JP2020020224A - Mortar joint formation method - Google Patents

Abstract

To provide a method of forming mortar joints when constructing a building by stacking large blocks 1, in which even if the number of bricklayers, such as furnace builders, is reduced, buildings with good installation accuracy can be constructed efficiently.SOLUTION: In a method of forming a mortar joint 4 when constructing a building by stacking the large blocks 1 of refractories of 300 kg or more per piece, a guide mechanism for adjusting the horizontal position of the large block to a predetermined position and a spacer 3 for adjusting the vertical position of the large block 1 to a predetermined position are arranged. The large block 1 is arranged at a predetermined position on the spacer 3 according to the guide mechanism. After the large block 1 is arranged at the predetermined position, the guide mechanism is removed. Thereafter, a mortar leakage prevention process is performed on the opening of the joint 4, and mortar is press-fitted from a predetermined pressure inlet 6 provided in the large block 1.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a mortar joint forming method.

  In a coke oven type coke oven, carbonization chambers and combustion chambers are alternately arranged in the furnace group length direction (furnace width direction), a furnace top is arranged at the upper part of the carbonization chamber and the combustion chamber, and a heat storage chamber is arranged at the lower part. I have. The part between the combustion chamber and the heat storage chamber is also called a bellows part. Sole flew is arranged in the lower part of the heat storage room. Usually, the dimensions of the carbonization chamber are about furnace height 4 to 7.5 m, furnace width 350 to 550 mm, and furnace length 13 to 17 m. The combustion chamber is composed of a row of combustion chamber flew arranged in the furnace length direction. The partition wall between the carbonization chamber and the combustion chamber, the partition wall between the combustion chamber flues, the furnace top, the bellows, the heat storage chamber, and the sole flue are all formed of a brick structure of refractory bricks. For example, a coke oven furnace having 50 carbonization chambers (hereinafter simply referred to as "coke oven") is configured using a total of one million refractory bricks.

Existing coke ovens are now aging nationwide after an operating period of 40 to 50 years, and the need to construct a new coke oven is imminent.
Conventionally, coke ovens have been constructed by furnace builders manually refractory bricks. In the manual construction, it is necessary to repeatedly apply mortar to each refractory brick with a trowel and pile up the mortar. Furthermore, each refractory brick used in a coke oven weighs more than ten kilograms, and the work of stacking the refractory bricks is extremely hard work.
Further, the coke oven requires a complicated combination of various types of refractory bricks of various shapes and sizes, and the installation accuracy must be kept within ± 2 mm. For that purpose, a large number of skilled furnace-builders are required, but skilled furnace-builders are aging and it is becoming difficult to secure a large number of them.

In order to reduce the number of necessary furnaces by shortening the construction period, a plurality of refractory bricks are piled up to a predetermined size in a wide area that is easy to work away from the furnace construction site. A prefabricated construction method is known in which a large block is integrated by using a large block, and the large block is assembled at a furnace construction site to stack a coke oven (Patent Documents 1 to 3).
In addition, in order to make the refractory bricks large blocks, a precast method is also known, in which water is added to a granular refractory composition, kneaded, poured into a mold, and dried to form a large block of refractories. (Patent Document 4).
The prefabrication method or the precast method reduces the number of blocks to be piled up at the furnace construction site due to the large number of refractory blocks per block, shortening the work at the narrow furnace construction site, It is said that the work efficiency is good and the furnace construction period is short. In particular, the pre-casting method has good work efficiency because the number of blocks to be stacked is reduced.
Patent Document 5 discloses a suitable component composition of a precast block refractory for a coke oven.

JP-A-2015-08300 JP-A-2006-223647 JP-A-2006-222758 JP 2016-210643 A International Publication WO2017 / 146254

  Conventionally, when building refractory bricks or blocks (hereinafter, referred to as "blocks") at a furnace construction site, regardless of the prefabricated method or precast method, mortar is first applied to the refractory blocks. Paint. Thereafter, the refractory blocks are stacked, and the mortar applied to the refractory blocks forms joints between the refractory blocks. That is, conventionally, all such mortar pre-coating methods are used.

