St Quentin Fallavier, January 15th 2004

From : A. MAGNO

To : Refractory Networking
Copy : F. DESMIDT

Ref. : PPP621-AMA(LP)N1413.04

USEFUL PRACTICE
CASTING LOW-CEMENT CASTABLES BY VIBRATION
Objective
The objective of this Useful Practice is to share practical knowledge about Low and/or Ultra Low
Cement Castables application by vibration in the Lafarge Group.
Best properties can only be acquired if the castable is densified by vibration. When the wet castable
is vibrated, the material is compacted and de-aerated.
GUIDELINES
An important cause of poor kiln reliability is failure in brick or concrete lining. This Useful
Practice states practical hints of castable application by vibration which have been experimented
with success in some Lafarge plants.
In the kiln outlet, at nose and retaining rings, there are options of laying bricks or casting
monolithic. The choice should be based on the lifetime of the material usually applied in this zone
and kiln shell condition. Flame condition, clinker quality and uniformity are also factors which
should be taken into account. Normally, bricks or concrete lining should last more than 1 year in
this zone.
Brick laying is recommended when the kiln shell has the correct thickness, is not deformed and its
ovality is less than 0.1 % times the kiln diameter. In this case, it is possible to lay high alumina or
spinel bricks. In general, high alumina bricks are more rigid than spinel bricks. For this reason, high
alumina bricks should be chosen when the kiln shell is in very good condition and has correct
thickness. The advantages of high alumina bricks are better thermal insulating material and cheaper
than spinel bricks. It is always recommended to use a lining machine to lay bricks despite the
difficulty of installing it in the kiln outlet.

L'Isle d'Abeau Parc de Chesnes - 95, rue du Montmurier - BP70 - F-38291 St Quentin Fallavier Cedex
Tlphone : 33 (0)4 74 82 16 16 Tlcopie : 33 (0)4 74 82 18 56
S.A. au capital de 250 000 F RCS Vienne B 350 207 387 Siret 350 207 387 00027

Casting monolithic is recommended when the lifetime of bricks is less than 1 year. But, monolithic
casting requires more time, attention and knowledge than brick application. That is one of the
reasons why this Useful Practice was written. Each step of castable application is decisive for the
lining success. See in the next figure a list of steps for castable and bricks application.

If there is a failure in one step, no matter which one even for castable or brick application, it is
probable that the lining will fail.
The lifetime of at least 1 year for casting will be reached when the proper castable is chosen and
every step is correctly applied, even if the kiln shell is not in good condition.

Flame condition, clinker quality and uniformity require special attention because they can damage
the refractory lining (brick or castable) in a few hours.
The organisation of refractory application greatly contributes to successful lining. Annex 1 includes
an example of personnel organisation and their role. In annex 2, there is a list of the useful tools
necessary for brick laying and monolithic casting.
This Useful Practice should always be updated according to the feed-back from the plant experts.
In case of doubt, do not hesitate to contact your Technical Centre for any questions you may have.
Within the Lafarge Group there is a Refractory Network whose role is to increase kiln reliability.

TABLE

OF

CONTENTS

1. GENERAL RECOMMENDATIONS ............................................................................................................... 5

2. CASTABLE STORAGE..................................................................................................................................... 5
3. INSULATION...................................................................................................................................................... 5
4. WATER................................................................................................................................................................ 5
5. CASTING IN WINTER...................................................................................................................................... 6
6. SHUTTERING .................................................................................................................................................... 6
7. GAS TRAPPING................................................................................................................................................. 6
8. MIXING PROCEDURE..................................................................................................................................... 8
8.1 BALL IN HAND TEST ....................................................................................................................................... 9
8.2 VIBRATING TEST ........................................................................................................................................... 11
9. COMPACTION................................................................................................................................................. 11
10. SETTING AND HARDENING...................................................................................................................... 11
11. DRYING AND HEATING-UP....................................................................................................................... 12
12. MAIN CASTABLE APPLICATION ............................................................................................................ 12
12.1 BLOCK POSITION......................................................................................................................................... 13
12.2 BLOCK INTERLOCKED (GAS TRAPPING)............................................................................................. 13
12.3 BLOCK SIZES................................................................................................................................................. 13
12.4 BLOCK THICKNESS ..................................................................................................................................... 14
12.5 TYPE OF ANCHORS...................................................................................................................................... 14
12.5.1METALLIC ANCHORS :........................................................................................................................................ 14
12.5.2 CERAMIC ANCHORS :........................................................................................................................................ 15
12.6 TYPES OF SUPPORT : .................................................................................................................................. 16
12.6.1 ROOFING :........................................................................................................................................................ 16
12.6.2 ROTARY KILN : ................................................................................................................................................ 18
12.6.3 STATIC PARTS : ................................................................................................................................................ 20
12.7 ANCHOR ARRANGEMENTS : .................................................................................................................... 21
12.8 TYPE OF CASTABLES.................................................................................................................................. 22
12.9 EXPANSION JOINTS..................................................................................................................................... 23
12.9.1 ROTARY KILN :................................................................................................................................................. 23
12.10 PROTECTION AGAINST FLAME RADIATION .................................................................................... 24
12.11 INSPECTION.................................................................................................................................................. 24
13 RETAINING RING ............................................................................................................................................ 27
ANNEX 1 : REFRACTORY WORKS ORGANISATION ................................................................................... 29
ANNEX 2 : OBJETIVES OF THE LEADERS INVOLVED IN REFRACTORY WORKS ............................. 30
ANNEX 3 : USEFUL TOOLS FOR REFRACTORY OPERATIONS ................................................................ 31
ANNEX 4 : USEFUL TOOLS FOR CASTING ..................................................................................................... 32
ANNEX 5 : USEFUL TOOLS FOR CARPENTERS AND KILN START-UP................................................... 33
ANNEX 6 : ANCHORING FOR 220 MM BLOCK THICKNESS....................................................................... 34
ANNEX 7 : ANCHORING FOR 250 MM BLOCK THICHNESS....................................................................... 35
ANNEX 8 : COOLER LINING GUIDELINE........................................................................................................ 36
ANNEX 9 : PREHEATER LINING GUIDELINE (LOWER CYCLONES) ...................................................... 37
ANNEX 10 : PREHEATER LINING GUIDELINE (UPPER CYCLONES) ...................................................... 38

