Calderys Installation Manual

Calderys Installation Manual
for Refractories (CIM)
First Edition
2010
first edition
Calderys
Installation Manual for Refractories
(CIM)
Calderys Solutions for Engineering & Construction

1st edition
Revisions
1st edition, revision 0.0
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1st edition
Preface
We are happy to introduce the first issue of the Calderys Installation
Manual, CIM. This manual is the essence of the installation practices in
the companies of the Calderys group.
We have tried to identify and select the best practices coming from the
different group companies.
Our primary aim with this manual is to describe the various installation
techniques practised within Calderys.
This manual will constitute a support, not only for the construction
department but for all departments linked to project execution, to clearly
define what is expected, how it should be carried out and what is required
in terms of equipment and other resources.
This manual can also be used as a guideline for those who are not
directly involved in project execution.
This manual is the first edition and will undergo revision as and when
required.
Your contribution in order to improve the quality of this manual will be
highly appreciated.
You will find us at: http://secintranet.calderys.com
Acknowledgement
A thank you to all the people involved in preparing this manual. A special
thanks to the SEC team who did much of the work in gathering together the
large amount of information spread throughout Calderys and compiling it into
something readable: Mikael Berg, Rien Boer, Patrik Eriksson, D.K. Singh,
Christian Reichard-Kron and Clete Reader.
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Table of contents
1 STORAGE OF MATERIAL...................................................................................6
1.1 General guidelines .......................................................................................6
1.2 Special remarks per material type ................................................................7
1.3 Storage guidelines........................................................................................9
2 WORKSITE ........................................................................................................10
2.1 General.......................................................................................................10
2.2 Personnel ...................................................................................................11
2.3 Resources ..................................................................................................11
2.4 Housekeeping ............................................................................................13
3 EQUIPMENT ......................................................................................................14
3.1 General.......................................................................................................14
3.2 Specific Tools .............................................................................................15
4 GENERAL INSTALLATION................................................................................18
4.1 Steel surface ..............................................................................................18
4.2 Anchoring ...................................................................................................18
4.3 Water quality ..............................................................................................25
4.4 Formwork / shuttering.................................................................................26
4.5 Joints in monolitics .....................................................................................29
4.6 Sampling ....................................................................................................31
5 APPLICATION METHODS.................................................................................33
5.1 Ramming ....................................................................................................33
5.2 Casting .......................................................................................................39
5.3 Gunning......................................................................................................48
5.4 Brickwork ....................................................................................................63
5.5 Back-up layer blankets/fibres .....................................................................66
6 DEMOLITION .....................................................................................................67
7 REPAIR METHODS ...........................................................................................68
7.1 Repair Procedure - Patching ......................................................................68
7.2 Repair Procedure -Gunning .......................................................................69
7.3 Repair Procedure -Castable .......................................................................69
7.4 Repair Procedure -Brickwork......................................................................70
8 CURING .............................................................................................................71
8.1 Wet curing ..................................................................................................71
8.2 Conservation ..............................................................................................71
9 DRY OUT ...........................................................................................................73
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10 CRITERIA FOR ACCEPTANCE ....................................................................74

10.1 Cracks ........................................................................................................74
10.2 Defects and acceptance criteria .................................................................74
11 INSPECTION .................................................................................................75
11.1 Final Documentation ..................................................................................75
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1 STORAGE OF MATERIAL
All refractory materials should be protected against extreme weather
conditions during installation & storage, e.g. shed to protect against
extreme sunshine, cold, wind or heavy rain.
1.1 General guidelines

Calderys monolithic materials are generally supplied in multiple layer
packing. Complete pallet loads are covered and sealed with shrink-foil.
The floor where material is to be stored must be straight and stable for
easy access by handling equipment.
If Calderys materials must be stored outdoors, the packages should be
raised off the ground and covered with tarpaulin or similar protection.
Fig 1.1: Storage on pallet, adapted to

rainy conditions.
In order to keep the binding cement fresh, it is necessary to store the

material dry. Moistening of the monolithic material due to poor storage will
affect the material properties.
Monolithic materials should be used in the same order in which they are
delivered/received at the job site, so that their consumption can be on
first-in first-out (FIFO) basis.
The material should be stored in such a way that it can be easily
identified or the label displayed.
It is recommended to only open the packing just prior to use as an extra
protection.
The average storage life of a Calderys material is mentioned on the
technical data sheet. Normally the shelf life will be between 6 and 12
months. If the shelf life is exceeded it is necessary to re-test the material
prior to use.
Please avoid storing heavier material on top of lighter material.
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Tropical conditions
It should be noted that at temperatures above 25 °C setting processes
might be considerably accelerated.
Do not store any Calderys monolithic products for an extended time in
strong direct sunshine.
The air in tropical countries has high humidity which can adversely affect
many of the Calderys materials with a hydraulic or chemical bonding
process. For this reason materials must be stored as dry and as cool as
possible.
Freezing
Below 5 °C setting processes might be considerably extended.
For the above reason Calderys materials, which are hydraulically or
chemically setting, must be stored dry and at temperatures above 5 °C.
Overseas, long term

Where it is not possible to guarantee satisfactory storage special
packaging should be used. Of particular concern is the binder which may
be ordered separately and equipped with special protection provisions.
1.2 Special remarks per material type

The following sections present storage guidelines for each material.
1.2.1 Castables & Gunning materials

Castable and gunning material is not vacuum sealed; some moisture is
included during packaging; this limits the lifetime of the material in
general.
For maximum shelf life the following measures are recommended:
• Material should be kept in dry location during storage

• Bags of castables and gunning materials should be stacked away
from the walls and covered with plastic sheets on all sides.
• Additional care should be taken if they are stored for longer
periods or in humid atmosphere.
• Stack maximum 3 pallets high to avoid compaction of the material.
Please also refer to instructions under Freezing and/or Tropical

conditions.
1.2.2 Plastics
Extruded plastic refractory slices are shrink-wrapped and packed in
cartons to minimize moisture and workability loss.
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Even though the plastic refractory is carefully packaged to retain

moisture, loss of moisture is possible if plastics are stored for too long,
especially in warm places.
For maximum shelf life the following measures are recommended:
• Plastics, when stored indoors, should be kept away from sources
of radiant heat.
• In hot outdoor areas, the tarpaulin or covering should be raised to
provide a 20 – 30cm space for air circulation. As a
recommendation, the material should not be stored at
temperatures above 25 oC.
• In winter, plastics should be prevented from freezing.
• Stack maximum 2 pallets high.

conditions.
1.2.3 Mortar
Mortars are provided in two types: dry and wet.
With dry mortars the concern is to avoid infiltration of moisture;
therefore, the recommendations outlined above in castable and gunning
materials should be followed
Wet mortars must be stored frost free.
Stack maximum 2 pallets high (dry mortars).
conditions.
1.2.4 Other (Ceramic fibres, vacuum shapes, bricks, etc.)

The storage of other materials such as ceramic fibres, vacuum shapes, or
bricks must be dry. It is advisable to retain the original packaging of the
material and shrink-foil around the pallet until needed.
If the materials are stored in the open they should be placed on a
ventilated platform off the ground and covered with tarpaulins to avoid
moisture coming into contact with any of the packed materials.
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1.3 Storage guidelines

The storage guidelines for various materials are compiled below for easy
reference.
Table 1.1 Material storage class
No Storage conditions
01 Always store covered.
02 Protect from moisture. Keep dry.
03 Avoid storing in direct contact with wall or ground.
04 First in first out (FIFO).
05 Must be used within shelf-life period.
06 Can be stored for long time.
07 Frost free
08 Stack maximum 2 pallets high
Table 1.2 Material storage conditions
No Item storage Code (see table 1.1)
A Dense and insulating castable, Gunning/ 01, 02, 03, 04, 05,
Spraycast material 07
B Plastic/ Ramming material,Wet Mortars 02, 03, 04, 05, 07
C Insulation bricks, Calcium silicate blocks, 01, 02, 03, 06

Ceramic board/ wool/ paper and dry mortars
D Basic bricks and mortars 01, 02, 03, 04, 05
E High alumina bricks 03,06
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2 WORKSITE
It is very important to prepare the worksite carefully considering all the
minute details required for successful and smooth execution.
2.1 General
A general guideline for the preparation of the job-site is highlighted below:
Ensure availability of refractory engineering drawings, sketches, or

Bill of Material (BOM).
Check material delivery plan / available stock at site.
Identify and ensure availability of sufficient storage for equipment,
material, tools and tackles.
Ensure appropriate measures for the protection of material and
equipment from extreme weather like heat, cold or rain.
Ensure the availability of all needed resources.

Examine the time schedule required for the execution of the job; for
complex projects a flow chart will help in monitoring the time
schedule.
Fig 2.1: Keep on schedule.
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Generate, store and update work records and the work schedule to
monitor progress of the job and percentage of complition.
Ensure availability of installation procedures for the actual project in
hand.
Identify and allocate/take possession of proper space for
accommodation and an office for the workforce.
Ensure that all the installation crew members have read and are
instructed about the Safety Guidelines (Calderys Construction Safety
Handbook).
It is very important to arrange and keep handy complete information
like telephone numbers, addresses, and personal details of the
emergency service providers as per Safety Handbook.
Identify any special conditions at site which may require additional
attention – e.g. presence of hazardous gases or process conditions.
Ensure availability of instructions and/or preparation for
drying/heating up.
2.2 Personnel
Study the procedure and time schedule for the job. Have a good
knowledge of what skills personnel are required to have. Verify all
necessary workforces have been recruited and will be available at site on
time.
Check if the chosen subcontractor has enough resources and commits
himself to the actual time schedule. Verify that items like the personnel’s
experience, capacity, skills, and performance is compliant with the
established agreement.
2.3 Resources
Prepare a checklist of
needed resources for the
execution of the job and
ensure all needed resources
are present. The following
questions can help when
preparing a checklist:
Have resources been

supplied/arrived at job
site as per job
requirement or not?
If you identify resources
which are needed but
not available at the job
site, mark it down and
send a request for date
Fig 2.2: Use available project tools.
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when resources can be made available.

