAS-Series & IT-3 Series Anchor Rod IT-3 Series Beam Hanger (2 Required per Anchor) 3" I @ 5. 19.5 IT-3-0.5 IT-3-0.5 111/16 11 12.5 IT-3-1.5 /16 3 8.5 14 RAS-13.5 IT-3-1.5 /16 10 RAS-12 3 13 IT-3-1 1 /16 13.5 /16 13 RAS-15 3 16 IT-3-1 1 /16 16.73 .5 IT-3-0.5 IT-3-1.5 IT-3-1 13/16 When ordering IT-3 Series Beam 18 IT-3-1.5 /16 3 11.5 111/16 11 9.5 IT-3-1 1 /16 9 IT-3-1.) 11 5.5 IT-3-1.5 /16 Ordering Information 17.5 IT-3-0.5 11 /16 the alloy must 16 RAS-18 3 be specified 19 IT-3-1 1 /16 (Example: IT-3-1.5 111/16 11 14.5 /16 7 RAS-9 10 IT-3-1 3 1 /16 10.5 17 RAS-16.) Anchor Rod (In.5 IT-3-0.5 IT-3-1 13/16 15 IT-3-1.5 IT-3-1 1 /16 12 IT-3-1.5 IT-3-0.5 111/16 11 15.) Thickness (In.5 8 RAS-7.5-304). 5 RAS-16.5 IT-4-1.5 IT-4-1 1 /16 9 IT-4-1. IR 74 .5 11 /16 Temperature Limit 14.5 11.5 111/16 11 15.) 8 IT-4-0.5 IT-4-1.5 111/16 309Alloy: 310 Alloy: 1650°F 1700°F (899°C) (926°C) 330 310Alloy: Alloy:1800°F (981°C) 1700°F (926°C) 18.5 IT-4-1 13/16 12 IT-4-1.7 11 11 IT-4-0.5 111/16 Lining Thickness "A" 14 IT-4-0.5 11 /16 11.REFRACTORY ANCHORS RAS SERIES Maximum Refractory RAS-Series & IT-4 Lining “A” (In.5 111/16 4" I @ 7.5 IT-4-1 13/16 304Alloy: 304 Alloy: 1600°F 1600°F (870°C) (870°C) 18 IT-4-1.5 IT-4-0.5-304).5 RAS-7.5 111/16 Refractory Anchor 17 IT-4-0.5 111/16 Ordering Information When ordering IT-4 Series Beam Hangers the alloy must be specified (Example: IT-4-1.5 IT-4-1.5 RAS-13.5 111/16 11 12.5 IT-4-0.5 3 14.5 /16 Drop 8.5 /16 13 RAS-15 3 16 IT-4-1 1 /16 RAS-Series 16.5 11 /16 16 RAS-18 3 19 IT-4-1 1 /16 19.5 at this Point 17.5 IT-4-0.) Anchor Anchor Rod Drop (In.5 3 8.5 /16 (2 Required per Anchor) 7 RAS-9 10 IT-4-1 3 1 /16 10.5 /16 10 RAS-12 113/16” 13 IT-4-1 13/16 13.5 RAS-10.5 IT-4-1.5 111/16 IT-4 Series 11 Beam Hanger 9.) Series Thickness (In.5 11 /16 Anchor Rod 5.Harbison-Walker .5 IT-4-1 1 /16 15 IT-4-1.5 IT-4-0. 5 17.) Anchor Bolt 6 H-W 3184 HW-878-2½ (152.) (In.5 8.5 RAS-16.5 H-W 3184 HW-878-3 7 H-W 3184 HW-878-3½ HW-3184 Front View Harbison-Walker IR .5 RAS-10.5 Temperature Limit at this Point RNP-1 Beam Hangers 13 16 RAS-15 the alloy must 304Alloy: 304 Alloy: 1600°F 1600°F (870°C) (870°C) 14.4) 6.REFRACTORY ANCHORS RAS & H-W 3184 SERIES RAS-Series & RNP-1 Beam Hanger 3" I @ 5.5 RAS-7.5 Lining Thickness "A" 7 10 RAS-9 RAS-Series 8.5 Refractory Anchor Ordering Information 10 13 RAS-12 When ordering 11.5 14.5 be specified 309Alloy: 310 Alloy: 1650°F 1700°F (899°C) (926°C) 16 19 RAS-18 (Example: RNP-1-304).) Anchor 5.000 6. 310Alloy: 330 Alloy: 1700°F 1800°F (926°C) (981°C) HW-3184 Anchor Assembly Bolt Arrangement Weld Nut To Shell HW-875-2½ Lining Refractory Anchor Thickness (in.7 RNP-1 Beam Hanger Drop 113/16 Maximum 113 /16 Lining “A” Refractory Thickness (In.5 RAS-13.5 11.75 . IR 76 .5 6.5 7.) (In.5 F-38 Carbon Steel Washer. F-260 304 Alloy or 309Alloy: 310 Alloy: 1650°F 1700°F (899°C) (926°C) F-429 310 Alloy) 330 310Alloy: 1800°F Alloy: (981°C) 1700°F (926°C) Ordering Information “A” “B” Clip* (In. X 1/16” O.D.5 12. KAC-3 9 3 KAC-3. Nut (F-95 Carbon Steel) 3" ½ .D. 12 & KAC uses one F-95 Carbon Steel Nut & KAC-2.REFRACTORY ANCHORS RKA SERIES Rotary Kiln Anchor Series (RKA) for Wall Applications Hardware Assembly Data RKA-6/KAC Series "A" ½ .5 KAC-7 13 7 KAC-7.5 13. 9. KAC 6 0 (Example: KAC-2. Other lengths of KAC Clips can be manufactured upon request.5 8.5 KAC-2 8 2 3.5 4. KAC-1.x 4" 1/8” Thick Plastic Washer 3/16” (F-94) for Walls.5 KAC-6 12 6 KAC-6. Roofs. When ordering KAC-Series Clips the alloy must be specified.D.5 1.5 KAC-5 11 5 KAC-5.5 11.D.5 9.5 KAC-4 10 4 KAC-4.5-304) KAC-1 7 1 2.13 UNC-2B Heavy Hex. and Other Static Applications or Bottom View For Use In Rotary Kiln or Other Dynamic Applications RKA-6 Temperature Limit 9/16” I. 10 Ga. Nut (Same Alloy as KAC.) 1.13 UNC-2B Heavy 5/8” Hex.5 7. F-223 304 Alloy or F-129 310 Alloy) Side View Min.x at this Point M\nv" Thick Metal Washer 304Alloy: Alloy: 1600°F (870°C) 304 1600°F (870°C) (Same Alloy as KAC.5 5.5 3. KAC (Cut-away) "B" Series 6 Nominal Clip 9/16” I. x 1 3/8" O.5 KAC-8 14 8 KAC-9 15 9 *See Ordering Information at Left. Pl. RKA-6.5 10.5 2.Harbison-Walker . 5 11.REFRACTORY ANCHORS RKA/KAC SERIES RKA-9/KAC Series RKA-12/KAC Series "A" "A" 5/8 5/ 8” 3" 3" Side View Side View (Cut-away) (Cut-away) "B" "B" 9 Nominal 12 Nominal 4" 4" Bottom View Bottom View Temperature Limit RKA-9 Temperature Limit at this Point at this Point RKA-12 304Alloy: 304 Alloy: 1600°F 1600°F (870°C) (870°C) 309Alloy: 310 Alloy: 1650°F 1700°F (899°C) (926°C) 304Alloy: 304 Alloy: 1600°F 1600°F (870°C) (870°C) 330 310Alloy: 1800°F Alloy: (981°C) 1700°F (926°C) 309Alloy: 310 Alloy: 1650°F 1700°F (899°C) (926°C) 330 310Alloy: Alloy:1800°F (981°C) 1700°F (926°C) Clip* “A” “B” Clip* “A” “B” (In.5 10. F-38 Carbon Steel Washer.5 KAC-5.5 4.5 16.5 KAC-2.5 2. Other lengths of KAC Clips can be manufactured upon request. Other lengths of KAC Clips can be manufactured upon request.5 5. (Example: KAC-2.) KAC 9 0 KAC 12 0 KAC-1 10 1 KAC-1 13 1 KAC-1.5 13. 12 & KAC uses one F-95 Carbon Steel Nut & 3. When ordering KAC-Series Clips the alloy must be specified.5 2.) (In.5 5.5-304) (Example: KAC-2.77 .5 7.5 15.5 KAC-1. Harbison-Walker IR .5 KAC-3 12 3 KAC-3 15 3 KAC-3.5 KAC-2 11 2 KAC-2 14 2 KAC-2.5 17. When ordering KAC-Series Clips the alloy must be specified.5 KAC-6 15 6 KAC-6 18 6 KAC-7 16 7 KAC-7 19 7 KAC-7.5 4.5 3. 9.5 14.5-304) 2.5 19. 3. 1.) (In.5 1.) (In.5 KAC-5 14 5 KAC-5 17 5 KAC-5.5 13. 9.5 7. 12 & KAC uses one F-95 Carbon Steel Nut & F-38 Carbon Steel Washer. RKA-6.5 16.5 KAC-8 17 8 KAC-8 20 8 KAC-9 18 9 KAC-9 21 9 Ordering Information Ordering Information 1.5 14.5 KAC-4.5 3.5 12.5 KAC-4 13 4 KAC-4 16 4 KAC-4.5 1. RKA-6.5 KAC-7.5 KAC-3. 2. ) 3 3 3 Vertical and circular units 9-12 15 12-15 18 S-191-083 S-191-082 S-191-084 4¾ 2 15+ 24 Roofs. Other available roof anchor (Below) In some plastic and castable assemblies include the S-191-075 installations where vessel geometry. 5. Dim A Dim B Typical Support Member 9 19/32 ” HW-20-247-F 1¼” 1¼” 6 11/16" 3 15/16" 3 or 4-inch I-beam HW-20-247-F-90 HW-20-249-F 8 9/16" 5 13/16" 3 or 4-inch I-beam 3” HW-20-249-F-90 4¾” 3” HW-20-2412-F 11 7/16" 8 11/16" 3 or 4-inch I-beam HW-20-2412-F-90 S-191-082.CUSTOM ANCHORS Roof Anchors Harbison-Walker supplies a variety of pre-welded metal anchor assem- blies referred to as the HW 20 Series. Bullnose Anchors Pre-welded metal anchor assemblies can be used where the (Above) Illustration shows three different metal anchors as used for shell geometry does not allow for roof construction. 41/8 61/8 91/8 Suggested Spacing for Ceramic Refractory Anchors Locations Lining Thickness (In. S-191-083. S-191-084 the use of wire or ceramic anchors special nose anchors shown below.7 pounds per foot. An example of this Contact your local H-W usage is the bull nose representative for more detailed configuration illustrated. wire anchors to be used. noses and arches 6+ 12 IR 78 . These are pipes or I-beams and extend into the generally fabricated from 310ss.) Anchoring Spacing (in. 4-inch I-beam. Although these assembles are adaptable for wall construction.3 &4 11/8 HW-20-548-F 9 3/4" 7" 5-inch I-beam HW-20-548-F-90 15/8 15/8 15/8 3-inch I-beam. suspended from supporting steel- work. they are most often used in roofs.7 pounds per foot 1¼ 1¼ 1¼ “90” assembly indicates anchor shank is turned 90 degrees to assembly without “90” ½ Dia. 7. The metallic anchors conventional ceramic anchor or are suspended from overhead rods.Harbison-Walker . S-191-075 41/8” 17/32 ” 111/16 ” 17/32 ” 1½” 13/16 ” Special Roof Anchors 513/32” ½” Dia. refractory mass to within approxi- mately one inch of the vessel’s hot Special Roof Anchors face. ½” Dia. impractical. Assembly No. metal anchors can be used. anchor drawings. pre-welded assembly and the loading or other considerations make S-191-082. 1” 10” MH-204 2” 11” MH-302 2½” 11½” MH-400 3” 12” MH-402 3½” 12½” MH-500 4½” 13½” MH-600 5” 14” MH-608 Harbison-Walker IR .79 . 1” 5½” MH-100 1½” 6” MH-200 2” 6½” MH-205 2½” 7” MH-300 3” 7½” MH-301 3½” 8” MH-401 4” 8½” MH-403 4½” 8½” MH-501 5½” 10” MH-601 6” 10½” MH-607 B-21280 & B-2180-3 Anchor Assembly NOTE: To insure proper location of B-2180 anchors.ANCHORS TIE BACK SYSTEM B-43401 & B-43401-3 Anchor Assembly NOTE: To insure proper location of brick anchors. weld F-21 clip to steel shell as brickwork progress. “A” “B” PART NO. weld F-21 clip to steel shell as brickwork progress. “A” “B” PART NO. Wall seats are available in lengths from 5 to 10 inches. Please review these For Tie-Back Brick arrangements with your Harbison-Walker representative. and are dependent on structural and load Lining Metal Arrangements Thickness considerations. ports or bull noses that might collapse under heavy loading. IR 80 . HW-4053 3 HW-4053-15 15 13½ Tie-back brick may be located at intervals as close as 12 inches on the HW-4053-18 18 16½ A vertical and 2 to 3 feet on the horizontal. Consider wall seats when using a dense monolith over 6 inches thick and /or 4 feet or more in height.ANCHORS TIE BACK SYSTEM HW-4053– Wall Tie-Back Brick– Tie Back Brick HW-4053 In large refractory brick walls or those Arrangement Shape Lining subject to particularly severe operational Number Thickness A problems. tie-back brick are used to help HW-4053-6 6 4½ maintain the structural integrity of the brick wall. HW-4053 3 HW-4053-12 12 10½ Tie-back plates and clip assembly HW-4053-13½ 13½ 12 (S-191-038/039) are used. Assembly wall seat assemblies like H-W WS Wall Seat with WSC Clip’s should be used where extremely heavy vertical or sloping wall loads are encountered. Wall seat are also important in areas above arches.Harbison-Walker . Harbison-Walker supplies the HW-4053-9 9 7½ HW-4053 brick shape in several HW-4053-10½ 10½ 9 refractory compositions and lengths. The HW WSC can be welded to the vessel shell. S-191-038 S-191-039 S-191-036 Wall Seat Assembly Wall Seat To reduce the stresses placed on anchors. The tapered design helps wedge the refractory lining in addition to the tongues and grooves.81 . -90-N and longer. There are Harbison-Walker IR .NON-STANDARD CREAMIC ANCHORS & “V” METALLIC ANCHORS “V” Metallic Anchor Series (VS) and (QVS) for Roof and Wall Applications VS and QVS Series "C" 876 Series TC Series "A" "B" 60˚ VS or QVS Series with Welded Nut Bolting “VS” & “QVS” (-N-Series) anchors. The ceramic anchor systems shown here “VS”-15 thru -80 (-N-Series) anchors are 5/16” diameter rod. TI Series Refractory tapered anchors for use in wall construction. TC Series (Example VS-50-N-304) Refractory tapered anchor for use in roof construction. This is primarily a roof and bullnose anchor. ordered. use 3/8” diameter bolt or stud. Standard stock ceramic anchors are available in the RAS. -80-N and smaller. Cross refrerence chart is on page IR-82 this anchor accepts a variety of C-Clip and slipover castings. They provide flexible attachment to accommodate lining thicknesses from 9 to 18 inches. use ½” diameter bolt or stud. “VS” & “QVS” (-N-Series) anchors.) RKA series. RAH and Dimension Table (In. When ordering “VS” & “QVS” (-N-Series) anchors alloy must be specified. Made in UFALA® brand. Available in UFALA® brand. but this anchor may be used VS-50/45 QVS-50/45 VS-50 QVS-50 5 4 1 in wall construction applications with the VS-60/55 QVS-60/55 VS-60 QVS-60 6 4 2 use of C-Clips. Primary use is in roof VS-40/35 QVS-40/35 VS-40 QVS-40 4¼ 3½ ¾ construction. depending on applica- tion. Note: These anchors are not standard stock. are nonstandard systems that can be “VS”-90 thru -200 (-N-Series) anchors are 3/8” diameter rod. WC Series TI Anchor Rod Diameters “QVS”-15 thru -100 (-N-Series) anchors are all ¼” diameter rod. Brand Brand Brand Brand “A” “B” “C” VS-15/10 QVS-15/10 VS-15 QVS-15 1½ 1½ Ceramic Anchors VS-20/15 QVS-20/15 VS-20 QVS-20 21/8 21/8 VS-25/20 QVS-25/20 VS-25 QVS-25 25/8 25/8 876 Series VS-30/25 QVS-30/25 VS-30 QVS-30 31/8 31/8 Refractory anchor designed to accept VS-35/30 QVS-35/30 VS-35 QVS-35 35/8 25/8 1 slipover castings. these anchors are attached with Z- RODS to the sidewall. VS-70/65 QVS-70/65 VS-70 QVS-70 7 4 3 VS-80/75 QVS-80/75 VS-80 QVS-80 8 4 4 WC Series VS-90/85 QVS-90/85 VS-90 QVS-90 9 4 5 Refractory wiggle anchor made in VS-100/95 QVS-100/95 VS-100 QVS-100 10 5 5 UFALA® brand only. This anchor VS-110/105 VS-110 11 6 5 maintains a constant cross section of 4½" VS-120/115 VS-120 12 6 6 x 4½". VS-50/45 VS-50 QVS-50/45 QVS-50 5 3A-6 /16” DIA.CROSS REFERENCE Cross Reference Table for Single Component Wire Anchors H-W ANCHOR ANCHOR DIA. VS-25/20 VS-25 QVS-25/20 QVS-25 1A-3 ¼” DIA.Harbison-Walker . VS-15/10 VS-15 QVS-15/10 QVS-15 1A-2 ¼” DIA.3/8 3 /8” DIA. VS-60/55 VS-60 QVS-60/55 QVS-60 5 3A-7 /16” DIA. VS-80/75 VS-80 QVS-80/75 QVS-80 3A-9. IR 82 .3/8 3 /8” DIA.3/8 3 /8” DIA.3/8 3 /8” DIA.3/8 3 /8” DIA. VS-110/105 VS-110 3A-12. VS-90/85 VS-90 QVS-90/85 QVS-90 3A-10. VS-30/25 VS-30 QVS-30/25 QVS-30 2A-3 ½ ¼” DIA. VS-100/95 VS-100 QVS-100/95 QVS-100 3A-11. BRAND BRAND BRAND BRAND 1A-1 ½ ¼” DIA. VS-120/115 VS-120 3A-12 ½. 3A-13. VS-40/35 VS-40 QVS-40/35 QVS-40 5 2A-5 /16” DIA.3/8 3 /8” DIA. VS-20/15 VS-20 QVS-20/15 QVS-20 1A-2 ½ ¼” DIA. VS-70/65 VS-70 QVS-70/65 QVS-70 3 3A-8 /8” DIA. VS-35/30 VS-35 QVS-35/30 QVS-35 2A-4 ¼” DIA. SECTION 8 Appendix Area and Volume A-1 Reference Tables A-7 Decimal Fractions Atomic Weights Melting Points Conversion Tables Temperature Conversion Glossary A-13 H-W Distribution Centers A-21 Standard Terms Of Sales A-22 . 3137r2 6 6. No matter how complex the shape of a figure.8284s2 = 3.5981s2 = 3.2154r2 Harbison-Walker A .1818s2 = 3. Volumes of shells are inside volume subtracted from outside volume.2492r2 12 11.1962s2 = 3.2757r2 10 7.AREA AND VOLUME The following simple formulas make it possible to calculate the area and volume associated with most refractory structures.4641r2 6 4.1 .6942s2 = 3. Volumes of regular figures will equal the area of a surface multiplied by its length or height. RECTANGLE PARALLELOGRAM a b a b a Area = ab Area = ab TRIANGLE b b a d a d c c Area = 1/2cd Area = s(s–a) (s–b) (s–c) when s = 1 /2 (a + b+ c) TRAPEZIUM REGULAR POLYGON s r e d b a c Area = 1/2 nsr Area = 1/2 [s(e+d)+bd+ce] when n = Number of sides Number of Sides Area 6 2. it is possible to derive a working approximation by dividing it by straight lines and arcs into a distinct number of units whose areas may be calculated and summed by simple arithmetic. 296˚ SEGMENT OF A CIRCLE SECTOF OF A CIRCLE L L h θ θC R R 2h Area = 1/2 LR Tangent 1/4 θ = C θ Area = 1/2 [LR–C(R–h)] Area = πR2 x 360 θ C(R–h) Area = πR2 x Area = 0.AREA AND VOLUME CIRCLE L h θ C R D θ (Theta) = included angle in degrees.648L÷R Radius. R = Circumference ÷2π 1/2 θ = 28.017453R θ Radius. D = 2R = 2 Area ÷ π θ Length of Arc. R = (C ÷ 2)2+h2 Sine 1/2 θ = C÷2R 2h 1˚ = 0. h = R –1/2 (2R+C) (2R–C) Diameter. 1 radian = 57.0087266R2 θ 360 2 A -2 Harbison-Walker . R = 1/2 D = Area ÷π 360 0. h = R – R2 –(C÷2)2 πD = 2πR = 2 π x Area Height of Arc.1416 Chord.017453 Radians. Area = 0.7854D2 = πR 2 π (pi) = 3. L = x 2πR = Radius. C = 2 h(D–h) = 2R x sine 1/2 θ Circumference = Height of Arc. 5708r(4h+ c) 2πrh = 0.2832rh h Total Surface = 2πr(r+ h) = 6.0944r2h Total Surface = 0.3 .7854(c2+4h2) Volume = 2/3 πr2h = 2.1309h(3c2 +4h2) CYLINDER Volume = πh2(3r –h) = 1.2832r(r+ h) Volume = r πr2h = 1/4 πd2h = 0.0472h2(3r– h) Cylindrical Surface = πdh = 2πrh = 6.7854d2h d Harbison-Walker A .AREA AND VOLUME THE TRAPEZOIDAL RULE y0 y1 y2 y3 y4 Area = h(1/2 y0+ y1+y2 + y3+1/2y4) approximately h = distance between equally spaced ordinates h h h h yn = length of appropriate ordinate SEGMENT OF A SPHERE SEGTOR OR A SPHERE c c h h r r Spherical Surface = Total Surface = 1.0472h2(3r– h) Volume = 1/24 πh(3c2 +4h2) = 0.7854(c +8rh) 2 Volume = 1/3 πh2(3r –h) = 1. 7854(D+d) (D—d) ELLIPSE PARABOLIC SEGMENT b h s a Area = πab = 3.5236d3 RING OF CIRCULAR CROSS SECTION (Torus) R d r D Area of Surface = 4π2Rr = 39.4 Harbison-Walker .1073C2 Area = 0.566r2 = πd2 Volume = 4/3 πr3 = 4.739Rr2 A .1416ab Area = 2/3 sh SPHERE d r Surface = 4πr2 = 12.2146R2 Area = 0.7854(D2— d2) Area = 0.1888r3 Volume = 1/6 πd3 = 0.AREA AND VOLUME SPANDREL CIRCULAR RING R D C d Area = 0.478Rr Volume = 2π2Rr2 = 19. 2618d2h d Harbison-Walker A .0472r2h = 0.5 .AREA AND VOLUME PYRAMID A = area of base P = perimeter of base h s Lateral Area = 1/2 Ps Volume = 1/3 Ah FRUSTUM OF A PYRAMID A = Area of base a = Area of top m = Area of midsection h s P = Perimeter of base p = Perimeter of top Lateral Area = 1/2 s(P+p) Volume = 1/3 h(a +A+ aA) Volume = 1/6 h(a +A+4m) CONE r Conical Area = πrs = πr r2 +h2 s h Volume = 1/3 πr2 h = 1. AREA AND VOLUME FRUSTUM OF A CONE A = Area of base a = Area of top d m = Area of midsection r Area of Conical Surface = 1/2 πs(D+d) s h Volume = 1/3 πh(r2 +rR +R2) Volume = h(a + aA +A) R Volume = 1/6 h(a +4m +A) D A .6 Harbison-Walker . 078125 37/64 .703125 7/32 .546875 1/16 .03125 17/32 .171875 43/64 .828125 11/32 .125 5/8 .578125 3/32 .7 .015625 33/64 .6875 13/64 .390625 57/64 .921875 7/16 .3125 13/16 .8125 21/64 .515625 1/32 .53125 3/64 .5625 5/64 .671875 3/16 .09375 19/32 .78125 19/64 .875 25/64 .625 9/64 .109325 39/64 .453125 61/64 .25 3/4 .890625 13/32 .359375 55/64 .796875 5/16 .328125 53/64 .59375 7/64 .90625 27/64 .0625 9/16 .484375 63/64 .234375 47/64 .203125 45/64 .4375 15/16 .296875 51/64 .046875 35/64 .75 17/64 .640625 5/32 .953125 15/32 .71875 15/64 .140625 41/64 .859375 3/8 .375 7/8 .40625 29/32 .984375 Harbison-Walker A .84375 23/64 .28125 25/32 .65625 11/64 .1875 11/16 .REFERENCE TABLE Decimal Fractions of an Inch for Each 1/64 Common Common Decimal Decimal Fraction Fraction 1/2 .34375 27/32 .96875 31/64 .265625 49/64 .765625 9/32 .21875 23/32 .46875 31/32 .9375 29/64 .5 1/64 .609375 1/8 .734375 1/4 .15625 21/32 .421875 59/64 . 9045 Iron Fe 26 55.08 Carbon C 6 12.0067 Oxygen O 8 15.69 Titanium Ti 22 47.90 Tungsten W 74 183.94 Neon Ne 10 20.9898 Sulfur S 16 32.30 Zinc Zn 30 65.9984 Gold Au 79 196.38 Zirconium Zr 40 91.17 Nickel Ni 28 58.80 Lead Pb 82 207.9815 Antimony Sb 51 121.9216 Barium Ba 56 137.904 Cadmium Cd 48 112.9380 Mercury Hg 80 200.59 Molybdenum Mo 42 95.9994 Phosphorous P 15 30.40 Calcium Ca 20 40.305 Manganese Mn 25 54.2 Lithium Li 3 6.8 Harbison-Walker .0079 Iodine I 53 126.996 Cobalt Co 27 58.09 Potassium K 19 39.868 Sodium Na 11 22.9665 Helium He 2 4.34 Beryllium Be 4 9.01218 Bismuth Bi 83 208.011 Chlorine Cl 17 35.08 Silver Ag 47 107.22 *International Atomic Weights (1970).REFERENCE TABLE Atomic Weights of Selected Elements* Atomic Name Symbol Weight Number Aluminum Al 13 26.9414 Xenon Xe 54 131.003 Hydrogen H 1 1. A .54 Fluorine F 9 18.098 Silicon Si 14 28.029 Vanadium V 23 50.9738 Platinum Pt 78 195.85 Uranium U 92 238.941 Magnesium Mg 12 24.75 Argon Ar 18 39.70 Nitrogen N 7 14.453 Chromium Cr 24 51.9806 Boron B 5 10.9332 Copper Cu 29 63.948 Arsenic As 33 74.84 Krypton Kr 36 83.81 Bromine Br 35 79.06 Tin Sn 50 118. 6 Beryllium 2341 1283 1556 Cadmium 609. ~ = Approximate. pure 2795 1535 1809 Cast iron.9 505.6 320.0 1336.5 Molybdenum ~4750 ~2620 ~2892 +10 Nickel 2647 1453 1744 Palladium 2826 1552 1827 Platinum 3216 1769 2045 Rhodium 3560 1960 2236 Silver 1761. Harbison-Walker A .9 594.1 327.300°F are given to the nearest five degrees.3 600.08 Tantalum 5425 2996 3258 +10 Tin 449.5 692.5 903.9 .9 630.1 419.4 231. white ~2100 ~1150 ~1423 Cast iron.58 Magnesium 1202 650 922+0.2 Iridium 4430 2443 2727 Iron.8 1235.4 960. gray ~2245 ~1230 ~1503 Steel.73 Zirconium ~3360 ~1850 2125 +20 Melting Points of Selected Mineral Oxides* Chromic Oxide (Cr2O3) ~4080 ~2250 2603 +15 Corundum (Al2O3) ~3720 ~2050 2327 +6 Cristobalite (SiO2) 3133 1723 1996 +5 Lime (CaO) ~4660 ~2570 ~3200+ 50 Magnetite (Fe3O4) 2901 1594 1864 +5 Periclase (MgO) ~5070 ~2800 3098+ 20 Rutile (TiO2) 3326 1830 2130 +20 Zirconia Unstabilized (ZrO2) 4890 2700 3123 5% Calcia stabilized (ZrO2) 4710 2599 ~2872 7% Calcia stabilized (ZrO2) 4532 2500 ~2773 * In converting temperatures from Centigrade to Fahrenheit.1181 Titanium ~3034 ~1668 1933 +10 Tungsten 6115 3380 3660 +20 Uranium 2071 1133 Vanadium ~3450 ~1900 ~2190 Zinc 787. plain carbon (1% carbon and less) ~2680 ~1470 Lead 621.4 1063.REFERENCE TABLE Melting Points of Selected Metals and Alloys* Degrees Degrees Degrees Fahrenheit Centigrade Kelvin Aluminum 1220 660 933 Antimony 1166. temperatures above 3.6 Gold 1945.258 Chromium ~3445 ~1895 2130 Cobalt 2718 1492 1768 Columbium 4380 2415 2743 Copper (reducing atmosphere) 1981 1083 1366. 832 x 10-2 cubic meters cubic feet 3.3048 meters feet 3.531 x 10-5 cubic feet cubic centimeters 6.0 x 103 liters cubic meters 2.52 x 10-1 kilogram-calories BTU/Hr 7.134 cubic feet gallons 3.048 x 102 millimeters gallons 3.39 cubic centimeters cubic inches 5.REFERENCE TABLE Conversion Table To Convert Multiply By: To Obtain: BTU 7.937 x 10-2 inches cubic centimeters 3.143 x 10-5 cubic yards cubic meters 35.787 x 10-4 cubic feet cubic inches 1.527 x 10-2 ounces (avdp.281 x 10-2 feet centimeters 3.7646 cubic meters °Fahrenheit . liquid) cubic centimeters 1.646 x 105 cubic centimeters cubic yards 27 cubic feet cubic yards 0.556(F-32) Centigrade or Celsius feet 30.102 x 10-2 cubic inches cubic centimeters 1.728 x 103 cubic inches cubic feet 2.48 centimeters feet 0.785 liters grams 3.785 x 10-3 cubic meters gallons 4.102 x 104 cubic inches cubic meters 1.31 cubic feet cubic meters 6.0481 pounds/sq/ft grams-calories 3.968 x 10-3 BTU A .642 x 10-4 gallons (U.8) + 32 Fahrenheit centimeters 3.308 cubic yards cubic meters 1.832 x 104 cubic centimeters cubic feet 1.10 Harbison-Walker .43 pounds/ft3 grams/cm2 2.S.52 x 102 gram-calories BTU 2.785 x 103 cubic centimeters gallons 0.0 x 10-3 liters cubic feet 2.639 x 10-5 cubic meters cubic inches 2.308 x 10-6 cubic yards cubic centimeters 2. liquid) cubic yards 7.205 x 10-3 pounds grams/cm3 62.S.951 x 10-3 cubic yards gallons 3.642 x 102 gallons (U.7816 x 102 foot-pounds BTU 2.0 x 10-2 gram-cal/sec °C (°C x 1.704 x 10-2 cubic yards cubic inches 16.) grams 2. 602 x 10-2 grams/cm3 pounds/ft3 16.464 x 102 cubic centimeters quarts (liquid) 3.609 kilometers millimeters 3.531 x 10-2 cubic feet liters 61.452 square centimeters tons (metric) 1000 kilograms tons (metric) 2.9144 meters Harbison-Walker A .29 x 102 square centimeters square inches 6.238 x 10-3 cubic yards quarts (liquid) 0.9078 tons (metric) yards 0.9463 liters square centimeters 0.REFERENCE TABLE Conversion Table .937 x 10-2 inches ounces 28.11 .205 x 103 pounds tons (short) 9.02 cubic inches liters 1.0 x 10-3 cubic meters liters 1.1550 square inches square feet 9.0718 x 102 kilograms tons (short) 0.1198 gallons pounds/ft3 1.S.4 millimeters kilograms 2.03 x 10-2 kgs/cm2 quarts (liquid) 9.2046 pounds kilograms/meters3 6.308 x 10-3 cubic yards liters 0.243 x 10-2 pounds/ft3 kilometers 0.68 cubic inches pounds of water 0.2642 gallons (U.6214 miles (statute) liters 3. liquid) miles (statute) 1.342 x 10-2 cubic feet quarts (liquid) 1.68 grams/cm3 pounds/in2 7.540 centimeters inches 25.4536 kilograms pounds of water 27.349 grams pounds 4.02 kgs/meter3 pounds/in3 27.continued To Convert Multiply By: To Obtain: inches 2.536 x 102 grams pounds 0. 0 500 932 1704 3100 5612 271.78 190 374 787.3 1100 2012 54.11 70 158 454.4 310 590 1149 2100 3812 160.4 220 428 898.4 1300 2372 76.7 620 1148 -6.3 380 716 1343 2450 4442 198.8 640 1184 -1.56 150 302 676.44 130 266 621.3 290 554 1093 2000 3632 148.9 660 1220 0.9 1000 1832 43.9 480 896 1649 3000 5432 260.89 120 248 593.78 100 212 537.2 270 518 1038 1900 3452 137.89 210 410 843.56 60 140 426.4 580 1076 1927 3500 6332 1982 3600 6512 A .9 750 1382 15.22 10 50 326.0 320 608 1177 2150 3902 165.7 1250 2282 71.22 180 356 760.6 240 464 954.8 460 860 1593 2900 5252 248.12 Harbison-Walker .7 350 662 1260 2300 4172 182.00 32 90 360.0 230 446 926.3 1550 2922 100.8 1450 2642 93.4 1750 3182 121.1 1150 2102 60.22 90 194 510.6 1500 2732 98.2 900 1652 32.11 30 86 348.11 160 320 704.8 280 536 1066 1950 3542 143.0 212 414 871.67 80 176 482.67 20 68 337.7 800 1472 21.6 330 626 1204 2200 3992 171.78 0 32 315.2 360 680 1288 2350 4262 187.7 1700 3092 115.9 390 734 1371 2500 4532 204.6 420 788 1482 2700 4892 226.1 700 1292 10.00 140 284 648.6 1050 1922 48.0 680 1256 4.33 110 230 565.67 170 338 732.1 250 482 982.1 340 644 1232 2250 4082 176.2 1350 2462 82.33 200 392 815.2 1800 3272 126.9 300 572 1121 2050 3722 154.0 950 1742 37.4 400 752 1427 2600 4712 215.7 260 500 1010 1850 3362 132.1 1600 2912 104.9 1650 3002 110.4 850 1562 26.7 440 824 1538 2800 5072 237.9 1200 2192 65.3 560 1040 1871 3400 6152 304.2 540 1004 1816 3300 5972 293.8 370 698 1316 2400 4352 193.1 520 968 1760 3200 5792 282.REFERENCE TABLE Temperature Scale Conversions Convert Convert to to to to F or C F or C 0 C 0 F 0 C 0 F -17.44 40 104 371.6 600 1112 -12.00 50 122 398.0 1400 2552 87. They are marketed in remains after burning a fuel or other com.460°F (1. Sprung: In furnace construction. silt.40. Specific gravity 5. and high resistance to structure spanning an opening and supported Bauxitic Clay: A natural mixture of bauxite chemical attack or penetration by most com. ramming Ash: The noncombustible residue which excess of that for which the material is intend- mixes and gunning mixes. Andalusite: A brown. formed by a number of special tapered brick. green. canic ash and characterized by extreme fine- brick which contain a substantial proportion of ness of grain. volume. a highly aluminous laterite. brown. Baddeleyite: A mineral composed of zirconia (ZrO2). Expansion). or ASTM “Tentative Definitions” are used where applicable.2. the oxide of aluminum. cumference. Anneal: To remove internal stress by first Absorption: As applied to ceramic products. Ball Clay: A highly plastic refractory bond Amorphous: Lacking crystalline structure or clay of very fine grain. the surfaces of refractory bodies in service by mullite (Al6Si2O13) and free silica. plastic refractories. color. bustible material. fireclay and kaolin extraction of the juice from sugar cane. chrome ore refractory brick are subjected in the firing gravity 3. various amorphous or crystalline hydrous alu- weight of the dry ware. some boehmite). cals.38 . any portion of a cir. One which usually spans an opening or space type has the capacity for absorption of large Aggregate: As applied to refractories. A soft. British Thermal Unit (BTU): The amount of with H2O (water). and Bagasse: The fibrous material remaining after the waxy. by abutments at its extremities. Its main constituent is the clay free silica and which when heated.3. which has a wide range Bunker Oil: A heavy fuel oil formed by stabi- definite molecular arrangement. Also called a jack Bentonite: A kind of clay derived from vol- Acid Refractories: Refractories such as silica arch. The process is carried out in a ves- which two faces (the sides) are inclined toward sel known as a converter. expressed as a percentage of the Arc: As applied to circles. in combination auger. a between two walls. slags and bowed or curved structure which is supported able in composition and usually contains 5 to fluxes. Mg(OH)2. furnace hearths. whereby most of the carbon and impuri- tory shapes. can react chemically with acid the scouring action of moving solids.890°F (2. Attrition: Wearing away by friction. ing steel by blowing air through molten pig Air-Ramming*: A method of forming refrac. Flat: In furnace construction. alumina forms kaolinite dard barometric pressure. The dry composi. translucent mineral which dissociates at including high-alumina. two edges and two ends). * ASTM Standard Definitions C 71-88.720°F (2. amounts of water. Alumina: Al2O3. An exception to this rule occurs in tions require tempering with water to develop the one type of ladle brick (See Secondary necessary consistency. Auger Machine: A machine for extruding ing point 3. It is somewhat vari- chemically with basic refractories. which withstands the thrust of an arch. slags and fluxes. MgO. nals. consisting of parti. Specific gravity 2. can react Arch. Melting point Brucite: A mineral having the composition Alumina-Silica Refractories: Refractories con- 4. of brick shapes suspended from overhead sup. and other clay minerals. refractories.050°C). bauxite and gibbsite. Bloating: Swelling of a refractory when in the strong bond upon drying. and Abutment: The structural portion of a furnace across a gap between two conductors or termi. lime. grayish. Specific sist essentially of magnesia. moderate temperatures with the formation of refractories. alumina forms the minerals through a die by means of a revolving screw or heat required to raise the temperature of one diaspore. Harbison-Walker A-13 . Acid-Proof Brick: Brick having low porosi. and 10% of alkalies or alkaline earth oxides. pound of water one degree Fahrenheit at stan- with SiO2 and H2O.1 . Bauxite: An off-white. and especially clay miner- als. ed. minum oxides and aluminum hydroxides nous bridge formed by the passage of a current (principally gibbsite. cles of various sizes. in combination ground clays in moist and stiffly plastic form. used with much finer Arch. sisting essentially of alumina and silica. more than 65% alumina on a calcined basis. Bloating impairs the useful properties of both wet and dry condition. by abutments at the sides or ends only. yellow. melt. as applied to electricity. Bessemer Process: An older process for mak- porting members. refractories. abrasion. red or Basic Refractories: Refractories which con. in oxidation. Decomposes on heating. iron. and the brick assembly is held in place by the keying action of the brick. a mineral montmorillonite. or other furnace Arch Brick: A brick shape having six plane ties are removed by parts by means of pneumatic hammers. The arch is and clay containing not less than 47% nor mercial acids and some other corrosive chemi.2.GLOSSARY Abrasion of Refractories: Wearing away of beginning at about 2. Often high in carbonaceous matter. caused by temperatures in include mortars. Suspended: A furnace roof consisting sizes for making formed or monolithic bodies. containing impurities in the form of free silica. yellow. the weight of water which can be absorbed by or reddish-brown rock composed of a mixture of the ware.350°C) to form or mixtures of two or more of these and. cracking of crude petroleum. Al2SiO5. heating and then cooling slowly. when heated. faces (two sides. Arch. iron hydroxides. These refractories thermo-plastic state. with enormous increase in ground mineral material.8. the lumi. a flat ty and permeability. Air-Setting Refractories: Compositions of each other and one edge face is narrower than the ground refractory materials which develop a other. without definite of vitrification and which burns to a light lization of the residual oil remaining after the external form.700°C). Burn: The degree of heat treatment to which gray orthorhombic mineral. GLOSSARY process. resulting from the decomposi. it is mixed with sory minerals and has physical properties that water and rammed. Al)2 petrographic microscope. 3. nal agencies.32. Congruent Melting: The change of a sub- Calcination: A heat treatment to which many stance. Convection: The transfer of heat by the circu- tery. chalk and marble and a minor Checkers: Brick used in furnace a wall. the highest point of an arch. tory to further processing or use. phous minerals are actually cryptocrystalline.133°F (1.678°F (1. easily suspended. * ASTM Standard Definitions C 71-88. but which 0. Chord: As applied to circles. Specific gravity 4. cast or gunned into place. Mg) (Cr. electrical lation or movement of the heated parts of a liq- insulating products and thermal insulating prod- Calcite: A mineral having the composition uid or gas. chemical element. essentially of hydrous aluminum silicates (See by plane faces. Refractory grade an electron microscope.720°F (2. When deposited within the pores tured substantially or entirely of chrome ore. cient pressure to destroy the bond and cause Chrome-Magnesite Brick: A refractory brick stable from 2. from the solid form to a Ceramics: Originally. Specific gravity 2. regenerators to recover heat from outgoing which each course projects beyond the one hot gases and later to transmit the heat to cold immediately below it to form a support. manufactured substantially of a mixture of 2. ware formed from clay liquid of the same composition. CaCO3. especially one which Chrome Ore: A rock having as its essential is dome-shaped. which can be either fired or chemically bond. theoretically consisting solely of alumina (Al2O3).e. Specific gravity ed. plaster. chrome ore and dead-burned magnesite. any finely divided substance that al. Carbon-Ceramic Refractory*: A manufac. carbon can build up suffi. ture range.71 for pure calcite nonmetallic mineral substances. pot- components and affecting physical changes. for the pur. constituent the mineral chromite or chrome tured refractory comprised of carbon (including spinel. becomes hard and stonelike as a result of originally. Clay: A natural mineral aggregate. ment which causes the cohesion of adjacent particles. ties. bon (including graphite). chemical reaction or crystallization. but can be seen with Castable Refractory: A mixture of a heat. also. and usually a small which the individual crystals are so small that such as fire clay and silicon carbide. glazes. cement. Cristobalite: A mineral form of silica (SiO 2). Calcite is the essential constituent Corbel: A supporting projection of the face of of limestone.050°C). Current usage includes all pose of driving off volatile chemically combined refractory materials.02. or ASTM “Tentative Definitions” are used where applicable. hydraulic cement. Al2O3. wearing away of refractory bodies largely at one degree Centigrade at standard barometric their surface through chemical action of exter- pressure. air or gas entering the furnace. tured by processes in which mechanical Cap or Crown: The arched roof of a furnace. of refractory brick. any fine-grained material in Burning (Firing) of Refractories*: The final and binds together the larger fragments or par. glass. tion of carbon monoxide gas into carbon Course: A horizontal layer or row of brick in a dioxide and carbon within a critical tempera. in of silica brick. solid body of a products. smaller than clay size. joining any two points on a circumference. enamels. tory comprised substantially or entirely of car. structure. Crown: A furnace roof. brick are subjected in the process of manufac- ture. (2) rock crystal. or any such material that can be heat treatment in a kiln to which refractory ticles in sedimentary rocks. mechanical strength developed by a heat treat. A -14 Harbison-Walker . For use. strength is imparted by chemical bonding Corundum: A natural or synthetic mineral especially a glass tank furnace. which they cannot be made visible by means of the is represented by the formula (Fe. for the purpose of developing bond and Ceramic Bond: In a ceramic body. consisting arrangement that can be outwardly expressed nently affected by the reaction. compound or isomorphous Catalyst: A substance which causes or accel.723°C). also Fire Clay). does not occur in crystalline form. Chemically-Bonded Brick: Brick manufac. making such ware. The melting ceramic raw materials are subjected. suspension. which is a combination of FeO and Cryptocrystalline: A crystalline structure in graphite) and one or more ceramic materials MgO with Cr2O3. with alternating brick units and open Corrosion of Refractories: Deterioration or to raise the temperature of one gram of water spaces. Hardness 9. Various so-called amor- resistant aggregate and a heat-resistant chrome ore has only minor amounts of acces. mixture having a regularly repeating atomic erates a chemical change without being perma. when heated. baffle or Calorie (Large): One thousand small calories. the Conductivity: The property of conducting other necessary physical and chemical proper. the degree to which desired Cement: A finely divided substance which is Colloid: (1 ) A particle-size range of less than physical and chemical changes have been workable when first prepared. prepara- and hardened by the action of heat. lime. in a more the compact groundmass which surrounds modern sense.00024 mm. a straight line point 3. proportion of Fe2O3. The composition. the art of of ice is an example of congruent melting. are suitable for the manufacture of refractory Crystal: (1 ) A homogeneous. is extremely variable. i.4.470°C) to the melting the brick to disintegrate. Melting Carbon Deposition: The deposition of amor. Also. Chrome Brick*: A refractory brick manufac. an arrangement of brick in a wall in constituent of many other rocks. point. agents instead of by firing. phous carbon. Cristobalite is an important constituent Carbon Refractory*: A manufactured refrac. (2) developed in the firing of a refractory materi. ucts made from clay or from other inorganic. which the chrome ore predominates by weight. crystals. electricity or sound. so-called shelf. because the brick are arranged in checkerboard Calorie (Small): The amount of heat required patterns. heat. O4. abrasives.00 . Dusting usually results from (1 ) chemi. of which albite (Na) and anorthite (Ca) complete shrinkage of the resultant magnesia.45. be bonded “directly” to the magnesite grains. principal clay mineral is halloysite.2. other refractory material. Fe2SiO4.85 . It is usually expressed either in cal reactions such as hydration.4.) present in the physical. Thermal: The capacity of a mate. nation. The oxide).820°F (1. prepared by firing raw magnesite (or Dolomite: The mineral calcium. rigid when subsequently Dutch Oven: A combustion chamber built dried. plastic when sufficiently pulver- crystalline condition. more components. 