1. GENERAL RECOMMENDATIONS
Units in which castables are to be installed must be checked to ensure that the installation zones are
safe and clean, i.e. dust-free, and remain clean during the work.
You must ensure that the work is carried out in safe conditions. Special care should be taken when
working on scaffoldings. Also remember that other people may be working in the same area, above
or beneath. So, nobody should work in an unsafe environment. See file Falls Prevention Version
3.
The total castable installation process should not take more than 20 minutes. To obtain a uniform,
homogeneously cast surface, the entire mix for the given zone should be prepared in a sufficient
quantity and applied without interruption.
All metallic expansion joints installed in the plant must be in good condition. They should be
checked during every kiln stoppage and the insulating wool should be replaced once a year.
2. CASTABLE STORAGE
In a dry place. The maximum storage capacity is stated on the individual data sheets. Material which
has hardened in the bags cannot be used by additional crushing. Do not use any refractory concrete
that has become lumpy. In all cases of material stored for a long time, samples should be taken
before use in order to determine the cold crushing strength.
3. INSULATION
The insulation underneath, consisting of lightweight refractory bricks, diatomaceous silica, calcium
silicate or insulating slabs thereof, should always be given a water-repellent surface, i.e. by an
insulating paint such as bitumen or acrylic lacquer or by a polyethylene cover. Best results are
obtained by impregnation and coating of the areas of the insulating slabs.
4. WATER
Respect the water requirement stated in the castable data sheet. Carry out some consistency tests
to determine the correct quantity of water. It should not exceed the maximum specified. See item 8,
page 8, Mixing Procedure.
The water for mixing the material should be of drinking-water grade and at a temperature between
15 and 25 C. The water should never be colder than + 5 C, since otherwise the mix will take too
long to set.

5. CASTING IN WINTER
If casting mix is used in winter at very low temperatures :
the castable should be stored in warm rooms at 25 C during 48 h.
the mixing water should be heated to about 25 to 30 C.
If necessary, the cast surface must be protected from frost by covering or heating.
6. SHUTTERING
The shuttering has to be clean and waterproof.
The shuttering can be smoothly planed wood, coated with suitable sealing agents (paraffin wax,
greases, silicones or plastic sheets) to prevent absorption of mixing water from the refractory, or
may be of metal. Both kinds of shuttering must be firmly anchored (stable bracing is required), since
strong forces occur during the use of mix and compaction with the immersion vibrator and often
deform the shuttering, resulting in layer formation in the mix.
The shuttering must be seal-tight, since otherwise the material will escape through residual cracks or
openings.
Remove the shuttering only after the form stability is achieved. The hardening time depends on the
castable type and ambient temperature. It means that the decision to remove the shuttering depends
on the rate of setting.
7. GAS TRAPPING
See in figure 1 gas trapping installation when many adjacent panels have to be cast. Gas trapping
works like a male/female interlocking. Firstly, divide the surface in even and odd panels.

Figure 1 : Gas trapping

6

Vertical wall : Nail prism of wood (trapping maker) on the middle of the shuttering wall sides of the
even panels. The prism should also be placed on the top of block, just before pouring the last batch
of concrete. They will be female blocks.
Roofing : install the prism of wood in the shuttering in the middle of all sides of the even panels.
Remove the shuttering on the sides of the even panels including the prism of wood, but leave the
main front formwork in place. You will see the gas trap shape in the concrete. Carry out a fine finish
in the gas trapping where it is necessary. They will be female blocks.
Cast odd panels. As the even blocks already have the gas trap shape on the sides, it is necessary to
install the prism of wood only on the top of blocks (vertical wall) by following the previous
recommendation. They will be male blocks.
It is necessary to wait until the end of the setting time before removing the shuttering including the
gas traps (prisms of wood on the top and sides of blocks).
Continue to cast the panels from bottom to top. Carry out staggered casting. See figure 2. Follow
the same procedures described previously.