Joints formed at the time of stacking blocks can be classified into horizontal joints mainly oriented in the horizontal direction and vertical joints oriented in the vertical direction.
When the blocks to be stacked are large blocks, the vertical joint length becomes long, and a high technology is required to pre-coat the mortar of the joint with a predetermined thickness.

Also, with regard to horizontal joints, in the mortar pre-coating method, it is difficult to apply mortar uniformly according to the required joint thickness in order to build a furnace with a predetermined installation accuracy in the furnace height direction Z. Therefore, in the mortar pre-coating method, an operation called a kneading operation is necessary in order to adjust the thickness of the joint to a predetermined thickness.
In the kneading operation, a spacer having the same thickness as a required joint is arranged on a block of the placed refractory, and mortar is applied to be thicker than a target joint. Then, another refractory block is pushed back and forth (right and left) back and forth until hitting the spacer, and excess mortar is pushed out from the joint and discharged.

  In the massaging work, the refractory blocks are moved manually, so a large number of prefabricated construction methods or precast construction methods, in which the size of each refractory block is as large as 1 ton, require a large number of people. . Further, the furnace height direction Z (vertical direction) can be determined to a predetermined joint thickness by the spacer, but the furnace width direction X and the furnace length direction Y (horizontal direction) deviate from predetermined positions by the kneading operation. The installation accuracy in the coke oven construction is required to be within ± 2 mm in the furnace width direction X, the furnace length direction Y, and the furnace height direction Z. Therefore, in kneading work, not only the number of people but also the installation position is required. It is necessary to re-adjust and to build many furnaces that can stack refractory blocks with high installation accuracy.

  The number of blocks to be piled up at the furnace construction site by making large blocks of refractory blocks by prefabrication method or precast method to re-adjust the mortar pre-coating, kneading work and installation position of vertical joints However, it was not always possible to reduce the number of furnaces required at the furnace construction site.

  In view of the above, the present invention, in the method of forming a mortar joint when building a building such as a coke oven by stacking large blocks, even if the number of bricklayers such as furnace builder is reduced, efficient And a mortar joint forming method capable of constructing a building with good installation accuracy.

The gist for solving the problem of the present invention is as follows.
(1) In a method of forming a mortar joint when building a building by stacking large blocks of refractories of 300 kg or more per piece,
A guide mechanism for adjusting the horizontal position of the large block to a predetermined position,
Arranging a spacer for adjusting the vertical position of the large block to a predetermined position,
The large block is arranged at a predetermined position on the spacer according to the guide mechanism,
After arranging the large block at a predetermined position, remove the guide mechanism,
After that, mortar leakage prevention treatment is applied to the joint opening,
Mortar joint forming method, characterized in that mortar is press-fitted from a predetermined pressure inlet provided in the large block or joint.
(2) For the mortar of the horizontal joint, first apply the large block before arranging the large block at a predetermined position. The mortar joint forming method according to (1), wherein the mortar is press-fitted from the press-in port.

  According to the present invention, since the large block can be positioned by the spacer and the guide mechanism, even if the large block is arranged by a heavy machine such as a crane, it can be smoothly arranged at a predetermined position. Further, since the mortar is press-fitted after positioning the large block by the spacer and the guide mechanism, there is no need to move the large block, and the installation accuracy is excellent. In addition, when the vertical joints are not manually painted, it is not necessary to hand-paint the joints having a predetermined thickness with high precision in advance, and the number of furnace construction workers having advanced technology can be reduced. Further, when the mortar of the horizontal joints is not hand-painted, the hand rubbing work becomes unnecessary, so that the required number of furnace-building works can be reduced, and the mortar construction efficiency is improved.