15% ucts. and to affect consists mainly of the mineral of that name group. rock.550°C). formed and either raw or fired. Eutectic Temperature: The lowest melting Flux: A substance or mixture which promotes nantly by a solid state of diffusion mechanism. light in weight and consists mainly of microscopic shells of diatoms or Erosion of Refractories: Mechanical wearing Flint Clay: A hard or flint-like fire clay which other marine organisms.2. Direct Bonded Magnesite-Chrome Brick: A Fluxing: Fusion or melting of a substance as a term applied to fired magnesite-chrome composi.Si)3 O8 tially of periclase (crystalline magnesium where M=K. under the action of phase (silicates. equipped with heavy steel rollers or perature. or ASTM “Tentative Definitions” are used where applicable. cracking.800°F (1. service by the washing action of moving liq. fine-grained cryto-crystalline Diatomaceous Earth: A hydrous form of sili. Commercial diaspore clay of the purest grade usually con. and of sufficient purity and refrac- Diaspore: A mineral having the theoretical outside and connected with a furnace. and can also contain a large amount of the min. temperature in a series of mixtures of two or fusion of a solid material by chemical action. Sr and Fe. Exfoliate: To expand and separate into rudely result of chemical action.0 . Direct Bonded Basic Brick: A fired refracto- ry in which the grains are joined predomi. tions when the amount of bonding mineral parallel layers or sheets. Fillets are used at re-entrant angles in the in an auger machine before extrusion by design of brick shapes to lessen the danger of means of a partial vacuum. ized and wetted.050 to 2. commonly expressed as inner surfaces are horizontal planes. of a substance. Specific gravity 3.205°C). shrinkage when again subjected to a high tem. form the end members of a continuous series thereby producing hard dense grains which eral calcite (CaCO3).GLOSSARY Crystalline: Composed of crystals. or (2) min- grams per cubic centimeter or in pounds per eral inversion accompanied by large and Fire Clay: An earthy or stony mineral aggre- cubic foot. etc. such as the inversion gate which has as the essential constituent of beta to gamma dicalcium silicate upon cool. The rock called dolomite are the most common. most important feldspars are: (1) the potash other substances convertible to magnesia) at magnesium carbonate.538°C). so as to form primarily lime and magnesia in a Division Wall: Wall dividing any two major Fayalite: A mineral having the composition matrix that provides resistance to hydration sections of a furnace. Specific gravity 2. De-airing: Removal of air from firebrick mixes ground material passes out. free silica. a fraction or percentage of the ideal “black body” radiation of heat which is the maxi. Flat Arch: An arch in which both outer and tains between 70 and 80% alumina after calci. perature above 2.1.76. Specific group. thermal or chemical forces producing matrix is sufficiently low that under microscopic * ASTM Standard Definitions C 71-88. water). Harbison-Walker A-15 . pressure. Ca. such as molten slags or metals. hydrous silicates of aluminum with or without Devitrification: The change from a glassy to a ing. forsterite. of which al is forced through a die by the application of dolomite with or without additives. one may be direct (diffusion) bonding. into fine powder or Density: The mass of a unit volume dust. erals with a general formula MAl (Al. composed essentially of silica. rial for radiating heat. to a tem.55 . Melting and carbonation.120° to and carbonation and free from excessive Dry Pan: A pan-type rotating grinding 1. either wholly or in part. machine. Flint: A hard. Br.201°F (1. Its uids. and (2) the soda-lime tically all of the volatile materials. Electron Beam Furnace: A furnace in which metals are melted in a vacuum at very high Fireclay Brick: A refractory brick manufac- Diaspore Clay: A rock consisting essentially temperatures by bombardment with electrons. Na. Fillet: The concave curve junction of two sur- ted plates in the bottom through which the faces which would otherwise meet at an angle. point 2. usually crudely Feldspar: A group of aluminum silicate min- lar dense refractory material composed essen. Emissivity. Rb. gravity 2. of which orthoclase and microcline (K) temperatures sufficiently high to drive off prac. Dead-Burned Dolomite: A coarsely granular The actual bonding mechanism in this instance Extrusion: A process in which plastic materi- refractory material prepared by firing raw is usually a combination of types. toriness for use in commercial refractory prod- composition Al2O3 • H2O (85% alumina. Specific gravity 4. ly breaks with a smooth or shell-like fracture. abrupt change in volume. mum theoretically possible. of diaspore bonded by flint clay. Firebrick: Refractory brick of any type. are entirely inert to atmospheric hydration Melting points 2. Dobie: A molded block of ground clay or Dead-Burned Magnesite: A coarsely granu. Dusting: Conversion of a refractory material. examination the chrome ore grains appear to differential stresses.95. tured substantially or entirely from fire clay. It is widely used for away of the surfaces of refractory bodies in has very low natural plasticity and which usual- furnace insulation. of solid solutions. mullers which do the grinding and having slot. CaMg (CO3)2. ca which is soft. Grog: A granular product produced by crush. for use in tamped linings. ing and grinding calcined or burned refracto. formation of alloys. usually of alumina-silica composi. * ASTM Standard Definitions C 71-88. Also the union or blending of ground refractory materials which require rela. The materials used in their production Confusion sometimes results from the use of include diaspore. Synonyms include vitre. Most refractory materi. the relative proportions of particles position and structure between muscovite and laying brick or for patching or daubing in fur. furnace masonry. naces. Used mostly as backing for brick tories by means of air-placement guns. ed silicate of alumina similar in composition to production due to shorter heat-up time. sition from the original compound. which have a PCE not lower than Cone 31½ or Melting point approximately 3. an adequate bond.450°F above 32½ . the softening of a solid body. slump or flow. dery condition. Specific gravity 3. a hydrat. materials. mica-like miner- Furnace Chrome: A mortar material prepared Grain Size: As applied to ground refractory als of small particle size. with the tively high temperatures for the development of the change from quartz to cristobalite. the change from low-quartz to high-quartz. Gunning: The application of monolithic refrac. tory shapes in which the ground particles of pared from finely ground dead-burned magnesite. or. Insulating refractories are available quence of heat. upon melting.21. economy through lower heat losses. ing and annealing. Fusion: A state of fluidity or flowing in conse. Header: A brick laid on flat with its longest as brick or monoliths. gous chemical composition and closely relat- als have no definite melting points. into vertical open joints when it is poured on Insulating Refractories: Lightweight. Compositions of ground refractory materials uid phase present on the hot face side of the in which some of the components react chemi- plane. Al(OH)3. intermediate in com- from finely ground chrome ore. High-Alumina Refractories: Alumina-silica Ganister: A dense. Grain Magnesite: Dead-burned magnesite in cally with water to form a strong hydraulic the form of granules. kaolinite. Specific gravity 2. but soften Specific gravity 4. bauxite. It always Halloysite: One of the clay minerals.2. this term. between the hot face and cold face of a refrac. porous It is clear without entrapped gas bubbles or horizontal courses of brick masonry. refractories. lizing. Hydraulic-Setting Refractories: ture corresponds to the freezing point of a liq. because it is also applied in some sillimanite.5. increased contains gas bubbles. from about 5/8 inch in diameter to very fine known as castables. and for patching or daubing tion. of such consistency that it will flow duced by melting clear quartz crystalline feed. silica rock with clay. with the formation of anoth- Fused-Cast Refractories: Refractories clays that have been subjected to no mechanical er compound and a liquid of different compo- formed by electrical fusion followed by cast. Synonyms tivity and heat-storage capacity than other include quartz glass and vitreous quartz.33.9 . particles. Hematite: The mineral Fe2O3 (red iron ore). kyanite. ed crystal habit crystallize together in various gradually over a range of temperatures. rapid vibration.900°C). Isomorphous Mixture: A type of solid solu- Fusion Point: The temperature at which tion in which mineral compounds of analo- melting takes place. ner walls and improved working conditions. gibbsite. the action of a flux. These materials provide fuel state produced by arc-melting sand. generally ranging in size bond. either through heat alone or through heat and dimension perpendicular to the face of a wall. montmorillonite. Incongruent Melting: Dissociation of a com- Ground Fire Clay: Fire clay or a mixture of fire pound on heating. econo- ous silica and silica glass. treatment other than crushing and grinding. proportions.GLOSSARY Forsterite: A mineral having the or to mixtures of either crushed firebrick or High-Duty Fireclay Brick: Fireclay brick composition Mg2SiO4. suitable for the manufacture of silica brick. Al2Si2O5(OH)4 • 2H2O. ration into a series of fractions by screening. andalusite and fused alumina (arti- parts of the United States to crushed firebrick ficial corundum). suitable for materials. magnesite brick. but will Heat-Setting Refractories: Compositions of change in chemical composition. as for example. but amorphous and containing more my of space (size and weight) because of thin- water.3 . Illite: A group of three-layer. A -16 Harbison-Walker . commonly called the ceramic bond. These refractories are commonly Friable: Easily reduced to a granular or pow. Jack Arch: See Arch. has cooled to a rigid condition without crystal. refractories containing 45 % or more alumina. such as metals. refractory material are packed closely together by suitable for use as a joint material in laying ry material. Hydrate (verb): To combine chemically with Freeze-Plane: An irregular plane lying water. high-silica rock (quartzite). Grout: A suspension of mortar material in Ingot Mold: A mold in which ingots are cast.4. or ASTM “Tentative Definitions” are used where applicable. Impact Pressing: A process for forming refrac- Furnace Magnesite: A mortar material pre. Fused Quartz: Silica in the glassy state pro. water. Gibbsite: A white or tinted monoclinic mineral. Glass*: An inorganic product of fusion which tory lining — any point on which the tempera. (1. of higher refractoriness and higher thermal Fused Silica: Silica in the glassy or vitreous conductivity. refractories with much lower thermal conduc- other impurities or diluents. to such a degree that it will Inversion: A change in crystal form without no longer support its own weight.3. usually determined by sepa. Flat. of different sizes. 56 . isometric. perfect cleavage in one direction and consisting Magnesite Brick: A refractory brick manufac. Mg(OH)2. Mineral: A mineral species is a natural inor- ial. Conventional chemical composition and physical charac- Kyanite (Cyanite): A blue or light-green tri. Monticellite: A colorless or gray mineral related Limonite: A mineral consisting of hydrous to olivine. two edges and two ends). in magnesite brick. CaMgSiO4. cite mixed with dolomite.17 . Caustic and Dead- Key: In furnace construction. (See also Magnesite. tion to provide specific refractory properties amorphous.Fe)Fe2O4.001 mm). after preliminary drying at a tempera. blowing oxygen on or through molten pig iron. Medium-Duty Fireclay Brick: A fireclay brick for making steel. manufactured substantially of a mix.1 - ferric oxides. i. Al2SiO5. Kaliophilite: A hexagonal mineral of volcanic origin. Magnesite-carbon brick are within definite natural limits. Modulus of Elasticity (Physics): A measure Ladle: A refractory-lined vessel used for the Magnesite. Magnesite-Carbon Brick: A refractory brick used in microscopy.311/2. Specific gravity 5.8. joints. The PCE of most commercial kaolins Magnesioferrite: One of the spinel group of melting points. Most minerals 3. The Kaldo Process (Stora): An oxygen process loss in weight upon drying is called “free mois. Specific gravity 4. expressed in standard units. Mica: A group of rock minerals having nearly the closing brick of a curved arch. The product is readily reactive to water and Modulus of Rupture: A measure of the trans- whereby most of the carbon and impurities are to atmospheric moisture and carbon dioxide. composition coexist in equilibrium. minerals.205°C). Naturally occurring magne- Lintel: A horizontal member spanning a wall sium hydroxide is known as brucite. a few are 2.4 . (Mg. body. opening. usually constitutes the brown coloring material However. refractory chrome ore. the essential component of Magnesium Hydroxide: The compound of 3. calcining magnesite. of thin elastic plates.499°C) to form MgO and a liquid.6.67. the ratio of temporary storage or transfer of molten metals. Specific gravity 3.4. L-D Process: A process for making steel by generally not exceeding 2. ture”.25.18. The most common vari- Key Brick: A brick shape having six plane tured substantially or entirely of dead-burned eties are muscovite and biotite. tar-bonded and tar-impregnated brick do not teristics or which varies in these respects clinic mineral. Kaolinite over a relatively wide range of temperatures. true melting points. Melting point about 2.415°F (1.594°C). magnesium oxide and chemically combined (1. Specific gravity is 2. (2) a type of brick shape intended for use in heating a sample of material to a high tem. ture just above the boiling point of water. (Fe.6 .” higher than 31 . gunned or sintered into place. but melt progressively lowish clay mineral. which can be either fired or chemically Monolithic Lining: A furnace lining without tially of the mineral calcite (CaCO3) or of cal. Loss on Ignition: As applied to chemical analy. the loss in weight which results from netic. verse or “crossbreaking” strength of a solid removed by oxidation. or ASTM “Tentative Definitions” are used where applicable. Specific gravity fall into this class.29. Caustic: The product obtained by of the elasticity of a solid body. opaque mineral of the spinel group. Micron: The one-thousandth part of a mil- toward each other and one of the end faces is limeter (0.0.200°F (1. Metals ite as its chief constituent. the sides of wall openings. that which occurs above the boiling point. bonded. mineral magnesite as its essential constituent thin steel casings. of) and carbon.2. strongly mag- ing the side of an opening in a furnace wall. Specific gravity 2. higher than 28 . Magnesite-Chrome Brick: A refractory brick Limestone: A sedimentary rock composed essen. beyond filling pores or acting as a bond. fused. stress (force) to strain (deformation) within the ible to magnesia. MgCO3. or other substances convert.GLOSSARY Jamb: (1 ) A vertical structural member form.e. the uppermost or Burned Magnesite).2. faces (two sides. The PCE of sium carbonate.65. KAlSiO4. which may be in the form of ganic substance which is either definite in various carbon-bearing materials.4. they change abruptly from ranges from Cone 33 to 35. in magnesite which consists essentially of magnesia which two faces (the edges) are inclined in crystalline form (periclase). solid to liquid at definite temperatures.325°C) with the formation of mul. perature. most refractory materials have no Kaolinite: A common white to grayish or yel. Harbison-Walker A-17 . A rock containing the Metalkase Brick: Basic brick provided with pure kaolinite is Cone 35. with a PCE value not lower than Cone 29 nor “loss on ignition.57 .3. is the principal constituent of most kaolins and Magnesite: A mineral consisting of magne- fire clays. Decomposition begins at about distinct in that carbon is present in the composi. Low-Duty Fireclay Brick: Fireclay brick Melting Point: The temperature at which which have a PCE not lower than Cone 15 nor crystalline and liquid phases having the same Kaolin: A white-burning clay having kaolin. manufactured of substantially magnesite K-factor: The thermal conductivity of a mater.59. (dead-burned.6 . Rarely found in nature. lite and free silica. in which the magnesite predominates by weight. Melts incongruently at 2.730°F “brown ore.” Specific gravity 3. Magnetite: A black. formed of material which is rammed. upon heating at a temperature elastic limit. or a combination there. a unit of measurement narrower than the other. water. Al2Si2O5 (OH)4. Specific gravity and most pure crystalline materials have sharp 2. ses. have a definite crystalline structure.901°F (1.5. Mg) Fe2O4. ture of dead-burned magnesite (magnesia) and cast. CaMg(CO3)2. * ASTM Standard Definitions C 71-88. Natural Permeability: The property of porous materi. Mullite: A rare orthorhombic mineral. Each cone is of a definite mineral com- is neither acid nor base.GLOSSARY Montmorillonite: A group of expanding-lattice Nozzle Brick: A tubular refractory shape used in ramming into place to form monolithic lin- clay minerals containing variable percentages a ladle.3.Mn. called “burley” clay or “burley flint” clay Pyrometric Cone Equivalent (PCE) of Plastic Fire Clay: A fire clay which has suffi- in some districts. and is approximately Specific gravity 2. isomorphous solid-solution series forsterite. face. “sealed” if impermeable.248°C) at which temper. uids under pressure. Al6Si2O13. pore-volume.37.25 cubic inches). Oxygen Process: A process for making steel in containing an optimum amount of added which oxygen is blown on or through molten water by means of high pressure applied verti- Muscovite: A mineral of the mica group. voids between solid particles. brown orthorhombic mineral. Specific gravity 3.2. (Na. enables it to be molded into desired forms Olivine: (l) An olive-green. “apparent porosity” on the open consisting predominantly of mullite (Al6Si2O13) pore-volume only. crystals formed either by conversion of one or Oxiduction: Alternate oxidation and reduc- more of the sillimanite group of minerals or by tion. KA12(AlSi3)O10(OH)2. tephroite and a hypothetical calcium constituent of fireclay and high-alumina orthosilicate. %. pig iron.Fe. als which permits the passage of gases and liq. The “true porosity” is based on the total Mullite Refractories*: Refractory products deformation or bloating of clay or clay ware. tempering clays in a moist or stiffly plastic con- some sedimentary rocks. whitish or pale brown and is a common miner. Pores are erals forming the isomorphous system described as “open” if permeable to fluids. brass- common reaction product in furnaces wherein small spheroids varying in size from small yellow. Stable at 2. bonded by flint accordance with the Method of Test for clay. A -18 Harbison-Walker . when heated under standard conditions it bends at a definite Nine Inch Equivalent: A brick volume equal Plasma Jet: Ionized gas produced by passing temperature. It comprises the mixed with water and is suitable for use in lay. effect. number of that Standard Pyrometric Cone industry. or both. fayalite. potassium.Ca) 2SiO4. Specific gravity 3. (Mg.070°F (2. the small ing refractory brick. or ASTM “Tentative Definitions” are used where applicable. Refractory Materials (ASTM Designation cient natural plasticity to bond together other C24). the upper end sium. Nepheline (Nephelite): A hexagonal mineral Pyrite: The most common sulfide mineral. When heated to a suitable temperature. Pores: As applied to refractories. A Perlite: A siliceous glassy rock composed of FeS2. bluish or brownish and is related to hauyne. sided truncated pyramid. usually expressed as a percent- Overfiring: A heat treatment which causes age. increasing with the amount of iron present. Na8Al6Si6O24(SO4). AlSi2O5(OH). the unit of measure. Pyrophyllite: A mineral consisting of hydrat- Plastic Refractory: A blend of ground refrac- ish. total volume. whereby most of the carbon and cally in a power-driven press. of the feldspathoid group. base or 11/8 inches high by 3/8 inch wide at the Neutral Refractory: A refractory material which size and shape of the open connecting pores base. It is gray. combined water content 3 to 4 and sulfates. impurities are removed by oxidation. perlite expands to form a lightweight glassy Pyrometric Cone: One of a series of pyrami- ature it inverts to the artificial mineral material with a cellular structure. Porosity of Refractories: The ratio of the vol- brick.27 .9 . dal-shaped pieces consisting of mineral mix- carnegieite. tory material which becomes plastic when (Mg. such as carbon. It is usually colorless. including forsterite. Used mainly for making sulfuric acid slags or vapors of high soda content come into shot to peas.850°C). (2) A name applied to a group of min. which has the same composition. ume of the pores or voids in a body to the tions approximately 3. materials which have little or no plasticity. Pug Mill: A machine used for blending and al in metamorphic and igneous rocks and in Periclase: An isometric mineral. ferruginous nodules. tures and used for measuring time-temperature but a different crystalline form. dition.67.K)AlSiO4. contact with fireclay or high-alumina brick.278°F (1.5. grayish-green or which are retained after the pressure of mold- Mortar (Refractory): A finely ground refrac. Plasticity: That property of a material that common constituent of bentonites. A of the shape serving as a seat for the stopper. and is measured by the rate of flow of a standard position and has a number stamped on one chrome or mullite. ing has been released. Specific gravity 4. sodium and calcium. tory materials in plastic form. of one or more of the cations of magne.362°F (1. temperatures up to tens of thousands of degrees Pyrometric Cone Equivalent (PCE)*: The ment of brick quantities in the refractories centigrade. A standard pyrometric cone is a three- nepheline contains a small amount of potash. The permeability of a either 25/8 inches high by 5/8 inch wide at the body is largely dependent upon the number.15. whose tip would touch the supporting plaque Plastic Chrome Ore: An air-setting ramming simultaneously with a cone of the refractory Nodule Clay: A rock containing aluminous or material having a base of refractory chrome material being investigated when tested in ore and shipped in plastic form ready for use. Specific gravity 3. Melting point approxi. ed silicate of aluminum. to that of a 9 x 4 1/2 x 2 1/2 inch straight brick an inert gas through a high-intensity arc causing (101. teemed at the bottom of the ladle.Fe)2SiO 4. Melting point under equilibrium condi. suitable for * ASTM Standard Definitions C 71-88. contains a hole through which steel is ings. MgO.58. Power Pressing: The forming of refractory synthesis from appropriate materials employing brick shapes from ground refractory material either melting or sintering processes. An important fayalite. mately 5. Color. fluid under definite pressure.800°C). Nosean (Noselite): A feldspathoid mineral of the sodalite group. such as limestone. for the purpose of effecting or aiding the Refractories: Nonmetallic materials suitable refining. protect the metal rod which holds the stopper aggregate which has as the essential con. released to cold air or gas. plastic when sufficiently als. Secondary Expansion: The property exhibit.785°F (1.4. Specific gravity Quartzite: A hard compact rock consisting of spar and quartz.24. Also. so-called phase with a variable composition. Al2SiO5. having an Ramming Mix: A ground refractory material Rowlock Course: A course of brick laid on inclined face. pale-green or white granite is an aggregate consisting essentially orthorhombic mineral.25. a gas-fired kiln that rotates at an angle and in Sintering: A heat treatment which causes sedimentary rock consisting of grains of sili. solid material in water of creamy consistency. 2. Sillimanite: A brown. essentially of crystals of the mineral quartz. refractory-lined. confused with the bloating caused by exces. (3) by chemical reaction between for use at high temperatures in furnace con. Soldier Course: A course of brick set on end. tion of a liquid. not such as abrasion.Fe)3Si2O5(OH)4. chemical attack the same as overfiring. nace operating temperatures: (1) in smelting ide (Ti2O). Rutile: A mineral consisting of titanium diox.65. (2) in the refining heat from a heated gas to colder air or gas. ash or between two different types of refrac- tance to high temperature. pressure.5 % of ing gases and later to release this heat to added lime.8 to 3.5 - pulverized and wetted. stable at high temperatures. SiC. own weight. quartzite. through the combination of a Recuperator: A system of thin-walled refrac. Specific gravity 2. the discharge end. Silicon Carbide Refractories*: Refractory prod- Rock: A naturally occurring mineral aggregate ucts consisting predominantly of silicon car- Quartz: A common mineral consisting of silica consisting of one or more minerals. quartzite bonded with about 1. * ASTM Standard Definitions C 71-88. by substances. regenerators to recover heat from hot outgo. sil. Silica: SiO2.): Chemically and physically properties of a refractory.GLOSSARY Pyroplasticity: The physical state induced by Rise of Arches: The vertical distance between Silicon Carbide: A compound of silicon and soaking heat which permits a refractory body the level of the spring lines and the highest carbon. cal action between refractories and external agen- sive temperatures which impair the useful cies at high temperatures resulting in the forma- Refractory (adj. Harbison-Walker A-19 . which is mixed with water and rammed into edge with their longest dimensions perpendicu- place for patching shapes or for forming lar to the face of a wall. A behavior not to be Slagging of Refractories*: Destructive chemi- and rapid changes in temperature. added through a series of standard screens. ed by some fireclay and high-alumina refracto. operations. cohering particles as determined by screening metals. such as lime. such as coal. sandstone and sand are composed of ferromagnesian silicate minerals. For exam. without free silica. waste portion of the ore. mainly of talc and derived from the alteration thermal energy from hot furnace gases is alter. Semi-Silica Fireclay Brick: A fireclay brick Sleeves: Tubular refractory shapes used to Refractory Clay: An earthy or stony mineral containing not less than 72% silica. flux. ness for use in commercial refractory products. Solid Solution: A homogeneous crystalline cold air or gas entering the furnace. the oxide of silicon. Slurry: A suspension of finely pulverized ly dried and of sufficient purity and refractori. the term can also refer to the often called silica cement. a common rock consisting essential. (Mg. they are usually ries of developing permanent expansion at tories. ple. While their primary function is resis. from which an arch is sprung. Specific gravity 2. which the charge is introduced into the higher adjacent particles of material to cohere at a ca sand cemented together by at least 10 % of end and travels down the slope of the kiln to temperature below that of complete melting. Skewback: The course of brick. rigid when subsequent. (SiO2). 3. ing of a finely ground mixture of quartzite. There are two types: dissociate into mullite and free silica. ing ladle. quartzite rock is an aggregate consisting posed largely of quartz. solution of small proportions of a material in a seemingly unrelated substance. precipitated silica. called on to resist other destructive influences temperatures within their useful range. At about 2. Quartz and Soapstone: A metamorphic rock consisting Regenerator: A refractory structure in which chalcedony are common silica materials. or ASTM “Tentative Definitions” are used where applicable. However. Sandstones and quartzites are com. and (2) orthoquartzite. bide. nately absorbed by checker brick work and largely of free silica in the form of quartz.18 . The most because of the checkerboard pattern in which Silica Fire Clay*: A refractory mortar consist. refractories and fluxing agents. Specific gravity 4.7.530°C) it begins to predominantly of quartz. grayish. Silica Brick: A fired refractory consisting little used in the case of refractories except Regenerator Checkers: Brick used in furnace essentially of silica and usually made from in the bottoms of some types of furnaces. (1) metaquartzite. ly of serpentine minerals. substances having the same crystalline struc- ica brick and fire clay of various proportions. ture. Slag: A substance formed in any one of sever- monolithic furnace linings. common solid solutions involve two or more the brick are arranged. head in the valve assembly of a bottom-pour- stituent hydrous silicates of aluminum with or Serpentine: A group of rock forming miner. derived from sandstone. a metamorphic rock usually Rotary Kiln: A cylindrical. struction. usually of a less al ways by chemical action and fusion at fur- plastic nature than plastic refractories. to be readily deformed under pressure or by its point of the under surface of an arch. with the gangue or tory ducts used for the purpose of transferring Screen Analysis: The size distribution of non. flow of molten glass from the glass tank to the the surface of a solid. exposure of inner portions of the original Hardness 1. to raise the temperature of a unit mass of a Wedge Brick: A brick shape having six plane substance one degree. parallel to the face of the wall.20 Harbison-Walker . which have a PCE not lower than Cone 33 and Vacuum Pressing: A method of forming brick Its chief source is the mineral baddeleyite. faces (two sides. to fire clays which have become bloated by structure. 1. ferrous iron. Begins to melt incongruently at 3. with the volume specific gravity is based on the volume development of a substantial proportion of as a whole. For Thermal Expansion: The increase in linear ing. shapes are suspended from overhead support. Stack Losses: The flue gas loss. Over its length.811°F (1. overfiring. all hydrated silicates. Zirconia: Zirconium oxide. The “true specific materials are heated and which is counterbal.2. Young’s Modulus: In mechanics. thus improving heat exchange between the charge and the hot combustion gases. included pores. (Mg. vermi- Taconite: A compact ferruginous chert or slate culite exfoliates and increases greatly in vol- in which the iron oxide is so finely disseminat. * ASTM Standard Definitions C 71-88. Tolerance: The permissible deviation in a refractory shape from that intended. position. ZrSiO4.6. the sensible heat carried away by the dry flue gas plus the TREFOIL® Heat Exchanger: A refractory Zircon: A mineral.200°C) to pseudowollastonite. Tridymite: A mineral form of silica. Specific gravity 2. applied ments (spalls) from the face of a refractory Talc: A hydrous magnesium silicate mineral.e.544°C). constituent of silica brick. vacuum during pressing in a power press.Al)3 (AlSi)4O10(OH)2 . (1.4H2O. in a ceramic body. Typical analy- ses of the ore grade show total iron at 32%. solids and liquids the specific gravity is based dimensions and volume which occurs when on water as the standard. completely melted at about 4.685°C) forming ZrO 2 solid solution plus shaped. inside surface of an arch and the skewback. the solid material with all Thermal Shock: A sudden transient tempera. caused by dimension or property of a material from an bending or bowing during manufacture. The apparent specific gravity ture change. ty 3. refractory mass. two edges and two ends).045°F the water vapor in the flue gas. The bulk or materials are cooled. An important toward each other and one end face is narrow- sium aluminate.7. Melts incongru- Spring Line: The line of contact between the device or furnace to a casting mold or another ently at 2. the ratio of Sprung Arch: An arch which is supported by Tuyere Brick: A refractory shape containing tensile stress to elongation within the elastic abutments at the side or ends only. Trough: An open receptacle through which Specific gravity 2. Vesicular: Having a cellular structure. Melting point 4.192°F molten metal is conveyed from a holding (1. Melting point 3. such as fire clay. ZrO2. receptacle. iron or chromium.7 . with Mg3Si4O10(OH)2. When heated above 302°F (150°C). the TREFOIL heat liquid.890°F (2. Vibratory Pressing: A process for forming Thermal Conductivity: The property of mat. CaSiO3. varying widely in com- ing members. i. A . AB2O4 Tweel: A refractory shape used to control the Wetting: The adherence of a film of liquid to where A represents magnesium.8. SiO2.9. also called impact press- conditions of temperature and pressure. together by rapid impact-type vibrations of the some other standard substance under standard top and bottom dies.678°F (870 to which two faces (the sides) are inclined Spinel: (1) The mineral composed of magne.8. in Stable from 1. openings which in cross-section are clover. one or more holes through which air and other limit.GLOSSARY Spalling of Refractories: The loss of frag. ume. zinc or manganese or any combination of these tin bath in the float glass process. which meet certain other requirements as out. Suspended Arch: An arch in which the brick Vermiculite: A group of micaceous minerals. through cracking and rupture.700°C).470°C). Specific Heat: The quantity of heat required established standard or from an average value. shapes by which they are subjected to a partial lined in ASTM Designation C 27-84. Inverts at 2. er than the other.598 to 2. MgAl 2O 4. is based on the volume of the solid material Warpage: The deviation of the surface of a plus the volume of the sealed pores. refractory shapes in which the ground parti- Specific Gravity: The ratio between the weight ter by virtue of which heat energy is transmitted cles of refractory material are packed closely of a unit volume of a substance and that of through particles in contact. (2. of elasticity. Specific gravi.875°F (2. the modulus gases are introduced into a furnace.135°C).800°F Stretcher: A brick laid on flat with its length exchanger divides the kiln into three equal parts.Fe. Specific gravity 2.650°C).26. Vitrification: A process of permanent chemi- gravity” of a body is based on the volume of anced by contraction of equal amount when the cal and physical change at high temperatures solid material excluding all pores. or ASTM “Tentative Definitions” are used where applicable. Specific Superduty Fireclay Brick: Fireclay brick gravity 5. (2) A group of minerals of general formula. glass. ed that substantially all of the iron-bearing par- ticles are smaller than 20 mesh. minerals and B represents aluminum ferric Wollastonite: A triclinic mineral. Specific gravity sensible heat and latent heat carried away by construction in a rotary kiln with three 4. 21 . TN (865) 546-4930 Los Angeles.HARBISON-WALKER REFRACTORIES DISTRIBUTION Harbison-Walker Refractories Company Distribution Centers Offering A. (West Haven) CT (203) 934-7960 New York. OH (216) 398-1790 Dallas. Call 1-800-887-5555 to reach the location nearest you. castables. (Lakeland) FL (713) 635-3200 Harbison-Walker A .S. OR (503) 227-7944 Roanoke. Atlanta. IA (563) 445-1244 Detroit. gun mixes. If you need material to complete a repair or for an emergency. (Leetsdale) PA (412) 741-3200 Portland. (Milford) OH (513) 576-6240 Cleveland. (Rahway) NJ (732) 388-8686 Philadelphia. TX (713) 635-3200 Kansas City. IFB. (Lenexa) MO (913) 888-0425 Knoxville. (Salem) VA (540) 375-2107 Salt Lake City. insulating board. (Trevose) PA (215) 364-5555 Pittsburgh. NC (704) 599-6540 Chicago. (Gonzales) LA (225) 644-2111 Birmingham. metallic anchors. NARCO and Harbison-Walker products H-W Refractories maintains stocks of a variety of standard brick. (Richmond) CA (510) 236-7415 St Louis. plastics. mortars. ceramic fiber. (Doraville) GA (770) 448-6266 Baton Rouge. patching materials.P. TX (214) 330-9243 Davenport. MO (314) 521-3314 Tampa. We are nearby and ready to service you. give us a call. (Pico Rivera) CA (562) 942-2151 New Haven. Green. (Tonawanda) NY (716) 692-1761 Charlotte. gasketing. (Taylor) MI (734) 287-2150 Houston. AL (205) 788-1685 Buffalo. UT (801) 886-0545 San Francisco. (Calumet City) IL (708) 474-5350 Cincinnati. and associated products at distribution centers throughout the U. in any event within one (1) year from shipment of the applicable product or drawing. Seller retains title. point or (ii) refund an equitable portion of the purchase price or (iii) reperform drawing services at no cost to customers. ANY ACTION BY BUYER ARISING HEREUNDER OR RELATING HERETO.000:3%. if any. Buyer agrees to keep the information confidential and shall not reproduce or make the drawings available to third parties. SPECIAL TOOLING Notwithstanding any molds. delays of vendors or carriers. EXCEPT FOR GROSS NEGLIGENCE. outfits. labor difficulties. TAXES Any sales. 11. WITHOUT LIMITATION. C. use or other similar type taxes imposed on this sale or on this transaction are not included in the price. Seller assumes no liability therefor. point upon request. INSPECTION AND ACCEPTANCE A. A . at Seller’s option repossess the same upon Buyer’s default in payment hereunder and charge Buyer with any deficiency. If this contract involves partial performances. Buyer’s purchase order. 4. WHETHER BASED ON BREACH OF CONTRACT. B. and (if) these terms are intended to cover all activity of Seller and Buyer hereunder. 6.b.000 – 1%. Seller’s performance or delivery. tool. 8. 3. especially in seasons when alternate freezing and thawing occur. Defective and nonconforming items must be held for Seller’s inspection and returned to the original f. Technical advice is furnished as an accommodation to the Buyer. Seller warrants only that its products. 12. Any references by Seller to Buyer’s specifications and similar requirements are only to describe the products covered hereby and no warranties or other terms therein shall have any force or effect. 5. Seller will accept a valid exemption certificate from the Buyer if applicable. complete and exclusive statement of the agreement between the parties and may not be modified. if an exemption certificate previously accepted is not recognized by the governmental taxing authority involved and the Seller is required to pay the tax covered by such exemption certificate. if in sets. Such taxes shall be billed separately to the Buyer. INCLUDING BUT NOT LIMITED TO CLAIMS BASED ON LATENT DEFECTS. MINIMUM INVOICE CHARGE Individual orders or shipments from any of seller’s plants will be subject to a minimum charge of $250. including sales and use of products and all related matters including technical advice and services.STANDARD TERMS OF SALE Harbison-Walker Refractories Company STANDARD TERMS OF SALE 1. NOTICE Harbison-Walker Refractories Company values highly the confidence and good will of its customers and suppliers. delivery and service. Only standard pallets suitable for reuse are acceptable.5. a course of dealing. B. Any delays so occasioned shall effect a corresponding extension of Seller’s performance dates which are. Seller shall at its option have a right to recover as damages either the price as stated herein (upon recovery of the price the items involved shall become the property of the Buyer) or the profit (including reasonable overhead) which the Seller would have made from full performance together with incidental damages and reasonable costs.00. however.001. DRAWING SERVICES Drawing Services are quoted and provided to offer suggested methods of installation.o. price. However. settle and make changes in the product for the purpose of avoiding infringement Seller assumes no responsibility for charges of infringement of any process o method claims unless infringement of such claims is the result of following specific instructions furnished by Seller.000: 7%. represents a final. Seller shall not be responsible for nonperformance or delays in performance occasioned by any causes beyond Seller’s reasonable control. Overage shall be allowable on all shipments of sizes and shapes that are not carried in stock in accordance with the following: 1-100: 10%. MUST BE COMMENCED WITHIN ONE (1) YEAR AFTER THE CAUSE OF ACTION ACCRUES OR IT SHALL BE BARRED. all products shall be finally inspected and accepted within ten (10) days after arrival at point of delivery. together with any additional writings signed by Seller. Seller shall at its option either (i) repair o replace its product or work at the original F. Buyer’s payment for any drawing services recognizes that the information contained in the drawings is proprietary and is the intellectual property of Harbison-Walker. Unless Seller specifically assumes responsibility for work. ALLOWABLE VARIATION. All claims under this warranty must be made in writing immediately upon discovery and. In no event shall Buyer be entitled to incidental or consequential damages for late performance or a failure to perform.o. and Buyer accepts such advice at Buyer’s sole risk B. We offer our products only on their merit and we expect our customers to judge and purchase our products and services solely on the basis of quality. governmental actions and material shortages. C.GENERAL A. Before returning any pallets.b. fires. All claims whatsoever by Buyer (including claims for shortages) excepting only those provided for under the WARRANTY AND LIMITATION OF REMEDY AND LIABILITY and PATENTS Clauses hereof must be asserted in writing by Buyer within said ten (10) day period or they are waived. 7. There shall be no revocation of acceptance. Harbison-Walker buys only on merit and we judge and purchase solely on the basis of quality. OVERSHIPMENT AND PALLET RETURNS A. 5. Catalogs. die or pattern changes or amortization in connection herewith. Seller’s prices are based on these sales terms and (i) this document. PALLET BREAKAGE CHARGE Individual orders or shipments from Seller’s plant warehouse or service center requiring less than a full pallet are subject to a charge of $25. Drawing Services furnished hereunder shall conform to the standards of practice customary in the refractories business for drawing services of a similar nature. INCLUDING.B.10. IN NO EVENT SHALL BUYER BE ENTITLED TO INCIDENTAL OR CONSEQUENTIAL DAMAGES. 9. C.00 for each pallet less than a full pallet. THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS. supplemented. for consigning and routing instructions. PATENTS Seller agrees to assume the defense of any suit for infringement of any United Stales patents brought against Buyer to the extent such suit charges infringement of an apparatus or product claim by Seller’s product in and of itself provided (i) said product is built entirely to Seller’s design. WILLFUL MISCONDUCT AND REMEDIES PERMITTED UNDER THE PERFORMANCE INSPECTION AND ACCEPTANCE AND THE PATENTS CLAUSES HEREOF. Over. PERFORMANCE. delivery and service. The agreement formed hereby and the language herein shall be construed and enforced under the Uniform Commercial Code as in effect in the State of Pennsylvania on the date hereof. all such claims must be asserted within said ten (10) day period for each partial performance. Buyer’s approval of drawings and/or Buyer’s decision to rely upon them for construction purposes is at the sole risk of Buyer/Installer. D. Buyer agrees to promptly reimburse Seller for the taxes paid.22 Harbison-Walker . TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES. THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER. WARRANTY AND LIMITATION OF REMEDY AND LIABILITY A. explained or waived by parole evidence. 1. 10. or in any other way except in writing signed by an authorized representative of Seller. but not less than one shape or. one complete set- 101 -1.001-10. TITLE AND RISK OF LOSS Full risk of loss (including transportation delays and losses) shall pass to the Buyer upon delivery of products to the f. protected against weather. THE FOREGOING IS SELLER’S ONLY OBLIGATION AND BUYER’S EXCLUSIVE REMEDY FOR BREACH OF WARRANTY AND. EXPRESS IMPLIED AND STATUTORY. All refractories should be stored in a dry place. for security purposes only. price. THE FOREGOING IS BUYER’S EXCLUSIVE REMEDY AGAINST SELLER FOR ALL CLAIMS ARISING HEREUNDER OR RELATING HERETO WHETHER SUCH CLAIMS ARE BASED ON BREACH OF CONTRACT. Allowable variations from specified dimensions are plus 2% to minus 2% on dimensions over 4’’ and plus 3% to minus 3% on dimensions of 4’’ or less. all special tooling and related items shall be and remain the property of Seller. Rejection may be only for defects substantially impairing the value of products or work and Buyer’s remedy for lesser defects shall be those provided for under the WARRANTY AND LIMITATION OF REMEDY AND LIABILITY Clause. TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES. including. of this agreement and will be free from defects in material and workmanship. Upon Buyer’s submission of a claim as provided above and its substantiation. If Buyer wrongfully rejects or revokes acceptance of items tendered under this agreement or fails to make a payment due on or before delivery or repudiates this agreement. This Harbison-Walker Company policy applies in all relationships with our customers and suppliers. B. Likewise. Refractory brick and shapes should be handled with care to avoid scuffing and breaking. BUYER’S FAILURE TO SUBMIT A CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR DAMAGES OR OTHER RELIEF. when shipped. in any event understood to be approximate.000 – 2%. circulars and similar pamphlets of the Seller are issued for general information purposes only and shall not be deemed to modify the provisions hereof. 