PDF Ce Verarbeitungsr Massen e 5 2017

REFRATECHNIK
Processing instructions
Refractory concretes
Storage instructions 3
Basis for calculation of material requirement

Dry gunning concretes 5
Wet gunning concretes 8
Regular cement vibration castables (RC-Vib.) 11
Low cement vibration castables (LC-Vib.) 17
No cement vibration castables (ED-Vib.) 23
Mixcrete vibration castables (Mix) 29
Basic vibration castables (MgO-Vib.) 35
Dense dry gunning concretes

(G-MCG-LCG-ED G) 41
Insulating dry gunning concretes (G-Iso.) 49
Low cement wet gunning concretes (LC-JC) 55
No cement wet gunning concretes (ED-JC) 61
Poured insulating concretes (Iso.) 67
Setting accelerator 71
Storage instructions 3
Storage instructions
• Store dry, well ventilated and cool, but frost-free.
• The packaging, a tarpaulin or a protective cover

cannot replace required roofing; therefore the
pallets have to be stored under roof.
• Big differences in temperature (e.g. in the

transport container), condensation reactions
(e.g. under a tarpaulin), and also standing humidity
(e.g. open-air space) may impair the refractory
concrete.
• Any improper storage or damaged packaging/bags

may cause cutbacks in quality within the prod-
uct-specific shelf life. Refractory concrete that has
become wet cannot be reused.
• The stated, product-specific shelf life will only be

reached in case of optimum storage conditions
prevailing.
• Liquid binders and accelerators always have to be

stored at temperatures above 5 °C. Any mix-up of
liquid containers filled with water, liquid binder or
accelerator or emptied and then refilled containers
(e.g. with mixing water or waste water) has to be
avoided by all means.
• In case of longer storage periods and processing

above 30 °C, it is advisable to store the pallets,
especially those containing wet gunning concretes
(REFRA JETCRETE®), in a refrigerated container at
15-20 °C.
©Refratechnik Cement GmbH

4 Basis for calculation of material requirement 5
Basis for calculation of

material requirement
Dense and insulating
dry gunning concretes
The calculation of material required depends on

the volume as well as on product-, installation- and
site-specific parameters. The production-dependent
anhydrous bulk density, the use of standard equip-
ment and homogeneous conveying conditions as well
as product-specific rebound losses, and the usual
scraping losses are mainly taken as a basis.
The calculation of material required is based on the

use of a gunning machine that operates on the rotor
principle, as well as on a conveying hose diameter
of 32 to 40 mm (1.26 up to 1.57 in), a conveying
distance of 40 to 60 m (131-197 ft) for ensuring a
homogeneous conveying and gunning process, a
high-pressure water pump with an initial pressure
of min. 12 bar (174 psi), a water ring or membrane
nozzle, on the external supply of compressed air with
recommended connected values, in dependency of
the conveying distance and the adjustment of the
recommended gunning pressure at the nozzle, and
finally on an uninterrupted, non-pulsating gunning
and a mix of wall and roof linings.
Any deviations from these preconditions may cause

an underconsumption or an increased consumption
of refractory concretes.
©Refratechnik Cement GmbH ©Refratechnik Cement GmbH

6 Basis for calculation of material requirement Basis for calculation of material requirement 7
Higher material consumption or higher • prewetted, already granulated material

compaction and dust development are due to:
• dimensional stability problems in case of roof
• inexperienced, non-trained nozzle operators linings due to too low material temperature
(≤ 10 °C, (≤ 50 °F))
• low layer thickness (≤ 100 mm, (≤ 3.94 in))
• dimensional stability problems due to large roof
• higher shares of suspended or roof linings panels or considerable layer thickness, with high
net weight of the refractory concretes and non-
• a short conveying distance (≤ 40 m, (131 ft)) adapted anchoring concept, such as anchor type,
in case of a non-adjusted gunning pressure spacing and length of anchors or overlapping
(as a measure for the conveying air volume, e.g. (collapsing of the lining).
insulating concretes with ≥ 1.5 bar, (≥ 21.8 psi))
Reduced material consumption or less
• a large conveying distance (≥ 60 m, (197 ft)), par- compaction and dust development by:
ticularly vertically, requiring a higher conveying air
volume fraction and conveying pressure combined • gunning behind brick linings and formwork
with a gunning pressure at the nozzle that is diffi- as well as in bottom sections
cult to estimate, causing in turn grain destruction
and higher compaction, especially in case of insu- • too low conveying and gunning pressure
lating concretes, due to friction effects
• higher dosage of water at the gunning nozzle.
• too dry gunning process with less compaction of
dense concretes and higher compaction of insu
lating concretes as well as missing adherence
along with higher dust development and higher
rebound losses
• the used gunning nozzle technology and the