Are required spares for necessary installation equipment present?
Is there sufficient power? (where x is number of sockets needed)
x · 220 V
x · 400 V / 16A
x · 400 V / 32A
x · 400 V / 64A
Is there sufficient fuel of the correct type (diesel, petrol, etc.) available
for compressors, vibrators, spraycast machines, etc.?
Is there sufficient capacity [pressure (bars) and flow (m3 / min)] of
compressed air available for the application method? Typically
compressed air is available in three levels:
Plant system (varies)
Compressor, standard (8 bar, 12 m3 / min)
Compressor, large (8 bar, 20 m3 / min)
Is suitable water available? Calderys requires potable quality of water
be used in application.
If gunning or spraycasting is there ~5-7 bar (~50-70 MPa) water
pressure available? In case pressure is inadequate use an additional
pump to increase pressure up to desired level. In such a situation,
ensure also the availability of water pump and accessories like
adequate hoses, spares, etc. for un-interrupted water supply during
installation.
Are welding machine/transformers, electric generators, or
compressors to be arranged by Calderys?
If so their status and condition must be checked before hand; ensure
the quality and quantity of the machine, electrodes, and all other
accessories, including special PPE for welding and cutting jobs, are
available.
The requirements for each application method are outlined in further

detail in chapter 5 Application Methods.
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2.4 Housekeeping
Good housekeeping is an important condition for high quality refractory

lining. Therefore clean up shall be carried out regularly during the job.
Fig 2.3: Keep the work site nice and tidy,

free of debris.
Please ensure the following:
Temporary power and lightning cables shall be neatly routed and

supported
Temporary water supply shall be routed adequately. Leaking hoses
shall be repaired immediately when a leak is noticed
Rebound is removed from scaffolding
A Plastic covering is placed over unused material
Old moulds/shuttering should not be left laying around
Boxes for waste material are present
Waste materials should be kept segragated - e.g. ceramic fibre, used
refractories, or cardboard all have different disposal requirements.
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3 EQUIPMENT
The equipment and accessories required for the installation of refractories
will vary depending upon method of application.
The equipment and tools used in several applications are specified
below; however, for each specific job it is advisable to use an equipment
preparation list.
3.1 General
Equipment common to most job sites.
3.1.1 Necessities
Electrical power 220 V / 400 V (see also 2.3)
Compressed air (see also 2.3)
Potable water (see also 4.3)
Fuel
Proper lighting in working areas
Low voltage lighting arrangements, if applicable
Scaffolding
Spares
Cleaning tools
3.1.2 Transport
Forklift / fork truck
Cranes,
Conveyor belt and hoists
Chain and pulley
Wheelbarrow
Brick carrier
(Temporary) hopper
Hoist/ Pulley
It is important to maintain test certificate for the critical parts used for
material lifting. Replace critical items when necessary.
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3.1.3 Safety
First Aid Box
Personnel Protection Equipment (PPE) such as safety shoes, gloves,
helmets, glasses, ear-plugs etc.
Suitable safety mask
Suitable working clothes
Rubber gloves when working with aggressive liquids (always check
the Material Safety Data Sheet)
Fig 3.1: Use your PPE (Personal Protection Equipment)
3.2 Specific Tools

Specific tools may include but are not limited to the following
3.2.1 Sorting tools

Hand tools to remove packing materials
Marking pen
3.2.2 Survey tools
Levelling tools
Folding ruler, measuring tape
Marking paint
3.2.3 Carpenter tools
Hammer; nails; wood;
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3.2.4 Brickwork tools

Hammer (metallic / rubber )
Buckets
Rigging chisels
Trowel for applying mortar
Measuring tools
Profiles; brick-layer string
Brick cutting machine (diamond saw)
Level instrument
Hand mixer for mixing mortar
3.2.5 Castable application tools
Concrete mixer for insulating castables (gravity type)
Counter current mixer for dense castables (paddle mixer)
Conveyor / hopper for big bags
Water coolers / water heaters
High pressure hoses for water and air for gunning and spraying
Water measuring jars and buckets,
Gunning machine (gunning; spraycast; spraying; HyRate ao)
Water pump
Add-mix pump for spray casting
Compressor (capacity depending on application method)
Welding machine
Ruler; marking pens; scraper
Moulds; formwork; boards
Ruler; thickness control device
Thermometers, vibrators
Set/s of spanners; set of screwdrivers
3.2.6 Ramming application tools
Pneumatic rammers
Sufficient steel, aluminium or rubber buts
Air distributor
Welding machine
Scraper
Drilling machine or pin for making holes
Moulds; formwork
Compressor (or company compressed air system if suited)
3.2.7 Tools for blankets/ boards/ Insulating bricks
Knife and ruler
Handsaw for insulating bricks and blocks
Brush for glue
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3.2.8 Demolishing/ wrecking tools

Wrecking machine,
Wrecking hammers
A more detailed summary of equipment will be available on the SEC intranet

soon.
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4 GENERAL INSTALLATION
Below are guidelines for processes common to most refractory
installation jobs.
4.1 Steel surface

Before installation of refractory material can begin the steel surface must
be prepared.
4.1.1 Inspection
Check the steel surface for the correct dimensions, straightness and
physical condition of the surface. Also be sure relevant dimensions like
burners, access doors, peep holes, etc. are in accordance with the
drawings.
Deviations exceeding the Calderys acceptance criteria shall be recorded.
Notify the customer for corrective actions.
4.1.2 Preparation
Clean the shell with wire brush or sandblasting (international standard SA
1 ½ - 2) thoroughly before application of refractory. The surface must be
free from grease, oil, dust, scale or any other foreign material.
For anchor welding a hand grinding tool is also often used.
4.1.3 Marking
Mark the anchor location on the shell as specified in the drawing. Mark
also the orientation (horizontal, vertical) of the anchors.
The marked anchor positions should be in line both vertically and
horizontally except near openings and manholes. It is recommended to
use a template for the marking.
4.2 Anchoring
Anchoring is divided into two general categories: metallic anchors used
when the temperature is less than 1000 ºC, and ceramic anchors for use
in higher temperatures.
4.2.1 Metallic Anchors (< 1000 ºC)

For metallic anchoring there are four factors to be considered: design,
steel quality, fixing, and testing
Design
The thickness and dimensions of the anchors selected depends on the
type of castable, the type of process/plant, and on process conditions
such as temperature and chemical environment.
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For example, an anchor used with insulating castable in a petrochemical

furnace can be much thinner than an anchor used with dense castable in
the roof of an alumina melting furnace.
The recommended anchor distribution depends on the wall thickness; a
thinner lining requires more anchors per square meter. See table 4.1
below.
Table 4.1: Metallic anchor distribution
Hotface thickness Roof (pcs/m2) Walls (pcs/m2) Dim/ type (mm)
50 mm 64 45 6-8 V
75 mm 60 25 6-8 V
100 mm 45 20 6-8 V
125 mm 45 16 6-8 V
150 mm 32 16 6-8 V / Y
175 mm 32 13 6-8 V / Y
200 mm 25 11 6-8 V / Y
> 225 mm 25 11 6-8 Y
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The commonly used V and Y anchors are pictured below.
Fig 4.1: V-anchors as per CASS (Calderys Anchoring Standard Solution)
Fig 4.2: Y-anchor as per CASS (Calderys Anchoring Standard Solution)
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Typically the pattern of the anchors will alternate: an anchor positioned

horizontally is surrounded by anchors oriented vertically; this applies
mainly to “V” and “Y” anchors.
A typical anchor pattern is shown below.
Fig 4.3: Typical anchor pattern shows the

alternating orientation of the anchors.
The distance between the anchor tip and the refractory hot face surface
should be 10 – 35 mm (recommended 25 mm).
Polyethylene (PE) caps should be provided at the tip of the anchors
unless otherwise advised. This is to provide the possibility for the anchor
to expand.
In case plastic caps are not provided / available, wrap the tip of anchors
with insulation tape; avoid a bituminous paint.
Anchor Steel Quality

Be sure the quality of anchors used matches the specifications in
drawings and the Bill of Material. It is not possible to distinguish between
AISI 304 and AISI 310 S visually, so identify and mark the anchors before
taking them out of the packaging if not already marked by the supplier.
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Within Calderys the following colour codes are defined in the Calderys
Anchoring Solution Standard (CASS):
RED 253 MA
YELLOW/ORANGE AISI - 310 S
GREEN AISI - 304
BLACK / NO COLOUR Carbon steel
Fixing (welding)
Follow the procedure for cleaning the surface before starting anchor
welding (Inspection and Preparation 4.1).
Check that the most suitable welding rods are used for the different
combinations of material qualities (anchors to straps, straps to walls, etc.)
Anchors should be welded in such a way that the legs aren’t touching nor
positioned too close to each other. One method for checking this is to
draw circles around the legs of two adjacent anchors taking the welding
points as the centre; the two circles should not overlap; if there is overlap
then the anchors are too close.
For V-anchors, the normal angle between the two legs of the anchors is
60 °. For Y-anchors 60° - 90° is used. This is in accordance with CASS.
Check the projection of anchors and ascertain the correctness of the
anchor as per drawing to ensure intended coverage of lining thickness.
Check the orientation of the anchor with respect to the shell; it should be
90º to the surface, if applicable.
After the welding of a few anchors check the quality of the welds by
Bending test. (See Bending Test) If satisfactory, continue welding of the
remaining anchors. During welding continue to bend test randomly to
ensure proper anchor welding.
Testing / Quality Checks

Prior to the application of refractory anchor welds are tested at random
using the bending test to ensure sound welding.
Additionally anchor welds should also be visually inspected. Manual stud
welds shall be fully fused over 360°. Semi-automatic stud welds shall
show a 360° flash.
A light hammer (approximately 200 g) shall be used to tap each anchor
end sharply without bending it. Each anchor having a dull, flat sound shall
be replaced.
The acceptability norms for the anchor welding should be in line with
Calderys Quality Assurance Criteria. To ensure proper quality, please
refer to the following attached sketches that provide a review of the
standards for visual inspection and the description of the bending test.
Fill in the welding inspection report after inspection with the client or the
client’s inspecting party.
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Bending Test
The standard for the bending test is described in DIN EN ISO 14555.
Anchors and welds shall be such that an anchor can be bent through 60°
and returned to its original position without failure of anchor or weld.
This testing shall be executed at random during anchor installation on
3-5% of the anchors. 90 % of the anchors tested shall be able to pass the
bending test successfully.
Typical welds with explanations
Fig 4.4: Good welding, clean closed Fig 4.5: Hot welding, check setting of
and uniform reinforcement weld welding device
Fig 4.6: Insufficient immersion, check Fig 4.7: Cold welding, check setting of
setting of device device
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4.2.2 Ceramic anchors

