Concise User’s Instructions MAT PLUS 80 EA

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MAT PLUS 80 EA

  1. Short Description: Monolithic, hydraulic-bonded, Low Cement Castable (LCC) material, with CaO content between 2.5% and 1%.

 

  1. Packaging-Storage
  • These refractory materials are packed in special paper sacks, of about 25 Kgr, in wooden pallets.
  • Shrink foil wrapping protects the refractory materials against moisture.
  • These refractory materials should be stored in dry place and cool warehouse (shelf life is indicative to the Technical Data Sheets).
  •  Pallet stacking is admissible and the max loaded pallets must not exceed 3 pallets. If the shelf life has been exceeded, our Technical Service Department should be contacted before use.
  • “First in – First out” management of stored materials is advisable.
  • The material has to be stored above freezing temperature.
  • Due to high humidity and strong solar radiation in tropical countries, storage in a dry, covered place is recommended.
  • The shrink wrapping should be removed only prior to mixing.

 

  1. Tools and Machnery/ Preparation before casting
  • Tools, mixer, vibrators and surrounds must be clean and free from foreign material.
  • The mould has to be stable to withstand stresses caused by vibration and the weight of the castable. The mould must be water tight. Always apply release oil to prevent the mould from adhering to the refractory material.
  • In a compulsory / forced action / paddle mixer, lumps can be produced which are dry inside and will not allow homogeneous curing.
  • This castable material has to be installed by vibration. Internal or external vibrators can be used. An external vibrator can vibrate the whole mould. Therefore, the filling of the mould has to be completed before curing, as vibration could disturb the curing process.
  • Dimensions and energy output of internal vibrators have to correlate with the wall thickness.
  • The area for casting must be clean.
  • The shuttering of the moulds (wood forms) as well as the back up materials should be waterproofed in order to minimize the water absorption from the mixed refractories. The shuttering can be removed after 24 hours by which time the exothermic reaction of alumina containing castables has taken place. The temperature increase should be checked with a recorder.

 

  1. Water required (lit/100 kg) (EN 1402-4): 4,5-5,5 
  1. Material Required at kg/m3 : 2800

 

  1. Mixing
  • L.C.C. materials are designed to be applied by casting.
  • The mixer and the accessories must be clean.
  • Do not mix refractory materials less than full paper bag.
  • The optimum quantity of dry material depends on the mixer capacity.
  • Only potable, drinking water must be added for the mixing of these refractory materials. Care should be taken when adding the water. It is recommended to start with 80% of the amount of water required (see the relevant specifications). After 2 minutes intensive mixing, it can be seen if sufficient water has been used.
  • A mixing of at least 3 up to 5 minutes is necessary. The mixing time has to be checked with a clock.
  • Minor adjustments to the added amount of water are permissible in order to achieve the desired flowability. Do not exceed the prescribed water content for each type of the refractory materials under any circumstances.
  • The added water as well as the refractory materials must be at temperatures higher than 10°C.
  • For application under 10oC the addition of accelerator is recommended. Otherwise a prolonged setting time is observed.

 

 

  1. Installation-Casting
  • The mixed castables (based on cement) must be installed within 15 minutes.
  • To avoid separation lines it is necessary to cast “wet in wet” and finish a complete section at a time.
  • Castables can also be pumped.
  • Immersion vibrators can homogenize the interface layers. To avoid holes these vibrators have to be pulled out very slowly.
  • If no air bubbles can be seen on the surface, the vibrator can be turned off until the next batch is ready.
  • Do not trowel to slick a finish surface.
  • Keep the surfaces damp and/or covered for at least 24 hours.
  • The refractory materials must be set prior the starting of dry out.
  • The setting time is strongly affected by the temperature.
  • Protect the cast materials from freezing because freezing of these materials prior to water removal can cause structural damage.

 

  1. Anchoring and Supporting
  • Depending on the dimensions and the location of the refractory lining it is necessary to use anchors; for temperatures up to 1200°C, steel anchors can be used and over 1200°C, ceramic anchors must be used.
  • Refractory grade anchors can be selected depending on the highest temperature, the corrosion environment and the specific project conditions.
  • Steel anchors can be selected depending on the highest temperature. They must be painted with bitumen or insulated with tape to avoid cracking.
  • Steel anchors have to be protected with 30 mm of refractory material against the hot face.