efficiency of water wetting in the material flow
• tight space conditions, increased or reduced

gunning distance (≥ 1.5 m / ≤ 0.5 m, (59 /20 in)),
and spacing of a larger number of anchors
• subsurface conditions, such as uneven places and

poor adhering strength

8 Basis for calculation of material requirement Basis for calculation of material requirement 9
Basis for calculation of • frequent and long interruptions

material requirement
• pulsating, inhomogeneous gunning
Low cement and no cement
wet gunning concretes • frequently changing the refractory concrete
types that requires in turn some additional
cleaning (loss of material that remains in the
The calculation of material required depends on mixer and in the hose)
the volume as well as on product-, installation- and
site-specific parameters. The production-dependent • low layer thickness (≤ 100 mm, (≤ 3.94 in))
anhydrous bulk density, the use of standard equip-
ment and homogeneous conveying conditions as • higher shares of suspended or roof linings
well as product-specific rebound losses, and the
usual scraping losses are mainly taken as a basis. • dimensional stability problems in case of roof
linings due to too low material temperature
The calculation of material required is based (≤ 15 °C, (≤ 59 °F)) or activation energy in case
amongst others on the use of an equipment that of no cement wet gunning concretes (loss of
operates on the double-piston principle, on a material)
conveying hose diameter of approx. 52 mm or 2”
(in front of the reducer), a conveying distance of • dimensional stability problems due to large roof
≤ 50 m (164 ft), an external compressed air supply panels or considerable layer thickness, with high
of min. 6 bar (87 psi) and min. 7 m3/minute net weight of no cement concretes and non-
(247 ft3/minute,) on uniform and continuous gunning adapted anchoring concept, such as anchor type,
of at least 25 tons of material per day and a mix of spacing and length of anchors or overlapping
wall and roof linings. (collapsing of the lining).
Any deviations from these preconditions may cause Reduced material consumption by:
an underconsumption or an increased consumption
of refractory concretes. • gunning behind linings and formwork as well as
in bottom areas.
Higher material consumption or higher
compaction are due to:
• loss of higher amounts of material that remain in

the hose after having finished the installation job,
especially in case of both, larger hose diameters
and conveying distances of 50 to 100 m (164 ft up
to approx. 328 ft)

10 Regular cement vibration castables (RC-Vib.) 11
Regular cement vibration castables
(RC-Vib.)
All regular cement types without any

further designation, such as
REFRALITE® 40, REFRACLAY 25,
REFRACLAY 40, REFRACLAY 50,
REFRACORUND 95
(Also refer to classification in the data sheet.)
Amount of water to be added

See respective data sheet,
data printed on respective bag.
Shelf life
12 or 18 months (see respective data sheet).
Do not use any castable that has become lumpy.
Processing
If the castable is placed in a formwork or a mould,
good stable bracing is required (particularly when
a bottle vibrator is used). The formwork has to be
clean, made of water-repellent material, and well
covered with mould oil.
For mixing the castable always use a clean mechani-

cal forced-action mixer. There must not be any impu-
rities (for instance concrete remainder) in the mixer.
The ideal mixing batch may come up to 100 kg.
efore adding water, the castable is to be mixed in

B
dry state for a short time (about 1 minute) to avoid
any segregations that may have occurred in the bag.
Do only use clean water (of potable quality) for mix-
ing. Add about 80% of the water amount required to

12 Regular cement vibration castables (RC-Vib.) Regular cement vibration castables (RC-Vib.) 13
the castable and mix for about 2 minutes. Then the Vibrating
remaining 20% of water are to be added and mixed Place the castable slowly and carefully, and vibrate
for another 1 to 2 minutes. The whole mixing time it. Vibrate only until no more air escapes. Remove
should ideally not exceed 4 minutes. the bottle vibrator slowly from the castable in order
to avoid any air inclusions.
The ball-in-hand test is a simple way to control the
consistency of the castable. A ball formed out of If water accumulates on the surface during pro
castable by hand must neither seem to be too dry cessing and compaction, the castable is too wet.
or crumbly nor must it slip through the fingers. Any formation of layers due to surplus water has
to be avoided by all means.
The water temperature should range between
12 and 25 °C, but must never fall below 5 °C. During For larger batches of castable, shuttering areas pro-
processing, the temperature of the materials to be vided with corresponding expansion joints should be
mixed and the finished mix should range between placed. For more details, please refer to the respec-
10 and 25 °C. Lower or higher temperatures either tive drawing.
reduce or accelerate the setting process significantly.
Setting and hardening
For to accelerate the setting process at low pro Low ambient and setting temperatures (< 10 °C)
cessing temperatures, the bagged material and the prolong the setting time significantly. For to shorten
water should be preheated. It is advisable to pre- the setting time, the ambient air should be preheat-
heat the bagged material 1 to 2 days before use ed above 10 °C (using for instance a radiant burner).
in a warm storage place or in a covered area. The During hardening, the castable must not freeze at
addition of any setting accelerator to regular cement any rate. Temperatures above 25 °C accelerate the
vibration castables is not required. Should a pro- setting time significantly.
longed period of time be required for completing pro-
cessing at elevated processing temperatures, cool Cement-containing castables generate heat during
the bagged material and the water (place the pallets the setting process. As a result of this heat being
in the shade) or add some ice (water amount to be generated, some of the moisture contained in the
considered). The mixer is to be positioned as close lining evaporates, causing an incomplete setting
as possible to the place of installation. and hence a reduced strength of the castable. For
to reduce the heat being generated and thus the
After having placed the castable behind the form- evaporation of the moisture, the surface of the
work, one has to compact it by vibration. The time lining must be kept damp and cool by slightly and
required for processing the castable is temperature- regularly spraying water on the surface, which
dependent and should therefore not exceed may be covered with jute for example.
20 minutes.