Install ceramic anchor holders as per the spacing and design indicated in
drawings.
Fix a wooden wedge and a PE washer in the gap between holder and
surface of ceramic anchor. This is done to ensure the ceramic anchor
does not move during installation of the back-up layer and thus provides
flexibility after heating up.
Ensure that the ceramic anchors are properly seated on the anchor
holder so that the metallic portion of the holder is engaged on the support
collar of the ceramic anchor. This will avoid a point load on the ceramic
anchors from the metallic holders.
When the anchor brick is installed in the ceiling, care must be taken that
the anchor is not lifted by the shuttering as this will unseat the anchor
from its holder. To avoid this possibility it is advisable to create a 5 to 10
mm gap between the brick’s front face and the form/mould.
In all other cases the front of the ceramic anchor should be in line with the
surface of the refractory layer.
The portion of the ceramic anchor that passes through the insulation or
back-up layer should be covered with a minimum of 6 mm thickness of
Polyethylene sheet (sheet-foam) to allow sufficient space for the anchor’s
movement during heating or operation of the furnace.
If a casted or gunned insulation layer is in direct contact with the front
layer, the sheet-foam wrapping should extend 15 mm into the front layer
to avoid stress due to different expansion behaviour of the two layers.
Misaligned anchors need correction/replacement to avoid failure during
operation of the furnace.
For further review of anchoring standards refer to the Calderys Anchoring
Standard Solution (CASS).
Fig 4.8: Fixing of ceramic anchor Fig 4.9: Fixing of ceramic anchor for
for roof installation. wall installation.
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Ceramic anchor bricks / m2 for lining thicknesses > 200 mm
Hotface thickness Roof (pcs/m2) Walls (pcs/m2)
> 200 mm 9 6,25
Note: 6,25/ m² based on panel size of 800 x 800 mm which equals

4pcs/panel
Fig 4.10: Anchor pitch for linings thicker than 200 mm
Table 4.2: Typical ceramic anchor lengths
Type L(mm) Quality Bond AL2 O3
T-12 215 Andalusite Ceramic 60/90%
4.3 Water quality

Normally drinking water is adequate; however, if the water is potable,
ground or river water can also be used. Water with the following
characteristics can not be used for castable installation:
Sea Water
Water containing sugar, suspended particles (e.g. excrements,
humus etc.) or any other foreign particles
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Water with more than 1000 ppm in total impurities such as sulphates,
carbonates, magnesium chloride, ammonia, etc.
Water having a pH less than 6 or higher than 8
Water temperature must be maintained between 5 oC and 25 oC
4.4 Formwork / shuttering

It is important to make a plan for how installation will be conducted.
Consider what shuttering will be needed, panel size, access to form work,
site conditions, etc.
Fixing of shuttering should be planned to allow casting of alternate
panels, and should preferably be staggered in respect to back up layer
panels as far as possible to ensure staggered joints.
Fix the panel size if not already decided. For Low Cement, Ultra Low
Cement and No Cement castables the recommended panel size is 600 to
800 mm; maximum panel size in these cases is 1000 x 1000 mm.
For the back-up insulation layer the panel size should be kept around
1000 x 1000 mm or larger.
Fig 4.11: Example of formwork for roof. Care must be taken that the
formwork does not lift the anchor from its holder.
The thickness of shuttering used for the sides of any segment should be
the exact thickness of the castable. Be sure the shuttering is placed tight
to the back-up layer or steel shell.
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Shuttering materials are normally made of wood, metal or plastic. Ensure

that the shuttering used is strong enough to withstand the weight of the
installed material, and to withstand the forces created by the installation
procedure - e.g. pressure of vibration, forces from ramming, etc.
When gunning or spraycasting straight Calde™Joint is preferred unless
otherwise specified in the drawing or recommended by
consultant/designer. Use a z-joint shape or tongue & groove form only
when specified.
All the formwork, shuttering and moulds shall be waterproof so that they
do not absorb moisture during installation of monolithics.
Apply grease/oil/paint at shuttering surface for easy removal and
prevention of water absorption.
If shuttering is reused the surface should be cleaned and coated again
with oil, liquid wax or paint.
In case of a two layer system the anchors must be cleaned before
installation of the second layer.
If work is in progress at several locations ensure separate manpower for
fixing the shuttering at each location so that steady work progress can be
achieved.
Ensure the availability of sufficient quantity of shuttering at the job site to
avoid delays during installation.
Fig 4.12: Formwork for a thin layer tube wall.
4.4.1 Calde™Joint
Calde™Joint is a specially designed plastic sheet of around 5 - 10 mm
with slots. 3-5 mm diameter pins are welded on the shell and
Calde™Joint is attached with the pins through slots.
It is preferable to use Calde™Joint shuttering to create expansion joints
which stay in place after installation; at 200 ºC the Calde™Joint will burn
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away leaving a small gap for expansion. When installing ensure that the
Calde™Joint is fixed properly. For expansion joints wider than 5 mm it is
advisable to add a layer of fiber material to the Calde™Joint; if gunning
or spraycasting then a sheet of Calde™Joint sheet is placed on both
sides of the fibre to protect it.
Fig 4.13: Example of Calde™ Pli-Joint. Note a small amount (5-10mm) of

material extends into the insulation layer.
4.4.2 Removal of shuttering

Before removing the moulding ensure the refractory has fully set by
attempting to drive a spike or similar object into the lining; the spike
should not enter.
Don’t apply heavy force when removing the supports. If heavy force is
applied when removing the supports it will disturb the castable surface
and destroy the smoothness of the surface.
Remove the shuttering with care!
4.4.3 Graphitic castables

Note: If graphitic castables (black castables) are applied care must
be taken regarding the risk of explosive conditions. During setting
these castables form highly explosive hydrogen gas; both the
shuttering and the surrounding area must have sufficient ventilation
to ensure that gas does not accumulate and create a risk of
explosion!
(For further details refer to CALDERYS Installation guideline nr.22 and
Safety guideline nr.1 )
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4.5 Joints in monolitics

We distinguish between two types of joints: construction joints and
expansion joints. Construction joints break up the job into conveniently
sized panels and prevent cracks from spreading through the entire face.
Expansion joints provide room for thermal expansion of the refractory
material. For a more detailed discussion of each see the respective
sections below.
General
It is important to check drawings for the type of joints required, the
thickness of joints, orientation of the segments, and anchor positioning
within the segment.
4.5.1 Construction joints

Construction joints are designed to break the job up into conveniently
sized panels, and keep any cracks which form from spreading through
the whole surface. Adjoining panels are installed against each other
without leaving any gaps. The fresh side of the previously installed
section is used as the formwork edge for the next panel. Sometimes a
thin layer of oil is applied first as a bond breaker.
It is recommended to keep panel dimensions uniform (square). Install the
panels in straight rows keeping the joints of adjacent rows offset.
For dense castables the recommended panel size is 600-800 mm, with a
maximum size of 1000mm for any dimension. Panels for insulating
castable are typically 1000-1500 mm; however, when the insulating
castable is the hot face layer a maximum size of 1000 mm for any
dimension is recommended.
The construction joints can be regarded as bond breakers; they will not
eliminate cracking, but replace uncontrolled cracking in the face of the
refractory with controlled grooves.
4.5.2 Expansion joints

Many Calderys materials undergo thermal expansion as they heat up. To
avoid stresses in the lining that lead to spalling or mechanical destruction
of the refractory, a joint is made so that the refractory has space to
expand into.
There are different shapes used for expansion joints (see fig. 4.14 below).
Our recommendation is to use the straight joint unless otherwise
specified by the customer or in special applications.
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Fig 4.14: Example of joints; unless otherwise specified

straight joints are recommended.
The thickness of the expansion joint will depend upon the type of material
being installed, the operating temperature, and process circumstances.
The required thickness must be calculated for each specific situation!
Always calculate enough expansion to avoid stress forces in the lining.
Note: Each material has different expansion behaviours at different
temperatures. Always calculate the expansion needed using the
worst case that could occur during the heating-up process.
Calculation of an expansion joint

To explain how the calculation of an expansion joint is performed we use
the example of a typical situation in a furnace.
The furnace is operating at a temperature of 1100 ºC.
After a heat transfer calculation was made the following design for the
refractory lining was determined:
Front: 150 mm CALDE™ GUN F 40 A dense castable
Back-up: 100 mm CALDE™ CAST XL 106 C/G insulating castable
Now we check the datasheet for the permanent linear change and the
reversible expansion values of the front layer material (back up layers
normally do not have expansion joints).
CALDE™ GUN F 40 A
PLC : -0,25 % at 1250 ºC
assume the plc change is linear so -0,22 % at 1100 °C
Rev. expansion: 0,6 % at 1000 ºC
assume expansion is linear so 0,66 % at 1100 ºC
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The minimal need for expansion in this example is the sum of the rev.
expansion and the PLC: 0,66 + (- 0,22) = 0,44 %. So the need for
expansion is at least 4,4 mm for every meter.
This is the theoretical approach. To leave margin for differing results
under actual conditions, and to ensure no stress forces develop, we
would choose an expansion thickness of at least 5 mm.
Material for Expansion Joints

The Calderys recommendation for material is Calde™Joint (see section
4.4.1). At 200 ºC the Calde™Joint will burn away leaving a small gap for
expansion.
When expansion joints are larger than 8 mm then filling the joint with fibre
material is advised.
A commonly used fibre material is ceramic fibre. Ceramic fibre will
typically compress up to 50% its original thickness. Referring to the
previous example, 5 mm of expansion space was needed so an
expansion joint would need to be 10 mm if filled with ceramic fibre.
4.6 Sampling
During the execution of refractory installation “as installed” samples have
to be prepared. When making the samples the corresponding sample
report has to be filled in. This is valuable information for evaluation of the
results.
In order to ensure sufficient material is provided to the laboratory to
prepare specimens for testing, Calderys prefers that the panels are
prepared on site to the following dimensions: 500x500x150mm.
When preparing the sample just fill the moulds. If rodding or vibrating is
needed, it should be carried out in the same manner that was used when
applying the material to the wall. Make sure the mould is filled
completely.
The samples are meant to be accurate representations of the refractory
material as it is installed; therefore, care must be taken that the samples
experience similar conditions to the installed material after they are
prepared.
4.6.1 Dimensions of specimens

Special attention must be given to the preparation of specimens; if it is
not, a perfect lining can be rejected simply because the test cubes were
prepared in a poor way.
All test cubes & test bars (specimen) must have perpendicular (90 o)
angles and all surfaces should be parallel within 0.5 mm. Specimen must
be marked on top casting/ gunning side.
The specimen size depends on the applicable testing method, e.g. ASTM
or EN 1402. Within Calderys we prefer the samples sizes given in EN
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1402 because all our QC statistics are based on this method; however, in
the petrochemical industry the ASTM testing procedure is often dictated
and must be followed.
For testing in a laboratory the following specimens are needed:
One specimen consists of:
2 bars halfbrick 54x65x230mm for dense materials EN 1402
or
2 bars Bricksize 64x114x230mm for insulating EN 1402
or
3/ 4 cubes 50mm + 1 bar 50x50x230mm ASTM 133/134,
and, if applicable
2 plates 115 x 115 x 25mm for erosion test according to ASTM C 704.
4.6.2 Quantity of testing

