Blanket and Wallpaper Linings Design and Installation Manual
Blanket and Wallpaper Linings Design and Installation Manual
Blanket and Wallpaper Linings Design and Installation Manual
Thermal Ceramics
TABLE OF CONTENTS
A. Preface
Introduction 3
B. Blanket and Wallpaper Linings
1. General
1.1 Lining Considerations 4
1.2 Site Preparation 4
1.3 Stud Welding 4
1.4 Butt Joint Construction 5
1.5 4” Overlap Construction 6
1.6 12” Overlap Construction 7
2. Installation
2.1 Geberal 8
2.2 Flue Opening 9
2.3 Corners 9
2.4 Burners 9
2.5 Miscellaneous 10
C. Glossary of terms 12
List of Figures
Figure 1 Anchoring System 4
Figure 2 Butt Joint Construction 5
Figure 3 Vertical Stud Layout 6
Figure 4 4” Overlap Construction 6
Figure 5 12” Overlap Construction 7
Figure 6 Corner Details 7
Figure 7 Blanket Lining for Flues 8
Figure 8 Alternate Corner Detail 9
Figure 9 Burner Wrap 9
Figure 10 Typical Lining Thickness Transition Detail 9
Figure 11 Typical Wallpaper Lining Detail for an Access Door 10
List of Tables
Table 1 Stud Estimate 6
• 300 amp welding machine • rubber bands (1 /4 " x 3") For operating conditions above 2000°F, ceramic cone
anchors or ceramic spike anchor systems can be consid-
• stud welding guns • lighting
ered. For more information on these designs, contact
• chalk line & soapstone • scaffolding
your Thermal Ceramics representative.
• tape measure • 3" side grinders
• 6" butcher knives • plumb line
• 4' straight edge
1.3 Anchor Layout
The anchor layout should be made on the inside of the
casing, making sure that the anchor system is appropri-
ately placed for the blanket lining. Typically, the anchor
layout begins at the endwall of the unit. Special attention
should be given to the corner anchors to ensure enough
distance from the adjacent wall.
The anchor layout is based upon the exposed or hot face
layer of blanket without regard to any of the back-up lay-
ers of blanket. Ensure that all joints in successive layers
of blanket are staggered or offset. Also, there should be
a 3" maximum distance between the last row of studs and
the end or edge of the blanket. In the majority of cases,
the required stud length will be the same as the nominal
thickness of the blanket lining. The layout should include
a minimum hot face blanket width of 12".
The maximum length of the hot face blanket layer should
not exceed 121 /2 '. This will prevent shrinkage tears from
developing along the length of the blanket.
1.4 Butt Joint Construction est the floor. These will be located in the same manner
as described earlier for intersecting another wall. To
The pattern for the horizontal spacing with butt joint con-
complete the vertical spacing, make the same measure-
struction is 9"-9"-5 1/2". This will be across the width direc-
ments down the opposite corner and mark each. The
tion of the blanket. The use of 51 /2" instead of 6" with a
horizontal lines can now be struck to complete the grid.
24" wide blanket ensures a slight compression of the
joint. A template can be made up to assist with the lay- This same procedure should be used for all the walls in
out. Repeat this pattern along the top and bottom of the the furnace and then recheck all corners to ensure that
wall as long as full width blankets can be used and strike the first stud row in each case is 3" plus the lining thick-
the vertical chalk lines by connecting the corresponding ness.
marks.