Figure 2 : Panels staggered

(M = male and F = female for gas trapping arrangement)
The joint in the gas trap is about 1 mm. Ceramic fibbers of about 5 to 6 mm should be installed on
the female panels after to remove the shuttering. The ceramic fibbers will be compressed by the
forces which occur during pouring and compaction of the male panels. In the end, the thickness of
the ceramic fibbers will be about 1 mm, which still prevents gas infiltration and allow expansion of
the concrete panels. Check if the joints are really about 1 mm. Otherwise, reduce/increase the
thickness of the ceramic fibbers. They should be glued on the panel sidewalls by using glue or
grease.
7

8. MIXING PROCEDURE
The entire mixing process should not take longer than 5 to 8 minutes, depending on the concrete
and mixer capacity. The mixed material should be used as quickly as possible. It is therefore
advisable to mix the material in the immediate vicinity of the place of use.
Always use a clean mechanical paddle mixer for the refractory concrete. There must not be any
impurities (i.e. concrete remainder) in the mixer.
Check the number of bags which can be mixed simultaneously and in batches. This number of bags
must be strictly observed.
Calculate the minimum and maximum amounts of water given in the castable data sheet. These
quantities of water must be strictly observed.
Dose 3/4 of the minimum amount of water in a plastic measuring beaker.
Empty the bags into the mixer
Dry mixing for 10 to 30 seconds, depending on fibbers mixing or not.
At this stage, metallic fibres (3 % on dry weight) or organic fibres (0,2 % on dry weight) can be
added to the concrete.
These fibres must be added progressively in small quantities to avoid the formation of bundles.
With the mixer turning, add 3/4 of the minimum water content progressively in small quantities.
Mix for 1 minute.
Stop the mixer and let the mix rest for 1 minute. Depending on the concrete type used, it is not
necessary.
Meanwhile, clean the paddles and break up any lumps with a small handspike. Make sure the
paddle mixer will not turn. Be careful!
Restart the mixer and add the rest of the water up to the minimum quantity given.
Calculate the amount of water to reach the maximum indicated in the castable data sheet. Dose the
amount of water previously calculated in a plastic measuring beaker.
Carry out the Ball in Hand or Vibrating test. If the mix is too dry, add the water available in the
plastic beaker gradually, without exceeding the maximum quantity specified.
Continue to carry out consistency test until it gives correct results.
Water to be adjusted according to conditions (mixing, temperature, particle size and distribution of
the material). Material kept warm in storage needs more water than in cold storage.
8

8.1 BALL IN HAND TEST

This test is the oldest and the most valuable test for checking the working properties of cast
material.
The procedure is to take a handful of material from the drum of the mixing machine, after stopping
it, and analyse its consistency. Be careful and do not forget to use gloves !
If the material can be formed into a ball which does not disintegrate when thrown and can be caught
while still in form of a ball, the correct processing consistency has been obtained. See figure 3.

Figure 3 : Ball in Hand Test Correct consistency

If the material disintegrates, more mixing water must be added. See figure 4.

Figure 4 : Ball in Hand Test Incorrect consistency dry

However if the ball can easily be dented or actually flows through the fingers, the moisture content
is too high and will adversely affect the final strength and porosity. See figure 5.

Figure 5 : Ball in Hand Test Incorrect consistency - wet

10

8.2 VIBRATING TEST

Vibrate the contents of a bucket half full of concrete with a high frequency vibrator.
It should settle and attain a flat surface in not more than 10 seconds.
If not, water must be added with care.
If there is any bleeding phenomenon, it means that too much water was added to the mixer. Throw
the concrete away and less water must be added next time.
9. COMPACTION
The mix should be compacted by an immersion vibrator, capacity about 15 000 to 20 000 vibration
per minute. Care must be taken that the material is uniformly distributed. The immersion vibrator is
operated so as not to leave any cavities when pulled out. Remove slowly the vibrator in order to
avoid any air inclusions.
Vibrate methodically all over the volume for a few seconds until a shiny surface is obtained. Do not
over-vibrate and do not smooth with a trowel.
The duration of compaction over each area of use should not be longer than 5 minutes, since unduly
long vibration will result in separation of the mix. If too much water appears on the surface during
compaction, the material is too wet, and the cold crushing strength and porosity of the material is
adversely influenced.
When the refractory concrete is applied to horizontal surfaces, the entire lining height should be
placed in one operation, i.e. should not be built-up layer by layer.
10. SETTING AND HARDENING
Low mixing, ambient and setting temperatures (< 10 C) prolong significantly the setting time. At
these low processing temperatures, the material in bags, the water and the ambient air should be preheated (e.g. with radiation burner or similar).
During hardening the castable must not freeze at any rate. Temperatures over 25 C accelerate
significantly the setting time. In this case, the material in bags and the water should be cooled. The
temperature of the hydraulically setting castable should be between 15 and 35 C during hardening.
Even low-cement castables generate heat during the setting process. Further, because of elevated
outside temperatures (> 25 C), some of the moisture contained in the lining evaporates
prematurely, resulting in an incomplete setting and hence reduced strength of the castable. To
reduce the evaporation of the moisture at elevated setting temperatures, the surface of the lining
must be kept damp and cool. Spray water slightly and regularly on the surface, which may remain
covered with jute or empty and wet castable bags, for at least a further 24 hours after fitting.
No processing of the castable may be carried out during this period.
11