Check the project documents for specific demands about the quantity of
tests. Otherwise, standard procedure is for every crew to prepare one set
of samples for each type of material used in a shift.
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5 APPLICATION METHODS
There are four primary application methods: ramming, casting, gunning,
and brickwork.
5.1 Ramming
Ramming is the oldest application method for installing monolithic
material.
Plastics, or “mouldable refractories,” consist of a mix of graded refractory
aggregates or clays, and are delivered to the user pre-mixed in watertight
containers ready for use.
5.1.1 General
Plastics are manufactured with different levels of humidity depending on
the installation requirement. The moisture content of a plastic affects its
workability. This workability can be important when deciding which
quality product to use.
All plastics must be checked for proper humidity/workability before use.
In hot conditions the moisture in a plastic can evaporate leaving it dry and
unworkable, therefore plastics must be stored in a cool place to reduce
the risk of moisture evaporation. In cold conditions they must be
protected from freezing.
Pneumatic rammers of suitable size are preferable to hand rammers. A
rammer weighing approximately 5 kg, with a stroke of about 125 mm and
a frequency of 800 - 1200 stokes per minute, is adequate for most
ramming mixes. A steel or aluminium head is normally used; however,
when working around boiler tubes rubber or nylon heads are also used.
During installation only the plastic which is immediately needed for
installation should be unwrapped. Pre-opened plastic may lose moisture
and hence lose workability resulting in improper knitting of slabs, and
ultimately, in unsatisfactory installation.
5.1.2 Pre-formed (Slabs)

The pre-formed pieces (slabs) from the carton box should be placed in
position one by one, not in bulk quantity, and rammed immediately by
applying a light force. Place the slabs in succeeding layers, staggered like
is done in brickwork.
Build a layer of 50 – 75 mm (one slab) of plastic refractory and start
ramming. If more than 75mm is applied at one time the compaction of the
deeper layers will not be uniform resulting in poor quality.
Move the rammer back and forth from hot face side to cold face side.
When all voids in this portion of the wall are closed up, add fresh slabs
and repeat the above procedure.
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Fig 5.1: Ramming direction for sidewall
Fig 5.2: Square angle top of ramming (left picture shows correct
procedure)
Fig 5.3: Strokes always toward the back layer and not parallel
with it (left picture shows correct procedure)
Before placing successive slabs on the wall the preceding course should
be rammed so as to project a few millimetres beyond the line of the hot
face. This allows for trimming or shaving the wall by using a scraper to
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ensure verticality of the lining. The wall should be built up evenly from
end to end.
Each installer should work on a one to two meter length of wall depending
on wall thickness and anchor pitch.
The lining should be rammed tightly around each anchor to ensure that
the plastic is applied homogeneously in the groves of the anchor to give a
better grip. When using ceramic anchors use a dummy to create the form
of the anchor brick into the layer on which the brick has to be placed
(bottom). This is to avoid damaging the anchor bricks to be used.
The trimming spade should be placed against the plastic at an angle
which prevents the point digging beyond the hot face line. Shave off the
surplus material using the ceramic anchor faces as guides. Avoid any
smoothing or trowelling of the surface. A coarse surface is necessary for
uniform drying and to prevent crack development.
When work is stopped for a period, like a coffee break, the fresh ramming
mix must be covered with plastic sheeting to avoid water evaporation.
Good practice is to roughen the layer after finishing the ramming and
again before placing the next slab.
As a last step, provide vent holes at a distance of approximately 100 –
150 mm. Make the hole through the complete lining thickness if possible.
The diameter of the hole should be 3 - 4 mm. The use of a drilling
machine is advisable.
Fig 5.4: Provide vent holes at a distance of 100-

150mm; the use of a drilling machine is advisable.
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5.1.3 Granulate
Granulate materials are delivered ready for use and packed in
polyethylene bags. Granulates are installed by the method of ramming.
Installation
Installation of granulate requires the usage of forms. These forms must
be strong to withstand the mechanical stresses generated during
ramming. The forms used for installation of ramming mass are normally
made of steel or wood.
During any repair job for maintenance, the existing refractory surface
should be saturated with water to make it non-absorbing.
An approximately 50 mm thick layer of granulate is added to forms and
rammed by means of pneumatic rammers. A pneumatic rammer of 40 -
60 mm head diameter and 4 – 6 bar air pressure should be used for
ramming the material.
While ramming the material a scraper must be used to roughen the
surface of already compacted material before further material is added.
This procedure ensures lamination-free lining.
Ramming mixes do not generally develop sufficient strength until fired.
Care should be taken while removing the forms off the unfired compacted
ramming mass. In some instances the furnace is heated up with the
burnable forms still in place.
If the refractory is left unfired after removal of the forms it is likely to
absorb moisture from the air and crumble. Firing, therefore, should be
done immediately after ramming is complete. If the rammed material
cannot be fired immediately after completion of installation the forms
should not be removed until firing can be commenced.
5.1.4 Shrinkage joints

Shrinkage cuts have to be created in the freshly installed ramming
material in order to avoid unwanted cracks from shrinkage of the plastic.
With the shrinkage cuts you guide where the lining will shrink. The
shrinkage cuts should be ⅓ - ½ of the lining thickness. The cuts shall be
kept as narrow as possible, and not exceed 1– 2 mm in any case.
Distance between the shrinkage cuts should not exceed 1 meter. The
panels shall be made as uniform as possible.
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Fig 5.5: Cutting shrinkage joints; joints should be as narrow

as possible and not exceed 1-2 mm.
5.1.5 Roofs, bullnoses and arches

Support forms are required to prevent slumping when installing roofs,
bullnoses and arches. In particular, plastic materials that have a
chemical bond will more readily absorb moisture from the air and slump,
so additional care must be taken in preparing the supports if the plastic
material has a chemical bond.
The shuttering must be well constructed and braced so that it can bear
the weight of the plastic mass without bending or buckling. Shutters are
erected progressively as the ramming proceeds.
The plastic refractory should be installed starting from the ends of the
supporting steel beams. Ramming must always be carried out in the
same direction as the supporting steel work runs. In the case of sloping
roofs ramming should always start from the bottom of the slope. In the
case of a bull-nose the procedure is similar to that of roofs.
Shrinkage cuts should be made immediately after formwork is removed.
Due to the fact that a fresh lining has the tendency to slump, “false
anchors” made of wooden board shall be installed to support the fresh
roof until the dry out is executed (fig. 5.6).
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Fig 5.6: False anchors in rammed roof prevent the material from
slumping before dry out
Fig 5.7: Typical scrape mould (flag) for installing a burner in

plastic material.
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5.1.6 Removal of formwork for plastics

Check the surface and level it by trimming. Roughen the surface with a
three point trimmer.
Remove the shuttering part by part after checking for slumping; to check
whether the lining is stable or slumping remove a small portion of the
forms. If the fresh lining has a tendency to slump “false anchors” made of
wooden board shall be installed to support the fresh roof until the dry out
is executed.
5.1.7 Dry out remarks

Plastic materials containing phosphate binder are hygroscopic in nature.
When installation is finished the lining should be heated as per the
Calderys recommended schedule as soon as possible.
In case of delay in heating due to unforeseen circumstances the area
should be kept dry and properly ventilated, or covered by plastic sheets,
in order to prevent the material from picking up moisture from the
atmosphere.
5.2 Casting
Prior to beginning a cast check the environment in the three following
areas:
1. Where the application will take place
2. Where the mixing will take place
3. The area of travel between the two
Prepare the casting job carefully and verify all the requirements outlined
in section 4.
The mixed castable should be installed as soon as possible. It is
recommended that the castable be installed within 15-20 minutes after
mixing (see 5.2.2)
Pour the mixed castable behind the shuttering and tamp or vibrate the
material thoroughly. Ideally material flow into the shuttering should be
continuous until the shuttering is filled.
Ensure mixing between the previously added batch and the current batch.
To facilitate this keep the height of the fresh material fed into the
shuttering below 200 mm for proper mixing.
Fill the material uniformly behind the shuttering; the castable level should
be uniform through out the panel after filling.
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5.2.1 Mixing
General
For dense and low cement castables a counter-current mixer or paddle
mixer is used (fig. 5.9). For insulating material only a gravity/concrete
mixer (fig. 5.8) should be used to avoid crushing the light fractions which
give the material its insulating properties.
Ensure that the water is clean and of potable quality with a temperature
between 5 and 25 °C (around 15 °C is optimum).
Place only known quantities of castable in the mixer. Water addition can
be better controlled by adding material to the mixer in full bag quantities;
do not add partial bags.
When a two-component castable is mixed, make sure that both
components are added in prescribed quantities.
If needed, place or construct a hopper with a capacity to handle big bag
quantities of up to 1000 kgs.
Check the material temperature which should be between 5 and 25 °C
(preferably around 15 °C).
Clean the mixer thoroughly after use.
Mixer check points

The following should be inspected on the mixer to ensure proper
functioning:
Make sure the gap between scraper and the bottom or side
plates does not exceed 10 mm
Check gear oil
Check condition of electrical fittings/ accessories
Verify speed/ strength (normally 50 RPM, minimum 25 Watt/
Kg)
Fig 5.8: Gravity mixer used for

insulating refractory materials;
avoids crushing the light
fractions which give the material
its insulating properties
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Fig 5.9: Pan/ paddle/

counter-current mixer used for
dense refractory materials;
ensures proper mixing.
Mixing schedule
Start the mixer and mix dry for about 10 - 30 seconds. (This step is
essential when the material is supplied in a two component system)
Determine the allowed quantity of water by checking installation
instructions or product data sheets. Start with the smallest quantity
possible and, while the mixer is running, add the specified quantity of
water to the mix quickly; the goal is to have all portions of the material mix
for a uniform length of time.
For insulating castables the mixing time should be as low as possible and
preferably below 3 minutes.
For conventional castables continue mixing for 3 - 5 minutes, and for low
cement/no cement castables about 5 - 7 minutes.
A summary guide to approximate mixing times can be found at the end of
the section; however, check installation instructions for specific
instructions.
Check for workability by the ‘Ball-in-hand’ consistency method as shown
below.
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Fig 5.10: Ball-in-hand test