In order to start the stud layout for roof or arch, the verti-
When intersecting another wall, the spacing is adjusted to cal lines on the end walls will be used for one set of mea-
ensure that the first stud row from the adjacent wall will surements. These will provide the 9"-9"-5 1/2" pattern
be 3" plus the lining thickness. Measure from the last full required along the width of the blanket. The chalk line
stud row to the corner and subtract 3" plus the lining can be lined up with these marks and the lines running
thickness. Take one half of this distance to determine the the length of the furnace struck. The stud spacing run-
location of the intermediate stud row. See Figure 2. ning along the length of the furnace will start from one
endwall. The first stud row is located by measuring in 3"
To obtain the vertical spacing between stud rows start in
plus the thickness of the lining. Subsequent stud rows
the same back wall corner. Measure down from the roof
will be located every 12" if the furnace operating temper-
3" plus the thickness of the lining and mark. The vertical
ature is less than 1900°F, or every 9" if the furnace oper-
spacing between each of the remaining rows is 14". The
ating temperature is equal to or greater than 1900°F. At
only exception to this will be the last two stud rows near-
the opposite end of the roof, place than last stud row in
An anchor overage of 10% in the appropriate stainless steel is recommended for most installations
Table 1 - Estimate of studs/anchors required per square foot for flat, unobstructed surface
A 6" thick lining is one of the most commonly used in Install enough of the first layer of blanket to allow the sec-
industry and will be used for the following example. ond layer to be started, while staggering the joints formed
along the length edge of the blanket. The full 24" wide
Our lining example shall consist of:
blanket used on the second layer will automatically cover
2", 4# ceramic fiber blanket the joint on the first blanket layer by 12". When placing
2", 4# ceramic fiber blanket the blanket, always butt adjoining blankets together tight-
1", 6# ceramic fiber blanket ly.
1", 8# ceramic fiber blanket The end of the second blanket layer should be started at
(Hot Face Layer) the point on the sidewall approximately 3' down from the
It is important to note that minimal cutting of the hot face roof. In this way, there will be a 12" offset at the end of
blanket is desirable and that blanket joints should be off- the blanket between successive layers. Each blanket
set or staggered from underlying layers. As a result, in layer should be staggered in this way.
this example, the initial blanket installed on the first and After a sufficient area has been covered with the second
third layers should be cut approximately in half to form a blanket layer, the third layer can be started following the
12" strip. same techniques to ensure all the joints are staggered.
Using a minimum of three people, start with the first layer On thick wallpaper roof applications, a Kao-Lok speed
of 2", 4# blanket in the back corner of the furnace. One clip can be installed prior to the hot face layer of blanket
person should hold the roll of blanket while the other two to help carry the weight of the lining.
pull out approximately 6 feet of material. For this exam- At this point, the hot face blanket layer can be installed.
ple, let the edge of the blanket hang down the sidewall In most situations it is advisable to install the roof hot face
approximately 4' from the roof and then push the blanket layer first, followed by the side and endwall hot face lay-
over the Kao-Lok studs. At the corner, be sure to mold ers. Compress the blanket, insert and rotate a Kao-Lok
the blanket into the corner before pushing onto the studs. washer onto each Kao-Lok stud to secure the blanket in
To install the blanket on the roof, the person with the roll place.
of blanket should place it over his head and walk back-
wards slowly, letting the blanket feed off the roll in a
straight line, while keeping the roll against the tips of the
studs. The other two workers should push the blanket
Amorphous: Having no definite crystalline structure or form. Lock Washers: Washers used in conjunction with Kao-Lok studs.
Back-up Insulating Material: The layer or layers of insulating They are slotted so that when pushed over the stud and then twist-
material that are located between the hot face insulating layer and ed 90° the washer is locked into place, other locking systems are
the outer casing. available, such as cone anchors. Lock anchors come in ceramics
or alloy metals to suit temperature requirements.
Blanket: A flexible unbonded ceramic fibrous insulating material of
reasonably determinate dimensions. Maximum Temperature Rating: The temperature which is used
by the industry as a loose classification of different grades of
Board: A substantially rigid or semi-rigid flat sheet produced by ceramic fiber. This is generally higher than the continuous use limit.
vacuum forming.
Module: A prefabricated unit which can be applied as a lining
Bulk Fiber: Ceramic fibers in the “as-produced” state. block to the inner face of a furnace structure.
Butt Joint: A ceramic fiber wallpaper construction joint where Mortar/Cement: A ceramic-based adhesive for attaching ceramic
edges of adjacent blankets meet. fiber products to other surfaces.
Cold Face Temperature: Term used to denote the outside casing Mullite: A crystalline phase of alumina-silica.
temperature.
