January 2018

Refractory

PIP RFSB1000
Brick Refractory Material Specification
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has been
prepared from the technical requirements in the existing standards of major industrial users,
contractors, or standards organizations. By harmonizing these technical requirements into a single
set of Practices, administrative, application, and engineering costs to both the purchaser and the
manufacturer should be reduced. While this Practice is expected to incorporate the majority of
requirements of most users, individual applications may involve requirements that will be appended
to and take precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering situations should
not be made solely on information contained in these materials. The use of trade names from time
to time should not be viewed as an expression of preference but rather recognized as normal usage
in the trade. Other brands having the same specifications are equally correct and may be substituted
for those named. All Practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these Practices or guidelines should
conflict with OSHA or other applicable laws or regulations, such laws or regulations must be
followed. Consult an appropriate professional before applying or acting on any material contained
in or suggested by the Practice.

This Practice is subject to revision at any time.

© Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at
Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP Member Companies and
Subscribers may copy this Practice for their internal use. Changes or modifications of any kind are not
permitted within any PIP Practice without the express written authorization of PIP. Authorized Users
may attach addenda or overlays to clearly indicate modifications or exceptions to specific sections of
PIP Practices. Authorized Users may provide their clients, suppliers and contractors with copies of the
Practice solely for Authorized Users’ purposes. These purposes include but are not limited to the
procurement process (e.g., as attachments to requests for quotation/ purchase orders or requests for
proposals/contracts) and preparation and issue of design engineering deliverables for use on a specific
project by Authorized User’s client. PIP’s copyright notices must be clearly indicated and
unequivocally incorporated in documents where an Authorized User desires to provide any third party
with copies of the Practice.

PUBLISHING HISTORY
January 2018 Issued

Not printed with State funds

 January 2018

Refractory

PIP RFSB1000
Brick Refractory Material Specification
Table of Contents
1. Scope ............................................ 2
2. References ................................... 2
2.1 Industry Codes and Standards .......... 2

3. Definitions .................................... 3
4. Requirements ............................... 4
4.1 Data Submittals ................................. 4
4.2 Refractory Properties......................... 5
4.3 Storage ............................................ 10
4.4 Shipping, Packaging and Marking ... 11

Appendices ...................................... 14
Appendix A – Refractory Brick Compliance
Requirements .................................. 14
Appendix B - Refractory Mortar Compliance
Requirements .................................. 14

Process Industry Practices Page 1 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

1. Scope
This Practice describes the requirements for certification and prequalification of the refractory
materials used to construct brick refractory linings in equipment and piping and provides a basis
for purchase and quality control of brick and mortar refractory materials before installation.

This Practice describes the material property, testing, documentation, storage, and shipping
requirements for industrial refractory materials used to construct brick refractory linings in
equipment and piping.

This Practice includes dense firebrick, shapes, insulating firebrick (IFB) and refractory mortars.

2. References
Applicable parts of the following industry codes and standards shall be considered an integral part
of this Practice. The edition in effect on the date of contract award shall be used, except as
otherwise noted. Short titles are used herein where appropriate.

2.1 Industry Codes and Standards

• ASTM International (ASTM)
– ASTM C16 – Standard Test Method for Load Testing Refractory Shapes at High
Temperatures
– ASTM C20 – Standard Test Methods for Apparent Porosity, Water Absorption,
Apparent Specific Gravity, and Bulk Density of Burned Refractory Brick and
Shapes by Boiling Water
– ASTM C24 – Standard Test Method for Pyrometric Cone Equivalent (PCE) of
Fireclay and High Alumina Refractory Materials
– ASTM C27 – Standard Classification of Fireclay and High-Alumina Refractory
Brick
– ASTM C71 – Standard Terminology Relating to Refractories
– ASTM C113 – Standard Test Method for Reheat Change of Refractory Brick
– ASTM C133 – Standard Test Methods for Cold Crushing Strength and Modulus of
Rupture of Refractories
– ASTM C134 – Standard Test Methods for Size, Dimensional Measurements, and
Bulk Density of Refractory Brick and Insulating Firebrick
– ASTM C155 – Standard Classification of Insulation Firebrick
– ASTM C182 – Standard Test Method for Thermal Conductivity of Insulating
Firebrick
– ASTM C198 – Standard Test Method for Cold Bonding Strength of Refractory
Mortar
– ASTM C199 – Standard Test Method for Pier Test for Refractory Mortars
– ASTM C201 – Standard Test Method for Thermal Conductivity of Refractories
– ASTM C210 – Standard Test Method for Reheat Change of Insulating Firebrick
– ASTM C1655 – Standard Classification of Fireclay and High-Alumina Mortars

Process Industry Practices Page 2 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

– ASTM E228 – Standard Test Method for Linear Thermal Expansion of Solid
Materials with a Push-Rod Dilatometer

