Guarantee Excellence When You Choose Our Cincinnati, Ohio, Refractory & Firebrick Contractors      (513) 738-4100

 

Expert Rebuilds Only through WW Services

We Specialize in Refractory Anchoring Systems

Refractory Anchoring Systems
A refractory anchoring system is the system that keeps the refractory lining of a thermal piece of equipment stationary. These anchoring systems are typically made of stainless steel, welded to the shell, and extend to the hot face of the lining. There are many types of anchors for different temperatures, different designs depending on the customer/manufacturer, and different designs for different types of materials. Despite the type of anchor, their purpose is always the same: to give the refractory lining itself something to hold it in place.

Ceramic fiber lined heat treating furnace

Ceramic Fiber Linings
Most refractory linings consist of a multi-component system in which there is a cold face lining that is backing up a hot face lining that is directly exposed to the heated gases. Ceramic fiber linings are an exception to this rule. They consist of multiple inches of ceramic fiber blanket that has been compressed and then securely welded to the steel exterior with a steel anchor.

There are multiple methods of installation for a single component ceramic fiber lining. One is the overlapping method in which the blanket and anchors are laid out in a particular manner so that the joints overlap, stainless steel anchors are laid out in a particular manner so that the overlapping is possible, and the blanket then secured to the anchor with a stationary clip.

Another method of ceramic fiber lining installation is called stack bond construction, where the blanket is cut to length, stacked on top of one another, compressed, and finally secured with a stainless steel anchor that is welded to the exterior shell. A third method is using folded quick weld modules. This method is similar to stack bond construction, yet in this method the module is pre-fabricated in the plant and therefore is already compressed and simply needs to be welded to the shell. In both stack bond construction and folded quick weld construction, the anchor is imbedded within the material, and is not exposed to combustion gases.

Ceramic fiber linings are a good economical choice because they heat up and cool down faster. They do not require a bake out, so the unit can almost immediately go back online once the rebuild is complete. Rated at up to 2,700 degrees, this blanket-like material provides excellent resistance against thermal shock and chemical attack. These products have high insulation properties, are lightweight, and are relatively quick and easy to install.


Cold Face Linings
Most refractory linings have at least a 2-component system. One component is the hot face that is directly exposed to the system's heated gases. The other is the cold face that insulates the hot face material from the exterior shell. Cold face linings, or backup linings as they are often called, are usually constructed of a 500-3000 degree insulating material. The type of material can vary from blanket to block, board brick, or castable depending on the equipment design. All cold face linings are secured to the shell to increase strength and stability. Generally, as a backup to the cold face material a mastic type material is applied. This is done to prevent oxidation of the steel as well as a break down that can occur in the lining itself.
Bricks - Refractory & Firebrick Contractors in Harrison, OH
Plastic Monolithic Linings
Ramming a shape out of plastic is another method of installing a monolithic refractory lining. The plastic is almost a clay-like consistency, is essentially a pre-fired brick and therefore can be rammed into placed and used to build nearly any imaginable shape or fill nearly any accessible void. This is done through repeatedly adding more material onto the material that has already been set into place, and then molding the desired shape. This type of monolithic construction does not need an air cure period and can begin bake out immediately.
Bricks - Refractory & Firebrick Contractors in Harrison, OH
This is a picture of a rear manway inspection plug for a firetube boiler.

Monolithic Castings
Casting is one method of installing a monolithic refractory lining. This is done by building a form out of any number of materials (most often lumber is used for ease of construction and removal). Once the form has been built to contain and shape your cast, you can fill your form with a selected castable. Once the cast has been air-dried and the forms have been removed, a cast of your desired shape will remain. Once this structure has been baked out appropriately and there is no water left in the structure, it can be put online.

Monolithic construction of any material type can be very useful to form irregular or custom shapes and designs. It is also useful for areas that may simply need a maintenance coating or patch repair.

Let the pros handle your refractory anchoring systems or ceramic fiber linings
by contacting our refractory and firebrick contractors today
at (513) 738-4100 in Cincinnati, Ohio.