2. but not limited to. will meet all applicable specifications and other specific product requirements (including those of performance).O. to all products until paid for in full in cash and Seller may. Buyer should communicate with Seller. (ii) Buyer notifies Seller in writing of the filing of such suit within ten (10) days after the service of process thereof and (iii) Seller is given complete control of the defense of such suit including the right to defend. point. SECTION 9 Literature Products L-1 Applications L-2 . VERSAFLOW® C & 2-TOUGH® EmisshieldTM EXCELrate Extra-High Alumina Brick High Alumina Brick INSWOOL® Blanket Products INSBOARD Ceramic Fiber Boards INSWOOL® Fiber Modules INSWOOL® Utility Paper INSWOOL® 2300 Paper INSWOOL® Rope and Braids INSWOOL® Pumpable MAGSHOT® Gun Mix Super-Duty Fireclay Brick VIB-TECH Engineered Shapes Harbison-Walker LR-1 . H-W LITERATURE BY PRODUCT H-W Industrial Products Alumina-Chrome Brick Coarse Aggregate Castables . H-W LITERATURE BY APPLICATION Aluminum Industry Aluminum Melting/Holding Furnaces Aluminum Transfer Trough Cement & Lime H-W Long Brick for Rotary Kilns High Alumina & Basic Brick for Rotary Kiln Systems Light Weight Castable/Gunning for Rotary Kiln MAGSHOT® for Cement & Line Refractories for the Lime Industry THOR AZS/AZSP for Cement Nose Ring THOR AZSP Pumpable Castable for Cement & Lime TZ 352 DRY MORTAR Anti-Buildup for Existing Linings VERSAFLOW® 70 ADTECH® for Cement Kiln Nose Ring Industrial Foundry AOD Refractories for Industrial Foundries Breast Wall & Trough CUPOLA Channel Induction Refractories for Industrial Foundries Electric Arc Furnace for Industrial Foundries Ladle Refractories for Industrial Foundries NARGON® Porous Plugs for Industrial Foundries Upper Stack to Melt Zone for CUPOLA Pulp & Paper Industry Lime Recovery Kiln MAGSHOT® Gun Mix Petroleum Refining Fluid Cat Cracking Unit Sulfur Recovery Units Power Industry Ash Hopper Refractories Boiler Refractory Applications Coal Fired Cyclone Boilers Refractory Block Slag Dam LR-2 Harbison-Walker . Alumina-Chrome Brick Alumina-Chrome Brick RUBY® LW: A lightweight version of RUBY intended for service in corrosive hot face and Harbison-Walker Refractories Company’s alumina. important is the absence of any silicate bond phases. In prism spall testing. chrome brick consist of combinations of the two oxides fired to develop a solid-solution bond. corrosion and SERV 80. consisting of cycling from 2200˚F to a water quench. taining 80 to 95% chromic oxide for exception- al corrosion resistance and refractoriness. AUREX® 75 & AUREX® 75 SR: This is a Brick are available with chromic oxide content very dense. gasifier. Equally enhanced corrosion resistance. slagging incinerators. and chemical incinerator service. The solid solution bond developed in AUREX® 30 SR: A high purity thermal firing results in brick with exceptional hot strength shock resistant product with 30% chromic and load bearing ability. designed for extremely high temperature and corrosive service. Representative for information on these prod- ucts. Used in the burning zone of chemical very resistant to many corrosive agents encountered in ferrous foundry. These products are used in coal gasifiers and RUBY®: This is a 10% chromic oxide. Following is a summary ry containing 75% chromic oxide. chrome brick with 20% chromic oxide to provide tion of any low-melting eutectic phases. high purity. AUREX® 90 and AUREX® 95: These extremely dense. This means that all ratios of alumina and AUREX® 20 SR: A shock resistant alumina- chrome can be combined without the forma. It provides extraordinary resistance to chemical attack. 90% alumi- other highly corrosive applications. The chromic oxide is oxide. back-up applications. . na brick. fused grain refracto- ranging from 5 to 95%. Available in of selected products the regular and shock resistant (SR) versions. RUBY® DM: A version of RUBY utilizing These products are used in the highest wear the Densified Matrix (DM) technology to achieve areas of coal gasifiers. RUBY SR withstands 25 cycles. refractories con- severe slag attack. Contact your H-W Sales lower porosity and improved slag resistance. compared to 3 for the standard RUBY product. RUBY® SR: A version of RUBY utilizing the Shock Resistance (SR) technology to provide excellent resistance to thermal shock. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.2 Lime (CaO) 0.2 12. All Rights Reserved.7 89.7 77. pcf 201 213 200 124 Apparent porosity.1 0.1 0.900 At 2.1 27. All statements.2 0.8 – – The data given above are based on averages of test results on samples selected from routine plant production by standard A.850 1. informa- tion. % 17.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2002 Harbison-Walker Refractories Company.1 Trace Trace 0.3 0.1 Trace Magnesia (MgO) 0.1 0.2 Titania (TiO2) 0.600 Chemical Analysis %: Approx.6 64.M.4 – AUREX® 20 SR AUREX® 30 SR AUREX® 75 AUREX® 75 SR Bulk Density.5 49.S. % 17.350 3. (Calcined Basis) Silica (SiO2) 0.890 4.8 Other Oxides – – 3.400 7.660 At 2.1 0. psi At 70˚F 1. These results cannot be taken as minima or maxima for specification purposes.4 15. PA 15108 www. The suggested use assumes that all safety measures are taken by the user.2 Trace Trace Chromic Oxide (Cr2O3) 19.hwr.1 0. psi At 70˚F 5.2 0.0 9.520 1.4 Modulus of Rupture.700˚F 1.5 15.1 0.4 2.2 9.1 Trace Trace Trace Iron Oxide (Fe2O3) 0.5 0.1 0.6 17.2 Lime (CaO) 0. pcf 204 217 258 151 Apparent porosity.5 14.4 Alumina (Al2O3) 89.1 0.1 0.000 1.3 2.0 0.1 0. Cat# HW 88 (11/02) 3C .3 2.1 24. (Calcined Basis) Silica (SiO2) 0.200 – 2.2 Magnesia (MgO) Trace 0.9 Modulus of Rupture.1 1.2 0.250 2. and data given herein are believed to be accurate and reliable but are presented without guarantee. Variation from the above data may occur in individual test. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.3 Alumina (Al2O3) 75.1 Alkalies (Na2O + K2O) 0.1 Alkalies (Na2O + K2O) 0.5 Other Oxides 3. expressed or implied.8 11.6 83.4 Titania (TiO2) 0. warranty.700˚F 2.1 0.9 Trace Trace Iron Oxide (Fe2O3) 0.0 89. or responsibility of any kind.650 1.9 22.150 1.490 – Chemical Analysis %: Approx.T.3 74.1 0.1 0.1 Chromic Oxide (Cr2O3) 9.2 0. procedures where applicable. Alumina-Chrome Brick RUBY® RUBY® DM RUBY® SR RUBY® LW Bulk Density.2 0. 0 1.6 56.5 92.hwr. These results cannot be taken as minima or maxima for specification purposes. Variation from the above data may occur in individual tests.4 mechanical impact applications? Toughness. expressed or implied.2 0. Wire fibers are TECHNICAL DATA 2-TOUGHTM HP 2-TOUGHTM FA 2-TOUGHTM AL compressible.8 Na2O & K2O 0.7 0. Moon Township.2 2.2 What makes a refractory castable durable enough to withstand the abuse of high P2O5 – – – – 0. coarse aggregate-containing castables have significant advantages After heating at 2500 °F 17000 11000 – over wire fiber-containing products. information.6 2.0 67.1 Other Oxides – – 3.2 0.4 0. They also oxidize and adversely affect Maximum Service Temperature (°F) 3300 3200 2500 thermal shock resistance.4 2. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.1 0.8 3. Density (lb/ft3) After drying at 230 °F 200 208 210 Modulus of Rupture (psi) What makes a refractory castable tough enough to withstand the abuse of high mechani- After drying at 230 °F 800 2000 1900 cal impact at high temperatures? Coarse Aggregates.4 38. warranty. reducing the potential for cracking.0 1.1 0.1 & 2000ºF Hot MOR TiO2 – 2.8 0.2 1.5 0.3 MgO 2.0 The data given above are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable.2 0. VERSAFLOW® COARSE AGGREGATE TECHNICAL DATA 45 C 55/AR C 65/AL C 70 C 80 C ADTECH® ADTECH® ADTECH® ADTECH® ADTECH® Maximum Service Temperature (°F) 2700 3000 2400 3100 2800 Density (lb/ft3) After drying at 230 °F Modulus of Rupture (psi) After drying at 230 °F 135 1560 152 2300 168 1570 171 2000 175 2100 CASTABLES After heating at 1500 °F 1410 2520 1670 1800 2100 Cold Crush Strength (psi) After drying at 230 °F After heating at 1500 °F 9470 7620 9470 7620 13870 10760 8300 11800 12000 14000 VERSAFLOW® C & 2-TOUGHTM Castables Abrasion Resistance (cc loss) After heating at 1500 °F 9. Hot Modulus of Rupture (psi) At 2700 °F 1500 – – Chemical Analysis (%): Al2O3 95. After heating at 1500 °F 5000 – – At high temperatures.9 80..0 for SiO2 49.8 High Strength Castables Chemical Analysis.4 MgO 0.5 2.6 – – – 3. Cat# HW 192 (12/03) 1C .9 1.4 CaO 2.4 1. and data given herein are believed to be accurate and reliable but are presented without guarantee. coarse aggregates aid in the dissipation of the force of an impact.3 Other Oxides – – 1.2 0.8 Mechanical Abuse at High Temperature Fe2O3 0.0 – – The conventional method of increasing toughness is adding wire fibers. The suggested use assumes that all safety measures are taken by the user.5 TiO2 2.0 25.%: Al2O3 44.9 1. and flexible. All Rights Reserved. Harbison-Walker Refractories Company 400 Fairway Drive Increasing Wire Fiber Content.3 2.1 CaO 1.1 0.2 0. or responsibility of any kind.0 2.6 Vs Wire Content Fe2O3 – 0.3 0..7 2.0 71. All statements. After heating at 1500 °F 900 – – Cold Crush Strength (psi) After drying at 230 °F 7000 12400 9800 Similar to wire fibers. PA 15108 After Firing to 2910°F www.4 2.0 22.2 90.2 2. Na2O & K2O 0.0 Thermal Shock Resistance SiO2 0.1 0. They help to dissipate the force of an impact over a larger ADTECH® ADTECH® ADTECH® surface area.9 12.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company. heated VERSAFLOW® 70 C ADTECH® purity mix outstanding corrosion resistance. Typical Versatility uses. aluminum furnace jambs aluminum penetration inhibitor. ramps and sills. VERSAFLOW® C Castables 2-TOUGHTM Castables VERSAFLOW® C family of castables offer VERSAFLOW® 45 C ADTECH® 2-TOUGHTM Castables take the coarse grain concept to the next level. rotary kiln contact. high refractoriness and excellent impact test. and include both aluminum and characterize this product. sills and 2-TOUGHTM HP ADTECH® At our Technology Center West Mifflin. surviving almost 70 impacts!! This unique to traditional low cement castables which typi. 2-TOUGHTM AL ADTECH® . VERSAFLOW® C castables sur.Aluminum Cup Test with excellent strength. Typical uses. lent balance of physical properties. aggregate has a higher density than tabular alumina. This makes it very and lintels. ® The other 50% of the product is a high purity. or pumping. physical properties.Aluminum Cup Test . coarse grain your application. ash 2-TOUGHTM castables are comprised of 50% coarse grain having a diameter up to about 1-inch. ladle bottoms lifters. abrasion and impact resistance. coarse environments. Formulations range from fireclay to Exceptionally high strength and impact resistance 80% alumina. from a vibcast to hoppers and ladle covers. Typical uses for 2-TOUGHTM FA ADTECH® include ladle bottoms. Specifically designed for impact and abrasion Density (pcf) resistance in high alkali environments. aluminum resistant. 2-TOUGHTM AL An 80% alumina low cement coarse castable ADTECH® is specifically designed for use in aluminum VERSAFLOW® 65/AL C ADTECH® . It is essentially silica free. EXPRESS®-type bonding matrix. and precast Special Features and electric furnace deltas. whether it’s vibration casting. This means you can select the installation method best suited to A 55% alumina low cement. rotary kiln nose rings and steel applications including well blocks. 2-TOUGHTM FA ADTECH® tundish furniture. we test cruce bottoms. and cruces. For use in high wear areas in 2-TOUGHTM HP ADTECH® Impact Resistant aluminum contact such as ramps. chain sections. Even though within a specific water range. and reheat furnace skid block. Typical used include precast hearths. VERSAFLOW C castables can be mixed. troughs. 2-TOUGHTM products utilize EXPRESS® technology. Typical uses. VERSAFLOW® C castables are available in a variety of compositions to meet your specific 2-TOUGHTM FA ADTECH® needs. alu- minum furnace jambs and lintels. compared strength. resulting in significantly lower porosity than traditional 90% alumina castables. product has solved severe wear problems in several cally fail after 15 to 20 cycles. and rotary kiln lifters. foundry ladles. castable based on bauxitic calcines. coarse grain castable with high 2-TOUGHTM HP ADTECH® has set a record in the vive close to 40 cycles in this test. incinerators and aluminum furnace 2-TOUGHTM HP ADTECH® 200 VERSAFLOW® C castables feature an excel. They were developed multiple benefits: Fireclay-based low cement castable for use in for the most severe mechanical abuse environments. Its fused alumina coarse alkali resistant variations. to 2000°F. incinerator charge zones. they still require vibration to achieve their a pumpable consistency with little effect on VERSAFLOW® 55/AR C ADTECH® full density. resistant to aluminum corrosion. roofs. Installation high impact and abrasion environments up to 2700ºF. and contains an lifters and feed ends. 70% alumina. 2-TOUGHTM AL ADTECH® VERSAFLOW® 80 C ADTECH® 2-TOUGHTM AL ADTECH® VERSAFLOW® 80 C ADTECH® (pictured above) Rounding out the product line. grain castable. conventional casting. Typical uses. belly bands. Each is 2-TOUGHTM FA ADTECH® 208 specially engineered to combat the problems VERSAFLOW® 65/AL C ADTECH® (pictured left) 2-TOUGHTM AL ADTECH® 210 associated with today’s demanding furnace A 65% alumina. The combination of a coarse tabular alumina aggre- impact resistance by repeatedly firing a 1/2 - gate and a fine tabular alumina matrix gives this high inch projectile at a refractory sample. foundry ladles. They were developed multiple benefits: Fireclay-based low cement castable for use in for the most severe mechanical abuse environments. coarse grain castable with high 2-TOUGHTM HP ADTECH® has set a record in the vive close to 40 cycles in this test. surviving almost 70 impacts!! This unique to traditional low cement castables which typi. VERSAFLOW® C castables are available in a variety of compositions to meet your specific 2-TOUGHTM FA ADTECH® needs. 2-TOUGHTM AL ADTECH® . The combination of a coarse tabular alumina aggre- impact resistance by repeatedly firing a 1/2 - gate and a fine tabular alumina matrix gives this high inch projectile at a refractory sample. VERSAFLOW C castables can be mixed. incinerators and aluminum furnace 2-TOUGHTM HP ADTECH® 200 VERSAFLOW® C castables feature an excel. Specifically designed for impact and abrasion Density (pcf) resistance in high alkali environments. Typical uses. coarse grain your application. Typical uses for 2-TOUGHTM FA ADTECH® include ladle bottoms. and rotary kiln lifters. 2-TOUGHTM AL An 80% alumina low cement coarse castable ADTECH® is specifically designed for use in aluminum VERSAFLOW® 65/AL C ADTECH® . belly bands. Installation high impact and abrasion environments up to 2700ºF. ladle bottoms lifters.Aluminum Cup Test . Even though within a specific water range. VERSAFLOW® C Castables 2-TOUGHTM Castables VERSAFLOW® C family of castables offer VERSAFLOW® 45 C ADTECH® 2-TOUGHTM Castables take the coarse grain concept to the next level. Typical Versatility uses. abrasion and impact resistance. aluminum resistant. high refractoriness and excellent impact test. incinerator charge zones. and include both aluminum and characterize this product. 70% alumina. resulting in significantly lower porosity than traditional 90% alumina castables. heated VERSAFLOW® 70 C ADTECH® purity mix outstanding corrosion resistance. roofs.Aluminum Cup Test with excellent strength. they still require vibration to achieve their a pumpable consistency with little effect on VERSAFLOW® 55/AR C ADTECH® full density. and reheat furnace skid block. lent balance of physical properties. VERSAFLOW® C castables sur. compared strength. coarse environments. Its fused alumina coarse alkali resistant variations. chain sections. physical properties. from a vibcast to hoppers and ladle covers. and cruces. and contains an lifters and feed ends. grain castable. castable based on bauxitic calcines. alu- minum furnace jambs and lintels. whether it’s vibration casting. sills and 2-TOUGHTM HP ADTECH® At our Technology Center West Mifflin. This means you can select the installation method best suited to A 55% alumina low cement. conventional casting. ramps and sills. EXPRESS®-type bonding matrix. Formulations range from fireclay to Exceptionally high strength and impact resistance 80% alumina. 2-TOUGHTM products utilize EXPRESS® technology. resistant to aluminum corrosion. to 2000°F. For use in high wear areas in 2-TOUGHTM HP ADTECH® Impact Resistant aluminum contact such as ramps. It is essentially silica free. and precast Special Features and electric furnace deltas. Typical uses. Each is 2-TOUGHTM FA ADTECH® 208 specially engineered to combat the problems VERSAFLOW® 65/AL C ADTECH® (pictured left) 2-TOUGHTM AL ADTECH® 210 associated with today’s demanding furnace A 65% alumina. rotary kiln contact. ash 2-TOUGHTM castables are comprised of 50% coarse grain having a diameter up to about 1-inch. rotary kiln nose rings and steel applications including well blocks. ® The other 50% of the product is a high purity. or pumping. 2-TOUGHTM FA ADTECH® tundish furniture. 2-TOUGHTM AL ADTECH® VERSAFLOW® 80 C ADTECH® 2-TOUGHTM AL ADTECH® VERSAFLOW® 80 C ADTECH® (pictured above) Rounding out the product line. product has solved severe wear problems in several cally fail after 15 to 20 cycles. Typical uses. This makes it very and lintels. we test cruce bottoms. Typical used include precast hearths. troughs. aggregate has a higher density than tabular alumina. aluminum furnace jambs aluminum penetration inhibitor. 0 2.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company.2 1.2 What makes a refractory castable durable enough to withstand the abuse of high P2O5 – – – – 0. information.1 0.8 Mechanical Abuse at High Temperature Fe2O3 0.0 The data given above are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable. They also oxidize and adversely affect Maximum Service Temperature (°F) 3300 3200 2500 thermal shock resistance. reducing the potential for cracking.3 MgO 2.3 2. All Rights Reserved.9 12.6 – – – 3.2 0.0 1.4 2. All statements. Harbison-Walker Refractories Company 400 Fairway Drive Increasing Wire Fiber Content. Variation from the above data may occur in individual tests. expressed or implied.8 High Strength Castables Chemical Analysis.7 2.2 0. Wire fibers are TECHNICAL DATA 2-TOUGHTM HP 2-TOUGHTM FA 2-TOUGHTM AL compressible.1 CaO 1.0 1...4 2. coarse aggregates aid in the dissipation of the force of an impact.5 TiO2 2.5 92.1 0.2 90.2 0.0 Thermal Shock Resistance SiO2 0.6 56.0 for SiO2 49.9 1.2 0.9 80. These results cannot be taken as minima or maxima for specification purposes.1 Other Oxides – – 3. Density (lb/ft3) After drying at 230 °F 200 208 210 Modulus of Rupture (psi) What makes a refractory castable tough enough to withstand the abuse of high mechani- After drying at 230 °F 800 2000 1900 cal impact at high temperatures? Coarse Aggregates.4 mechanical impact applications? Toughness. After heating at 1500 °F 5000 – – At high temperatures. The suggested use assumes that all safety measures are taken by the user.2 2.1 0.6 Vs Wire Content Fe2O3 – 0.4 MgO 0.0 67.0 25.0 71.8 3. Cat# HW 192 (12/03) 1C . warranty.%: Al2O3 44.3 Other Oxides – – 1. or responsibility of any kind.4 0. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.4 38. Hot Modulus of Rupture (psi) At 2700 °F 1500 – – Chemical Analysis (%): Al2O3 95.2 0.5 0.4 1.4 CaO 2. Moon Township. coarse aggregate-containing castables have significant advantages After heating at 2500 °F 17000 11000 – over wire fiber-containing products.8 Na2O & K2O 0.3 0.6 2.5 2.0 22. Na2O & K2O 0.hwr. They help to dissipate the force of an impact over a larger ADTECH® ADTECH® ADTECH® surface area.1 & 2000ºF Hot MOR TiO2 – 2.8 0.2 2. PA 15108 After Firing to 2910°F www.1 0. and flexible. and data given herein are believed to be accurate and reliable but are presented without guarantee. VERSAFLOW® COARSE AGGREGATE TECHNICAL DATA 45 C 55/AR C 65/AL C 70 C 80 C ADTECH® ADTECH® ADTECH® ADTECH® ADTECH® Maximum Service Temperature (°F) 2700 3000 2400 3100 2800 Density (lb/ft3) After drying at 230 °F Modulus of Rupture (psi) After drying at 230 °F 135 1560 152 2300 168 1570 171 2000 175 2100 CASTABLES After heating at 1500 °F 1410 2520 1670 1800 2100 Cold Crush Strength (psi) After drying at 230 °F After heating at 1500 °F 9470 7620 9470 7620 13870 10760 8300 11800 12000 14000 VERSAFLOW® C & 2-TOUGHTM Castables Abrasion Resistance (cc loss) After heating at 1500 °F 9.0 – – The conventional method of increasing toughness is adding wire fibers.7 0.9 1. After heating at 1500 °F 900 – – Cold Crush Strength (psi) After drying at 230 °F 7000 12400 9800 Similar to wire fibers. X-34. room temperature. al steel.8 .0. Metals that easily oxi. peratures up to 3000º F and beyond. However when temperatures adhere to most ferrous and non-ferrous alloys. 0 increased abrasion resistance. Emissivity .0 Benefits of Emisshield™ Coatings substrate. STG. Refractories/Ceramic Emissivty 0. improving the uniformity of heating and 0. For applications where there is not a cooler load pres- ly prone to severe emissivity degradation at high tem- ent to absorb the emitted heat energy.and M-series of coatings for metal substrates will retaining rings.8 Emisshield™ is particularly effective include boiler TM Steel Coated with Emisshield M-1 tubes and water wall tubes in power plants. They protect them from corrosion by acids. PA 15108 EmisshieldTM is a trademark of WESSEX INCORPORATED www. rotary kiln Emisshield™ was developed and Most substrates have a rela- compositions. Emisshield™ will peratures. such as carbon steel and aluminum. try. an Emisshield™ coating on metal will absorb and emit Several Emisshield™ products have been the heat to the load. These coatings will provide the same applications for Emisshield™ STG and M formulations NASA Technology high emissivity properties as the refractory/ceramic include water-cooled electric furnace roofs. Many X-34 and abrasion of atmospheric reen- X-33 dramatically. Emisshield™ metals and alloys have relatively high emissivities at dross removal tools.) from the extreme tempertures increase. These coatings can withstand process tem- peratures in excess of 3000ºF and can extend the use temperature of metal components in high temperature industrial processes. Coating these tubes the furnace load. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. tors.com Phone:(412) 375-6901 Fax: (412) 375-6783 © 2004 Harbison-Walker Refractories Company Cat# HW 150 (5/04) . skirts resist oxidation and warping materials where heat and thermal degradation are fac. air refined from NASA technology tively high emissivity value from oxidation and chemical attack.4 Inconnel tories and ceramics by absorbing and re-radiating thermal energy to the efficiency of steam generation.hwr.9 at Emisshield™ coated steel kiln car markedly at higher temperatures. it maintains that value at tem- dize. and room temperature. preventing heat loss through the designed specifically for metal and thermal oxidation of the substrate. Applications where this property of 0. however their emissivities decrease exposed furnace structur. 0. and provide increases the service life of the tubes. ladle used to protect the next generation at room temperature. raising skirts. oxidation. but they also protect metal substrates nose ring castings. and abrasion. Metals (Patent Pending) Emisshield™ STG and M coatings can be applied to most ferrous and WESSEX INCORPORATED non-ferrous alloys to protect them from high temperatures.Metal When a cooler furnace load or atmosphere is available. alkalies. and many molten metals.0 . The use of Emisshield™ will increase thermal transfer to water tubes in boilers and power generation units. are particular.6 Emisshield™ will increase the conductive heat transfer Emisshield™ ST coatings reduce the temperature exposure of refrac- Zirconia on to these tubes. corrosion. Typical metal substrates. kiln car of Space Orbiters (X-33. especially aluminum. Emisshield™ coatings may be applied to many not only has an emissivity value of 0. these values fall the effective service temperatures of all alloys.(Low) to 1.2 Aluminum Cold Rolled Steel with Emisshield™ also prevents scale buildup and Alloy-A3003 slags. EmisshieldTM is a trademark of WESSEX INCORPORATED. alloy injector tubes.0 . metal slag and etc. The Emisshield™ blasters and grates. The use of Emisshield™ coatings will 0 500 1000 1500 2000 2500 Emisshield manufactured under license from NASA by TM provide longer refractory life and reduced operating costs. Temperature 0F WESSEX INCORPORATED.the absorption and release of energy rated on a scale of 0.(High) conduct the absorbed heat through to the metal sub- strate which conducts the heat to the cold face of the 1. 7µm while purple light has a wavelength of about 0. ranging in color from red to Emisshield TM Coating maintenance purple. the red substrate which will result in reduced maintenance and operating costs. By reradiat- exists. are known as grey coatings will always reradiate the absorbed energy to the positions form strong. the substrate from the high heat. Radio Micro. Emisshield™ com- ing energy back to a cooler load.7µm 0.9. provide improved resistance to alkali and acid attack. The technology that temperature range from room temperature to over If a refractory is not protected with an Emisshield™ coating. An and protection of the underlying substrate. energy keep the substrate it is protecting cooler. 3000ºF. a large portion NASA developed and Emisshield™ uses is based of thermal energy will conduct throughout the refractory.85 to 0.03nm 0. Friedrick designed specifically for dense refractories. Wessex 0. By protecting the substrate from the high heat. a materi. 0.85 to 0. prism to show all the visible colors (red through purple) redirection of heat can save energy and increase production.0 is a perfect Incorporated has created Thermal Energy Conduction black body.9 at ambient tem- The value of emissivity assigned to a substrate measures hotter in temperature than the purple. At a very low ∆T sive coatings.9 Decreased Conduction during prolonged high temperature service. par. Emissivity is rated on a scale column: faster and increases the amount of energy conducted of 0.2 to 0. Coating re-radiated energy and emissivity is shown in the next ducted through the substrate. value of 0.0 is known as a black tures of the visible spectrum.85 to 0.0 (high). no such perfect black body According to the second law of thermodynamics. and refractory fiber products. By protecting Not to Scale most refractories will steadily lose their ability to rera.4µm in the costs. These binders are totally peratures increase above 3000°F.5 depending on their composition. the cooler refracto- Emisshield™ coating will absorb and reradiate the same ry tempera- energy at an 85% to 90% efficiency rate and therefore ture prolongs has an emissivity value of 0. but the Emisshirld™ at lower temperatures.3µm 0. and in applications such as boilers and power generation Emissivity is defined as a refractory's ability to Thermal Energy conduction of Thermal Energy units where the furnace atmosphere or load is hotter than the absorb and subsequently release energy from its sur. Conduction of energy through a substrate can be greatly reduced with Emisshield™ coated brick (right) in a tunnel kiln visible spectrum. Emisshield™ exhibits a relatively beneficial uses in the Refractory/Ceramic industry that constant emissivity of 0.2-0.0 to 1. glassy coatings that can reduce erosion caused by high veloc- wall.90 through the entire help save time and money.85 to 0. substrate which will result in reduced maintenance and operating costs. Emisshield™ coatings are grey bodies. refractories will only have an emissivity products. EmisshieldTM is a trademark of WESSEX INCORPORATED . the surface temperature of the Emisshield™ and the temper- ty coatings. highly abrasion-resistant. decreasing fuel consumption ity gases and particulates. As to previous high emissivity coatings is its binder system. One of the benefits of Emisshield™ is the ability to and good resistance to reactions with ferrous and non-ferrous energy it absorbs. Therefore. safety for people.8-0. Substrate the life of the All energy (heat) has a measured wavelength that Conduction Decreased refractory Thermal Energy conduction of corresponds to a point on the electromagnetic spectrum. inorganic and emit no hydrocarbon volatiles or combustion that has an emissivity value of 1. These coatings have many that hits its surface. When white light is refracted through a application of an Emisshield™ coating when a colder load is present. Emisshield™ will increase the amount of heat con. Emisshield™ will maintain its high emissivity ature of the cooler furnace load increases. he moved his thermometer peratures. In other coolest surrounding. application of an Emisshield™ coating when a colder load is present. In addition. lightweight refrac- perature. A black body will absorb all energy regardless of past the visible red and noticed the temperature rose still. This causes furnaces to cool face to a furnace load. lower operating costs. This results in decreased energy usage and words. will always flow from hot to cold. Thermal Energy and reduces Humans can see visible light. wavelength. A substrate eletromagnetic spectrum. absorbing and re-radiating all radiant energy Emisshield™ Coatings.0 (low) to 1. Red light has a wavelength of about 0. thus the rating of 1. Emisshield™ will prolong the life of the and temperatures are taken of the refracted light. determined by NASA scientists.003nm There are numerous Emisshield™ products that have been has an emissivity value of 0.9. particularly aluminum. A black body will also reradiate all of the The majority of thermal energy falls into this infrared zone. Emisshield™ metals. In addition. Refractory / Ceramic al's ability to absorb and re-radiate energy. This preheat zone abut uncoated brick in firing zone.5 measured on a scale of 0. While many refractories Conduction of energy through a substrate can be greatly reduced with through water tubes.0. it maintains that level of emissivity as tem- indicates its ability to absorb and reradiate energy in William Herschel discovered the infrared portion of the tories. This can have a major benefit in pro. Those that come close to black body capabilities. At these high tem- relation to the electromagnetic spectrum. crystalline or vents heat transfer via conduction through the furnace bodies. combined with the emissivi- body. Many substrate materials have a high emissivity The amount of energy re-radiated increases with increasing upon the property of emissivity. While measuring the tempera. Emisshield™ not only 3km 30cm 3cm 0. where 1. Emissivity is licensed from NASA. Emisshield TM The equation describing the relationship between coating. Technical Information Refractory/Ceramic Using space age technology Emisshield™ utilizes the property of emissivity. have a high emissivity value at ambient temperatures. ty agent. the binders. In service. Refractory / Ceramic cally at elevated temperatures. Emisshield™ pre- with emissivity values of 0. To date. Unlike other high emissivi. Emisshield™ will prolong the life of the diate that energy as the temperature increases. but their emissivity drops dramati- emissivity and rises exponentially as the difference between products are unique and different than previous emis. Infrared Visible UV X Gamma ticularly in the infrared zone of the electromagnetic One of the distinguishing features of Emisshield™ compared Waves waves Light Light Rays Rays Rays spectrum where 90% of radiant energy is found. a black body is 100% efficient at absorbing and ductivity.4µm 0. This redirection of heat can save energy and increase production. reradiating the same energy.0. 7µm 0. the surface temperature of the Emisshield™ and the temper- ty coatings. inorganic and emit no hydrocarbon volatiles or combustion that has an emissivity value of 1. it maintains that level of emissivity as tem- indicates its ability to absorb and reradiate energy in William Herschel discovered the infrared portion of the tories. a black body is 100% efficient at absorbing and ductivity. One of the benefits of Emisshield™ is the ability to and good resistance to reactions with ferrous and non-ferrous energy it absorbs. Technical Information Refractory/Ceramic Using space age technology Emisshield™ utilizes the property of emissivity. At these high tem- relation to the electromagnetic spectrum. A substrate eletromagnetic spectrum. 0. Those that come close to black body capabilities. value of 0. Wessex 0.2-0.90 through the entire help save time and money. where 1. These binders are totally peratures increase above 3000°F. EmisshieldTM is a trademark of WESSEX INCORPORATED . lower operating costs. Many substrate materials have a high emissivity The amount of energy re-radiated increases with increasing upon the property of emissivity. Emisshield™ will maintain its high emissivity ature of the cooler furnace load increases. reradiating the same energy. will always flow from hot to cold. prism to show all the visible colors (red through purple) redirection of heat can save energy and increase production. Friedrick designed specifically for dense refractories. Emisshield™ coatings are grey bodies.5 depending on their composition.0. a materi. the red substrate which will result in reduced maintenance and operating costs. par. Emisshield TM The equation describing the relationship between coating. decreasing fuel consumption ity gases and particulates. This can have a major benefit in pro. Emisshield™ will increase the amount of heat con. combined with the emissivi- body. Conduction of energy through a substrate can be greatly reduced with Emisshield™ coated brick (right) in a tunnel kiln visible spectrum. Radio Micro. he moved his thermometer peratures. The technology that temperature range from room temperature to over If a refractory is not protected with an Emisshield™ coating. a large portion NASA developed and Emisshield™ uses is based of thermal energy will conduct throughout the refractory. Emisshield™ metals.003nm There are numerous Emisshield™ products that have been has an emissivity value of 0. provide improved resistance to alkali and acid attack.8-0. glassy coatings that can reduce erosion caused by high veloc- wall. A black body will also reradiate all of the The majority of thermal energy falls into this infrared zone. absorbing and re-radiating all radiant energy Emisshield™ Coatings. application of an Emisshield™ coating when a colder load is present. but the Emisshirld™ at lower temperatures.7µm while purple light has a wavelength of about 0.0 (low) to 1. ranging in color from red to Emisshield TM Coating maintenance purple.0 to 1. Unlike other high emissivi.03nm 0. By protecting Not to Scale most refractories will steadily lose their ability to rera. Emisshield™ will prolong the life of the diate that energy as the temperature increases. Substrate the life of the All energy (heat) has a measured wavelength that Conduction Decreased refractory Thermal Energy conduction of corresponds to a point on the electromagnetic spectrum.85 to 0. This redirection of heat can save energy and increase production.0 is a perfect Incorporated has created Thermal Energy Conduction black body. thus the rating of 1. 3000ºF. Emissivity is rated on a scale column: faster and increases the amount of energy conducted of 0. Emisshield™ pre- with emissivity values of 0.9. wavelength. Refractory / Ceramic al's ability to absorb and re-radiate energy. As to previous high emissivity coatings is its binder system. In service. have a high emissivity value at ambient temperatures. While many refractories Conduction of energy through a substrate can be greatly reduced with through water tubes. This preheat zone abut uncoated brick in firing zone. This results in decreased energy usage and words. A black body will absorb all energy regardless of past the visible red and noticed the temperature rose still. Emisshield™ exhibits a relatively beneficial uses in the Refractory/Ceramic industry that constant emissivity of 0.3µm 0. While measuring the tempera. Thermal Energy and reduces Humans can see visible light. In addition. Emisshield™ will prolong the life of the and temperatures are taken of the refracted light.0. crystalline or vents heat transfer via conduction through the furnace bodies. are known as grey coatings will always reradiate the absorbed energy to the positions form strong. Emissivity is licensed from NASA. Refractory / Ceramic cally at elevated temperatures. Emisshield™ not only 3km 30cm 3cm 0.9 at ambient tem- The value of emissivity assigned to a substrate measures hotter in temperature than the purple. lightweight refrac- perature. An and protection of the underlying substrate. the cooler refracto- Emisshield™ coating will absorb and reradiate the same ry tempera- energy at an 85% to 90% efficiency rate and therefore ture prolongs has an emissivity value of 0. no such perfect black body According to the second law of thermodynamics. the binders. By reradiat- exists. energy keep the substrate it is protecting cooler. When white light is refracted through a application of an Emisshield™ coating when a colder load is present. By protecting the substrate from the high heat. refractories will only have an emissivity products.4µm in the costs. Coating re-radiated energy and emissivity is shown in the next ducted through the substrate.5 measured on a scale of 0.0 (high). determined by NASA scientists. ty agent. In other coolest surrounding. and in applications such as boilers and power generation Emissivity is defined as a refractory's ability to Thermal Energy conduction of Thermal Energy units where the furnace atmosphere or load is hotter than the absorb and subsequently release energy from its sur. Therefore. highly abrasion-resistant. To date.9 Decreased Conduction during prolonged high temperature service. These coatings have many that hits its surface. This causes furnaces to cool face to a furnace load.85 to 0. Emisshield™ com- ing energy back to a cooler load. particularly aluminum.85 to 0. and refractory fiber products.0 is known as a black tures of the visible spectrum.4µm 0. Infrared Visible UV X Gamma ticularly in the infrared zone of the electromagnetic One of the distinguishing features of Emisshield™ compared Waves waves Light Light Rays Rays Rays spectrum where 90% of radiant energy is found.2 to 0. substrate which will result in reduced maintenance and operating costs.85 to 0. the substrate from the high heat. safety for people. In addition. but their emissivity drops dramati- emissivity and rises exponentially as the difference between products are unique and different than previous emis.9. Red light has a wavelength of about 0. At a very low ∆T sive coatings. Refractories/Ceramic Emissivty 0.the absorption and release of energy rated on a scale of 0.0 . Temperature 0F WESSEX INCORPORATED. However when temperatures adhere to most ferrous and non-ferrous alloys. alkalies. Metals that easily oxi. and provide increases the service life of the tubes. room temperature. oxidation.8 .0. STG.8 Emisshield™ is particularly effective include boiler TM Steel Coated with Emisshield M-1 tubes and water wall tubes in power plants.(High) conduct the absorbed heat through to the metal sub- strate which conducts the heat to the cold face of the 1. The use of Emisshield™ will increase thermal transfer to water tubes in boilers and power generation units. These coatings will provide the same applications for Emisshield™ STG and M formulations NASA Technology high emissivity properties as the refractory/ceramic include water-cooled electric furnace roofs. preventing heat loss through the designed specifically for metal and thermal oxidation of the substrate. and room temperature. For applications where there is not a cooler load pres- ly prone to severe emissivity degradation at high tem- ent to absorb the emitted heat energy.