11. DRYING AND HEATING-UP

After hydraulic setting of the concrete is complete (in about 24 hours) it can be additionally dried
and heated. For precise control use thermocouples placed on hot side and cold side. A standard
curve does not exist. Guidelines for a 150 mm lining in Low Cement Castable (LCC) and Ultra Low
Cement Castable (ULCC) are stated in table 1.
Table 1 : Guidelines for drying and heating-up LCC and ULCC
Temperature
Classical version
20 to 150 C
30 C/hour
at 150 C
hold for 6 hours
150 to 450 C
15 C/hour
at 450 C
hold for 6 hours
450 to 600 C
20 C/hour
at 600 C
hold for 5 hours
Sub-total
49 hours
600 C to service temperature
50 C/hour
SR = fast drying

SR version
50 C/hour
hold for 3 hours
50 C/hour
hold for 3 hours
50 C/hour
hold for 3 hours
21 hours
50 C/hour

In parts of the unit in which the material is installed in front of insulation, residual mixing water can
escape through the insulating layer. The casing needs to be assisted by drilling vapour-venting holes
of the 10 mm in the upper part (spacing about 400 x 400 mm) and 15 mm in the lower part (spacing
about 300 x 300 mm). After this stage, the holes should be filled in with refractory mortar.

12. MAIN CASTABLE APPLICATION

Henceforward, the main castable applications are detailed according to the place of casting. The
lining design is based on the place of installation.
Table 2 : Place of casting and main equipment
Roofing
Rotary Kiln

"Static" Parts
Cooler sidewalls, tertiary air
setting chamber sidewalls,
Cooler, cyclones, tertiary air Nose ring, retaining ring, inlet
cyclones (cylinder and cone),
setting chamber, precalciner
cone, kiln shell
ducts and elbows (tertiary air,
risers, smoke chamber)

12

12.1 BLOCK POSITION

The position of the blocks is important to determine anchor, support and insulation types.
Table 3 : Block position
Roofing
Blocks are suspended.

Rotary Kiln
Blocks turn in function of kiln
shell rotation.
Their position varies from
suspended to lying on the kiln
shell.

Static Parts
Blocks are supported on the
walls or on a retaining ring, or
on the bottom of the
equipment.

12.2 BLOCK INTERLOCKED (GAS TRAPPING)

The blocks should be made as staggered ones, except in the kiln, to prevent penetration of dust and
other materials.
Table 4 : Block interlocked
Roofing

Rotary Kiln

"Static" Parts
Interlocking is required to
prevent gas infiltration and
penetration of dust which
Interlocking is required to There must be no interlocking. attacks the anchors and burns
blocks
should
be
prevent gas infiltration which The
the walls
attacks the anchors, holders independent and separated by
expansion joints (ceramic
and burns the beams
fibre).
They should be aligned in
function of the nose ring
plates.

12.3 BLOCK SIZES

In the nose ring, blocks should be cast individually for each plate.
Table 5 : Block sizes
Roofing

Rotary Kiln
"Static" Parts
400 x 400 mm or less than 0.16
800 x 800 mm or less than 0,64
Typical is 800 x 800 mm but
m. In the nose ring, it has the
m
always less than 1.0 m
same dimension as the plate.
13

12.4 BLOCK THICKNESS

See some guidelines in annexes 8, 9 and 10.
Table 6 : Block thickness
Roofing

Typical is 200 mm
according to lining design

Rotary Kiln

"Static" Parts

Typical
Cooler : 230 mm
Preheater : 150 mm
Minimum : 200 mm
Lining design should be
or
It can be thicker depending on followed.
kiln diameter
In this case, many different
thicknesses are possible
depending on the specific
casting place.

12.5 TYPE OF ANCHORS

12.5.1METALLIC ANCHORS :
Install floating anchors free to move in the 3 dimensions.
Anchoring of 16 to 20 per m2 (more at burner lining). See specific recommendation for
burner refractory lining in the file Burner Pipe Lining.
Coat the support including the internal hole with an insulating material (fibre or wool).
Coat the V anchors with scotch tape and provide plastic caps to the V tips which burn when
heated, so that the differences in expansion coefficient between the concrete and the steel
anchor do not result in spalling.
Do not paint the V because the paint can be scratched during the handling, concrete pouring
or compaction.
The two legs of the V have different lengths to prevent spalling in layers. They should not
exceed /3 and of the thickness of the concrete block for casting.
The V angle should be 15 (inside insulating layer) and 60 (inside concrete layer). The point
where the legs of the V are bent to form an angle of 60, should be 20 mm deep in the
concrete block.
The V anchors are always made of heat resisting steel (stainless steel AISI 310).
Typical anchor diameters are stated in table 7. Also, see some examples in figures 7 and 10
and annexes 6 and 7.
14

Table 7 : Anchor diameters

Roofing
8 to 10 mm

Rotary Kiln
8 to 10 mm

Static Parts
6 to 8 mm

12.5.2 CERAMIC ANCHORS :

Ceramic anchors are mainly responsible for surface anchoring and prevent spalling in layers.
Also, they replace metallic anchors when high temperature is stated on the wall. See figure 6.
The length of the ceramic anchors should be enough to reach the hot face of the concrete.
Various lengths and grades of ceramic anchors are available and they are supplied by the main
refractory material producers.
The ceramic anchor is usually helped by a gib secured to the outer casing.
Wooden wedges are used for fixing between the gib and the anchor brick.
Coat the metallic parts of the ceramic anchors (clamp and claw) with an insulating material
(fibre or wool).