3. Definitions
With the exception of the terms listed in this section, terms used in this Practice are defined in
accordance with ASTM C71. If a definition as used in this Practice differs from the one listed in
the referenced documents, the modified definition is included in the following listing:

batch: Brick refractory material produced in one kiln run of a specific composition. For mortar a
batch is a mixture run.

certification: Determination that an industrial refractory product meets all of the requirements to
be classified as a specific type of refractory in accordance with Appendix A or B of this Practice
as applicable.

industrial refractory: Refractory brick, shapes and mortar offered with data sheets, installation
information, Safety Data Sheets (SDSs), and other safety and handling information

compliance data sheet: Data sheet listing property values that the manufacturer certifies or
guarantees will be met by each sample tested. The values in the compliance data sheet shall
comply with values in Appendix A or B and, if more stringent, shall include the manufacturer’s
guaranteed values and any other values as agreed upon with the purchaser.

lining: Refractory brick placed over a surface for protection from the surrounding atmosphere.
The lining protects the surface from abrasion or acts as an insulator, shielding the surface from
excess heat.

lot: Portions of a batch included in one order and shipped together

manufacturer: Party who manufactures the refractory brick, shapes or mortar

material prequalification: Determination that the as-manufactured refractory material to be

shipped to the site meets all of the requirements for the specified type of refractory in accordance
with the compliance data sheet

owner: Party who owns the facility wherein the refractory will be used

purchaser: Party who awards the contract to the supplier. The purchaser may be the owner or the
owner’s authorized agent.

refractory: A non-metallic material that has a high melting point and ability to retain its physical
shape and chemical identity when subjected to environmental conditions

supplier: Party who furnishes the packaged refractory to the installation site. The supplier may or
may not be the same as the manufacturer.

Process Industry Practices Page 3 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

4. Requirements
4.1 Data Submittals
4.1.1 Conflicts, Exceptions, and Deviations
4.1.1.1 All conflicts between the referenced documents and this Practice shall be
submitted in writing to the purchaser for clarification and resolution
before proceeding.
4.1.1.2 All exceptions, deviations, and substitutions to the requirements of this
Practice and in referenced documents shall be approved by the purchaser.
4.1.2 Regulations and Safety Data Sheets (SDSs)
4.1.2.1 Refractory materials shall be in accordance with all applicable federal,
state, and local codes and regulations for storage, handling, safety, and
environmental requirements.
4.1.2.2 Complete and current Safety Data Sheets (SDSs) shall be provided for each
product and to each location where the product is to be used.
4.1.2.3 The SDSs shall include all hazards and cautions associated with the
handling, storage, and use of the product, and the appropriate counter
measures to be taken to prevent and react to any event of personnel harm
(short-term and long-term) that may occur.
4.1.3 Material Properties Information
4.1.3.1 Manufacturer’s standard technical data sheets shall be provided for each
product and to each site where the product is to be used.
4.1.3.2 Compliance data sheets shall be provided for each product and to each
site where the product is to be used.
4.1.3.3 If alternate product property values are agreed upon with the purchaser,
this information shall be included on the compliance data sheets.
4.1.3.4 The results of material prequalification testing shall be provided. The
results shall be approved by the purchaser before shipment of the product.
4.1.4 Mixing and Placement Instructions
4.1.4.1 Complete, step-by-step instructions shall be provided for mixing the
refractory mortar components and water, including the optimal total
water content.
4.1.4.2 Special placement instructions and/or cautions beyond those typically used
for the chosen method of refractory mortar placement shall be provided.
4.1.5 Curing and Heat Dryout Schedules
4.1.5.1 Recommended heat dryout schedules shall be provided for each
refractory brick lining.

Process Industry Practices Page 4 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

4.1.5.2 Heat dryout schedules shall be in accordance with the manufacturer’s

recommendations. A manufacturer’s heat dryout schedule shall specify
the following:
a. Hold temperatures (if required) and the maximum temperature to be
achieved.
b. Minimum hold times.
c. Maximum heating and cooling rates for each material.
d. Other requirements pertaining to the proper heat drying of the material.
4.2 Refractory Properties
4.2.1 General
4.2.1.1 The refractory installed in each location shall be of the type specified in
the contract documents (e.g., purchaser’s specifications and drawings)
and defined in Appendices A and B of this Practice.
4.2.1.2 Asbestos shall not be permitted in refractory materials.
4.2.2 Certification
4.2.2.1 General
1. Refractory products shall be certified before being considered for
installation in any process equipment.
2. Certification shall include testing of refractory properties.
3. Testing methods and procedures, and the resultant property values,
shall be in accordance with the requirements of Appendices A and B
of this Practice for the applicable refractory type.
Comment: Adherence to technical data is not sufficient to ensure
adequate refractory performance in the field. Technical
data is a means of characterizing a candidate material as
being (or not being) a reasonable choice for a given
application. Use of refractory materials with a successful
record of service in the same or very similar application is
recommended before making the selection.
4.2.2.2 Sampling
1. Specimens shall be cut from 230-mm (9-inches) straight brick provided
by the manufacturer as produced, using the same material, manufacturing
process and equipment to be used for normal brick production.
2. Large shapes shall be cut down in size to the appropriate test specimen
dimensions. Cutting shall be by water-cooled diamond blade saw.
3. Select representative samples of mortar sufficient for the required testing.
4. The number of specimens shall be sufficient to conduct tests required
in accordance with Appendices A and B.

