US2212411A - Firebrick wall construction - Google Patents

Description

Aug. 20, 1940. w. A. WAITE FIREBRICK WALL CONSTRUCTION Filed July 18, 1958 2 Sheets-Sheet l j IT INVENTOR M a M W ATTORNEY Patented Aug. 20, 1940 OFFICE 2,212,4r1w 1 v FmEBnicK WALL CQNSrrtUCTrON William A. Waite, Providence,- R. I. I Application July 18, 193 8,i fSerial 1N3. 219x19 12 Claims. (01.- rag-n2) U attendee. getting the side viewthereof; and

YA present inventionrelates to furnace wall constructions, and has particular reference to a novel arrangement, of brick therefor. It is the principal object of my invention to providea furnace wall construction designed to overcome mechanical failure due to expansion, and contraction strains on the inner lining of the wall. It; is another object of my invention to provide a wallconstruction which resists the tendency of the inner lining brick courses to bend and buckle inwardly and to'pull away from the portion ofthe wall.

A further object of my invention is to utilize theweight of the inner lining to press the inner lining, courses toward the outer portion. Still another object is to progressively transfer the-weight of the furnace wall from the inner lining. to the cooler outer portion.

. -An additionalobject of myinvention is to pro-' videssimple and effective provision for the uneven vertical expansion and contraction that normally occursin a furnace wall.

1 A further object is to provide a wall construction" comprising a plurality of separate wall panels on the furnace face, each of which may independently expand andcontract and may be removed and replaced with minimum disturbance tothe a'djacent panels and the outer supporting walla 1 With'the'above and other objects and advantageous features in view, my;,.invention consists of. a novel arrangement of parts more fully disclosed in the detailed description following, in conjunction with the accompanying drawings, and more specifically defined in the appended claims.- I y 'In the drawings:

Fig.1 is an elevation of a furnace wall embody ing the novel invention;

Fig. 2 is a vertical section thereof;

--';Fig.-3 is a vertical section of a modified con-:

struction, designed for air cooling; I

Fig. 4a is a plan view of a standard header-used for the outer portion, Fig. 41) being a side elevation thereof;

Fig. 5a is a plan View of a header used for the inner lining, side View thereof;

6.0 is a plan view of another modifiedform o'f header, Fig. 6b being the side view thereof;

and Fig. 5b is a Figs. 7a and 7b are respectivelyv a plan view a; side view of a stretcher;

J Fig. 8a is an end view of a special he'ader, F1g. 81; being the side view thereof;

.Fig.' 9c is a plan view of a further modified form 1 cool-er outer modified form or Figs. l-Qc, and lOb are respectively a plan View and-aside view rof amodified form of stretcher.

One of the most difficult conditions to provide for .inlthez on tru of effect of-theviolently fluctuating expansion and contraction strains in the hotter courses of brick o .the insidelining of the wall, the firebrick being arelatively poor conductor of heat and the temperature dropthrough the wall normally being veryusteep. ,Thus, eight hours or more are required after a cold furnace is put into operation for the wall to heat up to the proper furnace temperature; ,conversely the hot exposed surface face cools off at a much faster rate than the interior. of thewall, when the furnace is shut down Since manyplants operate for a part only of each-gday, with, additional weakend shut downs, the expansionand contraction strains, and particularly in thefurnace lining courses, are very severe andresult in failure of the furnace walls due to mechanicalfailure of the inside courses of brick. q