14 Regular cement vibration castables (RC-Vib.) Regular cement vibration castables (RC-Vib.) 15
The formwork must not be removed before the The castable expands during heating-up and within
castable has reached its full dimensional stability. the process. Therefore it is necessary to provide
Before that step, there should be carried out a sound expansion joints at regular distances (see installa-
test (bright sound) or a nail test (metal nail that has tion instructions in the drawings). A panel size of
been driven-in should bend) to the set castable. For 0.8-1.0 m2 with a maximum edge length of 1 m is
hardening and until first heating-up, the castable commonly chosen.
requires at least 24-48 hours. Any processing of the
built-in castable must be avoided during that period. Heating-up of the lining is to be carried out strictly
Once the hardening process has been completed, in accordance with the heating-up recommenda-
drying and heating-up can be started, according to tions, as otherwise damages to the structure of
the instructions. the castable are to be expected. Once started, the
heating-up process must not be stopped or inter-
Drying and heating-up rupted. For instance in case of a possible breakdown
Evaporation holes of 3 to 4 mm in diameter being of a burner, the lining will have to be kept warm. If
placed at a distance of approximately 100-150 mm cooling down is inevitable, heating-up is to be done
each, depending on the application conditions, have to very carefully once again, beginning with the first
be provided, particularly in case of wall thicknesses/ heating-up step.
linings exceeding 230 mm and linings without any
insulation layer (independently of the wall thickness), In order to achieve optimum product properties, the
in order to support evaporation of water during heating- processing instructions and heating-up recommen-
up. During the setting process, the evaporation holes dations must be strictly followed.
should be driven as far as the back lining, at least
to a depth of 80% of the lining thickness. This should Personnel protection and safety
not be done too soon after installation of the castable, Always wear your personal protective equipment
as otherwise the holes will close again. Evaporation (respiratory protection, tightly sealed safety goggles,
holes can be formed, for example, by insertion of safety gloves and tightly fitting protective clothing).
greased steel pins or rods (which are removed before Wash thoroughly after processing of refractory
the end of the setting process) or by drilling etc. concretes. Always refer to the material safety
Installation instructions are to be strictly followed. data sheet.
Drying and heating-up process depend on the dimen-

sions of the lining, the castable, and the processing
technique chosen.

16 Low cement vibration castables (LC-Vib.) 17
Low cement vibration castables
(LC-Vib.)
All types with the designations:

LCC, LCC AR, AR, and Z AR

Shelf life
12 months (see data sheet).
Processing
If the castable is placed in a formwork or mould,
For mixing the castable always use a clean mechan-

ical forced-action mixer. There must not be any
impurities (i.e. concrete remainder) in the mixer. The
ideal mixing batch may come up to 100 kg. Before
adding water, the castable is to be mixed in dry
state for a short time (about 1 minute) to avoid any
segregations that may have occurred in the bag. Do
only use clean water (of potable quality) for mixing.
Add about 80% of the water amount required to
the castable and mix for about 2 minutes. Then the
remaining 20% of water are to be added and mixed
for another 1 to 2 minutes. The whole mixing time
should ideally not exceed 4 minutes. The correct
and suitable consistency of deflocculated castables
18 Low cement vibration castables (LC-Vib.) Low cement vibration castables (LC-Vib.) 19
is often achieved at the end of the wet mixing time Vibrating