Figure 6 : Example of ceramic anchor application

15

Table 8 : Types of anchors

Roofing
Rotary Kiln
"Static" Parts
Mixed anchoring of ceramic V hung on a holder made by a Mixed anchoring of ceramic
and metallic anchors.
small bent rod.
and metallic anchors or only
V of the metallic anchor and
metallic anchors.
the support of the ceramic
V hung on a steel plate and
anchors are hung on boiler
ceramic anchor hung on clamp
steel pipe
and claw holders

OBS:
we
recommend
anchoring with two angles (15
and 60 ) instead of only one
as it is stated in the figure
above and in the right side.

See some guidelines in annexes 8, 9 and 10.

12.6 TYPES OF SUPPORT :
First of all, grind the surface (casing, shell or nose ring plates) where the anchoring supports will be
welded. Be sure that the thickness of the plate is proper, clean by grinding (rusty surface is removed)
and mechanical characteristics of the metal is suitable for welding (it is not burnt). Otherwise,
replacement of the plate is recommended.
12.6.1 ROOFING :
The V of the metallic anchors and the gib of the ceramic anchors are hung on the boiler steel
pipe.
The V of the metallic anchors does not need any extra support. It is hung directly on the
boiler steel pipe. See figure 7. A flat iron support is required when the V is under a beam,
which is described next.

16

The ceramic anchors can have two types of support : clamp and claw ensemble or twin hooks.
See figure 8.

Figure 7 : Roof metallic anchor

17

Figure 8 : Roof ceramic anchor

12.6.2 ROTARY KILN :
Anchors support should be an inverted U (omega ) with the tips bent 90 and welded on
the plates (nose ring) or on the kiln shell (retaining ring).
The diameter is always at least 2 mm thicker than the anchors diameter.
The should be made with the same mechanical characteristics of the metal base quality,
where they are welded, or according to table 9.
Table 9 : Steel quality of the support
Welding place
Steel quality of the support
Nose ring (plates) Stainless steel AISI 310
Same mechanical characteristics as kiln shell quality
Kiln shell
or boiler steel H1/A42 CP
or DIN 25Cr Mo6

Electrode
Proper electrodes
must be used

18

See an example of the support for an anchor diameter of 8 mm, figure 9.

= 10 mm
Continuous welding

R = 20 mm
30 mm

30 mm

Figure 9 : Anchor support to be welded in the kiln

The support should be welded in the kiln axis direction.
Coat the support with scotch tape and fill up the empty space of the hole with an insulating
material (fibre or wool).
The V should be positioned in the middle of the hole and tack welded in the support. Be
sure that the anchors are only tack welded, which means that the welding will easily be
broken by hands. Confirm this point trying to break the welding of some anchors.
The support tips should be continuously welded in both sides but not at the ends. See figure
10 and annexes 6 and 7.

Figure 10 : Anchor and support details for a block thickness of about 220 mm.
19

At nose ring plates, it is also possible to weld the support on the head of the bolts, taking into
account the number of bolts available at each plate and anchoring arrangement. In this case, the
steel quality of the support and bolts should be compatible taking into consideration welding
process. The support shape should be as described in following item 12.6.3..
12.6.3 STATIC PARTS :
The support must be made of flat iron (boiler steel).
It must be continuously welded in the casing (both sides) and a proper electrode type has to
be used.
Supports and anchors have the same thickness.
The support dimensions depend on the thickness of the insulating layer (L) and on the V
diameter (). As a guideline, the dimensions are :
Support dimensions = (L-20) [height] x (7*) [width] x () [thickness]
For example, 100 x 70 x 10 mm for a wall with an insulating thickness of 120 mm and a V of
10 mm in diameter.
A hole should be drilled in the support. As a guideline, the hole diameter is equal to V
diameter * 1.75
The minimum distance between the hole and the edges of the support is 20 mm. See figure
11.

Figure 11 : Support for walls

20

The V should be positioned in the middle of the hole and tack welded in the support. Be
sure that the anchors are only tack welded, which means that the welding will easily be
broken by shaking the anchors. Try to break the welding of some anchors. The hole should
be completely filled by wool.
The support must be inserted in the insulating layer and coated by insulating material (fibre,
wool). The concrete must not reach the holder.
Protect the insulating layer and supports against gas infiltration by spreading a thin layer of
mortar (1 to 2 mm) on the hot face of the insulating layer.
When a whole equipment is being lined and a plastic film is applied between the insulating
and concrete layers, small holes should be made in the plastic film to allow the steam to
escape through the casing vapour-venting holes.
12.7 ANCHOR ARRANGEMENTS :
Nose ring : the number of anchors required is defined in function of the plate size. Typically, 2 , 3 or
4 anchors are enough. In general, it is recommended anchoring of 16 to 20 per m2.
Table 10 : Anchor arrangements
Roofing
Rotary Kiln
Mixed anchoring : V of the Holders are always continuous
metallic anchors are installed welded in the kiln axis direction.
inverted, staggered and always V are staggered at 90 and 45
perpendicular to the pipes.
in reference to the holders. The
V tips are bent at 0 and 90 .
anchor
and
holder
Ceramic anchors are located in arrangements should be decided
the middle of the metallic in local.
anchors and hung in any
position.