Process Industry Practices Page 5 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

4.2.2.3 Testing
1. Brick
a. The requirements of this section shall apply to the properties
listed on the manufacturer’s compliance data sheets to evaluate
candidate brick for a type as defined by Appendix A.
b. The specimen requirements (i.e., preparation, number, and
shape) and testing for each property shall be in accordance with
the ASTM test procedure listed in Appendix A.
c. Special techniques to enhance the test results shall not be permitted.
d. Testing shall be in accordance with Appendix A and may include
chemistry, pyrometric cone equivalent (PCE), density, cold
crushing strength, modulus of rupture (MOR), thermal
conductivity, and reheat change.
e. Each test specimen result shall be in accordance with the
requirements of the compliance data sheet.
f. The test result values for any specimen in the test sample shall
not differ from the average of the sample by greater than plus or
minus 20 percent of the average values.
g. The purchaser may require additional tests as necessary to meet
process requirements.
2. Mortar
a. The requirements of this section shall apply to the properties
listed on the manufacturer’s compliance data sheets to evaluate
candidate mortar for a type as defined by Appendix B.
b. The specimen requirements (i.e., preparation, number, and
shape) and testing for each property shall be in accordance with
the ASTM test procedure listed in Appendix B.
c. Special techniques to enhance the test results shall not be permitted.
d. Each test specimen result shall be in accordance with the
requirements of the compliance data sheet.
e. The test result values for any specimen in the test sample shall
not differ from the average of the sample by greater than plus or
minus 20 percent of the average values.
f. The purchaser may require additional tests as necessary to meet
process requirements.
4.2.2.4 Tolerance Requirements
1. Dense Brick
a. For all standard sized brick dimensions (e.g., 230 by 115 by
75 mm (9 by 4.5 by 3 inches) or 230 by 115 by 65 mm (9 by 4.5

Process Industry Practices Page 6 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

by 2.5 inches), etc.) and shapes, the following tolerances shall

apply:
1) For 115 mm (4.5 inches) and smaller dimensions, plus or
minus 0.5 mm (0.02 inch)
2) For greater than 115 mm (4.5 inches) up to 345 mm
(13.5 inches) dimensions, plus or minus 1 mm (0.04 inch)
3) For greater than 345 mm (13.5 inches) dimensions, plus or
minus 1.5 mm (0.06 inch)
b. For all standard sized brick and shapes, the following surface
warpage tolerances shall apply:
1) For 115 mm (4.5 inches) and smaller dimensions, plus or
minus 0.25 mm (0.01 inch)
2) For greater than 115 mm (4.5 inches) up to 345 mm
(13.5 inches) dimensions, plus or minus 0.5 mm (0.02 inch)
3) For greater than 345 mm (13.5 inches) dimensions, plus or
minus 1.0 mm (0.04 inch)
c. For standard brick, the brick shall be stacked 10 brick high on
the largest surface (e.g., 230 by 115 mm (9 by 4.5 inches)) and
the total height measured. The height tolerance shall be plus or
minus 0.5 percent of the nominal height.
d. For brick or shapes designed to produce a contour geometry, the
design number of pieces shall be laid out in the contour with 1
mm (0.04 inch) shims for mortar joints and the inside dimension
of the contour measured. The dimensional tolerance shall be plus
or minus 0.5 percent of the design value.
2. Insulating Firebrick
a. For pressed insulating firebrick sizes and shapes, the dimensional
tolerances in Section 4.2.2.4 Items 1 (a) through (d) shall apply.
b. For machined insulating firebrick shapes, all the dimensional
tolerances shall be plus or minus 0.5 mm (0.02 inch).
4.2.2.5 Visual and Dimensional Inspection – Acceptance/Rejection Criteria
1. Brick or shape which shows cracking shall be rejected.
2. Brick or shape with suspected cracks may be tapped with a brick
hammer and, if the refractory does not break and rings solid, the
refractory may be used.
3. Brick or shape with missing corners or chips from edges, with any
dimension greater than the thickness of the proposed mortar joint,
shall be rejected.
4. Brick or shape with voids or pockets, with any dimension greater
than 3 mm (1/8 inch) on the surface, shall be rejected.