(Low) to 1. X-34.) from the extreme tempertures increase. Typical metal substrates.com Phone:(412) 375-6901 Fax: (412) 375-6783 © 2004 Harbison-Walker Refractories Company Cat# HW 150 (5/04) . Applications where this property of 0. EmisshieldTM is a trademark of WESSEX INCORPORATED. an Emisshield™ coating on metal will absorb and emit Several Emisshield™ products have been the heat to the load.0 Benefits of Emisshield™ Coatings substrate.and M-series of coatings for metal substrates will retaining rings.Metal When a cooler furnace load or atmosphere is available. these values fall the effective service temperatures of all alloys. Emisshield™ will peratures. but they also protect metal substrates nose ring castings. ladle used to protect the next generation at room temperature. try. it maintains that value at tem- dize. rotary kiln Emisshield™ was developed and Most substrates have a rela- compositions. and abrasion. 0. Emissivity . Emisshield™ metals and alloys have relatively high emissivities at dross removal tools.6 Emisshield™ will increase the conductive heat transfer Emisshield™ ST coatings reduce the temperature exposure of refrac- Zirconia on to these tubes. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. Coating these tubes the furnace load. peratures up to 3000º F and beyond. 0 increased abrasion resistance.9 at Emisshield™ coated steel kiln car markedly at higher temperatures. such as carbon steel and aluminum.4 Inconnel tories and ceramics by absorbing and re-radiating thermal energy to the efficiency of steam generation. however their emissivities decrease exposed furnace structur. PA 15108 EmisshieldTM is a trademark of WESSEX INCORPORATED www. especially aluminum. Metals (Patent Pending) Emisshield™ STG and M coatings can be applied to most ferrous and WESSEX INCORPORATED non-ferrous alloys to protect them from high temperatures. al steel. These coatings can withstand process tem- peratures in excess of 3000ºF and can extend the use temperature of metal components in high temperature industrial processes. They protect them from corrosion by acids. corrosion. The Emisshield™ blasters and grates. tors.2 Aluminum Cold Rolled Steel with Emisshield™ also prevents scale buildup and Alloy-A3003 slags. skirts resist oxidation and warping materials where heat and thermal degradation are fac. and many molten metals. The use of Emisshield™ coatings will 0 500 1000 1500 2000 2500 Emisshield manufactured under license from NASA by TM provide longer refractory life and reduced operating costs. raising skirts. air refined from NASA technology tively high emissivity value from oxidation and chemical attack. improving the uniformity of heating and 0. kiln car of Space Orbiters (X-33. Emisshield™ coatings may be applied to many not only has an emissivity value of 0. metal slag and etc. are particular. Many X-34 and abrasion of atmospheric reen- X-33 dramatically. alloy injector tubes.hwr.0 . down comers. hand packed. return lines Precast shapes Air Heaters Cement preheaters Paper kiln firing hoods. yielding good performance in exposure to alkali/salt conditions Set in four hours. This product can be rammed. regenerator return lines CFB cyclones. feed lines. slide valves. Features and Benefits: Maximum continuous service temperature of 2400OF One component requires the addition of water only Can be vib-cast. hand packed. can be heated immediately after set Rapid dryout Superior abrasion resistance Suitable for manufacturing precast shapes Typical Uses: Non-ferrous ladles and crucibles FCCU cyclones. Cement free. or gunned. cast. 80% alumina. phosphate bonded monolithic refractory that takes an air set. gunned. nose rings Brass rotary and induction furnace repairs Incinerators feed chutes. air rings. rammed. no air cure required. firing hoods Boilers Annealing furnace Coke calciners General repairs Packaging: Shipped in 55lb bags . erate EXCELERATE ABR PLUS Description: A one-component. dams. (Typical) VIBRATION CAST English Units Si Units Maximum Service Temperature: 2400OF 1316OC Approximate Amount of Water Required Per 55 lbs.hwr.400 91.0 Lime 3(CaO) 2. warranty.9 Titania (TiO2) 2. U.5 After Heating at 1500OF (816OC) 21. PA 15108 www.4 The data given above are based on averages of test results on samples selected from routine plant production by standard A. expressed or implied.3 Chemical Analysis: (Approximate) (Calcined Basis) Silica (SiO2) 8.8 After Heating at 1500OF (816OC) 14. information.com Phone: (412) 375-6600 Fax: (412) 375-6783 © 2004 Harbison-Walker Refractories Company. All Rights Reserved. procedures where applicable.9 Alkalies (Na2O) 1. Pints 3.T.866 After Heating at 1500OF (816OC) 172 2. and data given herein are believed to be accurate and reliable but are presented without guarantee.3 After Heating at 1500OF (816OC) 2200 15. The suggested use assumes that all safety measures are taken by the user..6 Iron Oxide (Fe2O3) 1. All statements.745 Modulus of Rupture lb/in2 MPa After Drying at 230OF (110OC) 1650 11.. Liters 1.S.6 Dry Weight Required for Installing lb/tf3 kg/m3 172 2.9 Phosphorus Pentoxide (P2O5) 3. Variation from the above data may occur in individual test.S.4 Abrasion Test -ASTM C-704 (cc loss) After Heating at 1500OF (816OC) 4.95 kg.1 Crushing Strength After Drying at 230OF (110OC) 13. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. TECHNICAL DATA EXCELERATE ABR PLUS Physical Properties. These results cannot be taken as minima or maxima for specification purposes.5 Apparent Porosity. or responsibility of any kind. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.754 Bulk Density .5 Per 24.0 Permanent Linear Change After Drying at 230OF (110OC) Negligible After Heating at 1500OF (816OC) -0.950 102. After Drying at 230OF (110OC) 179 2. Cat# HW 95 (1/04) 1C .9 Magnesia 3(MgO) 1.M. % After Drying at 230OF (110OC) 16.4% Alumina (Al2O3) 77. resistant extra-high alumina brick. KORUNDAL KORUNDAL XD® DM (5) XD is used in a wide range 20 TUFLINE™ 95 DM (40+) TUFLINE™ 90 DM (40+) of applications including TUFLINE™ 98 DM (26) 15 ferrous foundry. Extra-High Alumina Brick Extra-High Alumina Brick KORUNDAL XD® DM: A version of KORUNDAL XD offering the proprietary dense matrix (DM) formulation.200˚F With Water Quench 40* refractoriness and excellent physical properties. load test. Its high purity matrix improved bonding and lower porosity. na content of more than 80%. to thermal shock. chemical processing 10 units. All of these extra. enhanced resistance to alkali. 5 0 * Test concluded with maximum of 40 cycles. Those products with silica additions rely on the development of mullite as the TUFLINE® 90 DM: A version of KORUNDAL XD bonding phase. TUFLINE® 95 DM: This is a high-purity. ceramic TUFLINE™ 90 (35) kilns. mullite bonded brick. corundum- high alumina brick possess excellent hot strength as bonded product offering both the DM and thermal measured by hot modulus of rupture.Failure 1960’s. out DM technology. H-W® CORUNDUM DM: A 99% alumina refracto- TUFLINE® 90: This is an economical. GREENAL 90: A 90% alumina. Also available with- provides excellent physical properties. Other products rely on corundum as offering both the DM technology and enhanced resistance the bonding phase. The high purity formulation and low porosity of the used in chemical incinerators and quench chambers of DM (dense matrix) technology yields excellent incinerators processing fluorine-containing waste. . and creep shock resistance technology. TUFLINE® 98 DM: This product is the highest purity member of our corundum-bonded TUFLINE Family. particularly those con- taining iron oxide. which utilizes the DM technology to achieve. thermal shock ry brick.To . Special versions of these products. It offers pheres. The term extra-high alumina brick refers to refractory brick This product provides even lower porosity and better hot based on high-purity alumina and having an overall alumi. It continues to offer the best hot load strength in KORUNDAL XD® (10) 25 the industry. It The members of this family of extra-high alumina brick offers excellent high temperature strength and thermal include: shock resistance along with low porosity. resistance to corrosive slags. This brick has high Prism Spalling Test 2. and incinerators. phos-added 80% environments such as to fluorine and hydrogen atmos- alumina brick based on tabular alumina. This product is primarily test. with phosphorous pentoxide addition. strength than the standard product. have enhanced resistance to thermal shock. The very low sil- ica content makes it suitable for service in corrosive GREENAL 80 P: This is a burned. members of the TUFLINE® Family. 35 KORUNDAL XD : ® This product has been the 30 premier mullite-bonded 90% alumina brick since the Cycles . Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.3 0.3 Titania (TiO2) 1.5 17.4 12. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.9 19.1 Lime (CaO) <0.1 0.2 0.2 Alumina (Al2O3) 89.1 0.1 0.9 94.1 Trace Trace Trace 0.0 16.1 Alkalies (Na2O + K2O) 0.4 Modulus of Rupture. PA 15108 www.1 0. Cat# HW 87R (5/04) 3C . pcf 199 205 210 208 192 Apparent porosity.700˚F 2.4 Modulus of Rupture.1 0.T. % 13.9 – – Alkalies (Na2O + K2O) 0. psi At 70°F 2. expressed or implied.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2004 Harbison-Walker Refractories Company.6 99.1 97.730 4.1 0.1 Trace Trace Iron Oxide (Fe2O3) 0.1 90.230 1.M. information.070 1.5 9. or responsibility of any kind.2 Trace Trace Other Oxides 3.2 Phosphorus Pentoxide (P2O5) 2.050 2.6 13. and data given herein are believed to be accurate and reliable but are presented without guarantee.700˚F 1.6 Titania (TiO2) Trace Trace 0. pcf 177 182 189 186 195 Apparent porosity.7 9.500 1.S.1 0.370 1.1 0.000 2.930 Chemical Analysis: % Approximate (Calcined Basis) Silica (SiO2) 14.330 3.1 0.1 Magnesia (MgO) <0.320 1.3 90.1 0.4 89. % 15.5 0.0 12.2 0. Extra-High Alumina Brick GREENAL 80P TUFLINE® 90 GREENAL 90 KORUNDAL XD® KORUNDAL XD® DM Bulk Density.1 12.500 2.2 0.0 90.1 0.1 0.4 1.210 2.1 0.2 0.1 The data given above are based on averages of test results on samples selected from routine plant production by standard A.5 99.3 2.hwr.2 Alumina (Al2O3) 81.5 3.6 Trace Trace Trace Iron Oxide (Fe2O3) 0. Variation from the above data may occur in individual test. procedures where applicable.1 Lime (CaO) 0.1 0.9 – – TUFLINE® TUFLINE® TUFLINE® H-W® H-W® 90 DM 95 DM 98 DM CORUNDUM DM CORUNDUM Bulk Density. psi At 70°F 2.7 7.760 4.2 9.040 2.1 0.1 0.1 13. The suggested use assumes that all safety measures are taken by the user. warranty.1 0. These results cannot be taken as minima or maxima for specification purposes.840 At 2.800 At 2.080 810 – Chemical Analysis: % Approximate (Calcined Basis) Silica (SiO2) 6.1 Trace Trace Trace Trace Magnesia (MgO) Trace 0.2 0.990 1. All statements.6 – 1.1 0. All Rights Reserved. 60% alumina brick shows andalusite which enhances the load bearing ability. The very good physical properties and corrosion resistance. good spalling resistance. attack a n d c r e e p u n d e r s u s t a i n e d l o a d s . ARCO® 60: Is a 60% alumina firebrick exhibiting good properties for use at intermediate temperatures.5% or higher. and the ability to withstand attack by corro- low porosity and exceptional resistance to alkali sive slags. It also offers excel- KALA® SR: A shock resistant version of KALA . The term high-alumina brick refers to refractory brick hav. This product has good acceptance in CFB’s and incin- ing an alumina content of 47. The properties of these brick an be modified by the addition of other RESISTAL SM60C: This andalusite contening. very good hot strength. This descrip. The principle used in applications requiring excellent creep resistance bond phase is mullite with some amount of free silica such as sodium silicate melter and regenerator crowns. tive title distinguishes them from brick made predomi- nantly of clay or other alumino-silicates which have a UFALA® XCR: A further improvement to UFALA lower alumina content. bauxitic kaolins.It lent thermal shock resistance. Of particular interest is the addition of phosphorus pentoxide added. erators. 70% alu- mina brick with. UFALA® : This product manufactured from high purity bauxitic kaolin displays low porosity. materials. and good resistance to thermal shock and alkali attack. izes an addition of phosphoric acid. iron oxide and titania.High Alumina Brick High Alumina Brick (50 to 70% Al2O3) NIKE 60 AR: A 60% alumina andalusite contening brick. or reach high temperatures in service. KRUZITE® -70: Is a dense. lizing a high-purity mullite bond. 50% alumina refractory with strength. Major applications are chemical incinera- tors and lime sludge kilns. This product potash and lithia). It’s principle use has been in carbon black reac- ca to form a low melting glass when the brick are fired tor quench zones. Alkalies can be offers excellent resistance to both thermal cycling and particularly harmful since they ultimately react with sili. Brick of this class typically are with additional andalusite. creep. and glass. hot load KALA® : High-purity. This redues poros- ity and enhances alkali resistance. . This product has been widely based on low alkali. minor addition of phosphoric acid can improve the alkali resistance of these products. and incinerators. low porosity. P r i m a r y applications include carbon-baking VALOR® 70P: this burned 70% alumina brick utl- flues. but with much improved resistance to ther- mal cycling. Most naturally UFALA® UCR: A special version of this family uti- occurring minerals contain amounts of alkalies (soda. The presence of certain impurities is crit- ical in determining refractoriness. glass tank regenerators. possesses a similar degree of alkali and creep resistance.with excellent creep and abrasion resistance. 0 Phosphorus Pentoxide (P2O5) – – – – – Alkalies (Na2O + K2O) 0.hwr. warranty. or responsibility of any kind.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2002 Harbison-Walker Refractories Company.9 1. expressed or implied.7 0. % Prism Spalling Test At 2.2 The data given above are based on averages of test results on samples selected from routine plant production by standard A.S. psi 2.3 Phosphorus Pentoxide (P2O5) – – 2.6 61.1 0.350 Load Test.640°F 0.700 2. Cat# HW 91R (11/02) 3C . pcf 159 160 155 165 166 Modulus of Rupture.1 0.8 71.4 0.6 0.0 69. psi 2.3 62.4 0. These results cannot be taken as minima or maxima for specification purposes.M.3 0. information. and data given herein are believed to be accurate and reliable but are presented without guarantee.3 60.200 2.T.0 – Subsidence.3 0.2 0. % Prism Spalling Test At 2.2 0.0 – 1.200°F with Water 5-8 37-40 – 10-13 18-21 Quench Cycles to Failure Chemical Analysis % Alumina (Al2O3) 50. 25 psi At 2.820 1.6 0.6 Alkalies (Na2O + K2O) 0.400 Load Test.2 UFALA® XCR UFALA® UCR RESISTAL SM60C KRUZITE® -70 VALOR® P70 Density.200°F with Water 18-21 37-40 – 19-22 23-36 Quench Cycles to Failure Chemical Analysis % Alumina (Al2O3) 60.640 2.3 2. Variation from the above data may occur in individual test. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.060 1. 25 psi At 2. The suggested use assumes that all safety measures are taken by the user. pcf 153 153 155 157 159 Modulus of Rupture.600 2. High Alumina Brick KALA® KALA® SR ARCO® 60 UFALA® NIKE 60 AR Density.1 63.150 2. PA 15108 www.500 1.0 – 1.4 Subsidence.0 58. All Rights Reserved.0 51.640°F 0. All statements. procedures where applicable. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. . INSWOOL® HP is a high purity blanket that is made from a 50/50 blend of alumina and silica that has superior tensile strength and handling capabilities. silica and zirconia. Furnace structures can be Furnace Linings & Seals made lighter and furnace components can be shop fabricated with fiber linings. The only Furnace Packing Material exceptions are hydrofluoric and phosphoric acid. These linings can be fired to peak operating Backup for Fiber Linings temperature immediately after installation. This product can be used in applications up to 2300 0F and is available in 4. Petrochemical and Metals Markets Lower Thermal Conductivity Removable Insulating Blankets & Pads Heat losses are reduced at high temperatures Furnace & Boiler Repair Lower Heat Storage Furnace Door Linings Faster heat up and cool down for increased Glass Furnace Crown Insulation productivity Soaking Pit Seals Reduces Fuel Consumption Flexible High Temperature Pipe Insulation Lowers Operating Costs Insulation for Steam & Gas Turbines Expansion Joint Seals Thermal Shock Resistance High Temperature Gasketing Lightweight Allows for extreme change in temperatures INSWOOL® HTZ Longer furnace campaigns Reheat Furnaces Soaking Pit Seals Allows flexibility in firing cycles Refractory and Ceramic Kilns Completely inorganic with no binders Boiler Linings INSWOOL® blanket products are easy to install. INSWOOL® Ceramic Fiber Blankets provide excellent Typical Applications handling strength. The product is made from a blend of alumina. ® INSWOOL Blanket products INSWOOL® Ceramic Fiber Blankets are a complete INSWOOL® CG is an alumina silica blanket used in product line for applications temperatures up to 2600oF. Furnace Linings for Ceramic. low thermal conductivity. 6 and 8 pound densities. INSWOOL® HTZ is a blanket used in higher temperature applications up to 2600 0F with low shrinkage characteristics. which is needled into lightweight. Expansion Joint Material INSWOOL® fiber blankets have excellent chemical Insulation Pads stability and are unaffected by most chemicals. low heat INSWOOL® HP storage and are resistant to thermal shock. It is a high quality product These products are produced from a spun ceramic fiber that can be used as back up insulation for most furnace applications. applications up to 2000 0F. there is no curing or dry out time when using INSWOOL® ceramic fiber INSWOOL® CG blankets. flexible blankets. No Glass Furnace Crown Insulation special forming is required and plant personnel can be Refractory Kilns used to install the product. Also. 4 1. oF: 3200 3200 2750 Fiber Diameter. 1 in.78 1. lb.2 1.S. Cat# HW 99R (01/04) 3C .43 The data given above are based on averages of test results on samples selected from routine plant production by standard A.2 Lime (CaO3) 0.4. procedures where applicable. oF: 2300 2600 2000 Continous Use.0 44. microns: 3 3 3 . warranty.85 8# 0.55 1.43 0.1 0.2 0. PA 15108 www. BTU-in/ hr ft2 0F: INSWOOL® HP and INSWOOL® HTZ BLANKET 600oF 800oF 1000oF 1200oF 1400oF 1600oF Blanket Density 4# 0.85 1. or responsibility of any kind.3 48. The suggested use assumes that all safety measures are taken by the user./in2: 10 10 8 Cross Direction.0 36.1 -- Magnesia (MgO)2 0.97 1.8lb/ft2.1 -- Alkalies (Na2O+K2O) 0.1 -- Titania (TiO2 0.2 0.2 1.16 1.8 2.1 0.2 <0.63 0. All statements.: Machine Direction. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.1 <1. lb.M.5 Average Fiber Length.0 1.0 Silica (SiO2) 54.0 54. information. and data given herein are believed to be accurate and reliable but are presented without guarantee. % (Calcined Basis) Alumina (Al2O3) 45. All Rights Reserved.1 0. oF: 2150 2450 1800 Melting Point. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.T.2 6# 0.0 Zirconia (ZrO2) -.4 -- Iron Oxide (Fe2O3) 0. These results cannot be taken as minima or maxima for specification purposes. Variation from the above data may occur in individual test.56 0.7 0./in2: 6 6 5 Chemical Analysis: (approximate). TECHNICAL DATA Typical Physical Properties INSWOOL® HP INSWOOL® HTZ INSWOOL® CG Color: white white white Maximum Recommended Temperture: Intermittent Use. inches: 3 3 3 Tensile Strength . expressed or implied.73 0.5 Typical Thermal Conductivity. 15.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company.hwr. Each CSW module is then attached over the stud and tightened with a bolt. This is done by welding a 304 stainless steel 3/8" stud to the furnace wall. The CSW blanket module that is made into 2 halves with (Center Stud Weld) and FQW (Folded a Quick Weld attachment. It requires no stud pattern or superior handling characteristic and layout. quality spun INSWOOL® HP and HTZ The advantage to the FQW module is the speed blanket. Spun INSWOOL® blanket has of installation. CSW modules linings can be installed in parquet or soldier course pattern using batten strips. This new design Quick Weld) modules are made from high provides for no blind welds in the lining design.3# is standard. Dual studs and holes attachments can be added for larger size CSW modules upon request. Both attachment place the module on the wall and pull the systems provide for quick installation and trigger.7# and 12# densities are available. parquet or soldier course pattern using batten strips. CSW Modules (Center Stud Weld) The CSW Module system is a module using a 304 stainless steel channel and Hot Face Cold Face two rods that runs through the blanket. 10#. The modules are compressed to the specific density's to prevent shrinkage for longer module life and durability. Using a quick weld stud gun. Special size CSW Modules modules are also available upon request. Hot Face Cold Face . Standard sizes for both types of modules are 12" long x 12" wide. FQW modules can be installed in a less downtime for the installer. This module is installed by using a pre. Various densities are available. simply strength characteristics. FQW Modules positioned stud pattern. 8#. 10. 9. ® INSWOOL Ceramic Fiber MODULES INSWOOL® Ceramic Fiber Modules are a FQW Modules (Folded Quick Weld) product line designed for full thickness The FQW Module system is a folded linings in furnace applications. 3#.add 20000 F to 21500F use one batten strip 2-3 weeks delivery for special hardware -over 21500F use a double batten strip Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.> 21500F 3’ .SOLDIER · Special Hardware available upon request Soldier Course Design.For applications of 20000 F and less Blanket Options · HP . 12" x 24" 3’ .1¾” 6” 1¼” NOM. Cat# HW 96 (05/04) 25C . INSWOOL® Ceramic Fiber Modules Applications Furnace Design Perimeters · Stress Relieving Furnaces 3’ . 10#. 9.0” 6” Thickness · 4" -12" Thick 6” 1’ . Sizes ONE FOLD 1” 8PCF BLANKET · CSW .0” 6” 1’ . PA 15108 www.For applications of o 310SS.0” · Annealing Furnaces · Car Bottom Furnaces · Process Heaters · Refinery Heaters 3’ .12" x 12".1¾” 1’ . 316SS.2½” · FQW .heat Ladles Covers Fold · Forge Furnaces Orientation PARQUET Specifications Parquet Design .0” · Reheat Furnaces · Furnace Linings for Kilns & Boilers · Soaking Pit Covers · Pre.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2004 Harbison-Walker Refractories Company. 10. 330SS and Inconel .7# & 12# Fold Orientation Hardware · 304 SS Standard Base and Rods WELD STUD ASSEMBLY . All Rights Reserved.0” 1’ .15000F .12" x 12" · Sidewalls only 24" x 24" · Special sizes available upon request Density · 8#.hwr.21500F · HTZ . GAP. These products are rigid and 2". INSBOARD® products can also be from 2300oF to 3000oF. 11/2" and easy to install. ceramic fiber boards with excellent insulating properties and high mechanical strength. 1". 1/2". The products possess superior strength and good handling INSBOARD® comes in standard size of 36" characteristics. vibration or mechanical stress. It is manufactured from bulk ceramic fiber and special binders. ® INSBOARD Ceramic Fiber Boards INSBOARD® is a family of vacuum-formed. dense product that has low thermal conductivity and excellent resistance to thermal shock and chemical attack. The product line has three types and self supporting which makes installation of products for applications that range simple. INSBOARD® is lightweight x 48" with thicknesses of 1/4". This yields a strong. They offer good thermal stability. Applications 2300LW 2300HD 2600 3000 Full Thickness Furnace Linings x x x Board over Blanket Linings x x x x Refractory Backup Insulation x x x x Rigid High Temperature Gaskets x x Hot Face Linings for Ceramic Kilns & Petrochemical Furnaces x x Glass Tank Side & End Wall Insulation x x x x Insulation with High Velocities x x x x Hot Gas Duct Linings x x x x Expansion Joint Material x x Heat Shields for Personnel Protection x x x x Pouring Forms for Castable x Combustion Chambers x x x x High Temperatures Dryers x x x x Industrial Heat Shields x x x x Flue & Chimney Linings / Kilns & Furnaces x x x x High Temperature Muffles x x x Heat Treating Furnaces x . machined or cut into shapes. INSBOARD® is an excellent choice for applications with high velocity. 9 2400oF – – – 2. F: o 2100 2100 2400 2700 Melting Point.8 0.M.oF: 400oF 0. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.9 1.2 1. psi: 10% Deformation: 20 50 30 18 25% Deformation: 65 110 50 30 Hardness.6 0.4 The data given above are based on averages of test results on samples selected from routine plant production by standard A.T. procedures where applicable. expressed or implied.6 0.1 2. or responsibility of any kind. warranty. %: After 2000OF 2.5 After 2600OF – – 3.3 0. The suggested use assumes that all safety measures are taken by the user. information.3 – – After 2200 F O 3.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company. TECHNICAL DATA Physical Properties INSBOARD® 2300 LW 2300 HD 2600 3000 Density.4 Thermal Conductivity. Btu-in/hr-ft2 .).4 2. OF: 3200 3200 3200 3200 Modulus of Rupture.2 1. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.4 – – 800oF 0. lbs/ft2: 14-18 26 18 12 Continuous Use Limit. oF: 2300 2300 2600 3000 Recommended Use Limit. Cat# HW 102 (09/03) 5C .0 1.6 0.9 1600oF 1. All statements.4 2000oF 1.8 0.0 1. All Rights Reserved. and data given herein are believed to be accurate and reliable but are presented without guarantee.1 1.S.8 2. These results cannot be taken as minima or maxima for specification purposes.hwr. PA 15108 www.0 1.8 – After 2400OF – – 2. Variation from the above data may occur in individual test. lbs.6 After 3000OF – – – 3.6 1200oF 0. psi: 75 200 120 70 Compressive Strength.: 10% Deformation: 18 50 30 15 25% Deformation: 40 120 60 40 Shrinkage (24hrs.9 After 2800OF – – – 2.8 0.2 1. Wrap or Form fibers formed into a highly flexible sheet./in2: 8 22 Transfer Line Protection Welding & Brazing Protection Thickness Specifications Nominal: 1/16" 1/8" Steel & Nonferrous Investment Casting Mold Wrap Ladle Refractory Backup Backup Linings for Metal Troughs Hot Top Linings Coke Oven Door Seals . It is recommended for continuous use at Low Thermal Conductivity temperatures up to 2300OF in applications Thermal Shock Resistant where insulating efficiency is less critical.lbs. high purity alumina-silica Easy to Cut. Applications INSWOOL® Utility Paper resists both oxidation Ware Separator and reduction. INSWOOL® Utility Paper is designed for use Temperature Stability primarily in applications where thermal stability Resilient and high temperature protection up to 2300OF are most important. Kiln Car Deck Covering Machine Direction: 3500 5800 Cross Direction: 2400 5000 Petrochemical Mullen Burst .gms. If it becomes wet due to water.in. its thermal and physical Ceramic and Glass properties with return upon drying. steam. Because of its high-purity chemistry. Metal Clad Brick UG-F UG-J Glass Tank Backup Tensile Strength . INSWOOL ® Utility Paper INSWOOL® Utility Paper is processed from Features unwashed spun. UG-F and UG-J Low Heat Storage INSWOOL® Utility Paper contains an organic Good Dielectric Strength binder to provide increased handling strength at room temperature. It possesses excellent Excellent Corrosion Resistance chemical stability and resists attack from High Heat Reflectance corrosive agents. It is avaiable in two Lightweight grades. or oil. Exceptions are hydrofluoric and phosphoric acids and concentrated alkalis. or responsibility of any kind. The suggested use assumes that all safety measures are taken by the user.67 The data given above are based on averages of test results on samples selected from routine plant production by standard A. expressed or implied. TECHNICAL DATA Typical Physical Properties INSWOOL® Utility Paper Melting Point.03 Others2 0. Cat# HW 97 (09/03) 3C .com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company.S. All Rights Reserved. procedures where applicable.M.OF: Mean Temperature OF 500 0. Variation from the above data may occur in individual test. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.71 1300 1. OF: 3200 Maximum Use Temperature. LOI: 8% Density lbs/ft2: 6-9 Dielectric Strength: 50 Thermal Conductivity.hwr. All statements. Btu-in/hr-ft2 . These results cannot be taken as minima or maxima for specification purposes. warranty. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.17 Loss on Ignition.18 Iron Oxide (Fe2O3) 0.0 Silica (SiO2) 52. information. F: O 2300 Chemical Analysis: (approximate). PA 15108 www.47 800 0.T.6 Alkalies (Na2O) 0. % (Calcined Basis) Alumina (Al2O3) 47.19 1600 1. and data given herein are believed to be accurate and reliable but are presented without guarantee. Steel & Nonferrous Machine Direction 2400 3200 6000 Cross Direction 2200 2700 5200 Investment Casting Mold Wrap Mullen Burst . Good Dielectric Strength and its high tensile strength makes it ideal as a gasket. F. A. Excellent Corrosion Resistance High Heat Reflectance INSWOOL® 2300 Paper contains an organic binder to provide increased handling strength Applications at room temperature. and J. Metal Clad Brick Because of its high purity chemistry.gms. Kiln Car Deck Covering steam or oil./in2 7 10 24 Ladle Refractory Backup Backup Linings for Metal Troughs Thickness Specifications Nominal 1/32" 1/16" 1/8" Hot Top Linings Coke Oven Door Seals .in. It possesses excellent Ware Separator chemical stability and resists attack from most corrosive agents. ® INSWOOL 2300 Paper INSWOOL® 2300 Paper is processed from Features washed.lbs. its thermal and physical properties will return upon drying. has low shot Lightweight content and offers low thermal conductivity. Low Heat Storage It’s highly uniform structure assures homogeneous thermal conductivity throughout. If it becomes wet due to water. INSWOOL® 2300 Paper resists both oxidation Glass Tank Backup and reduction. high purity fibers formed into Easy to Cut. It is available in three grades. Wrap or Form highly flexible sheet. Temperature Stability Resilient Because it is processed from washed fiber. spun. It is recommended for continuous use at temperatures up to 2300OF Low Thermal Conductivity in applications where insulating efficiency and Thermal Shock Resistant high strength are important. Exceptions are hydrofluoric Ceramic and Glass and phosphoric acids and concentrated alkalis. seal or spacer material. INSWOOL® 2300 Paper is clean. Petrochemical Transfer Line Protection INSWOOL® 2300 Paper Welding & Brazing Protection A F J Tensile Strength . warranty.hwr. LOI: 8% Density lbs/ft2: 6-9 Dielectric Strength: 50 Thermal Conductivity.OF: Mean Temperature OF 500 0. The suggested use assumes that all safety measures are taken by the user. TECHNICAL DATA Typical Physical Properties INSWOOL® 2300 Paper Melting Point. All statements.87 1600 1. Btu-in/hr-ft2 .05 The data given above are based on averages of test results on samples selected from routine plant production by standard A. All Rights Reserved. and data given herein are believed to be accurate and reliable but are presented without guarantee.18 Iron Oxide (Fe2O3) 0. These results cannot be taken as minima or maxima for specification purposes. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. Cat# HW 98 (05/03) 3C . OF: 3200 Maximum Use Temperature.39 800 0. procedures where applicable.M. % (Calcined Basis) Alumina (Al2O3) 47.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company. Variation from the above data may occur in individual test.03 Others 2 0.6 Alkalies (Na2O) 0. expressed or implied.17 Loss on Ignition.T.0 Silica (SiO2) 52. PA 15108 www. or responsibility of any kind. F: O 2300 Chemical Analysis: (approximate).55 1300 0.S. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. information. the ceramic fiber is braided to provide maximum resistance to mechanical abuse. No water of hydration is present. Aside from its superior strength. Exceptions are hydrofluoric and phosphoric acids and concentrated alkalies. packing and sealing in and around high-temperature heating equipment. In choosing the most appropriate product for a particular application. resisting attack from most corrosive agents. . Typical applications for these products include gasketing. Produced from ceramic fibers. round and square braids also exhibit minimal unravelling when cut. these prod- ucts exhibit excellent chemical stability. resulting in a product that is higher in density and thus more durable than 3-ply Twisted Rope. this product is relatively soft and lower in density than other ropes or braids. These fiber ropes and braids also resist oxidation and reduction. thermal properties are completely restored upon drying. High Density Rope High Density Rope is made from many strands of ceramic fiber yarn formed into three plys and then twisted. 3-ply Twisted Rope is the most economical choice. the following product descriptions should be considered: 3-Ply Twisted Rope Produced by twisting 3-plys of ceramic fiber wicking.INSWOOL ® Ropes & Braids 3-Ply High Density Square Round Twisted Rope Rope Braid Braid INSWOOL® Ropes and Braids H-W Refractories provides a family of ropes and braids for industrial use in temperatures up to 2300°F (1260°C). If wet by water or steam. Round Braid and Square Braid The highest density of all our rope offerings. This prod- uct is also available with an inconel insert which drastically increases resistance to mechanical abuse. 2 7/8 275 11.8 1-1/2 50 4.6 3/8 500 45 5/8 200 21.) 1/4 1700 91.1 1-1/4 100 3.5 3/8 250 26.2 5/8 250 9.4 1-1/2 50 2.8 3/4 375 16.5 3/4 250 9.3 7/8 175 7.9 1/4 450 58. All Rights Reserved.0 2 50 1.1 3/4 175 7.1 3/8 900 42.7 1 125 5. PA 15108 Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2002 Harbison-Walker Refractories Company.4 Round Braid Square Braid Diameter of Feet Per Approximate Yield Diameter of Feet Per Approximate Yield Section (Inches) Roll (Feet/Lb. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.) 1/4 2250 110 1/4 500 101.4 1 225 10.3 1/2 725 30 3/4 100 15.) Section (Inches) Roll (Feet/Lb. INSWOOL® ROPES AND BRAIDS Product Availabilty 3-Ply Twisted Rope High Density Twisted Rope Diameter of Feet Per Approximate Yield Diameter of Feet Per Approximate Yield Section (Inches) Roll (Feet/Lb.3 Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.3 3/8 400 42.5 3/8 575 26.5 2 35 1.6 5/8 525 18. The suggested use assumes that all safety measures are taken by the user.8 1-1/2 75 2.0 1-1/4 175 6.8 1/2 200 23.3 1/2 500 23.0 1/2 300 30 7/8 100 10.3 2 50 2.3 1/4 900 110 3/8 300 51.1 1/4 700 91.) Section (Inches) Roll (Feet/Lb.1 7/8 125 5.5 1-1/4 75 2.9 1/4 1075 58.5 1-1/2 125 4.8 5/8 350 11.3 3/8 1300 45 1/2 200 28.2 1-1/4 75 6.6 1 50 8.5 1/2 150 17.5 1/2 325 17.3 2 50 2. Cat# HW 100 (9/02) 3C .1 1 100 4. caulking tube in addition to standard 5 gallon buckets Ready to use Easy to apply INSWOOL® PUMPABLE is a 23000F ceramic fiber. INSWOOL ® PUMPABLE INSWOOL® PUMPABLE 23000F Ceramic Fiber Pumpable Material High temperature caulking putty Now available in standard 101/2 oz. After heating to 20000F -3.S. or responsibility of any kind. The data given above are based on averages of tests results on samples selected from routine plant production by standard A. All statements./ft. but compressible board-like consistency. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. These results cannot be taken as minima or maxima for specification purposes. and for filling contraction cracks. The suggested use assumes that all safety measures are taken by the user. and can generally be dried or put into heat Alkalies Na2O + K2O 0.0% joints. Variation from the above data may occur in individual test.2% INSWOOL® PUMPABLE has excellent Lime CaO 7.3): 68 or can be used to fill small voids and thin Dried Density (lbs. expressed or implied. caulking tube (12 per case) and 29 oz. procedures where applicable. information. warranty. putty-like consistency material and was especially formulated for pumping with special equipment.9% containment service without preheating. It can be used to Maximum temperature ratings: 23000F fill hot spots behind existing hot face lining Wet Density (lbs.3% thermal shock resistance. caulking tubes (6 per Physical Properties case) and are available through our Plant or Distribution Centers.Calcined basis to a firm. .M. and data given herein are believed to be accurate and reliable but are presented without guarantee. Permanent Linear Change: INSWOOL® PUMPABLE is a lightweight After heating to 15000F + 0. It dries Chemical Analysis . It is suitable for expansion Silica SiO2 60.1% It is an excellent thermal insulator./ft.3): 27 cracks. and 29 oz.1% material with very low thermal conductivity. Alumina Al2O3 31.6% Iron Oxides Fe2O3 0. It is now available in 101/2 oz.T. ladles. minerals processing and other industries… Harbison-Walker Refractories Company (H-W) provides high-per- formance refractory solutions to all non-steel-related industries. In addition to its own outstanding line of products. LMFs. finish- ing. Products from all these companies are available through: For Industrial Sales: Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. The compa- ny makes high-performance products for BOFs. glass. and hydrocarbon and minerals processing industries. along with a full line of insulating ceramic fibers. copper. Manufacturing products exclusively for NARCO and Harbison-Walker… A. aluminum. casthouses. many of which have become indus- try standards. incineration. PA 15108 Phone: (412) 375-6600 Fax: (412) 375-6783 © 2002 Harbison-Walker Refractories Company. H-W is recognized worldwide for its technical support and expertise. EAFs. cement. NARCO also can design and implement a turnkey refractory management program to meet your facility’s specialized requirements. ferrous foundry. and flow control applications. # HW106 (8/02) 3C . In addition to providing complete technical support services. Founded in 1875. Exclusively serving the non-ferrous metals. the company is North America’s oldest refrac- tory maker. Cat. glass. Exclusively serving the iron and steelmaking industries… North American Refractories Company (NARCO) is a leading supplier of refractory solutions to the iron and steel industries. hydro- carbon. blast furnaces.P. alternative ironmaking. Green Refractories (APG) makes products for the iron and steel. The company also has one of the world’s top capabilities for cus- tomized pre-cast shapes. All rights reserved. • Superior Smelt Resistance • Chrome-Free Composition • Good Thermal Conductivity • Ease of Installation • Proven Track Record MAGSHOT was developed to help meet the environmental and performance needs of the pulp and paper industry. laboratory tests have shown that this unique dicalcium silicate bonded magnesite product provides an exceptional level of chemical resistance to molten smelt. Other features include: • Low dust and rebounds Typical 80% Alumina- Phosphate Bonded Plastic • Quick dry-out schedule Remarks: Eroded. hand-packed. As for performance. Cracked. Both products require mini- Alteration. A long record of success in numerous recovery boiler systems throughout the industry testifies to the durability of MAGSHOT where it matters most – MAGSHOT installed in the lower section under demanding field conditions. No Build-up mal curing time – heat-up (100˚F/hr. For larger cast MAGSHOT installations this product is available as Remarks: No Erosion. Superior Smelt Resistance Demonstrated in Drip Slag Tests Ease of Installation Ease of installation makes MAGSHOT® the product Samples After Drip Test: of choice for quick-turnaround repairs.) can begin two hours after installation. proven to give superior life in recovery boiler systems in pulp and paper mills. Bloated Slag Build-up • Up to one year shelf life . No MAGSHOT® CASTABLE. Its chrome-free composition eliminates concerns about disposal of possibly hazardous chrome-containing refractory waste. It can be gunned. of a recovery boiler. or cast.MAGSHOT ® MAGSHOT® GUN MIX Magnesite-based chrome-free gun mix. 870 10. Cat# HW 88 (11/02) 3C .7 68.8 Alumina (Al2O3) 1.9 The data given above are based on averages of test results on samples selected from routine plant production by standard A.100 After 1500°F 5. pcf After 230°F 160 179 Modulus of Rupture.0 Lime (CaO) 6.1 9.7 Alkalies (Na2O + K2O) 0. PA 15108 www. procedures where applica- ble.7 1.S. psi After 230°F 1. Variation from the above data may occur in individual test. (Typical) Maximum Service Temperature. ˚F 2700°F 2700°F Bulk Density.M. warranty.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2002 Harbison-Walker Refractories Company.2 Phosphorous Pentoxide (P2O5) 1.690 1. expressed or implied. The suggested use assumes that all safety measures are taken by the user.7 Titania (TiO2) 0. and data given herein are believed to be accurate and reliable but are presented without guarantee. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. information.5 Magnesia (MgO) 76.1 0.480 Crushing Strength.000 Chemical Analysis.T.510 After 1500°F 1.1 Iron Oxide (Fe2O3) 5.560 1.2 5.hwr. