• Insulation concretes, produced with a technology similar to concretes, are products manufactured from low-density raw materials in order to reduce final densities and provide good insulation. These types of products are used in almost every industry, both as the main refractory material and as a secondary product behind denser and heat-resistant materials. During the mixing and application of the material, the air temperature and the temperature of the water used should be +5/+25°C.
• It is checked whether the materials and equipment to be used are clean.
• The preparation of the mixer, dry mortar to be used, and water is carried out.
• If insulation product (fiber blanket) is to be used, it should be cut with the help of a utility knife and placed on the ground.
• The insulation product must be covered with stretch film to prevent the concrete from absorbing water.
• The most ideal method for mortar mixing is a mortar mixing machine.
• The amount of mortar to be mixed should be adjusted to be used within 30 minutes at most. Since hardening will start in mortar kept for more than 30 minutes without being used after mixing with water, it also affects its strength in the service environment.
• To start the mortar preparation process, the dry mortar should be poured into the mixer according to the amount to be used and mixed dry for 1 minute for homogeneity.
• After the dry mixing period is completed, the amount of water determined according to the water ratio should be poured slowly into the mixer.
• Although the mixing time varies from material to material, it can be taken as 3-5 minutes.
• After the mixing period is completed, the ready mortar is poured onto the area to be applied (from a height of maximum 1 meter); since applying vibration is not correct in insulation concretes, compaction by hand is applied. (If necessary, it can be rammed with a mallet.)
• After the application of the ready mortar is completed, its surface is smoothed with the help of a moistened trowel. The surface of the completed mortar is smoothed with a wooden trowel; if a wooden trowel is not available, the same process can be done with a sponge.
• After all pouring stages are completed, the natural drying process of the refractory material is started. The concrete is checked with 10-minute intervals after the pouring process, and it is observed whether there is temperature on its surface. An exothermic reaction starts in the mortar mixed with water. This reaction shows itself by heating up 3-4 hours after water is added. This heating of the mortar leads to early setting and then to cracks in its structure.
• As soon as the concrete surface starts to heat up, the poured area is covered with a damp bag or cloth. The purpose here is to slow down the drying process and prevent cracks that may occur.
• The mold in which the mortar is placed is not removed for 24 hours. After the mold is removed, the material is left to air dry on its own for 48 hours.
• Afterwards, the refractory material is subjected to the heat curing program.
• In case of any mishap during concrete pouring, technical support should be obtained from authorized persons.