Bricklaying Method for Kiln Lining

The bricklaying method is a traditional approach for installing kiln linings using refractory bricks. It involves carefully laying and bonding the bricks together using refractory mortar or adhesives.
Here are the key steps involved in the bricklaying method:

Preparation:

Before starting the bricklaying process, ensure that the kiln shell is clean and free from debris or any loose material.

Prepare the refractory bricks by inspecting them for any defects or damage. Discard any bricks that are cracked, chipped, or unsuitable for use.

Mortar Mixing:

Prepare the refractory mortar according to the manufacturer's instructions. Typically, it involves mixing refractory cement with fine aggregates and water to form a workable consistency.

Follow the recommended proportions and mixing time to ensure a reliable and durable mortar.

Layout Planning:

Plan the layout of the bricks, considering the kiln design, curvature, and any specific requirements of the lining.

Determine the proper orientation and position of each brick to achieve a tight and secure fit. Mark guidelines on the kiln shell to aid in the bricklaying process.

Brick Placement:

Apply a thin layer of refractory mortar onto the kiln shell using a trowel. This serves as a bonding agent between the bricks and the shell.

Place the first brick carefully onto the mortar bed, ensuring it aligns with the marked guidelines. Press it firmly to create a strong bond.

Continue placing the subsequent bricks, applying mortar between each brick to create a solid, interlocking structure. Maintain uniform joint thickness throughout the lining.

Jointing and Leveling:

As you lay each brick, use a jointing tool or trowel to remove excess mortar and create a smooth, even joint between the bricks.

Regularly check the alignment and levelness of the bricks using a spirit level or straightedge. Make adjustments as needed to maintain a uniform and straight lining.

Curing and Drying:

Allow the kiln lining to cure and dry according to the manufacturer's instructions. This typically involves keeping the lining moist and protected from rapid drying for a specific duration.

Follow recommended curing temperatures and timeframes to ensure the mortar develops its strength and the lining achieves its desired properties.

Quality Inspection:

Once the bricklaying is complete and the lining has cured, conduct a thorough inspection of the kiln lining.

Check for any loose bricks, gaps, or irregularities in the joints. Address any issues by repositioning or replacing bricks and applying additional mortar as necessary.

Calculations in the Bricklaying Method for Kiln Lining:

Calculate the number of bricks required based on the dimensions of the kiln lining.

Measure the length, height, and thickness of the lining area to determine the surface area to be covered.

Divide the surface area by the face area of the bricks to estimate the number of bricks needed.

Surface Area:

Measure the length, height, and thickness of the kiln's inner surface to calculate the total surface area to be lined.

Multiply the length by the height to determine the kiln's sidewall area

Multiply the diameter of the kiln by π (pi) to find the circumference, and then multiply the circumference by the height to calculate the kiln's end wall area.

Add the sidewall area and the end wall area to obtain the total surface area.

Kiln Sidewall Area: Length × Height

Kiln End Wall Area: π (Pi) × Diameter × Height

Number of Bricks:

Determine the number of bricks required based on the dimensions of the kiln and the size of the bricks.

Calculate the total volume of the kiln lining by multiplying the surface area by the thickness of the lining.

Divide the total volume by the volume of one brick to estimate the number of bricks needed.

Consider any extra bricks required for cuts, replacements, or waste.

Total Volume of Lining: Surface Area × Thickness of Lining

Number of Bricks: Total Volume of Lining ÷ Volume of One Brick

Mortar Quantity:

Determine the amount of refractory mortar required for the bricklaying process.

Calculate the volume of mortar needed by multiplying the length, height, and thickness of the joints between the bricks.

Consider the joint thickness, which is typically specified by the manufacturer or based on industry standards.

Estimate the volume of mortar required by multiplying the surface area of the bricks by the thickness of the mortar joint.

Volume of Mortar: Surface Area of Bricks × Thickness of Mortar Joint

Determine the volume of mortar in cubic units (e.g., cubic inches or cubic centimeters).

Convert the volume to the appropriate units for purchasing materials (e.g., bags of mortar).

Refractory Mortar Mix:

Calculate the proportions of refractory cement, fine aggregates, and water required to prepare the mortar mix.

Refer to the manufacturer's instructions or industry guidelines for the recommended mix ratios.

Typically, the mix proportions are specified in terms of parts, such as 1 part cement to 3 parts aggregates.