Technical Paper

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The next Generation of Monolithic Installation

Technology: Continuous Mixing of Low Cement Castables
for Wet Shotcreting Applications

Josh Pelletiera, Charles Alta, Chris Parrb, Jim Farrellc, Tripp Farrellc

a
Kerneos Inc., USA, bKerneos SA, Paris, France, cBlastcrete Equipment Company, USA

Presented at UNITECR, Victoria, Canada, September 2013

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ABSTRACT

Lengthy mixing times of low cement castables, when considered over the full volume of material to be
installed, can contribute significantly to the timeline of a refractory installation. On construction projects,
timing is critical. By reducing or eliminating the residence time inside the mixer, installation times can
be reduced. This paper will examine the use of new equipment technology – the MX20-CM, a two-
stage continuous mixer – to address this issue. Commercially available refractory castables based on
high-quality CAC (Calcium Aluminate Cement) were prepared three ways: (1) traditional batch mixer,
(2) MX20-CM, and (3) Hobart mixer. When the castables’ physical properties are compared, the
results show that material of comparable quality and performance can be produced on a continuous
basis at a feed rate up to 25 tons per hour. By providing material in an as-needed manner, cost
savings can be realized in an overall reduction in job timeline, waste, and manpower.

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1 Introduction
As monolithic refractory technology has evolved
over the years, the trend of refractory castables
moving to consistently lower water and lower
cement contents has been seen. By lowering
the cement content of these mixes, enhanced
thermo-mechanical properties can be obtained
by virtue of the reduced lime (CaO) content
and lower water demand[1]. When lowering the
binder content and water additions of these
castables, high-tech admixtures must be used
to disperse the reactive fine fillers within the
wet mix. This, in turn, guarantees homogeneity
and complete hydration within the hardened
monolithic. Two effects of the widespread
use of advanced admixtures have been the
expansion of pumpable castable technology
and the emergence of wet shotcreting as an
increasingly popular installation option[2].
The improvement of installed properties and
the capability for even faster installations has
advanced the field of monolithics to the point
where they are now preferentially selected in
applications where only bricks have been used
in the past – including secondary steel ladles,
rotary kilns, and CFB boilers. In cases like these,
CAC-bonded monolithics possessing equivalent
or superior performance characteristics to their
brick counterparts can be installed with greatly-
reduced turnaround times[3].
The benefits of wet shotcreting over dry
gunning have been well-documented[2,4].
However, improvements seen in terms of
installed properties often come at the expense
of required setup time, labor costs, and wasted
material. Dry gunning, installed at rates of 2-6
tons per hour, has typically been preferred for
smaller jobs (i.e. < 10 tons) due to the minimal
amount of setup required and fast turnaround
time.
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Wet shotcreting has traditionally been reserved
only for larger jobs (> 10 tons) where the costs
of additional labor and setup time can be
eclipsed by the time savings gained with faster
installation rates (up to 15 tons per hour)[4].
All wet shotcreting installations of CAC-bonded
castables require a mixer to blend the dry material
with water prior to conveyance to the delivery
hose. When using a batch mixer such as rotary
drum or pan, longer mixing times (≥ 5 minutes)
have been required to ensure full dissolution and
effectiveness of the dispersing admixtures. One
of the main reasons for the longer mixing times
is the time required for these mixers to deliver
sufficient energy into the system[2].
Another means of mixing concrete systems, a
continuous mixer, works to provide material in a
constant stream rather than in batches. It does
this by combining the dry material with water
inside a mixing tube with an auger (rotating at
30-50RPM). Though these types of mixers have
been used in the construction industry for many
years, common use in dense refractory systems
has been limited by two things: their ability to
guarantee the water content of highly-sensitive
LCCs and the perception that continuous
mixers could never deliver enough energy into
the system given the short residence time.
By combining high-speed/high-shear functionality
with improved water metering technology, the
MX-20CM (Fig. 1) addresses these concerns. By
incorporating a second-stage passive mixer, this
equipment offers an additional buffer of residence
time to remove any doubt of a consistent wet
mix. The mixing head of the MX20-CM is driven
by a hydraulic motor and runs at speeds up to
400 RPM.
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The accelerated shear rate produced by the Table 1 : Materials used.