Process Industry Practices Page 7 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

4.2.3 Material Prequalification

4.2.3.1 General
1. The requirements of this section shall be used for prequalification of
brick and mortar to be installed:
Comment: Prequalification testing is intended to determine if the
product has been properly manufactured and can be
expected to perform similarly to product of the same brand
identification that has been certified for the application.
Comment: Prequalification visual and dimensional inspection is
intended to determine if the product has been properly
manufactured in accordance with the specifications.
2. Material prequalification shall include testing and visual inspection
before shipment from the manufacturer’s facility.
3. Each lot, or portion thereof, shall be certified as being in accordance
with the required test values and visual inspection criteria before
shipment from the manufacturer’s facility.
4. Samples shall be tested and visually inspected at the manufacturer’s
facility or, at the purchaser’s discretion, at an independent laboratory
approved by the purchaser.
5. Purchaser may choose to witness the testing and visual inspection. If
so, the purchaser shall be notified of the time and place as specified in
the contract documents. Notice shall be given far enough in advance
so that the purchaser or the authorized purchaser’s representative may
arrange to be present and the material can be replaced without
affecting the delivery schedule should replacement be necessary.
4.2.3.2 Sampling
1. Sampling of brick shall be in accordance with Table 1.

Table 1 – Sampling of Brick

Number of pieces Number of Samples

< 25 2
26 – 100 5
101 – 250 10
251 - 500 20
501 – 1000 25
> 1000 4%

2. All samples shall be taken from the brick to be shipped. Samples shall
not come from a portion of a batch not included in the shipment.

Process Industry Practices Page 8 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

3. Brick shall be randomly selected from various locations on the

pallets, not just from the top.
4. One randomly selected mortar container shall be taken from each
mixer batch.
4.2.3.3 Brick Testing
1. The requirements of this section shall apply to the properties listed
on the manufacturer’s compliance data sheets to evaluate candidate
brick for a type as defined by Appendix A of this Practice.
2. The specimen requirements (i.e., preparation, number, and shape)
and testing for each property shall be in accordance with the ASTM
test procedure listed in Appendix A of this Practice.
3. Special techniques to enhance the test results shall not be permitted.
4. Testing shall be in accordance with Appendix A and may include
chemistry, PCE, density, cold crushing strength, MOR, thermal
conductivity, and reheat change.
5. Each test specimen result shall be in accordance with the
requirements of the compliance data sheet.
6. The test result values for any specimen in the test sample shall not
differ from the average of the sample by greater than plus or minus
20 percent of the average values.
7. The purchaser may require additional tests as necessary to meet
process requirements.
8. The results of the material prequalification testing shall be reported
to the purchaser.
9. In addition to the test results, the refractory product name and
manufacturer, batch number, date of manufacture, pallet number,
date of testing and the name of the testing agency shall be provided.
4.2.3.4 Mortar Testing
1. Mortar shall be tested in accordance with the requirements of
Appendix B.
2. The specimen requirements (i.e., preparation, number, and shape)
and testing for each property shall be in accordance with the ASTM
test procedure listed in Appendix B
3. Special techniques to enhance the test results shall not be permitted.
4. Each test specimen result shall be in accordance with the
requirements of the compliance data sheet.
5. The test result values for any specimen in the test sample shall not
differ from the average of the sample by greater than plus or minus
20 percent of the average values.

Process Industry Practices Page 9 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

6. The purchaser may require additional tests as necessary to meet

process requirements.
7. The results of the mortar prequalification testing shall be reported to
the purchaser.
8. In addition to the test results, the refractory product name and
manufacturer, batch number, date of manufacture, pallet number,
water content and mixing time, date of testing and the name of the
testing agency shall be provided.
4.2.3.5 Mortar Retesting
1. If the mortar is not used within one year or manufacturer’s shelf life,
whichever is less, the mortar shall be requalified/retested
immediately before use. Material more than 18 months from date of
manufacture shall be discarded.
2. Material requalification/retesting shall also be performed if the
packaging or mortar has been exposed to heat or cold beyond the
manufacturer’s recommended storage temperature.
3. Retesting shall be performed by a qualified laboratory approved by
the purchaser.
4. The sampling, required tests, test procedures, and acceptance criteria
shall be the same as for the initial prequalification testing, in
accordance with Section 4.2.3.4.
5. The retest results shall not differ by greater than 20 percent from the
prequalification values, and shall be in accordance with the
compliance data sheet.
6. If the samples do not pass the testing requirements, the sampled lot
shall not be used.
4.2.3.6 Visual Inspection, Dimensional Inspection, and Tolerance
Requirements
1. Brick shall be in accordance with the tolerance requirements of
Section 4.2.2.4.
2. Brick shall be in accordance with the visual inspection requirements
of Section 4.2.2.5.
3. Brick that is not in accordance with Section 4.2.2.4 or 4.2.2.5 shall
not be used.
4.3 Storage
4.3.1 General
4.3.1.1 Brick and mortar materials shall be stored on an elevated, ventilated
platform, supported by a concrete slab or a compacted, durable surface
sloped to direct moisture away from the materials.