The verticaland horizontal expansion which periodicallygqocurs, in the hotter section of the wall produces-a very marked tendency for the inside-coursestobend orpull inwardly and so pull away-from the-cooler portion of the wall. The standard typeof firebrick construction relies on the weight of the superimposed wall to hold the inside courses .;to the rest of the wall, it being standard practicegtmuse a strong bond of overlapping;headers. ;through the wall so as to progressivelywtransmit the weight of the superimposed wall totheinherlining. This type of construction-causes the .weight on the supporting headers to become progressively greater in the lower portions of the wall, where the highest temperature andthe most violent fluctuations of temperature occur, ithresultant violent expansion andcontraction. The supporting headers normaly project half their length into the hottest zone of; the-walL-and the projecting half is thus heatedtoya high temperature and is forced to expand; upwardly before any material temperaoreover, noifsuitable provision can be cona furnace wall is the veniently made with standard construction to relieve vertical expansion other than to leave the top of the Wall clear. There is an additional disadvantage with standard constructions in that the refractory qualities of firebrick which are exposed to high temperatures decrease with increase of the super-imposed load, wherefore the exposed brick in the lower part of the furnace Wall are subjected to the most unfavorable conditions, because they are subjected to the maximum load, to the highest temperature, and to the greatest temperature range.

I have found it desirable to use a wall constructlon which more effectively meets these conditions, and thereby assures longer service and lower cost for repairs than it is possible to obtain with the use of standard brick, the construction being applicable to either nace walls of any desired thickness. To this end, I provide special brick which has the same overall dimensions as standard firebrick, and occupies the same space in the wall, so that it may be laid up in the Wall with a standard brick backing by usual brick laying methods. 1

Referring to the drawings, and particularly to Figs. 1 to 3, the furnace wall construction includes a plurality of separate panel sections l5, Which are formed of special brick, the special brick being laid up with standard brick which forms the outer wall portion I6. Each of these panels may independently expand both vertically and horizontally, the brick being so arranged as to bond each panel independently to the outer portion of the wall so as to be independently supported thereby.

Standard brick, as illustrated as H in Figs. 4a and 4b are used to lay up the outer portion of the wall, and the inner lining starts with a brick of the A type, indicated at l8 in Figs. 5a and 5b, half of which lays up with the standard brick used in the outer portion of the wall. B headers, designated l 9 in Figs. 6a and 6b, then overlap the inclined portions of the A headers, and C stretch- H ers such as illustrated at 20 in Figs. 7a and 7b fit or nest together with the A and B headers. There are many possible combinations in which these three bricks can be layed up together, an illustrative combination being shown in Fig. 2, the essential features of the construction residing in the use of inclined joints instead of horizontal joints on the headers between the inside courses of brick onthe furnace face. The joints on the furnace face of the, wall may be changed at any point from horizontal to inclined and back to horizontal by the use of standard feather edges, a special feather edge header D illustrated at 25 in Figs. 8a and 8b being preferred to make a firm base for starting the change from hori-' zontal to inclined joints as shown in Fig. 2.

The above described construction locks the inner lining firmly to the rest of the wall by its own weight, and at the same time relieves the inner lining from the progressively increasing weight of the superimposed wall. This relief is accomplished by the overlapping of A and B headers so that the weight of the superimposed inner lining is progressively transmitted through the inclined portion of the A header beneath, to the 'cooler outer part or section of the wall. Each course of B headers, irrespective of, its position in the wall, thus supports the superimposed load of a relatively small number of courses of stretchers. The exposed furnace face of the wall is therefore divided into separate horizontal panels, separated by expansion joints each self solid or air cooled fursupporting and each consisting of B headers and a small number of superimposed courses of C stretchers. Although any angle of incline found desirable may be used, the preferred angleis approximate1y30, more exactly 29 3', so as to provide bricks in which the rise is in the ratio of the thickness of a standard firebrick to its width.

The projecting portions of the A and B headers are. thus cantilevers which each support a load uniformly distributed over its length, the maximum force acting vertically downward being exerted at the point of support and diminishing to zero at the furnace face of the wall. The load on each brick in the inner lining thus progressively falls and is negligible at the hottest section nearest the face. Moreover, the weight on each successive brick is progressively reduced so that the top stretchers in any section on the exposed face support no load at all.