high-speed/high-torque mixing agitator delivers Castable A B C D

a significant amount of energy to the system in General High hot strength,

High abrasion and
thermal shock
High strength,
rapid heat-up
60% Alumina,
chemical and
a very short period of time. Description good abrasion
resistance ("fast-fire") abrasion resistant

Suggested Aluminum Tundish safety Biomass boilers,

Cement coolers,
This paper demonstrates that, with the Installation
Areas
furnace sidewalls,
steel ladle covers
kiln risers
linings, rotary
kiln nose rings
chain sections of
rotary kilns
additional energy imparted by the MX20-CM Aggregate
Bauxitic calcines Mullite Mullite Mullite
during the mixing stage of an LCC installation, System

final properties can meet or exceed those of an Svc. Temp. (°C) 1700 1650 1700 1700

LCC mixed by conventional methods. Existing Secar® 71 5% 8% 5% 8%

measurement techniques were used to prove Fired Density

(g/cc)
2.40 2.40 2.35 2.45
this concept in four commercially-available Water Content
7% 7% 7% 7%
LCCs. All four systems were prepared three for Pumping

ways: in a traditional paddle mixer, in the MX20-

CM, and in a laboratory Hobart mixer. The 2.2 Equipment
Hobart mixer served as a method to compare 2.2.1 Paddle Mixer
how ideal lab conditions translate to actual The paddle mixer used in this study was a
field results. The properties of each mix were standard 0.2 m3, 6HP, gas-powered steel drum
compared side-by-side. unit.
By pairing continuous mixing technology with a
2.2.2 Continuous Mixer
refractory pump, low-cement shotcrete systems
The continuous mixer used in this study was a
based on SECAR® 71 can be installed at
480V hydraulic-powered unit, the MX20-CM,
incredibly rapid rates (up to 25 tons per hour)
from Blastcrete Equipment Company (Fig. 1).
with little to no waste. The innovative design
This was a smaller demonstration version of the
of this piece of equipment also allows for much
mixer only, no pump attached.
faster setup and cleanup than traditionally
associated with shotcrete jobs. This changes
the thought process of choosing installation
methods, making even smaller installations
(<10 tons) eligible for the inherent benefits of a
wet shotcrete lining.

2 Experimental details
2.1 Materials
General descriptions of the LCC materials used
in testing are outlined in Table I. This information Fig. 1 – Blastcrete MX20-CM.
(except SECAR® 71 content) was taken from
the manufacturer’s published data sheets.