– wet mix

– dry mix

– correct mix
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Correct the percentage of water in the mix based on the results of the
Ball-in-hand test. If the material has no flowabillity during the Ball-in-hand
test more water is needed.
If required, increase water percentage step by step. Keep the quantity of
water to the minimum required. In any case, the water percentage should
not be more than 10% of typical water requirement range mentioned in
the product specification.
If consistency is not obtained even after addition of the maximum water
recommend, inform the responsible technical department.
Any deviation in addition of water beyond specified limit must be as per
instruction of technical department or competent authority.
For a view of the effects of water on castable strength see figure 5.13 at
the end of the section.
After fixing the water requirement for a particular type of castable, make a
mark in a container (preferably plastic bucket or barrels) and make a hole
above the marked line. This will facilitate fast and accurate water addition
in the mixer subsequently.
Discharge the mixed material and install the material as quickly as
possible. ( see 5.2.2 Setting Time)
The mixing schedule should be checked for every batch; water addition
should be adjusted as required within the specified limit defined in the
product specification sheet.
Keep a record of the mixing time and quantity of water added per batch.
Fig 5.13: Castable strength related to percentage of water
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Table 5.1: Summary of approximate mixing times
Material Dry mixing Wet mixing Mixer types
Insulating 10 – 30 sec 2 – 3 min Gravity/ concrete

mixer
Dense 10 – 30 sec 3 – 5 min Pan/ paddle mixer,

counter current
Low cement 10 – 30 sec 5 – 7 min Pan/ paddle mixer,

counter current
5.2.2 Setting time

After mixing and discharging there is a limited time during which the
castables must be installed. Setting of the cement in the castable starts
the moment water is added. Normally material should be installed within
20 minutes after discharging.
The following table gives the impact of temperature on lead time - the
time after mixing and before actual installation.
As shown in the table below, it is very important that the water, material
and mixed castable temperatures be between 5 - 25 oC (15 oC is
optimum) to get adequate lead time for installation.
Table 5.2: Setting times at ambient temperature
Type of material, Surrounding Lead time before loss of

group Temperature oC consistency, minutes
Castable with High Approximately 25 Approximately 15-20

Alumina Cement as
Approximately 30 Approximately 8
Binder
Castable with Medium Approximately 25 Approximately 15-20

Alumina Cement as
Binder
Castable with Sodium Approximately 15 Approximately 120

Silicate as binder for
trowelling
More than 25 Approximately 5-10
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Determination of setting time

It is recommended that for each new castable to be used a mock-up test
be conducted to determine the actual setting time under site conditions.
Final setting of the castable takes normally between 12 and 24 hours;
however, temperature has a major influence on this.
If material does not set or is setting too fast, then consult the technical
department. If so instructed by the technical or QC departments,
accelerators or retarders can be added; these will be made available in
small packets as per mixing quantity/quality of material. Repeat the mock-
up test mentioned above to fix the new setting and shuttering removal
times after the addition of additives.
5.2.3 Rodding
Rodding is the process of inserting a rod into the newly poured castable
mix so that trapped air bubbles can come up to the surface.
Rodding is commonly used during the installation of light weight
castables. Rodding is used to avoid breaking the insulating grains by
vibrating, which would decrease the porosity and increase the density
and thermal conductivity of the material.
When rodding, add only a small quantity of material before rodding; build-
ups of more than 50 mm should be avoided. The procedure is repeated
until the required height of the lining is achieved.
A mould height of more than 500 mm is not recommended for purely
practical reasons; it is impossible to ensure sufficient rodding when the
mould is too high.
If rodding is used in the application of castable material, or if the
insulating layer is also the front face, it is necessary to evacuate any
trapped air.
5.2.4 Vibrating
Low cement and ultra low cement castables are mixed with a very low
percentage of water to achieve high strength with minimum porosity. In
such a situation it is necessary to vibrate the castable to achieve the
proper densification.
High-frequency vibrators can be fixed onto the shuttering;
poker/needle/pencil vibrators are used directly in the castable.
Insert the poker at an angle of 90 degrees to the surface of the castable.
While vibrating, observe the action circle of the vibrating poker to
determine the proper pitch for poker insertion. (See table 5.3)
After densification pull back the poker slowly in order to avoid air
inclusions or voids in the fresh casted material.
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Please note that vibrating too long may result in segregation of the
material which must be avoided. Vibrators suitable for use with refractory
materials are listed in the equipment section.
Table 5.3: Parameters for poker vibrators
Poker 40 mm 40 mm 57 mm 57 mm
diameter (air) (electric) (air) (electric)
Action circle 40 cm 40 cm 70 cm 65 cm
Working 6 bar 6 bar

pressure
Consumption 0,8 m3/h 1,3 m3/h
5.2.5 Self-flowing castables

Self-flowing castables don’t require vibration; however, the shuttering
must be water tight. Self-flowing castables are mainly used for intricate
areas where vibration may not be possible.
The self-flowing castable should then level itself uniformly throughout the
panel.
5.2.6 Pumping
Instead of using a separate mixer and manually transporting the mixed
material to the point of application, a dual function piece of equipment
may be used that first mixes the material and then pumps the wet slurry
to the point of application.
Before pumping castable ensure that the pipes have been laid in a
manner that keeps the number of bends and turnings to a minimum. It is
also of utmost importance that the feed lines are free of even the smallest
obstacle.
Also ensure the hoses are moistened with slime glide or mortar slurry in
order to lubricate the feed-lines.
The following points are important when mixing water with castable which
is to be pumped:
Engage the pump only when the castable has attained proper
flowable consistency.
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Do not use material if it has lost consistency because it was too long
in the mixer. Never attempt to re-mix - once setting has started the
properties of the material will be affected!
Once the pumping operation is stopped the machine and hoses should
be cleaned thoroughly.
Never leave without cleaning because otherwise material inside the hose
and machine will set and prevent proper flow when restarted!
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5.3 Gunning
With the gunning application method refractory materials are
pneumatically conveyed through suitably designed pipes or flexible hoses
to the location where the material has to be installed; a hand-held nozzle
is then used to apply material to the target area. This type of installation
has the following advantages:
Generally, installation time and costs are reduced (especially for the
backup layer on multi-layered walls)
Minimal shuttering is needed
Can be applied when access is difficult
Solves installation problems for certain overhanging and roof
locations
For multi-layered walls it is often easier and more cost effective to
gun backup layers rather than use two sets of formwork.
Thin linings are easier to place
Difficult geometries are possible
5.3.1 Slurry gunning

Slurry gunning involves mixing all of the required water with the dry mix in
a paddle mixer prior to conveying the material to the nozzle. This method
requires higher water content and thus the density of the placed material
may be lower; however, there is little or no dust, low rebound, and
lamination-free linings. Working linings in tundishes are often installed
using this method.
The machine used for this purpose (screw mixer, fig. 5.15) is easy to use
and has a capacity of 500 kg to 2000 kg per hour.
Fig 5.14: Slurry gunning
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Fig 5.15: Screw mixer for Slurry gunning
5.3.2 Dry gunning

Dry gunning is a popular installation method. The dry mix is conveyed
pneumatically from the machine (either rotary or single chamber) to the
nozzle where pressurized water is injected through a nozzle ring.
The quality of this method of application is very dependent on the
experience of the operator, or nozzle-man.
There are four parameters that must be considered when gunning:
1. The material being applied
2. Output of the machine (Speed of rotor, height of rotor, and
diameter of outlet)
3. Air pressure for conveyance
4. Water pressure
A nozzle-man must be able to quickly judge the gunned material as it is

being applied and make frequent corrections to one or more of the
parameters mentioned above to achieve an optimal installation.
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Pre-dampening
For dense gunning materials, pre-dampening with 2–3 % of the total
water requirement in a paddle or similar mixer is recommended. Pre
dampening helps in reduction of dust generation and reduces re-bound.
Lightweight and medium weight gunning materials will require more water
for pre–damping, approximately 5% of total requirement.
Material consistency after pre–dampening should allow a handful of the
gunning material to be squeezed into a column, which when tapped
breaks into pieces.
Reduction of dust at the nozzle improves visibility enabling the nozzle-
man to control water addition more accurately and thereby to establish
thickness more accurately and reduce the chances of rebound being
entrapped.
Pre-damped material accepts further water at the nozzle more readily
helping to reduce rebound.
The additional mixing during pre-damping helps to minimize segregation.
Air pressure
The desired air pressure at the nozzle is about 2.5 bars. The experienced
nozzle-man shall adjust the air in a way that the material is installed with
a minimum of rebound. For insulating materials, not only a minimum of
rebound but also a minimum of compaction must be maintained.
If the pressure is too high material density and rebound will increase;
however, too low pressure results in low strength and lack of compaction.
The recommended minimum capacity of the air compressor is 7 Nm3/
minute, and a minimum pressure of 5 bars (if operating only a single
gun).
Larger compressors are recommended when several guns are used
simultaneously.
Water pressure
Water pressure at the nozzle must be at least 0.5 bars higher than the air
pressure to ensure that the water is able to completely wet the material
as it passes the water ring. A water booster pump usually is required to
increase plant water pressure. The recommended water pressure at the
source is 4 – 5 bars. (~60-75 psi)
The water requirement will be around 250 to 1200 litres per hour;
however, this will depend upon material quality, capacity of the gunning
machine, etc.
For the low porosity gunning method (LPGM) a medium pressure pump is
needed to provide pressure in the range of 15 bars (~220 psi).
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Nozzle control
The appearance of the gunned refractory surface is the best indicator of
correct water/mix ratio.
Fig 5.16: Typical dry gunning nozzle
Freshly placed material should have a wet, silky surface which rapidly
disappears when the nozzle is moved away from the area.
The coarse aggregate should make small craters on the surface on
impact.
A sandy, gritty surface indicates too little water is being used.
Slumping, ripples of a washboard surface indicate too much water.
Apparent inconsistent mixing of water is often caused by either the

pressure being too low or blocked holes in the nozzle ring. The ring
should be periodically checked and cleaned.
The water ring and nozzle must be clean and in good condition.
Prior to start-up it is necessary to check that the hoses are laid with no
loops to prevent plugging.
Air and water pressures, as well as the material feed rate, needs to be
controlled so that proper flow occurs and material of correct consistency
emerges from the nozzle.
When making changes be sure to point the nozzle away from the
point of installation!
Once proper flow and consistency are achieved, the nozzle operator
should direct the stream of the material at the base of the wall and
proceed to build upwards.
The build-up is to be conducted by circular movements as shown in fig
5.17. The nozzle should be kept between 500-1200 mm from the
surface. The angel to the surface should be as near as possible to 90o.
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Rebound should fall or bounce clear of the target and should not be
entrapped. Entrapment of rebounds by the fresh stream from the nozzle
can lead to laminations or spots of low density in the lining.
In order to avoid generation of honeycomb or nests, each panel must be
gradually built up from bottom to top until the final thickness is reached.
Particular attention must be given to the areas around the anchors as it is
important to ensure satisfactory filling around the anchors. With ceramic
anchors care must be taken to ensure all the grooves have been filled
and that there is no shadowing.
Fill the panel completely without any significant over gunning of the
surface. Any extra thickness leads to additional time expenditure and
material loss during trimming of the surface.
Each panel should be completely filled without interruption.
When gunning overhead, water addition should be reduced slightly to
prevent slumping prior to initial setting of the material. An increase in
rebound should also be expected when gunning overhead.
Lining thickness control

