Pyro-Bloc M Module: Design and Installation Guidelines
Pyro-Bloc M Module: Design and Installation Guidelines
Pyro-Bloc M Module: Design and Installation Guidelines
Pyro-Bloc ®
M Module
Design and installation guidelines
THERMAL CERAMICS
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Table of contents
1 Overview of the Pyro-Bloc® Module
Pyro-Bloc Module history and Pyro-Log™ base............................................................. 03
Pyro-Bloc Module composition and hardware overview................................................04
Pyro-Bloc M-Module at a glance ......................................................................................06
Pyro-Bloc velocity.............................................................................................................07
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THERMAL CERAMICS
Pyro-Bloc® Module
For more than 50 years, the Thermal Ceramics Pyro-Bloc Module
has been the industry standard for furnace, boiler and kiln linings.
For more than 50 years,
This design and installation manual will cover the Pyro-Bloc Modules,
boiler and kiln linings.
hardware options, recommended installation instructions and typical lining
and design details that are common across many industrial applications in
markets from Petrochemical to Iron and Steel to Aluminum.
All Pyro-Log fibre is produced with a special lubricant that allows the fi-
bres to be intensely needled to attain densities up to 15 pcf (240 kg/m3).
The lubricant also adds pliability which allows true multi-directional
compression during installation. At moderate temperatures, typically no
more than 400°F (204°C), this lubricant burns out and the fibre mass
becomes rigid.
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Fibre grade offers varying features and benefits dependent upon your application,
atmosphere, and operating temperature. Technical aspects of the fibre grade should be
discussed with your local Morgan Advanced Materials Account Manager to ensure the best
Pyro-Bloc Module is selected for your application requirements.
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THERMAL CERAMICS
The internal anchor hardware is stainless steel for the Pyro-Bloc M Module.
Pyro-Bloc Studs, nuts and installation tools are purchased separately. The installation
M Module equipment and tools described in this manual have been developed to ensure
hardware a quick, reliable installation.
(standard)
Pyro-Bloc
T-Bar Module
hardware
Full T-Bar Yoke between
Corner Modules
Hex Nut
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Pyro-Bloc® M Module
The Pyro-Bloc M and M2 Modules are often used in furnace lining
system designs where a corrosion barrier on shell is required.
12” 12”
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THERMAL CERAMICS
Turbulent flow occurs in areas that restrict or dramatically change the flow characteristics. In these areas it is important to consider a
lining that has a higher velocity resistance for improved longevity and performance.
Coatings
With the application of specific coatings, it is possible to raise the velocity resistance of a hot face. Coatings are generally spray applied and
are typically either silica or alumina.
Caution should be exercised with coatings. Some coatings can reduce the temperature capability of the fibre.
Consult with your Morgan Advanced Materials Account Manager.
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THERMAL CERAMICS
Prior to installing Pyro-Bloc M Modules, it is necessary to lay out the required stud pattern and weld the studs in place. The
specific operating conditions for your particular furnace will determine the need for the next recommended lining and installation
considerations - a stalastic coating, back-up blanket or vapor barriers.
The stalastic coating can now be applied to the steel casing. Depending on the design, a layer of Thermal Ceramics Blanket for
back-up as well as a layer of stainless steel foil for a vapor barrier may be installed.
Once the studs and back-up materials are in place, our recommended installation steps of the Pyro-Bloc M-Modules can begin.
The yoke in the Pyro-Bloc M Modules have an offset to allow for the stud to be in the center of the module.
Pyro-Bloc M Modules are easy to cut or trim to allow for obstructions such as burners or peep sites. Best results will be achieved
if the module is trimmed equally from opposite sides of the module, so that the stud will remain centered as closely as possible
as illustrated in below. It is best to cut less than what is necessary and compress the module into place to ensure the tightest
possible joint.
Length
Cutlength
)
Length
o
less than module
Cut
Original Module
Original module
Length
Length
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Site Preparation:
• It is required that chalk lines be applied to the walls and roof prior to the installation of any Thermal Ceramics
Pyro-Bloc M Modules.
- M Modules: chalk lines show compressed, stud-to-stud dimensions of the module installation
• Roof installation recommendations for the Pyro-Bloc M Modules are to typically install in a parquet pattern.
• Side wall installation recommendations for the Pyro-Bloc M Modules are to install in a soldier course pattern with
batten strips.
• Bullnose areas, which cause problems for other modular systems, are easily accommodated by Pyro-Bloc Corner-Bloc
Modules. Pyro-Bloc Corner Modules are typically installed using the T-Bar hardware system. Images on pages 18-19
illustrate anchoring options for Pyro-Bloc Corner Modules.
• When cutting and fitting of Pyro-Bloc M Modules is required, best results will be obtained by trimming equally from opposite
edges of the module to keep the stud centered as much as possible. It is recommended to cut less than necessary and
compress the module into place to get a good tight joint.
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THERMAL CERAMICS
Equipment:
Pyro-Bloc M Modules requires the following equipment:
• M Modules • Welding machine
• Stud and nut hardware (sold separately) • Guide rod
• Compression box • Ratchet or drill
• Compression funnel • Plastic thread covers (used with back-up lining or stalastic coating) optional
• Steel slide plate
Morgan Advanced Materials recommends that when selecting the stud welding equipment, that you select a stud welding system
similar to the Nelson Stud Gun and Welding Unit, Miller Stud Welding, or a similar reputable welding gun and welding machine.