"Static" Parts
Holders are staggered at 0 and
90 and continuous welded.
V are positioned 90 in
reference to the holders.
Ceramic anchors are hung in
position where the bent face of
the clamp are in horizontal
position.

See figure 12.

21

Figure 12 : Mixed anchor arrangement in the roof.

12.8 TYPE OF CASTABLES
See some guidelines in annexes 8, 9 and 10.
Table 11 : Type of castables
Roofing
Corners (Bull nose) : Gibran SR
or similar.
Upstream Cooler Roof : Low
Cement Castable (LCC) with
High Alumina (> 80 %).
Cyclones Roof : LCC with 45 %
alumina.

Rotary Kiln

Static Parts

Smoke chamber and Riser duct

Retaining Ring and Nose Ring : : LCC 45 to 50 % alumina.
Gibran SR or similar.
Precalciner : LCC 45 to 85 %
Inlet Cone : LCC 45 to 60 % alumina, depending on
alumina.
precalciner type.
Cyclones : LCC 45 % alumina

It is necessary to evaluate the alkali content in the system in order to avoid alkali bursting (volume
increase : formation of cracks, structural desegregation, brick head bursting and premature wear of
large areas).
Where there are build-ups and alkali attack, smoke chamber and lower cyclones for example, it is
advisable to cast low cement castable with silicon carbide (SiC). This type of castable reduces the
22

porosity of the hot face by forming a protecting layer, which reduces the adhesive forces between
the coatings and the monolithic refractory lining.

Mix 3% on dry weight of the metallic fibres (Dramix or similar) in the concrete to reduce the
abrasion. Gibran does not require metallic fibres mixing, except at burner pipe lining.
12.8.1 NOSE RING AND RETAINING RING :
Add organic fibres (< 0,2 % w/w) in the castable or order them with these fibres which serve as
vaporisation assistance for the drying and heating-up period due to shrinking reaction already
below the boiling point of water leaving a channel system.
12.9 EXPANSION JOINTS
Table 12 : Expansion joints
Roofing
Cool expansion joint but lay
some insulation wool at ceiling
sides to be compressed by the
concrete expansion. Follow the
expansion joint recommended
in the refractory design.

Rotary Kiln

Static Parts
Cool expansion joint but lay
some insulation wool at wall
corners to be compressed by
See the recommendations next.
the concrete expansion. Follow
the
expansion
joint
recommended in the refractory
design.

12.9.1 ROTARY KILN :

Expansion joints are used to prevent damages in the nose ring caused by the brick lining
expansion.
The thickness of the expansion joints depends on the shell and concrete reversible linear
expansion. Sometimes, only cool expansion joints are required.
12.9.1.1 Nose ring :
Each nose ring plate must be cast separately and 4 mm ceramic cardboard should be
installed between them (side to side).
Install 4 mm ceramic cardboard nose ring upstream.
Cover nose ring plates sidewall with 4 mm ceramic cardboard or compressed ceramic
fibre covered by a plastic film.
12.9.1.2 Retaining ring upstream and downstream :
Each block should be separated with 4 mm ceramic cardboard in the four edges (side to
side and front and back sides).

23

12.10 PROTECTION AGAINST FLAME RADIATION

Gun 2 cm insulating castable layer on the concrete blocks surface in order to protect them against
high flame radiation during the kiln heating-up. It is also recommended to be applied in the cooler
roof and bull nose. This layer protects the new concrete against thermal shock caused by the first
clinker which usually arrives in the cooler very hot after the feeding start-up.
12.11 INSPECTION
If for any reason, the kiln is stopped and it is possible to do refractory/brick inspection, it is strongly
recommended to do it. Take care about safety !
During this short stoppage some action can be taken to repair any failure in refractory lining
(brick or concrete). It will avoid a refractory failure immediately after the kiln starts. This inspection
is also a good opportunity to gather information for preparation for the next kiln shutdown.
13. LINING AT KILN OUTLET
There are many possibilities to line refractories at kiln outlet. Bricks or concrete can be used,
depending on plant experience. The lining lifetime target should be at least 1 year, no matter which
kind of material was used and the condition of the kiln shell. If this target was not reached and
according to the historical data, the plant should try different arrangements. See some examples at
figures 13, 14, 15 and 16.
The next recommendation is for kiln shell in good condition, low ovality (< 0.1 % x kiln diameter)
and no abnormal wearing phenomenon. High alumina or spinel bricks can be used. Bricks can have
either a special shape to cover nose ring plate or a rectangular shape. Lining lifetime is about 1 year.
See figure 13. More than one brick ring can be laid between nose and retaining rings.

Figure 13 : Kiln outlet lined with bricks

24

When there is collapse of bricks ring against retaining ring from pinch spalling, it is recommended to
cast monolithic at retaining ring upstream. See figure 14.

Figure 14 : Kiln outlet lined with bricks and 1 ring of concrete at retaining ring upstream
When there is collapse of bricks ring against retaining ring from pinch spalling and against retaining
ring segments, it is recommended to cast monolithic at retaining ring upstream and downstream. See
figure 15.