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.9 1.5 2.930 7.8 10. All Rights Reserved. or responsibility of any kind. psi After 230°F 5. MAGSHOT TECHNICAL DATA MAGSHOT® MAGSHOT® CASTABLE Physical Properties. % Approximate (Calcined Basis) Silica (SiO2) 7. These results cannot be taken as minima or maxima for specification purposes. All statements. KX-99® offers similar strength and resistance to alkalies and carbon monoxide as does KX-99®-BF.5 x 2. KX-99®-BF provides very high strength and excellent resistance to attack by alkalies and carbon monoxide. It is available in a large number of sizes and shapes. KX-99®-BF is available in a large number of sizes and shapes. CLIPPER® DP is our regular fired premium dry-pressed super-duty fireclay brick. Typical Applications KX-99®-BF KX-99® CLIPPER® DP ALAMO® Stacks Boiler Linings Air Heaters Charcoal Furnaces Hot Gas Ducts Rotary Kilns Zinc Galvanizing Furnaces Low Temp Incinerators Blast Furnace Stoves Blast Furnace Sidewalls Checkers Oil Heater Division Walls Oil Heater Floors Low Temp Metal Ladles Floors Around Furnaces Heat Exchangers Cement Preheaters .5" and 3" sizes. CLIPPER® DP is available in a large number of sizes and shapes. Super-Duty Fireclay Brick KX-99®-BF is our high fired dry-pressed coarse grain super-duty fireclay brick. It exhibits very good thermal shock resistance for this type brick. It is similar to KX-99®-BF but without the coarse grains. It offers very good resistance to thermal shock and alkali attack. ALAMO® is our regular fired conventionally dry-pressed super-duty fireclay brick. ALAMO® is available in standard 9 x 4. KX-99® is our high fired dry-pressed super-duty fireclay brick. CLIPPER® DP also provides excellent strength to better resist conditions such as impact from process feed. It is intended for general service conditions. 2 12. Variation from the above data may occur in individual tests.9 0. All statements.26 Apparent Porosity.3 0.3 -0.9 The data given above are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable.2 42.3 Magnesia 2MgO 0. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. lbs/in2: 8000 8500 6300 4000 Pyrometric Cone Equivalent Orton Standard Cones: 33-34 33-34 33-34 33-34 Permanent Linear Change After 2910oF.9 0.7 15. or responsibility of any kind. warranty.9 0. and data given herein are believed to be accurate and reliable but are presented without guarantee.2 0.3 16.6 52. All Rights Reserved.2 42.7 Chemistry Analysis.4 1. expressed or implied.29 2. % subsidence: o 0.4 1.4 Titania TiO2 2.3 +0. 2640 F. %: 12.27 2.6 52.H-W Super-Duty Fireclay Brick Physical properties KX-99®-BF KX-99® CLIPPER® DP ALAMO® Type High Fired High Fired Regular Fired Regular Fired Coarse Aggregate Bulk Density.3 2.3 2.com Phone: (412) 375-6600 Fax: (412) 375-6783 © 2004 Harbison-Walker Refractories Company.6 Silica Si02 52.3 Iron Oxide Fe2O3 1.3 0. Cat# HW 89R (4/04) 2C .1 Modulus of Rupture.7 0. PA 15108 www. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. These results cannot be taken as minima or maxima for specification purposes. lbs/ft3: 142 143 142 141 g/cm3: 2.3 0. The suggested use assumes that all safety measures are taken by the user. lbs/in2: 1950 2050 1350 1000 Cold Crushing Strength.4 1.3 1.3 2. %: -0. information.6 52. Approximate (Calcined Basis).6 1.3 Alkalies Na2O+K2O 0.4 -0.28 2.2 42.2 0.2 0.2 Lime 2 CaO 0.5 Hot Load. %: Alumina Al2O3 42.hwr. . such as air ramming or cement- bonded precast shapes.VIB-TECH Engineered Shapes Shapes for High Performace Engineered Complex Shapes VIB-TECH shapes from Harbison-Walker provide our customers with complex shapes made from the same proven compositions • Thixotropic-Formed Shapes found in Harbison-Walker’s high-performace refractory bricks. • HARBIDE® /C hot strength and thermal shock resistance. They can be manufactured in intricate shapes. Harbison-Walker’s • VISIL/C® VIB-TECH family of fired ceramic-bonded shapes yield dramatic improvement in density. • High Fired/Ceramic Bond • Brick-Like Properties PRODUCTS • Improved Properties • KORUNDAL® XD/C – Density • TUFLINE® 90 DM/C – Porosity • TUFLINE® 95 DM/C – Strength • TUFLINE® 98 DM/C • Execellent Resistant Thermal Shock • TUFLINE® DM/C AL • H-W® CORUNDUM DM/C The Ultimate Combination of • RUBY® SR/C Products and Processes • AUREX® 75 SR/C When compared to traditional shape forming • ® AUREX 75/C techniques. 7 620 5. 91.120 89.1% Al2O3 RUBY®SR/C 204 15.4 Cr2O3 AUREX® 75 SR/C` 262 13. Cat# HW 105 (3/03) 2C .0 .840 20.hwr.3% Cr2O3 AUREX® 75/C 258 14.6% Al2O3 TUFLINE® DM/C AL 211 14.080 16.0% Al2O3 VISIL/C® 118 14.5 16-18 15-17 Hot MOR @ 2700OF (psi) 1.CONVENTIONAL PRODUCTS 90%AL2O3 90% AL2O3 Properties TUFLINE 90 DM/C* AIR RAMMED SHAPE** ULTRA-LOW CASTABLE** Heat Treatment Fired (ceramic bond) Fired (ceramic bond) Dried Density (pcf) 195 186 184 Porosity (%) 14.9 1.1% Al2O3 83. All Rights Reserved. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.VIB-TECH Family of Proven Products Three current commercial methods of special shape manufacture are shown in the table below. Consult your local sales representative for additional information.5% Al2O3 HARBIDE® /C 157 17.4 3. Harbison-Walker currently manufactures VIB-TECH shapes in the following high performance brick compostions: VIB-TECH Products Density Porosity MOR CCS Major Products* pcf % psi psi Chemistry 77.5 1.710 11.500 1. **Typical data meant to represent comparable air rammed and cast product.520 99.380 12.1% Al2O3 73.3%Al2O3 TUFLINE® 95 DM/C 200 15. Only the VIB-TECH shapes from Harbison-Walker combine outstanding hot strenth with excellent thermal shock resistance.720 8.5 1.5% SiC Note: Data subject to reasonable variation and should not be used for specification purposes.2% Al2O3 TUFLINE 98 DM/C ® 203 16. .8 1.700 90.140 12.900 11.850 12.820 22.7% SIC2 KORUNDAL XD/C ® 188 14.560 8.1 Al2O3 H-W® CORUNDUM DM/C 198 16.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company. TUFLINE® 90 DM/C vs.160 .2 2.250 .000-1. 99.1% Cr2O3 TUFLINE® 90 DM/C 197 14.5 4.0 4.200 600-800 Shock Resistance Excellent Fair Fair to Good Shape Complexlly Excellent Poor to Fair Fair to Good *Data subject to reasonable deviation and should not be used for specification purposes.6 1. PA 15108 www.400 82.590 94. 97. Zinc Harbison-Walker Refractories Company metal melting. copper. hearth. Some of the destructive condi- tions that these modern operating practices generate include: Manufacturing products exclusively for NARCO and Harbison-Walker… be abusive too. alternative ironmaking. glass. hydrocarbon. of increasing throughput. and results Temperature is generally the simplest method in high mechanical impact on the ramp and industries. LMFs. Temperature aluminum. Good furnace The data given in this flyer are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable. ladles.P. While higher temper. free of patent infringement of a third party. it is very important to employ thor- ed refractory castables. or other contaminated scrap can introduce components that are highly reactive with refrac- tory linings. Efficient cleaning can also and data given herein are believed to be accurate and reliable but are presented without guarantee. Chlorine containing fluxes Cleaning Fax: (412) 375-6826 can degrade the bond system of cement-bond. The compa- Melting/Holding Furnace ny makes high-performance products for BOFs. Pushing large scrap into the A. Green Refractories (APG) makes products for the iron and steel. cleaning can help minimize corundum growth. PA 15108 alumino-silicate refractories as they have on Phone: 1-800-377-4497 aluminum metal. These operating Harbison-Walker Refractories Company (H-W) provides high-per- formance refractory solutions to all non-steel-related industries. All rights reserved. leading to corundum formation and refractories. the furnaces are being pushed to pro- Exclusively serving the non-ferrous metals. ALUMINUM Exclusively serving the glass. In all cases. EAFs. finish- ing. These results cannot be taken as minima or maxima for specification purposes. Painted ing thermal gradients and melt losses. For Industrial Sales: Fluxing practices. In addition conditions have created a to its own outstanding line of products. Variation from the above data may occur in individual tests. fluid and can penetrate further into furnace lin- Products from all these companies are available through: ings. cement. Silicon alloys tend to be highly accelerated wear. reduc- Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is detrimental to refractory performance. and blast furnaces. along with a full line of insulating ceramic fibers. ough furnace cleaning practices. The suggested use assumes that all safety measures are taken by the user. All statements. incineration. In many cases. Cat. they can cause problems. information. ronment. Magnesium alloys are prone to thermiting Fluxing which produces extremely high temperatures. ously being pushed harder and harder to produce more metal in shorter time. expressed or implied. Moon Township. alloys also tend to promote corundum forma- 400 Fairway Drive Alkali based fluxes can have the same effect on tion. In addition to pro- viding complete technical support services. and hydrocarbon and minerals processing furnace causes abrasion on the sill. # HW190 (6/03) 1C . iron and steelmaking industries… North American Refractories Company (NARCO) is a leading supplier of refractory solutions to the iron and steel industries. are damaging to refractories. the company is North America’s oldest refrac. tory maker. The size and charging method can © 2003 Harbison-Walker Refractories Company. warranty. Higher temperatures increase the Alloys rates of reaction between the metal and the Various alloying components can degrade refractories. while necessary for efficient and can lead to corundum formation. atures do decrease melt times. many of which have become indus. casthouses. NARCO also can design and Many modern aluminum melting implement a turnkey refractory management program to meet your facility’s and holding furnaces are continu- specialized requirements. Charging and refractory wear. H-W is recognized worldwide for its technical support and withstand the more severe envi- expertise. demand for refractories that can try standards. minerals processing and other industries… duce a variety of different alu- minum alloys. The company also has one of the world’s top capabilities for cus- tomized pre-cast shapes. Founded in 1875. Scrap quality and charging practice can also be help to improve heat transfer to the bath. ferrous foundry. or responsibility of any kind. 6 1.3 161 ALSTOP GREFCON® 80 A VER 2.3 0.8 3.2 THO - - - - - - H TEC ® FIRECLAY CASTABLES X A L AD RMA ® VERSAFLOW 45/AL ADTECH ® ® H-W® ES CASTABLE C AL THE AFLOW ® 11370 Good 1660 1650 8630 Poor 23.2 2. proven problem solver in hearths.3 0. Cold Crush Strength (psi) After drying at 230 °F After drying at 230 °F After drying at 230 °F Modulus of Rupture (psi) Corundum Resistance Aluminum Resistance Chemical Analysis. 1800 2200 4650 C 57.5 0. pumpable.4 59. GREENKLEEN-60 PLUS is a 60% alumina. pumping over long distances and for casting into intri.1 0. low cement castable.4 0.1 2. ES S 70 PR 65/AL C ADTECH® is the coarse aggregate containing andalusite containing. ARMORKAST 80AL is designed ULTRA-EXPRESS 70 AL is very strong and is ideal for GRE - - - for the most severe aluminum contact applications.1 1.4 169 1.1 3.3 0.2 6.8 Fair 144 1.7 0. US ® L PL W ® cate form patterns. H-W® ES CASTABLE C AL is a coarse aggregate -45-L AL castable with excellent impact and thermal shock ENL IT E ® GRE Good 3000 1450 resistance.3 3. It has high A-EX Excellent Excellent ULTR 22000 Good version.8 72.4 57. It is ideally suited for insulating sub.3 10.0 74 - - - R/AL ECH ® ST XPU 60-65% ALUMINA CASTABLES Excellent Excellent Excellent Excellent ADT A ORK 1500 90.4 0.4 aluminum resistance.7 Fair 136 970 380 Because it is silica free. ALSTOP L GREFCON® 80A is a high strength.9 0. pumpable. THOR 60 ABR ADTECH® is a Hot Modulus of Rupture (psi) After heating at 1500 °F After heating at 1500 °F hearths.8 3.3 aluminum resistance. silica-free.2 3.0 A 45% alumina.2 0.1 24.0 29. ings.1 37.9 1.1 3.8 2. It has A 60% zirconia castable with excellent corundum resist- Na2O & K2O Sub-Hearth Tap Blocks Belly Band At 1500 °F Density (lb/ft ) ance.1 1. Coarse aggregates provide improved impact strength and excellent aluminum resistance.6 0.1 ARM - - - - - - ARMORKAST 65AL NARCOTUFFTM SUPER AL ECH ® ARMORKAST 65AL is a very high purity low cement With a minor zircon addition.6 30.8 3.4 49.1 0.5 0.2 - - 90+% ALUMINA CASTABLES 65AL RK AST VERSAFLOW® XPUR/AL ADTECH® ARMORKAST XPUR/AL ADTECH® ARM O 10000 1900 2300 4000 62.1 1.3 0.2 0.7 163 1. 80% alumina low cement castable.3 0. low - - - - This tabular alumina based castable is also silica-free.0 - - - AL and versatile installation characteristics.5 2. Its unique bonding matrix provides exception.9 0.0 VER - - - GREENLITE -45-L AL ® THOR 60 ABR ADTECH® This lightweight castable has a very high strength to 60% silicon carbide castable with very high strength weight ratio.1 0. and abrasion resistance. VERSAFLOW® able. low-cement castable with An industry standard for aluminum furnace safety lin. Crucibles Trough Hearth VERSAFLOW® THERMAX® AL ADTECH® is an excel.5 38.7 0. 70% alumina castable designed S -60 for corrosion resistance. CH ® L ADTE 45/A LOW ® MISCELLANEOUS CASTABLES SAF Good 1520 1770 9840 6970 42.2 S 193 0. ECH ® 80AL 70-80% ALUMINA CASTABLES ADT RKAST Excellent 10900 10900 1850 2200 3250 O 80.2 A tabular alumina based.2 - - - An industry standard for more than 15 years. NARCOTUFFTM SUPER /AL ADT R castable. It has exceptional strength and with enhanced flow.8 1.2 - - - and thermal shock resistance.6 176 A 65% alumina. PLU NKLEEN 15000 10000 Good Good 2350 2000 3800 59. VERSAFLOW® XPUR/AL ADTECH® C AL and is designed to be a more cost effective corundum T A BLE has excellent strength and non-wetting characteristics.1 0.2 0.2 0.4 214 C 7.0 E 161 1.1 3. H-W ® - - - - corundum belly bands. Zoning belly bands with NARCON ZRAL has 3 exceptional thermal shock and abrasion resistance.3 0.1 8.2 0.2 0.1 0.4 14. proven to be very successful in furnaces prone to Fe2O3 Other Al2O3 MgO CaO ZrO2 SiO2 TiO2 SiC lent choice for troughs. It also shows very high strength and excellent CA S ES Good 7100 4100 49.0 R 165 0.6 34.7 1.6 NAR 162 1. AL is an excellent choice for the lower sidewall or belly XPU AFLOW ® 10800 1680 1330 9220 92. and self-leveling characteristics. ALST 8.8 0. VER - - - improved strength versus conventional castables. 80% alumina castable is built An ultra-low cement.1 5. pumpable. - - - 80 A FCON ® VERSAFLOW® 65/AL PLUS® GREENKLEEN-60 PLUS GR E OP Good Good 1600 1600 3000 6300 7700 81.6 1.1 0.2 0.%: VERSAFLOW® THERMAX® AL ADTECH® NARCON ZRAL Typical Applications Lower Sidewall A vitreous silica based low cement castable.5 0.1 0. 65/A LO SAF 16820 14780 Good Good 1790 2800 3300 64.4 0. ramps and sills.5 1.1 2.1 0.2 Fair 500 320 2. it is an excellent choice for high 2. cement castable.1 0.7 VER ally high strength and ultimate corrosion resistance. .8 0.4 0.8 171 ARM 1.2 0. fighter.0 2.0 129 S 0.7 0.5 - - ARMORKAST 80AL ADTECH® ULTRA-EXPRESS 70 AL This high purity. 42. 1500 2800 5000 7000 69.7 1. corundum formation. low cement castable with high strength Among the most popular maintenance materials avail. high corrosion ER A SUP OTUFF TM Excellent Excellent Excellent Excellent 13000 11500 resistance. band in a furnace with slight corundum growth.4 10. Harbison-Walker Castables for Aluminum RAL Excellent Excellent Excellent ON Z 13000 11000 2100 2600 3600 33.5 27. and crucibles.8 196 0.8 3.1 NAR - - - Melting/Holding Furnaces ECH ® ADT 60 ABR 15000 Good 2400 4900 23.1 3. US ® L PL cate form patterns.4 aluminum resistance.2 0. VERSAFLOW® XPUR/AL ADTECH® and is designed to be a more cost effective corundum E C TABL has excellent strength and non-wetting characteristics.1 0. fighter. ings. it is an excellent choice for high 2.2 0. silica-free.1 24.1 3. 1500 2800 5000 7000 69.7 1. PLU NKLEEN 15000 10000 Good Good 2350 2000 3800 59.8 0. ECH ® 80AL 70-80% ALUMINA CASTABLES ADT RKAST Excellent 10900 10900 1850 2200 3250 O 80.6 0.3 161 ALSTOP GREFCON® 80 A VER 2. proven to be very successful in furnaces prone to Fe2O3 Other Al2O3 MgO CaO ZrO2 SiO2 TiO2 SiC lent choice for troughs.4 0. Harbison-Walker Castables for Aluminum L Excellent Excellent Excellent ZRA 13000 11000 CON 2100 2600 3600 33.1 8.1 NAR - - - Melting/Holding Furnaces ECH ® ADT ABR 15000 R 60 Good 2400 4900 23. and self-leveling characteristics.8 3. ramps and sills.2 THO - - - - - - H TEC ® FIRECLAY CASTABLES X A L AD RMA ® VERSAFLOW® 45/AL ADTECH® H-W® ES CASTABLE C AL THE AFLOW ® 11370 Good 1660 1650 8630 Poor 23. VER - - - improved strength versus conventional castables.1 3.6 1.0 165 0.7 ally high strength and ultimate corrosion resistance. and crucibles.2 - - - An industry standard for more than 15 years.1 1. 42. 70% alumina castable designed S -60 for corrosion resistance.1 37. It has A 60% zirconia castable with excellent corundum resist- Na2O & K2O Sub-Hearth Tap Blocks Belly Band At 1500 °F Density (lb/ft ) ance. low - - - - This tabular alumina based castable is also silica-free.3 0. 80% alumina castable is built An ultra-low cement.6 NAR 162 1. AL cement castable. THOR 60 ABR ADTECH® is a Hot Modulus of Rupture (psi) After heating at 1500 °F After heating at 1500 °F hearths. ALSTOP L GREFCON® 80A is a high strength.3 0. - - - 0A N 8 FCO ® VERSAFLOW® 65/AL PLUS® GREENKLEEN-60 PLUS GRE OP Good Good 1600 1600 3000 6300 7700 81.1 2. corundum formation. high corrosion ER A SUP OTUFF TM Excellent Excellent Excellent Excellent 13000 11500 resistance.2 3.8 0. Coarse aggregates provide improved impact strength and excellent aluminum resistance. low-cement castable with An industry standard for aluminum furnace safety lin.5 2.2 - - 90+% ALUMINA CASTABLES 65AL AST VERSAFLOW® XPUR/AL ADTECH® ORK ARMORKAST XPUR/AL ADTECH® ARM 10000 1900 2300 4000 62. . 80% alumina low cement castable.5 1.0 29.4 169 1.4 0.3 0.1 0. low cement castable with high strength Among the most popular maintenance materials avail.4 0.1 0. NARCOTUFFTM SUPER ADT R/AL castable.2 - - - and thermal shock resistance. pumpable.4 49. H TEC ® L AD 45/A AFLOW ® MISCELLANEOUS CASTABLES Good 1520 1770 9840 6970 42.5 38.2 6. GREENKLEEN-60 PLUS is a 60% alumina.0 A 45% alumina.%: VERSAFLOW® THERMAX® AL ADTECH® NARCON ZRAL Typical Applications Lower Sidewall A vitreous silica based low cement castable.2 0.2 2. H-W® ES CASTABLE C AL is a coarse aggregate 45-L AL castable with excellent impact and thermal shock ITE ®- ENL GRE Good 3000 1450 resistance.1 3. 1800 2200 4650 C 57.4 14.2 Fair 500 320 2.8 S Fair 144 1.9 1.8 171 ARM 1.0 - - - and versatile installation characteristics.8 3. It is ideally suited for insulating sub.9 0. It has exceptional strength and with enhanced flow.1 0.7 0. pumping over long distances and for casting into intri.7 0. and abrasion resistance.1 5.5 0. It also shows very high strength and excellent CAS ES Good 7100 4100 49.1 3.2 S 193 0.2 0.5 - - ARMORKAST 80AL ADTECH® ULTRA-EXPRESS 70 AL This high purity.9 0.1 0.5 27.0 2. 0 AL SS 7 PRE 65/AL C ADTECH® is the coarse aggregate containing andalusite containing.5 0.2 0.0 VER - - - GREENLITE®-45-L AL THOR 60 ABR ADTECH® This lightweight castable has a very high strength to 60% silicon carbide castable with very high strength weight ratio.4 10. pumpable.1 0.3 10. ARMORKAST 80AL is designed ULTRA-EXPRESS 70 AL is very strong and is ideal for GRE - - - for the most severe aluminum contact applications.8 196 O 0. Crucibles Trough Hearth VERSAFLOW® THERMAX® AL ADTECH® is an excel.8 3.6 34.1 ARM - - - - - - ARMORKAST 65AL NARCOTUFFTM SUPER AL ECH ® ARMORKAST 65AL is a very high purity low cement With a minor zircon addition.1 0.2 0. VERSAFLOW® able. pumpable.1 2.4 57. Cold Crush Strength (psi) After drying at 230 °F After drying at 230 °F After drying at 230 °F Modulus of Rupture (psi) Corundum Resistance Aluminum Resistance Chemical Analysis.8 72.1 0.7 Fair 136 970 380 Because it is silica free.8 1.7 163 1. It has high A-EX Excellent Excellent ULTR 22000 Good version.8 3. 65/A AFLOW ® 16820 14780 Good Good 1790 2800 3300 S 64.0 74 - - - R/AL ECH ® XPU 60-65% ALUMINA CASTABLES Excellent Excellent Excellent Excellent ADT RKAST 1500 90. low cement castable.4 0.6 1.1 1.4 214 7.3 0.4 59. ALST 8.8 2. H-W ® - - - - corundum belly bands.1 0.2 0.3 0. proven problem solver in hearths.2 0.2 A tabular alumina based.6 176 A 65% alumina.5 0. Zoning belly bands with NARCON ZRAL has 3 exceptional thermal shock and abrasion resistance.7 1.7 0.3 aluminum resistance.1 1. VER band in a furnace with slight corundum growth.0 E 161 1. AL is an excellent choice for the lower sidewall or belly XPU AFLOW ® 10800 1680 1330 9220 92.3 0.3 3.6 30. Its unique bonding matrix provides exception.0 129 S 0. ALUMINUM Exclusively serving the glass, iron and steelmaking industries… North American Refractories Company (NARCO) is a leading supplier of refractory solutions to the iron and steel industries. The compa- Melting/Holding Furnace ny makes high-performance products for BOFs, EAFs, LMFs, ladles, finish- ing, alternative ironmaking, casthouses, and blast furnaces. In addition to pro- viding complete technical support services, NARCO also can design and Many modern aluminum melting implement a turnkey refractory management program to meet your facility’s and holding furnaces are continu- specialized requirements. ously being pushed harder and harder to produce more metal in shorter time. In many cases, the furnaces are being pushed to pro- Exclusively serving the non-ferrous metals, ferrous foundry, hydrocarbon, incineration, minerals processing and other industries… duce a variety of different alu- minum alloys. These operating Harbison-Walker Refractories Company (H-W) provides high-per- formance refractory solutions to all non-steel-related industries. In addition conditions have created a to its own outstanding line of products, many of which have become indus- demand for refractories that can try standards, H-W is recognized worldwide for its technical support and withstand the more severe envi- expertise. Founded in 1875, the company is North America’s oldest refrac- ronment. tory maker. Some of the destructive condi- tions that these modern operating practices generate include: Manufacturing products exclusively for NARCO and Harbison-Walker… be abusive too. Pushing large scrap into the A.P. Green Refractories (APG) makes products for the iron and steel, Temperature aluminum, cement, copper, glass, and hydrocarbon and minerals processing furnace causes abrasion on the sill, and results Temperature is generally the simplest method in high mechanical impact on the ramp and industries. The company also has one of the world’s top capabilities for cus- tomized pre-cast shapes, along with a full line of insulating ceramic fibers. of increasing throughput. While higher temper- hearth. atures do decrease melt times, they can cause problems. Higher temperatures increase the Alloys rates of reaction between the metal and the Various alloying components can degrade refractories, leading to corundum formation and refractories. Silicon alloys tend to be highly accelerated wear. fluid and can penetrate further into furnace lin- Products from all these companies are available through: ings. Magnesium alloys are prone to thermiting Fluxing which produces extremely high temperatures, For Industrial Sales: Fluxing practices, while necessary for efficient and can lead to corundum formation. Zinc Harbison-Walker Refractories Company metal melting, are damaging to refractories. alloys also tend to promote corundum forma- 400 Fairway Drive Alkali based fluxes can have the same effect on tion. Moon Township, PA 15108 alumino-silicate refractories as they have on Phone: 1-800-377-4497 aluminum metal. Chlorine containing fluxes Cleaning Fax: (412) 375-6826 can degrade the bond system of cement-bond- In all cases, it is very important to employ thor- ed refractory castables. ough furnace cleaning practices. Good furnace The data given in this flyer are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable. cleaning can help minimize corundum growth, Variation from the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information, Charging and refractory wear. Efficient cleaning can also and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied. Scrap quality and charging practice can also be help to improve heat transfer to the bath, reduc- Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is detrimental to refractory performance. Painted ing thermal gradients and melt losses. free of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user. or other contaminated scrap can introduce components that are highly reactive with refrac- tory linings. The size and charging method can © 2003 Harbison-Walker Refractories Company. All rights reserved. Cat. # HW190 (6/03) 1C ALUMINUM TRANSFER TROUGHS Transfer Trough Conditions: Erosion Abrasion Thermal Shock Aluminum Penetration Mechanical Abuse Harbison-Walker offers a complete line of refractory castables, plastics and shapes for aluminum transfer troughs. HARBIDE® PLASTIC 70 AL GREENKLEEN-60 PLUS A 70% silicon carbide, phosphate bonded A 60% alumina, andalusite containing castable. plastic with an aluminum penetration inhibitor. GREENKLEEN-60 PLUS has excellent resistance HARBIDE® PLASTIC 70 AL is an excellent to molten aluminum, and has been a standard for choice for patching. aluminum troughs for more than 10 years. NOVACON® S ARMORKAST 65AL NOVACON® S is a cement-free, vitreous silica A 65% alumina, low cement, pumpable castable. based castable. It shows outstanding hot ARMORKAST 65AL has a very high purity bond- properties, as well as thermal shock and ing matrix, leading to very high physical proper- abrasion resistance. ties, and outstanding corrosion resistance. VERSAFLOW® THERMAX® AL ADTECH® ULTRA-EXPRESS 70 AL A vitreous silica based, low-cement castable An ultra-low cement, 70% alumina castable with an aluminum penetration inhibitor. designed with enhanced flow, and self-leveling VERSAFLOW® THERMAX® AL ADTECH® characteristics. ULTRA-EXPRESS 70 AL is very offers exceptional thermal shock and abrasion strong and is ideal for pumping over long dis- resistance, as well as volume stability. tances and for casting into intricate form patterns. VISIL®/C AL 2-TOUGH AL ADTECH TM ® A unique, vitreous silica product developed for A silica free, coarse aggregate containing custom shapes. VISIL®/C AL has excellent castable, designed for precast trough sections. thermal shock and abrasion resistance and This 2-component mix contains 50% coarse volume stability. aggregate, providing outstanding thermal shock, impact and abrasion resistance. GREENLITE®-45-L AL A lightweight, insulating mix, with an exceptional THOR 60 ABR ADTECH® strength to density ratio. GREENLITE®- 45-L AL A 60% silicon carbide castable. SiC offers also contains a penetration inhibitor, which improved thermal shock and abrasion resistance. provides resistance to molten aluminum. THOR 60 ABR ADTECH® has exceptional resist- ance to molten aluminum. TECHNICAL DATA GREENKLEEN- ARMORKAST ULTRA-EXPRESS 2-TOUGHTM AL THOR 60 60 PLUS 65AL 70 AL ADTECH® ABR ADTECH® Form Castable Castable Self-Flowing Vib-Cast Castable Castable Density, pcf After 230˚F 161 163 158 169 210 165 Ater 1500˚F 157 160 157 169 -- 162 Modulus of Rupture, psi After 230˚F 2,350 1,900 1,000 1,500 1,900 2,400 After 1500˚F 5,000 2,300 2,700 2,800 -- -- @ 1500˚F 3,800 4,000 4,700 5,000 -- 4,900 @2000˚F -- 3,000 -- -- -- 5,500 C-704 Abrasion Test CC Loss After 1500˚F 6 -- 4 3 -- 6 Chemical Analysis,% (Approximate) Silica (SiO 2) 34.0 27.7 24.4 1.1 14.4 Alumina (Al2O3) 59.6 62.5 69.1 90.0 23.4 Silicon Carbide (SiC) -- -- -- -- 59.0 HARBIDE® VERSAFLOW® THERMAX® PLASTIC 70 AL NOVACON® S AL ADTECH® VISIL®/C AL GREENLITE®-45-L AL Form Plastic Castable Castable Shape Castable Vib-Cast Density, pcf After 500˚F 57 113 129 117 69 74 After 1500˚F -- -- -- 64 67 -- Apparent Porosity, % -- -- 14 -- -- -- Modulus of Rupture, psi After 500˚F -- -- -- 620 400 500 After 1500˚F 2,230 1,060 1,650 -- 250 320 @ 1500˚F -- -- -- -- -- -- C-704 Abrasion Test CC Loss After 1500˚F 4.5 -- -- -- -- -- Chemical Analysis,% (Approximate) Silica (SiO 2) 6.5 96.9 72.0 96.4 38.3 Alumina (Al2O3) 20.4 2.1 23.8 0.6 42.5 Silicon Carbide (SiC) 67.0 -- -- -- -- The data given above are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable. Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township, PA 15108 www.hwr.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company. All Rights Reserved. Cat# HW 192 (07/03)) H-W LONG BRICK For Rotary Kilns Long Brick from Harbison-Walker Eliminates double cuts Use for your cut rows 8” up to 12” Greater flexibility when old section is spiraled Reduce the number of rings to install Reduce downtime - Labor savings Available in High Alumina and Basic Brick qualities Closure Courses From two courses to One 12” (305 mm) brick Retainer Rings More stable construction More mass More Strength H-W LONG BRICK for Rotary Kilns H-W Long brick are available in the following sizes: Manufactured in U.S.A. Shape # B-222-L B-322-L B-622-L B-822-L Key-Ups B-228-L-K-1 B-228-L-K-2 Manufactured in Canada Shape # Shape # Shape # VDZ B222/30 ISO 222/30 ISO 325/30 VDZ B322/30 ISO 322/30 ISO 825/30 VDZ B622/30 ISO 822/30 Key-Ups Key-Ups Key-Ups P251/30A P220/30 P221/30 P252/30A P221/30 P222/30 * All ring counts follow standard ring combinations Harbison-Walker Refractories Company 400 Fairway Drive Moon Township, PA 15108 Phone: (412) 375-6600 1-800-377-4497 Fax: (412) 375-6846 © 2002 Harbison-Walker Refractories Company. All Rights Reserved. Cat# HW131 R(8/02) 2C High Alumina & Basic Bricks Exclusively serving the iron and steelmaking industries… North American Refractories Company (NARCO) is a leading supplier of refractory solutions to the iron and steel industries. The compa- For Rotary Kiln Systems ny makes high-performance products for BOFs, EAFs, LMFs, ladles, finish- ing, alternative ironmaking, casthouses, blast furnaces, and flow control applications. In addition to providing complete technical support services, NARCO also can design and implement a turnkey refractory management SUPER DUTY program to meet your facility’s specialized requirements. CLIPPER® DP HIGH ALUMINA Exclusively serving the non-ferrous metals, ferrous foundry, glass, hydro- carbon, incineration, minerals processing and other industries… ARCO® 50 Harbison-Walker Refractories Company (H-W) provides high-per- KALA® formance refractory solutions to all non-steel-related industries. In addition to its own outstanding line of products, many of which have become indus- ARCO® 60 try standards, H-W is recognized worldwide for its technical support and expertise. Founded in 1875, the company is North America’s oldest refrac- UFALA® tory maker. KRUZITE® - 70 ALTEX® 75B Manufacturing products exclusively for NARCO and Harbison-Walker… ALADIN® 80 A.P. Green Refractories (APG) makes products for the iron and steel, CORAL® BP aluminum, cement, copper, glass, and hydrocarbon and minerals processing industries. The company also has one of the world’s top capabilities for cus- tomized pre-cast shapes, along with a full line of insulating ceramic fibers. BASIC ANKRAL - R1 ANKRAL - R2 Products from all these companies are available through: ANKRAL - ZE For Cement and Lime Sales: MAGNEL® RS Harbison-Walker Refractories Company MAGNEL® RSV 400 Fairway Drive Moon Township, PA 15108 MAGNEL® RSX Phone: (412) 375-6600 • 1-800-377-4497 Fax: (412) 375-6846 MAGNEL® RS/AF © 2003 Harbison-Walker Refractories Company. All rights reserved. Cat. # HW132 R(7/03) 3C Can ical properties up to 2600oF. % 14.4 1.0 76. and chlorine. purity 60% alumina products.9 0.000* 8.2% Silica (SiO2) 0.0 — 5.1 0. resistance to mechanical abuse from abrasion and impact. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is of patent infringement of a third party.5 1.3 0.S.6% 42.8 17. warranty. It is highly resistant to cyclical redox conditions and attack by excellent physical properties at a cost-effective price.3 0.350 1.4 10.6 15. % 15.1 0. The suggested use assumes that all safety measures are taken by the user. This patented combination yields a product that is excep. Large crystalline magnesia grains make it extremely corrosion resistant.5 49. subsequent distribution within the matrix makes this product to clinker liquids while maintaining lower thermal conductivity and ARCO® 50 A conventional 50% alumina brick that has good phys.6 83.0 The data given above are based on averages of test results on samples selected from routine plant production by standard ASTM procedures where applicable.1 +4. MAGNEL® RSX Manufactured from the same raw materials as excellent high temperature strength.3 18.4 92.4 88.6% 32.2% 23.3 +1.3 0. sition zones. -.0 78.500 13. vides low thermal conductivity and low thermal expansion. meability values also give it excellent resistance to sulfur and High degree of phosphate bonding gives this product excellent cynite).5% 0. low shrinkage.950 Modulus of Rupture.600 2.2 0.M. burning zones areas.6 5.3 1.4 Apparent Porosity.5 15.2 0. Can be used in preheating zones of ALADIN® 80 An 80% alumina brick produced from imported cal.2 Lime (CaO) 1. from the above data may occur in individual test.5 +0. It is extremely flexible and has excellent imported bauxitic calcines.640 1.8 1. MAGNEL® RS/AF A combination high-purity synthetic magnesite.3 0.7 Titania (TiO2) -.700 2.3 2. Can be used in all areas of the lower thermal expansion than similar products of the same class.0 0. Low per- heater vessels.2 3.700 7.3 0.3% 0.T.3 0.8 1. lb/in2 Crushing Strength. Has good hot strength.5 Lime (CaO) 0. The unique spinel formation and ate amount of spinel yields a product that has excellent resistance be used in the lower calcining zone and the cooling zone. -.3 Iron Oxide (Fe2O3) 0.1 0. 0. CORAL® BP An 80% alumina. warranty.7 89. make this patented product unique.5 1.300 7. These results cannot be taken as minima or maxima for specification purposes. phosphate-bonded.1 0.8 1. expressed or implied.5% 15. be used in all basic zones but best suited for lower transition and long wet and long dry kilns and preheater tower vessels.2 0. It is ideally suited for burning and upper tran. All statements. Variation and data given herein are believed to be accurate and reliable but are presented without guarantee.2 0.6 1.4 -0.3 Iron Oxide (Fe2O3) 1. Ideally KRUZITE® – 70 A conventional 70% alumina brick manufactured suited for all areas of the basic zone of a cement and lime kiln. magnesia and a fused spinel consisting of iron and alumina (her.2 51.250 670 At 2300OF (1260OC) -.100 8.4% Alumina (Al2O3) 42.3 0. The moder- kilns and preheater tower vessels.2 0. 920 1. Ideally suited for use in the cooling zones and selected corrosion resistance. CLIPPER® DP A dry-pressed. information. for kilns utilizing oxygen enrichment. Ideally suited for use in pre. from imported bauxitic calcines.4 1.2 1.1 0. cined bauxite. sition zones where alkalis and sulfates are present. and good thermal shock resistance. It also exhibits excellent kilns.0 19.0 15. strengths.6 Permanent Linear Change.3% 0.8 +3.1 0.2 Phosphorous Pentoxide (P2O3) — — — — — — 3. or responsibility of any kind. normal shell flexing is present. Ideally suited for high thermal stress zones of rotary cement fused spinel.5 0.3 3.2 -0.6 0.0 15.0 17. -. fused spinel and a matrix of reinforced spinel along with selected calcining zones. or responsibility of any kind.7 0.4 3.2% 0.y lb/ft3 187 186 187 182 187 187 188 Apparent Porosity. Designed for use in UFALA® A 60% alumina brick manufactured from high purity MAGNEL® RS A combination high-purity synthetic magnesite.320 At 70OF (21OC) 800 870 900 690 840 1.000 8.3 17. with high hot strengths and low porosity. .0 82.9 83.700 2. alkali salts.2 0. -. Can tion with the higher magnesia levels yields a product that is highly also be used as an upgrade to conventional fireclay brick in pre. Lower spinel levels in conjunc- heating and calcining zones where alkali salts are present.2% 7. expressed or implied. 0. that has excellent high temperature strength and low porosity.610 20. burned brick ANRKAL-ZE This product is manufactured from natural sintered resistant to clinker liquid infiltration and alkali salt attack. The data given above are based on averages of test results on samples selected from routine plant production by standard A.4% 0.0 16.700* 4.4 Alkalies (Na2O+K2O) 0. It's mechanical flexibility is important when higher than fused magnesite. The matrix spinel aids in the formation and retention of coating.1 0. -.4 1. burned. These results cannot be taken as minima or maxima for specification purposes. All statements.4 2. sion characteristics.060 1. Can be used in preheating zones lower calcining zones areas. predictable reheat expan. chlorine. superduty brick that exhibits good ALTEX® 75B A 75% alumina.0 Crushing Strength.700 1. and data given *-DIN Test herein are believed to be accurate and reliable but are presented without guarantee.3 1.750 At 70OF (21OC) 8. lb/in2 Modulus of Rupture. Can be ANKRAL-R2 A high-purity synthetic sintered magnesite and sin- KALA® A high purity 50% alumina brick with low porosity and used in the lower calcining and cooling zones where greater tered spinel makes this product well suited for lower and upper tran.7 87.4 0.000 9. fused the high wear areas of the lower transition zones of kilns burning domestic calcines.ALUMINA BRICK CLIPPER® DP ARCO® KALA® ARCO® UFALA® KRUZITE® ALTEX® ALADIN® CORAL® BASIC BRICK ANKRAL ANKRAL ANKRAL MAGNEL® MAGNEL® MAGNEL® MAGNEL® (SUPER DUTY) 50 60 70 75B 80 BP R1 R2 ZE RS RSV RSX RS/AF Bulk Density. procedures where applicable. phosphate-bonded brick ANKRAL-R1 Manufactured from high purity magnesite and spinel MAGNEL® RSV A combination high-purity synthetic magnesite.5 14.2 3.1 Magnesia (MgO) 90. information. A cost effective alternative to higher ranges.3 Alumina (Al2O3) 7. -.7 0. and a matrix of reinforced spinel give this product its Used in the preheating zones of long wet and long dry process excellent resistance to alkali salt attack. The high amount of fused spinel pro.700* 10. lb/in2 At 70OF (21OC) 1.1 Magnesia (MgO) 0. Can sulfur. Variation from the above data may occur in individual tests.100 5.0 0.100 910 Reheat Test Permanent Linear Change. Exhibits excellent resistance to alkali salt spinel.6 61.5 0.4 Titania (TiO2) 2.610 3.7 15. refractoriness is required.0 0.2 3. Ideally suited for use in calcining and cooling zones where normal operating conditions are pres- ent. and good thermal shock resistance. % Reheat Test After Heating at 2910OF (1600OC) -0.0 13.5 6.410 8.5 +2. lb/in2 At 70OF (21OC) 6. ARCO® 60 A conventional 60% alumina brick manufactured from strength and abrasion resistance throughout all temperature tionally coating friendly. It's low porosity gives it grains. Can be used in excellent physical properties. and upper transition zones and the burning zone.2 0.2 1.2 0.3 2. lb/ft3 142 149 153 155 157 165 175 170 177 Bulk Densit.100 9.0% 15.1% 46.2 9. % After Heating at 2910OF (1600OC) -.4 15. Also well suited attack and has good thermal shock resistance.000 7.5 2.0 14.0 58.5 17.100 1. and a matrix of reinforced spinel (RS) give this product its waste fuel and/or high levels of petroleum coke.1 71.3 0.3 +1.1 1.6% 38.1 0. extremely coating friendly.3 0. preheating and calcining zones where chemical attack is prevalent. MAGNEL RS and MAGNEL RSV.0 Chemical Analysis: (Approximate) (Calcined Basis) Chemical Analysis: (Approximate) (Calcined Basis) Silica (SiO2) 52.2% 0. All statements. for kilns utilizing oxygen enrichment. vides low thermal conductivity and low thermal expansion.3 Iron Oxide (Fe2O3) 0. Lower spinel levels in conjunc- heating and calcining zones where alkali salts are present. Ideally KRUZITE® – 70 A conventional 70% alumina brick manufactured suited for all areas of the basic zone of a cement and lime kiln. A cost effective alternative to higher ranges.0 15. It is extremely flexible and has excellent imported bauxitic calcines.5% 0. warranty.4 1.2 0.2 0.5 Lime (CaO) 0. expressed or implied. Can be used in preheating zones lower calcining zones areas.5 49.2% 0. cined bauxite.3 Iron Oxide (Fe2O3) 1.0 Chemical Analysis: (Approximate) (Calcined Basis) Chemical Analysis: (Approximate) (Calcined Basis) Silica (SiO2) 52.7 15. Has good hot strength. It also exhibits excellent kilns.250 670 At 2300OF (1260OC) -.2 0. and a matrix of reinforced spinel (RS) give this product its waste fuel and/or high levels of petroleum coke. chlorine.5 6.8 1.0 58. Ideally suited for use in calcining and cooling zones where normal operating conditions are pres- ent.7 89.5 0. burning zones areas. procedures where applicable.6 Permanent Linear Change.2 1.0 0. MAGNEL® RSX Manufactured from the same raw materials as excellent high temperature strength. Exhibits excellent resistance to alkali salt spinel.1 0.100 5.350 1. normal shell flexing is present. It's low porosity gives it grains. The unique spinel formation and ate amount of spinel yields a product that has excellent resistance be used in the lower calcining zone and the cooling zone. low shrinkage.0 76.7 Titania (TiO2) -. preheating and calcining zones where chemical attack is prevalent.2% Silica (SiO2) 0.0 13. make this patented product unique.1 0.640 1. Variation from the above data may occur in individual tests.0 0. burned brick ANRKAL-ZE This product is manufactured from natural sintered resistant to clinker liquid infiltration and alkali salt attack. It is ideally suited for burning and upper tran.060 1. and upper transition zones and the burning zone.4 Apparent Porosity. and data given *-DIN Test herein are believed to be accurate and reliable but are presented without guarantee.1 +4.500 13.2 Lime (CaO) 1.5% 15.0 0.T.750 At 70OF (21OC) 8.1 0.2 0.610 3. meability values also give it excellent resistance to sulfur and High degree of phosphate bonding gives this product excellent cynite). fused spinel and a matrix of reinforced spinel along with selected calcining zones.4% Alumina (Al2O3) 42. % 14.3 0.4 2.3 0.5 1.4 3.4 Alkalies (Na2O+K2O) 0.3 0.3 18.0 — 5.y lb/ft3 187 186 187 182 187 187 188 Apparent Porosity. and good thermal shock resistance.8 17.100 1.4 92. extremely coating friendly.8 +3.1 71.3 2. Can be used in all areas of the lower thermal expansion than similar products of the same class. Ideally suited for use in pre. sition zones.2% 23.5 0. magnesia and a fused spinel consisting of iron and alumina (her. The high amount of fused spinel pro.2 3. predictable reheat expan.6% 32.1 0. from imported bauxitic calcines.3 3.410 8. Can be used in excellent physical properties. -.0 17.3 +1.700* 10. be used in all basic zones but best suited for lower transition and long wet and long dry kilns and preheater tower vessels. strengths. Also well suited attack and has good thermal shock resistance.S. CORAL® BP An 80% alumina.3 0.2 0. lb/in2 Crushing Strength.3 1.700 2. or responsibility of any kind.1 Magnesia (MgO) 90.2 0. with high hot strengths and low porosity.6% 38.5 +2. -.2 0. Can ical properties up to 2600oF. subsequent distribution within the matrix makes this product to clinker liquids while maintaining lower thermal conductivity and ARCO® 50 A conventional 50% alumina brick that has good phys.3 2.700 1. 