Block F – Refractories and corrosion resistant materials

Trends

Refractories and corrosion resistant materials are constantly evolving for cost effectiveness and longevity. Safety procedures continue to improve. Environmental considerations are being emphasized in the selection, application and disposal of materials.

Related Components (including, but not limited to)

Insulation (ceramic modules, ceramic blankets, boards), firebrick, brick (insulation, thermal, ceramic, lead, carbon, magnesia chrome, alkaline resistant, acid-resistant), corrosion resistant tile, carbon and high temperature mortars, bracing, vessels, anchoring systems, lock-out box, membranes, vertical/horizontal reinforcing, embedded plates, grout, ties (anchors), adhesives, resin injections, stickclips, plastics, wood forms, draining systems, lateral support systems, lintel supports, sills and soffits, water repellents, fire stops, cast iron doors, fireclay, angle iron, castables, arch centre, arch templates, sheet metal, lumber, polyethylene (plastic sheets), metal shims.

Tools and Equipment

See Appendix A.

Task 16 Installs and maintains refractories.

Context

Refractories are used in various settings such as refineries, pulp mills, steel mills, crematoriums and incinerators. Refractory materials are used to contain the burning process and retain or refract heat. Refractory materials are selected according to criteria such as ease of installation, cost effectiveness and durability. The skills involved in installing refractories encompass many of the general masonry skills as well as specialized knowledge of these materials and applications. Due to the use of products containing refractory ceramic fibres (RCFs) and the need to work in confined spaces, maintaining personal safety is paramount.

Required Knowledge

• K 1 safety regulations
• K 2 safety procedures such as lockout, confined space, fall arrest, FLRA, emergency evacuation and temporary bracing
• K 3 types of PPE for refractory material installation and material removal (tearouts)
• K 4 types of refractory materials such as bricks (alumina/silica, insulating, carbon), accessories and blanket, board insulation, castables and plastics
• K 5 types of refractory mortar such as air setting and heat setting
• K 6 sequence of installation of brick and tile according to number and application
• K 7 types and use of insulations
• K 8 forms and arches

Sub-task F-16.01 Prepares for installation of refractories and accessories.

Key Competencies

• F-16.01.01 select and use tools and equipment such as dead blow hammers, rawhide hammers, knives, trowels, wet saws, hand saws, air compressors and gunite equipment
• F-16.01.02 establish points and grid lines for anchors such as V-ties, stick pins and threaded studs to maintain integrity of wall
• F-16.01.03 position and secure accessories such as nuts, clips and V-ties
• F-16.01.04 cut and shape insulation such as modules, blanket and j-paper for installation
• F-16.01.05 cut and shape refractory units such as insulating, ceramic and arch bricks for installation
• F-16.01.06 build and install forms and arch centre for specific application

Sub-task F-16.02 Prepares mortar for refractories.

Key Competencies

• F-16.02.01 select, set up and use tools and equipment such as mixing drills, pails and mixers
• F-16.02.02 select and measure admixtures such as needles, resins and epoxies according to manufacturers’ specifications
• F-16.02.03 select, measure and mix mortars such as silica, high alumina mortar and fireclays according to manufacturers’ specifications

Sub-task F-16.03 Removes existing refractories.

Key Competencies

• F-16.03.01 select and use tools and equipment such as pneumatic hammers, chisels and grinders
• F-16.03.02 cut, grind and hammer to remove specified material
• F-16.03.03 clean up and dispose of materials according to site requirements

Sub-task F-16.04 Installs refractories.

Key Competencies

• F-16.04.01 select and use hand tools such as trimming trowels, dead blow hammers, ratchet wrenches and curry combs specific to refractories
• F-16.04.02 select and use equipment such as reed guns and high-pressure hoses specific to refractories
• F-16.04.03 pour and vibrate castables to consolidate
• F-16.04.04 apply castables using methods such as hand packing, gunning and casting to protect the substrate
• F-16.04.05 install insulation such as blanket and modules and materials such as rigidizer
• F-16.04.06 lay and sequence the installation of refractory material such as brick and tile according to number and application
• F-16.04.07 ram plastics to consolidate and vent plastics to remove moisture
• F-16.04.08 install movement joints as specified
• F-16.04.09 place material separation such as j-paper and blanket insulation to accommodate expansion and contraction of materials

Sub-task F-16.05 Repairs refractories.

