CONVENTIONAL REFRACTORY CASTABLES

BY CASTING
DESIGN AND INSTALLATION MANUAL

Thermal Ceramics
TABLE OF CONTENTS
A. Preface
Introduction 2
B. Refractory Castables by Casting
1. General 3
1.1 Dense Castables 3
1.2 Lightweight Castables 3
1.3 Gunning Castables 3
1.4 Special Purpose Castables 3
2. Pre-Installation 3
2.1 Storage 3
2.2 Surface Preparation Prior to Refractory Placement 4
2.3 Formwork 3
2.4 Anchors 4
3. Installation 4
3.1 Water 4
3.2 Temperature 4
3.3 Mixing 5
3.4 Placement 6
3.5 Multilayer Linings 7
3.6 Joints 7
3.7 Finishing 7
3.8 Curing 7
4. Firing 8
List of Figures
Figure 1 Proper Bag Storage 4
Figure 2 Formwork 4
Figure 3 Paddle Mixer 5
Figure 4 Shaking Needles 5
Figure 5 Ball in Hand Test 6
Figure 6 Standard Vibrator 6
Figure 7 Vibrating Behind Forms 6
Figure 8 Multilayer Linings 7
Figure 9 Consruction Joints 7
Figure 10 Expansion Joints 7
Figure 11 Finishing 7
Figure 12 Cast with Forms in Place 8
Figure 13 Spraying with Curing Compound 8

December 2002 Thermal Ceramics Page 2


CONVENTIONAL REFRACTORY CASTALBES BY CASTING
INTRODUCTION
Over the past 75 years, Thermal Ceramics has proven
to be a world leader in solving heat intensive problems.
In addition to manufacturing ceramic fiber, brick and
fired shape products, a wide range of refractory mono-
lithic products are available. From lightweight, highly
insulating materials to dense, high strength products,
Thermal Ceramics has a refractory castable to meet
the needs of the customer. All industries are serviced
with these products, including ferrous, non-ferrous,
chemical, utility and ceramic related markets.
The Thermal Ceramic operation in Augusta, Georgia
has been certified to ISO 9002 standards for refracto-
ry monolithic production. At this facility, both raw mate-
rials and finished products are routinely tested to make
sure they meet a demanding quality level.
An experienced staff of refractory specialists is on
hand at Thermal Ceramics to assist you in product
selection, system design, and installation techniques.
This Design and Installation Manual is intended to give
the designers, installers and users of Thermal
Ceramics monolithic products a broad range of infor-
mation guidelines on the particular topic. Any ques-
tions or comments regarding this manual should be
addressed to your local Thermal Ceramics represen-
tative.
December 2002 Thermal Ceramics
DESIGN & INSTALLATION MANUAL
1. GENERAL
Castable refractories are classified into 4 major groups –
dense castables, lightweight castables, gunning casta-
bles and special purpose castables.
1.1 Dense Castables
Dense castables are designed for strength, abrasion and
erosion resistance and are primarily used as the working
hot face.
1.2 Lightweight Castables
Lightweight castables are used primarily for their thermal
insulating properties behind dense castables, or in cer-
tain conditions as working hot face linings. Their inherent
low density significantly reduces structural loading.
1.3 Gunning Castables
Gunning castables are modified versions of the above
castables allowing them to be effectively placed using
pneumatic guns. Some grades are dual purpose allowing
both casting and gunning without change. Installation of
gunning grade castables is discussed in the procedures
titled “Refractory Castables by Gunning” (M 148).
1.4 Special Purpose Castables
This grouping covers the modern range of low cement
castables and castables with less conventional binders
and are discussed in other procedures.
This procedure, “Conventional Refractory Castables by
Casting,” covers the installation of dense and lightweight
castables (groups 1.1 and 1.2 of the above) by casting.
2. PRE-INSTALLATION
2.1 Storage
Castables should be stored in a dry, well-ventilated area
and held off the floor on pallets (Figure 1). If stored out-
side, the bags must be protected from rain or dripping
water by a fixed cover. Storage temperature is not a con-
sideration as long as the castable is in the desired tem-
perature range prior to casting (See Section 3.2). If the
bags are further protected by plastic sheeting, ensure
that there is sufficient ventilation underneath the plastic
sheet to prevent water from condensing on the bags.
Avoid storing in areas of high humidity.
Pallets should not be stacked more than three high when
in storage. This should be reduced to two pallets when
storing lightweight castables. This is to prevent the con-
solidation and caking of material on the bottom rows of
the pallet.
Page 3

