As one of the three major thermal equipment in glass production, the installation of tin bath bottom bricks requires high standards and strict specifications. The quality of the bottom brick installation directly affects the production of float glass, the service life of the tin bath, and the quality of the final glass products. Since several tons of glass float on the molten tin surface and tin has a higher density than bottom bricks, tin infiltration occurs in the later stages of use, potentially damaging stud bolts and causing brick displacement. Therefore, strict adherence to the design and installation process is crucial.
Tin Bath Bottom Brick Installation Process
The construction process for tin bath bottom bricks follows a step-by-step approach:
➡ Inspection & Layout of Steel Structure
➡ Bottom Brick Masonry & Pre-Arrangement
➡ Cleaning & Inspection
➡ Stud Bolt Welding for Bottom Bricks
➡ Cleaning & Inspection
➡ Graphite Filling for Bolt Holes
➡ Sealing Material Packing
➡ Edge Sealing Material Filling
➡ Bottom Brick Cleaning & Protection
➡ Tin Bath Wall Masonry & Top Cover Brick Installation
➡ Final Stud Bolt Welding for Bottom Bricks
General Requirements for Bottom Brick Installation
- The installation must be carried out by designated personnel in an orderly and precise manner.
- Proper construction methods and specialized tools should be used, and bricks must be handled carefully.
- Strict adherence to procedures is essential to prevent issues such as missing graphite gaskets.
- Vacuum cleaning and protective measures must be applied to each stage.
- Before commissioning the tin bath, all metal spacers between the bottom bricks must be removed.
Key Steps in Tin Bath Bottom Brick Installation
Step 1: Transportation of Bottom Bricks
- The first step is transporting the bricks, which have been fully polished on all six sides.
- Arrange bricks in order of installation, stacking them in a single layer near the tin bath.
- Cover the bricks at the worksite to protect them from contamination.
Step 2: Inspection of the Tin Bath Steel Structure
- Verify the distance from the first column of the tin bath to the small furnace centerline matches the design drawings.
- Measure the flatness and elevation of the bottom plate to ensure compliance with design specifications.
- Check the alignment of the longitudinal centerline and confirm that the steel plate is properly cleaned and rust-free.
Step 3: Marking Layout for Brick Installation
- Once the steel structure passes inspection, layout marking begins.
- Using the column centerline as a reference, mark control lines at every three rows to maintain alignment.
- Mark design elevations on the tin bath side panels and ensure all markings are clear and precise.
Step 4: Leveling and Positioning Bottom Bricks
- Pre-arrange the bottom bricks when using manual welded bolts.
- Workers must wear soft-soled fabric shoes when entering the tin bath.
- Vacuum the surface before installation and start from the entry end, installing bricks symmetrically from the centerline outward.
- Position the first brick using a dedicated crane, ensuring a stable placement.
- Level each brick using a precision leveling instrument; adjustments should be ±0.5mm.
- Use steel spacers of varying thicknesses if needed, ensuring maximum adjustment of no more than 2mm.
- Maintain uniform brick gaps with expansion boards, removing them after every three rows and sealing gaps with tape.
Step 5: Final Cleaning and Stud Bolt Welding
- Thoroughly clean the tin bath after installation before proceeding with stud bolt welding.
- Conduct weld tests to verify that bolts meet design and material specifications.
- Clean and dry the bolt holes before welding.
- Use arc welding to secure bolts and perform torque and strength tests post-welding.
Step 6: Sealing the Stud Bolt Holes
- Fill the stud bolt holes with graphite powder to a density of >1.3 g/cm³.
- Compress the graphite powder manually using specialized tubing.
- Once filled, install graphite gaskets, steel washers, and tighten the nuts manually.
- Vacuum clean the bolts after sealing and cover with fiberboard for protection.
Step 7: Packing of Sealing Material
- Mix sealing materials with water as per the manufacturer’s guidelines.
- Apply the material after every five rows to prevent brick displacement due to vibration.
- The initial filling should cover the bolts by at least 60mm and continue until the holes are fully sealed.
- Level the top surface, cover it with rubber sheets, and allow for proper curing.
Step 8: Edge Sealing
- Apply edge sealing materials to fill the gaps between the wall bricks and the side panels.
- Use customized hoppers to ensure uniform filling and proper compaction.
Step 9: Observation Port Alignment
- During wall and top brick installation, ensure accurate placement of observation ports.
- Align heating holes correctly, maintaining ≤2mm variation between individual bricks and ≤6mm overall deviation.
- Ensure proper spacing between top bricks and sidewall bricks.
Conclusion
The installation of tin bath bottom bricks is a high-precision task requiring strict adherence to technical specifications. Proper transport, alignment, leveling, welding, sealing, and curing ensures stable furnace operation, prevents failures, and extends the service life of the tin bath. By following this detailed step-by-step process, the installation achieves high efficiency, structural integrity, and optimal float glass production quality.