only. That is why the castable possibly seems to Place the castable carefully and slowly, and vibrate
be too dry and crumbly when starting the mixing it. Vibrate only until no more air escapes. Remove
process. the bottle vibrator slowly from the castable in order
to avoid any air inclusions.
consistency of the castable. A ball formed out of the If water accumulates on the castable surface during
castable by hand must neither seem to be too dry or processing and compaction, the castable is too wet.
crumbly nor must it slip through the fingers. Any formation of layers due to surplus water has to
be avoided by all means.
The water temperature should range between
12 and 25 °C, but must never fall below 5 °C. During For larger batches of castable, shuttering areas pro-
processing, the temperature of the materials to be vided with corresponding expansion joints should be
mixed and the finished mix should range between placed. For more details, please refer to the respec-
15 and 25 °C. Lower or higher temperatures either tive drawing.
reduce or accelerate the setting process significantly.
Setting and hardening
For to accelerate the setting process at low process- Low ambient and setting temperatures (< 10 °C)
ing temperatures, preheat the bagged material and prolong the setting time significantly. For to shorten
the water, or add the recommended powdery setting the setting time, the ambient air should be preheat-
accelerator (see chapter on “Setting accelerator”). ed above 10 °C (using for instance a radiant burner).
It is advisable to preheat the bagged material 1 to During hardening, the castable must not freeze at
2 days before use in a warm storage place or in a any rate. Temperatures above 25 °C accelerate the
covered area. Should a prolonged period of time be setting time significantly. In this case, the bagged
required for completing processing at elevated material and the water should be cooled.
processing temperatures, cool the bagged material
and the water (place the pallets in the shade) or add Even low cement castables generate heat during the
some ice (water amount to be considered). The mixer setting process. Elevated outside temperatures may
is to be positioned as close as possible to the place additionally make some of the moisture contained
of installation. in the lining evaporate prematurely, resulting in an
incomplete setting and hence reduced strength of
After having placed the castable behind the form- the castable. For to reduce the heat being generated
work, one has to compact it by vibration. The time and thus the evaporation of the moisture at elevat-
required for processing the castable is temperature- ed setting temperatures, the surface of the lining
dependent and should therefore not exceed must be kept damp and cool by slightly and regu-
20 minutes. larly spraying water on the surface, which may be
covered with jute for example.

20 Low cement vibration castables (LC-Vib.) Low cement vibration castables (LC-Vib.) 21
Before that step, one may carry out a sound test expansion joints at regular distances (see installa-
(bright sound) or a nail test (metal nail that has tion instructions in the drawings). A panel size of
been driven-in should bend) to the set castable. For 0.8-1.0 m2 with a maximum edge length of 1 m is
hardening and until first heating-up, the castable commonly chosen.
requires at least 24-48 hours. Any processing of the
built-in castable must be avoided during that period. Heating-up of the lining is to be carried out strictly
Once the hardening process has been completed, in accordance with the heating-up recommenda-
drying and heating-up can be started, according to tions, as otherwise damages to the structure of
the instructions. the castable are to be expected. Once started, the
Drying and heating-up rupted. For instance in case of a possible breakdown
Evaporation holes of 3 to 4 mm in diameter being of a burner, the lining will have to be kept warm. If
placed at a distance of approximately 100-150 mm each, cooling down is inevitable, heating-up is to be done
depending on the application conditions, have to be very carefully once again, beginning with the first
provided, particularly in case of wall thicknesses/ heating-up step.
linings exceeding 230 mm and linings without any
insulation layer (independently of the wall thickness), In order to achieve optimum product properties, the
in order to support evaporation of water during processing instructions and heating-up recommen-
heating-up. dations must be strictly followed.
During the setting process, the evaporation holes Personnel protection and safety
should be driven as far as the back lining, at least Always wear your personal protective equipment
to a depth of 80% of the lining thickness. This (respiratory protection, tightly sealed safety goggles,
should not be done too soon after installation of the safety gloves and tightly fitting protective clothing).
castable, as otherwise the holes will close again. Wash thoroughly after processing of refractory
Evaporation holes can be formed, for example, by concretes. Always refer to the material safety
insertion of greased steel pins or rods (which are data sheet.
removed before the end of the setting process) or by
drilling etc. Installation instructions are to be strictly
observed.

technique chosen.