Process Industry Practices Page 10 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

4.3.1.2 Brick and mortar materials shall not be stored on grass, soil, or other
non-compact surface or any area where moisture may collect, stand, or
come into contact with the materials.
4.3.2 Weather Protection
4.3.2.1 The stored brick and mortar materials shall be protected by a
weatherproof covering above and on all sides.
4.3.2.2 The covering shall be arranged so that moisture cannot come into contact
with the materials.
4.3.2.3 The covering shall be arranged so that moisture cannot pond or collect
and is directed away from the materials.
4.3.2.4 Care shall be taken to avoid high humidity under the covering.
4.3.3 Discarding Criteria
The following materials shall not be used and shall be discarded immediately:
a. Bags or containers of mortar which are damaged, wet or open before use.
b. Mortar which contains lumps of hard material which cannot be broken up
during mixing.
c. Brick or shapes which are broken, chipped, or damaged during transit or
storage and are not in accordance with Section 4.2.2.5.
4.4 Shipping, Packaging and Marking
4.4.1 General
4.4.1.1 Brick and mortar shall be secured and protected from moisture exposure,
heat or cold beyond the manufacturer’s recommended storage
temperature, mechanical damage or other factors that may affect its
properties or performance.
4.4.1.2 Brick and mortar shall be shipped by means that minimizes its time in
transit and in-transit storage.
4.4.1.3 Mortar shall be ordered to minimize the time between its manufacture
and use.
4.4.1.4 If mortar is taken from the existing stock, the mortar shall be the most
recently manufactured material and shall not be older than 3 months
from date of manufacture.
4.4.2 Packaging
4.4.2.1 Mortar shall be shipped in polyethylene-lined bags, pails, or boxes
grouped on pallets.
4.4.2.2 Other shipping means for mortar may be used if in accordance with all
requirements of this Practice and other contract documents and approved
by the purchaser. A means of obtaining representative samples shall be
provided, including resealing of the container if required.

Process Industry Practices Page 11 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

4.4.2.3 The actual weight of mortar shall be within plus or minus 2 percent of
the nominal weight marked on each container.
4.4.2.4 Pallets of brick or mortar shall hold 1800 kg (4,000 pounds) or less of the
material.
4.4.2.5 Pallets of mortar shall not include material from more than one batch and
date of manufacture.
4.4.2.6 The product on each pallet shall be enclosed by plastic wrap.
4.4.2.7 The plastic wrap shall cover all sides of the shipment, including the
underside, between the brick or mortar and the pallet.
4.4.2.8 The plastic wrap shall be completely sealed so that moisture cannot enter
or become trapped within the wrap.
4.4.2.9 A desiccant shall be provided on each pallet (inside the plastic wrap) to
prevent the accumulation of moisture within the plastic wrap in the event
of condensation (e.g., because of a temperature decrease).
4.4.2.10 The plastic wrap shall not be removed, cut, or opened until the brick or
mortar is to be used.
4.4.2.11 If material is removed for sampling and testing, the plastic wrap shall be
immediately resealed.
4.4.3 Marking
4.4.3.1 Each brick or shape shall have the product’s name or identification
stamped into the brick surface.
4.4.3.2 Each container of mortar and each pallet of brick or mortar shall include
the following information:
a. Product brand name
b. Manufacturer’s name
c. Plant of manufacture
d. Shift
e. Manufacturing line (if more than one)
f. Lot and batch identifications
g. Date of manufacture
h. Purchase order number (applies to each pallet)
4.4.3.3 Each container of mortar shall include the following information:
a. Container weight
b. Mixing instructions
c. Mixing or tempering water range as required
d. Special cautions and/or requirements for storage, handling, mixing,
application, curing, heat drying, etc.

Process Industry Practices Page 12 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

4.4.3.4 Pallet numbering shall be in accordance with the following:

a. The pallets of brick and mortar in each lot shall be numbered
consecutively, beginning with 1.
b. The total number of pallets in the lot shall be included in the
identifying number (e.g., 3 of 7).
4.4.3.5 Material identification signs shall be posted prominently on all four sides
of each pallet.

Process Industry Practices Page 13 of 18

 PIP RFSB1000
Brick Refractory Material Specification January 2018

Appendices
Appendix A – Refractory Brick Compliance Requirements
Table A-1 - Dense Refractory Brick Compliance Requirements
Table A-2 - Specialty Dense Refractory Brick Compliance Requirements
Table A-3 - Insulating Firebrick (IFB) Compliance Requirements

Appendix B - Refractory Mortar Compliance Requirements

Process Industry Practices Page 14 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

Table A-1 – Dense Refractory Brick Compliance Requirements (Note 4)

Fireclay Brick High-Alumina Brick (% Al2O3 Content)

Classification Medium Semi-

High-Duty Super-Duty 50 60 70 80 85 90 94 99
Properties Duty Silica

Density, kg/m3 (lb/ft3 ) per

2,050 1,840 2,115 2,240 2,400 2,480 2,560 2,640 2,800 2,880 3,060 3,090
ASTM C134
(128) (115) (132) (140) (150) (155) (160) (165) (175) (183) (191) (193)
(Minimum)
Apparent Porosity
Per ASTM C20 17-21% 27-30% 15-25% 9.0-17.5% 13-16% 17-20% 18-21% 17-22% 18.5-22.5% 8-12% 12-18% 18-21%