The above described construction has great advantages when compared with standardfirebrick construction, as the load on the exposed face of the brick at the lower, hotter half is very much less, and depends on the small number of brick in each pan-e1. The inclined arrangement of the inner lining provides a gravity load on theinner lining which tends to press the inner lining towards the outer wall portion, whereby abreaking of headers does not result in a separation of the inner lining, and instead will cause the inner lining to settle on the panel-below and to hug the outer wall portion with aforce dependent on its Weight. The relief of the super-imposed weight on the hot lining and the locking of the inner lining firmly tothe rest of the wall permits more effective provision for expansionthan is intervals as required as illustrated in Fig. 1. 7

Vertical expansion is provided for by leaving an open horizontal joint beneath spaced courses of B headers, as indicated in Figs. 1 and 2, the described arrangement in effect dividing the entire inner face of the wall into comparatively small rectangular panels which are self supported and are free to move both Vertically and horizontally as they expand and contract, independently of the adjacent panels.

The provision of separate panels facilitates the making of necessary replacements, as vany panels, including all of the supporting B headers, can be removed and replaced with a minimum of disturbance to the rest of the wall. The replacements require a minimum of new material .as compared with those necessary to replace a bonded standard firebrick wall, which uses more header than stretcher courses on the furnace face. Instead of replacing all the headers, as is necessary when the face of a standard furnace wall is replaced, the novel construction only requires a replacement of a large number of stretchers and a relatively small number of head ers, thus lowering the cost of repairs. Q

The above described construction may also be applied 'to air cooled walls which have lanes or channels behind thehot face through which air is passed to cool the refractories. The thickness of the wall in this typeof constructionmust be reduced to a relatively thin section in order to effectively lower t e temperature in the'heated portion. This requires special steel supports for standard type walls,as a relatively thin section is too 2. weak to :carryi the superimposed. weight; moreover, the supporting steel work, and especially the hangers holding zithe inner-lining, must be protected from high -temperatures, thus requiring thick refractory? shapes to protect the hangers: Since :the novel/construction heretofore dcscribedidivides-the inner lining: intoself supporting 1 sections which: do not .support substantial weight, thenovel construction may be readily adapted to air cooled walls, the exposed face being thin enough toeffectively reduce-the temperature onthe hotface-without requiring special supporting steel work and vulnerable metalhangers." v

-Referring to-Fig. 3, theinner lining is "made up of special headers-El, as shown at 22 inFigs. 9a and 9b, and superimposed stretchers F,-designated 23 in Figsr la and-b, which are joined together as illustrated to provide air passages 'ly suitable for air cooling, as the'E header which carries the stretcher load is very effectively air cooled. The brick in the exposed inner lining is also effectively air cooled, except the F stretcher at the top; this stretcher, however, carries no superimposed load. I

While I have described a specific constructional embodiment of my invention, itis obvious that any change in size and shape of the firebrick and in their arrangement, may be made to suit tions without departing from the spirit and the scope of the invention as defined in the appended claims.

I claim:

1. In a furnace wall construction, an outer section of standard brick, and an inner lining,

said inner lining having a plurality of headers bonded to said outer section, said headers having rhomboidal portions extendingfrom said outer section, rhomboidal headers on said first headers and projecting therefrom, and rhomboidal stretchers on said headers.

2. In a furnace wall construction, an outer section of standard brick, and an inner lining, said inner lining having a plurality of headers bonded to said outer section, said headers having rhomboidal portions extending from said outer section, rhomboidal. headers onsaid first headers and projecting therefrom, and rhomboidal stretchers on said headers, the inner liningcomprising horizontal sections formed of sets of stretchers mounted on vertically spaced header courses, the sections having horizontal expansion joints therebetween.

3. In a furnace wall construction, an outer section of standard brick, and an inner lining, said inner lining having a plurality of headers bonded to said outer section, said headers having rhomboidal portions extending'from said outer section, rhomboidal headers on said first headers and projecting therefrom, and rhomboidal stretchers on said headers, the sections being divided into panels havingyertical expansion joints therebetweenr e v 4. In a furnace wall construction; an outersection of standard brick, and aninnerlining, said inner lininghaving a plurality. of headers bonded to said outer section, said headershaving rhomboidal portions extending from said outer-sec-= tion, rhomboidal headers .on-said' first headers and projecting therefrom,., and 'rhomboidal stretchers on said second headers spaced from said outer section, whereby air passageways are provided between said lining and said outer section. I I

