A full rounded project is what Robtek is inspired to do. Our client needed to replace the tyre on section 2 of their kiln, Robtek supplied the brand-new tyre, a new shell section with the sizing of 2m long x 4.2 inner diameter x 65mm thick and new chair plates, shims, tyre retainers and blocks.
The project would require the damaged section of shell to be removed and replaced with a new kiln section to minimise the shutdown window the tyre and chair plates were prefitted onto the shell on site as ‘preshut’work.
In order to replace a shell of this size it can only be done by supporting the remaining kiln. Our team then installs Robtek’s own support towers to assist in doing this correctly and safely. Internal spiders are installed inside the existing shell to maintain its roundness. The cut lines on the shell are marked and verified to ensure that the correct amount of shell is removed. The kiln shell is then carefully cut using a Magnetic track cutter enabling a precision cut.
Before the cutline has completed the circumference, the rigging gear and crane are attached to the section that will be removed. Once the cutting of the kiln is complete it is removed by a qualified Robtek red seal rigger and his team.
After the shell piece was safely placed on the ground, work then commenced on weld prepping the existing seams. The pre-assembled new tyre, shell and chairs was then rigged up into place for temporary joining using custom designed erection steel.
Alignment of the new shell section began and the alignment was confirmed and in tolerance. Prior to welding taking place the seams need to be pre-heated as this is in line with the welding procedure.
Welding was done by using a sub-arc welding machine and took a period of approximately 18hrs of continuous welding for the outside seam and 10hrs of the inside seam.
A non-destructive testing analysis was then carried out on all welding to ensure no defects were found and it passed 100%.