22 No cement vibration castables (ED-Vib.) 23
No cement vibration castables
(ED-Vib.)

ED, ED AR, and ED Z AR (ED: Easy Dry)

Shelf life
Processing
If the castable is placed in a formwork or a mould,
For mixing the castable always use a clean mechani-

cal forced-action mixer. There must not be any impu-
rities (for instance concrete remainder) in the mixer.
The ideal mixing batch may come up to 100 kg.
Before adding water, the castable is to be mixed in
ing. Add about 80% of the water amount required
to the castable and mix for about 1 to 2 minutes.
Then the remaining 20% of water are to be added
and mixed for another 2 to 3 minutes. The correct
and suitable consistency of deflocculated castables
is often achieved at the end of the wet mixing time
24 No cement vibration castables (ED-Vib.) No cement vibration castables (ED-Vib.) 25
only. That is why the castable possibly seems to Vibrating

be too dry and crumbly when starting the mixing Place the castable slowly and carefully, and vibrate
process. Low processing temperatures extend and it. Vibrate only until no more air escapes. Remove
higher processing temperatures shorten the whole the bottle vibrator slowly from the castable in order
wet mixing time, which should ideally not exceed to avoid any air inclusions.
5 minutes.
If water accumulates on the surface during process-
The ball-in-hand test is a simple way to control the ing and compaction, the castable is too wet. Any
consistency of the castable. A ball formed out of formation of layers due to surplus water has to be
castable by hand must neither seem to be too dry avoided by all means.
or crumbly nor must it slip through the fingers.
For larger batches of castable, shuttering areas
The water temperature should range between provided with corresponding expansion joints should
15 and 35 °C, but must never fall below 10 °C. Dur- be placed. For more details, please refer to the
ing processing, the temperature of the materials to respective drawing.
be mixed and the finished mix should range between
15 and 30 °C. Lower or higher temperatures either Setting and hardening
slow down or accelerate the setting process signifi- Low ambient and setting temperatures (< 10 °C)
cantly. prolong the setting time significantly. For to shorten
the setting time, the ambient air should be preheat-
For to accelerate the setting process at low processed above 10 °C (using for instance a radiant burner).
ing temperatures, the bagged material and the water During hardening, the castable must not freeze at
should be preheated. It is advisable to preheat the any rate. Temperatures above 30 °C accelerate the
bagged material 1 to 2 days before use in a warm setting time significantly. In this case, the bagged
storage place or in a covered area. The setting accel- material and the water should be cooled.
erators recommended for low cement castables are
not suitable for no cement ED castables. Should a No cement ED castables do not generate heat during
prolonged period of time be required for completing the setting process, but elevated outside tempera-
processing at elevated processing temperatures, tures may additionally make some of the moisture
cool the bagged material and the water (place the contained in the lining evaporate prematurely,
pallets in the shade), or add some ice (water amount resulting in an incomplete setting and hence in a
to be considered). The mixer is to be positioned as reduced strength of the castable. For to reduce the
close as possible to the place of installation. evaporation of the moisture at increased setting
temperatures, the surface of the lining must be kept
After having placed the castable behind the form- damp and cool by slightly and regularly spraying
work, one has to compact it by vibration. The time water on the surface, which may be covered with
required for processing the castable is temperature- jute for example.
dependent and should therefore not exceed
20 minutes.
26 No cement vibration castables (ED-Vib.) No cement vibration castables (ED-Vib.) 27
The formwork must not be removed before the Drying and heating-up process depend on the
castable has reached its full dimensional stability. dimensions of the lining, the castable, and the
For assessing whether the castable has already processing technique chosen.
reached its full dimensional stability, it is recom-
mended to determine the same under identical The castable expands during heating-up and within
installation conditions parallely in a cup test or using the process. Therefore it is necessary to provide
a separate test specimen. Contrary to cement- expansion joints at regular distances (see installa-
containing concretes, no cement castables show a tion instructions in the drawings). A panel size of
typically lower structural strength or do not have 0.8-1.0 m2 with a maximum edge length of 1 m is
any striking sound (sound test) after demoulding. commonly chosen.
After having reached its full dimensional stability
or once the hardening process has been completed, Heating-up of the lining is to be carried out strictly
drying and heating-up can be started, according to in accordance with the heating-up recommenda-
the instructions. At low processing temperatures and tions, as otherwise damages to the structure of
for obtaining a higher structural strength, it is par- the castable are to be expected. Once started, the
ticularly recommended to extend the hardening time heating-up process must not be stopped or inter-
of the castable until the first heating-up (e.g. 24-48 rupted. For instance in case of a possible breakdown
hours). Any processing of the built-in castable must be of a burner, the lining will have to be kept warm. If
avoided during that period. cooling down is inevitable, heating-up is to be done
very carefully once again, beginning with the first
Drying and heating-up heating-up step.
Evaporation holes of 3 to 4 mm in diameter are to be
placed at a distance of approximately 100-150 mm In order to achieve optimum product properties, the
each for supporting evaporation of water during processing instructions and heating-up recommen-
heating-up. Particularly in case of wall thicknesses/ dations (ED: Easy Dry) must be strictly followed.
linings exceeding 230 mm, linings without any insu-
lation layer (independently of the wall thickness) Personnel protection and safety
and projects, where the lined castable panels will Always wear your personal protective equipment
for instance only be dried after 4 weeks or more, (respiratory protection, tightly sealed safety goggles,
evaporation holes must have already been provided. safety gloves and tightly fitting protective clothing).
During the setting process, these evaporation holes Wash thoroughly after processing of refractory
must be driven as far as the back lining, at least to a concretes. Always refer to the material safety data
depth of 80% of the lining thickness. This should not sheet.
be done too soon after installation of the castable,
as otherwise the holes will close again. Evaporation
holes can be formed, for example, by insertion of
greased steel pins or rods (which are removed before
the end of the setting process) or by drilling etc.
Installation instructions are to be strictly followed.
28 Mixcrete vibration castables (Mix) 29
Mixcrete vibration castables
(Mix)
AR-Mixcrete combinations
Mixing ratio*: 3:1 / 2:1 / 1:1
REFRACLAY 40 LCC - REFRA-SiC 50 AR