 

  1. Drying and Heating up
  • Cement based castables must be dried before starting pre-heat.
  • All castables have to be compatible with the pre-heat schedule for the whole kiln.
  • The drying and pre-heat temperature is available on request from our Technical Service Department.

 

  1. Winter precautions
  • The L.C.C shall be installed from 10oC up to 30oC.
  • If the temperature at the point of installation is below 10 °C, pre-heating is strongly recommended.
  • Temperature during setting should be above 10OC.
  • In case of, out of temperature limit conditions, please contact our Technical Service Department.

 

Important Note: The above instructions are suitable for the most of uses. The final User must follow carefully the instructions of Designer of each specific project.

 

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Concise User’s Instructions MAT PLUS 97 W

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MAT PLUS 95 W

  1. Short Description: Monolithic, hydraulic-bonded, Low Cement Castable (LCC) material, with CaO content between 2.5% and 1%.

 

  1. Packaging-Storage
  • These refractory materials are packed in special paper sacks, of about 25 Kgr, in wooden pallets.
  • Shrink foil wrapping protects the refractory materials against moisture.
  • These refractory materials should be stored in dry place and cool warehouse (shelf life is indicative to the Technical Data Sheets).
  •  Pallet stacking is admissible and the max loaded pallets must not exceed 3 pallets. If the shelf life has been exceeded, our Technical Service Department should be contacted before use.
  • “First in – First out” management of stored materials is advisable.
  • The material has to be stored above freezing temperature.
  • Due to high humidity and strong solar radiation in tropical countries, storage in a dry, covered place is recommended.
  • The shrink wrapping should be removed only prior to mixing.

 

  1. Tools and Machnery/ Preparation before casting
  • Tools, mixer, vibrators and surrounds must be clean and free from foreign material.
  • The mould has to be stable to withstand stresses caused by vibration and the weight of the castable. The mould must be water tight. Always apply release oil to prevent the mould from adhering to the refractory material.
  • In a compulsory/ forced action/ paddle mixer, lumps can be produced which are dry inside and will not allow homogeneous curing.
  • This castable material has to be installed by vibration. Internal or external vibrators can be used. An external vibrator can vibrate the whole mould. Therefore, the filling of the mould has to be completed before curing, as vibration could disturb the curing process.
  • Dimensions and energy output of internal vibrators have to correlate with the wall thickness.
  • The area for casting must be clean.
  • The shuttering of the moulds (wood forms) as well as the back up materials should be waterproofed in order to minimize the water absorption from the mixed refractories. The shuttering can be removed after 24 hours by which time the exothermic reaction of alumina containing castables has taken place. The temperature increase should be checked with a recorder.

 

  1. Water required (lit/100 kg) (EN 1402-4): 4,5-5,5

 

  1. Material Required at kg/m3 : 3100

 

  1. Mixing
  • L.C.C. materials are designed to be applied by casting.
  • The mixer and the accessories must be clean.
  • Do not mix refractory materials less than full paper bag.
  • The optimum quantity of dry material depends on the mixer capacity.
  • Only potable, drinking water must be added for the mixing of these refractory materials. Care should be taken when adding the water. It is recommended to start with 80% of the amount of water required (see the relevant specifications). After 2 minutes intensive mixing, it can be seen if sufficient water has been used.
  • A mixing of at least 3 up to 5 minutes is necessary. The mixing time has to be checked with a clock.
  • Minor adjustments to the added amount of water are permissible in order to achieve the desired flowability. Do not exceed the prescribed water content for each type of the refractory materials under any circumstances.
  • The added water as well as the refractory materials must be at temperatures higher than 10°C.
  • For application under 10oC the addition of accelerator is recommended. Otherwise a prolonged setting time is observed.

 

 

  1. Installation-Casting
  • The mixed castables (based on cement) must be installed within 15 minutes.
  • To avoid separation lines it is necessary to cast “wet in wet” and finish a complete section at a time.
  • Castables can also be pumped.
  • Immersion vibrators can homogenize the interface layers. To avoid holes these vibrators have to be pulled out very slowly.
  • If no air bubbles can be seen on the surface, the vibrator can be turned off until the next batch is ready.
  • Do not trowel to slick a finish surface.
  • Keep the surfaces damp and/or covered for at least 24 hours.
  • The refractory materials must be set prior the starting of dry out.
  • The setting time is strongly affected by the temperature.
  • Protect the cast materials from freezing because freezing of these materials prior to water removal can cause structural damage.