Cold Crushing
13.8 9.7 14.5 27.6 52 27.6 27.6 34.5 69 103 48
Strength, MPa (psi) per
(2,000) (1400) (2100) (4000) (7500) (4,000) (4,000) (5,000) (10,000) (15,000) N/A (7,000)
ASTM C133
(Minimum)
Modulus of
Rupture, MPa (psi) 2.1 3.5 4.1 17 7.7 6.2 9.0 14 16.5 24.8 17
3.5
per ASTM C133 (300) (500) (600) (2,500) (1,100) (900) (1,300) (2,000) (2,400) (3,600) (2,500)
(500)
(Minimum)
Hot Load Test
0.2-2.0% 1.0-2.5% 1.0-2.5% 1.0-2.5% 0.1-2.5% 0.5-2.0% 0.1-1.0% 0-1% 0.6 to +0.2% 0.5-1.4%
per ASTM C16
N/A @1450°C @1450°C @1450°C @1450°C @1450°C @1450°C @1450°C @1450°C @1700°C N/A @1700°C
(Deformation at
(2640°F ) (2640°F) (2640°F ) (2640°F ) (2640°F ) (2640°F ) (2640°F) (2640°F) (3100°F) (3100°F)
Temperature) (Note 5)
Reheat Permanent Linear 0-0.5% 0- 0.5% 0-1.0% 0-1.0% 0-1.5% 0.2% C to 3.0-5.5% 1.0-4.0% 1.4% C to 0-2.0% 0-1.0% 0.1-0.4%
Change C E C C E 1.5% E E E 0.2% E E C C
per ASTM C113 @1350°C @1400°C @1400°C @1600°C @1600°C @1600°C @1600°C @1600°C @1600°C @1760°C @1760°C @1760°C
(@ Temperature) (Note 6) (2460°F) (2550°F ) (2550°F) (2910°F) (2910°F) (2910°F) (2910°F) (2910°F) (2910°F) (3200°F) (3200°F) (3200°F)
Pyrometric Cone
Equivalent (PCE)
29 26 31 ½ 33 34 35 36 37 39-40 N/A N/A N/A
per ASTM C24
(Minimum)
Thermal Conductivity - K,
W/moK ((Btu·in)/(h·ft2· oF)) 1.38 1.41 1.59 1.64 1.43 1.92 2.39 3.94 3.9 3.76
N/A N/A
per ASTM C201 at 425oC (9.6) (9.8) (11.0) (11.4) (9.9) (13.3) (16.6) (27.3) (27) (26.1)
(800oF) (Maximum)
AI2O3 (wt. %)
34 ± 2 N/A 40 ± 2.5 43 ± 2.5 50 ± 2.5 60 ± 2.5 70 ± 2.5 80 ± 2.5 85 ± 2.0 90 ± 2.0 93 Min 97 Min
SiO2 (wt. %)
60 ± 2 72 (Minimum) 52 ± 2.5 52 ± 2.5 48 ± 2 36 ± 2 24.0 ± 2 15.0 ± 2 10.0 ± 2 9±2 <7 < 1.0
Fe2O3 (wt. %)
3.0 2.0 2.0 1.2 1.5 2.0 2.0 1.5 0.5 0.1 <0.5
(Maximum) 3.0
NOTES:
1. Data is for proprietary, industrial brick only and is not applicable to pre-cast castable shapes.
2. Testing shall comply with the requirements of Sections 4.2.2.3.1 or 4.2.3.3 as applicable.
3. N/A indicates that the property test is not available.
4. Dense Brick classifications are in accordance with ASTM C27.
5. All values are contraction except where shown as ”+”.
6. E indicates expansion. C indicates contraction.

Process Industry Practices Page 15 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

Table A-2 – Specialty Dense Refractory Brick Compliance Requirements

Phosphate Bonded High Alumina

Alumina Magnesia Carbon Brick Alumina-Chrome Brick
Brick

Classification 10.0% 5.7% 6.7% 72% 80% 82% 9% 15% 20% 30% 40% 60% 75% 90%
Magnesia Magnesia Magnesia Alumina Alumina Alumina Chrome Chrome Chrome Chrome Chrome Chrome Chrome Chrome
Properties
Density, kg/m3 (lb/ft3 )
2,880 2,800 3,200 2,720 2,870 2,840 3,220 3,200 3,570 3,480 3,640 3,910 4,130 4,230
per ASTM C134
(180) (175) (200) (170) (179) (177) ( 201) (200) (223) (217) (227) (244) (258) (264)
(Minimum)
Apparent Porosity
ASTM C20 (percent) N/A N/A N/A 10 - 14 12 - 16 15 - 19 15 - 19 15 - 19 9 - 13 13 - 17 12 - 16 11 - 17 12 - 16 12.5-16