920 1.2 1.2 9.M.5 +0. lb/ft3 142 149 153 155 157 165 175 170 177 Bulk Densit.700 2.4 1.4 1.5 14. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is of patent infringement of a third party. -.8 1.6 5.0 19. Large crystalline magnesia grains make it extremely corrosion resistant. expressed or implied. Ideally suited for use in the cooling zones and selected corrosion resistance.700 7.8 1. lb/in2 Modulus of Rupture.610 20. warranty. burned.7 0. fused the high wear areas of the lower transition zones of kilns burning domestic calcines.3 Alumina (Al2O3) 7. % Reheat Test After Heating at 2910OF (1600OC) -0. Can tion with the higher magnesia levels yields a product that is highly also be used as an upgrade to conventional fireclay brick in pre. superduty brick that exhibits good ALTEX® 75B A 75% alumina. and good thermal shock resistance. ARCO® 60 A conventional 60% alumina brick manufactured from strength and abrasion resistance throughout all temperature tionally coating friendly. It is highly resistant to cyclical redox conditions and attack by excellent physical properties at a cost-effective price. resistance to mechanical abuse from abrasion and impact.4 Titania (TiO2) 2.3% 0. Variation and data given herein are believed to be accurate and reliable but are presented without guarantee.3 0.3 0. and chlorine.3 0. The data given above are based on averages of test results on samples selected from routine plant production by standard A. Can be used in preheating zones of ALADIN® 80 An 80% alumina brick produced from imported cal. Ideally suited for high thermal stress zones of rotary cement fused spinel.6 1. alkali salts.1 0.0 16. sion characteristics.6 61.4% 0.4 10.6 83.1% 46.0 The data given above are based on averages of test results on samples selected from routine plant production by standard ASTM procedures where applicable. Can be ANKRAL-R2 A high-purity synthetic sintered magnesite and sin- KALA® A high purity 50% alumina brick with low porosity and used in the lower calcining and cooling zones where greater tered spinel makes this product well suited for lower and upper tran. sition zones where alkalis and sulfates are present.100 910 Reheat Test Permanent Linear Change.2 0. % After Heating at 2910OF (1600OC) -. and a matrix of reinforced spinel give this product its Used in the preheating zones of long wet and long dry process excellent resistance to alkali salt attack. MAGNEL RS and MAGNEL RSV.100 9.5 2.2% 7. CLIPPER® DP A dry-pressed. These results cannot be taken as minima or maxima for specification purposes. information.2 3.5 15. 0.700* 4.3% 0. Can sulfur. phosphate-bonded.0 15. MAGNEL® RS/AF A combination high-purity synthetic magnesite.2 51. These results cannot be taken as minima or maxima for specification purposes. Low per- heater vessels.000 7.3 17. Designed for use in UFALA® A 60% alumina brick manufactured from high purity MAGNEL® RS A combination high-purity synthetic magnesite.0 78.4 -0. This patented combination yields a product that is excep.6% 42.7 0.950 Modulus of Rupture.ALUMINA BRICK CLIPPER® DP ARCO® KALA® ARCO® UFALA® KRUZITE® ALTEX® ALADIN® CORAL® BASIC BRICK ANKRAL ANKRAL ANKRAL MAGNEL® MAGNEL® MAGNEL® MAGNEL® (SUPER DUTY) 50 60 70 75B 80 BP R1 R2 ZE RS RSV RSX RS/AF Bulk Density. . It's mechanical flexibility is important when higher than fused magnesite.0 82.0% 15.2 -0.7 87.1 0. The moder- kilns and preheater tower vessels. that has excellent high temperature strength and low porosity.3 +1.600 2.000* 8. information.100 8.5 17. % 15.1 Magnesia (MgO) 0. The suggested use assumes that all safety measures are taken by the user.1 0.1 1.000 9.000 8. phosphate-bonded brick ANKRAL-R1 Manufactured from high purity magnesite and spinel MAGNEL® RSV A combination high-purity synthetic magnesite.4 88.2 Phosphorous Pentoxide (P2O3) — — — — — — 3.320 At 70OF (21OC) 800 870 900 690 840 1.4 15.300 7.3 0.5 1.1 0. from the above data may occur in individual test. lb/in2 At 70OF (21OC) 1.3 1. -.0 14.9 0. or responsibility of any kind. -.6 0.9 83.2 3.3 0. lb/in2 At 70OF (21OC) 6. 0. All statements. refractoriness is required. -. The matrix spinel aids in the formation and retention of coating. purity 60% alumina products.4 0.6 15.2% 0.0 Crushing Strength. H-W is recognized worldwide for its technical support and expertise. cement.70 ALTEX® 75B Manufacturing products exclusively for NARCO and Harbison-Walker… ALADIN® 80 A. Green Refractories (APG) makes products for the iron and steel. alternative ironmaking. finish- ing. In addition to its own outstanding line of products. NARCO also can design and implement a turnkey refractory management SUPER DUTY program to meet your facility’s specialized requirements. ferrous foundry. incineration. many of which have become indus. LMFs. the company is North America’s oldest refrac. CLIPPER® DP HIGH ALUMINA Exclusively serving the non-ferrous metals. PA 15108 MAGNEL® RSX Phone: (412) 375-6600 • 1-800-377-4497 Fax: (412) 375-6846 MAGNEL® RS/AF © 2003 Harbison-Walker Refractories Company. Founded in 1875. BASIC ANKRAL . UFALA® tory maker. glass. blast furnaces. along with a full line of insulating ceramic fibers. All rights reserved. CORAL® BP aluminum. and hydrocarbon and minerals processing industries. hydro- carbon. EAFs. High Alumina & Basic Bricks Exclusively serving the iron and steelmaking industries… North American Refractories Company (NARCO) is a leading supplier of refractory solutions to the iron and steel industries. glass.ZE For Cement and Lime Sales: MAGNEL® RS Harbison-Walker Refractories Company MAGNEL® RSV 400 Fairway Drive Moon Township. Cat. and flow control applications. The company also has one of the world’s top capabilities for cus- tomized pre-cast shapes. minerals processing and other industries… ARCO® 50 Harbison-Walker Refractories Company (H-W) provides high-per. KALA® formance refractory solutions to all non-steel-related industries. ladles. casthouses. # HW132 R(7/03) 3C . KRUZITE® . In addition to providing complete technical support services.R2 Products from all these companies are available through: ANKRAL .R1 ANKRAL . The compa- For Rotary Kiln Systems ny makes high-performance products for BOFs.P. copper. ARCO® 60 try standards. and hydro-carbon and minerals processing Mean Temperature (Btu/Hr ft2 F/in) industries. Castables 6 5. # HW139 (3/03) 1C . the company is North America’s oldest refrac. LIGHTWEIGHT CASTABLES AND Exclusively serving the glass. fin- ishing. 2 1.5 2600°F Series KAST-O-LITE® 20-45 K-Values 3 KAST-O-LITE® 22 Products from all these companies are available through: 2. KAST-O-LITE® 22 G 4 3000°F Series formance refractory solutions to all non-steel-related industries. 2. FOR ROTARY KILN SYSTEMS pany makes high-performance products for BOFs. NARCO also can design and implement a turnkey refractory management program to meet your facility’s specialized requirements.5 tory maker.5 to its own outstanding line of products. Green Refractories (APG) makes products for the iron and steel.5 KAST-O-LITE® 23 ES 2 For Cement and Lime Sales: KAST-O-LITE® 23 LI 1. Founded in 1875. minerals processing and other industries… KAST-O-LITE® 19 L 4. copper. EAFs. glass. PA 15108 0 Phone: (412) 375-6600 • 1-800-377-4497 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 Fax: (412) 375-6846 2 Mean Temperature (Btu/Hr ft F/in) © 2003 Harbison-Walker Refractories Company.5 Harbison-Walker Refractories Company (H-W) provides high-per. alternative ironmaking.P. casthouses. hydro-carbon.5 Manufacturing products exclusively for NARCO and Harbison-Walker… 0 A. 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 aluminum. and blast furnaces. H-W is recognized worldwide for its technical support and 3 KAST-O-LITE® 30 LI G 2200°F Series expertise. GREENLITE® -45-L GR 5 2600°F Series incineration. In addition to providing complete technical support services.5 1900°F Series 1 0. iron and steelmaking industries… GUNNING MIXES North American Refractories Company (NARCO) is a leading supplier of refractory solutions to the iron and steel industries.5 KAST-O-LITE® 20 LI 4 3.5 2000°F Series KAST-O-LITE® 26 LI Harbison-Walker Refractories Company 1 400 Fairway Drive 0. Cat. In addition KAST-O-LITE® 26 LI G 3. All rights reserved.5 1900°F Series KAST-O-LITE® 30 LI Moon Township. Gunning Mixes 6 GUNNING MIXES 5. ferrous foundry. cement. The company also has one of the world’s top capabilities for cus- tomized pre-cast shapes. ladles. along with a full line of insulating ceramic fibers. LMFs.5 Exclusively serving the non-ferrous metals.5 CASTABLES 5 3000°F Series KAST-O-LITE® 20 4. many of which have become indus- K-Values try standards. The com. ˚F 2500 1900 2000 2000 2000 2200 Maximum Service Temperature.7 1. furnace stacks and flues. KAST-O-LITE® 26 LI G is a low iron content 2.8% 38. All statements. The suggested use assumes that all safety measures are taken by the user. carbon black back-up linings.5 3. given herein are believed to be accurate and reliable but are presented without guarantee. expressed or implied. low iron. flame impinge. lightweight panel construction. KAST-O-LITE® 19 L is an insulating castable that can KAST-O-LITE® 22 is a lightweight castable for tempera- easily conform to an irregular shell and will not smoke. and data given herein are believed to be accurate and reliable but are presented without guarantee.3 1.7 2. and low thermal conductivity. petrochem transfer and Typical applications are aluminum furnace stacks.0 1. and data from the above data may occur in individual tests.2 0.7 0.2 0. alu- KAST-O-LITE® 20 is a hydraulic setting insulating riser back-up linings.1 2. reheat furnace discharge castable that can be installed by pouring.0 6.5 44.2 0. .500˚F insulating gunning KAST-O-LITE® 20-45 is a hydraulic setting insulating KAST-O-LITE® 23 ES is an intermediate strength insu.0 2.300°F (1.2% -0.3 11. lating castable. low thermal conductivity. air heaters.4 4.4 Magnesia (MgO) 2. (1.2% 44. castable usable in direct contact with hot gases under steel shell flexing.4 0.0 Titania (TiO2) 2.000°F (1.0 Alumina (Al2O3) 41.4% -0. These results cannot be taken as minima or maxima for specification purposes.0 Titania (TiO2) 2.0 0. flue and duct linings. low iron. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.5 6. complete monolithic linings.6 17. After Heating at 1500˚F (815˚C) -0. ideal for overhead gunning applications. strengths.6 8. lb/ft3 76 86 53 92 111 95 102 Maximum Service Temperature.4 4. may be cast or gunned in place and is suitable for hot It is ideal for boilers.0 20.4 0.7% -0.205°C) insulating gunning castable. KAST-O-LITE® 23 ES cracking from mechanical abuse or steel shell flexing.5 10. It exhibits moderate density. heaters and petrochem oil heaters. Ideal for back-up linings behind dense refrac. It is ideal for boil.2 Alkalies (Na2O+K2O) 1. ment or mechanical wear does not present a problem.6% -0. GREENLITE® -45-L GR is a 2. furnace stacks and nace back-up linings. KAST-O-LITE® 20 LI is a high efficiency insulating strengths reduce cracking from mechanical abuse or excellent strengths.0 2.5% -0. sulphur 2. It is ideally used as a gunned or cast back-up lining ductivity and good strength for such a lightweight mate. Its vastly improved ing gunning castable. 36 41 50 53 Bulk Density.200°F (1.5 57.7 The data given above are based on averages of test results on samples selected from routine plant production by standard ASTM procedures where applicable.9 0.5 0. air face or back-up linings. castable that can be installed by pouring or gunning.5 Alkalies (Na2O+K2O) 1.095°C) is extremely resistant to thermal steam pressure during initial heat up. breechings.5% 35.9 Lime (CaO) 10.2 2.0 1.0 39. petrochem oil heaters.0 2.1 0.2 0. pumping or KAST-O-LITE® 22 G is an economical 2.0 0.2 0.600°F (1. requiring low densities and high strength. free of patent infringement of a third party.0 21. These results cannot be taken as minima or maxima for specification purposes. Variation from the above data may occur in individual tests.6% 35. maximum service temperature to 2. and as a back-up material. stacks.8% After Heating at 1500˚F (815˚C) -0. warranty. fluid coking units and other industrial linings as an exposed lining where slagging.5 1. or responsibility of any kind. and catalytic reformer back-up lin- flues. doors.0 0. trolled atmosphere furnaces.2% -0.7 Magnesia (MgO) 0. reheat furnace floor backup. lb/in2 At 220˚F (105˚C) 600 20 75 100 150 140 At 220˚F (105˚C) 460 490 90 700 720 550 525 Reheat Test Reheat Test Permanent Linear Change. or responsibility of any kind.0 12.8% -0. .1% Chemical Analysis: (Approximate) Chemical Analysis: (Approximate) (Calcined Basis) (Calcined Basis) Silica (SiO2) 40.5 1.260°C) maximum KAST-O-LITE® 30 LI is a high-alumina.000°F (1. service temperature insulating castable.6 1.2 4. furnace stacks.5 42. Typical applications are aluminum continuous or intermittent operation without loss of ther. reheat fur- shock and has low thermal conductivity. flame formulated for gunability.0 Lime (CaO) 15. ers. easily flowing through the KAST-O-LITE® 26 LI has now been improved to meet impingement or mechanical wear does not present a hose with minimum rebound.7 0.5 41. All statements. Permanent Linear Change. information. It is an ideal candidate for fluid catalytic cracking is ideal for back-up linings behind dense refractories or It combines good strength with high insulating value gunning castable. lb/in2 Modulus of Rupture.3 1.9% 46. catalytic reforming linings behind minum holding furnace doors.0% 54. lightweight. lb/in2 Crushing Strength. KAST-O-LITE® 20 LI can be used to Lower water content for placement reduces internal furnace discharge doors. information.4 14. It is especially reheat furnace backup linings.0 0. The suggested use assumes that all safety measures are taken by the user. lb/ft3 . con.5 2.425°C).0% Silica (SiO2) 34. insu- behind other hot face refractory lining to lower shell rial.5% -0.3% -0.2% -0.3% -0. lb/in2 At 220˚F (105˚C) 3200 35 150 310 200 575 At 220˚F (105˚C) 810 2350 300 3000 2400 2850 2200 Modulus of Rupture. problem.7 2.3 6.3 5. Vastly improved strengths reduce units.2 1. and excellent volume stability. Recommendations include oil stills and heaters. KAST-O-LITE® 22 G is the demands of severe furnace environments. expressed or implied. petrochem heaters.205°C).2% 34. ˚F 2200 2300 2300 2600 2600 3000 3000 Crushing Strength.1% 39. It contains low 3. content minimizes destructive CO disintegration attack 3000°F (1650°C) maximum service temperature insulat- by reducing furnace atmospheres.3 33. recovery unit back-up linings.3 0. and waste heat boilers. aluminum furnace roof backup and ing behind stainless steel shroud.0% 43.425°C) maximum service temperature limit insulating sities. It features low thermal con.0 31. warranty.5 57.3 30.0% Alumina (Al2O3) 45. Higher alumina content improves its and low rebound.6 3. Typical applications are: flues.200°F stainless steel shroud.650°C) maximum service temperature.0 Iron Oxide (Fe2O3) 3. It exhibits moderate density.2 36. reheat mal efficiency. excellent temperatures. air heaters and gunning. It lating castable with standard calcium-aluminate binder.7 16.1 1. tories or as an exposed lining where slagging. aluminum holding furnace doors.3% 25.0% 26. Variation The data given above are based on averages of test results on samples selected from routine plant production by standard ASTM procedures where applicable. lightweight. LIGHTWEIGHT LIGHTWEIGHT GUNNING GREENLITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® GUNNING KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® MIXES 45-L GR 19 L 20 20 LI 20-45 22 MIXES 22 G 23 ES 23 LI 26 LI 26 LI G 30 LI 30 LI G Bulk Density. tures to 2. iron to resist detrimental reducing furnace conditions. air heaters. (1. Low iron KAST-O-LITE® 30 LI G is a high-alumina.5 Iron Oxide (Fe2O3) 1.3 1.600°F castable combining exceptional strengths and low den.5 46.1 2. KAST-O-LITE® 23 LI is a 2. 2 2. castable that can be installed by pouring or gunning.0% 43.000°F (1. KAST-O-LITE® 20 LI can be used to Lower water content for placement reduces internal furnace discharge doors.7 The data given above are based on averages of test results on samples selected from routine plant production by standard ASTM procedures where applicable. furnace stacks and flues. It is an ideal candidate for fluid catalytic cracking is ideal for back-up linings behind dense refractories or It combines good strength with high insulating value gunning castable.6% 35. KAST-O-LITE® 26 LI G is a low iron content 2.0 6. . lightweight. and data given herein are believed to be accurate and reliable but are presented without guarantee.0 Lime (CaO) 15. and as a back-up material. petrochem heaters.8% 38. air heaters and gunning. excellent temperatures.0 Titania (TiO2) 2.6 3. carbon black back-up linings. KAST-O-LITE® 23 ES cracking from mechanical abuse or steel shell flexing. and low thermal conductivity. ˚F 2200 2300 2300 2600 2600 3000 3000 Crushing Strength.5 57.7 2.7 1. easily flowing through the KAST-O-LITE® 26 LI has now been improved to meet impingement or mechanical wear does not present a hose with minimum rebound. air heaters. free of patent infringement of a third party.5 6.8% After Heating at 1500˚F (815˚C) -0.2 0.4 0. .5 1. content minimizes destructive CO disintegration attack 3000°F (1650°C) maximum service temperature insulat- by reducing furnace atmospheres.0 0. LIGHTWEIGHT LIGHTWEIGHT GUNNING GREENLITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® GUNNING KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® KAST-O-LITE® MIXES 45-L GR 19 L 20 20 LI 20-45 22 MIXES 22 G 23 ES 23 LI 26 LI 26 LI G 30 LI 30 LI G Bulk Density.200°F stainless steel shroud.0 39. expressed or implied. Recommendations include oil stills and heaters. It features low thermal con. con.3 11. heaters and petrochem oil heaters. petrochem oil heaters. Typical applications are aluminum continuous or intermittent operation without loss of ther. All statements.260°C) maximum KAST-O-LITE® 30 LI is a high-alumina. It contains low 3.425°C) maximum service temperature limit insulating sities.0 21. Its vastly improved ing gunning castable. furnace stacks and nace back-up linings. lb/ft3 76 86 53 92 111 95 102 Maximum Service Temperature.3 1.205°C). ideal for overhead gunning applications. After Heating at 1500˚F (815˚C) -0.3 30. doors. (1.8% -0.7 0.3 6.1% 39. warranty.3% 25. lating castable. reheat fur- shock and has low thermal conductivity. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. iron to resist detrimental reducing furnace conditions. aluminum furnace roof backup and ing behind stainless steel shroud. and data from the above data may occur in individual tests.2 36. It is ideal for boil.4% -0.0% 54.7 Magnesia (MgO) 0. given herein are believed to be accurate and reliable but are presented without guarantee. may be cast or gunned in place and is suitable for hot It is ideal for boilers.5 Alkalies (Na2O+K2O) 1.000°F (1. Typical applications are: flues. reheat furnace discharge castable that can be installed by pouring.4 Magnesia (MgO) 2.0 1. air face or back-up linings.5% -0.1% Chemical Analysis: (Approximate) Chemical Analysis: (Approximate) (Calcined Basis) (Calcined Basis) Silica (SiO2) 40.0 2.600°F castable combining exceptional strengths and low den.0 Alumina (Al2O3) 41.6 8. It exhibits moderate density. It exhibits moderate density. Ideal for back-up linings behind dense refrac.2 0. requiring low densities and high strength.300°F (1.095°C) is extremely resistant to thermal steam pressure during initial heat up.0 0.425°C). lb/in2 At 220˚F (105˚C) 3200 35 150 310 200 575 At 220˚F (105˚C) 810 2350 300 3000 2400 2850 2200 Modulus of Rupture.600°F (1.5 2.5 46.0 0. insu- behind other hot face refractory lining to lower shell rial. lb/in2 Modulus of Rupture. KAST-O-LITE® 20 LI is a high efficiency insulating strengths reduce cracking from mechanical abuse or excellent strengths. information.7% -0.9% 46. 36 41 50 53 Bulk Density.2% 34.0% Alumina (Al2O3) 45. and waste heat boilers. warranty.5 1. expressed or implied.9 0. tories or as an exposed lining where slagging.5 41. lb/in2 Crushing Strength.4 4.2% 44.1 2. low iron.4 14.3 5. breechings.0% Silica (SiO2) 34. The suggested use assumes that all safety measures are taken by the user. KAST-O-LITE® 22 G is the demands of severe furnace environments.5 57.9 Lime (CaO) 10. petrochem transfer and Typical applications are aluminum furnace stacks. air heaters.5% 35.3% -0.0 20. and catalytic reformer back-up lin- flues.4 0. It lating castable with standard calcium-aluminate binder. Higher alumina content improves its and low rebound. service temperature insulating castable.2 0.5 44.3 1.7 2.2 1.0 12.3 0. low thermal conductivity.0 Iron Oxide (Fe2O3) 3. strengths.2% -0. It is especially reheat furnace backup linings.3 1.2 4. GREENLITE® -45-L GR is a 2.0 2. or responsibility of any kind. flame impinge. and excellent volume stability. stacks. reheat furnace floor backup. Vastly improved strengths reduce units. ers. Low iron KAST-O-LITE® 30 LI G is a high-alumina. lb/in2 At 220˚F (105˚C) 600 20 75 100 150 140 At 220˚F (105˚C) 460 490 90 700 720 550 525 Reheat Test Reheat Test Permanent Linear Change. flame formulated for gunability. tures to 2. furnace stacks. alu- KAST-O-LITE® 20 is a hydraulic setting insulating riser back-up linings. information.5 10. lightweight.5% -0.7 16.5 3.3 33. Variation from the above data may occur in individual tests. problem.0% 26. Variation The data given above are based on averages of test results on samples selected from routine plant production by standard ASTM procedures where applicable.4 4.2 0. All statements. KAST-O-LITE® 19 L is an insulating castable that can KAST-O-LITE® 22 is a lightweight castable for tempera- easily conform to an irregular shell and will not smoke. sulphur 2. castable usable in direct contact with hot gases under steel shell flexing. Permanent Linear Change. The suggested use assumes that all safety measures are taken by the user.0 31. recovery unit back-up linings.0 0. ment or mechanical wear does not present a problem. reheat mal efficiency.6 1.0 1.2 Alkalies (Na2O+K2O) 1. trolled atmosphere furnaces.5 42. (1. aluminum holding furnace doors.5 Iron Oxide (Fe2O3) 1.1 1.2% -0.5 0.1 2. flue and duct linings.0 2.0 Titania (TiO2) 2.6% -0.205°C) insulating gunning castable.1 0. complete monolithic linings.2% -0. ˚F 2500 1900 2000 2000 2000 2200 Maximum Service Temperature. These results cannot be taken as minima or maxima for specification purposes.650°C) maximum service temperature. KAST-O-LITE® 23 LI is a 2.7 0. fluid coking units and other industrial linings as an exposed lining where slagging. low iron.6 17. or responsibility of any kind.200°F (1. These results cannot be taken as minima or maxima for specification purposes.3% -0. pumping or KAST-O-LITE® 22 G is an economical 2.2 0. catalytic reforming linings behind minum holding furnace doors. lb/ft3 . lightweight panel construction. It is ideally used as a gunned or cast back-up lining ductivity and good strength for such a lightweight mate.500˚F insulating gunning KAST-O-LITE® 20-45 is a hydraulic setting insulating KAST-O-LITE® 23 ES is an intermediate strength insu. maximum service temperature to 2. 5 1900°F Series KAST-O-LITE® 30 LI 400 Fairway Drive Moon Township. 2 1. Founded in 1875. KAST-O-LITE® 22 G 4 3000°F Series formance refractory solutions to all non-steel-related industries. casthouses. The com. GREENLITE® -45-L GR 5 2600°F Series incineration. EAFs.5 2600°F Series KAST-O-LITE® 20-45 K-Values 3 KAST-O-LITE® 22 Products from all these companies are available through: 2. and blast furnaces. the company is North America’s oldest refrac. alternative ironmaking. ferrous foundry.5 tory maker.5 Manufacturing products exclusively for NARCO and Harbison-Walker… 0 A.5 Exclusively serving the non-ferrous metals. along with a full line of insulating ceramic fibers. LMFs. NARCO also can design and implement a turnkey refractory management program to meet your facility’s specialized requirements. # HW139 (3/03) 1C . cement. hydro-carbon and minerals processing Mean Temperature (Btu/Hr ft2 F/in) industries. hydro-carbon. All rights reserved. LIGHTWEIGHT CASTABLES AND Exclusively serving the glass. copper. PA 15108 0 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 Phone: (412) 375-6600 • 1-800-377-4497 2 Fax: (412) 375-6846 Mean Temperature (Btu/Hr ft F/in) © 2003 Harbison-Walker Refractories Company.5 1900°F Series 1 0.P. Gunning Mixes 6 GUNNING MIXES 5. In addition KAST-O-LITE® 26 LI G 3. 2. ladles. glass.5 KAST-O-LITE® 23 ES 2 KAST-O-LITE® 23 LI For Cement and Lime Sales: 1. fin- ishing. many of which have become indus- K-Values try standards. The company also has one of the world’s top capabilities for cus- tomized pre-cast shapes. In addition to providing complete technical support services. Cat. Castables 6 5.5 CASTABLES 5 3000°F Series KAST-O-LITE® 20 4.5 2000°F Series KAST-O-LITE® 26 LI 1 Harbison-Walker Refractories Company 0. iron and steelmaking industries… GUNNING MIXES North American Refractories Company (NARCO) is a leading supplier of refractory solutions to the iron and steel industries. H-W is recognized worldwide for its technical support and 3 KAST-O-LITE® 30 LI G 2200°F Series expertise.5 to its own outstanding line of products. FOR ROTARY KILN SYSTEMS pany makes high-performance products for BOFs.5 Harbison-Walker Refractories Company (H-W) provides high-per.5 KAST-O-LITE® 20 LI 4 3. Green Refractories (APG) makes products for the iron and steel. minerals processing and other industries… KAST-O-LITE® 19 L 4. 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 aluminum. Heat-up can begin 2 hours after installation .multi-wall moisture .MAGSHOT ® For Cement & Lime Kilns Description: Magnesite-based chrome-free gunning mix Features & Benefits: • Chemistry similar to basic brick • Ease of installation • Quick turnaround for repairs .resistant sacks MAGSHOT Patch in place Wire Anchors Welded to the shell .Does not require lengthy cure times or slow heat-up schedules • Low dust and rebounds • Prolong existing lining until scheduled outage • Castable variant (MAGSHOT® CASTABLE) for larger installations • Proven track record Uses: • Burning zone patches in cement and lime rotary kilns • Nose rings in lime kilns • Flash coating basic brick in vertical lime shaft kilns • Throat areas of cement coolers • Patch where needed • Manways or access doors Packaging: Shipped in 55 pound . 8 10. warranty.6 Magnesia (MgO) 76.T. % Approximate (Calcined Basis) Silica (SiO2) 7. information. Cat# HW133R (9/02) 2C .510 After 1500°F 1.7 Titania (TiO2) 0. procedures where applica- ble. expressed or implied. pcf After 230°F 160 179 Modulus of Rupture.1 Iron Oxide (Fe2O3) 5. psi After 230°F 5.2 5.M.9 1.100 After 1500°F 5. All statements. All Rights Reserved.7 68. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.8 Alumina (Al2O3) 1.480 Cold Crushing Strength. (Typical) Bulk Density.000 Chemical Analysis. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.1 9.690 1. PA 15108 Phone: (412) 375-6600 1-800-377-4497 Fax: (412) 375-6846 © 2002 Harbison-Walker Refractories Company.5 2.9 The data given above are based on averages of tests results on samples selected from routine plant production by standard A. Variation from the above data may occur in individual test.870 10.930 7. MAGSHOT® TECHNICAL DATA MAGSHOT® MAGSHOT® CASTABLE Physical Properties.2 Phosphorous Pentoxide (P2O5) 1.0 Lime (CaO) 6. or responsibility of any kind. These results cannot be taken as minima or maxima for specification purposes. psi After 230°F 1.7 1.S. and data given herein are believed to be accurate and reliable but are presented without guarantee.560 1.1 0.7 Alkalies (Na2O + K2O) 0. When installed in a kiln section the lifters act to increase the tumbling efficiency of the kiln feed which exposes a larger percentage of feed to hot kiln gas and thereby reduces the heat consumption and improves fuel efficiency of the kiln system.. The sections generally consist of four (4) to six (6) rows running parallel with the kiln axis. PA 15108 Phone: (412) 375-6600 1-800-377-4497 Fax: (412) 375-6846 © 2001 Harbison-Walker Refractories Company. Lifters within the same row interlock together through a unique steel footing system which is also welded to the carbon steel bar. Cover Photo Courtesy of Dravo Lime Inc. Our precast lifters can be made to fit any kiln diameter and can be incorporated with any brick shape or castable lining. PRECAST KILN TUMBLER BLOCK Harbison-Walker Refractories Company. Once the lifters are in place the main lining can then be installed. Lime Industry Installation requires welding a piece of carbon steel bar stock for each row to the kiln shell. If you are interested in more information on increasing your kiln’s fuel efficiency contact your local HW representative. PRECAST LIFTERS Precast lifters or tumblers are large kiln blocks made out of our castable refractories. Equipment manufactur- Refractories for the ers generally place the lifter section within the preheating zone of a rotary lime kiln. Cat# HW135 (9/02) 2C .. again running parallel with the kiln axis. 400 Fairway Drive Moon Township. All Rights Reserved. The lifters are typically designed to be 5” to 6” taller than the existing refractory lining. 52 0.3 0.I 1.4% 0. lb/in 2 At 70OF (21OC) 690 840 800 960 Modulus of Rupture. lb/in2 At 70OF (21OC) 1.450 (10.500 (10. NARCON 65. information.4 14. .3% 0.4 1. suited for temporary repairs.05 Magnesia (MgO) 0.3 1.6 -0. % After Heating at 2910OF (1600OC) 0.19 0. lb/ft3 165 175 152 157 170 L.1 0.Magnesia based gunning mix that is ideally Chemical Analysis: (Approximate) VERSAFLOW® 45C.M.250 (8. Products include MAGSHOT® . lb/in2 (Mpa) At 2300OF (1260OC) 920 1. feed end linings.2 2.Dense.500 (10. Uses include pre. All statements.59 1. and nose/tail rings.500 13.000 (13.86 68.18 0. procedures where applicable.5 Crushing Strength. in shotcrete versions (SHOTKAST®).59 2.4 Alumina (Al2O3) 55. % 17. These results cannot be taken as minima or maxima for specification purposes.0 — — Permanent Linear Change. lb/ft3 At 70OF (21OC) 4. Alumina (Al2O3) 71.00 83. conven.3) Permanent Linear Change. free- Magnesia (MgO) 0.6 58.4 3.2 0.800 After Drying at 230OF (110OC) 147 154 170 After Drying at 1500OF (816OC) 144 151 166 Modulus of Rupture. Can be used for general-purpose repairs in all areas.0 16.2 0.2 9.4 cure therefore it can be heated immediately after place- NARCON CASTABLES .200 1. It can be Phosphorous Pentoxide (P2O5) — 3. Products include HPV 3000. Also available in a gunning version (LO-ABRADE® GR). HPV CASTABLE and HPV GUN MIX. VERSAFLOW® 57A. or responsibility of any kind.6) 1.5 As Rammed lb/ft3 (kg/m3) 156 (2.1 78.6 1.1 — — Silica (SiO2) 35.2 0.Dense.4 86.8 -0. conventionally EXPRESS® 27 C PLUS® is a 2700oF (1480oC) dense.3 cast or pump cast into place.7 15.Conventional. Can be vibcast. precast lifter sections. VERSAFLOW® 70.6 available in shotcrete versions (PNEUCRETE®).0% 15.610 VERSAFLOW® CASTABLES . Iron Oxide (Fe2O3) 1.11 ALUMINA BRICK KRUZITE®-70 ALTEX® 75B KALA® UFALA® ALADIN® 80 Alkalies (Na2O+K2O) 0. Possible uses include precast lifter shapes and feed end linings.91 Phosphorus Pentoxide (P2O5) 3.5% Chemical Analysis: (Approximate) Alumina (Al2O3) 15. Products include NARCON either cast or pumped.100 1.8 (Calcined Basis) After Heating at 3000OF (1649OC) +0.86 Bulk Density.8 Chemical Analysis: (Approximate) After Heating at 1500OF (816OC) -0.6 0. and data given herein are believed to be accurate and reliable but are presented without guarantee.100 5.700 1.4 15.5 0. Uses include preheater flowing refractory castable.1 0. Reheat Test tionally cast or pump cast into place.659) 184 (2.2 cast dams.0 (Calcined Basis) Titania (TiO2) 0.499) 166 (2.4 shelfs.2 Silica (SiO2) 0.2 0.4) At 1500OF (816OC) 1. warranty.000 7.61 3.03 1.8 -0.000 7.T. It has unique property that Alkalies (Na2O+K2O) 0.3 +0.730 2.500 At 230OF (110OC) 1.8 -0.2% 15.1 0.3) 2.59 0. lb/ft3 182 187 180 182 Approximate Amount Required Apparent Porosity.8 exhibiting excellent mechanical strength and excellent Lime (CaO) 0.6 11.100 7.650 (11.3 -0.0 76. Its density together with very good 60.2 0. lb/in2 CASTABLES At 70OF (21OC) 8.8) 1.640 1.08 1.Unique group of products that Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free are light in weight yet exhibit physical properties of patent infringement of a third party.0 0.0 49. lb/in2 Bulk Density. % 18.33 Apparent Porosity. The data given in this brochure are based on averages of tests results on samples selected from routine plant production by standard A.09 0.1 +1.5% 46. HPVTM CASTABLES .410 9. Can be vibcast. BASIC BRICK MAGNEL® MAGNEL® NOKROME® NOKROME® PLASTIC NARPHOS 55S REDD RAMM NARPHOS 80S RS RSV 87LK 92LK Maximum Service Temperature 3000oF (1649oC) 3100oF (1740oC) 3200oF (1760oC) Bulk Density.3) 1. % After Drying at 230OF (110OC) -0.73 0.610 castables exhibiting high mechanical strength and castable that exhibits good resistance to abrasion and ero- excellent abrasion resistance.250 (8.5% 0.6) 1.31 Lime (CaO) 1.1 0.800 (12.3 abrasion resistance.2 2. precast lifter sections.O.6 1.0) 1. sion.3 19.5 +0. After Heating at 2910OF (1600OC) +4. expressed or implied.700 2. high strength 2600O F Modulus of Rupture.22% 9.5 1. approaching those of denser materials.2 0.11 1. Variation from the above data may occur in individual test. Magnesia base makes it (Calcined Basis) VERSAFLOW® 60. low cement LO-ABRADE® .948) Crushing Strength. and nose/tail rings.91 Magnesia (MgO) 82.S.0 14.4 Iron Oxide (Fe2O3) 0. cast vibration is not required to remove air voids.0 18.26 1.6% 38.5 +2. NARCON products are also available abrasion resistance make it an ideal hot face lining material. % heater shelves.7 -0.2% VERSAFLOW® 80C. feed end linings.14 Lime (CaO) 0. Unique bonding mechanism does not require a 24-hour air Titania (TiO ) 2 3.400 8.5 Titania (TiO2) 1.1 0. The suggested use assumes that all safety measures are taken by the user. Permanent Linear Change.98% 24.500 (10.25 0. and compatible for use in burning zone areas where conven- Silica (SiO2) 23.1 0.4) Reheat Test At 2700OF (1482OC) 1.2 3.77 1.4 1.5 91.22% Iron Oxide (Fe2O3) 0. VERSAFLOW products are also tional alumina products do not have enough refractoriness. low cement castables ment to allow for quick turnaround.0 — — — dams.4 88.0 6.2 1. Magnesia based gunning mix that is ideally Chemical Analysis: (Approximate) VERSAFLOW® 45C.O. and compatible for use in burning zone areas where conven- Silica (SiO2) 23. precast lifter sections. All statements.2 2. % 17. Iron Oxide (Fe2O3) 1.8) 1.2 3. It has unique property that Alkalies (Na2O+K2O) 0. Products include HPV 3000.5% 46.73 0.000 (13.499) 166 (2.0 16. Products include NARCON either cast or pumped.5 Titania (TiO2) 1.3% 0.6) 1.7 15.2 9. The data given in this brochure are based on averages of tests results on samples selected from routine plant production by standard A.8 -0.948) Crushing Strength.2 0.659) 184 (2. % After Drying at 230OF (110OC) -0.Conventional.500 13.000 7.640 1.59 1.4 cure therefore it can be heated immediately after place- NARCON CASTABLES .500 At 230OF (110OC) 1.800 (12. Uses include preheater flowing refractory castable.4 Iron Oxide (Fe2O3) 0.91 Magnesia (MgO) 82.5 Crushing Strength.Dense.4 88.3 0.700 2.Dense.3) 1. sion.S. lb/ft3 165 175 152 157 170 L.610 castables exhibiting high mechanical strength and castable that exhibits good resistance to abrasion and ero- excellent abrasion resistance. or responsibility of any kind. in shotcrete versions (SHOTKAST®).400 8.0 0.100 5.86 68. % After Heating at 2910OF (1600OC) 0.2 0.19 0. approaching those of denser materials. After Heating at 2910OF (1600OC) +4.5 0.5 91.05 Magnesia (MgO) 0. information.1 0. free- Magnesia (MgO) 0.4 86.2 0. procedures where applicable. .5 1. % heater shelves.5% 0.4) At 1500OF (816OC) 1.4% 0.91 Phosphorus Pentoxide (P2O5) 3.6 0.25 0.5 +0.18 0. low cement LO-ABRADE® . It can be Phosphorous Pentoxide (P2O5) — 3. expressed or implied.500 (10.22% 9.6 1. Variation from the above data may occur in individual test. Alumina (Al2O3) 71.1 0.00 83.000 7.800 After Drying at 230OF (110OC) 147 154 170 After Drying at 1500OF (816OC) 144 151 166 Modulus of Rupture.33 Apparent Porosity.2 0.1 0.11 ALUMINA BRICK KRUZITE®-70 ALTEX® 75B KALA® UFALA® ALADIN® 80 Alkalies (Na2O+K2O) 0. Possible uses include precast lifter shapes and feed end linings. feed end linings.5% Chemical Analysis: (Approximate) Alumina (Al2O3) 15.0 (Calcined Basis) Titania (TiO2) 0.4 14.500 (10.2 Silica (SiO2) 0. VERSAFLOW® 57A. Can be vibcast.610 VERSAFLOW® CASTABLES .6 58.31 Lime (CaO) 1. conven.2% VERSAFLOW® 80C.3 cast or pump cast into place.26 1.4 1.200 1.1 78.1 0.98% 24.5 +2. These results cannot be taken as minima or maxima for specification purposes.4) Reheat Test At 2700OF (1482OC) 1.730 2.7 -0.3) 2.61 3. cast vibration is not required to remove air voids. Also available in a gunning version (LO-ABRADE® GR). The suggested use assumes that all safety measures are taken by the user.700 1.1 0.100 7.3 1.2 cast dams.2 0. Reheat Test tionally cast or pump cast into place.03 1. NARCON 65. and data given herein are believed to be accurate and reliable but are presented without guarantee. VERSAFLOW® 70.3 19.0% 15.08 1. Its density together with very good 60. HPV CASTABLE and HPV GUN MIX.2% 15. % 18.4 3. VERSAFLOW products are also tional alumina products do not have enough refractoriness.I 1.0 6. lb/in2 Bulk Density. lb/in 2 At 70OF (21OC) 690 840 800 960 Modulus of Rupture.500 (10.4 1.3 -0. Unique bonding mechanism does not require a 24-hour air Titania (TiO ) 2 3.11 1. and nose/tail rings.8 exhibiting excellent mechanical strength and excellent Lime (CaO) 0.3) Permanent Linear Change.0 76.2 0. Magnesia base makes it (Calcined Basis) VERSAFLOW® 60. suited for temporary repairs.59 0.6) 1. Permanent Linear Change.0 — — — dams. lb/in2 At 70OF (21OC) 1.0 18.09 0.2 2.410 9. NARCON products are also available abrasion resistance make it an ideal hot face lining material.1 0.14 Lime (CaO) 0.0 — — Permanent Linear Change.1 +1. Can be used for general-purpose repairs in all areas.4 15.6% 38.450 (10.8 -0.3 +0.M.4 Alumina (Al2O3) 55.6 -0. lb/ft3 At 70OF (21OC) 4. feed end linings. and nose/tail rings.100 1.0) 1.77 1. conventionally EXPRESS® 27 C PLUS® is a 2700oF (1480oC) dense.59 2.86 Bulk Density.22% Iron Oxide (Fe2O3) 0. lb/in2 CASTABLES At 70OF (21OC) 8. low cement castables ment to allow for quick turnaround.3 abrasion resistance.8 -0.2 1.6 1. Uses include pre.0 49.8 (Calcined Basis) After Heating at 3000OF (1649OC) +0. Products include MAGSHOT® .T.1 — — Silica (SiO2) 35.6 11.250 (8.52 0.8 Chemical Analysis: (Approximate) After Heating at 1500OF (816OC) -0. warranty.650 (11. precast lifter sections.250 (8.6 available in shotcrete versions (PNEUCRETE®). high strength 2600O F Modulus of Rupture.0 14. lb/ft3 182 187 180 182 Approximate Amount Required Apparent Porosity.5 As Rammed lb/ft3 (kg/m3) 156 (2.4 shelfs. lb/in2 (Mpa) At 2300OF (1260OC) 920 1. BASIC BRICK MAGNEL® MAGNEL® NOKROME® NOKROME® PLASTIC NARPHOS 55S REDD RAMM NARPHOS 80S RS RSV 87LK 92LK Maximum Service Temperature 3000oF (1649oC) 3100oF (1740oC) 3200oF (1760oC) Bulk Density.Unique group of products that Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free are light in weight yet exhibit physical properties of patent infringement of a third party. HPVTM CASTABLES . Can be vibcast. Equipment manufactur- Refractories for the ers generally place the lifter section within the preheating zone of a rotary lime kiln. PRECAST KILN TUMBLER BLOCK Harbison-Walker Refractories Company. Once the lifters are in place the main lining can then be installed.. If you are interested in more information on increasing your kiln’s fuel efficiency contact your local HW representative. Cover Photo Courtesy of Dravo Lime Inc.. again running parallel with the kiln axis. Cat# HW135 (9/02) 2C . Our precast lifters can be made to fit any kiln diameter and can be incorporated with any brick shape or castable lining. Lifters within the same row interlock together through a unique steel footing system which is also welded to the carbon steel bar. PA 15108 Phone: (412) 375-6600 1-800-377-4497 Fax: (412) 375-6846 © 2001 Harbison-Walker Refractories Company. Lime Industry Installation requires welding a piece of carbon steel bar stock for each row to the kiln shell. PRECAST LIFTERS Precast lifters or tumblers are large kiln blocks made out of our castable refractories. All Rights Reserved. The lifters are typically designed to be 5” to 6” taller than the existing refractory lining. 