It is a perspective view explaining the process of arranging a large block in a predetermined position. (A) It is a side view of the furnace width direction X about the process of arrange | positioning a large block in a predetermined position. (B) It is a side view of the furnace length direction Y about the process of arrange | positioning a large block in a predetermined position. (A) It is a top view of the large block arrange | positioned. (B) It is a side view of the large block arranged. (A) It is a side view which shows that the opening part of the joint of the arrange | positioned large block was sealed. (B) It is a key map showing the flow of the mortar which flows to the joint of the arranged large block. It is a figure which shows the case where mortar is press-fitted in a vertical joint, (A) is a top view, (B) is a side view.

  Hereinafter, mortar joint formation in the case of constructing a coke oven will be described as an example, but the present invention is not limited to the construction of a coke oven.

The present invention is based on the premise that the large blocks are stacked. The large block refers to a refractory block in which one unit weighs 300 kg or more. More preferably, one unit is a large block of 800 kg or more. The large block may be one in which a plurality of refractory blocks are joined together by mortar by a prefabricated construction method, or one in which a large refractory large block is directly manufactured by a precast construction method. Since the work load at the furnace construction site is reduced by using a large block, the furnace can be efficiently constructed.
When constituting the combustion chamber of the coke oven, it is preferable that the large block has a height equal to or more than 1/20 of the height of the carbonization chamber and a width equal to the width of the combustion chamber (furnace width direction X).
When the heat storage chamber of the coke oven is configured, the large block preferably has a height of 1/6 or more of the height of the heat storage chamber and a width of 1/2 or more of the width of the heat storage chamber (furnace width direction X). .
When constituting the sole flue of a coke oven, the large block has a height equal to or greater than half the height of the sole flue and a width equal to or greater than half the width (furnace width direction X) of one set of sole flue. Is preferred.
When configuring the combustion chamber, heat storage chamber and sole flue of the coke oven, the size of the large block is 750 mm or less in height, 1000 mm or less in width (furnace width direction X), and 2000 mm or less in length (furnace height direction Z). Is preferred.

The large-sized precast refractory block used in the room-type coke oven of the present invention is required to have high hot strength and stable expansion behavior under load at high temperatures. In order to achieve such quality, it is preferable to use the following raw material composition. That is, as described in Patent Document 5, the content of the SiO ₂ component as a main component is generally 65% by mass or more and 99% by mass or less, and the P ₂ O ₅ component is contained by 0.3% by mass or more and 2% by mass or less. contains. As the SiO ₂ component source, the amount of fused silica is preferably 65% by mass or more, the amount of silica is 17% by mass or less, and the amount of fumed silica is preferably 0.5% by mass or more and 15% by mass or less. By setting the blending amount of the fused silica to 65% by mass or more, shrinkage due to dehydration during drying can be canceled. The P ₂ O ₅ component functions as a binder component. By applying the P ₂ O ₅ component as the binder component, it is possible to stably control the swelling behavior under load at high temperatures while maintaining high hot strength. The amount of the alkaline earth metal compound is preferably 0.05% by mass or more, and more preferably 1.9% by mass or less. The above-mentioned siliceous raw materials and phosphate are blended as raw material blends, and if necessary, organic fibers, dispersants, curing accelerators, curing retarders, sintering aids, etc. are blended, and the resulting raw material blends After adding an appropriate amount of construction water to the product, kneading, molding, curing, and demolding can be performed by a usual method for producing a large-sized precast refractory block refractory.

Since each refractory block to be stacked becomes a large block, the weight per unit becomes large, so that it becomes difficult to stack the large blocks by hand as in the related art. It is also difficult to hand-paint the mortar that forms the joints of the large blocks, perform the hand rubbing of the mortar, readjust the installation position, and increase the installation accuracy.
Therefore, in the present invention, joints are formed by press-fitting the mortar without performing the hand-painting and hand-rubbing operations of the mortar.

The specific procedure will be described in detail below.
FIG. 1 is a view in which a large block 1 having three holes in the furnace height direction Z is to be arranged at a predetermined position, FIG. 2 is a side view thereof, and FIG. FIG. 3B is a side view of the large block 1 arranged as viewed from above, and FIG.