When ceramic anchors are used they act as a guide since the end face of
the anchor brick is required to be flush with the lining.
When metallic anchors are used they are generally 25 mm inside from
the hot face, so the shutter boards can work as a guideline for
determining the correct thickness.
After completing the gunning a simple method to check the thickness of
installed lining is to place a bend in a piece of 2 mm wire at a length equal
to the desired thickness, thus forming a sort of crank; this is then inserted
into the lining up to the point of the bend and rotated; if the thickness is
correct the wire tip should be resting against the shell/back-up layer and
friction should be felt when the wire is rotated.
Fig 5.17 Circular movement of

gunning nozzle
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Fig 5.18: Distance between gunning

nozzle and wall
Fig 5.19: Start filling from the bottom

and work upwards
Finishing
The gunned finish surface is quite acceptable as it is. But if a smoother
surface is required, it can be scraped with the edge of a trowel or wooden
board within 15 minutes after finishing the gunning.
Generally, a rough, open texture is preferred and should be left
untouched; smoothing can cause fine particles rich in cement to float to
the surface which may result in crack development or spalling during
operation.
The general tolerance for thickness of the layer is +/- 6 mm.
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Caldegun™ XL types
The Caldegun™ XL type of material has a high content of very light
fractions, therefore this material needs to be gunned with a minimum of
pressure. Too high pressure will result in high density and decrease the
technical properties of the product.
For a hose length of about 30 m, an air pressure of 0,5 bar is sufficient.
Add 0,1 bar extra for every 25 m of hose, and/or 2 m of height.
Use a water pump with a capacity of about 15 bars to have enough water
pressure for mixing at the nozzle.
Trouble shooting gunning

While gunning disturbances may occur due to technical reasons. The
most common reasons are stated below:
Insufficient water at the nozzle outlet
Insufficient air supply
Air hose is obstructed/ blocked
High pressure water pump may have entrapped air
Power supply not connected correctly (220/380 V)
The water-ring is not clean
The rubber gaskets have become worn; visual wear on the steel and
1 mm wear of the rubber discs indicate a need for replacement.
Fig 5.20: Single chamber Gunning machine
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5.3.3 Wet gunning (SprayCast™)

The SprayCast™ products are normally semi self-flowing, deflocculated
LC or LCC castables. After mixing, these products are pumped with a
double piston or screw type pump to the place of installation. When
installing the product you can chose to either cast the material in-situ, or,
using a spray nozzle with compressed air and add-mix, spray the material
into place.
The add-mix will stabilize the material and prevent the product from
slumping from the roof or wall. Note: The setting process caused by the
add-mix is a separate process from the hydraulic setting process which
must still take place.
Preparation
Since the SprayCast™ installation method has a high output rate (making
it very efficient when properly applied) it requires that the job site be well
prepared in order to avoid unwanted stops or interruptions during the
installation. It is strongly recommended to have an experienced
SprayCast™ operator on site.
Work place preparation
A fork lift or a crane for lifting two tons to the height of the mixer
Water proof container for cleaning purposes
Air supply; minimum 6 m3 per minute and 7 bar
Hopper with cutting knife for material discharging if necessary
Clean potable water for mixing and cleaning. One water outlet at the
place of installation with a minimum pressure of 7 bar to be
connected to a reverse nozzle when cleaning the pipes
Approved scaffolding to allow a smooth installation. Normally a
working space between scaffold and steel shell is about 30 - 50 cm
Sufficient lightning of the work place and in all working areas
Anchoring installed in all areas with correct welds, clean, and for
ceramic anchors, flexible and coated
Straight, rigid shuttering installed in all working areas
Fig 5.21: Everything has its own place
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Checklist for the SprayCast™ pump and mixer

Check the inventory of the SPRAYCAST container
Check the fluids of the machine (diesel, hydraulic oil, water etc)
Lubricate all filling spots on the machine
Check that all pipes and hoses are clean and that all pipe
connections are clean and well lubricated. Steel pipes shall be used
as close to the place of installation as possible (normal diameter is
50-80 mm). If needed a size-reduction pipe of 40-50 mm length is
connected to the rubber hose. Rubber hose is recommended for the
last 5-10 meters only.
Check the water holes in the nozzle for good flow of add-mix in all
holes. The hole at the nozzle end is about 30 – 35 mm. Add-mix
connection is 13mm, air inlet connection is10mm.
SprayCast™ machine
The SprayCast™ machines are normally of double piston pump type,
powered either by an electrical motor or diesel engine. The power needs
to be sufficient to convey the refractory at least 40 meters vertically plus
20 meter horizontal, including the rubber hose where the nozzle is
attached.
The SprayCast™ machines are either provided with a built in mixer, or
alternatively the material has to be mixed in a separate mixer or concrete
pump and then fed to the SprayCast™ machine.
Before starting the mixing of the first mix

Connect all pipes, hoses and the SprayCast™ nozzle
Connect the compressed air hose and the add-mix hose to the
nozzle. Check the PH value of the add-mix at the nozzle –it should be
> 12,5 (consider PPM’s!)
Mix two or more buckets of slime glide( this is to be preferred above
chamotte powder) to ensure that all inner surfaces of the pipes and
hoses will be properly covered
Start the machine and let it run for 30 minutes to ensure that all oils
have reached working temperature
Connect the water hose to the reverse nozzle
Check all functions
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Mixing and pumping

Wet the mixer in the barrel before starting the first mix
Add one big bag and water according to the product data sheet; for
the first mix 0,5 - 1 litre of extra water will be required to avoid
clogging in the pipes or hoses
Mix for 4-5 minutes
Check that the consistency of the mix is almost self flowing
Check that the temperature of the mix is between 5 - 25 oC; 15 oC
recommended
Let the material into the pump hopper
Pump 2-4 strokes on low speed so the material fills the inlet of the
pipe
Nozzle team shall then fill the slime into the feeding hose and pipe
system and make sure it flows all the way down to the hopper. Note
that every 10 meter of horizontal pipe requires 10 litres of slime glide
to cover all surfaces
Start pumping with slow strokes
Pump until material comes out of the hose at the nozzle connection
and all slime glide is removed
Connect the nozzle and start the air and the add mix
Start pumping and, when everything works well, start mixing more
material
Lubricate the machine continuously at every 3rd mix as a guideline
Spraycasting process
Recommended distance between the nozzle and the surface is 0,5 m or
less for good access around anchors. When finishing a panel increase
the distance for easier control of the final thickness.
Fig 5.22: SprayCast™ nozzle; notice the additional line

for the add-mix.
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Fig 5.23: Starting at the bottom working

upwards
Fig 5.24: Panel prepared for Spraycasting
Start spraying in the bottom corners of each panel, then around the
anchors
Use less add-mix near the borders of each panel for easier trimming
of the surface
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Trimming of the surface can be done with a joint ladle or a tree-edge

scraper; the smoothness of the surface shall be within +/- 6mm
Trimming must be done during the application or immediately after
pausing
Check that every expansion joint is clearly visible and clean
Finishing the installation and dismantling

Good communication is needed between the teams at the mixer and
at the nozzle to determine the amount of material that will be needed
to finish the planned work as accurately as possible; use 25 kilo bags
of material near the end of installation
Stop the pumping
Disconnect the pipe from the machine and position it into the water-
proof container
Disconnect the nozzle
Connect the reverse nozzle to the hose and open the water valve to
press the remaining material backwards into the waterproof
container. When only water appears from the pipe blow the pipe with
compressed air to remove any remaining material. Then install the
cleaning balls and press these from the nozzle side to the container
using water. Repeat this procedure two times and then blow the
system a final time with air.
Fig 5.25: Finished surface, spraycast
Clean the Spraycast nozzle with compressed air and water

Clean the add-mix pump with clean water and check the pH value to
ensure that all add mix is disappeared (pH should be around 7)
Clean the machine carefully with pressurized water
Lubricate all spots on the machine while it still is running
Check and put all equipment back into the container and report any
damages or losses in the log for the machine
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Communication
When Spraycast is in progress it is most important to keep open
communication between the nozzle team and machine crew. A walkie-
talkie or radio communication system should be made available during
the entire spraycast operation to ensure its complete success.
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5.3.4 Plastic gunning (Hyrating)

Plastic granulate material is normally installed by ramming; however,
specially designed granulate is available which allows plastic material to
be gunned.
The material is a plastic granulate and will be normally delivered in either
25 kg bags on a pallet, or small big-bags.
There is a risk that the material becomes compacted during
transportation; this can cause difficulties while charging the hopper;
therefore, check the material before adding it to the hopper.
As this compaction could make the filling of the machine more difficult it is
highly recommended not to store one pallet on top of the other to avoid
further compacting of the material.
Around the workplace of the machine all remarks for normal gunning are
valid (see section 5.3.2).
There are two major issues which are different from regular dry gunning:
No water will be added at the nozzle; with Hyrate the “nozzle” is just the
end of the hose.
A much larger volume of air is required for pumping. A large compressor
(20 m³ / min) is needed - disqualifying the use of local air nets.
For a good application of the material the same rules as in ordinary
gunning apply for the nozzle-man, with the following exceptions:
Rebound
One of the characteristics of this application method is higher rebound
compared to normal dry gunning.
Pay attention to this during calculation and supply of material, as well as
when arranging waste disposal.
Gunning distance
One important factor for good material performance is the compaction of
the plastic. During gunning the compaction will be generated by the
speed of the impacting grains.
The maximum grain size of Hyrate material is 7 mm. Due to the high
speed of application, the rebound also impacts on the nozzle man.
Under these circumstances operators have the tendency to step back
from the surface, but the optimum distance between the nozzle (hose
end) and the surface is around 50 cm or less.
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Plastic Gunning (Hyrate) machines

A special type of gunning machine is required for the Hyrate application
method.
The principal operation method of this machine is quite simple and
maintenance is very easy.
The pockets of a pocket wheel located under the hopper are filled with
material; the filled pockets make a half turn and arrive at the air hose
connection; with air pressure, the material is blown out from the pockets
into the hose. The area of the hose connection is sealed with special
segments.
The theoretical connection/media figures and technical data of this
machine are as follows:
Power: 400 V / 50 Hz
Pocket wheel (Rotor): 80 mm / 12 or 15 pockets
120 mm / 12 or 21 pockets
Belt pulley: Dw 80 / 100 / 120 mm
Hoses: Ø 32 or Ø 50 mm
Table 5.4: Theoretical capacities of plastic gunning machines
Rotor 80 mm Rotor 120 mm
Belt pulley Dw 80 mm 2,0 m3/ h 3,0 m3/ h
Belt pulley Dw 100 mm 3,0 m3/ h 4,5,0 m3/ h
Belt pulley Dw 120 mm 4,0 m3/ h 6,0 m3/ h
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Pressurized air demand