400 Fairway Drive Moon Township. The sections generally consist of four (4) to six (6) rows running parallel with the kiln axis. When installed in a kiln section the lifters act to increase the tumbling efficiency of the kiln feed which exposes a larger percentage of feed to hot kiln gas and thereby reduces the heat consumption and improves fuel efficiency of the kiln system. pcf After 230°F 178 After 1500°F 175 Water Required to Cast. and high refractoriness. information. or responsibility of any kind. expressed or implied.3 Iron Oxide (Fe2O3) 0. it has excellent abrasion and anti. These results cannot be taken as minima or maxima for specification purposes. psi After 230°F 8. TECHNICAL DATA THOR AZSP ADTECHT® Physical Properties (Typical) Maximum Service Temperature.THOR AZSP ADTECH ® Pumpable Castable for Cement & Lime Kiln Systems THOR AZSP ADTECH® . .2 Lime (CaO) 1. The suggested use assumes that all safety measures are taken by the user.% 5.4 Alumina (Al2O3) 47. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such prod- uct is fit for such use or that such use is free of patent infringement of a third party.2 Titania (TiO2) 0. and data given herein are believed to be accurate and reliable but are presented without guarantee.a premium anti-buildup product THOR AZSP ADTECH® is a pumpable special low-moisture fused zirconia-mullite castable with a silicon carbide addition that can also be shotcreted with GT activator.7 Silica (SiO2) 21. psi After 230°F 1.200 Abrasion Resstance After 1500°F 6.8 cc Chemical Analysis. Variation from the above data may occur in individual tests. It is totally inert and will not react with alkalis.050 Crushing Strength. lb/ft 3 177 Bulk Density.5 The data given above are based on averages of test results on samples selected from routine plant production and are determined by standard ASTM procedures where applicable.9 Silicon Carbide (SiC) 4. % Zirconia (ZrO2) 23. The zircon is tied up with the mullite and will not reduce.8 Alkalies (Na2O) 0. Like others in the THOR family. weight .5 Modulus of Rupture. All statements. chlorides and sulfates. It is unique in that it is pumpable giving you a faster turnaround in tight outage situations. warranty.750 After 1500°F 2. wt.600 After 1500°F 8.buildup resistance. °F 2800 Material Required. H-W is recognized worldwide for its technical support and expertise. incineration.P. minerals processing and other industries… Harbison-Walker Refractories Company (H-W) provides high-per- formance refractory solutions to all non-steel-related industries. Exclusively serving the non-ferrous metals. ferrous foundry. glass. iron and steelmaking industries… North American Refractories Company (NARCO) is a leading supplier of refractory solutions to the iron and steel industries. Manufacturing products exclusively for NARCO and Harbison-Walker… A. and blast furnaces. along with a full line of insulating ceramic fibers. LMFs. In addition to pro- viding complete technical support services. Founded in 1875. alternative ironmaking. # HW139 (9/04) 2C . the company is North America’s oldest refrac- tory maker. ladles. casthouses. NARCO also can design and implement a turnkey refractory management program to meet your facility’s specialized requirements. copper. Exclusively serving the glass. finish- ing. many of which have become indus- try standards. The compa- ny makes high-performance products for BOFs. hydrocarbon. cement. All rights reserved. Green Refractories (APG) makes products for the iron and steel. PA 15108 Phone: 1-800-377-4497 Fax: (412) 375-6846 © 2002 Harbison-Walker Refractories Company. aluminum. and hydrocarbon and minerals processing industries. In addition to its own outstanding line of products. The company also has one of the world’s top capabilities for cus- tomized pre-cast shapes. Products from all these companies are available through: For Mineral Processing: Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. EAFs. Cat. Zirconia-Mullite Castable that can be conventionally cast or pumped Features & Benefits: • 2800°F Service Temperature • High Hot Strength • Excellent Thermal Shock Resistance • Ease of Installation • Conventional Casting or Pumping • High Refractoriness • Proven Track Record • Unique Flex-O-Anchor design Packaging: Shipped in 55 pound .multi-wall moisture .THOR AZS CASTABLE THOR AZSP ADTECH® For Cement Kiln Nose Rings Description: A Special Low-Moisture.resistant sacks CONSTRUCTION JOINTS THOR AZS CASTABLE OR THOR AZSP ADTECH FLEX-O-ANCHOR 1/8” CERAMIC PAPER RETAINING RING RAS ANCHOR . The suggested use assumes that all safety measures are taken by the user. steam spalling during heat-up may occur. psi After 230°F 12.1 Lime (CaO) 1. psi After 1500°F 4. or responsibility of any kind.0 5. pcf After 230°F 180 179 Hot Modulus of Rupture.4 1.2 0. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.100 -- After 2500°F 1.2 The data given above are based on averages of tests results on samples selected from routine plant production by standard ASTM procedures where applicable.500 After 2200°F 15.1 21.4% Alumina (Al2O3) 55.2 0. All statements.1 0. and data given herein are believed to be accurate and reliable but are presented without guarantee.4 Silicon Carbide (SiC) 5.600 After 1500°F 10.8% 18. (Typical) Bulk Density. Warning: If proper procedures for preparation. warranty.4 Alkalies (Na2O + K2O) 0. Phone: 1-800-377-4497 Fax: (412) 375-6846 Cat# HW134 R (03/03) 2C .800 10.000 1.3 Titania (TiO2) 0. infor- mation. PA 15108 © 2003 Harbison-Walker Refractories Company. TECHNICAL DATA THOR AZS CASTABLE THOR AZSP ADTECH® Physical Properties.950 After 2000°F 5. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.2 53. % Approximate (Calcined Basis) Silica (SiO2) 17. These results cannot be taken as minima or maxima for specification purposes.2 Iron Oxide (Fe2O3) 0. application and heat-up of this material are not observed. Variation from the above data may occur in individual tests.0 Zirconia (ZrO2) 20. expressed or implied.000 -- Cold Crushing Strength.300 11. All Rights Reserved.200 -- Chemical Analysis. information. TZ 352 DRY MORTAR is chemically inert and if a buildup does occur. wt.0 Silica (SiO2) 32. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such prod- uct is fit for such use or that such use is free of patent infringement of a third party.125 .25 Water Required: For trowelling add 12-15% For spraying add 20-25% Chemical Analysis.7 Alkalies (Na2O+K2O) 1. or responsibility of any kind.TZ 352 DRY MORTAR Anti-Buildup For Existing Linings TZ 352 DRY MORTAR TZ 352 DRY MORTAR is a heat-set Zircon-containing dry mortar that is an effective anti- buildup material for nonbasic refractory linings. expressed or implied. All statements. Variation from the above data may occur in individual tests.6 The data given above are based on averages of test results on samples selected from routine plant production and are determined by standard ASTM procedures where applicable. . The application method is either by trowel or spraying. It can be installed over monolithic or brick linings thereby saving time and money. warranty. it is easily removed. The suggested use assumes that all safety measures are taken by the user. and data given herein are believed to be accurate and reliable but are presented without guarantee.(3150) Cement Required. % Zirconia (ZrO2) 60.(°F) 1732 .0 Alumina (Al2O3) 1.. These results cannot be taken as minima or maxima for specification purposes. °C . tons per 1000 ft2 1 Required Installation Thickness. TECHNICAL DATA TZ 352 DRY MORTAR Physical Properties (Typical) Maximum Service Temperature. inches 0.0 Phosphorous Pentoxide (P2O5) 4. hydrocarbon. EAFs. alternative ironmaking. The compa- ny makes high-performance products for BOFs. Products from all these companies are available through: For Mineral Processing: Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. minerals processing and other industries… Harbison-Walker Refractories Company (H-W) provides high-per- formance refractory solutions to all non-steel-related industries. # HW138 (11/02) 2C . finish- ing. PA 15108 Phone: 1-800-377-4497 Fax: (412) 375-6846 © 2001 Harbison-Walker Refractories Company. Exclusively serving the glass. along with a full line of insulating ceramic fibers. many of which have become indus- try standards. LMFs. and blast furnaces. Green Refractories (APG) makes products for the iron and steel. ladles. ferrous foundry. cement. NARCO also can design and implement a turnkey refractory management program to meet your facility’s specialized requirements. In addition to its own outstanding line of products. incineration. copper. Exclusively serving the non-ferrous metals.P. Founded in 1875. glass. The company also has one of the world’s top capabilities for cus- tomized pre-cast shapes. casthouses. Cat. and hydrocarbon and minerals processing industries. Manufacturing products exclusively for NARCO and Harbison-Walker… A. In addition to pro- viding complete technical support services. iron and steelmaking industries… North American Refractories Company (NARCO) is a leading supplier of refractory solutions to the iron and steel industries. H-W is recognized worldwide for its technical support and expertise. aluminum. All rights reserved. the company is North America’s oldest refrac- tory maker. resistant sacks CONSTRUCTION JOINTS VERSAFLOW® 70 ADTECH® FLEX-O-ANCHOR 1/8” CERAMIC PAPER RETAINING RING RAS ANCHOR .multi-wall moisture .VERSAFLOW 70 ADTECH ® ® For Cement Kiln Nose Rings Description: A 70% High Alumina Low Cement Castable Features & Benefits: • 31000F Service Temperature • High Hot Strength • Excellent Abrasion Resistance • Ease of Installation • Vibcasting • Conventional Casting • Pumping • High Refractoriness • Proven Track Record • Unique Flex-O-Anchor Design Packaging: Shipped in 55 pound . VERSAFLOW® 70 ADTECH® TECHNICAL DATA VIBCASTING CONV.S. % Approximate (Calcined Basis) Silica (SiO2) 27. (Typical) Bulk Density. psi After 230°F 21.300 2. expressed or implied. or responsibility of any kind. All statements. psi After Drying at 230°F 1. and data given herein are believed to be accurate and reliable but are presented without guarantee.990 1. These results cannot be taken as minima or maxima for specification purposes.2 The data given above are based on averages of tests results on samples selected from routine plant production by standard A. information. application and Heat-up of this material are not observed.500 At 2500 °F 750 -- Cold Crushing Strength. Cat# HW137R (8/02) 2C .T.160 After 1500°F 15.430.439 Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. steam spalling during heat-up may occur. PA 15108 Phone: (412) 375-6600 1-800-377-4497 Fax: (412) 375-6846 © 2002 Harbison-Walker Refractories Company.9 Lime (CaO) 2.4 Iron Oxide (Fe2O3) 0.660 18. Variation from the above data may occur in individual test.770 Chemical Analysis. 4.M. warranty. The suggested use assumes that all safety measures are taken by the user. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. pcf After 230°F 158 153 Modulus of Rupture. This product is covered by Patent No. Warning: If prpoer procedures for prepration.1 Alkalies (Na2O + K2O) 0.3 Titania (TiO2) 2.980 After Heating at 1500°F 3.1 Magnesia (MgO) 0. All Rights Reserved.0% Alumina (Al2O3) 67.000 14. procedures where applica- ble. CASTING/PUMPING Physical Properties. This product is for normal basic steel and iron NARMAG® 95LS CASTABLE: This is a 96% containing conditions. shock resistance. allows the dry out to begin sooner than for periclase ramming mix with chemical bonds. 50% fused grain and TOMAHAWK® with improved thermal shock resistance. The coarse NARMAG® 60DBR can be considered as grained structure provides for very good thermal economical alternatives in zoned linings. SUPER NARMAG® 142: This product is a burned 20% fused Mg-Cr grain brick. TAYCOR® 414-C HYDROCAST: This is a coarse Other Brands: NARMAG® 60DB and grained. Other Selections FASTDRY 8 CASTABLE: This is a high alumi- na. cement free castable with an alumina rich Mortars: Mag-Chrome brick should be laid spinel matrix. density. This NARMAG® 60DB product is for normal basic steel and iron con- taining conditions. It is intended for basic steel Problem Solvers: SUPER NARMAG®145 with and iron operations. and iron slags. The cement free formulation Bottom Leveling: H-W® C Mix is a high purity.AOD Refractories for Industrial Foundries Mag-Chrome Brick Selections NARMAG® 95LS CASTABLE TAYCOR® 414-C HYDROCAST FASTDRY 8 CASTABLE SUPER NARMAG® FG: This product is a NARMAG® 142 burned 100% fused Mg-Cr grain brick with chrome enhancement. This yields excellent porosity. SUPER NARMAG® FG is intended for the most extreme basic steel and iron con- taining conditions with regards to slag corro. NARMAG® FG is intended for extreme basic steel and iron containing conditions. density. NARMAG® 60DB NARMAG® 142: This product is a burned SUPER NARMAG® FG NARMAG® 60DB NARMAG® FG Mg-Cr brick containing no fused grain. cement containing castables. It offers good resistance to steel with NARMAG® FG FINE MORTAR DRY. NARMAG® 142 has slightly higher porosity Castable Selections along with lower density and strength. magnesia castable with high density and out- standing hot strength. 96% alumina castable. and strength. . H-W C Mix ® Compared to the above products. and strength. NARMAG® FG: This product is a burned 100% fused Mg-Cr grain brick. very high density. NARMAG® FG SUPER NARMAG® 142 siveness and temperature. It offers very good porosity. This yields extremely low porosity. and excellent strength. 1 Lime (CaO) 0. procedures where applicable. 0.0 -. Variation from the above data may occur in individual test.0 12. -. 7. All Rights Reserved.8 Iron Oxide (Fe2O3) 12.0 12. % (Approximate) Silica (SiO2) 0.0 19. pcf After 230°F 210 207 205 204 178 182 195 Modulus of Rupture.0 -.3 6.S. All statements. -. Photo shows AOD vessel with NARMAG® FG and SUPER NARMAG® 142 zoned by brand and thickness for optimal performance.1 0.0 61.600 -. These results cannot be taken as minima or maxima for specification purpos- es.2 96. The sug- gested use assumes that all safety measures are taken by the user.5 0. -.6% 0.0 0.8 2. -- Alkalies (Na2O + K2O) -.2% 1.1 0.7% 0. or responsibility of any kind.0 59.2 The data given above are based on averages of test results on samples selected from routine plant production by standard A.8 Chromic Oxide (Cr2O3) 22.8 2.8 0. warranty. and data given herein are believed to be accurate and reliable but are presented without guarantee. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.0 62.700 1. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. -.1 6.8 6.900 At 2700°F 850 700 300 400 1.7 0. 700 Apparent Porosity % 12 13 14 15 -.0% Alumina (Al2O3) 6. information.800 1.2 0.5 90.5 % 0. expressed or implied. -- Chemical Analysis.5% 0. -. psi At 70°F 1. PA 15108 Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company.T.9 0. AOD Refractories BRICK CASTABLES SUPER SUPER NARMAG® TAYCOR® FASTDRY NARMAG® NARMAG ® NARMAG® NARMAG ® 95LS 414-C 8 Typical Test Data FG FG 142 142 CASTABLE HYDROCAST CASTABLE Bulk Density.0 13.5 0. -.0 20.0 18.M. Cat# HW103R (01/03) 2C .0 96.1 Magnesia (MgO) 58.3% 0.500 700 600 500 1. 5 11. or responsibility of any kind. -.1 0.300 -.1 0.300 -.4 1.7 0. -.1 0. -.3 19.0 6. expressed or implied.1 0.7 0. Cat# HW115R (1/03) 2C . procedures where applicable. Metal.7 7. Maintenance SUPER NARCARB PLASTIC NARCARB ZP PLASTIC Bottom* Front Slagger & Dam Iron Runner NARCARB ZP PLASTIC D-CAST TRC-SR-CC D-CAST TRC-SR-CC RAMAL 85G SUPER NARCARB PLASTIC/RAM RAMAL 85G NARPHOS 55R (FINE) SUPER GRAPHPAK-85 GREENPAK-85-MP *All used in combination with sand RAMAL 85G Installation of RAMAL 85 G in cupola trough application. -. Precast Options NARCARB ZP PLASTIC SUPER NARCARB PLASTIC/RAM Apparent Porosity. Breast Wall & Trough Plastics Ram Mixes SUPER NARCARB PLASTIC NARCARB ZP SUPER GRAPHPAK GRAPHPAK -85 -85 GRAPHPAK -45 GREENPAK 85 MP SUPER NARCARB RAM NARCARB XZR RAMAL 85G CUPOLA Refractories Max.0 62.6 The data given above are based on averages of test results on samples selected from routine plant production by standard A.100 -. oF 3275 3275 3200 3100 2950 3000 3275 3275 3275 Material Required. 18 17 -. 900 -. 1.7 72. All Rights Reserved. -.3 0.4 0. -. D-CAST TRC 69 Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use VERSAFLOW® 70/CU ADTECH® is free of patent infringement of a third party. and data given herein are believed to be accurate and reliable but are presented without guarantee.3 2. -. -- Silicon Carbide + Carbon (SiC+C) 27. % RUBY® SR/C SUPER GRAPHPAK-85 SUPER GRAPHPAK-85 After Heating to 1800oF 20 22.1 Alumina (Al2O3) 61. -.8 70. TUFLINE® 95 DM/C RAMAL 85G Chemical Analysis: % TUFLINE® 90 DM/C (Approximate) D-CAST TRC-SR VERSAFLOW® 70/CU ADTECH® Silica (SiO2) 8.3 1. 4. 125 200 1.8 13. lb/in2 184 178 185 166 142 178 184 188 160 Breast Wall & Trough After Heating to 300°F 1.4 2.2 0. -.6 1.600 200 After Heating to 1500°F -.1 0.0 64.5 0.0 -. -.4 1.3 1. NARCARB ZP Plastic lining a cupola well zone Service Conditions • Temperature (2000oF . -. Service Temp.5 1.6 SUPER GRAPHPAK-85 Magnesia (MgO) 0.0 -. 1. All statements. -. -.4 0. warranty.1 0. 27. information.3 Phosphorus Pentoxide (P2O5) -.1 0.2 0.4 10.300 2.1 Monolithic Options Titania (TiO ) 2 1.4 0.7 1. -. -. -.5 1.1 0.5 NARCARB XZR RAM Lime (CaO) 0.3 1.1 0.7 11.9 2.9 76. The suggested use assumes that all safety measures are taken by the user. -. -.0 20. PA 15108 Phone: (412) 375-6600 w Fax: (412) 375-6783 • Metal Erosion and Velocity © 2003 Harbison-Walker Refractories Company. Taphole Shapes Breast Wall Slag Trough At 2000°F -.4 46. Oxygen Reactions Moon Township. -.300 800 900 350 250 750 1.200 640 -.1 0.1 0. lb/ft3 Modulus of Rupture.5 -.1 39.5 9. -.0 8.6 80.2 0. -. -.1 0.2 0.S.2 0.1 22. Well Variation from the above data may occur in individual test.M. -. -- After Heating to 1800°F 700 900 -.1 Alkalies (Na2O+K2O) 0.7 SUPER NARCARB PLASTIC/RAM NARCARB ZP PLASTIC Iron Oxide (Fe2O3) 0.9 12.660 760 SUPER NARCARB PLASTIC D-CAST TRC-SR-CC At 2500°F 1.1 0.T.1 0.6 6. These results cannot be taken as minima or maxima for specification purposes. 1.0 68.5 1.3000oF) Harbison-Walker Refractories Company 400 Fairway Drive • Slag.2 0. -. Iron Oxide (Fe2O3) 1.4 GRAPHPAK-85.8 15. Examples of VIBTECH® shapes. -. -.2 0.2 0. non-wetting components. 0. It can be ordered as a castable or 70/CU ADTECH®: precast shape.0 -.1 -. -.5 -- life.360 -. % -.0 Lime (CaO) 2. NARCARB XZR RAM provides Modulus of Rupture. 1. Service Temp. or responsibility of any kind. D-CAST TRC 69 This a low cement. and volume stability for negligible sintering cracks during service. -. -.1 1.1 -. -. -. NARCARB ZP provides excellent performance in extended After Heating to 1500°F 2. 14.2 Trace Magnesia (MgO) 0. This material is ideally suited for well zone and melt At 2500°F 700 600 -.1 0.5 89.5 & RAMAL 85G: for cupolas. This plastic possesses good Chemical Analysis: % (Approximate) resistance to hot metal and slag erosion and represents an economical alternative to NARCARB ZP and SUPER NARCARB in less severe conditions.S. All statements.1 0. -.5 -. excellent hot strengths.900 -. warranty. -. 300 -- SUPER This air-setting. well blocks.1 0.M. It features improved strengths above 1500oF.100 650 zone maintenance during bottom drops. -.2 1.0 69. VERSAFLOW® This is a 70% alumina low cement castable containing SiC. These properties make D-CAST TRC-SR-CC an outstanding option for severe slag and metal contact applications.1 0.9 8. .800 1. information. expressed or implied. it The data given above are based on averages of test results on samples selected from routine plant production by standard A. This product is a lower cost version of the other D-CAST products but is not as oxidation resistant. -.320 -. lb/in2 excellent performance in maintenance situations or as the original lining in Cupola bottoms and troughs. silicon carbide and graphite containing.0 54. shock resistance. TUFLINE® 95 DM/C. contains oxidation inhibitors. It is non-wetting to iron and slag. Depending on the specific mix.1 Taphole Material Selections: Alkalies (Na2O+K2O) 0. D-CAST TRC-SR is an excellent choice for taphole free of patent infringement of a third party. 1.2 83. high hot strengths. -- GRAPHPAK-85: pitch or resins. -. oxidation resistance plastic contains no Apparent Porosity.600 -.Cupola Brand Description Taphole Well and Bottom Materials SiC / Graphite Plastic & Ram Selections: TUFLINE® TUFLINE® SUPER NARCARB These products are based on fused alumina with SiC and oxidation inhibitors. lb/ft3 NARCARB This is a phenolic resin bonded ramming mix with the second highest amount of non-wetting compo. or long iron runners. it does not give off polluting emissions.720 1.4 1.5 72. 3. 1.100 PLASTIC: contains SiC with oxidation inhibitors.0 18. These results cannot be taken as minima or maxima or specification purposes. Other Oxides -.2 0. This product is used in applications where service demands are less severe. well blocks.0 2.2 1.7 6. The SiC provides enhanced corrosion resistance in taphole blocks. At 2700°F -. low porosity.2 0.0 0.1 0.5 -. graphite containing materials.1 -. At 70°F -. 11. After Heating to 230oF 173 194 197 200 204 185 156 XZR RAM: nents.3 Alumina (Al2O3) 68. a modified matrix for enhanced slag resistance.3 VIBTECH Shapes: These are thixotropic-formed shapes which are fired to high temperatures to achieve properties ® Chromic Oxide (Cr2O3) -. -.6 15. 17. F o 2850 3100 3300 3400 3300 3100 3000 offer a more environmentally friendly bond system than the phenolic resin bonded materials. Bulk Density.1 0. blocks. Trace 0. -- NARCARB ZP This phenolic resin bonded plastic provides high strengths at iron producing temperatures.6 -.5 3. -. These are high alumina and fireclay. -.7 39. -. procedures where applicable. Either way. and exhibits slag Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is resistance comparable to resin-bonded plastis. 0. and excellent thermal data given herein are believed to be accurate and reliable but are presented without guarantee. 3.9 1.1 2.2 0. and RUBY® SR/C. These products Max. 400 1. excellent thermal shock resistance. GRAPHPAK-45 and GRAPHAK-85 are plastics while RAMAL 85G is a wet ramming mix. Options for cupola taphole service include TUFLINE® 90 DM/C.1 0. and provides exceptional properties such as 9% porosity.1 1. The suggested use assumes that all safety measures are taken by the user.3 94.3 D-CAST TRC-SR: This SiC and carbon containing castable can also be ordered as a precast shape. Silica (SiO2) 11. Such shapes can provide excellent performance in cupola well blocks and taphole applications. Cast & Shapes Cast & Shapes Shape Shape Shape Castable Ram Both products offer the highest level of carbon containing. This yields very low VERSAFLOW® D-CAST 90 DM/C 95 DM/C RUBY® SR/C D-CAST NARPHOS PLASTIC & RAM: porosity for enhanced corrosion resistance to cupola slags. SiC and carbon containing castable.710 1. They exhibit better corrosion GRAPHPAK-45 resistance to molten iron and slag than conventional materials. SiC containing castable with improved slag resistance compared with other D-CAST materials. low porosity and high hot strengths. or long iron runners. -. Variation from the above data may occur in individual test.890 1.1 7. -. As a result. VIBTECH shapes can provide longer service Silicon Carbide + Carbon (SiC+C) 14. Both of these SUPER NARCARB 70/CU ADTECH® TRC-SR-CC VIBTECH ® VIBTECH ® VIBTECH® TRC 69 55R (FINE) materials are intended for extended cupola campaigns and the most severe service conditions. It After Heating to 230°F 1.T. -. and excellent thermal shock resistance. -- equivalent to brick. 700 cupola campaigns under severe conditions. These are workhorse type materials Titania (TiO2) 2. This mix offers high density. Castables for Cupola Applications D-CAST TRC-SR-CC This is a low cement.5 3. The SiC provides enhanced corrosion resistance in taphole blocks.0 18.800 1. 17. -. high hot strengths. or long iron runners. and excellent thermal data given herein are believed to be accurate and reliable but are presented without guarantee. -.Cupola Brand Description Taphole Well and Bottom Materials SiC / Graphite Plastic & Ram Selections: TUFLINE® TUFLINE® SUPER NARCARB These products are based on fused alumina with SiC and oxidation inhibitors.9 1.100 PLASTIC: contains SiC with oxidation inhibitors. TUFLINE® 95 DM/C. Depending on the specific mix. -. This product is used in applications where service demands are less severe. well blocks. This yields very low VERSAFLOW® D-CAST 90 DM/C 95 DM/C RUBY® SR/C D-CAST NARPHOS PLASTIC & RAM: porosity for enhanced corrosion resistance to cupola slags. graphite containing materials. All statements.5 3. These are high alumina and fireclay. -- equivalent to brick.5 & RAMAL 85G: for cupolas. At 2700°F -.710 1. lb/in2 excellent performance in maintenance situations or as the original lining in Cupola bottoms and troughs. and exhibits slag Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is resistance comparable to resin-bonded plastis. -. or responsibility of any kind.5 -. The suggested use assumes that all safety measures are taken by the user.8 15. Both of these SUPER NARCARB 70/CU ADTECH® TRC-SR-CC VIBTECH ® VIBTECH ® VIBTECH® TRC 69 55R (FINE) materials are intended for extended cupola campaigns and the most severe service conditions.5 -.M.1 Taphole Material Selections: Alkalies (Na2O+K2O) 0. This material is ideally suited for well zone and melt At 2500°F 700 600 -. It After Heating to 230°F 1. non-wetting components. -. GRAPHPAK-45 and GRAPHAK-85 are plastics while RAMAL 85G is a wet ramming mix. well blocks.T. Silica (SiO2) 11. 0. -. This product is a lower cost version of the other D-CAST products but is not as oxidation resistant. Either way. -.1 -.1 0. At 70°F -.0 2. procedures where applicable. excellent hot strengths.7 39. -. contains oxidation inhibitors. 1. Iron Oxide (Fe2O3) 1. -- GRAPHPAK-85: pitch or resins.2 1. low porosity.0 69.1 1.1 -. 3.1 0. -. Other Oxides -. and provides exceptional properties such as 9% porosity. It can be ordered as a castable or 70/CU ADTECH®: precast shape. 11. Service Temp. This mix offers high density.360 -.1 0.S.0 0. 300 -- SUPER This air-setting.0 -. or long iron runners. Trace 0.0 54.2 0. This plastic possesses good Chemical Analysis: % (Approximate) resistance to hot metal and slag erosion and represents an economical alternative to NARCARB ZP and SUPER NARCARB in less severe conditions. -. it The data given above are based on averages of test results on samples selected from routine plant production by standard A.2 1. -.3 94. -. and excellent thermal shock resistance. % -.6 15.4 1.1 7. F o 2850 3100 3300 3400 3300 3100 3000 offer a more environmentally friendly bond system than the phenolic resin bonded materials.5 3. -. These properties make D-CAST TRC-SR-CC an outstanding option for severe slag and metal contact applications. expressed or implied. Such shapes can provide excellent performance in cupola well blocks and taphole applications. VIBTECH shapes can provide longer service Silicon Carbide + Carbon (SiC+C) 14. -- NARCARB ZP This phenolic resin bonded plastic provides high strengths at iron producing temperatures. It is non-wetting to iron and slag.5 -- life. .3 VIBTECH Shapes: These are thixotropic-formed shapes which are fired to high temperatures to achieve properties ® Chromic Oxide (Cr2O3) -. warranty. These results cannot be taken as minima or maxima or specification purposes.2 0. SiC containing castable with improved slag resistance compared with other D-CAST materials. 14. 1. Options for cupola taphole service include TUFLINE® 90 DM/C.900 -. -. low porosity and high hot strengths. 400 1.720 1.100 650 zone maintenance during bottom drops.2 0. NARCARB XZR RAM provides Modulus of Rupture. D-CAST TRC-SR is an excellent choice for taphole free of patent infringement of a third party. -.1 0. information. These are workhorse type materials Titania (TiO2) 2.1 1. VERSAFLOW® This is a 70% alumina low cement castable containing SiC. -. blocks.1 -.9 8.1 2. As a result. Bulk Density. oxidation resistance plastic contains no Apparent Porosity.1 0. excellent thermal shock resistance.6 -.5 72. Examples of VIBTECH® shapes.2 83.7 6.3 D-CAST TRC-SR: This SiC and carbon containing castable can also be ordered as a precast shape. They exhibit better corrosion GRAPHPAK-45 resistance to molten iron and slag than conventional materials.320 -. SiC and carbon containing castable. Cast & Shapes Cast & Shapes Shape Shape Shape Castable Ram Both products offer the highest level of carbon containing.600 -. These products Max. 1. 700 cupola campaigns under severe conditions. -. and volume stability for negligible sintering cracks during service. silicon carbide and graphite containing. -. 0.1 0.4 GRAPHPAK-85.890 1.2 Trace Magnesia (MgO) 0.0 Lime (CaO) 2. NARCARB ZP provides excellent performance in extended After Heating to 1500°F 2. lb/ft3 NARCARB This is a phenolic resin bonded ramming mix with the second highest amount of non-wetting compo. and RUBY® SR/C. -. 3.1 0. Variation from the above data may occur in individual test. it does not give off polluting emissions. -. a modified matrix for enhanced slag resistance.2 0. After Heating to 230oF 173 194 197 200 204 185 156 XZR RAM: nents.2 0. shock resistance.5 89. Castables for Cupola Applications D-CAST TRC-SR-CC This is a low cement. D-CAST TRC 69 This a low cement. It features improved strengths above 1500oF.3 Alumina (Al2O3) 68. 3 0. -.2 0. -. 125 200 1.S. Precast Options NARCARB ZP PLASTIC SUPER NARCARB PLASTIC/RAM Apparent Porosity. All Rights Reserved.6 SUPER GRAPHPAK-85 Magnesia (MgO) 0. -.1 0.1 0.3 1.4 10. PA 15108 Phone: (412) 375-6600 w Fax: (412) 375-6783 • Metal Erosion and Velocity © 2003 Harbison-Walker Refractories Company.5 11.6 6. 4. -- After Heating to 1800°F 700 900 -. procedures where applicable.7 SUPER NARCARB PLASTIC/RAM NARCARB ZP PLASTIC Iron Oxide (Fe2O3) 0. These results cannot be taken as minima or maxima for specification purposes. -.1 0.1 Alumina (Al2O3) 61.7 0.3 2. Cat# HW115R (1/03) 2C .0 68. TUFLINE® 95 DM/C RAMAL 85G Chemical Analysis: % TUFLINE® 90 DM/C (Approximate) D-CAST TRC-SR VERSAFLOW® 70/CU ADTECH® Silica (SiO2) 8. Service Temp.7 0.1 Monolithic Options Titania (TiO ) 2 1.1 22. All statements.2 0.2 0. 1.6 The data given above are based on averages of test results on samples selected from routine plant production by standard A.3 1. 27.3 Phosphorus Pentoxide (P2O5) -. or responsibility of any kind.4 2. oF 3275 3275 3200 3100 2950 3000 3275 3275 3275 Material Required. NARCARB ZP Plastic lining a cupola well zone Service Conditions • Temperature (2000oF .4 1.2 0.100 -. lb/in2 184 178 185 166 142 178 184 188 160 Breast Wall & Trough After Heating to 300°F 1. information.1 0. Maintenance SUPER NARCARB PLASTIC NARCARB ZP PLASTIC Bottom* Front Slagger & Dam Iron Runner NARCARB ZP PLASTIC D-CAST TRC-SR-CC D-CAST TRC-SR-CC RAMAL 85G SUPER NARCARB PLASTIC/RAM RAMAL 85G NARPHOS 55R (FINE) SUPER GRAPHPAK-85 GREENPAK-85-MP *All used in combination with sand RAMAL 85G Installation of RAMAL 85 G in cupola trough application.4 1. -.1 0. -.1 0. -.8 70.3000oF) Harbison-Walker Refractories Company 400 Fairway Drive • Slag. -.660 760 SUPER NARCARB PLASTIC D-CAST TRC-SR-CC At 2500°F 1. -. lb/ft3 Modulus of Rupture.0 -.9 12.3 1.0 20.2 0.0 8.4 0.300 -. Metal.1 0.300 -.3 19.5 9.4 46.1 Alkalies (Na2O+K2O) 0. -.200 640 -. D-CAST TRC 69 Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use VERSAFLOW® 70/CU ADTECH® is free of patent infringement of a third party.0 -. -.4 0.5 1.T.M.7 1. -.4 0. Taphole Shapes Breast Wall Slag Trough At 2000°F -. -.1 39. and data given herein are believed to be accurate and reliable but are presented without guarantee. Well Variation from the above data may occur in individual test.8 13.300 2. -- Silicon Carbide + Carbon (SiC+C) 27. expressed or implied.6 80. 1.0 6. -.0 64. -.1 0.1 0.5 1. -. -.0 62. -.5 0. -.300 800 900 350 250 750 1. 1. % RUBY® SR/C SUPER GRAPHPAK-85 SUPER GRAPHPAK-85 After Heating to 1800oF 20 22.600 200 After Heating to 1500°F -. -.1 0. -.9 2. Oxygen Reactions Moon Township.2 0.1 0.7 11.5 NARCARB XZR RAM Lime (CaO) 0.7 72.5 -.1 0. -.5 1.9 76. warranty.7 7.1 0.1 0. Breast Wall & Trough Plastics Ram Mixes SUPER NARCARB PLASTIC NARCARB ZP SUPER GRAPHPAK GRAPHPAK -85 -85 GRAPHPAK -45 GREENPAK 85 MP SUPER NARCARB RAM NARCARB XZR RAMAL 85G CUPOLA Refractories Max.6 1. -. 18 17 -. 900 -. The suggested use assumes that all safety measures are taken by the user. 340 1. -.2 0.M.700 2.Temperatures of 2750oF + . pcf 165 179 159 182 186 195 198 213 Apparent Porosity.6 19. 3.1 0. 175 146 172 195 182 167 192 194 203 Crushing Strength. psi (500oF) After 230OF -.CHANNEL INDUCTION REFRACTORIES for Industrial Foundries Technical Data Brick Brand KRUZITE® -70 DV-38 UFALA® XCR TUFLINE® 90 KORUNDAL XD® KORUNDAL XD® DM RUBY® RUBY® DM Channel Induction Refractories Density.1 0.Temperatures of 2800oF + Silica (SiO2) 8.6 72.6 Trace Trace 0.000 7. -.8 0.2 0. -.3 89.2 0. The suggested use assumes that all safety measures are taken by the user. 10.2 0.1 0.3 0.2 0.2 0.200 1. -.600 1.225 6.350 12.0 80.2 0.000 Service Conditions After 1500OF 2.000 17.7 1.0 18.1 Alkalies (Na2O+K2O)3 0.1 88.7 8.5 8.2 0.1 Magnesia 2(MgO) 0. 2.1 11.1 0.More Use of Chrome Containing Brick Lime 2 (CaO) 0. C6.1 0.5 1. procedures where applicable. -.500 16.3 0.2 0.6 Silica (SiO )2 23. or responsibility of any kind. -. -. 3.1 0.0 9. psi After 230OF -. Statements or suggestions concerning possible use of our products are made without representation or GREENCAST®-94 warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.8 Horizontal Channel Induction Furnace Refractory Selection Chromic Oxide (Cr2O3) -.7 89. Variation from the above data may CORAL® BP CLIPPER® DP CORAL® BP KORUNDAL® PLASTIC KORUNDAL® PLASTIC occur in individual tests.4 16.4 0.580 -. 1.Slag Buildup . psi At 70oF 18.1 1.3 Titania (TiO2) 3.5 0. -.3 9.400 720 -.3 0.700 Chemical Analysis.400 1. -.0 18.8 94.6 Trace .800 Modulus of Rupture.1 0.500 2.500 12.2 0.1 90. 3.400 2.730 2.700 3.1 0.6 1.hwr. 980 9. -.1 0.6 6. warranty.3 89.7 1.1 Trace Trace 0.2 0.0 85.2 Phosphorous Pentoxide (P2O5) 3.500 14.2 0.500 12.1 Trace Iron Oxide (Fe2O3) 1.2 0.0 36.4 0. -.1 -. -.1 0. 18.1 90.930 1.0 11.T.330 3. -- Technical Data Monolithic Products KORUNDAL® KORUNDAL® GREENCAST® HP-CAST D-CAST RUBY® FUSECRETE® D-CAST RUBY® Brand PLASTIC HOT GUN 94 ULTRA 85TMCC PLASTIC AMC C10 TRC-SR-CC RAM MIX Density.5 0.3 0. All statements.5 1.840 4.8 .8 Phosphorus Pentoxide (P2O5) -.4 2.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company.8 12.CaC2 & MgO Attack Titania (TiO2) 0.1 1.000 14.1 Lime 3 (CaO) 0. These results cannot be taken as minima or maxima for specification purposes.5 9.500 After 1500OF -.1 0. All Rights Reserved. % Crushing Strength.7 -. Cat# HW 122R (2/03) 3C .1 Operating Slag & Metal Slag & Metal Receivers & Repair & Silicon Carbide + Carbon (SiC + C) -.890 4.2 0.1 61.S. 3. % Gray & Malleable Iron: Ductile Iron: (Approximate) Alumina (Al2O3) 87.040 1.050 1.2 0. 2. C10 Harbison-Walker Refractories Company KORUNDAL XD® KRUZITE®-70 UFALA® XCR RUBY® PLASTIC AMC RUBY® PLASTIC 10 400 Fairway Drive KORUNDAL XD® DM DV-38 TUFLINE® 90 RUBY® PLASTIC 10 Ductile Iron Moon Township. C6.1 0.1 0.9 -.1 1.320 1. -.1 0.8 .1 0.000 HORIZONTAL CHANNEL INDUCTION FURNACES Chemical Analysis.0 -- Conditions Contact Backup Crown Pour Spouts Mainteance The data given above are based on averages of tests results on samples selected from routine plant production by standard A.4 60.2 0. TUFLINE® 90 KRUZITE® 70 CORAL® BP KORUNDAL® PLASTIC GREENPAK-90-P Malleable Iron KORUNDAL® XD CORAL® BP UFALA® XCR D-CAST TRC-SR-CC KORUNDAL XD® DM KORUNDAL XD® FUSECRETE® C. 14.1 7. -.150 At 2700oF -. 4. 680 9.500 9. -.5 83. 14.2 0.000 9.2 0. C10 RUBU® DM www.4 0. and data given herein are believed to be accurate and reliable but Gray Iron KORUNDAL® XD D-CAST 85TMCC are presented without guarantee.6 0.1 Trace Alkalies (Na2O+K2O) 0.1 0. % (Approximate) Alumina (Al2O3) 71.450 For Industrial Foundries Modulus of Rupture.3 83. information.2 0. -.500 7.3 1.000 1.0 0.7 1.1 .1 0. pcf After Drying.Slag Line Erosion Iron Oxide (Fe2O3) 0. -.7 0.2 0.1 11.900 3.1 0. -. -.1 0.2 0. -. 9.1 Magnesia 3 (MgO) 0.1 1. -. PA 15108 RUBY® KORUNDAL XD® FUSECRETE® C.1 0.1 Chromic Oxide (Cr O ) 2 3 -.750 2.160 1.8 1. -.200 -.180 340 1.8 9. expressed or implied.1 0.500 13. -.7 9. -.400 17. -.1 96.6 11.1 2.7 -.6 5.200 -.4 -. psi At 70oF 1. Slag Buildup Open Cracks & Porosity Ductile Iron: Milder Operating Conditions due . 1 plus years of service in a pouring arm. and KORUNDAL XD® forming the jack arch and floor.Temperatures of 2800OF + to Reduction in Slag Generation.VERTICAL CHANNEL INDUCTION FURNACES PRESSURE POUR CHANNEL INDUCTION FURNACES Service Conditions Service Conditions Narrow Inlet & Outlets Gray & Malleable Iron: Prone to Choking . C6. . C10 ® RUBY PLASTIC 10 KORUNDAL XD® DM FUSECRETE C. C6. C6. C6.CaC2 & MgO Attack and the Absence of Tilting or . C6. C10 KORUNDAL XD® D-CAST TRC-SR-CC CORAL® BP EXPRESS®-30 D-CAST TRC-SR-CC GREFCOTE® 70 KORUNDAL XD® DM MIZZOU® CASTABLE® FUSECRETE® C. C10 Ductile Iron RUBY® MIZZOU CASTABLE® FUSECRETE® C. C6. C10 DV-38 EXPRESS®-30 RUBY® PLASTIC 10 KORUNDAL® HOT GUN FUSECRETE® C. C10 RUBY® RAMMING MIX KAST-O-LITE® 26 LI KAST-O-LITE® 97-L RUBY® PLASTIC AMC RUBY® PLASTIC 10 KORUNDAL XD® RUBY® RAMMING MIX KRUZITE®-70 KAST-O-LITE® 97-L RUBY® PLASTIC AMC RUBY® PLASTIC 10 Ductile Iron ® FUSECRETE C. Can Reduce SiO2 in Refractories Vertical Channel Induction Furnace Refractory Selection Pressure Pour Channel Induction Refractory Selection Operating Slag & Metal Slag & Metal Slag & Metal Receivers & Repair & Operating Slag & Metal Slag & Metal Receivers & Repair & Conditions Contact Brick Contact Monolithic Backup Roof Pour Spouts Maintenance Conditions Contact Backup Roof Pour Spouts Mainteance NARPHOS 90R RAM KAST-O-LITE® 23 ES KAST-O-LITE® 97-L KORUNDAL® PLASTIC KORUNDAL® PLASTIC ® CORAL BP NARPHOS 85R RAM ® CLIPPER DP ® KAST-O-LITE 97-L ® KORUNDAL PLASTIC ® KORUNDAL PLASTIC Gray Iron D-CAST 85TMCC D-CAST 85TMCC Gray Iron KORUNDAL® XD D-CAST 85TMCC EXPRESS®-30 D-CAST 85TMCC GREFCOTE® 50 GREENCAST®-94 MIZZOU CASTABLE ® ® GREENCAST -94 HP CAST ULTRA KAST-O-LITE® 26 LI KAST-O-LITE® 97-L KORUNDAL® PLASTIC GREENPAK-90-P Malleable Iron D-CAST TRC-SR-CC D-CAST TRC-SR-CC TUFLINE 90 ® HP CAST ULTRA ® KRUZITE -70 ® KAST-O-LITE 97-L ® KORUNDAL PLASTIC GREENPAK-90-P Malleable Iron FUSECRETE® C.Slag Line Erosion Rolling Movements Thermal Shock a Concern for Potential Reducing Atmosphere Furnaces Without a Receiver. C10 RUBY® DM RUBY® RAMMING MIX lining the upper case D-CAST TRC-SR-CC being pump cast into the pour D-CAST TRC-SR-CC showing little signs of wear after spout and receiver.Temperatures of 2750OF + Pressure Can Force Metal into . . Temperatures of 2800OF + to Reduction in Slag Generation. . C6. .VERTICAL CHANNEL INDUCTION FURNACES PRESSURE POUR CHANNEL INDUCTION FURNACES Service Conditions Service Conditions Narrow Inlet & Outlets Gray & Malleable Iron: Prone to Choking . C10 RUBY® DM RUBY® RAMMING MIX lining the upper case D-CAST TRC-SR-CC being pump cast into the pour D-CAST TRC-SR-CC showing little signs of wear after spout and receiver.CaC2 & MgO Attack and the Absence of Tilting or . C6.Slag Buildup Open Cracks & Porosity Ductile Iron: Milder Operating Conditions due . C10 DV-38 EXPRESS®-30 RUBY® PLASTIC 10 KORUNDAL® HOT GUN FUSECRETE® C. C6.Slag Line Erosion Rolling Movements Thermal Shock a Concern for Potential Reducing Atmosphere Furnaces Without a Receiver. C6. C10 Ductile Iron RUBY® MIZZOU CASTABLE® FUSECRETE® C.Temperatures of 2750OF + Pressure Can Force Metal into . C6. C10 ® RUBY PLASTIC 10 KORUNDAL XD® DM FUSECRETE C. Can Reduce SiO2 in Refractories Vertical Channel Induction Furnace Refractory Selection Pressure Pour Channel Induction Refractory Selection Operating Slag & Metal Slag & Metal Slag & Metal Receivers & Repair & Operating Slag & Metal Slag & Metal Receivers & Repair & Conditions Contact Brick Contact Monolithic Backup Roof Pour Spouts Maintenance Conditions Contact Backup Roof Pour Spouts Mainteance NARPHOS 90R RAM KAST-O-LITE® 23 ES KAST-O-LITE® 97-L KORUNDAL® PLASTIC KORUNDAL® PLASTIC ® CORAL BP NARPHOS 85R RAM ® CLIPPER DP ® KAST-O-LITE 97-L ® KORUNDAL PLASTIC ® KORUNDAL PLASTIC Gray Iron D-CAST 85TMCC D-CAST 85TMCC Gray Iron KORUNDAL® XD D-CAST 85TMCC EXPRESS®-30 D-CAST 85TMCC GREFCOTE® 50 GREENCAST®-94 MIZZOU CASTABLE ® ® GREENCAST -94 HP CAST ULTRA KAST-O-LITE® 26 LI KAST-O-LITE® 97-L KORUNDAL® PLASTIC GREENPAK-90-P Malleable Iron D-CAST TRC-SR-CC D-CAST TRC-SR-CC TUFLINE 90 ® HP CAST ULTRA ® KRUZITE -70 ® KAST-O-LITE 97-L ® KORUNDAL PLASTIC GREENPAK-90-P Malleable Iron FUSECRETE® C. C10 RUBY® RAMMING MIX KAST-O-LITE® 26 LI KAST-O-LITE® 97-L RUBY® PLASTIC AMC RUBY® PLASTIC 10 KORUNDAL XD® RUBY® RAMMING MIX KRUZITE®-70 KAST-O-LITE® 97-L RUBY® PLASTIC AMC RUBY® PLASTIC 10 Ductile Iron ® FUSECRETE C. C6. and KORUNDAL XD® forming the jack arch and floor. 