Since the large blocks 1 are heavy, they are stacked by a heavy machine such as a crane. Since heavy machinery is used, the burden on the furnace builder is reduced, and the number of required furnace builder can be reduced.
However, when the large block 1 is arranged at a predetermined position by a heavy machine, the installation accuracy of the heavy machine is ± 10 mm, which is less than the installation accuracy required for the coke oven construction of ± 2 mm. In addition, the safety of workers must be ensured.

  Therefore, the guide mechanism 2 shown in FIGS. 1 and 2 and the spacer 3 shown in FIGS. 1 to 3 are arranged in order to safely and accurately arrange the large block 1 at a predetermined position by a heavy machine. When arranging the large block 1, the guide mechanism 2 aligns predetermined positions in the horizontal direction, that is, the furnace width direction X and the furnace length direction Y, and the spacer 3 moves in the vertical direction, that is, the position in the furnace height direction Z. To a predetermined position. After the arrangement of the guide mechanism 2 and the spacer 3, the large block 1 is arranged at a predetermined position by a heavy machine. Here, the order in which the guide mechanism 2 and the spacer 3 are arranged is not particularly limited as long as it is before the predetermined large block 1 is arranged.

  By arranging the guide mechanism 2, even if the large block 1 is arranged with a heavy machine having a low installation accuracy, it can be arranged at a predetermined position in the furnace width direction X and the furnace length direction Y with an installation accuracy of ± 2 mm. . Further, since there is no need for manual re-adjustment for precise installation accuracy, there is no need for a person to work under the large block 1 and the large block 1 can be safely disposed.

  As shown in FIGS. 1 and 2, for example, the guide mechanism 2 may have a plate-like shape in which an upper portion thereof is opened obliquely from below to above (furnace height direction Z). If it is made into such an obliquely open plate shape, the large block 1 slides down the surface of this open plate, and the horizontal position is set to a predetermined position, that is, a predetermined furnace width direction X and a furnace length direction Y. The large block 1 can be stored in the position of. The surfaces opened obliquely from below to above may be formed in the furnace width direction X and the furnace length direction Y by one guide mechanism 2. Further, two types of guide mechanisms 2 for adjusting the furnace width direction X and the guide mechanism 2 for adjusting the furnace length direction Y may be arranged.

  Then, it is preferable that the lower portion of the guide mechanism 2 is fixed so as to be along the side surface of the previously installed base portion or large block. For fixing, an adhesive or a tape may be used in consideration of removal later. Alternatively, it is preferable that the shape viewed from above is an H shape or a U-shape so that the base portion or the large block, etc. installed earlier can be fixed therebetween. As the material of the guide mechanism 2, it is preferable to use a plate-like material having a certain strength, such as a metal plate or a plastic plate.

  On the other hand, to adjust the vertical position to a predetermined position, that is, to a predetermined position in the furnace height direction Z, as shown in FIG. 3, the spacer 3 is arranged at a predetermined position between the large blocks 1. Do. The spacer 3 also has a function of adjusting the thickness of the joint 4 in the furnace height direction Z to a predetermined thickness. Note that the spacer 3 remains in the joint 4 even after the joint 4 is formed. Therefore, it is preferable to manufacture the spacer 3 by solidifying the mortar so that the spacer 3 is made of the same material as the mortar forming the joint.

  When the large block 1 is arranged at a predetermined position as shown in FIG. 3, the guide mechanism 2 is removed. Unless the guide mechanism 2 is removed, the mortar cannot be pressed. The arranged large block 1 is placed on the spacer 3 and not on the guide mechanism 2, so that the guide mechanism 2 can be removed after the large block 1 is arranged.

  After the guide mechanism 2 is removed, as shown in FIG. 4A, the opening of the joint 4 is subjected to a mortar leakage prevention process using a seal tape 5 or the like. Although not shown in FIG. 4A, not only the horizontal joints 4 but also the openings of the vertical joints 4 are sealed so that mortar can be pressed into the vertical joints 4 as well. . Thereafter, mortar is press-fitted from a predetermined pressure inlet 6 provided in the large block 1. As shown in FIG. 4 (B), the mortar press-fitted from the pressure inlet 6 spreads over the joint 4 as a mortar flow 7 to form the joint 4. When constructing a coke oven, the thickness of the joint 4 is preferably 2 to 6 mm, more preferably 3 to 5 mm.