REFRAMULLITE 60 LCC - REFRA-SiC 50 AR
REFRAMULLITE 63 LCC - REFRA-SiC 50 AR
REFRABAUXITE 75 LCC - REFRA-SiC 50 AR
REFRABAUXITE 85 LCC - REFRA-SiC 50 AR
Z AR-Mixcrete combinations
Mixing ratio*: 1:1
REFRACLAY 40 LCC - REFRAZIRCON Z AR

REFRAMULLITE 60 LCC - REFRAZIRCON Z AR
REFRAMULLITE 63 LCC - REFRAZIRCON Z AR
REFRABAUXITE 75 LCC - REFRAZIRCON Z AR
REFRABAUXITE 85 LCC - REFRAZIRCON Z AR
* The mixing ratio is only applicable to the respective

Mixcrete combination. Always use up the full bag
contents.

See respective data sheet.
Shelf life
Processing
If the Mixcrete mix is placed in a formwork or mould,
©Refratechnik Cement GmbH covered with mould oil. ©Refratechnik Cement GmbH
30 Mixcrete vibration castables (Mix) Mixcrete vibration castables (Mix) 31
For mixing the two Mixcrete types always use a correct and suitable consistency of deflocculated
clean mechanical forced-action mixer. There must Mixcrete mixes is often achieved at the end of the
not be any impurities (e.g. concrete remainder) in wet mixing time only. That is why Mixcrete mixes
the mixer. possibly seem to be too dry and crumbly when start-
ing the mixing process.
The ideal mixing batch for a mixing ratio of
3:1 or 1:1 (e.g. 3 bags : 1 bag) is 100 kg. The ball-in-hand test is a simple way to control the
consistency of the castable. A ball formed out of the
The ideal mixing batch for a mixing ratio of castable by hand must neither seem to be too dry or
2:1 (e.g. 2 bags : 1 bag) is 75 or 150 kg. crumbly nor must it slip through the fingers.
When processing the Mixcrete mix, always make The water temperature should range between
sure that 12 and 25 °C, but must never fall below 5 °C. During
processing, the temperature of the materials to be
• the respective Mixcrete combination is used, since mixed and the finished mix should range between
the processing properties were optimally adjusted 15 and 25 °C. Lower or higher temperatures either
to each other; reduce or accelerate the setting process significantly.
• the full contents of the 25 kg bag is used up, since For to accelerate the setting process at low process-
segregations between coarse and fine grains may ing temperatures, the bagged material and the water
occur during transportation; are to be preheated, or the recommended powdery
setting accelerator (refer to chapter on “Setting
• the specified mixing ratio is applied, since pro- accelerator”) is to be added. It is advisable to preheat
cessing and product properties were adjusted to it the bagged material 1 to 2 days before use in a warm
accordingly; storage place or in a covered area. Should a pro-
longed period of time be required for completing pro-
• the specified amount of mixing water is used to cessing at elevated processing temperatures, cool
achieve optimum processing and product proper- the bagged material and the water (place the pallets
ties. in the shade) or add some ice (water amount to be
considered). The mixer is to be positioned as close as
Before adding water, the Mixcrete types are to be possible to the place of installation.
mixed in dry state for a short time (about 1 minute)
to avoid any segregations that may have occurred After having placed the castable behind the form-
in the bag. Then the whole amount of water is to work, compact it by vibration. The time required for
be added within 1 minute. Do only use clean water processing the castable is temperature-dependent
(of potable quality) for mixing. The whole wet mix- and should therefore not exceed 20 minutes.
ing time should ideally not exceed 4 minutes. The

32 Mixcrete vibration castables (Mix) Mixcrete vibration castables (Mix) 33
Vibrating The formwork must not be removed before the