Figure 15 : Kiln outlet lined with bricks and two rings of concrete at retaining ring upstream and
downstream
When there is collapse of bricks ring against retaining ring from pinch spalling, against retaining ring
segments and nose ring plates, it is recommended to cast monolithic at retaining ring upstream and
downstream and at nose ring plates. See figure 16.

25

Figure 16 : Kiln outlet lined with concrete

A. MAGNO
Senior Process Manager
LAFARGE - CTI

26

13 RETAINING RING
We recommend to use the following retaining ring design shown at figure 17.
10

10

10
10

Figure 17 : Sketch of the retaining ring

The ring will be done in sectors according to kiln diameter, not connected together (clearance of 10
mm).
Kiln diameter (D)
D < 3m
3m < D < 5 m
D > 5m

Number of sectors
8 Sectors
12 Sectors
16 Sectors

The sizes of the retaining ring (X) depends on the kiln diameter and lining thickness (practical
ranges), stated in the table below:
Lining thickness (mm)
180
200
220
220 or 250 (*)
(*) to be confirmed.

Kiln diameter (m)

Less than 3.6
3.6 to 4.2
4.2 to 5.2
More than 5.2

Retaining ring (X in mm)

60
70
80
80 or 100 (*)

Each sector of the brick retaining ring will have to be welded continuously (7mm).
Steel quality : Standard steel ( ex : P265 GH according DIN 17 155 Mat 1.0425 or EN 10028.2)
The objective of this design is to reduce the risk of failure in the concrete or bricks downstream the
ring.
27

Risk of failure due to high

stress concentration
PRESSURE
Brick

Concrete
or
Bricks

Kiln outlet

Shell
Figure 18 : Old design
After some time in running condition, the bricks from uphill the retaining ring apply a pressure on
the bricks or concrete that are downhill the retaining ring and shear stresses are developed and
create cracks.
Ceramic fibber

Concrete
or
Bricks

Concrete
or
Bricks

Kiln outlet

Shell
Figure 19 : Proposed design
The brick profile at the downhill side of the ring reduces the stress concentration factor and the risk
of cracks in this area.
Roger LAMBRECHT
Senior Mechanical Engineer
LAFARGE - CTI

28

ANNEX 1 : REFRACTORY WORKS ORGANISATION

Item
1

Function

Responsibility
Takes the main decisions and is responProduction sible for the planning, jobs quality and
Manager
time schedule. In charge of purchasing
decisions.

Refractory
Shift
Leader

Manages all jobs executed during his

shift. Takes technical decisions (knowhow). When the kiln is running, one of
them is responsible for preparing the
next kiln stoppage concerning refractory
material purchasing and stock, and
planning of next work. In charge of
regular inspections with kiln operators.

Kiln
operators

Supervise and guarantee the progress of

the jobs, related to time and material.

5
6
7
8

9
10
11

Is responsible for a specific work, in a

Refractory specific place. Number of them should
mason
be determined in function of jobs. Is
leader
responsible for refractory tools and
guarantees the quality of the job.
Refractory Is responsible for laying bricks and
mason
casting monolithic
Is responsible for formwork and
Carpenter
supports the refractory mason
Equipment Operates the main machine like Bobcat,
operator
forklift, etc
Removes kiln shell and casing
reformation, removes and installs new
Welder
anchors and supports mason leader
when required.
Support the refractory mason in manual
jobs. Some of them should be
Assistants
determined according to type and
number of jobs.
Warehouse
Supplies materials.
responsible
Safety
Ensures job follow-up and is
Leader
responsible for personnel safety.

Daily Timing
Adm. time

Report to
Plant Manager

12 hours

Production
Manager

8 hours

Refractory Shift
Leader

12 hours

Refractory Shift
Leader

12 hours
12 hours

Refractory
mason leader
Refractory
mason leader

Means/tools
BRIKK
WINBRIX
Stoppage Planning
BRIKK
WINBRIX
Stoppage Planning
CTI Refractory
Training
Material Data
Sheet
BRIKK
CTI Refractory
Training
BRIKK
CTI Refractory
Training
Material Data
Sheet
Refractory Tools
Carpenters tools

12 hours

Kiln operators

Bobcat, forklift,
demolition eq.

12 hours

Refractory
Mason Leader

Welding tools

12 hours

Manual tools for

Skilled refractory
material handling
mason
and cleaning

12 hours

Kiln operators

Pick-up

12 hours

Safety Manager

Whistle

29

ANNEX 2 : OBJETIVES OF THE LEADERS INVOLVED IN REFRACTORY WORKS

Item

Function

Objectives

Starting from Action Plans described in Kiln Stoppage Plan and

P.I.P., give practical objectives to the Refractory Leaders, with
Production Manager
success indicators. Organise regular feed-back to be informed of any
progress made.

Refractory Leader

Give practical objectives to kiln operators and masons to control the

quality of refractory operations (done on time according to the Lining
Chart, application of the Lafarge Best and Useful Practices). In
charge of the Lining Chart in co-ordination with Production
Manager. Train Kiln Operators to assume the responsibility of the
Refractory Supervisors during kiln shutdown.

Kiln operators and

Refractory Mason
Leader

Put into daily practice the Lafarge Best and Useful Practices for
refractory operations. Train the Refractory Masons, Carpenters,
Equipment Operators and Assistants for daily application of the
Lafarge Best and Useful Practices (on-the-job-training).