  As described above, in the present invention, the mortar construction is performed by press-fitting after the large block 1 is arranged, so that the mortar hand painting and the mortar kneading work can be omitted. After the large block 1 is arranged, it is not moved, so that it is not necessary to readjust the installation position for improving the installation accuracy. For this reason, the furnace builder need only supervise the mechanic who operates the heavy equipment to place the large block 1, and the number of necessary furnace builder can be greatly reduced.

  FIG. 5 shows that the mortar of the horizontal joint 4H is pre-coated before the large block 1 is arranged at a predetermined position, and the mortar of the vertical joint 4V is subjected to the mortar leakage prevention processing at the opening of the joint. 3 shows a mortar joint forming method of the present invention in which mortar is press-fitted through a press-in port 6 provided. Regarding the horizontal joint 4H, before arranging the large block 1 at a predetermined position, a spacer having the same thickness as the necessary joint is arranged on the refractory block already placed, and the target joint is set. The mortar is applied thicker than the thickness (first coating). Mortar is not pre-coated on the vertical joints 4V. A kneading operation after placing the large block 1 is required, but it is not necessary to pre-coat mortar on vertical joints with a predetermined thickness accuracy.

  The above preparation and the arrangement of the guide mechanism for adjusting the horizontal position of the large block to the predetermined position are performed. After the large block is arranged at the predetermined position, the guide mechanism is removed, and the sealing tape is attached to the opening of the vertical joint 4V. The mortar leakage prevention process is performed by 5 or the like. The seal tape 5 is provided on the vertical joint 4V opening on the side surface of the large block, and the mortar leakage prevention processing is performed on the other part of the vertical joint 4V opening on the upper surface of the large block using the seal tape 5 or the like. Apply. The portion of the vertical joint 4V opening on the upper surface of the large block, where the seal tape 5 is not provided, becomes the mortar pressure inlet 6. Then, mortar is press-fitted from the press-in port 6. The mortar press-fitted from the press-in port 6 spreads in the vertical joint 4V and forms the joint 4.

  As described above, according to the present invention, the work of stacking refractory blocks is made into a large block, mechanized, and mortar is pressed in, so that the mortar construction efficiency is improved, and the labor of a bricklayer such as a furnace builder can be reduced. Also, since the installation accuracy is good, the construction of the building in which the large blocks 1 are stacked can be performed at low cost, safely, and in a short construction period.

      DESCRIPTION OF SYMBOLS 1 ... Large block, 2 ... Guide mechanism, 3 ... Spacer, 4 ... Joint, 4H ... Horizontal joint, 4V ... Vertical joint, 5 ... Seal tape, 6 ... Press-in, 7 ... Flow of mortar, X ... Furnace width direction, Y: Furnace length direction, Z: Furnace height direction

Claims (2)

In the method of forming mortar joints when building a building by stacking large blocks of refractories of 300 kg or more per one,
A guide mechanism for adjusting the horizontal position of the large block to a predetermined position,
Arranging a spacer for adjusting the vertical position of the large block to a predetermined position,
The large block is arranged at a predetermined position on the spacer according to the guide mechanism,
After arranging the large block at a predetermined position, remove the guide mechanism,
After that, mortar leakage prevention treatment is applied to the joint opening,
Mortar joint forming method, characterized in that mortar is press-fitted from a predetermined pressure inlet provided in the large block or joint.   For mortars with horizontal joints, the large blocks are pre-coated before arranging the large blocks at predetermined positions. For mortars with vertical joints, the mortar leakage prevention treatment is applied to the openings of the joints, and the mortar is provided at the joints. The mortar joint forming method according to claim 1, wherein the mortar is press-fitted.

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