Place the castable carefully and slowly, and vibrate castable has reached its full dimensional stability.
it. Vibrate only until no more air escapes. Remove Before that step, one should carry out a sound test
the bottle vibrator slowly from the castable in order (bright sound) or a nail test (metal nail that has
to avoid any air inclusions. been driven-in should bend) to the set castable. For
hardening and until first heating-up, the castable
If water accumulates on the surface during process- requires at least 24-48 hours. Any processing of the
ing and compaction, the castable is too wet. Any built-in castable has to be avoided during that peri-
formation of layers due to surplus water has to be od. Once the hardening process has been completed,
avoided by all means. drying and heating-up can be started, according to
the instructions.
For larger batches of castable, shuttering areas
provided with corresponding expansion joints should Drying and heating-up
be placed. For more details, please refer to the Evaporation holes of 3 to 4 mm in diameter being
respective drawing. placed at a distance of approximately 100-150 mm each,
depending on the application conditions, have to be
Setting and hardening provided, particularly in case of wall thicknesses/
Low ambient and setting temperatures (< 10 °C) linings exceeding 230 mm and linings without any
prolong the setting time significantly. For to shorten insulation layer (independently of the wall thickness),
the setting time, the ambient air should be preheat- in order to support evaporation of water during heat-
ed above 10 °C (using for instance a radiant burner). ing-up. During the setting process, the evaporation
During hardening, the castable must not freeze at holes should be driven as far as the back lining, at
any rate. Temperatures above 25 °C accelerate the least to a depth of 80% of the lining thickness. This
setting time significantly. In this case, the bagged should not be done too soon after installation of the
material and the water should be cooled. castable, as otherwise the holes will close again.
Evaporation holes can be formed, for example, by
Even low cement castables generate heat during the insertion of greased steel pins or rods (which are
setting process. Elevated outside temperatures may removed before the end of the setting process) or by
additionally make some of the moisture contained drilling etc. Installation instructions are to be strictly
in the lining evaporate prematurely, resulting in an observed.
incomplete setting and hence reduced strength of
the castable. For to reduce the heat being generated Drying and heating-up process depend on the
and thus the evaporation of the moisture at elevat- dimensions of the lining, the castable, and the
ed setting temperatures, the surface of the lining respective processing technique chosen.
must be kept damp and cool by slightly and regu-
larly spraying water on the surface, which may be
covered with jute for example.

34 Mixcrete vibration castables (Mix) Basic vibration castables (MgO-Vib.) 35
The castable expands during heating-up and within Processing instructions

the process. Therefore it is necessary to provide Basic vibration castables
expansion joints at regular distances (see installa-
(MgO-Vib.)
tion instructions in the drawings). A panel size of
0.8-1.0 m² with a maximum edge length of 1 m is
commonly chosen. All types with the designation:
REFRA-MgO…
Heating-up of the lining is to be carried out strictly
in accordance with the heating-up recommenda- (Also refer to classification in the data sheet.)
tions, as otherwise damages to the structure of
the castable are to be expected. Once started, the Amount of water to be added
heating-up process must not be stopped or inter- See respective data sheet,
rupted. In case of a possible breakdown of a burner data printed on respective bag.
for instance, the lining will have to be kept warm. If
cooling down is inevitable, heating-up is to be done Shelf life
very carefully once again, beginning with the first 12 months (see data sheet).
heating-up step. Do not use any castable that has become lumpy.
In order to achieve optimum product properties, the Processing

processing instructions and heating-up recommen- If the castable is placed in a formwork or a mould,
dations must be strictly followed. good stable bracing is required (particularly when
Personnel protection and safety clean, made of water-repellent material, and well
Always wear your personal protective equipment covered with mould oil.
(respiratory protection, tightly sealed safety goggles,
safety gloves and tightly fitting protective clothing). For mixing the castable always use a clean mechani-
Wash thoroughly after processing of refractory cal forced-action mixer. There must not be any impu-
concretes. Always refer to the material safety data rities (for instance concrete remainder) in the mixer.
sheet. The ideal mixing batch may come up to 100 kg.
Before adding water, the castable is to be mixed in
ing. Add about 80% of the water amount required to
the castable and mix for about 2 minutes. Then the
remaining 20% of water are to be added and mixed
for another 1 to 2 minutes. The whole mixing time
may take up to 5 minutes. The correct and suitable

