Professional Documents
Culture Documents
Rev.
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QC/M / R EF/001
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Paoe:
09-Ju n-12
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APPROVED BY
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Doc No:
QC/ M/REF/00 I
Rev. No:
Date :
09-Jun-12
Page:
2 of 10
TABLE OF CONTENTS
1.0
4.0
GENERAL REQUIREMENTS
5.0
APPLICATORS'S QUALIFICATION
6.0
7.0
TOLERANCES
8.0
9.0
10.0 INSPECTION
11.0 REPAIRS TO REFRACTORY LINING
DESCO N ENGINEERING
REFRACTORY APPLICATION PROCEDURE
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3ofl0
2.0
1 .1
1.2
1 .3
1.4
1.5
1.6
The general guidelines of this procedure are mm1mum care and quality
requirements. The installation contractor is expected to utilize his expertise in
refractory installation, if and where conditions require, to exceed these
minimums or take additional steps to insure a satisfactory, serviceable lining is
provided.
1 .7
2.1 AMBHertel shall check all materials upon receipt at the site of installation for
damage such as broken bags, moisture infiltration, etc., to assure the refractory
containers (bags, drums, etc.) as marked are material specified on the
arrangement drawing, and that the refractory is the specific mix for the intend
method of applkation (Casting).
2.2 Prior to starting refractory installation, Descon shall verify that 5% random bend
test of the anchors has been performed and recorded.
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REFRACTORY APPLICATION PROCEDURE
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2.3 When castable tie back has been installed by a party other than the AMBHertel,
AMBHertel shall assure by hammer or bend test, that the tieback is suitabl y
welded to the shell before starting work.
2.4 Bagged refractory shall have the batch date checked prior to mixing to confirm
that the material has not passed the manufacturer 's recommended shelf life.
2.5 Castables which show signs of having set (lumps or hardness throughout) prior to
mixing shall be rejected, regardless of shelf life expiration date.
3.0
BESCDII
4.0
DESCON ENGINEERING
REFRACTORY APPLICATION PROCEDURE
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5 of 1 0
GENERAL REQUIREMENTS
4.1
4.2
5.0
APPLICATOR'S Qualification
1. Each team of mixer operations and APPLICATORS shall prepare either a standard
shape (230 X 114 X 64 mm minimum dimensions) of a box specimen (280 X 180 X 75
mm minimum dimensions) in a hardwood box.
2. The box should contain the same anchor system (type and spacing) as to be using in
the actual installation.
3. The specimen shall be placed by hand in approximately 25 mm thick layers,
subsequently poked to achieve accurate filling and good workmanship.
4. Vibrators shall not be used with castables having a bulk density of less than 1750
kg/ m3.
5. During installation of dense and medium weight refractory materials, the APPLICATOR
shallcheck the consistency of the ready mixed refractory material using the "Ball-in
Hand" method (ASTM C860). In the cast of a viibra cast installation, a similar form and
vibration system should be modelled with a similar anchor system.
Doc No:
DESCON
ENGINE
ERING
Rev. No:
I
REF
-RA
DCTO
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9
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ATI
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PRO
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an
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6
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f
1
0
APPLICAT
OR'S test
samples
shall be
stored to
set and
dry.
6.0
APPLICATION
OF POURED
REFRACTOY
(CASTING)
6. 1
Preparat
ion
a.
(
a
s
6.2
Installation
a. The lining shall be applied in narrow areas,
starting at the bottom and working upward.
DESCO N ENGINEERING
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E
F
R
A
C
T
O
R
Y
A
P
P
L
I
C
A
T
I
O
N
P
R
O
C
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D
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7ofl0
b.
Eac
1.
Surfa
ce
tempe
rature
s
must
be
maint
ained
betwe
en
1030C
for 36
hours
during
curing
. If
ambie
nt
tempe
rature
s
above
30C
are
antici
pated
during
the
cure,
AMBH
ertels
hall
provid
e the
coolin
g
metho
d by
sprayi
ng the
water
on the
surfac
e to
maint
ain
the
temp
eratur
e.
d. If an unavoidable interruption
occurs, the wet ending of the
lining shall be cut back at an
angle to the surface to provide
a slight "keyed" effect when the
final material is cast.
All material ahead of the cut
shall be discarded.
e. Care should be taken that no
castable materials
should
protrude inside the tube sheet
or ferrules. If it happens, then
the same to be cleaned.
f.
2.
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REFRACTORY APPLICATION PROCEDURE
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DESCO N ENGINEERING
REFRACTORY APPLICATION PROCEDURE
IIESCIIN
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Date :
09-Ju n- 12
Page:
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DESCON ENGINEERING
REFRACTORY APPLICATION PROCEDURE
10.2
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Hammer Testing
1. The type of inspection is generally referred to as a Hammer test. It involves the
practice of striking the lining over its entire area with a ball point machinist
hammer having a recommended weight of 450grams.
2. Hammer testing will indicate whether or not a lining is homogeneous. An
experienced ear will determine, in more detail, faults which might cause a lining
to collapse such as voids eliminations etc.
11.
1. If inspection reveals defective areas as previously defined greater than 150 mm x 150
mm, the full thickness of the defective concrete layer must be removed for a
minimum area that include 3-4 anchors.
2. Care must be taken in the removal of the faulty material that the surrounding sound
lining is not damaged
3. The removal of the refractory concrete should progress at a small angle to the shell
and the periphery of any repair be located mid-way, between anchors.
4. The area being repaired should be cleaned of all loose concrete and debris and the
adjacent sound material thoroughly wetted before any new concrete is installed.
5. Only the same concrete as originally employed should be used for replacement and
wherever possible, especially in large areas the same installation method as was
originally used.