5. In a furnacewall construction, an outer.-

section of standard brick,- and' an innerlining, said inner lining having a plurality of headers bonded to said outersection, said headers-having rhomboidal portions extending from said: outer section, rhomboidalheaders on said first. head ers and projecting therefrom, and rhomboidal. stretchers on saidsecondheaders spaced from said outer section, whereby air passagewaysare;

provided between said lining and-.saidouter sec-. tion, the inner lining. comprising horizontal sec-.-= tions formed of sets of stretchers mounted on vertically spaced header courses, the sections having horizontal expansion joints therebe tween. 7

6. In a furnace wall construction, an outer section of standard brick, and an inner lining,

, said inner lining having a plurality of headers bonded to said outer section, said headers having rhomboidal portions extending from said outer section, rhomboidal headers on said first. head-v ers and projecting therefrom, and rhomboidal stretchers on said second headers spaced from said outer section, whereby air passageways are provided between said lining and said outer section, the sections being divided into panels having vertical expansion joints therebetween.

'7. In a furnace wall construction, an outer the requirements f different furnace.instaua section of standard brick, and an inner lining,

said inner lining having a plurality of headers bonded to said outer section, said headers having rhomboidal portions extending from said outer section, rhomboidal headers on said first headers and projecting therefrom, and rhomboidal stretchers on said second headers spaced from said outer section, whereby air passageways are provided between said lining and said outer section, said second headers and said stretchers having cooperating locking shoulders.

8. In a furnace wall construction, an outer section of standard brick, and an inner lining, said inner lining having a plurality of headers bonded to said outer section, said headers having rhomboidal portions extending from said outer section, rhomboidal headers on said first headers and projecting therefrom, and rhomboidal stretchers on said second headers spaced from said outer section, whereby air passageways-are provided between said lining and said outer section, the inner lining comprising horizontal sections formed of setsof stretchers mounted on vertically spaced header courses, the sections having horizontal expansion joints therebetween, said second headers and said stretchers having cooperating locking shoulders.

9. In a furnace wall construction, an outer section of standard brick, and an inner lining, said inner lining having a plurality of headers bonded to said outer section, said headers having rhomboidal portions extending from said outer section, rhomboidal headers on said first iii boidal stretcher's on :said second headers spaced from said outer section, whereby-air passageways are provided between said lining =andlsaid outer section, the sections 'being divided into panels havin vertical expansion joints therebetween, said second headers and said-stretchershaving cooperating locking shoulders. i

10. In a furnace-wall construction an-outer section, and an .innerv lining, said inner lining comprising a plurality of headers bonded to said outer section and-having portions upwardly inclined with respect thereto, a plurality of'headers each mounted on the inclined portion of one of said first-named headers and having the in- 3 ner ends thereof locked to the outer section, and

stretchers similarly inclined and mounted on said headers. i.

11. In a furnace wall-construction, anouter section, and an inner lining, said'inner-lining comprising a plurality of. headers bondedto said outer section and having portions upwardly inv clined with respect-thereto, a plurality of headers each mounted ontheinclined portion of one of said first-named headers and having the inner ends 'thereofilocked to the outer section and stretchers similarly inclined and mounted onsaid headers; 2. .the' inner lining comprising horizontal 'sections'formed. of sets .of stretchers mounted'uon vertically spaced header courses, the sections havinghorizontal expansion joints therebetween.

12,.In a-furnace wall: construction, an outersection;v and/an inner lining said inner lining comprising a-plurality bf headers bonded to said outer, section and having portions upwardly inclined-with respect "thereto, a plurality of head-v ers each mounted onthe inclined portion'of one ofsaidmfirst named' headers and'having the inner ends thereof locked to the outer section,and

stretchers similarly; inclined and mounted on saidlheaders; the. inner lining comprising vertical sections formed .of sets. of. stretchers mounted-on vertically spaced'header courses, the sections having-v horizontal expansion joints therebetw'een, the sections being divided into panelswhaving vertical expansion joints therebetween.- 7 I; WILLIAM A.-WAITE- 2

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