1 plus years of service in a pouring arm. C10 KORUNDAL XD® D-CAST TRC-SR-CC CORAL® BP EXPRESS®-30 D-CAST TRC-SR-CC GREFCOTE® 70 KORUNDAL XD® DM MIZZOU® CASTABLE® FUSECRETE® C. 0 18.6 0.1 0. % Gray & Malleable Iron: Ductile Iron: (Approximate) Alumina (Al2O3) 87.7 1. -.7 1. 980 9.450 For Industrial Foundries Modulus of Rupture. expressed or implied.1 90.1 0.5 83. C6.800 Modulus of Rupture. 3. pcf 165 179 159 182 186 195 198 213 Apparent Porosity. or responsibility of any kind.000 1. -.3 0. 3.1 11.3 89. psi At 70oF 18.1 1.S.1 0.5 9. 680 9.600 1. -.3 0.Temperatures of 2800oF + Silica (SiO2) 8. 340 1.000 Service Conditions After 1500OF 2.4 16.6 72.1 Magnesia 2(MgO) 0. -.1 0.6 Trace Trace 0.4 2. Cat# HW 122R (2/03) 3C .0 85.500 16.400 720 -. C6. % Crushing Strength. 1.9 -.2 0.8 .000 HORIZONTAL CHANNEL INDUCTION FURNACES Chemical Analysis.5 1.700 2.6 Trace .840 4.500 12.3 83.500 After 1500OF -. All Rights Reserved.1 0.200 -.2 0.7 -.1 11.1 Operating Slag & Metal Slag & Metal Receivers & Repair & Silicon Carbide + Carbon (SiC + C) -.1 1. -. % (Approximate) Alumina (Al2O3) 71.040 1.3 0.5 0.1 0. -. -- Technical Data Monolithic Products KORUNDAL® KORUNDAL® GREENCAST® HP-CAST D-CAST RUBY® FUSECRETE® D-CAST RUBY® Brand PLASTIC HOT GUN 94 ULTRA 85TMCC PLASTIC AMC C10 TRC-SR-CC RAM MIX Density.7 9. -.200 1.1 0.6 Silica (SiO )2 23.1 0. PA 15108 RUBY® KORUNDAL XD® FUSECRETE® C.050 1.8 94. procedures where applicable.1 61.5 1. warranty.160 1. -. and data given herein are believed to be accurate and reliable but Gray Iron KORUNDAL® XD D-CAST 85TMCC are presented without guarantee.2 0. 10. -.8 0.700 3.2 0. -. 175 146 172 195 182 167 192 194 203 Crushing Strength.1 90.2 0.6 19.5 0.1 0.580 -.1 . -.8 . -. 9. -.500 13.1 0. 3.1 0.6 6.More Use of Chrome Containing Brick Lime 2 (CaO) 0. -.1 7.2 0.2 0.1 0.4 0.4 0.330 3.T.1 0.2 0.1 0. psi At 70oF 1.1 -.0 80. C10 Harbison-Walker Refractories Company KORUNDAL XD® KRUZITE®-70 UFALA® XCR RUBY® PLASTIC AMC RUBY® PLASTIC 10 400 Fairway Drive KORUNDAL XD® DM DV-38 TUFLINE® 90 RUBY® PLASTIC 10 Ductile Iron Moon Township.8 Horizontal Channel Induction Furnace Refractory Selection Chromic Oxide (Cr2O3) -.CaC2 & MgO Attack Titania (TiO2) 0. -.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company. 14.7 -.2 0. Statements or suggestions concerning possible use of our products are made without representation or GREENCAST®-94 warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.4 -.8 12.1 Trace Iron Oxide (Fe2O3) 1. information.3 0.400 17.0 9.2 0.6 11.7 0.2 0. -.1 Chromic Oxide (Cr O ) 2 3 -. -.3 1.1 Trace Alkalies (Na2O+K2O) 0.Slag Buildup .180 340 1.3 9.930 1.0 -- Conditions Contact Backup Crown Pour Spouts Mainteance The data given above are based on averages of tests results on samples selected from routine plant production by standard A.hwr.400 2.900 3. TUFLINE® 90 KRUZITE® 70 CORAL® BP KORUNDAL® PLASTIC GREENPAK-90-P Malleable Iron KORUNDAL® XD CORAL® BP UFALA® XCR D-CAST TRC-SR-CC KORUNDAL XD® DM KORUNDAL XD® FUSECRETE® C. 14.1 88.2 0.8 9. C10 RUBU® DM www.0 36.1 Magnesia 3 (MgO) 0. -.Slag Line Erosion Iron Oxide (Fe2O3) 0.1 96. -.000 9.1 2.1 Alkalies (Na2O+K2O)3 0.000 17. All statements.500 2.1 0.730 2.Temperatures of 2750oF + .500 14. Variation from the above data may CORAL® BP CLIPPER® DP CORAL® BP KORUNDAL® PLASTIC KORUNDAL® PLASTIC occur in individual tests.0 11.1 Lime 3 (CaO) 0. -.3 89. These results cannot be taken as minima or maxima for specification purposes. 2.2 0. The suggested use assumes that all safety measures are taken by the user.4 0. -.3 Titania (TiO2) 3.7 8.2 0.7 89. -.500 9.350 12.320 1. 2.8 Phosphorus Pentoxide (P2O5) -.0 18.1 1.5 8.150 At 2700oF -. pcf After Drying. psi (500oF) After 230OF -.000 7.500 12.400 1.200 -. psi After 230OF -.1 0.1 0.6 5.6 1.750 2. -.4 60.2 0.2 0.2 0.225 6.CHANNEL INDUCTION REFRACTORIES for Industrial Foundries Technical Data Brick Brand KRUZITE® -70 DV-38 UFALA® XCR TUFLINE® 90 KORUNDAL XD® KORUNDAL XD® DM RUBY® RUBY® DM Channel Induction Refractories Density. -.M.1 0.1 Trace Trace 0.500 7. 4.1 1.2 0. 3.000 14.1 0.2 0.700 Chemical Analysis.1 0.2 0. -.1 0.8 1.2 Phosphorous Pentoxide (P2O5) 3.890 4.7 1.0 0.2 0. 18. Electric Arc Furnace Refractories For Industrial Foundries UPPER SIDE WALL ROOF DELTA/ELECTRODE RINGS Acid Practice Acid & Basic Practice Acid & Basic Practice ALADIN® 80 ALADIN® 80 GREENPAK-85-MP KRUZITE®-70 KRUZITE®-70 SUPER HYBOND 80 Basic Practice Precast NARMAG® 80DB NOVACON® 65 NARMAG® 60DB D-CAST 85TMCC ULTRA-GREEN SR SLAG LINE Acid Practice SLAG DOOR & SPOUT ALADIN® 80 Acid Practice KRUZITE®-70 GREENPAK-85-MP LOWER SIDE WALL BOTTOM/HEARTH Basic Practice RUBY® PLASTIC AMC Acid Practice Acid Practice SUPER NARMAG® B FUSECRETE® C10 ALADIN® 80 GANNISTER MIX NARMAG® 142 ® Basic Practice KRUZITE -70 NARMAG® FG SUPER NARMAG® B Basic Practice NARTAR 7 SUPER NARMAG® B NARMAG® FG RAM MIX NARTAR 7 MAINTENANCE Acid Practice GREFCOTE® 70 . 1 3.9 1.800 -- Apparent Porosity.3 6.8 Iron Oxide (Fe2O3) 12.5 Magnesia3 (MgO) 62.2 1.2% 23. ACID PRACTICE BRICK & MONOLITHICS RUBY® BRAND ALADIN® KRUZITE®.1 10.1 0. -.700 1. At 70oF 12.000 Apparent Porosity.0 85.4 0. expressed or implied.5 -. lb/in2.0 21.0 13.4 0.400 -. -.2 0.700 14.6 70.0 0.040 600 Crushing Strength. D-CAST GREENPAK.7 0. % (Approximate) Silica (SiO2) 0. NOVACON® PLASTIC FUSECRETE® GREFCOTE® 80 70 85TMCC 85-MP 65 AMC C10 70 Density.3 0.0 -.1 2.3 6.0 Chemical Analysis.7 13. -. -- Crushing Strength.0 18.0 83. -- BASIC PRACTICE BRICK & MONOLITHICS BRAND SUPER NARMAG® NARMAG® NARMAG®FG NARMAG® FG NARMAG® 142 NARMAG® B NARTAR 7 80DB 60DB RAM MIX Density.5% 0.1% 18. and data given herein are believed to be accurate and reliable but are presented without guarantee.0 1.6 7. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. 14.2 Alkalies (Na2O+K2O) 0.9 0.0 16.0 21.S. -.2 0. 3.610 8.9 -- Phosphorous Pentoxide (P2O5) -. These results cannot be taken as minima or maxima for specification purposes.4 2.4 0. lb/in 2 At 70oF/After 230oF 9. -- Chemical Analysis.7% Alumina (Al2O3) 6.3 0.7 -.6% 22. lb/ft3 170 165 182 178 155 180 189 130 Modulus of Rupture.3 9.7 1.700 1. 7.225 2.2 0.8 1.2 0.8 2.7 2. PA 15108 Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company. -.0 12.4 0.1 0. % 19.490 1.0 Magnesia3 (MgO) 0.000 750 650 1.6 1.1% 0.6 0.0% 1.160 1.610 1.000 AT 2700 F o 700 400 -.9 0. 5. -. 4.950 -.000 -.3 16.2 78. All Rights Reserved.1 0.6% 0.3 6.500 600 2. 8. or responsibility of any kind.0 15. information.2 1.8 2.0% 31. -.8 61.4 3. Variation from the above data may occur in individual tests.0% Alumina (Al2O3) 78. warranty. procedures where applicable. -.5 2.1 0.5 96.1 0.0 14. -.0% 11. 9.7 3. The suggested use assumes that all safety measures are taken by the user. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.4 0.0 The data given above are based on averages of tests results on samples selected from routine plant production by standard A.400 750 1.0 Chromic Oxide (Cr2O3) 18. All statements.200 -.000 -.M.0 64.4 3.9% 1. -.3 0.3 Iron Oxide (Fe2O3) 1.4 Lime (CaO)3 0. lb/ft3 207 204 185 197 191 191 195 Modulus of Rupture.T.0 59.2 0.0 20. lb/in 2 (500 F) o At 70oF/After 230oF 1.2 0.5 18.500 9.0 59.8 0.1 1.3% 2. % 13.3% 0. Cat# HW119 (1/03) 2C . -.2 1.0 15.8 62.6 71.4 0.1 0.1 80.0 0. -.500 3.2 0.0 Lime (CaO)3 0.5 Titania (TiO2) 3.0 96. lb/in 2 At 70oF 1. % (Approximate) Silica (SiO2) 15. -. 160 220 -- At 2800oF -.0% 11.6 Chromic Oxide (Cr2O3) -. 1. LADLE REFRACTORIES For Industrial Foundries Performance Factors Dimensional Stability Resistance to Slags. PA 15108 Phone: (412) 375-6600 w Fax: (412) 375-6783 . Molten Iron & Steel Thermal Shock Resistance High Strength Ease of Installation Proven Performance Record Fast Turn-around Iron & Steel Ladle Refractory Selections Brick Castables Vibratables Plastics & Application Rams Steel & Alloy COMANCHE® FASTDRY 8 GREFVIBE® 850 GREENPAK-90-P ALADIN 85 ® HP-CAST ULTRA ALADIN® 80 D-CAST 85TMCC Iron Transfer ALADIN® 80 D-CAST 85TMCC GREFVIBE® 850 GREENPAK-85-MP & Inoculation KRUZITE®-70 ULTRA-GREEN 70 TASIL® 570 LM RAMAL 80 KRUZITE CASTABLE ® GREFVIBE 700 Iron Pouring KRUZITE®-70 EXPRESS®-30 PLUS GREFVIBE® 700 H-W® BULL ULTRA-GREEN 45 RAM PLASTIC MIZZOU CASTABLE Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. 7 Modulus of Rupture.0% 0.1 0.3 0. -.550 550 2.1 0.600 500 1.600 1.7% Alumina (Al2O3) 91.500 2.850 -.4 1.4 2. 2.5 0.1 2.000 9. 7.700 3.600 7.Net.2 0.2 0.5 Magnesia (MgO) 7.6 PLASTIC & RAMMING MIXES GREENPAK-90-P RAMAL 80 GREENPAK-85-MP H-W® BULL RAM Maximum Service Temperature 3200OF 3200OF 3000OF 3000OF Quantity Required .7 0.5 0.500 13. Variation from the above data may occur in individual test.500 2.1 71.1 0.500 20.4 0.4 78.8 -- Carbon (C) -. -.4 3.8 2.700 Chemical Analysis: (Approximate) Silica (SiO2) 3. 5.5 0. lb/in2 After 230OF (110OC) 1.2 1.000 -- Chemical Analysis: (Approximate) Silica (SiO2) 9.3 Alkalies (Na2O+K2O) 0.2 CASTABLES FASTDRY 8 HP-CAST D-CAST ULTRA-GREEN KRUZITE® EXPRESS®-30 ULTRA-GREEN MIZZOU CASTABLE ULTRA 85TMCC 70 CASTABLE PLUS 45 CASTABLE Maximum Service Temperature 3300oF 3400oF 3200oF 3100oF 3200oF 3000oF 3000oF 3000oF Quantity Required . -.3 Alkalies (Na2O+K2O) 0.2 Magnesia (MgO) 0.6% Alumina (Al2O3) 82.0 71.2 2. 15. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.3 0.600 2.500 -.610 1.2% 23. -. 3.0 80.4 1.500 2. and data given herein are believed to be accurate and reliable but are presented without guarantee.1 1.6% 11.200 8.1% 11.7 2.4 Iron Oxide (Fe2O3) -.1 -.7 3.3 0.3 <0.1 0.7 Iron Oxide (Fe2O3) 1.4 81.2 0.0 1.2 0.3 0.0% Alumina (Al2O3) 82.0 76.5 1.7% 46.0% 21.4 1.4 0.0 1.3 3.6 Lime (CaO) -.3% 28.0 1. -.Net.4 Magnesia (MgO) 0.6 1.000 3.1 1.8 1.0% 32.1 0.0 80.400 1. All statements.9 1.1 0.8 83.080 4.0 2.8 96.6 VIBRATABLES & PLASTICS Vibratable Plastics Patching Materials GREFVIBE® 850 GREFVIBE® 700 WET TASIL® 570 LM GREFPATCH 85 NARCOLINE C & M MORTAR Maximum Service Temperature 3200oF 3100oF 3200oF 3100oF 3000oF Quantity Required .8 0. or responsibility of any kind.500 700 Crushing Strength.1 0.400 5.9% 15. Cat# HW123R (01/03) 2C .8 69.0 The data given above are based on averages of tests results on samples selected from routine plant production by standard A. 0.080 After 1500OF (816OC) 1.0 Titania (TiO2) -.100 1.500 1.1 2. -.300 1.H-W LADLE REFRACTORIES For Industrial Foundries BRICK COMANCHE® ALADIN® 85 ALADIN® 80 KRUZITE®-70 Density.9 2.000 Chemical Analysis: (Approximate) Silica (SiO2) 1.1 1.2 0.5% 13.700 1.750 1.0 19.000 14.0 60.8 Iron Oxide (Fe2O3) 0.4 0. lb/in2 After1500OF (816OC) 2. procedures where applicable.6 0.8 1.200 11.3 0.7 29.2 Magnesia (MgO) 8.1 0.0 3.S.2 0.000 2.2 0.700 2.5 1. lb/in2 After 230OF (110OC) -.0 Titania (TiO2) -.5% 23.0% 17.2 0. © 2003 Harbison-Walker Refractories Company. warranty. 12.5 Lime (CaO) 0.4 1.2 Phosphorus Pentoxide (P2O5) 4.1 0.0% 24. lb/ft3 195 160 178 168 Modulus of Rupture. -- Alkalies (Na2O+K2O) -.0 48.000 9. % 7.2 0.000 1. lb/in2 3.0 1. All Rights Reserved. 2.070 Chemical Analysis: (Approximate) Silica (SiO2) 3.5 18.500 20.6 71. These results cannot be taken as minima or maxima for specification purposes.3 2. lb/ft3 189 172 170 165 Porosity.2 1.5 Phosphorus Pentoxide (P2O5) 3.100 2.8 0. The suggested use assumes that all safety measures are taken by the user.2 Carbon (C) 5. 4. lb/ft3 175 174 176 165 -- Modulus of Rupture. -- After 2550OF (1400OC) -. lb/ft3 195 195 182 166 155 154 146 139 Modulus of Rupture.Net.4 0.1 3.1 Lime (CaO) 0.1 <0.1 Lime (CaO) 0.000 After 1500OF (816OC) 5.1 1.0 -.8 68.0 20.5 Iron Oxide (Fe2O3) 0.4 1.2 <0.3 60. 1.T.5 2.8 1. 0.1 0. expressed or implied.300 9.2 <0. lb/in2 After 1500OF (816OC) 5.4 Titania (TiO2) 2.M.8 -.3 0.4 Alkalies (Na2O+K2O) 0.8 2.0% 10.0% 32.1 0.5% Alumina (Al2O3) 90.800 -- Crushing Strength. lb/in2 After 2500OF (1371OC) 1.1 0. information.3 83.5 Titania (TiO2) 0.700 400 3.2% 52.2 0.9% 12. The gas bub- bles rise and produce the following effects: Dispersion & Stirring of Additives Temperature Adjustments for Optimum Teeming & Homogeneity Removal of Non-Metallic Inclusions Degassing PRESSURE REDUCING METER VALVE These illustrations show typical porous plug arrangements and piping used for OPERATING ferrous foundry ladle VALVE applications.NARGON® Porous Plugs For Industrial Foundries NARGON® Porous Ladle Plugs allow the introduction of inert gases via one or more permeable plugs in the ladle bottom. . FLOW METER ARGON OR NITROGEN GAS CYLINDER Typical arrangement BOTTOM OF LADLE HOLE FOR STOPPER ROD POROUS OR OR SLIDE GATE SOLID PLUG Recommended location of NARGON® Porous Plug. Cat# HW121R (1/03) 2C .8 5.0 6.5 . The suggested use assumes that all safety measures are taken by the user. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.5 . It is designed for Silica (SiO2) 7.2 *S-Castable sleeve between plug and can. % 24 23 shock are severe.2 6.M available with a variety of CAN MATERIAL options. lbs/ft3 165 184 for applications where erosion and thermal Apparent Porosity.6 2. These results cannot be taken as minima or maxima for specification purposes.8) ..8 4.8 9.T.5 10. This information gives PIPE LENGTH the specific details for these PIPE DIAMETER parts. warranty. Variation from the above data may occur in individual test.8 5. or responsibility of any kind.5 10.38 4.5 10. and data given herein are believed to be accurate and reliable but are presented without guarantee. 1.8 8.9 5 NP-8 3. All Rights Reserved. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. NARGON® Porous Plugs are NP . It is designed Bulk Density.3 9. Centidarcy 570 950 bubbling with small bubbles.1 15.1 NPG-15S 3.8 4.4 applications where erosion and metal Chromic Oxide (Cr2O3) -.0% 95. This plug is best suited for shops requiring periods of gentle Permeability.5 penetration are more severe. expressed or implied.S. % NARGON® A-94 This permeable composition is based on Alumina (Al2O3) 90.0% high-purity fused alumina.Available NARGON® Porous Plug Sizes (Dimension in Inches) Plug Dimensions Sleeve Dimensions (A) (B) (C) (D) (E) Top Bottom Top Bottom Dia Dia Height Dia Dia NP-3 2.1 15.11(3.M.9 NPG-11S 3. procedures where applicable.G .8 6. information.2 3. Mean Pore Diam.38 5.1 4. PA 15108 Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company. NARGON PLUG Porous Plug Typical Test Data NARGON® A-90 NARGON® NARGON® This permeable composition is based on A-90 A-94 high-purity sintered alumina.3 NP-11 & NPG-11 3.8 NP-11S* 3. The data given above are based on averages of test results on samples selected from routine plant production by standard A.2 NP-15 & NPG-15 3.6 .9 3. microns 55-70 50-70 Chemical Analysis. All statements. Please contact your OPTION NUMBER H-W sales representative or NARGON PLUG SIZE Technical Marketing for further GEOMETRIC SHAPE CHANGE details.8 4.1 NP-5 3. 2000 F Temperature o • 2000 .2400 F Temperature o • 2000 . 60.3200 oF Temperature . 70 ADTECH® MELT ZONE Premium Work Horse & Maintenance KORUNDAL XD® ALADIN® 85/80 TUFLINE 90® KRUZITE®-70 DV-38 NARCARB ZP PLASTIC NARCOGUN BSC-DS Service Conditions CHARGE ZONE PREHEAT ZONE MELT ZONE • Abrasion from Charging • Abrasion from Charge Movement • Slag Attack • Thermal Shock • Thermal Shock Reduced • Metal Corrosion • 600 . 70 ADTECH® KS-4V® GR PLUS CHARGE ZONE Premium Work Horse & Maintenance TUFLINE® 90 ALADIN® 80 UFALA® XCR KRUZITE®-70 UFALA® KX-99® VERSAGUN® 50. 70 ADTECH® PREHEAT ZONE Premium Work Horse & Maintenance TUFLINE® 90 ALADIN® 80 GREENAL®-80 KRUZITE®-70 ALADIN® 85 KX-99® VERSAGUN® 50. 60.CUPOLA Refractories Upper Stack to Melt Zone UPPER STACK Premium Work Horse & Maintenance UFALA® TUFSHOT® LI/OT KRUZITE®-70 VERSAGUN® 50 ADTECH® CLIPPER® DP NARCO GUNCRETE AR VERSAGUN® 60. 3 3.2 58. procedures where applicable. lb/ft3 120 169 143 151 153 127 132 146 Crushing Strength.0 14. The suggested use assumes that all safety measures are taken by the user.2 0.7 0.3 0.5 2.720 7.6 1. 19.0 7. -.1 18.7 0.730 3.3 0.1 0. lb/ft3 186 182 179 170 172 159 165 143 157 Modulus of Rupture.3 0.2 0. -.2 0.6 14.0 2.1 45.6 38. warranty.300 2. -.9 48.8 40.3 0.3 66.2 1.2 Alumina (Al2O3) 90.4 0.1 0.1 1.4 2.2 12.4 1.330 1. -.1 40.0 42. All Rights Reserved.S.1 0. After 1500oF 1.1 89.3 2.6 23.2 Lime (CaO) 0.1 0.6 0.320 1.2 0.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company.5 1.4 60.9 0. information.610 1.8 30.1 3.340 7.5 3.T.7 Alumina (Al2O3) 46.1 Alkalies (Na2O+K2O) 0.0 15.2 0.3 Chemical Analysis: % (Approximate) Silica (SiO2) 9. % 16.4 10.9 0. -.0 70.5 9.670 7.3 0.6 0.3 1.8 1.1 Alkalies (Na2O+K2O) 0.9 1.1 0.2 0.4 78.M.hwr.4 0.200 1.7 2. -.6 2.7 11.2 3.200 2.3 0.5 9.1 0.4 Titania (TiO2) 3.3 0.1 Magnesia (MgO) Trace Trace 0.2 Iron Oxide (Fe2O3) 0. 18.2 1.4 0.7 37.5 0. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.0 14. lb/in2 At 70°F 2. -- Apparent Porosity.4 1.1 Lime (CaO) 8.2 0.4 0.6 1. -.4 Iron Oxide (Fe2O3) 1. These results cannot be taken as minima or maxima or specification purposes.5 20.1 Titania (TiO2) Trace 0.2 0.500 -.600 Chemical Analysis: % (Approximate) Silica (SiO2) 40. All statements.3 1. -.700 2.1 63.3 Magnesia (MgO) 0. -.6 70.1 80.9 36.8 1.2 0.5 0.4 -.3 0.700 2. -.0 52. 7.700 3.0 -.0 53.1 17.3 1. Variation from the above data may occur in individual test.3 0.1 0. -. lb/in2. Cat# HW 117R (2/03) 3C .1 0.050 -.1 Silicon Carbide + Carbon (SiC+C) -.3 71.6 81.5 The data given above are based on averages of test results on samples selected from routine plant production by standard A. and data given herein are believed to be accurate and reliable but are presented without guarantee.2 0. -- MONOLITHICS KS-4V® NARCARB VERSAGUN® VERSAGUN® VERSAGUN® TUFSHOT® NARCO NARCOGUN GR PLUS ZP PLASTIC 50 ADTECH® 60 ADTECH® 70 ADTECH® LT/OT GUNCRETE AR BSC-DS Bulk Density.4 3.4 0.7 12.640 At 2700°F 1. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.0 19. or responsibility of any kind. 4.0 0. -.0 3.8 23.9 0.3 0. -. PA 15108 www. -. expressed or implied. BRICK KORUNDAL XD® TUFLINE® 90 DV-38 ALADIN® 80 ALADIN® 85 UFALA® XCR KRUZITE®-70 KX-99® UFALA® Bulk Density.400 1.1 Phosphorus Pentoxide (P2O5) -.2 0.3 9. It offers superior hot strength and alkali resistance compare to 70% alumina and other 60% alumina products. na brick.LIME RECOVERY KILN SECTIONS CHAIN TUMBLER PREHEATING BURNING ZONE DAM NOSE REFRACTORY ISSUES SOLUTIONS CHAIN Abrasion & Impact LO-ABRADE GR Gun Mix MC-25 PLUS ® Castables PNEUCRETE® BF ADTECH® Spray Mix TUMBLER Strength & Lining Stability VERSAFLOW® 45 C ADTECH® Precast PREHEATING Alkali & Insulation GREENLITE® HS CLIPPER® DP BURNING Temperature & Alkali UFALA® ZONE KRUZITE® 70 MAGNEL® N/XT NOKROME® 92 LK MAGNEL® RS & RSV DAM Strength & Abrasion UFALA® VERSAFLOW® 60 PLUS NOSE Volume Stability & Strength NARPHOS 85P PLASTIC VERSAFLOW® 60 PLUS Harbison-Walker Refractories Company manufactures both high alumina and basic brick for burning zones of lime Three H-W burning zone refractories: (from left) UFALA. H-W has proven performance with the MAGNEL and NOKROME families of products. UFALA is the industry standard for 60% alumi- MAGNEL N/XT. For kilns requiring basic brick. KRUZITE 70 and recovery kiln. . 1 0. -.4 0.500 920 1. 164 -.410 5.0 44.6 0.4 Alkalies (Na2O+K2O) -.2 1.640 1.0 80.4 2. -. -.4 0.6 42.4 4.0 Magnesia (MgO) 3 0.3 0.M.2 0.2 0.100 8.5 1.8% 42.410 1. -- Chemical Analysis: (Approximate) % (Calcined Basis) Silica (SiO2) 2.1 3.8 1.2 2. PA 15108 www.0 0.1 42.0% 38.2 -. % After Heating at 1500OF -0.1 2.6 43. % 17.0 16. Cat# HW 104R (11/02) 3C .4 83. These results cannot be taken as minima or maxima for specification purposes.6% 57.1 91.0% 49.1 6. The suggested use assumes that all safety measures are taken by the user. All Rights Reserved.5 2.6 Lime (CaO)3 1.S.1 0.4% 0.2 - Crushing Strength.T.800 6.5 15.500 8.2 0. lb/in2 At 70OF 7.3 -0.7 -.3 Alkalies (Na2O+K2O) 0. procedures where applicable. BRICK MAGNEL® NOKROME® MAGNEL® MAGNEL® KRUZITE® UFALA® CLIPPER® GREENLITE® N/XT 92 LK RS RSV -70 DP -HS Bulk Densit. lb/in2 At 70OF 930 950 710 840 1.2 0.3 0. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. warranty. -- The data given above are based on averages of test results on samples selected from routine plant production by standard A. 0.2 Chemical Analysis: (Approximate)% (Calcined Basis) Silica (SiO2) 40.2 0. -- Modulus of Rupture lb/in2 After 1500OF 1.7 6.7 0.3 Lime (CaO)3 6.6 1.0 Phosphorous Pentoxide (P2O5) -.135 -.1 0.hwr. expressed or implied.2 36.9 0.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2002 Harbison-Walker Refractories Company.8% 0.2% 52. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.2 2. All statements.0 58.250 950 At 2300OF 870 1.5 0.310 350 Permanent Linear Change. information.100 7.100 -.3 2.000 7. -. 135 135 130 After Drying at 500OF -.3 -0.1 2.3 0.5 15.3 1.3 1.5 Iron Oxide (Fe2O3) 1.4 1.7 1.750 2.8 Magnesia (MgO)3 85. -. or responsibility of any kind.0 14.150 980 1.2 1.8 Iron Oxide (Fe O ) 2 3 0.700 2.8 Titania (TiO2) 0.800 Modulus of Rupture.2 Alumina (Al O ) 2 3 9. 2.2 -0. 2.2 88.1 0.6 71.0 2.4 1.5% Alumina (Al O ) 2 3 49. and data given herein are believed to be accurate and reliable but are presented without guarantee.4 0.3% 11.4% 50. Variation from the above data may occur in individual test.3 15.4 MONOLITHIC LO-ABRADE GR NARPHOS 85P VERSAFLOW® 45C PNEUCRETE® BF MC-25 PLUS PLASTIC ADTECH® ADTECH® Maximum Service Temperature 2600OF 3150OF 2700OF 2800OF 2550OF Approximate Amount Required As Installed (No Allowance for Rebound Loss) lb/ft3 1127 171 132 133 125 Bulk Density lb/ft3 After Drying at 230OF 136 -.9 1.3% 0.1 0. 0.7 14.0 18.8 -0.7 0.4 0.2 0.y lb/ft3 183 182 186 187 165 157 142 75 Apparent Porosity.2% 23.5 1.5 Titania (TiO2) 2. No Build-up mal curing time – heat-up (100˚F/hr. Both products require mini- Alteration. A long record of success in numerous recovery boiler systems throughout the industry testifies to the durability of MAGSHOT where it matters most – MAGSHOT installed in the lower section under demanding field conditions.) can begin two hours after installation. • Superior Smelt Resistance • Chrome-Free Composition • Good Thermal Conductivity • Ease of Installation • Proven Track Record MAGSHOT was developed to help meet the environmental and performance needs of the pulp and paper industry. Other features include: • Low dust and rebounds Typical 80% Alumina- Phosphate Bonded Plastic • Quick dry-out schedule Remarks: Eroded. For larger cast MAGSHOT installations this product is available as Remarks: No Erosion. hand-packed. No MAGSHOT® CASTABLE. Superior Smelt Resistance Demonstrated in Drip Slag Tests Ease of Installation Ease of installation makes MAGSHOT® the product Samples After Drip Test: of choice for quick-turnaround repairs. Bloated Slag Build-up • Up to one year shelf life . Its chrome-free composition eliminates concerns about disposal of possibly hazardous chrome-containing refractory waste. proven to give superior life in recovery boiler systems in pulp and paper mills.MAGSHOT ® MAGSHOT® GUN MIX Magnesite-based chrome-free gun mix. laboratory tests have shown that this unique dicalcium silicate bonded magnesite product provides an exceptional level of chemical resistance to molten smelt. As for performance. Cracked. or cast. of a recovery boiler. It can be gunned. 930 7.1 9.9 The data given above are based on averages of test results on samples selected from routine plant production by standard A. Variation from the above data may occur in individual test.560 1. (Typical) Maximum Service Temperature. warranty. and data given herein are believed to be accurate and reliable but are presented without guarantee.7 Alkalies (Na2O + K2O) 0.2 5.100 After 1500°F 5. % Approximate (Calcined Basis) Silica (SiO2) 7. or responsibility of any kind.7 Titania (TiO2) 0.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2002 Harbison-Walker Refractories Company.M.8 10. All Rights Reserved. The suggested use assumes that all safety measures are taken by the user. These results cannot be taken as minima or maxima for specification purposes. pcf After 230°F 160 179 Modulus of Rupture. psi After 230°F 1.5 Magnesia (MgO) 76.7 68.5 2. All statements. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.S. ˚F 2700°F 2700°F Bulk Density.8 Alumina (Al2O3) 1. procedures where applica- ble.T.hwr.0 Lime (CaO) 6. information. MAGSHOT TECHNICAL DATA MAGSHOT® MAGSHOT® CASTABLE Physical Properties.480 Crushing Strength.2 Phosphorous Pentoxide (P2O5) 1. Cat# HW 88 (11/02) 3C .1 0. PA 15108 www.000 Chemical Analysis. psi After 230°F 5. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.1 Iron Oxide (Fe2O3) 5.870 10.510 After 1500°F 1. expressed or implied.7 1.690 1.9 1. high strength • Coke penetration castable providing volume stability Solutions: with resistance to chemical attack: High strength. HPV GUN MIX STRIPPER Service Conditions: • Mild to moderate erosion Solutions: Medium weight castables with superior strength: • Gun Mix – GREENLITE®-45-L GR. resistance: EXPRESS® THERMAX® • Vibracast – GREENKLEEN-60 PLUS. • Gun Mix – LO-ABRADE® GR. HPV GUN MIX • Spraying – PNEULITE® SPRAY 26 . COREX EXPRESS®. VERSAFLOW® THERMAX® PLUS. EXPRESS® THERMAX® HPV GUN MIX • Gun Mix – VERSAGUN® THERMAX®. phosphate • Coking bonded plastics or castables with Solutions: Highest strength to density excellent installation characteristics. • Self Leveling Pumpable – COREX GUN MIX. KAST-O-LITE® 23 ES. ratio with use of GREENLITE® aggregate • CORAL PLASTIC® (28-82) for superior service with: • GREENPAK-85-P • Gun Mix – GREENLITE®-45L GR. low porosity castable with • Self Leveling Pumpable – superior erosion and thermal shock EXPRESS®-27 PLUS.FLUID CATALYTIC CRACKING UNIT REGENERATOR & REACTOR WALLS CYCLONES Service Conditions: Service Conditions: • Relatively mild • Severe erosion and impingement • Reducing environment Solutions: High strength. COREX GUN MIX. KAST-O-LITE® 23 ES. LO-ABRADE® GR. GREENLITE®-45-L GR. EXPRESS®-27 Plus. HPV GUN MIX FLUE GAS LINES AND SEAL POT • Spraying – PNEULITE SPRAY 26 Service Conditions: • Thermal shock TRANSFER LINES • Chemical reaction Service Conditions: • Mild to moderate erosion • Severe erosion and abrasion Solutions: Low iron. • EXCELERATE ABR PLUS KAST-O-LITE® 26 LI G. VERSAGUN® THERMAX®. KAST-O-LITE® 26 LI G. 1 -0.3 0.300 1.630 1. Erosion Mod. to Sev.0 15. Med.500 6. Weight Med. Weight Med.3 C-704 Abrasion.100 8. and data given herein are believed to be accurate and reliable but are presented without guarantee. Cat# HW94R (11/02) 2C .1 -0.000 Permanent Linear Change. FLUID CATALYTIC CRACKING UNIT TYPICAL DATA After 1500oF CORAL GREENPAK VERSAFLOW® EXECELERATE VERSAGUN COREX COREX LO-ABRADE® HPV PLASTIC® 85-P THERMAX® ABR PLUS THERMAX® GUN MIX EXPRESS® GR GUN (28-82) PLUS ADTECH™ MIX Type Dense Dense Dense Dense Med.580 2. Erosion Erosion Plastic Plastic Castable Gun/Castable Gun Mix Self Leveling Gun Mix Gun Mix Density. Erosion Mod.2/-0. cc: 3.000 2. Wt. psi 8. The suggested use assumes that all safety measures are taken by the user.370/2./Gun Gun Mix Gun Mix Castable Self-Leveling Density.000 – 11.2 -0.200 Permanent Linear Change.200 820 750 1.M.200 – 300/480 500 350 2.S.190 4.000 Crushing Strength. Weight Dense Med.2 -0.480 1. Erosion Insulation Insulation Insulation Insulation Severe Erosion Mod.000 Crushing Strength. Variation from the above data may occur in individual test. Med. psi 11. Erosion Self-Leveling Spray Cast. pcf 169 183 126 172 120 100 116 127 110 Modulus of Rupture.0 12.2 -0. Dense Dense Mod. Names: KAST-O-LITE 23 ES (formerly H-W LIGHTWEIGHT ES REFRACTORY) KAST-O-LITE 26 LI G (formerly H-W LIGHTWEIGHT GUN MIX 26) GREENLITE 45 L GR (formerly GREENCAST 45-L-GR) Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. All Rights Reserved.T.1 7.150 1.1 C-704 Abrasion.950 5. cc: 12. PA 15108 Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2002 Harbison-Walker Refractories Company. Erosion Mod.1 5. % -0.800 14.0 12. Wt.8 4.980 1. psi 1.900 6. Erosion Mod.000 1.3 -0. to Sev.2 -0. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. pcf 135 92 78/91 105 71 157 124 Modulus of Rupture. warranty.0 8.500 10.0 12. % -0. to Sev.0 19.2 -0.4 -0. Weight Severe Erosion Severe Erosion Mod. Erosion Mod.0 EXPRESS® PNEULITE™ KAST-O-LITE® KAST-O-LITE® GREENLITE® GREENKLEEN EXPRESS® 27-PLUS SPRAY 26 23 ES 26 LI G 45-L GR -60 PLUS THERMAX® Type Dense Med.0 – – – – 6.000 8. All statements. psi 1.2 -0. expressed or implied. procedures where applicable.1 -0.2 -0. Wt. Med. Wt.3 -0. These results cannot be taken as minima or maxima for specification purposes. information.3 The data given above are based on averages of test results on samples selected from routine plant production by standard A.500 1. or responsibility of any kind.500 1. GREENAL and TUFLINE® SERIES BRICK.THERMAL REACTOR SULFUR RECOVERY UNIT BURNER THROAT COMBUSTION CHAMBER CHECKER WALL TUBE SHEET SERVICE LOCATION BRICK MONOLITH BRICK MONOLITH BRICK MONOLITH Hot-Face KORUNDAL XD® DM TUFLINE ® 98 DM NOVACON® 95 KORUNDAL XD® NOVACON® 95 Most H-W® CORUNDUM DM Severe Back-Up G-3000 LI KAST-0-LITE® 30 LI G Hot-Face KORUNDAL® XD GREENPAK-90-P KORUNDAL XD® KORUNDAL XD® GREENCAST®-94 PLUS GREENAL-90 GREENCAST® 94 PLUS GREENAL-90 GREENAL-90 Severe G-28 LI Back-Up KAST-O-LITE® 30 LI G G-3000 LI Hot-Face GREENCAST®-94 PLUS NOVACON® 95 GREENCAST®-94 PLUS UFALA® UCR KRUZITE®-70 UFALA® UCR Less GREENPAK-90-P GREENCAST®-94. use KORUNDAL® BOND.000-2.400-2.700˚F) Less Severe = Lower Temperatures (2. 2) Most Severe = Oxygen Enrichment (up to 3.GR PLUS GREENCAST®-94-GR PLUS Severe Back-Up G-28 LI KAST-O-LITE® 26 LI G Notes: 1) Mortar for laying brick linings with KORUNDAL®.000˚F) Severe = Higher Temperatures (2.400˚F) . lb/ft3 185 158 105 99 163 195 After Heating to 1.1 Alkalies (Na2O + K2O) 0.2 0.700˚F 1.1 .2 1.12 9.7 36.6 35.4 6.9 93.750 9.1 0.1 12.1 Trace Trace 0. PA 15108 Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2002 Harbison-Walker Refractories Company.150 284 210 Modulus of Rupture. Phosphorus Pentoxide (P2O5) 0.3 1.500 10.840 2.080 1. 0. lb/ft3 210 195 186 208 165 Apparent Porosity.16 0.700˚F 2.1 Trace 2. lb/in2 — At 70˚F 4.1 Magnesia (MgO) – Trace 0.1 25.04 0.0 -0. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.1 0.5 Alumina (Al2O3) 93.6 0.0 Titania (TiO2) Trace 0.7 71.2 3.4 16.M.0 14.8 The data given above are based on averages of test results on samples selected from routine plant production by standard A.1 Trace 44.1 0.1 99. These results cannot be taken as minima or maxima for specification purposes.1 2. lb/in2 — At 2.1 0.1 0. SULFUR RECOVERY UNIT THERMAL REACTOR BRICK DATA TUFLINE® 98 DM KORUNDAL XD® DM KORUNDAL XD® H-W CORUNDUM DM® KRUZITE®-70 Bulk Density. % 13.0 12.1 0. - Chemical Analysis % (Calcined Basis) Silica (SiO2) 7.330 4.05 Trace Trace Trace 3.2 Alkalies (Na2O + K2O) .1 0.S.4 0.000 500 375 1. procedures where applicable. lb/in2 — At 2.9 0.6 90.5 0.2 – 0.0 0.2 0.1 Trace 0.2 0.9 18. Variation from the above data may occur in individual test.0 94.600 After Heating at 1.3 Phosphorus Pentoxide (P2O5) 1. All Rights Reserved.4 4.8 0.2 44.0 – After Heating at 1.9 0.630 1. lb/in2 9.070 1.500 620 .0 Titania (TiO2) <0.94 – – – – GREENAL-90 UFALA® UCR G-3000 LI G-28 LI Bulk Density.1 Trace 0. lb/ft3 189 160 62 51 Apparent Porosity.2 -0.1 0.2 23. Cat# HW170 (11/02) 2C .700 Modulus of Rupture.1 1. lb/in2 2.3 73.1 6. or responsibility of any kind.0 Alumina (Al2O3) 97.0 Iron Oxide (Fe2O3) 0.500 1. information.3 Alumina (Al2O3) 90.0 0. expressed or implied.2 0.760 3.580 1.1 1. The suggested use assumes that all safety measures are taken by the user.8 0.4 Iron Oxide (Fe2O3) 0.0 Titania (TiO2) 0.5 0.1 Alkalies (Na2O + K2O) 0. % 12.3 Magnesia (MgO) Trace 0.1 0. All statements.2 9.320 – – Chemical Analysis % (Calcined Basis) Silica (SiO2) 0.6 Lime (CaO) 0.0 Lime (CaO) 0.1 91.500˚F Chemical Analysis % (Calcined Basis) Silica (SiO2) 5.2 0.09 0.0 62.500˚F Crushing Strength.930 1.1 Iron Oxide (Fe2O3) 0.5 57.6 Other Oxides 1. and data given herein are believed to be accurate and reliable but are presented without guarantee.3 0.750 2.2 0.3 90.2 Magnesia (MgO) 0.500˚F Modulus of Rupture.000 After Heating at 1. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.280 6.500˚F Permanent Linear Change 0.2 0.3 – – – – 4.9 – – – MONOLITH DATA NOVACON® 95 GREENCAST®-94 GR KAST-O-LITE® 26 LI G KAST-O-LITE® 30 LI G GREENCAST®-94 GREENPAK-90-P Bulk Density.7 5.4 45.7 Modulus of Rupture.T. lb/in2 — At 70˚F 2. - Modulus of Rupture. warranty.0 0.000 2.1 0.2 Lime (CaO) 0.5 0.1 51.1 Trace 0. gunned or sprayed. and minimal thermal shock. severe abrasion and thermal shock. . moderate abrasion and thermal shock. which can be detrimental to a refractory lining. Refractories used in this service must show good resistance to a variety of destructive conditions. Severe: High impact. • Airborne particulate generated during combustion can cause severely abrasive conditions. • In the case of wet-bottom ash hoppers. ASH HOPPER REFRACTORIES Ash-Hopper Service Ash hopper service includes a number of conditions. The impact of this clinker upon the refractory can be quite severe. Most Severe: High impact. the splash generated by falling clinker can introduce severe thermal shock. • Slag can fall into the hopper in large chunks called “clinker”. • Products installed in ash hoppers can be cast. THERMAL SERVICE INSTALLATION IMPACT SHOCK ABRASION CLASSIFICATION METHOD RESISTANCE RESISTANCE RESISTANCE TUFSHOT® LI/OT Less Severe Gun Good Fair Fair NARCO® GUNCRETE AR Less Severe Gun Excellent Good Good LO-ABRADE GR PLUS ® Severe Gun Excellent Good Good VERSAFLOW® 45 Severe Cast Excellent Fair Good PNEUCRETE 45 ® Severe Spray Excellent Fair Good VERSAFLOW® THERMAX® Most Severe Cast Excellent Excellent Excellent VERSAGUN THERMAX ® ® Most Severe Gun Excellent Excellent Good PNEUCRETE® THERMAX® Most Severe Spray Excellent Excellent Good Less Severe: Low impact. mild abrasion. 1 Lime (CaO) 9.7 0.8 0.3 75.1 2. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. information.2 0. PA 15108 Phone: (412) 375-6600 l Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company.4 1.000 4.0 7.3 0.5 0.7 37.520 1.150 1.560 After Heating at 1500˚F 3.3 2.2 51.4 40.3 Titania (TiO2) 2.6 23. Variation from the above data may occur in individual test.7 0. and data given herein are believed to be accurate and reliable but are presented without guarantee.600 10.4 76.9 48.030 After Heating at 1500˚F 480 1.5 0.500 6.4 0.270 1.1 0.300 6.0 44.3 0.T.0 10.6 0.0 – 16. expressed or implied.3 0.0 0. psi After Drying at 230˚F 770 1. All statements.4 0.5 2.1 0.4 2.0 2. These results cannot be taken as minima or maxima for specification purposes.3 9.180 5.1 The data given above are based on averages of test results on samples selected from routine plant production by standard A.340 7.200 540 1.700 1. The suggested use assumes that all safety measures are taken by the user.2 0. All Rights Reserved.500 6.4 0.6 43.S.3 0.1 – 0.1 3.˚F 2600 2500 2600 2700 2700 2000 2000 2000 Density.0 21. psi After Drying at 230˚F 3.1 Alkalies (Na2O & K2O) 0.400 1.9 Magnesia (MgO) 0.190 5.0 Chemical Analysis. Cat# HW75R (12/03) 2C .620 C-704 Abrasion Test CC Loss After 1500˚F – 12. or responsibility of any kind.1 73. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.3 49.620 8.2 2.5 6.350 1.1 1.3 49.260 10.000 820 840 Crushing Strength. warranty.1 21.2 0.500 1.050 1.5 Iron (Fe2O3) 0.2 1.M.500 5.8 15.2 0. pcf After Drying at 230˚F 127 132 136 136 131 126 126 125 Modulus of Rupture.0 Alumina (Al2O3) 45.9 1.600 5.0 12. ASH HOPPER REFRACTORIES TECHNICAL DATA LESS SEVERE SERVICE SEVERE SERVICE MOST SEVERE SERVICE TUFSHOT® NARCO® LO-ABRADE® VERSAFLOW® PNEUCRETE® VERSAFLOW® VERSAGUN® PNEUCRETE® LI/OT GUNCRETE AR GR PLUS 45 45 THERMAX® THERMAX® THERMAX® Maximum Service Temperature.000 8. procedures where applicable.% (Approximate) Silica (SiO 2) 40.800 7. Harbison-Walker Refractories Industrial Chemicals and Metals Product / Application Update Boiler Refractory Applications Penthouse Superheater Furnace Walls Burners Ducts Ash Hopper . Tubes. Nipples 4 4 4 Drum Head Insulation 4 4 4 4 Ash Hopper Lining 4 4 4 4 4 4 4 4 4 Ducts Inside Lining 4 4 4 4 4 4 4 4 Outside Lining and Piping Insulation 4 4 4 Burners Tangential and Front Fired 4 4 4 4 4 4 4 4 4 4 4 Slagging Bottom Boiler 4 4 4 4 4 4 4 4 Cyclone Boiler Studded Tubes 4 4 4 4 4 4 4 4 Special Applications Baffles and Boiler Seals 4 4 4 4 Floors (Industrial Boilers) 4 4 Stoker Pier (Industrial Boilers) 4 4 4 4 Hearth (Recovery Boilers) 4 4 .Boiler Application Guide GREENGUN ECLIPSE 73-P H-W BULL RAM PLASTIC VERSAFLOW THERMAX PNEUCRETE THERMAX INSWOOL HP BLANKET NARCO GUNCRETE AR NARCOGUN SiC-80 AR VERSAGUN THERMAX INSULATING CEMENT INSWOOL PUMPABLE GREENLITE 45 L GR GREENPATCH 421 THOR 80 ADTECH KAST-O-LITE 19-L COREX GUN MIX GREENPAK-90-P GREENPAK 50-P INSBOARD 2300 GREENCAST 94 KAST-O-LITE 22 TUFSHOT LI/OT RUBY PLASTIC GREENLITE 22 ECLIPSE 60-P ECLIPSE 70-P ECLIPSE 80-P LO-ABRADE MAGSHOT KS-4 Inside Casing & Tangent Wall Outside Casing 4 4 4 4 4 4 4 4 Tangent Wall Inside Furnace Walls Casing 4 4 4 4 4 4 4 4 4 4 4 4 Opening Patch and Access Doors 4 4 4 4 4 4 4 4 Floor 4 4 4 4 4 Penthouse Headers. thermal cycling potential . super-heaters. abrasion LO-ABRADE GR PLUS. NARCOGUN SIC 80AR LOOP SEAL Combustor Service Conditions: . NIKE 60AR. Partly burned fuel and ash flow through the system to a cyclone separator Paticulates separate from the gas stream in the cyclone and re-circulate to the fluid-bed Hot gases escape from the cyclone and move down stream to various boilers. NARPHOS 85 P.most severe abrasion .severe abrasion Solutions: volume stable. CIRCULATING FLUIDIZED BED COMBUSTOR CFB OPERATION Fuel to be burned is injected into the fluidized bed of inert media Efficient combustion at relatively low temperatures.media collection and return Loop Seal Solutions: vitreous silica to minimize thermal shock and withstand abrasion THERMAX PRODUCTS . VERSAGUN 60.particulate removed from gas . The solids that return to the fluid-bed enjoy an effectively long residence time in the combust CROSS-OVER DUCT CYCLONE Service Conditions: Service Conditions: . KALA. VERSAGUN 60 resistant brick and gun mixes ADTECH. abrasion resistant . GREFCON 70GR COMBUSTOR Service Conditions: .thermal shock gun mixes and phosphate bonded plastics Solutions: volume stable. high alumina phosphate bonded plastics Cyclone ECLIPSE PLASTICS. NARMUL P KX-99 BF.zoning may be required . and other heat exchange equipment to create steam and electricity. avoiding the formation of harmful pollutants. economizers.abrasion .thermal cycling Cross-Over Duct Solutions: silicon carbide. High Density Low Porosity Shock Resistant Slag Resistant The dams are made of 8 pieces that come together to form an Octagon. The dams protect the tubes around the slag tap. Features: Improved slag flow characteristics and floor sintering Reduced floor repairs by extending floor life Reduce repairs of frozen slag taps Unit output increased based on reduction of planned unit outages. In a continued effort to improve the life of their refractory around the slag tap of their boiler floors. Exelon Generation (formerly Commonwealth Edison) has designed and patented their "Refractory Block Slag Dam*. 5. Patent No.REFRACTORY BLOCK SLAG DAM RUBY® SR/C Refractory Block Slag Dam.S.775 . *The design is covered by U.800. manufacture and sell the dams. thus eliminating lost generation capacity Slag Dams are made of RUBY® SR/C." Harbison Walker has been given the rights to make. 1 Iron Oxide (Fe2O3) 0.TECHNICAL DATA RUBY® SR/C Classification: Spall Resistant Chrome . These results cannot be taken as minima or maxima for specification purposes. information. or responsibility of any kind.360 lb/in2 Chemical Analysis: (Approximate) (Calcined Basis) Silica (SiO 2) 1. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party.com Phone: (412) 375-6600 w Fax: (412) 375-6783 © 2003 Harbison-Walker Refractories Company. 5.800.S.2 Other Oxides 3.1 Alkalies (Na2O+K2O) 0. expressed or implied. The suggested use assumes that all safety measures are taken by the user.5 This design is covered by U. and data given herein are believed to be accurate and reliable but are presented without guarantee.hwr.1 Titania (TiO2) 0.5 Modulus of Rupture: At 70oF (21oC) 12.1 Lime (CaO) 0. procedures where applicable. warranty. %: 15. All statements.900 lb/in2 Crushing Strength: At 70oF (21oC) 1. Harbison-Walker Refractories Company 400 Fairway Drive Moon Township. Patent No. Cat# HW125 (12/03) 2C .T.775 The data given above are based on averages of test results on samples selected from routine plant production by standard A.Alumina Vib-Cast/Fired Shapes Bulk Density: 204 /b/ft3 Apparent Porosity.S. All Rights Reserved. PA 15108 www.9% Alumina (Al2O3) 83.M. Variation from the above data may occur in individual test.1 Magnesia (MgO) Trace Chromic Oxide (Cr2O3) 11. . The ANH Refractories Family of Compaines Harbison-Walker Refractories Company 400 Fairway Drive Moon Township.com © 2005 Harbison-Walker Refractories Company.hwr. PA 15108 Phone: (412) 375-6600 Fax: (412) 375-6783 www. All Rights Reserved.