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DESIGN AND INSTALLATION MANUAL
Thermal Ceramics
TABLE OF CONTENTS
A. Preface
Introduction
B. High Technology Castables by Casting
1. General
2. Pre-Installation
2.1 Storage
2.2 Surface Preparation Prior to Refractory Placement
2.3 Formwork
2.4 Anchors
3. Installation
3.1 Water
3.2 Temperature
3.3 Mixing
3.4 Placement
3.5 Multilayer Linings
3.6 Joints
3.7 Finishing
3.8 Curing
4. Firing
List of Figures
Figure 1
Proper Bag Storage
Figure 2
Formwork
Figure 3
Paddle Mixer
Figure 4
Typical Large Paddle Mixer
Figure 5
Continuous Mixer
Figure 6
High Frequency Vibrator
Figure 7
Multilayer Linings
Figure 8
Construction Joints
Figure 9
Expansion Joints
Figure 10 Finishing
Figure 11 Cast with Forms in Pace
Figure 12 Spraying With Curing Compound
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Thermal Ceramics
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Thermal Ceramics
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1. GENERAL
High technology castables, such as Kaocrete
249C/250C and the Kaocrete HPM grades have lime
contents of 1-3%. High densities and strengths are
achieved in these low cement products by careful grain
sizing and the use of additives to reduce the water needed to cast.
2. PRE-INSTALLATION
2.1 Storage
High technology castables should be stored in a dry, wellventilated area and held off the floor on pallets (Figure 1).
If stored outside, the bags must be protected from rain or
dripping water by a fixed cover. Storage temperature is
not a consideration as long as the castable is in the
desired temperature range prior to casting (See Section
3.2). If the bags are further protected by plastic sheeting,
ensure there is sufficient ventilation underneath the plastic sheet to prevent water from condensing on the bags.
Avoid storing in areas of high humidity. Pallets should not
be stacked more than three high when in storage to prevent the consolidation and caking of material on the bottom rows of the pallets.
Figure 2 - Formwork
The surface of the formwork must be lightly and thoroughly oiled or greased to facilitate removal from the face
of the casting. The surface of the formwork should be uniform and smooth to give a good surface finish to the casting. It also aids in formwork release.
Formwork must be as watertight as possible, so all joints
and holes must be sealed. The use of vibrators during
casting will cause liquids and fines to bleed through
cracks in the formwork. These liquids will be rich in fine
particles and can thus leave a weakly bonded material
adjacent to the leaking joint with detrimental results.
Thermal Ceramics
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3.2 Temperature
Ambient conditions as well as casting water and material
temperatures can significantly affect the setting time of
high technology castables. In very cold conditions, the
bags should be kept in warm storage, not less than 60F,
for at least 48 hours before use. The ideal temperature of
mixed low cement castables lies between 62F and 77F.
When cast in place until thoroughly dried, the castable
and environment preferably should not fall below 60F
and certainly not below 50F as the castable will take
much longer to set.
If the castable freezes before the hydraulic set is completed, the ultimate strength of the material can be
reduced by 50% or more. Therefore, until the cast material is fired, freezing conditions must be avoided.
3.3 Mixing
Add all of the mixing water to the mixer and begin its
operation. Then add the castable in full bag lots. After the
mix becomes uniform in color, the remainder of the water
is added in small increments to bring the mix to the correct consistency. Do not use more than the recommended amount of water without direct authorization from the
manufacturers representative. When using a bottom discharge mixer, discharge at least two buckets of product
from the mixer to clear the gate. This material can be
immediately returned to the mixer and re-mixed. The discharge gate should be cleaned out after every mix to prevent buildup of old material in this region.
In very hot weather, the bags should be kept in cool storage (a temperature-controlled container may be required)
and the outer steel shell and formwork should be cooled
with water sprays. When spraying, extreme care needs to
be taken to ensure that no cooling water seeps into the
casting cavity. If it does, it must be dried before casting
commences. Cool water should be used for mixing. At
high temperatures, the time available to place the material is dramatically shortened; e.g. at 100F, the working
time can be as little as two minutes.
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Thermal Ceramics
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Once the installation has started, it should proceed without interruption until the lining of the part or section concerned is completed. Consolidation of the castable is produced using a high frequency vibrator (Figure 6). The
vibrator must have a minimum rated speed of 14000 VPM
(vibrations per minute) when immersed in the mass. A
poker type vibrator gives maximum strength and densification in the finished casting and assists flow around
anchors and into recesses.
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Thermal Ceramics
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3.6 Joints
The two types of joints used in casting are construction
joints and expansion joints.
Thermal Ceramics
Figure 10 - Finishing
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3.8 Curing
Curing prevents the loss of moisture from freshly cast
refractory concrete. Loss of water from the surface of the
cast before the bond is fully hydrated results in a weaker
cast. To prevent this, various methods of moist curing can
be used.
Formwork should be left in place for a minimum of 24
hours and exposed refractory concrete either sprayed
with water, covered with plastic sheeting, or sprayed with
a concrete curing compound (Figure 12). This is called
moist curing. The concrete curing compound forms an
impermeable membrane to prevent moisture loss during
curing but will burn out at low temperatures during firing.
Curing is essential to the achievement of maximum
strength in the green unfired state which will effect the
ultimate fired strength.
Notice:
Thermal Ceramics
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For further information, contact your nearest Thermal Ceramics technical sales office. You may also fax us
toll-free at 1-800-KAOWOOL, or write to Thermal Ceramics, P. O. Box 923, Dept. 140, Augusta, GA 30903.
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12.02/M147/1.5M
COPYRIGHT 2002