 

  1. Anchoring and Supporting
  • Depending on the dimensions and the location of the refractory lining it is necessary to use anchors; for temperatures up to 1200°C, steel anchors can be used and over 1200°C, ceramic anchors must be used.
  • Refractory grade anchors can be selected depending on the highest temperature, the corrosion environment and the specific project conditions.
  • Steel anchors can be selected depending on the highest temperature. They must be painted with bitumen or insulated with tape to avoid cracking.
  • Steel anchors have to be protected with 30 mm of refractory material against the hot face.

 

  1. Drying and Heating up
  • Cement based castables must be dried before starting pre-heat.
  • All castables have to be compatible with the pre-heat schedule for the whole kiln.
  • The drying and pre-heat temperature is available on request from our Technical Service Department.

 

  1. Winter precautions
  • The L.C.C shall be installed from 10oC up to 30oC.
  • If the temperature at the point of installation is below 10 °C, pre-heating is strongly recommended.
  • Temperature during setting should be above 10OC.
  • In case of, out of temperature limit conditions, please contact our Technical Service Department.

Important Note: The above instructions are suitable for the most of uses. The final User must follow carefully the instructions of Designer of each specific project.

 

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Concise User’s Instructions MAT 48 HGF

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MAT 48 HGF

  1. Short Description: Insulating gunning material, to be used as insulating lining. Insulating gunning materials are categorized in different categories according to their density.

 

  1. Packaging-Storage
  • These refractory materials are packed in special paper sacks, of about 20 Kgr, in wooden pallets.
  • Shrink foil wrapping protects the refractory materials against moisture.
  • These refractory materials should be stored in dry place and cool warehouse (shelf life is indicative to the Technical Data Sheets).
  •  Pallet stacking is admissible and the max loaded pallets must not exceed 2 pallets. If the shelf life has been exceeded, our Technical Service Department should be contacted before use.
  • “First in – First out” management of stored materials is advisable.
  • The material has to be stored above freezing temperature.
  • Due to high humidity and strong solar radiation in tropical countries, storage in a dry, covered place is recommended.
  • The shrink wrapping should be removed only prior to mixing.

 

  1. Tools and Machnery/ Preparation before casting
  • Gunning machines, accessories and surrounds must be clean and free from foreign material.
  • The area for gunning must be clean.

 

 

  1. Water required: 10-12 / at nozzle

 

 

  1. Material Required at kg/m3 : 2220

 

 

  1. Installation-Casting
  • Insulating gunning materials are fed to the hopper of the gunning machine.
  • The compressed air pressure and the added water must be carefully adjusted.
  • The mixing of the gunned material with the potable water takes place at the gunning nozzle, which is equipped with a water control valve.
  • Good communication between the nozzle and gunning machine operators is required at all times to ensure the installation is correct.
  • The control of the added water is critical for the stickiness, the rebound and the generated dust.
  • If the gunning mix sticks to the wall with the smallest rebound, the amount of water used is correct. If the gunning mix is too wet, it will slide down the wall.
  • The rebound contains set cement and can not be reused anymore.
  • The processing quality depends on striking angle, gunning pressure, gunning mix thickness etc.

 

 

  1. Anchoring and Supporting
  • Depending on the dimensions and the location of the refractory lining it is necessary to use anchors; for temperatures up to 1200°C, steel anchors can be used and over 1200°C, ceramic anchors must be used.
  • Refractory grade anchors can be selected depending on the highest temperature, the corrosion environment and the specific project conditions.
  • Steel anchors can be selected depending on the highest temperature. They must be painted with bitumen or insulated with tape to avoid cracking.
  • Steel anchors have to be protected with 30 mm of refractory material against the hot face.

 

 

  1. Drying and Heating up
  • Cement based gunning materials must be dried before starting pre-heat.
  • All gunning materials have to be compatible with the pre-heat schedule for the whole kiln.
  • The drying and pre-heat temperature is available on request from our Technical Service Department.

 

 

  1. Winter precautions
  • If the temperature at the point of installation is below 5°C, pre-heating is strongly recommended.
  • Temperature during setting should be above freezing point.
  • In case of, out of temperature limit conditions, please contact our Technical Service Department.

 

Important Note: The above instructions are suitable for the most of uses. The final User must follow carefully the instructions of Designer of each specific project.

