• Concrete refractories are applied by mixing with water, similar to normal concretes in terms of application. Attention should be paid to the required amount of water. If mixing is done with too little water, the material cannot reach the required fluidity; in case of excess water addition, the material loses its strength and cracks occur.
• The water to be used can be tap water, provided that it does not contain more than 1000 ppm of impurities and its pH is not lower than 5.
• It is checked whether the materials and equipment to be used are clean.
• Before mixing with water, the dry powder should be mixed for approximately 1 minute to ensure homogeneity.
• Half of the water, which is between 15-20°C, is added to the dry powder. After mixing for a while, the remaining water is added.
• Although the mixing time varies from material to material, it can generally be taken as 3 minutes.
• All equipment to be used in mixing must be clean.
• The mixing process is carried out in a mixing machine. If this is not possible, it can be done with a shovel or trowel in a clean container.
• Correct calculation of material mixtures is required. Piece-by-piece pouring should not be allowed.
• After the refractory material is poured into the mold (the moment it starts to heat up), it is necessary to cure it with water to form the bond structure of the material, increase its physical strength, and prevent cracks that may occur, and this process should be repeated frequently. If the method to be applied after the end of the shift is used, since it is not possible to repeat the watering process after starting the heat curing, a wet cardboard should be placed on the surface of the material and it should be covered with nylon stretch wrap to prevent contact with air.
• In winter months, the storage temperature of all refractory materials must not be lower than 10°C and must not be humid. In cast refractories, the water to be mixed should be lukewarm (25°C) so that the setting time resulting from water crystallization does not prolong. In summer months, the material should not be applied in the sun; it must be applied in a shaded and cool place.
• If a wooden mold is preferred, the wood must be coated so that the mold does not absorb the water from the mortar.
• To ensure that the poured concrete completely fills all edges of the mold, the mold is tapped from the outside with a hammer or the material is mixed from bottom to top with a mixing rod.
• If vibration is to be applied to the concrete, attention should be paid to its duration. If applied for a long time, it causes the separation of particles.
• After all pouring stages are completed, the natural drying process of the refractory material is started. The setting time is accepted as 48 hours. The material must be kept humid during this period.
• The time required for removing the molds differs for each material. However, this period must be at least long enough to allow the material to harden thoroughly.
• After the setting period is completed, the refractory material is subjected to the heat curing program.
• Refractory anchoring systems show differences according to the materials used and the design to be made. When more information is required regarding anchoring systems, you need to contact us.
• In case of any mishap during concrete pouring, technical support should be obtained from authorized persons.