Proper Anchor Selection

Proper anchor selection and installation is one of the foundations to help assure a successful refractory installation project.

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Over 60% of structural monolithic refractory failures are caused by the contractor&#;s (or design engineer&#;s) lack of understanding of proper anchor design and installation.

A Brief History of Refractory Anchors

The early twentieth century monolithic refractories were commonly plastic. At that time brick was still the predominant refractory material. The refractory plastic was &#;anchored&#; by ramming into pockets created in common brick walls.

The first &#;true&#; refractory anchor was the &#;Flexo-Anchor&#; designed and supplied by Plibrico Company. This anchor was designed to allow for movement in two axes.

The &#;Flexo&#; went through various improvements during the mid-twentieth century.

Ceramic Tile Anchors were engineered into the &#;Flexo&#; system.

This ultimately led to the current version of floating Ceramic Tile Anchors.

Anchor Selection

Proper anchor system designs should take into consideration the following:

• Type of refractory (plastic, castable, etc.)
• Installation technique (gunite, cast, rammed, etc.)
• Lining configuration (single, dual, multiple, etc.)
• Operating and interface temperatures
• Geometry of the vessel
• Joints, penetrations, etc.

There are essentially three (3) types of Anchor Systems:

• Metallic (alloy) anchors
  • Cast iron (usually good up to °F)
  • Fabricated stainless steel (good to about °F depending upon grade)
• Ceramic Tile Anchors (can withstand over °F)
• Wall support systems &#; castings and fabricated stainless steel

With metallic anchor systems the fabricated anchors are primarily used for castables and gunned/shotcrete refractory. There are several types of configurations but predominantly a &#;V&#; type shape is used.

Alloy castings are traditionally used for plastics in low to moderate temperature applications (Flexo-type and arch hangars.)

An experienced refractory contractor should consider all of these important factors and offer the best anchoring system for your application.

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Here are the highlights of Ceramic Anchor Systems:

• Used for plastic refractory linings
• Used for castable linings where service temperatures are extremely high
• Able to extend full lining thickness
• Available in various compositions
• Anchor shape & design varies with supplier
• Various attachment systems are available (both casting and fabricated)
  • C-clip
  • C-clip & stud
  • Ice tong
  • Casting insert

Here is a typical anchor installation for refractory plastic.

And for gunning or shotcreting (plastics or castable).

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Different Types of Refractory Anchors

Refractory anchors are critically important to doing high-heat work. They&#;ve gone to space on the Space Shuttle, used to secure the famous silicate tiles that protected the Shuttle from the incredible heat of reentry. Refractory anchors hold a refractory lining to the wall of an industrial application, keeping it from falling in and protecting your forge, kiln, or other high-heat application from the heat that it contains.

According to New Equipment Digest, it&#;s estimated that over 40% of refractory lining failures happen because of a failure in the anchor design. When designing an anchor system, it&#;s important to choose a type of refractory anchor that works seamlessly with the system, because a monolithic wall against heat transfer is the most important barricade against a failure of the heating system&#;s wall. Here&#;s an overview of the different types of refractory anchors for your reference.

Metallic Anchors

The most common anchor system is a metallic anchor. Metallic anchors are typically designed in a V shape and have a maximum depth of penetration into the material to avoid their being damaged by the extreme heat the refractory is exposed to. Metallic anchors are durable and versatile, able to handle high-heat environments well. They are typically cast within the castable insulation and cannot be removed from the cast material once it&#;s cured. Alloy castings are also traditionally used for plastics in low-heat and moderate-heat applications.

Metallic anchors typically come with plastic caps to help manage the difference in thermal expansion between the anchor material and the refractory material. The plastic caps should be polyethylene plastic, which melts more cleanly and is chlorine-free. Chlorine is not good for castables or steel alloy and can cause failure. The caps have a low melting point and, after melting, leave behind a void space for the metallic anchors to expand into, mitigating expansion damage to the lining.

The most common metal to use in a refractory anchor is Inconel, a high-nickel steel alloy with a very high melting point. Inconel anchors are reliable and relatively inexpensive.

Ceramic Anchors

A ceramic anchor is preferred for thicknesses above 9 inches or temperatures above two thousand degrees Fahrenheit. These anchoring devices have much greater heat tolerance than metallic ones and are made to order. They are typically cast in place and secured to the wall with a metallic bracket.

Choosing the right type of refractory anchors will be crucial to the success of a refractory wall. Knowing your application and the heat it will be exposed to will help you to make the correct decision. If you&#;re in need of refractory anchors, check out the wide selection available at Refractory Anchors Inc (RAI) today.

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