30

ANNEX 3 : USEFUL TOOLS FOR REFRACTORY OPERATIONS

ELECTRICAL DEVICES
Electric extension with plug sockets 24V
Electric light
Swing lamps
Spare lamps
COATING & LINING DEMOLITION
Compact Excavator Breaker
Pneumatic drill (Jackhammer)
Handspike
Spade
Wheelbarrow
CLEANING
Bobcat
Spade
Wheelbarrow
Handspike
Broom
INSPECTION
Torch
Notebook
Pencil
Camera
Film
Battery
Tapes-measure (2 m and 30 m)
Refratechnik Report N 55
Kiln Lining Chart (WINBRIW)
Electric drill
Drill bit = 8 mm
Electric extension with plug sockets and light
String
Metal rods of 30 cm = 6 mm (3 uds)
Shell scanner printing
Shell temperature chart (pyrometer)
REBRICKING PREPARATION
Compressed air flexible tubes
Broom
Spade
Grinding machine

BRICK HANDLING
Forklift
Wheelbarrow
Pliers to open the pallets
Crowbar
Truck
REBRICKING
Bricks
Mortar proper for brick quality and prepared
Carton paper-made (2 mm)
Spirit-level
Spirit-level support (aluminium strip)
Plumb bob
Hammer rubber-made
Chalk
String
Flexible ruler of metal (to trace radial lines) (2 m)
Lining machine
Hydraulic jack with pressure gauge
Steel plates 50x180x1 mm (to correct conicity)
Shim plates 180 x 180 x 1 mm
Steel plates 180x180x3 mm with sharp edges
Grease
Pieces of wood (plates)
Compressed air flexible tubes
Hammer of metal (3, 5 and 10kg) wood handle
Spoon for mortar
Nailing guide
Tape-measure (2 m)
Brick cutter machine
Disk cut (diamond)
MORTAR PREPARATION
Mortar
Mortar Data Sheet
Drinkable water
Watering can
Plastic measuring beaker
Electric drill
Stirring bit for electric drill
Tin can for mortar mixed handling
31

ANNEX 4 : USEFUL TOOLS FOR CASTING

CASTABLE DEMOLITION
Scaffolding
Pneumatic drill (Jackhammer)
Handspike
Spade
Wheelbarrow
Grinding machine
Oxygen and acetylene cylinders
Oxy-acetylene torch
Welding machine
Electrode for cut
Broom

SHUTTERING (continuation )
Binding wire (rod)
Prism of wood (trapping maker)
Heap of wood
Water proofing material
Nuts and washers
Long screws to hold the formwork
Screw key
Welding facilities

ANCHORING
Anchoring design
Anchor support
Insulating wool
Scotch tape
Electrode
Welding machine
Ceramic anchor
Holders
Metal anchor
Plastic caps

CASTABLE MIXING
Mixing procedure
Ball in Hand Test procedure
Castable
Castable Data Sheet
Ceramic fibre
Organic fibres
Metallic fibres
Paddle mixer
Chronometer
Drinkable water
Watering can
Plastic measuring beaker
Tin for concrete handling (30 litres)
Spoon for mortar
Handspike for mixer cleaning (small)

INSULATION MATERAL
Insulating castable
Light weight refractory bricks
Calcium silicate
Insulating slabs
Insulating wool
Expansion joint material

CASTABLE POURING
High Frequency Vibrator (at least 2 units)
Wet paper bags
Watering can
Pieces of wood
Hammer
Nails

SHUTTERING
Pliers
Hard-fibre boards
Sheet-metal
Plywood
Plastic film
Wooden wedges

REMOVING THE SHUTTERING

Pliers
Screw key
Hand scraper
Hammer
Water spray

CASTING MONOLITHICS

32

ANNEX 5 : USEFUL TOOLS FOR CARPENTERS AND KILN START-UP

CARPENTER TOOLS AND MATERIAL

Handsaws
Electric drill
Power saw
Manual drill
Hammer
Pencil
Pliers
Hatchet
Tape-measure (5 m)
Crowbar
Binding wire
Nail
Broom
Electric light
Electric extension with plug sockets
Swing lamps
Rope
Wheelbarrow

PATCHING
Prop (stay/strut) or Lining Machine
Shields for protection
Pieces of wood
Bricks
Mortar proper for brick quality and prepared
Hydraulic jack with pressure gauge
Hammer rubber-made
Steel plates 50x180x1 mm (to correct conicity)
Shim plates 180 x 180 x 1 mm
Steel plates 180x180x3 mm with sharp edges
Grease
Compressed air flexible tubes
Hammer of metal (3, 5 and 10kg) wood handle
Spoon for mortar
Nailing guide
Tape-measure (2 m)
Brick cutter machine
Disk cut (diamond)

KILN START-UP
Heating-up curve (file)
Kiln start-up procedures (file)

33

ANNEX 6 : ANCHORING FOR 220 MM BLOCK THICKNESS

34

ANNEX 7 : ANCHORING FOR 250 MM BLOCK THICHNESS

35

ANNEX 8 : COOLER LINING GUIDELINE

36

ANNEX 9 : PREHEATER LINING GUIDELINE (LOWER CYCLONES)

37

ANNEX 10 : PREHEATER LINING GUIDELINE (UPPER CYCLONES)

38