Cold Crushing
Strength, MPa (psi) 86.2 124.1 143 141 84 154 55 100 105 88 48
N/A N/A N/A
per ASTM C133 (12,500) (18,000) (20,750) (20,500) (12,160) (22,290) (7,920) (14,500) (15,240) (12,820) (7,000)
(Minimum)
Modulus of
Rupture, MPa (psi) 15.9 17.9 25.9 20.7 23.4 23 37 11 41 9 31 25 27 14
per ASTM C133 (2,300) (2,520) (3,750) (3,000) (3,400) (3,300) (5,400) (1,650) (6,010) (1,350) (4,500) (3,560) (3,850) (2,000)
(Minimum)
Reheat Permanent
Linear Change 0 - 2% 0 - 2% 0 - 2% 0 - 2% 0 - 2% 0 - 2% 0 - 2% 0 - 2% 0 - 2% 0 - 2% 0 - 2%
per ASTM C113 E E C E C E E E E E E
N/A N/A N/A
(@ Temperature) @ 1600°C @ 1600°C @ 1600°C @ 1816°C @ 1727°C @ 1727°C @ 1727°C @ 1727°C @ 1727°C @ 1727°C @ 1727°C
(Note 4) (2910°F) (2910°F) (2910°F) (3300°F) (3140°F) (3140°F) (3140°F) (3140°F) (3140°F) (3140°F) (3140°F)

AI2O3 (wt.%)
(Minimum) 78.0 81.0 88.2 72 80 82 89 83 75 64 57 37 22 10

SiO2 (wt.%)
Maximum 8.0 8.8 2.7 18 11 8.5 0.5 2.0 0.6 0.4 0.4 0.3 0.2 0.2

Fe2O3 (wt.%)
(Maximum) 0.2 1.0 1.0 0.2 0.1 0.1 0.2 0.1 0.3 0.1 0.2 0.1 0.2 0.2

8 - 12 5 - 6.5 6 - 7.5 4-5 4-5 5 - 5.5 8 - 10 14 - 16 18 - 22 28 - 30 38 - 42 58 - 62 73 - 76 88 - 90

Other (wt. %)
MgO MgO MgO P2O5 P2O5 P2O5 Cr2O3 Cr2O3 Cr2O3 Cr2O3 Cr2O3 Cr2O3 Cr2O3 Cr2O3

NOTES:
1. Data is for proprietary, commercial brick only and is not applicable to pre-cast castable shapes.
2. Testing shall comply with the requirements of Sections 4.2.2.3.1 or 4.2.3.3 as applicable.
3. N/A indicates not applicable.
4. E indicates expansion. C indicates contraction.

Process Industry Practices Page 16 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

Table A-3 – Insulating Firebrick (IFB) Compliance Requirements

Insulating Fire Brick (Note 4)

Class
20 B4 23 2300 LI B5 2500 2600 LI 26 2800 LI 28 2900 30 32

Temperature (⁰C)
1100 1200 1260 1260 1300 1350 1430 1430 1540 1540 1580 1650 1760
Properties

Density, kg/m3 (lb/ft3) per ASTM

500 800 500 480 800 800 800 800 890 900 1,020
C134 (Minimum) 1100 (68.8) 1,250 (78.1)
(31.2) (50) (31.2) (30) (50) (50) (50) (50) (55.6) (56.2) (63.8)
Cold Crushing
Strength, MPa (psi) per ASTM 0.8 2.0 1.0 1.2 2.0 1.8 1.6 2.0 2.1 2.5 3.0 2.1 3.5
C133 (Minimum) (116) (290) (145) (174) (290) (261) (232) ( 290) (305) (363) (435) (305) (508)

Modulus of
0.7 1.2 0.7 1.0 1.2 1.2 1.5 1.8 1.8 1.8 2.0 2.0 305
Rupture, MPa (psi)
(102) (174) (102) (145) (174) (174) (218) (261) (261) (261) (290) (290) (2.1)
per ASTM C133 (Minimum)
Reversible Linear Thermal
Expansion, % per ASTM E228 0.6 0.7 0.6 0.5 0.7 0.7 0.7 0.7 0.8 0.8 0.9 0.9 1.1
(Maximum)
Permanent Linear
0.5 @ 1.0 @ 0.2 @ 0.2 @ 1.0 @ 0.5 @ 0.2 @ 0.5 @ 0.4 @ 1.0 @ 1.0 @ 0.8 @ +0.6 @
Change,Maximum %
1070⁰C 1170⁰C 1230⁰C 1230⁰C 1300⁰C 1350⁰C 1400⁰C 1400⁰C 1510⁰C 1510⁰C 1550⁰C 1620⁰C 1730⁰C
Per ASTM C210
(Note 3) (1958⁰F) (2138⁰F) (2246⁰F) (2246⁰F) (2372⁰F) (2462⁰F) (2552⁰F) (2552⁰F) (2750⁰F) (2750⁰F) (2822⁰F) (2948⁰F) (3146⁰F)