Transformer /
Rectifier Power Disconnect Switch
Source
Control Cable
Workpiece Cable
and Clamp
(Positive)
Welding Cable
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Chuck
Stud
Ferrule
a. Gun is properly positioned. b. Trigger is depressed and stud is lifted, creating an arc.
c. Arcing period is completed and stud is plunged into the d. Gun is withdrawn from the welded stud,
molten pool of metal on the base metal. and ferrule is removed.
Bending Tool
Bushing
Stud
Weld
Test Plate
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THERMAL CERAMICS
a. Good stud weld with a good flash formation b. Stud weld in which plunge is too short
e. Stud weld made with insufficient heat f. Stud weld made with excessive heat
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Installation Steps:
Now that the site preparation work and testing of the installation equipment is complete, it is time to begin installation of the
Pyro-Bloc M Module. Follow these simple steps to ensure your Pyro-Bloc M Modules are installed to the manufacturer’s
recommended guidelines. There are a number of factors which must be considered when designing a Pyro-Bloc M Module lining.
The typical dimensions of Pyro-Bloc M Modules should be used only as a guide when considering lining design and installation.
Higher temperature applications may require greater compression. At any time during this installation, if you have questions,
we recommend you contact your Morgan Advanced Materials Account Manager or the on-site installation advisor.
Step 1 1
Measure the correct distance vertically and horizontally and mark with a chalk line.
Typically, for walls the stud spacing is 111/ 2 inch (292mm) horizontally and 12 inch (305mm)
vertically while on roofs the spacing will be 111/ 2 x 111/ 2 inch (292 x 292mm).
Step 2 2
At the points where the chalk lines cross, weld an M-Module two-step stud onto the steel
casing. Install the plastic covers over the studs and coat the steel casing with stalastic. At this
point, back-up layers of blanket and stainless steel foil vapor barriers should be installed if
being incorporated into the lining of the furnace.
*Plastic covers for the studs are not used if a coating or back-up blanket is not installed.
Step 3 3
Pyro-Bloc M Modules can now be installed. Insert the module (hot face side down) into a
compression box using a compression funnel.
Step 4 4
Insert the guide rod through the red access tube and into the hole in the yoke tab. Lift
compression box with module and guide rod into position and thread the guide rod onto
the small tip on the M Module stud.
The module and compression box can now be pushed into place with the module yoke tab
sliding onto the stud and against the steel casing.
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THERMAL CERAMICS
Step 5 5
Insert a hex nut into the end of the nut driver and slide onto the guide rod.
Thread the nut by hand onto the stud. Remove the guide rod.
Step 6 6
Remove the collapsible red access tube.
Pinch the fibre closed over the stud to protect it from the heat.
Step 7 7
When all Pyro-Bloc M-Modules have been installed, the lining should be tamped out to
further tighten all joints and close any gaps that may exist.
After installation of the module Close tube opening Tamp module in accordance with
REMOVE TUBE. Pyro-Bloc M Modules - appropriate installation manual
red plastic access tube
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Step 2: Insert the T-Bar yoke tines into the first module support tubes.
Step 3: Screw the nut on the stud using the M module nut driver as required. Do not tighten the nut this will allow the yoke free
movement in order to position the next module.
Step 4: Install the next corner module by sliding the internal tubes over the extending T-Bar yoke tines from the 1st module installed.
Step 5: Compress the unsupported side of the module and push the module towards the steel shell between the exposed stud on one
side and the already installed module on the other side. Manipulate the next set of T-Bar yokes over the studs in this process.
Both corner module legs should be installed at the same time.
Step 6: Screw and fully tighten nuts for the first corner module installed using the M module nut driver.
Step 7: Repeat steps 1-6 for following corner modules until course of modules is complete.
Step 8: Pat the fiber face to close any gaps and to smooth the fiber surface.
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THERMAL CERAMICS
Internal Tubes
Hex Nut
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Stud and
Nut sold Yoke
separately
Stud Tube
Pyro-Bloc® M Module
Ferrule
Y X
Nut
Access
tube
Pyro-Bloc M Modules are available in the
Z following designs for single yoke, double tube,
X (width) x Y (height) x Z (thickness):
X (width) x Y (height)
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THERMAL CERAMICS
Pyro-Bloc
Details illustrate use of 12”x12” M Module
(305mm x 305mm) Pyro-Bloc M Module Thermal
Ceramics
Note blanket,
There are a number of factors which must be considered 1” (25mm)
when designing a Pyro-Bloc M Module lining. The typical thick @
6 pcf (96kg/m3)
dimensions of Pyro-Bloc Modules should be used only as
density
a guide when considering lining installation and design. compressed to
Higher temperature applications may require greater 1/2” (13mm)
compression. thick
Pyro-Bloc
This is a typical lining detail. For specific layout
internal
recommendations, reference the Morgan layout drawings Module
provided for your project. hardware
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THERMAL CERAMICS
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