 

 

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16Mo3 Boiler Mat Pins

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16Mo3 Boiler Mat Pins & Flat Bars

Description:

External boiler insulation holding Pins specifically formed for stud welding and Flat Bars.

They are made out of 16Mo3 steel which exhibits exceptional corrosion resistance and high temperature resilience due to it being a chrome – molybdenum alloy. They come as set with their respective ferrules.

 

 

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Concise User’s Instructions MAT 124 GP

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The following instructions will help you make the most out of our quality.

 

MAT 124 GP

  1. Short Description: Insulating gunning material, to be used as insulating lining. Insulating gunning materials are categorized in different categories according to their density.

 

  1. Packaging-Storage
  • These refractory materials are packed in special paper sacks, of about 20 Kgr, in wooden pallets.
  • Shrink foil wrapping protects the refractory materials against moisture.
  • These refractory materials should be stored in dry place and cool warehouse (shelf life is indicative to the Technical Data Sheets).
  •  Pallet stacking is admissible and the max loaded pallets must not exceed 2 pallets. If the shelf life has been exceeded, our Technical Service Department should be contacted before use.
  • “First in – First out” management of stored materials is advisable.
  • The material has to be stored above freezing temperature.
  • Due to high humidity and strong solar radiation in tropical countries, storage in a dry, covered place is recommended.
  • The shrink wrapping should be removed only prior to mixing.

 

  1. Tools and Machnery/ Preparation before casting
  • Gunning machines, accessories and surrounds must be clean and free from foreign material.
  • The area for gunning must be clean.

 

 

  1. Water required: 34-45/ at nozzle

 

 

  1. Material Required at kg/m3 :1250

 

 

  1. Installation-Casting
  • Insulating gunning materials are fed to the hopper of the gunning machine.
  • The compressed air pressure and the added water must be carefully adjusted.
  • The mixing of the gunned material with the potable water takes place at the gunning nozzle, which is equipped with a water control valve.
  • Good communication between the nozzle and gunning machine operators is required at all times to ensure the installation is correct.
  • The control of the added water is critical for the stickiness, the rebound and the generated dust.
  • If the gunning mix sticks to the wall with the smallest rebound, the amount of water used is correct. If the gunning mix is too wet, it will slide down the wall.
  • The rebound contains set cement and can not be reused anymore.
  • The processing quality depends on striking angle, gunning pressure, gunning mix thickness etc.

 

 

  1. Anchoring and Supporting
  • Depending on the dimensions and the location of the refractory lining it is necessary to use anchors; for temperatures up to 1200°C, steel anchors can be used and over 1200°C, ceramic anchors must be used.
  • Refractory grade anchors can be selected depending on the highest temperature, the corrosion environment and the specific project conditions.
  • Steel anchors can be selected depending on the highest temperature. They must be painted with bitumen or insulated with tape to avoid cracking.
  • Steel anchors have to be protected with 30 mm of refractory material against the hot face.

 

 

  1. Drying and Heating up
  • Cement based gunning materials must be dried before starting pre-heat.
  • All gunning materials have to be compatible with the pre-heat schedule for the whole kiln.
  • The drying and pre-heat temperature is available on request from our Technical Service Department.

 

 

  1. Winter precautions
  • If the temperature at the point of installation is below 5°C, pre-heating is strongly recommended.
  • Temperature during setting should be above freezing point.
  • In case of, out of temperature limit conditions, please contact our Technical Service Department.

Important Note: The above instructions are suitable for the most of uses. The final User must follow carefully the instructions of Designer of each specific project.

 

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Concise User’s Instructions MAT LG 10 SIC M

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MAT LG 10 SIC M

  1. Short Description: Monolithic, hydraulic-bonded, Low Cement Gunning (LCG) material, with CaO content 1.5% and 10% Silicon Carbide.
  • These refractory materials are packed in special paper sacks, of about 25 kg, on wooden pallets.
  • Shrink foil wrapping protects the refractory materials against moisture.
  • These refractory materials should be stored in a dry cool warehouse (shelf life is indicated on the Technical Data Sheet). If the shelf life has been exceeded, our Technical Service Department should be contacted before use
  •  Pallet stacking is admissible and the max loaded pallets must not exceed 3 pallets.
  • “First in – First out” management of stored materials is advisable.
  • The material has to be stored above freezing temperature.
  • Due to high humidity and strong solar radiation in tropical countries, storage in a dry, covered place is recommended.
  • The shrink wrapping should be removed only prior to mixing.

