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- Short Description: Insulating castable material, to be used as insulating lining. Insulating castables are categorized in different categories according to their density.
- 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.
- 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 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.
- Water required (lit/100 kg) (EN 1402-4): 70-80
- Material Required at kg/m3 : 800
- 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.
- 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.
- 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.
- 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.