Capacity of compressor: 6-16 m³/h
Air Pressure: min. 6 bar
Based on experience it is highly recommended to not use the figures

given above. More realistic figures are as follows:
Compressor:
Output: 18,0 – 21,0 m³/min
Pressure: 8,0 – 12,0 bar
Realistic output
Theoretical figures are valid for an ideal fluid (sand).
Calderys materials are not ideal fluids, so we have to reduce the data
by approximately 50 %
Realistic output: 1,0 – 3,0 m³/h,
If densities 2,0/2,5 t/m³ 2,0 – 6,0 to/h
Necessary man-power
Min. 1 HyRate Operator (Nozzleman)
Min. 4 Helpers :
1 Material feeder
1 Cleaner of the surface
1 Rebound handler inside
1 Rebound handler outside
5.4 Brickwork
Bricks are produced in a wide variety of qualities based on materials like
C, SiC, MgO, Al2O3 and SiO2. In this manual, however, we only describe
aluminium-silicate based bricks.
Dense refractory bricks can be produced in two different ways: dry or wet
pressed. In the dry-press method a dry mass is pressed with high
pressure (~400 kg / cm²) in a hardened steel mould. A wet-pressed brick
is produced with an extruder using much lower pressure and the mix
before pressing is much wetter.
The advantage of a dry-pressed brick is better control of the final shapes,
a lower porosity, and a better cold crushing strength (ccs). The
temperature at which the bricks are fired is also an important parameter.
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Before starting the brickwork it is important to check the tolerances of the

bricks; the quality of the work will be dramatically disturbed when bricks
differ too much in their dimensions. Generally, at the jobsite bricks should
be checked for the following items:
Chemical and physical specifications; check the test certificate

provided along with the material
Verify the packing list of the supplied material
Physical appearance of the packing and bricks before and after
opening the packing, looking for any visible defects. The most
common physical defects are loose or broken edges and corners
Dimensional size tolerances (explained more thoroughly under
“tolerances” further on in this chapter)
The brickwork has to be installed according to the drawing and or

specification. Special attention must be given to the first layer of
brickwork; the base must be correct because corrections in installed
brickwork are very difficult. While the mortar is still flexible the installed
bricks can be readjusted; however, when the mortar has started to set or
harden readjustment is not permitted. If the brickwork is not installed
according to drawing and/or specification the bricks have to be removed,
cleaned, and re-installed with fresh mortar.
Brick lining work should be carried out in sections and proceed one layer
after another. Normally expansion joints define a usable border for the
sections.
The lining of the bottom/floor should be installed at the end after the wall
and/or roof lining are finished.
It is important to ensure correct geometric alignment of all the brick faces.
Bricks must be straight and in line.
When cut bricks are needed for closing a ring, ending a layer at an
expansion joint, or making the lining staggered, it is preferable that the
size of the cut brick to be at least 75 % of the original dimension. Closing
bricks smaller then 50 % of the original dimension are not accepted. If a
single closing brick would be less than 50% its original size, consider
using two closing bricks instead of just one. Use of a brick cutting
machine equipped with a diamond-tip sawing blade is preferred to get a
smooth surface.
Check the verticality and horizontality of the brick lining for each and
every layer of installation with the help of a 2 meter long straightedge,
plumb, bricklayer string and other levelling instruments.
Wooden or rubber hammers are used to align bricks; however, a skilled
bricklayer places the bricks just with a smooth movement and light
tapping. Correction with a hammer is normally not necessary.
Never use a metal hammer with insulating bricks. When such a hammer
is used for dense bricks don’t apply too much force; the bricks can be
damaged by this. A sand hammer is preferred.
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After the mortar has set or dried, clean the brickwork by scraping with a
trowel. This “Pointing“ is carried out after brick lining is completed; if it is
done directly after application the brickwork acquires a dirty look. There
should be no mortar left outside the joints. Joints should be clearly visible.
The thickness of the mortar in the brickwork can vary; small dimensional
differences in the bricks are compensated with the mortar joint; also the
‘texotropity ’(foam, cream) of the mortar varies; however, the total mortar
thickness should not be more than 1-3 mm. Specific demands for mortar
joint thickness are normally specified in the detailed design.
Check for uniformity of mortar filling. In cases of excessive thickness of
mortar, or gaps between two layers, the brick lining should be removed
and replaced.
Mortars
Mortars come in two general types: wet mortars which are ready to use
out of the bucket, and dry mortars which must be first mixed before use.
If mixing the mortar, use a paddle counter-current mixer. The mortar
must be mixed thoroughly; no lumps or coarse material can be present in
the mix.
The ball-in-hand test is not applicable for mortars; the bricklayer will
confirm the right consistency.
With air setting mortars mix only the amount the bricklayers are using.
The mortar has to be applied uniformly on the surface of the brick and
should cover the entire surface of the bricks. Never place extra mortar on
the sides of the brick (collars) because this will cause hollow spaces in
the joints. The success of the lining depends on the uniformity of mortar
on each side of brick and its thickness. Any void/gap/non-uniformity will
lead to channelling of hot gases and can result in failure.
Tolerances
It is very important to note that the dimensional tolerance defined in the
specification sheet may not be adequate for the satisfactory performance
of the lining. For this reason, it becomes essential to specify the critical
dimensions as an additional parameter and ensure they are strictly
adhered to.
For example:
A brick with a specified dimension of 200 mm and a size tolerance of
1.5% might actually be between 197mm and 203 mm. If these bricks are
installed it could be the case that a 197 mm brick and a 203 mm brick are
installed side by side causing a gap of 6 mm!
Such a situation will result in skewing of the lining and its premature
failure. The above situation can be dealt with effectively by sorting the
bricks in an early stage based on dimension. In the provided example you
could make three groups:
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A. The First group should be of 198 +/- 1 mm

B. The Second group should be of 200 +/- 1 mm
C, The Third group should be of 202 +/- 1 mm
Not all variation in brick dimensions cause problems; it depends fully on

the orientation of the brick in the brickwork.
Expansion joints in brickwork

Provide expansion joints as per drawing. Often special shaped bricks are
used to form expansion joints.
Expansion joints should be kept clean of any contamination.
It is very important that expansion joints are kept straight: if a brick
located in an expansion joint sticks out, the expansion will get stuck on
this location and enormous forces will destroy the brickwork around this
point.
Make sure that expansion is calculated for the correct operating
temperature and specific brick values.
If the required expansion joint is so large as to cause worry about the
back-up layer being attacked consider breaking up the section into
smaller fields with correspondingly smaller expansion joints.
Note: Most problems that occur with refractory brick linings are
caused by insufficient expansion room!
5.5 Back-up layer blankets/fibres

Working with ceramic fibres should be avoided as much as possible;
these products can cause cancer and should be replaced by more
environmentally friendly soluble insulating fibre products. The Calderys
safety precautions must be followed in all cases.
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6 DEMOLITION
When the demolition of existing refractory is in the scope of work, a plan
detailing the execution has to be created.
Before starting the job you have to:
Consider what type of equipment is best suited for the job. Quantity
of material, hardness, available access, and available time, are all
factors which affect the choice of equipment.
Verify what is underneath the demolished linings that could be
potential hazards. (Steel tubes, dangerous linings, etc.)
Make sure everyone involved understands where and what is to be
demolished, and that everyone is briefed on proper safety
procedures.
Develop a transport plan for the demolished materials. Both where
the material is going to fall down and how the waste material will be
transported out of the installation. In some cases a conveyor belt can
be used as long as it is not directly underneath the falling materials!
Make sure there are enough waste containers.
Make sure the scaffolding will not be overloaded, and will be cleaned
on a regular basis.
Tube walls/ boilers

Special attention has to be made when demolishing a refractory lining on
a tube-wall in a boiler. If demolition takes place using hand tools like
pneumatic jack hammers, the chances of damaging the tubes is very
high; the cost of repairing the damaged tubes is also very high!
For larger surfaces consider the following methods for removal of the old
lining: grit blasting, high pressure water blasting, or ice blasting. Some
experience with these methods is available within the company.
If the work is executed with jack hammers use flat chisels instead of
pointed chisels; a pointed chisel can easily enter a tube without it being
noticed that you are ruining the tube sheets!
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7 REPAIR METHODS
The following repair procedures are discussed below: use of a patching
material, repairing gunned material, repairing castable material, and
repairing brickwork
Before carrying out a repair conduct a thorough inspection of the area.
Check for honey comb, rat hole, segregation, lamination, and other
commonly occurring problems. Mark the area to be repaired.
7.1 Repair Procedure - Patching

Patching refractory products can be hand-packed, trowelled, gunned,
veneered, or painted onto worn-out refractory surfaces requiring repair. If
the patching material is supplied in dry powder form it shall be mixed with
liquid bonding compound onsite. The material should be mixed in a
manner that is suitable for the chosen repair method.
When patching the damaged refractory surface the surface should be
clean from slag and have a rough surface. The surface must be wetted
/moistened before application of patching material for proper adhesion.
For cement materials use water for moistening; for phosphate based
materials use mono-aluminium phosphate.
Recommended equipment for trowelling
Paddle/Pan mixer or Bowl mixer is recommended
Drilling/scrapping tools,
Patching and finishing tools
Mixing, placing and finishing

Patching materials that are trowelled are mixed with a binder. Please
carefully follow the directions outlined below when trowelling or hand
packing.
Never use water in the mix; water in the mix can cause catastrophic
failure, including explosive spalling!
Do not mix more material at one time than can be placed within 15-20
minutes at a temperature around 15 – 20 °C.
When troweling the materials, use a trowel with a large surface area
for the best finish. When hand packing the materials, rubber gloves
should be worn. To improve the appearance of the face of the
material wet the trowel or gloves slightly with the appropriate liquid
activator when finishing the material.
When troweling or hand packing on horizontal surfaces to repair
existing fired refractories, it is recommended that good contact
between the surfaces be ensured by tamping.
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7.2 Repair Procedure -Gunning

Check what kind of anchoring is available for the gunned material. If an
existing anchor is damaged then it should be replaced. If there is no
anchor, as is often the case when repairing brickwork, then anchors must
be installed prior to the application of the gunned material.
Corners or narrow areas should be gunned first in order to prevent
entrapment of rebound.
The work should be limited to an area which can be kept moist.
The edges should be square and the patch area should be clean.
For better adhesion the existing refractory should be wetted immediately
before placement.
If the area to be repaired is large, remove the damaged material back to
the next layer, and reapply material to the original thickness specified in
drawings.
7.3 Repair Procedure -Castable