 

  1. Tools and Machinery/ Preparation before gunning
  • Tools, gunning machine and surrounds must be clean and free from foreign material.
  • The mould has to be stable to withstand stresses caused by vibration and the weight of the material. The mould must be water tight. Always apply release oil to prevent the mould from adhering to the refractory material.
  • The area for gunning must be clean.
  • The shuttering of the moulds (wood forms) as well as the back up materials should be waterproofed in order to minimize the water absorption from the gunned refractories. The shuttering can be removed after 24 hours by which time the exothermic reaction of alumina containing castables has taken place. The temperature increase should be checked with a recorder.

 

  1. Water required (l/100 kg): Mixing at nozzle

 

  1. Material Required at kg/m3 : 2400

 

  1. Installation-Gunning
  • The gunning machine and the accessories must be clean and free from any foreign materials
  • The refractory materials are fed to the hopper of the gunning machine.
  • The compressed air pressure and the added water must be carefully adjusted.
  • The mixing of the gunned material with the potable water takes place at the gunning nozzle, which is equipped with a water control valve.
  • Good communication between the nozzle man and the men operating the gunning machine is required at all times to ensure the installation is correct.
  • The control of the added water is critical for the stickiness, the rebound and the generated dust.
  • If the gunning mix sticks to the wall with the smallest rebound, the amount of water used is correct.
  • If the gunning mix is too wet, it will slide down the wall. The rebound contains set cement and can not be reused anymore.
  • The processing quality depends on striking angle, gunning pressure, gunning mix thickness etc.
  • The surface of the cast section should be covered with layer sacking material which is to be kept moist during the curing time.

 

  1. Anchoring and Supporting
  • Depending on the dimensions and the location of the refractory lining it is necessary to use anchors; for temperatures up to 1200°C steel anchors can be used, and over 1200°C ceramic anchors must be used.
  • Refractory grade anchors can be selected depending on the highest temperature, the corrosion environment and the specific project conditions.
  • Steel anchors can be selected depending on the highest temperature. They must be painted with bitumen or insulated with tape to avoid cracking.
  • Steel anchors have to be protected with 30 mm of refractory material against the hot face.

 

  1. Drying and Heating up
  • Cement based gunning materials must be dried before starting pre-heat.
  • All castables have to be compatible with the pre-heat schedule for the whole kiln.
  • The drying and pre-heat temperature is available on request from our Technical Service Department.

 

  1. Winter precautions
  • The L.C.G shall be installed from 10oC up to 30oC.
  • If the temperature at the point of installation is below 10 °C, pre-heating is strongly recommended.
  • Temperature during setting should be above 10°C.
  • In case of, out of temperature limit conditions, please contact our Technical Service Department.

Important Note: The above instructions are suitable for the most of uses. The final User must follow carefully the instructions of Designer of each specific project.

 

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Concise User’s Instructions MAT PLUS 20 SIC M

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The following instructions will help you make the most out of our quality.

 

MAT PLUS 20 SIC M

 

  1. Short Description: Monolithic, hydraulic-bonded, Low Cement Castable (LCC) material, with CaO content between 2.5% and 1% and 20% Silicon Carbide.
  1. Packaging-Storage
  • These refractory materials are packed in special paper sacks, of about 25 Kgr, in wooden pallets.
  • Shrink foil wrapping protects the refractory materials against moisture.
  • These refractory materials should be stored in dry place and cool warehouse (shelf life is indicative to the Technical Data Sheets).
  •  Pallet stacking is admissible and the max loaded pallets must not exceed 3 pallets. If the shelf life has been exceeded, our Technical Service Department should be contacted before use.
  • “First in – First out” management of stored materials is advisable.
  • The material has to be stored above freezing temperature.
  • Due to high humidity and strong solar radiation in tropical countries, storage in a dry, covered place is recommended.
  • The shrink wrapping should be removed only prior to mixing.