Figure 1 - Proper Bag Storage
Most Thermal Ceramics castables have a finite shelf life
called a “nominal shelf life.” When quoting shelf life, a
period of one year is used. Product that is older than the
nominal shelf life should be checked for setting properties
prior to use.
Signs of aging are longer setting times and reduced
strengths. All bags have the date of manufacture printed
on them to aid in determining the age of the material.
Always use the oldest materials first and, if aged beyond
the nominal shelf life, have the material tested before
use.
The work surface shall be substantially free of dust,
scale, oil, water, dirt and loose foreign material and
should be cleaned if necessary.
2.3 Formwork
Formwork should be constructed from strong materials
that resist water absorption (Figure 2). Generally 3¼4
inch plywood or steel forms are favored for this job
because of their inherent strength and non-absorbent
nature. The surface of the formwork must be lightly but
thoroughly oiled or greased to facilitate removal from the
face of the casting. The surface of the formwork should
be uniform and smooth to give a good surface finish to
the casting. It also aids in formwork release.
Formwork must be as watertight as possible with all joints
and holes sealed. The use of vibrators during casting will
cause liquids and fines to “bleed” through cracks in the
formwork. This liquid will be rich in cement and can leave
a weakly bonded material adjacent to the leaking joint
causing detrimental results.
December 2002 Thermal Ceramics
Where refractory concrete is to be cast in tall vertical sec-
tions, the formwork should generally have a height of not
more than 48 inches, with provision for additional sec-
tions to be mounted rapidly to ensure the continuous
casting of panels between designated joints.
Figure 2 - Formwork
2.4 Anchors
Both ceramic and metallic anchors are appropriate for
use with conventional castable refractories. This subject
is treated in a separate procedure, “Anchoring of
Monolithic Refractories” (M 150).
3. INSTALLATION
3.1 Water
The water used for mixing should be clean and of drink-
able quality – potable water. Since the amount of water
added to the castable does more to affect the properties
than any other factor, it must be accurately measured.
Water amounts are shown on the back of the monolithic
bags, but these are intended as a guide only. Actual
amounts will depend upon field conditions and should
adhere to that recommended on the manufacturer’s data
sheet. This may only be varied at the manufacturer’s rep-
resentative’s direct instruction.
3.2 Temperature
Ambient conditions as well as casting water and material
temperatures can significantly affect the setting time of
castables. In very cold conditions, the bags should be
kept in warm storage, though not less than 60°F, for at
least 48 hours before use.
Page 4
 DESIGN & INSTALLATION MANUAL
CONVENTIONAL REFRACTORY CASTALBES BY CASTING

The ideal temperature of mixed castables lies between
60°F - 80°F. When cast in place until thoroughly dried,
the castable and environment preferably should not fall
below 50°F and certainly not below 40°F as the castable
will take longer to set. If the castable freezes before the
hydraulic set is completed, the ultimate strength of the
material can be reduced by 50% or more. Therefore, until
the cast material is fired, freezing conditions must be
avoided.
can be placed within 20 minutes from the start of mixing
and do not combine different types of material.
Add one half to three quarters of the mixing water to the
mixer and begin its operation. Then add the castable in
full bag lots.
After the mix becomes uniform in color, the remainder of
the water is added in small increments to bring the mix to
the correct consistency. Do not use more than the rec-
ommended amount of water without direct authorization
from the manufacturer’s representative.