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2.2.3 Hobart Mixer
A 12-Qt. Hobart mixer was used in the lab.
2.2.4 Furnace
For firing specimens, a Lucifer 7000 series
furnace (max 1100°C) was used.
2.3 Methods
2.3.1 Flow Value
Flow values were determined using ASTM
C1445. Flow is expressed as a percentage of
the original base diameter.
2.3.2 Working Time
Working time, as defined by ASTM C71, is the
“elapsed time from the first addition of liquid
during mixing of the refractory castable until the
first indication that it can no longer be placed by
the desired placement method.” Working time
was defined during this project by the time the
mix could no longer be manipulated by vibration.
2.3.3 Exothermic Profiles
Exothermic profiles were determined on 7.6
cm x 15.2 cm cylinders at 20°C with samples
placed in insulated boxes. An embedded
thermocouple was linked to a data capture
system and temperature was recorded as a
function of time. The time to reach maximum
(peak) temperature was recorded as was the
maximum temperature achieved.
2.3.4 Apparent Bulk Density
Apparent Bulk Density was calculated from 51
mm cube samples of each material in each
lifecycle stage – green, dried, and fired. The
mass of each specimen was divided by the
calculated volume to obtain the bulk density.
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2.3.5 Cold Crushing Strength
After preparing 51 mm cube samples of
each material according to ASTM C862, cold
crushing strength was measured according to
ASTM C133. Three cubes of each castable
comprised a sample group for each lifecycle
stage: green, dried, and fired. Fired specimens
were cured at 20°C for 24 hours, dried at 110°C
for 24 hours, and then fired at 100°C per hour
to 800°C (ASTM C865). Samples were held at
800°C for five hours and then allowed to cool
at 100°C per hour to 110°C at which point they
were held until testing could be performed.
CCS is reported in MPa.
2.3.6 Abrasion Loss
Abrasion loss measurements were performed
according toASTM C704/C704M-12 Supplement.
Plates measuring 100mm x 100mm x 25mm
were prepared from each LCC as produced by
each mixing method (two plates per material,
per method). Plates were dried and then fired to
800°C as described in Section 2.3.5. Results are
reported as an average of the two plates in units
of cubic centimeters (cc) loss.
2.4 Experimental Detail
The four castables, having similar recommended
water requirements for “pumping consistency,”
were prepared using a 7.0% addition of potable
water. For the paddle and continuous mixer
work, the same external plant water source was
used. For the Hobart mixing trials in the refractory
lab (20°C, 50%RH), distilled bottled water was
used. For consistency, this water addition was
used in preparing the castables both in the batch
and continuous mixers. Materials prepared in
the batch mixers were mixed for the standard
5 minutes after the measured amount of water
was added. After mixing, the full batch was
discharged and transferred to the appropriate
testing equipment.
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For the continuous mixer work, once the water 3.1.1 Flow
and feed rate were properly set and adjusted (1.5 From mixer to mixer, initial flow values were
gal/min), materials were mixed and discharged consistent within the accuracy of the test. There
continuously into buckets. Halfway through is a difference, however, in the flow decay of
the six-bag run, representative samples were each mixing method, or how the flow evolved
collected and the remainder of the material was over time. The continuously-mixed materials
allowed to run through. Setting the water flow maintained a higher level of flow at 60 minutes
meter on the continuous mixer based on the than their counterparts mixed by the other
dry feed rate of the material proved too difficult two methods. Though this could potentially
and imprecise. It was instead set once the be attributed to higher water content, the
discharged material met the desired initial flow similarity of the wet densities across all mixer
value (ASTM C1445). This flow meter setting types within each sample set suggests that the
was used for all continuous mixer runs. water contents are indeed similar. Instead, this
After casting, all specimens were cured until is most likely attributed to the higher degree of
they could be demolded (min. 24hrs) and mixing imparted by the continuous mixer, thus
green measurements were taken. Demolding more efficiently distributing the additives and
time varied for each set of samples and fine fillers and leading to higher flow values. In
was determined by the working time. After nearly all cases, the continuous mixer produces
demolding, samples were dried to 110°C for 24 castables with higher flow values.
hours, at which time dried measurements were
taken. Finally, the samples were fired to 800°C 3.1.2 Working Time
as described in Section 2.3.5. Generally, in Castables B, C, and D, working
times were consistent across all mixer types
and aligned with the manufacturers’ estimated
3 Results and discussions initial set values. The greatest variation came
with Castable A. The Hobart-mixed sample of
Castable A showed an abnormally long working
3.1 Placing properties
time (54 hours). This also correlated with the
Table 2 : Placing Properties.
extended exothermic profile peak for that mix (56
Water Wet Flow Flow Flow Exo Wrking
Addition Density (T=0) (T=30) (T=60) Peak Time hours). This could be a function of sample size,
Castable % g/cc % % % hrs hrs being that only enough dry mix was removed
Paddle 7% 2.48 75 67 62 30.8 26
A Hobart 7% 2.53 75 69 62 56.0 54 from the paper sacks to run the lab batch. With
MX20CM 7% 2.47 83 80 75 13.9 10 only 5% SECAR® 71 in this particular castable,
Paddle 7% 2.35 86 84 78 29.2 20
B Hobart 7% 2.25 85 81 80 22.0 20
it is possible that, if there was any segregation
MX20CM 7% 2.46 95 92 92 21.4 12 within the bag, the sample taken could have
Paddle 7% 2.50 80 79 70 8.3 4 contained very little cement and, therefore,
C Hobart 7% 2.52 84 75 56 6.3 2
MX20CM 7% 2.47 84 81 71 8.8 4 had a longer setting time. However, it’s worth
Paddle 7% 2.45 86 83 78 26.2 20 considering here that, in a shotcrete application,
D Hobart 7% 2.38 102 74 71 20.0 15
MX20CM 7% 2.45 92 89 86 21.1 14 these materials would all be accelerated at the
nozzle with a gelling agent that would set the
material immediately on the wall.