 

  1. Tools and Machnery/ Preparation before casting
  • Tools, mixer, vibrators and surrounds must be clean and free from foreign material.
  • The mould has to be stable to withstand stresses caused by vibration and the weight of the castable. The mould must be water tight. Always apply release oil to prevent the mould from adhering to the refractory material.
  • In a compulsory / forced action / paddle mixer, lumps can be produced which are dry inside and will not allow homogeneous curing.
  • This castable material has to be installed by vibration. Internal or external vibrators can be used. An external vibrator can vibrate the whole mould. Therefore, the filling of the mould has to be completed before curing, as vibration could disturb the curing process.
  • Dimensions and energy output of internal vibrators have to correlate with the wall thickness.
  • The area for casting must be clean.
  • The shuttering of the moulds (wood forms) as well as the back up materials should be waterproofed in order to minimize the water absorption from the mixed refractories. The shuttering can be removed after 24 hours by which time the exothermic reaction of alumina containing castables has taken place. The temperature increase should be checked with a recorder.

 

  1. Water required (lit/100 kg) (EN 1402-4): 4.0-5.0

 

  1. Material Required at kg/m3 : 2500

 

  1. Mixing
  • L.C.C. materials are designed to be applied by casting.
  • The mixer and the accessories must be clean.
  • Do not mix refractory materials less than full paper bag.
  • The optimum quantity of dry material depends on the mixer capacity.
  • Only potable, drinking water must be added for the mixing of these refractory materials. Care should be taken when adding the water. It is recommended to start with 80% of the amount of water required (see the relevant specifications). After 2 minutes intensive mixing, it can be seen if sufficient water has been used.
  • A mixing of at least 3 up to 5 minutes is necessary. The mixing time has to be checked with a clock.
  • Minor adjustments to the added amount of water are permissible in order to achieve the desired flowability. Do not exceed the prescribed water content for each type of the refractory materials under any circumstances.
  • The added water as well as the refractory materials must be at temperatures higher than 10°C.
  • For application under 10oC the addition of accelerator is recommended. Otherwise a prolonged setting time is observed.

  

  1. Installation-Casting
  • The mixed castables (based on cement) must be installed within 15 minutes.
  • To avoid separation lines it is necessary to cast “wet in wet” and finish a complete section at a time.
  • Castables can also be pumped.
  • Immersion vibrators can homogenize the interface layers. To avoid holes these vibrators have to be pulled out very slowly.
  • If no air bubbles can be seen on the surface, the vibrator can be turned off until the next batch is ready.
  • Do not trowel to slick a finish surface.
  • Keep the surfaces damp and/or covered for at least 24 hours.
  • The refractory materials must be set prior the starting of dry out.
  • The setting time is strongly affected by the temperature.
  • Protect the cast materials from freezing because freezing of these materials prior to water removal can cause structural damage.

 

  1. Anchoring and Supporting
  • Depending on the dimensions and the location of the refractory lining it is necessary to use anchors; for temperatures up to 1200°C, steel anchors can be used and over 1200°C, ceramic anchors must be used.
  • Refractory grade anchors can be selected depending on the highest temperature, the corrosion environment and the specific project conditions.
  • Steel anchors can be selected depending on the highest temperature. They must be painted with bitumen or insulated with tape to avoid cracking.
  • Steel anchors have to be protected with 30 mm of refractory material against the hot face.

 

  1. Drying and Heating up
  • Cement based castables must be dried before starting pre-heat.
  • All castables have to be compatible with the pre-heat schedule for the whole kiln.
  • The drying and pre-heat temperature is available on request from our Technical Service Department.

 

  1. Winter precautions
  • The L.C.C shall be installed from 10oC up to 30oC.
  • If the temperature at the point of installation is below 10 °C, pre-heating is strongly recommended.
  • Temperature during setting should be above 10OC.
  • In case of, out of temperature limit conditions, please contact our Technical Service Department.

Important Note: The above instructions are suitable for the most of uses. The final User must follow carefully the instructions of Designer of each specific project.

 

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Concise User’s Instructions MAT 125P CG

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MAT 125P CG

  1. Short Description: Insulating castable material, to be used as insulating lining. Insulating castables are categorized in different categories according to their density.

 

  1. Packaging-Storage
  • These refractory materials are packed in special paper sacks, of about 20 Kgr, in wooden pallets.
  • Shrink foil wrapping protects the refractory materials against moisture.
  • These refractory materials should be stored in dry place and cool warehouse (shelf life is indicative to the Technical Data Sheets).
  •  Pallet stacking is admissible and the max loaded pallets must not exceed 2 pallets. If the shelf life has been exceeded, our Technical Service Department should be contacted before use.
  • “First in – First out” management of stored materials is advisable.
  • The material has to be stored above freezing temperature.
  • Due to high humidity and strong solar radiation in tropical countries, storage in a dry, covered place is recommended.
  • The shrink wrapping should be removed only prior to mixing.