Defects in a casted lining should not be filled or patched up. When part of
the lining is rejected, the applicable part must be demolished down to the
shell or back-up layer and in surrounding areas until good material is
found. This dismissed area must then be relined.
If the repair area is very small, then as a temporary measure the loose
material may be removed and the hole filled with fresh new material
which is then densified. This method should be considered only for
emergency situations; otherwise the surrounding material should be
removed and replaced as described above.
In order to key or lock in the new refractory, it is recommended the
existing lining be cut back in a tapered shape and in such a way that the
new lining will be anchored by at least three (3) anchors.
Fig 7.1: Castable repair method (change block insulation)
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7.4 Repair Procedure -Brickwork

Repair of defects in refractory brick linings should always be executed
from below a shelfplate support section. In this way the shelfplates will
always support the above installed brick lining when removing the
defective bricks in the lower section. Always remove the total brick lining
layers starting directly under the shelfplate and continue until the
defective area has been reached.
Fig 7.2: Brick repair method (Gunnite new material)
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8 CURING
The purpose of curing is to prevent the premature loss of moisture from
freshly installed refractory concrete during the chemical changes
associated with hydration of the cement used as binder. When the cement
is mixed with water an exothermic reaction (due to hydration) takes place
driving off water at an early stage. Loss of water from the surface of the
castable before the cement is fully hydrated results in a weaker lining and
sometimes fine surface cracks.
8.1 Wet curing

After the material has had its initial set the exposed refractory surface can
be lightly sprayed with water, covered with plastic sheeting, or sprayed
with a concrete curing compound. This is called wet/moist curing.
The concrete curing compound forms an impermeable membrane to
prevent moisture loss during curing but will burn out at low temperatures
during pre-heating or firing.
Wet or Moist curing needs to be performed for approximately 24 hours.
Cover the cast area with plastic sheet and/or put wet fabric or rags. This
will prevent the evaporation of water from the castable.
8.2 Conservation
If a dry-out is not conducted immediately after an installation some
precautions need to be observed to preserve the installed lining.
8.2.1 Plastics
Plastic installed lining should be kept dry and ventilated. The installed
plastic material has a tendency to absorb moisture from the atmosphere
becoming bloated and slumping. The heating of the plastic lining should
be carried out at the earliest opportunity. The special arrangement
recommended by Calderys (see 5.1.5) for the roof should be left in place
during heating.
8.2.2 Cement bonded castables ( Carbolic reaction )

The cement bonded castables have a tendency to react with Carbolic
acid if moisture condensation is allowed. This will result in a powdery
surface that is sometimes white in appearance with loose material on the
surface. The sound of the lining also becomes dull. To avoid such a
situation the lining should be kept properly ventilated to avoid
condensation of moisture, and heating should be started at the earliest
opportunity.
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8.2.3 Extra lightweight castables (flaking)

After installation of extra lightweight castables like CALDE™ CAST XL
135, if a dry-out is not performed directly after finishing, it somtimes
happens that after a few weeks a surface layer of 1 – 3 mm thickness
flakes off over large areas. The flaked off material can be considered as
“cement skin”. The surface flaking is a phenomenon that can happen with
most (extra) lightweight castables and is often referred to as
“carbonation/alkali hydrolysis”. It occurs mostly if installed monolithic
material is left without dry-out for months.
The only known way to prevent this is to execute dry-out of the monolithic
parts directly after full cement setting (>24 hours).
This surface flaking is most probably caused by transport of water added
at installation from inside the monolithic towards the surface where the
water is evaporated.
Water soluble salts, coming from the raw materials, are transported by
this water to the surface. The salts dry out and crystallize just under the
less porous “cement skin.”
Most soluble salts show a volume increase at drying.
This volume increase creates a mechanical pressure at the cement skin
causing the cement skin to flake off as can be seen in fig 8.1 below.
Fig 8.1: Flaking in insulation castable
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9 DRY OUT
The service life and operational safety of an entire plant depends on
proper drying and heating up of the refractory lining; therefore it is
important to understand the reason for a controlled process.
Almost all monolithic refractory material contains water after installation.
As heat is applied, the free water in the pores begins turning to steam at
100 °C, while chemically bonded water begins the transition to steam
around 450°C.
This conversion of water to steam results in significant pressure building
up inside the refractory material. This steam must find its way to the
surface and out into the atmosphere. If the rate the steam is evacuated
at is significantly lower than the rate the steam is generated at, steam will
build up in the pores creating immense pressure, which in the worst
cases can cause an explosive failure!
By controlling how quickly heat is applied it is possible to control the rate
of generation of steam, and allow the generated steam time to evacuate
from the refractory. This process is called “Dry Out.”
Once all the water has been evacuated, the temperature can be taken to
operating temperature, but again care must be taken that this not be
done too rapidly as the different amounts of expansion that occur
between areas that have not yet reached a temperature equilibrium will
create stresses which can cause significant mechanical damage to the
refractory lining. This stage of the process is called “Heating Up.”
Both these processes are difficult to model analytically and are typically
approached empirically.
For every group of materials, Calderys has produced an installation
guideline (Nr. 1 – Nr. 33) which include specific drying and heating up
instructions.
Additionally, most projects will have specific dry out and heating up
instructions prepared for the project due to the mixture of the materials
used in the project.
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10 CRITERIA FOR ACCEPTANCE

During inspection it is important to know what kinds of cracks are
acceptable and which kinds of cracks require (partial) replacement of the
lining; this should be clear to all parties involved.
10.1 Cracks
A refractory lining sometimes shows cracks. These cracks are normally
caused by differential movement between the refractory lining and the
steel structure to which the refractory lining is anchored. Although a
refractory lining is usually provided with construction / expansion joints,
crack formation by the above mentioned cause can not always be
avoided, especially when the refractory lining is stiffly connected to the
steel shell by means of anchors.
Cracks can also be caused by rapid temperature changes. This cracking
is not a reason for failure and normally does not affect the good
performance or lifetime of the refractory lining. In most cases the cracks
will close completely at higher temperatures due to reversible expansion
of the material; this can sometimes be observed when the lining is cold -
i.e. when the surface of the lining is covered with soot or is discoloured
the cracks will be clean internally and will show the colour of the pure
refractory material. It is clear that these cracks must not be filled, as later
on, when the refractory lining is again subject to a higher temperature, the
lining can be damaged due to lack of expansion space. These, mostly
shallow, cracks often have a tapered form and they do not reach to the
steel shell or back-up insulation.
10.2 Defects and acceptance criteria

Cavities : Due to air bubbles during casting.
Cavities are acceptable if not deeper and not wider than 10% of the lining
thickness, not to exceed 25 mm. The area with cavities shall not exceed
10% of total lining area.
Surface cracks : Hair cracks, only on surface due to dry-out.

Surface cracks are a common appearance and are acceptable.
Large cracks : Cracks going completely trough the material.

Large cracks in the insulation layer are acceptable if no parts of the
insulation layer can fall out, and the cracks are not wider than 3 mm at
any location.
Cracks in the (dense) top layer are acceptable if no parts can fall out and
no part of the crack is wider than 3 mm.
Chips : Pieces fallen off from edged or chipped off the surface
- 74 -
1st edition
Chips are acceptable on corners if not deeper than 10% of the lining
thickness.
11 INSPECTION
Prior to the dry out, and after finishing your own inspection, a final
inspection with the client or the client representative shall be executed. A
notification of acceptance shall be made after this inspection /
acceptance.
11.1 Final Documentation

When a job is ready all documentation must be finished.
All documents such as final protocol, installation reports, sampling
reports, and as-built drawings must be filled in. Make sure the dimensions
of each panel, casting date, and time are recorded. Complete the
Castable Installation Details Report
Complete the detailed gunning installation reports (if applicable).
-------------------------XXXXX--------------------------
All documentation forms will be available at the SEC Intranet site.
- 75 -
© CALDERYS SEC
http://secintranet.calderys.com/

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Calderys Installation Manual

for Refractories (CIM)

Calderys Solutions for Engineering & Construction

1st edition, revision 0.0

You will find us at: http://secintranet.calderys.com

10 CRITERIA FOR ACCEPTANCE ....................................................................74

1.1 General guidelines

Fig 1.1: Storage on pallet, adapted to

In order to keep the binding cement fresh, it is necessary to store the

Overseas, long term

1.2 Special remarks per material type

1.2.1 Castables & Gunning materials

• Material should be kept in dry location during storage

Please also refer to instructions under Freezing and/or Tropical

Even though the plastic refractory is carefully packaged to retain

Please also refer to instructions under Freezing and/or Tropical

1.2.4 Other (Ceramic fibres, vacuum shapes, bricks, etc.)

1.3 Storage guidelines

Table 1.1 Material storage class

01 Always store covered.

02 Protect from moisture. Keep dry.

03 Avoid storing in direct contact with wall or ground.

04 First in first out (FIFO).

05 Must be used within shelf-life period.

06 Can be stored for long time.

08 Stack maximum 2 pallets high

Table 1.2 Material storage conditions

No Item storage Code (see table 1.1)

B Plastic/ Ramming material,Wet Mortars 02, 03, 04, 05, 07

C Insulation bricks, Calcium silicate blocks, 01, 02, 03, 06

D Basic bricks and mortars 01, 02, 03, 04, 05

E High alumina bricks 03,06

Ensure availability of refractory engineering drawings, sketches, or

Ensure the availability of all needed resources.

Fig 2.1: Keep on schedule.

Have resources been

Fig 2.2: Use available project tools.

when resources can be made available.

The requirements for each application method are outlined in further

Good housekeeping is an important condition for high quality refractory

Fig 2.3: Keep the work site nice and tidy,

Please ensure the following:

Temporary power and lightning cables shall be neatly routed and

Fig 3.1: Use your PPE (Personal Protection Equipment)

3.2 Specific Tools

3.2.1 Sorting tools

3.2.4 Brickwork tools

3.2.8 Demolishing/ wrecking tools

A more detailed summary of equipment will be available on the SEC intranet

4.1 Steel surface

4.2.1 Metallic Anchors (< 1000 ºC)

For example, an anchor used with insulating castable in a petrochemical

Table 4.1: Metallic anchor distribution

Hotface thickness Roof (pcs/m2) Walls (pcs/m2) Dim/ type (mm)

> 225 mm 25 11 6-8 Y

The commonly used V and Y anchors are pictured below.

Fig 4.1: V-anchors as per CASS (Calderys Anchoring Standard Solution)

Fig 4.2: Y-anchor as per CASS (Calderys Anchoring Standard Solution)

Typically the pattern of the anchors will alternate: an anchor positioned

Fig 4.3: Typical anchor pattern shows the