Figure 3 - Paddle Mixer

In very hot weather, the bags should be kept in cool stor-

age and the outer steel shell and formwork cooled with
water sprays. When spraying, care needs to be taken to
Figure 4 - Shaking Needles
ensure that no cooling water seeps into the casting cavi-
ty. If it does, it must be dried before casting commences.
Cool water should be used for mixing. At high tempera- When using a bottom discharge mixer, discharge at least
tures, the time available to place the material is dramati- two buckets of product from the mixer to clear the gate.
cally shortened; e.g. at 100°F the working time can be as This material can be immediately returned to the mixer
little as two minutes. and re-mixed. The discharge gate should be cleaned out
after every mix to prevent buildup of old material in this
3.3 Mixing
region.
Mixing combines the dry materials and water into a
If stainless steel fibers are to be added to the castable,
homogenous mass. Mixing must be done in a paddle type
they should be added after all the refractory and water
or continuous augur type mixer of sufficient capacity to
has been added to the mixer. The fibers should be intro-
ensure thorough mixing (Figure 3). Small cement drum
duced by sprinkling them into the mixer or preferably by
type mixers generally do not have enough energy to get
shaking them through a wire basket (Figure 4). If the
thorough mixing. The level of dry product in the mixer
fibers are already contained in the castable, the water
must not be above the center paddle shaft. Paddle type
addition should be made on the basis of the powder
mixers incorporate rotating shafts with paddles attached.
weight, not the bag weight. The weight of fibers present
The paddles, which put a high level of work energy into
in the mix needs to be subtracted from the bag weight
the mixing operation, must be made of steel and have no
before calculating the casting water needed. Care needs
more than 3¼4 inch clearance from the mixer walls. They
to be taken here since the addition of fibers will cause a
assure a rapid, thorough mix and virtually clean them-
lowering of the mix fluidity. NO EXTRA WATER needs to
selves from batch to batch.
be added to compensate for this loss in fluidity.
The mixer and tools used in casting must be clean. Some
Lightweight castables should be mixed for approximately
substances like lime or portland cement found in dirty
six minutes and dense castables for a minimum of three
mixers can cause flash setting or otherwise lower the ulti-
minutes when using a paddle mixer. Excess mixing gen-
mate strength of the castable. The mixer should also be
erates heat causing a decrease in the setting time, while
washed periodically during the course of mixing to pre-
vent buildup of material. Do not mix more material than

December 2002 Thermal Ceramics Page 5

 Figure 5 - Ball In Hand Test Figure 6 - Standard Vibrator
insufficient mixing will result in a non-homogenous batch Vibrate (or rod) until the material has settled. The surface
and reduce the strength. should have a wet appearance and air bubbles rising to
the surface will cease. Best results are achieved by
The “ball in hand” test is a useful guide to proper casting
inserting the poker to a depth of no greater than 12-16
consistency. Tossed one to two inches in the air, a ball of
inches, keeping it vertical, and letting the vibrator move
properly mixed castable should adapt to the shape of the
slowly through the castable mass. DO NOT force the
hand when it is caught. The ball should not flow through
vibrator through the material as this will cause pockets of
the fingers or break apart. Breaking may indicate insuffi-
air to be left behind. The vibrator head size should be
cient water in the mix. Flowing through the fingers may
suited to the size of the section being cast - generally a
indicate that the mix is too wet. In contrast insulating
2-2 1/2 inch diameter head is used for large casts, while a
castables are wetter and thus will slightly flow through the
1-1 1/2 inch diameter head can be used in smaller casts.
hand when thrown in the air and caught. This test is
Smaller vibrators require a higher VPM rating. When
unsuitable for the thixotropic, vibratory cast, low cement
materials.
3.4 Placement

The work of placement of the mixed refractory castable

covers several functions:
• To position and consolidate freshly mixed material
within 20 minutes of it leaving the mixer
• To work in a manner which minimizes material segre-
gation

• To fill all voids, particularly around obstructions and in

corners and to eliminate all air bubbles.
Once application has started, it should proceed without
interruption until the lining of the part or section con-
cerned is completed. Consolidation of dense castables is
done by means of a medium to high frequency vibrator,
applied either internally or externally. High frequency is
desirable as a lower water content can then be used,
causing an increase in strength, density and abrasion
resistance. A poker type vibrator (internal) gives maxi-
mum strength and densification in the finished casting
and assists flow around anchors and into recesses.
Insulating castables should be lightly vibrated with a
medium frequency vibrator or rodded into place.
Figure 7 - Vibrating Behind Forms
removing, the vibrator should be drawn upwards very
slowly through the castable so it does not leave any holes
or channels behind. The mix is too stiff if holes are left
behind.
When vibrating around anchors and other obstructions,
add fresh material from one side and allow the vibrator to
feed the material around and under the obstruction to
avoid the formation of air pockets (Figure 7). For deep
cavities requiring successive layers of castable mix, the
poker should pass through the freshly added mix into the
previously cast material to ensure a homogenous lining
free of laminations.