 

  1. Tools and Machinery/ Preparation before casting
  • Tools, mixer, vibrators and surrounds must be clean and free from foreign material.
  • The mould has to be stable to withstand stresses caused by vibration and the weight of the insulating castable. The mould must be water tight. Always apply release oil to prevent the mould from adhering to the refractory material.
  • The area for casting must be clean.
  • The shuttering of the moulds (wood forms) as well as the back up materials should be waterproofed in order to minimize the water absorption from the mixed refractories. The shuttering can be removed after curing at the earliest. The temperature increase should be checked with a recorder.
  • A longer time period is not critical. The surface of the newly cast section should be covered with layer sacking material which is to be kept moist during the curing time.

 

  1. Water required (lit/100 kg) (EN 1402-4): 42 – 52 / At nozzle

 

 

  1. Material Required at kg/m3 : 1010

 

 

  1. Installation-Casting
  • The insulating castables are designed to be applied by casting techniques.
  • Do not mix refractory materials less than full paper bag. The optimum quantity of dry material depends on the mixer capacity.
  • Only potable, drinking water must be added for the mixing of the insulating refractory materials. Light-weight castables have to be mixed by hand or with a standard mixer.
  • The mixer must not destroy the light weight grains. Do not dry mix because the lightweight raw materials are crushed increasing the density of the refractory insulating refractories.
  • The major part of the recommended amount of water can be poured into the mixer before adding the material. After adding the rest of water a mixing time of 2 – 4 minutes should be allowed.
  • Light weight castables should be mixed for a shorter time period than standard castables.
  • Do not exceed the prescribe water content for each type of insulating materials under any circumstances. The water content of the light weight castables is high and they do not normally require stirring or vibrating.
  • If a vibrator is used in combination with a mixer, it is important to avoid separation. The mixed insulating castables (based on cement) must be installed within 15 minutes. To avoid separation lines it is necessary to cast “wet in wet” and finish a complete section at a time.
  • Castables can also be pumped.

 

  1. Anchoring and Supporting
  • Depending on the dimensions and the location of the refractory lining it is necessary to use anchors; for temperatures up to 1200°C, steel anchors can be used and over 1200°C, ceramic anchors must be used.
  • Refractory grade anchors can be selected depending on the highest temperature, the corrosion environment and the specific project conditions.
  • Steel anchors can be selected depending on the highest temperature. They must be painted with bitumen or insulated with tape to avoid cracking.
  • Steel anchors have to be protected with 30 mm of refractory material against the hot face.

 

  1. Drying and Heating up
  • Cement based castables must be dried before starting pre-heat.
  • All castables have to be compatible with the pre-heat schedule for the whole kiln.
  • The drying and pre-heat temperature is available on request from our Technical Service Department.

 

  1. Winter precautions
  • If the temperature at the point of installation is below 5°C, pre-heating is strongly recommended.
  • Temperature during setting should be above freezing point.

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Concise User’s Instructions MAC 35-D

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The following instructions will help you make the most out of our quality.

 

MAC 35-D

 

  1. Short Description: Air setting mortar to be used in the installation of bricks and refractory bricks masonry.

 

 

  1. Packaging-Storage
  • These refractory materials are packed in special paper sacks, of about 25 Kgr, in wooden pallets.
  • Shrink foil wrapping protects the refractory materials against moisture.
  • These refractory materials should be stored in dry place and cool warehouse (shelf life is indicative to the Technical Data Sheets).
  •  Pallet stacking is admissible and the max loaded pallets must not exceed 3 pallets. If the shelf life has been exceeded, our Technical Service Department should be contacted before use.
  • “First in – First out” management of stored materials is advisable.
  • The material has to be stored above freezing temperature.
  • Due to high humidity and strong solar radiation in tropical countries, storage in a dry, covered place is recommended.
  • The shrink wrapping should be removed only prior to mixing.

 

 

  1. Tools and Machnery
  • Tools and all equipment must be clean and free from dirt and pollutants.
  • Mortars can be mixed with mechanical mixers or by hand.
  • To ensure thin joints the brick should be coated homogeneously with mortar using a trowel.
  • Mortar which has already set, cannot be used anymore. If the mortar loses its plasticity during the application to the surface, it is advisable to moisten the brickwork prior to coating.

