This drawing and the design it covers are the property of Enereff Engineers Pvt. Ltd.

They are merely loaned and on the borrower’s express agreement that they will not be
reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the borrower.

0
NO.
DATE
25.10.94

NEW DELHI
ENEREFF ENGINEERS PVT. LTD.
REVISIONS

INSULATING CONCRETE
ISSUED AS STANDARD SPECIFICATION

MANUAL APPLICATION OF
GENERAL SPECIFICATION FOR
INSULATING CONCRETE
MANUAL APPLICATION OF

BY
GENERAL SPECIFICATION FOR

CHD

3-12-005
SPECIFICATION NO.
0
REV.
APPROVALS
SHT 1 OF 6
 This drawing and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they will not
be reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the borrower.

8.
7.
6.
5.
4.
3.
2.
1.

NEW DELHI
S.NO.

ENEREFF ENGINEERS PVT. LTD.

CURING
GENERAL

MATERIALS

DRYING OUT
APPLICATION

PRECOUTIONS
PREPARATION
DESCRIPTION

INTERRUPTION OF APPLICATION
LIST OF CONTENTS

INSULATING CONCRETE
MANUAL APPLICATION OF
GENERAL SPECIFICATION FOR
3-12-005
5
5
5
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3
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3

SPECIFICATION NO.
PAGE NO.

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REV.
SHT 2 OF 6
This drawing and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they will not

1.0 GENERAL
1.1 This specification covers the application of insulating concrete for Fired Heaters, APH system,
other equipment and Incinerators. Any equivalent/ alternate material and application suggested
be reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the borrower.

by the Contractor/ vendor shall be subject to the approval of EEL in writing.

1.2 In addition to this specification, any other referred specifications and codes shall also be
followed as required.
1.3 Insulation concrete could be applied to steelwork either at the shop or at site. This specification
covers the application procedure etc. for both conditions.

2.0 MATERIALS
2.1 Insulating concrete is a ready mix hydraulic bonded material which can be applied manually. It
requires addition of only water for its application.
2.2 Water that is used should be fresh, clean, cool and potable.
2.3 It should be ensured that all equipment and tools used for mixing are free of foreign matter
particularly portland cement & lime. Contamination will affect setting and strength of
concrete.

3.0 PREPARATION
3.1 All reinforcement required for anchoring insulating concrete shall be placed where required.
Support anchors shall be as shown in the drawings and as approved by the Engineer-in-
Charge.
3.2 Entire surface including the anchors shall be mechanically cleaned using wirebrush etc. Oil,
rust, loose mill scale and any foreign matter shall be removed.
3.3 After the above operation, the entire surface shall be thoroughly cleaned with airjet. Water
should not be used for cleaning purpose.
3.4 Anchors shall be tested for soundness of their weld with the help of light hammer and
necessary repair made for defective anchors.
3.5 Instrument sleeves or other sleeves in lining shall have openings which shall be plugged with
oiled/ greased wooden inserts. These wooden inserts shall be removed after the setting of the
castable.
3.6 When tube supports require clearances for expansion, particularly in convection sections, these
must be coated with insulating materials and expansion joints must be provided in accordance
with the drawings.
3.7 Sight doors, access doors and similar openings in lining shall be fitted with forms (wood or
sheet metal) of such dimensions that it extends beyond the lining thickness. Forms shall fit
smoothly into openings. Forms shall be coated with grease so that it can be easily removed
after lining has fully set.

4.0 APPLICATION
4.1 Mixing
4.1.1 Dry mix the concrete before the addition of water.

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ENEREFF ENGINEERS PVT. LTD. GENERAL SPECIFICATION FOR SPECIFICATION NO. REV.
NEW DELHI MANUAL APPLICATION OF
INSULATING CONCRETE 3-12-005 0
This drawing and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they will not

4.1.2 Mix a predetermined amount of water within the range of specified by the manufacturer to
obtain a rodding consistency for proper placement of concrete. Mixing should be thorough but
must be kept to a practical minimum duration to avoid pre-setting. The mixed concrete should
be applied within half an hour.
be reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the borrower.