Overlap Construction: A construction technique used to accom-
Continuous Use Limit: Long-term (continuous) temperature limit modate shrinkage in ceramic fiber or to improve velocity resistance
for a product installed as a lining. This temperature is based upon in which one edge of a blanket is lapped over an adjacent blanket
product shrinkage, specifically what is considered to be a “man- edge by 4" to 12" and shares a common anchor stud and washer.
ageable” or “controllable” shrinkage. This term is not to be confused
with temperature rating. Paper: A roll product produced from ceramic fibers and organic
binders on conventional paper-making machinery.
Cristobalite: A crystalline phase of silica which will begin to form
above 1800°F. Parquet: A method of installing modular edge-grained forms of
ceramic fiber so that the edge grain of one module is perpendicular
Devitrification: The phase transformation from glass to crystalline to the edge grain of the adjacent modules.
structure.
Rigidizing: The practice of applying an inorganic hardening agent
Edge-grain: The orientation of a fiber system in which strips of to the surface of ceramic fiber (by spray or brush) in order to
ceramic fiber blanket or felt are oriented perpendicular to the plane improve its velocity resistance.
of the furnace casing.
RCF: Refractory Ceramic Fiber.
Felt (Pressed): A flexible sheet product formed from ceramic
fibers and bonded with an organic binder. Shingled Joint: A method of applying double layers of ceramic
fiber blanket in such a way that half the width of each layer overlaps
Heat Loss: The term used to denote the amount of heat being lost half the width of the adjacent layer.
through a lining construction over time, measured in BTU/sq ft/min,
(watts/sq in). Shot: A glassy material formed during fiberization.
Heat Storage: The thermal property of a material wherein heat Textile: Cloth, tape, sleeving, tubing, or other forms manufactured
accumulates in the mass (which in refractories is a function primar- from ceramic fiber yarn.
ily of the material’s specific heat, mass, and temperature rise mea- Thermal Conductivity: The property of material to conduct heat -
sured in Btu/lb/°F (Cal/g/°C). measured in Btu flow per hour through a square foot of area across
Heat Transfer: The study of heat flow mechanisms - conduction, one inch of thickness Btu•in/hr•ft•°F (w/m •C°) .
convection, and radiation. Thermal Resistivity: The property of a material to resist the flow
High Alumina Fiber: A ceramic fiber containing more than 90% of heat; the reciprocal of thermal conductivity.
alumina, giving a high use limit. Mullite fiber is also used in high Thermal Shock: A failure mechanism wherein sudden changes in
temperature applications. temperature bring sufficient thermal mechanical stress in a materi-
High Purity (HP) Fiber: A ceramic fiber produced from synthetic al to cause cracking or spalling. As a general rule, the thermal
alumina and silica. shock resistance of a material is greater as the strength and ther-
mal conductivity of a material increase and as the thermal expan-
Hot Face Insulating Material: The layer of lining insulating mater- sion and modulus of elasticity decrease.
ial that has at least one surface exposed to the full temperature of
the furnace gases. Turbulent Flow: Fluid flow in which the velocity of a given stream
of gas changes constantly both in magnitude and direction.
Kaolin Fiber: A ceramic fiber produced from calcined kaolin.
Vacuum Forming: A method of producing molded shapes and flat
Laminar Flow: The flow of a gas in which the gas stream moves
board by converting fibers into a slurry and vacuuming them onto a
in straight lines parallel to the direction of the flow. screen former.
Layered Lining Wallpaper: Lining that is composed of several Veneer: Layer of ceramic fiber in either blanket or module form
layers and thicknesses of refractory ceramic fiber. which is attached to the hot face of a brick, module or monolithic
Linear Shrinkage: The amount of shrinkage which occurs along lining.
the length of a material after it has been subjected to elevated tem- Wallpaper Construction: The term used to describe a ceramic
peratures and then cooled - measured in percent of original prefired fiber lining construction technique where the blanket is installed on
length. a wall like a roll of wallpaper.
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