Instructions for Use
Importance of Application
Castable refractory is delivered for inspection by the manufacturer who supplies the raw material, processes it, and ensures control over the entirety of its mixing with water, shaping, drying under a specific cure, and/or firing by the user. This shows that the manufacturer carries out only 2 pre-processes, whereas the user conducts at least 5 complementary processes critical for material performance. In the end, the material is either rejected or accepted by the user.
Storage
It can be stored for 1 year without losing its properties, provided that it is kept in a closed and dry environment and a maximum of 6 rows of bags are stacked on top of each other.
Mechanical Mixing
Care should be taken to ensure that the mixer is very clean. One bag of mortar (Castable) is poured into the mixer. (If a part of the bag has not been mixed, it must be mixed again before the entirety is poured into the mixer to avoid separation of refractory mortar particles.) Water should be added slowly until fluidity and rapid setting acceleration are noticed and the desired consistency is achieved; clumping of the mortar (Castable) on the surface should be prevented. Mixing time should be kept to a minimum. (1 - 2 minutes is sufficient.)
The mixer should be kept close to the pouring equipment to prevent separation of refractory mortar particles that may occur during transport.
The mixer must be completely cleaned before use.
Absolutely clean water must be used.
Manual Mixing
A clean flat or mortar container should be used. Castable refractory mortar (Castable) should be mixed dry before adding water, and should be shoveled a few times by slowly adding clean water.
Setting
It should be covered with a polyethylene sheet to prevent evaporation loss. (A wet sack should be used to prevent rapid drying and obtaining a weak surface that absorbs moisture.) Maximum strength and performance are achieved through setting during composition at 20-30°C. Setting should not be applied below 20°C. Its duration is 24 hours.
Drying
After setting, the polyethylene sheet is removed and left to rest for 24 hours. The temperature is raised to 300°C by increasing it by 30°C per hour. It is kept at this degree for 5 hours. After this, the temperature is raised to 800°C by increasing it by 50°C per hour. It is kept for another 5 hours. It is put into service.
Anchoring
It is recommended to use the types of anchors shown above for better bonding of the castable refractory mortar to the applied area. Anchors should be fixed at intervals of 20 fingers cm to the surface, and care should be taken to ensure that they are 2 cm shorter than the material thickness to be applied. The representative diagram of needles manufactured from 308 or 310 grade steel, in sizes of 25-35 mm, used as reinforcement to prevent the growth of micro-cracks against thermal and mechanical stress of the material and to ensure an increase in the modulus of rupture value with rising temperature is shown above.