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3.1.3 Exothermic Profile tendency to produce heterogeneous samples

Castables C and D have nearly identical based on the degree of mixing achieved.
exotherms from all three mixer types. In terms The degree of mixing can be affected by
of the paddle and continuous mixers, Castable blade clearance, mixer loading, and non-
A had nearly 16 hours separating the peaks, representative sampling. The higher-intensity,
Castable B had 8 hours. Castable A showed higher-volume field methods of mixing provided
the most variability of all four products. The more consistency in the quality of all materials.
continuously mixed castable showed the earliest
exotherm in both A and B. 3.2.2 Cold Crushing Strength – Fired
In the cases where there was any difference, the Similar to the densities, the cold crushing
MX-20CM produced materials with consistently strengths of the fired specimens were more
shorter working times and faster sets. In the consistent for the continuous mixer for all
case of A and B, the castables that were mixed four castable formulas. This consistency
more intensely set more quickly, perhaps due to would be expected given the information on
the higher level of shear. the manufacturers’ data sheets. The widest
variation in strength for this set of data can be
3.2 Physical Properties seen in castables A and D. Castables B and C
Table 3 : Physical Properties. seem to be inherently similar in terms of CCS,
Water Fired ABD Fired CCS Abrasion independent of mixing method. Castables A and
Addition (800°C) (800°C) Loss D had significantly longer working times when
Castable % g/cc MPa cc loss
they were mixed in the paddle mixer than they
Paddle 7% 2.25 65.58 7.26
A Hobart 7% 2.38 89.46 7.13 did when they were mixed in the continuous
MX20CM 7% 2.22 52.35 8.88 mixer. This caused these samples to be left
Paddle 7% 2.19 29.18 11.04 in the molds for longer time periods and could
B Hobart 7% 2.13 33.12 17.70
have affected their final strengths.
MX20CM 7% 2.26 31.17 16.34
Paddle 7% 2.32 49.26 11.37 Another possible explanation for the difference
C Hobart 7% 2.32 33.12 12.12 in fired strengths is porosity. The installed
MX20CM 7% 2.32 46.42 12.76 porosity of monolithics can be affected by two
Paddle 7% 2.25 92.50 9.78
D Hobart 7% 2.20 41.20 17.65
things – air entrainment and water content.
MX20CM 7% 2.23 42.64 13.69 Generally, for castables of this type with similar
densities, 1% additional water content equates
3.2.1 Apparent Bulk Density – Fired to 3% additional porosity. If the continuous
The firing temperature chosen for this study was mixer was inadvertently adding supplemental
800°C. This temperature is often specified for water or air into the castables, it could explain
ASTM C704 test specimens in the petrochemical the lower strengths in those mixes. This would
industry. It represents the low-end temperature not, however, explain the difference in the CCS
of many processes and also provides a worst- values of the paddle and Hobart mixes of A
case scenario in terms of CCS and abrasion and the similarity of the CCS seen between
resistance. The fired densities of the castables the Hobart and continuous mixes of D. In
were fairly consistent across all mixer types. these cases, the water content was precisely
The Hobart-mixed samples showed the least measured and equal.
consistency of the three mixers pointing to its

