CONSTRUCTION OF RENEWABLE ROOFS FOR CONTINUOUS
I. I. Shakhov,
N. N. Kalinina,
A. S. Belkin,
and V. V. Kurnosov
Translated from Novye Ogneupory, No. 11, pp. 23 – 27, November 2007.
Original article submitted July 31, 2007.
Constructions are considered for renewable roofs of continuous heating furnaces using different lining mate
rials: chamotte refractories, monolithic refractory concrete, and refractory ceramic fiber. It is established that
it is most desirable to use panel roofs using modular blocks made of refractory ceramic fiber.
Continuous furnaces are intended for heating metal
ahead of rolling. The construction of the roof of a furnace,
the materials used, method of assembly and maintenance
govern the operating reliability of a furnace and its produc-
tivity. In enterprises of ferrous metallurgy and engineering
there are a considerable number of furnaces of different
types, and improvement of their construction is desirable.
The traditional structure of roofs for continuous furnaces
with a width of more than 4 m is made flat with use of
shaped chamotte suspended refractories on suspenders made
of heat-resistant steel . Construction of these roofs has a
number of disadvantages: significant loss of heat as a result
of the high thermal conductivity and low gas sealing; consi
derable waste of refractories and heat-resistant steel for the
suspenders; the complexity and difficulty of construction and
repair; the considerable weight of the metal structure of the
For lining roofs overseas firms use monolithic refractory
concrete and ceramic rammed mixes extensively with fasten
ing to the metal frame by means of ceramic ties and metal
suspenders made of heat-resistant cast material . Here
there is a marked reduction in heat loss and gas sealing is im
proved, although the high labor content of repairing linings
and the desirability of prolonged drying are retained, and
there is also strict observation of the temperature schedule
during subsequent heating and cooling of a furnace. In Rus
sia studies for creating monolithic concrete roof structures
and assembly methods have been carried out in the laborato
ries of VNIIteploproekt together with the Soyuzteplostroi
trust [3, 4].
In OAO Revyakinsk Metal Rolling Plant (OAO RMZ) in
the maintenance period for the continuous heating furnace,
intended for heating slabs up to 1300ºC before rolling in a
280 mill, a panel roof was used made of refractory concrete
and panel arches with a low-inertia lining modular blocks
made of refractory fiber. The furnace dimensions are: width
4.5 m, length 18 m.
ROOFS USING A REFRACTORY CONCRETE
The construction of panel roofs made of refractory con-
crete and the method of assembly have been developed by
NPP Teploograzhdenie. Panels combine supporting and pro
tecting functions (Fig. 1), and the size of panels is 1.2´5.5 m.
The metal structure of panels was prepared in OAO RMZ,
and the lining was made in the Aprelevsk NPP Teplo
ograzhdenie. The lining consists of a layer of vibrated refrac
tory concrete, ceramic ties and metal suspenders. In order to
prepare the concrete and additional insulation domestic ma
terials were used. The ceramic ties and metal suspenders
were supplied by Vhi, Germany. After manufacture of pa
nels, protection of the concrete from moist conditions,
strength and quality verification for the panels and supporting
structure, it was transferred to the area of assembly by motor
transport (Fig. 2). The weight of the panels, including the
weight of the metal structure, was 5.5 tons. In order to pro
vide panel integrity during transportation special jigs were
provided. Assembly of the panels was carried by efforts of
the plant using a workshop production crane (Fig. 3). At the
end of assembly additional insulation was applied and joints
between the panels were fixed. Installation of a single panel
lasted not more than 2 h. It should be noted that during
planned maintenance of the furnace hearth in order to acce
Refractories and Industrial Ceramics Vol. 48, No. 5, 2007
1083-4877/07/4805-0337 © 2007 Springer Science+Business Media, Inc.
NPP Teploograzhdenie, OAO Revyansk Metal Rolling Plant,
ZAO KOMAS, Russia.