Capital Equipment News August 2023

HEAVY-DUTY TRAILERS

meaningless if the quality is poor and results in failures. Refractory issues, such as spiralling and twisting, account for as much as 50% of unscheduled outages and are almost always tied to the quality of the installation. Downtime aside, the brick itself is a large investment that is wasted if it’s improperly installed and fails prematurely. An important aspect of achieving a tight, high-quality installation is a bricking machine that fits the kiln and accounts for any distortions, conical sections or ovality. Bargain machines are bargains because they are manufactured with a one-size fits-all approach. They won’t fit perfectly, which can result in air gaps between the shell and brickwork and interlocking rings. Then it’s a matter of when, not if, the premature failure will happen. The initial investment will be higher, but there are bricking machines on the market that are custom designed to fit the kiln and can provide reliable, quality installations, double arch, for example, is designed to be fully adjustable inside the kiln to accommodate distortions or tapered areas. Even if there are irregularities in the kiln, the arch holds each brick firmly against the kiln shell until the key brick is installed. Then the master valve retracts or extends all cylinders simultaneously, allowing the arch to advance to the next row. This ensures a tight fit. The cut-away section for keying is also critical. It gives the keying mason a clear view of the previously keyed ring. The mason can then use that ring as a guide and will immediately see any open space between bricks. Should there be any sagging, it can be immediately corrected. Bargain machines have a solid arch, giving no such assurances that a problem can be identified and addressed immediately. The mistake becomes apparent when brick starts falling out. By thinking long-term about the kind of installation your bricking machine will deliver, you are not only guarding against downtime and safety risks, you’re also protecting your investment in the brick. And a quality bricking machine that is custom designed to fit the kiln and offers a dual arch and a keying section virtually eliminates the risk of loose brick. A bargain machine that lacks these design elements cannot make the same claim. b twice a year, for 20 to 30 years. The elements of a custom, high productivity bricking machine are also elements that help achieve precision that prevents unplanned, costly problems. The

Plants that want to complete maintenance as quickly as possible and have the best quality installation must make sure to invest in equipment that is not the least expensive to buy – but the least inexpensive to own.

Productivity Setup is just one aspect of an efficient refractory installation process. A well designed bricking machine can significantly improve installation productivity and save the operation thousands of dollars in labour with a single use. Consider arch design. Most bargain bricking machines have only a single arch. Some bricking machines are designed with a double arch, making it possible for a crew to install a second ring of brick while the first is being keyed, doubling productivity. Using a bricking machine with a dual arch, a crew can complete up to one metre of brick per hour compared to 0.5 metres with a single arch machine.

Keying access is another design feature that has a major effect on productivity. A cut-away section in the front arch allows keying masons to have an unobstructed area and see the previously keyed ring as a guideline when placing bricks. Bargain bricking machines typically don’t include an opening in the arch, which means the installers must try to reach around the arch, reducing the speed and quality of installation. The cut-away section is a simple but effective design element that can save up to 37.5 hours per job. Quality Installation A quick installation and the savings associated with it, however, are

CAPITAL EQUIPMENT NEWS AUGUST 2023 24