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Further testing should be performed on a larger
sample set and perhaps even different sample
types to determine if the outliers were truly
representative.
3.2.3 Abrasion Loss
The paddle-mixed samples showed consistently
lower abrasion loss than the samples mixed by
the other methods. This trend would have to be
confirmed with testing on larger sample groups
as the results were not substantially different. It
is interesting to note, however, that Castable A
showed such consistency across all mixer types
in this test after showing the widest variation in
every other test.
4 Conclusions
The MX20-CM produces material at an incredibly
fast rate, up to twice the speed of traditional batch
mixing. More importantly, this study shows that
the material produced at this rapid rate is nearly
equivalent, and often more consistent, than that
produced by traditional methods. The placing
characteristics and installed properties of the
four castable types studied here were consistent
between the paddle mixer and the continuous
mixer most of the time. The largest variation
was seen between the field-mixed and lab-
mixed samples. This points to a widely-known
gap between what is produced in the lab and
what is seen on a jobsite, clearly showing one
of the variables that affects this discrepancy, the
degree of mixing that is achievable with smaller
batches and mixers.
The most abnormalities in the data gathered
seem to come from Castable A. This points to
an issue with the castable itself, either related
to formulation, a lack of robustness, or perhaps
aging. With limited capability available to
determine the true final water content of the
continuously-mixed castables, it’s difficult to say
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whether the differences seen in the final data
can be attributed to water content or mixer type.
Water content is one of the most important
factors affecting the installed properties of
LCCs, slight variations can have a large effect.
The MX20-CM has good consistency in its
ability to meter water into a castable as long
as the pressure from the water source remains
constant. Variations in water pressure can
affect the flow meter and require on-the-fly
adjustments. While the MX20-CM has decent
water metering capabilities, a large portion of
the water dosing responsibility still remains in
the hands of the operator.
Continuous gains in advanced monolithic
installation technology have provided inroads
for monolithics to successfully replace bricks
not only for their improved performance
characteristics but also for the installation rates
and reduction in wasted refractory materials
that are achievable. By providing an even faster
option for installing high-quality, low-cement,
SECAR®71-based, shotcrete linings, the MX20-
CM is certainly making shotcrete an even more
attractive installation method for previously
unavailable application areas.
5 Future Work
a) TGA to determine equivalent water content
and hydrate formation.
b) A riffler-type sample splitter to obtain smaller,
more consistent lab samples.
c) Final porosity testing.
d) PLC measurements on 23 cm prisms.
e) HMOR would be another means of
determining material equivalency.
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5 Acknowledgements
Kerneos thanks Blastcrete for contributing their
equipment and expertise. Also thanks to Allied,
ANH, Reno, Riverside, and Spar Refractories for
donating their SECAR® 71-based LCCs. Finally,
we would like to thank the lab technicians of
Kerneos, Inc. (KDCA) and Resco Products for
their hard work.

6 References
[1] C. Parr, H. Fryda, R. Roesky, “Out of the
Mold and into the Fire – a new perspective
on the optimization of castables.” UNITECR
2001 proceedings, Cancun, Mexico, 2001.
[2] W. G. Allen, “Advanced Equipment Systems
for Refractory Placement.” UNITECR 1997
proceedings, New Orleans, LA, USA.
[3] S. Woodcock, Z. Carden, A. Brewster,
“Saving time on turnaround maintenance –
recent advances in monolithic refractories
technology and installation methods.” The
Refractories Engineer, July 2008.
[4] N. Cassens, Jr., R.A. Steinke and R.B.
Videtto, “Shotcreting Self-flow Refractory
Castables.” UNITECR 2001 proceedings,
Cancun, Mexico, 2001.

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