Hot Load Strength, % Deformation

after 90 minutes per ASTM C16 0.1 @ 0.2 @ 0.1 @ 0.1 @ 0.2 @ 0.7 @ 0.2 @ 0.3 @ 0.2 @ 0.2 @ 0.1 @ 0.5 @ 0.2 @
(Maximum) 1100°C @ 1100°C @ 1100°C @ 1100°C @ 1100°C @ 1260°C @ 1260°C @ 1260°C @ 1320°C @ 1320°C @ 1320°C @ 1370°C @ 1320°C @
0.034MPa 0.034MPa 0.034MPa 0.034MPa 0.034MPa 0.069MPa 0.069MPa 0.069MPa 0.069MPa 0.069MPa 0.069MPa 0.069MPa 0.069MPa
(2012°F @ (2012°F @ (2012°F @ (2012°F @ 5 (2012°F @ (2300°F @ (2300°F @ (2300°F @ (2408°F @ (2408°F @ (2408°F @ (2498°F @ (2408°F @
5 PSI) 5 PSI) 5 PSI) PSI) 5 PSI) 10 PSI) 10 PSI) 10 PSI) 10 PSI) 10 PSI) 10 PSI) 10 PSI) 10 PSI)

Thermal Conductivity -
K, W/moK ((Btu·in)/(h·ft2 - oF)) 0.22 0.30 0.22 0.14 0.30 0.28 0.27 0.32 0.32 0.34 0.42 0.39 0.50
at 600°C (1112⁰F) (1.54) (2.09) (1.54) (0.98) (2.09) (1.96) (1.89) (2.23) (2.23) (2.37) (2.86) (2.72) (3.49)
per ASTM C182 (Maximum)
AI2O3 (%)
45 45 45 37 45 50 58 55 67 64 70 73 77
(Minimum)
SiO2 (%)
50 50 48 44 48 45 39 41 31 32 28 25 21
(Minimum)
Fe2O3 (%)
1.0 1.0 1.0 0.7 1.0 0.9 0.7 0.9 0.6 0.7 0.7 0.5 0.3
(Maximum)
NOTES:
1. Data is for proprietary, industrial brick only and is not applicable to pre-cast castable shapes.
2. Testing shall comply with the requirements of Sections 4.2.2.3,1 or 4.2.3.3 as applicable.
3. All values are contraction except where shown as “+”.
4. IFB classifications 20, 23, 26, 28, 30 and 32 are in accordance with ASTM C155. Other classifications are per manufacturer specialty materials.

Process Industry Practices Page 17 of 18

PIP RFSB1000
Brick Refractory Material Specification January 2018

Appendix B – Refractory Mortar Compliance Requirements

Phosphate Bonded Alumina

Classification Fireclay Mortar (Note 1) High-Alumina Mortar (wt. % Al2O3 Content) (Note1) Chrome-Alumina Mortar (wt% Cr2O3)
Mortar (wt. % Al2O3) (Note 2)
(Note 2)
Medium Super
Properties High Duty 70 80 85 90 85 90 10 70 90
Duty Duty

Refractoriness Test per No Flow No Flow No Flow No Flow No Flow No Flow No Flow No Flow No Flow No Flow No Flow No Flow
ASTM C199 @ 1400⁰C @ 1500⁰C @ 1600⁰C @ 1705⁰C @ 1705⁰C @ 1705⁰C @ 1705⁰C @ 1705⁰C @ 1705⁰C @ 1705⁰C @ 1705⁰C @ 1705⁰C
(2550⁰F) (2730⁰F) (2910⁰F) (3100⁰F) (3100⁰F) (3100⁰F) (3100⁰F) (3100⁰F) (3100⁰F) (3100⁰F) (3100⁰F) (3100⁰F)

Cold Bonding Strength

per ASTM C198
Using Modulus of 4.5 4.5 5.5 5.3 5.5 3.4 1.45 9.0 6.9 9.7 1.2 0.7
Rupture, MPa (psi) (650) (650) (800) (775) (800) (490) (210) (1300) (1000) (1400) (180) (100)
per ASTM C133
(Minimum)

AI2O3 (wt%)
30 40 54 67 79 83 88 81 90 89 26 9
(Minimum)

SiO2 (wt%)
60 53 40 25 9 14.5 9.5 7.0 1.2 0.2 0.3 0.2
(Typical)

Fe2O3 (wt%)
1.4 1.2 1.1 1.5 1.5 0.2 0.2 1.5 0.1 0.1 0.5 0.1
(Maximum)

P2O5 (wt%)
N/A N/A N/A N/A N/A N/A N/A 6.5 6.3 N/A N/A N/A
Minimum

Cr2O3 (wt%)
N/A N/A N/A N/A N/A N/A N/A N/A N/A 9.0 69 88
(Minimum)

NOTES:
1. Fireclay and high-alumina mortars are per ASTM C1655.
2. Phosphate-bonded and chrome-alumina mortars are vendor proprietary classifications.
3. N/A indicates not applicable.
4. Testing shall comply with the requirements of Sections 4.2.2.3.2 or 4.2.3.4 as applicable.

Process Industry Practices Page 18 of 18