Coke oven reconstruction

A method of reconstructing a heating wall of a coking chamber in a coke oven battery from one end of the chamber to an opposite end, comprising:

• a) laying a course of large size cast modules using thermally stable, non-expanding large size modular cast modules, each module having at least one vertical opening which defines a portion of a flue;
• b) on a first course of large size cast modules, setting proper measurements between the large size cast modules and existing heating walls to insure proper taper of the oven;
• c) leveling and aligning the course of large size cast modules using at least one of story poles and levels;
• d) mortaring the large size cast modules into place;
• e) repeating steps (a), (c), and (d) to install subsequent layers of large size cast modules to create a newly laid heating wall;
• f) laying a plurality of courses of thermally stable, non-expanding large size modular cast ceiling blocks on the top of adjacent heating walls, at least one of the adjacent heating walls being the newly-laid heating wall, the cast ceiling blocks including (i) flue ceiling blocks stacked from a top of each wall to a top of a ceiling thereby extending the flue through the ceiling and (ii) second ceiling blocks stacked from the top of each wall to the top of the ceiling, defining passageways through the ceiling from the coking chamber bounded by the adjacent heating walls, each of the second ceiling blocks being wider than the distance between the adjacent heating walls;
• g) mortaring the large size cast ceiling blocks into place;
• and
• h) pouring a top cover between the flue ceiling blocks and the second ceiling blocks to complete the ceiling.