4.1.3 Mixing of concrete should be undertaken preferably in a paddle mixer. Before use, the mixer
should be cleaned from all foreign matter. Mixing box may be used only when small quantity
of concrete is required.
4.1.4 Do not make any additions to the above mixture. All tools used in mixing and applying shall
be kept clean and free from such substances, particularly portland cement and concrete.
4.2 Wooden Form
4.2.1 The inner surface of the wooden form shuttering should be plain and smooth. Machine oil/
grease etc. shall be applied on the surface of wooden form to make it water-proof and easy to
remove after installation.
4.2.2 While fixing the shutterings, care should be taken to keep the inner surface of the form in one
plane. There should not be any depression or projection on the surface.
4.2.3 Wooden form shall not be connected to any other temporary structure/ arrangement such as
working platform etc.
4.2.4 Forms shall be tight enough to prevent leakage of water from the concrete.
4.2.5 The shuttering fixed should be strong and sound to take the load of concrete and any
vibration during application.
4.3 Pouring/ Placement of Insulating Concrete
4.3.1 When the area of application is large, pouring/ placement of the insulating concrete should be
done in smaller segments in panel form.
4.3.2 In case if placement on ground, spread the mix with the help of ‘mason patta’ over the shell.
Thoroughly compact the mix, tamping and working as needed with the help of trowel to
eliminate air bubbles or pockets.
4.3.3 When concrete shall be poured behind the shutterings against walls, the height of the wall shall
be gradually built up. The compaction shall be done either by rodding or vibration.
4.3.4 Placement/ pouring shall be made in a layer of 50-75 mm thick and be well compacted to
uniform density. Successive layers shall then be placed and well compacted in the same
manner until t he desired thickness is obtained. The successive layer shall be placed
immediately, without any delay; otherwise laminations may occur causing the concrete lining
to be replaced.
4.3.5 After packing as above, the thickness of the concrete packing should be maintained slightly
greater than the thickness required.
4.3.6 Screed the surface of the concrete lining to the required thickness, with the help of ‘mason
patta’ discarding surplus material. This process should not be repeated. A screed finish is
required. Excessive smoothing or trowelling should be avoided.
4.3.7 When the application area is too large, the scoring of the surface shall be done in 1 - 1.5 square
metre of 3-4 mm width and about 10 mm depth.

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NEW DELHI MANUAL APPLICATION OF
INSULATING CONCRETE 3-12-005 0
This drawing and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they will not

4.3.8 Concrete joints should preferably be made staggered instead of straight.

4.3.9 Concrete should remain undisturbed during setting for a minimum period of 24 hours after
placing and should not be allowed to dry.
be reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the borrower.

4.3.10 While pouring, pneumatic vibrators shall be used for compaction. In absence of vibrators,
manual rodding can be done. Excessive rodding shall be avoided as this may cause
densification and reduce the insulating properties.

5.0 CURING
5.1 The concrete shall be properly cured by keeping the surface moist during its period of setting.
The curing shall consist of light application of clean, cold water and shall be started as soon as
the exposed surface is hard enough to permit spraying without washing out the cement. This is
normally indicated by no cement adhering to a wet hand placed lightly on the surface.
Normally the concrete is ready for curing 6 to 8 hours after application, assuming normal
atmospheric temperature. The sprinkling shall consist of a fine spray of water for curing.
5.2 In hot, dry weather, curing may be necessary to start earlier, i.e., 3 to 4 hours after lining has
been placed. In such cases, arrangement shall be made for spraying over the concrete already
placed, while the succeeding sections are being placed.
5.3 Once started, the curing shall continue without interruption until the concrete is 24 hours old.
At no time during the curing period the intervals between spraying be more than 30 minutes or
such as to make surface dry.

6.0 DRYING OUT

6.1 Before carrying out the drying out operation, the lining should be visually examined.
6.2 After the water curing is completed, the lining shall be allowed to dry under ordinary
atmospheric condition for a minimum period of 24 hours.
6.3 Thermal drying can start (if required) immediately after the above air-drying. The thermal
drying should be carried out as recommended by the manufacturer or the designer.
6.4 Steam should not be used for the purpose of heating.

7.0 PRECAUTIONS
7.1 If there is any delay in installing the insulating lining after the anchors have been welded and
prepared for lining, the entire area should be recleaned if necessary.
7.2 Shuttering should be removed after minimum 24 hours of castable application. However, for
arch and overhead surfaces, shuttering shall be removed only after minimum 48 hours of
application.
7.3 While setting, the lining should not be disturbed during initial 36 hours after its application.
During initial 48 hours after application, no shifting or lifting of lined sections should be
undertaken.

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NEW DELHI MANUAL APPLICATION OF
INSULATING CONCRETE 3-12-005 0
 8.0 INTERRUPTION OF APPLICATION
This drawing and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they will not

8.1 Interruption is not allowed unless permitted by the Engineer-in-Charge.

8.2 When interruption occurs, the lining shall be cut back immediately to the steel plate surface.
be reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the borrower.

This cut shall be made at an angle sloping downward towards plate, and shall be made at
locations where the full thickness has already been applied. This exposed edge shall be scored.
All material beyond the cut shall be discarded.
8.3 During this period, the curing procedure previously discussed shall be applied.
8.4 When lining application is to be resumed, the exposed surfaces as per Para 8.2 shall be
thoroughly wetted just before beginning of the application.

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INSULATING CONCRETE 3-12-005 0