December 2002 Thermal Ceramics Page 6


CONVENTIONAL REFRACTORY CASTALBES BY CASTING
It is important to note that over vibration will tend to seg-
regate water from the mix, weakening the cast and
should thus be avoided.
3.5 Multilayer Linings
Where an insulating lining has previously been installed,
if possible, the lining should be coated with an imperme-
able membrane to prevent premature moisture loss from
the fresh castable into the insulating layer. The mem-
brane used should burn out at low temperature when the
drying cycle is started. Alternatively, the back-up layer
may be dampened prior to casting by lightly spraying with
water.
Figure 8 - Multilayer Linings
3.6 Joints
The two types of joints used in casting are construction
joints and expansion joints.
Construction joints (Figure 9) are designed to break the
job up into conveniently sized panels. Adjoining panels
are cast up against each other without leaving any gaps
using the set face of previously cast sections as the form-
work edge. Panels are generally 10-15 ft2 . This size can
generally absorb stresses without cracking. The con-
struction joint can be regarded as placing a crack where
Figure 9 - Construction Joints
December 2002 Thermal Ceramics
DESIGN & INSTALLATION MANUAL
you require it, rather than leaving the castable to stress
relieve itself in a random crack pattern.
For expansion joints, adjacent panels are separated and
offset during installation by materials such as cardboard
or plastic that will burn out during firing and leave a gap,
or by high temperature materials such as ceramic fiber
which remain in the gap, but have some degree of recov-
ery after compression.
Figure 10 - Expansion Joints
3.7 Finishing
When finishing the exposed surface of the refractory
casting to the necessary level or shape, it is important to
avoid excessive troweling of the surface. This draws
water to the surface and produces a fine finish of cement-
rich segregated material which is easily dislodged under
alternate heating and cooling. It also seals the surface
retarding the escape of moisture during dry-out.
Figure 11 - Finishing
3.8 Curing
Curing prevents the premature loss of moisture from
freshly cast refractory concrete during the chemical
changes associated with hydration of the calcium alumi-
nate binder. When mixed with water, an exothermic
hydration reaction takes place that drives off water at an
early stage.
Loss of water from the surface of the cast before the
cement is fully hydrated results in a weaker cast. To pre-
vent this, various methods of moist curing can be used.
Page 7
Formwork should be left in place for a minimum of 24
hours and exposed refractory concrete either lightly
sprayed with water, covered with plastic sheeting, or
sprayed with a concrete curing compound. The concrete
curing compound forms an impermeable membrane to
prevent moisture loss during curing but will burn out at
low temperatures during firing.
it should be sprayed or brushed with Kao-Seal™ surface
coating to resist the onset of alkali hydrolysis attack.
4. FIRING
Detailed firing schedules are separate from this proce-
dure. They are available from any Thermal Ceramics
office or representative.

Notice:

Some of the products described in this literature contain

Refractory Ceramic Fiber (RCF) and/or crystalline silica
(cristobalite or quartz). Based on experimental animal
data, the International Agency for Research on Cancer
(IARC) has classified RCF, along with fibrous glasswool
and mineral wool, as a possible human carcinogen
(Group2B) and respirable crystalline silica as a probable
Figure 12 - Cast with Forms in Place human carcinogen (Group 2A).
To reduce the potential risk of health effects, Thermal
The lower the ambient temperature, the longer the curing Ceramics recommends engineering controls and safe
time required for proper strength generation. External
work practices be followed by product users. Contact the
heating (using a small space heater or similar) may be
Thermal Ceramics Product Stewardship Group (1-800-
required to keep the ambient temperature high enough
722-5681) to request detailed information contained in its
for effective curing (and also casting).
MSDSs and product literature and videos.
After the initial 24-hour moist cure, formwork can be
stripped away, being careful not to damage the lining as
this could possibly occur. A further 24 hours drying is
generally allowed before the lining is fired to further
increase the final strength.

Figure 13 - Spraying with Curing Compound

If the freshly placed castable is not scheduled to be thor-

oughly dried (above 500°F) or fired for an extended peri-
od of time, then under certain conditions, alkali hydrolysis
may result. Alkali hydrolysis is a gradual deteriorating
process that begins by attacking the castable surface and
continues into the interior. Insulating castables are more
susceptible due to their porosity, particularly in a warm,
humid environment. Unless the castable can be heated,

December 2002 Thermal Ceramics Page 8

For further information, contact your nearest Thermal Ceramics technical sales office. You may also fax us
toll-free at 1-800-KAOWOOL, or write to Thermal Ceramics, P. O. Box 923, Dept. 140, Augusta, GA 30903.
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12.02/M146/1.5M COPYRIGHT © 2002 THERMAL CERAMICS INC.