Key Competencies

• F-16.05.01 select and use tools and equipment such as pneumatic, hydraulic, power and hand tools specific to refractory
• F-16.05.02 isolate and remove damaged material
• F-16.05.03 cut and shape replacement material to required dimensions
• F-16.05.04 apply castables using methods such as hand packing, gunning and casting to protect the substrate
• F-16.05.05 install replacement material according to deficiency identified such as damaged insulation, deteriorated bricks, damaged anchors, cracks and refractory mortar erosion

Task 17 Installs and maintains corrosion resistant materials.

Context

Corrosion resistant applications are used in sites such as pulp mills, food processing plants and gas plants. The materials are used to protect containment units such as vessels, towers and chests, and the surrounding environment. The skills involved in installing and maintaining corrosion resistant materials encompass many of the general masonry skills as well as specialized knowledge of these materials and applications. Due to the presence of carcinogens and the need to work in confined spaces, maintaining personal safety is paramount.

Required Knowledge

• K 1 safety regulations
• K 2 safety procedures such as lockout, confined space, fall arrest, FLRA, emergency evacuation and temporary bracing
• K 3 types of PPE for corrosion resistant material installation and material removal (tear outs)
• K 4 types of hazards such as ammonia, chlorine and hydrogen sulphate
• K 5 types of corrosion resistant units, mortars, accessories, membranes and concrete
• K 6 causes of corrosion such as friction and chemicals
• K 7 sequence of installation of brick and tile according to number and application
• K 8 forms and arches

Sub-task F-17.01 Prepares for installation of corrosion resistant materials and accessories.

Key Competencies

• F-17.01.01 select and use tools and equipment such as wet saws and trowels specific to application and chisels for acid tile
• F-17.01.02 establish points for anchors to maintain integrity of wall
• F-17.01.03 position and secure accessories such as anchors
• F-17.01.04 prepare the vessel surface for installation using methods such as sandblasting, chemical etching and coating
• F-17.01.05 select membrane according to application
• F-17.01.06 cut and shape corrosion resistant materials such as brick, tile and membranes for installation
• F-17.01.07 build and install forms and arch centre for specific application

Sub-task F-17.02 Prepares mortar for corrosion resistant materials.

Key Competencies

• F-17.02.01 select, set up and use tools and equipment such as mixing drills, pails and mixers
• F-17.02.02 select and measure admixtures such as resins and epoxies according to manufacturers’ specifications
• F-17.02.03 select, measure and mix mortar ingredients such as resins and epoxies according to manufacturers’ specifications

Sub-task F-17.03 Removes existing corrosion resistant materials.

Key Competencies

• F-17.03.01 select and use tools and equipment such as pneumatic hammers, grinders, chisels and hand tools
• F-17.03.02 cut, grind and hammer existing material
• F-17.03.03 clean up and dispose of materials according to site requirements

Sub-task F-17.04 Installs corrosion resistant materials.

Key Competencies

• F-17.04.01 select and use tools and equipment such as gunite machines, concrete pumps, wet saws and vibrators
• F-17.04.02 pour and vibrate to consolidate
• F-17.04.03 apply castables using methods such as hand packing, gunning and casting to protect the substrate
• F-17.04.04 lay and sequence the installation of corrosion resistant materials such as brick and tile according to number and application
• F-17.04.05 form and pour concrete to create base for containment area

Sub-task F-17.05 Repairs corrosion resistant materials.

Key Competencies

• F-17.05.01 select and use tools and equipment such as pneumatic, hydraulic, power and hand tools specific to corrosion resistant materials
• F-17.05.02 isolate and remove damaged material
• F-17.05.03 cut and shape replacement material to required dimensions
• F-17.05.04 apply castables using methods such as hand packing, gunning and casting to protect the substrate
• F-17.05.05 install corrosion resistant materials according to deficiency identified such as the erosion of brick, tile, membrane and refractory mortar