 

 

  1. Water required: 23-30

 

  

  1. Installation-Casting
  • The mixing water has to be potable.
  • The major part of the recommended amount of water can be poured into the mixer before adding the material.
  • The mortar should be mixed until the mix is free of lumps.
  • If a chemical-ceramic binding mortar is used, only such an amount of mortar should be pre-mixed which can be processed within 2 hours.
  • To ensure thin joints the brick should be coated homogeneously with mortar using a trowel.
  • Mortar which has already set, cannot be used anymore. If the mortar loses its plasticity during the application to the surface, it is advisable to moisten the brickwork prior to coating.

 

 

  1. Drying and Heating up
  • Mortars are dried during pre-heat of the refractory lining.

 

 

  1. Winter precautions
  • If the temperature at the point of installation is below 5 °C, pre-heating is recommended. Temperature during setting should be above freezing point.
  • In case of, out of temperature limit conditions, please contact our Technical Service Department.

 

Important Note: The above instructions are suitable for the most of uses. The final User must follow carefully the instructions of Designer of each specific project.

 

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Concise User’s Instructions MAT 124 PL

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The following instructions will help you make the most out of our quality.

 

MAT 124 PL

  1. Short Description: Insulating gunning material, to be used as insulating lining. Insulating gunning materials are categorized in different categories according to their density.

 

  1. Packaging-Storage
  • These refractory materials are packed in special paper sacks, of about 20 Kgr, in wooden pallets.
  • Shrink foil wrapping protects the refractory materials against moisture.
  • These refractory materials should be stored in dry place and cool warehouse (shelf life is indicative to the Technical Data Sheets).
  •  Pallet stacking is admissible and the max loaded pallets must not exceed 2 pallets. If the shelf life has been exceeded, our Technical Service Department should be contacted before use.
  • “First in – First out” management of stored materials is advisable.
  • The material has to be stored above freezing temperature.
  • Due to high humidity and strong solar radiation in tropical countries, storage in a dry, covered place is recommended.
  • The shrink wrapping should be removed only prior to mixing.

 

  1. Tools and Machnery/ Preparation before casting
  • Gunning machines, accessories and surrounds must be clean and free from foreign material.
  • The area for gunning must be clean.

 

 

  1. Water required: 42 – 52 l/100kg

 

 

  1. Material Required at kg/m3 : 1180

 

 

  1. Installation-Casting
  • Insulating gunning materials are fed to the hopper of the gunning machine.
  • The compressed air pressure and the added water must be carefully adjusted.
  • The mixing of the gunned material with the potable water takes place at the gunning nozzle, which is equipped with a water control valve.
  • Good communication between the nozzle and gunning machine operators is required at all times to ensure the installation is correct.
  • The control of the added water is critical for the stickiness, the rebound and the generated dust.
  • If the gunning mix sticks to the wall with the smallest rebound, the amount of water used is correct. If the gunning mix is too wet, it will slide down the wall.
  • The rebound contains set cement and can not be reused anymore.
  • The processing quality depends on striking angle, gunning pressure, gunning mix thickness etc.

 

 

  1. Anchoring and Supporting
  • Depending on the dimensions and the location of the refractory lining it is necessary to use anchors; for temperatures up to 1200°C, steel anchors can be used and over 1200°C, ceramic anchors must be used.
  • Refractory grade anchors can be selected depending on the highest temperature, the corrosion environment and the specific project conditions.
  • Steel anchors can be selected depending on the highest temperature. They must be painted with bitumen or insulated with tape to avoid cracking.
  • Steel anchors have to be protected with 30 mm of refractory material against the hot face.

 

 

  1. Drying and Heating up
  • Cement based gunning materials must be dried before starting pre-heat.
  • All gunning materials have to be compatible with the pre-heat schedule for the whole kiln.
  • The drying and pre-heat temperature is available on request from our Technical Service Department.

 

 

  1. Winter precautions
  • If the temperature at the point of installation is below 5°C, pre-heating is strongly recommended.
  • Temperature during setting should be above freezing point.
  • In case of, out of temperature limit conditions, please contact our Technical Service Department.

 

Important Note: The above instructions are suitable for the most of uses. The final User must follow carefully the instructions of Designer of each specific project.

 

 

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