Specialized Masonry – A Bit of Griffin Work History

Working in the field of specialized masonry was not my first job, but it was easily the toughest.  When I am asked about my work history, it is also the most difficult to explain, so here is a post to show you what goes on.

The company I worked for, Industry Services Co. Inc., is located in Theodore, Alabama and is still in business (as far as I know).  My father worked for the company for many years, so it was the perfect opportunity for a summer job.  I started out in the warehouse.  Packing out the work boxes for large jobs was my main task, but there were plenty of opportunities for learning.  At this point I had only worked with my father and grandfather in residential construction and marble restoration, but I was soon to get my feet wet with the cool waters of industrial construction….

Because industrial processes often require extreme environments, specialized masonry products are needed to maintain the life of the vessels which contain these environments.  High temperatures, abrasives, and acids are typical challenges which can be solved with the right combination of ceramic materials.

Above: Avery Welch and I are removing masonry units from molds at ISCI’s warehouse in Mobile, AL….Good Times!

After turning 18 I could legally enter the mills where most of the work was being done.  I quickly learned that all mills are unique, micro-cities with smells and characteristics all of their own.  Paper mills were the most odorous.   I never could figure out if it was coming from the kraft process or the “black liquor” they burned in the recovery boilers.  Either way, its not mom’s fresh baked apple pie, I can assure you.  Cement plants were also a favorite of mine.  If you like tons of dust, and flames of death, this is the place for you.  Below are some of the mills I worked in frequently while with Industry Services.

Recovery Boilers are common to all paper mills.  They allow “black liquor“, produced during the pulp–making process, to be burned as fuel for steam and ultimately, electricity.  By burning wastes and other fuels, the boiler heats huge networks of water-filled tubes.  These tubes supply pressure to generators which produce electricity for the mill.

Where the tubes terminate and where burner pipes, sensors, and manholes protrude often need to be packed with refractory ceramics.  While crawling around in these tubes, I used to wonder how long someone could last if they were trapped inside.  That may seem dreadful, but when you are in a mill you constantly think about things like that for some reason…

To produce and bleach the wood pulp (concentrated cellulose fibers) mills commonly use solutions of sodium hydroxide, sodium sulfide, and chlorine which can accelerate deterioration of the vessels holding the material.  Therefore, the tanks which hold the pulp and the surrounding areas need to be chemically resistant.  Glazed tile and acid resistant brick are used to reduce damage in these areas.

Above: Empty pulp tank lined with ceramic tile

Above & Below: Acid resistant brick protect pads of concrete supporting vital equipment

Most of the excitement in a mill is where things get hot.  Incinerators, reactors, cyclonic separators, and rotary kilns are some of the coolest looking structures when viewed from the inside.  I still remember the feeling of awe that came over me when I saw a lime kiln in operation for the first time.  I also remember the strange beauty of the radius brick laid around a burner opening, and thinking that is was a shame it was never again to be seen by human eyes (until, of course, when it needed repair).

Above: Reactors lined with refractory brick – top image shows burner opening

Rotary kilns are at the heart of any cement plant and are used in many paper mills to produce lime in the recovery process .  They are huge, rotating steel tubes, which are constantly being heated by an enormous natural gas burner.  Kilns are lined with layers of refractory brick which insulate the reaction, and keep it from burning through the outer hull.  They are also sloped to help coax the material down the shaft as it rotates.  When the product (clinker) exits, it is glowing red-hot, much like magma.  Working in a kiln after it has been shut down is always hot, even in the winter, because the brick retains much of the heat from continuous operation.  The burners are the main attraction when it comes to kilns.  The ones used in industry dwarf the type used in pottery kilns.

Below: End view of the burner injector

Repairing Kilns is almost as interesting as watching them in operation.  The old brick used to be torn out by hand, but over the years it was obvious that it is just too dangerous.  Specialized machines, which are often remote controlled, are now used to remove the rings of brick with much less liability.  Installing the new rings is a fairly interesting process which requires a customized rig.  The rigs consist of a rolling scaffold and a radial template.  The brick on the upper portion of the ring are in the form of an arch, so they need to be held in place until they set completely.  This is done by placing a tension rod (pogo stick) between the template and the brick.  Once the course is in place, the rods are removed and the rig is rolled into position for the next ring.  The video below shows a state-of-the-art rig, which is more advanced than any I ever used, but illustrates the process fairly well.

I learned a great deal from working for ISCI.  The work was fast paced and never the same.  I must admit that residential work is far more enjoyable, because of the time you are allowed to take on each project.  When working in industry, every minute a machine is down, money is being lost. That means there is only one working-speed…FAST! There were many night-shifts when I wanted to lay down on a pallet of bricks and go to sleep!  Mills are loud, smelly and dangerous, but I do miss the excitement sometimes…

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