36 Basic vibration castables (MgO-Vib.) Basic vibration castables (MgO-Vib.) 37
consistency of deflocculated castables is often Vibrating

achieved at the end of the wet mixing time only. Place the castable slowly and carefully, and vibrate
it. Vibrate only until no more air escapes. Remove
That is why the castable possibly seems to be too the bottle vibrator slowly from the castable in order
dry and crumbly when starting the mixing process. to avoid any air inclusions.
The ball-in-hand test is a simple way to control the If water accumulates on the surface during process-
consistency of the castable. A ball formed out of ing and compaction, the castable is too wet. Any
castable by hand must neither seem to be too dry or formation of layers due to surplus water has to be
crumbly nor must it slip through the fingers. avoided by all means.
The water temperature should range between For larger batches of castable, shuttering areas pro-
12 and 25 °C, but must never fall below 5 °C. During vided with corresponding expansion joints should be
processing, the temperature of the materials to be placed. For more details, please refer to the respec-
mixed and the finished mix should range between tive drawing.
15 and 25 °C. Lower or higher temperatures either
slow down or accelerate the setting process signifi- Setting and hardening
cantly. Low ambient and setting temperatures (< 10 °C)
prolong the setting time significantly. For to shorten
For to accelerate the setting process at low process- the setting time, the ambient air should be preheat-
ing temperatures, the bagged material and the water ed above 10 °C (using for instance a radiant burner).
should be preheated. It is advisable to preheat the During hardening, the castable must not freeze at
bagged material 1 to 2 days before use in a warm any rate. Temperatures above 25 °C accelerate the
storage place or in a covered area. Should a pro- setting time significantly. In this case, the bagged
longed period of time be required for completing pro- material and the water should be cooled.
cessing at elevated processing temperatures, cool
the bagged material and the water (place the pallets These basic castables do not generate heat during
in the shade) or add some ice (water amount to be the setting process, but elevated outside tempera-
considered). The mixer is to be positioned as close as tures may additionally make some of the moisture
possible to the place of installation. contained in the lining evaporate prematurely,
resulting in an incomplete setting and hence in a
After having placed the castable behind the form- reduced strength of the castable. For to reduce the
work, one has to compact it by vibration. The time evaporation of the moisture at increased setting
required for processing the castable is temperature- temperatures, the surface of the lining must be kept
dependent and should therefore not exceed damp and cool by slightly and regularly spraying
20 minutes. water on the surface, which may be covered with
jute for example.

38 Basic vibration castables (MgO-Vib.) Basic vibration castables (MgO-Vib.) 39
Contrary to cement-containing concretes, basic expansion joints at regular distances (see installa-
castables may show a typically lower structural tion instructions in the drawings). A panel size of
strength or may not have any striking sound (sound 0.8-1.0 m2 with a maximum edge length of 1 m is
test) after demoulding. After having reached its full commonly chosen.
dimensional stability or once the hardening process
has been completed, drying and heating-up can be Heating-up of the lining is to be carried out strictly
started, according to the instructions. At low process- in accordance with the heating-up recommenda-
ing temperatures and for obtaining a higher structural tions, as otherwise damages to the structure of
strength, it is particularly recommended to extend the castable are to be expected. Once started, the
the hardening time of the castable until the first heating-up process must not be stopped or inter-
heating-up (e.g. 24-48 hours). Any processing of the rupted. For instance in case of a possible breakdown
built-in castable must be avoided during that period. of a burner, the lining will have to be kept warm. If
cooling down is inevitable, heating-up is to be done
Drying and heating-up very carefully once again, beginning with the first
Independently of the wall thicknesses, of linings heating-up step.
with/without any insulation layer or the period of time
that has passed after lining of the castable panels or In order to achieve optimum product properties,
when drying is started, basic castable linings must the processing instructions and heating-up
be provided with evaporation holes of 3 to 4 mm in recommendations must be strictly followed.
diameter being placed at a distance of approximately
100-200 mm each, in order to support evaporation of Personnel protection and safety
water during drying and heating-up process. During Always wear your personal protective equipment
the setting process, the evaporation holes must be (respiratory protection, tightly sealed safety goggles,
driven as far as the back lining, at least to a depth of safety gloves and tightly fitting protective clothing).
80% of the lining thickness. This should not be done Wash thoroughly after processing of refractory
too soon after installation of the castable, as other- concretes. Always refer to the material safety
wise the holes will close again. Evaporation holes data sheet.
can be formed, for example, by insertion of greased
steel pins or rods (which are removed before the end
of the setting process) or by drilling etc. Installation
instructions are to be strictly followed.

technique chosen.

40 Dense dry gunning concretes (G-MCG-LCG-ED G) 41
Dense dry gunning concretes
(G-MCG-LCG-ED G)

G, MCG, MCG AR, LCG, LCG AR, LCG Z AR,
ED LCG, ED LCG AR, ED LCG Z AR, ED G,
ED G AR, and ED G Z AR
The optimum amount of water required is to

be adjusted directly at the gunning nozzle.
The MCG types that are also suitable for Dense

Gunning, but particularly the LCG and ED G types
that have especially been developed for Dense
Gunning, require an advanced gunning nozzle
technology for their processing.
Shelf life
Do not use any refractory concrete that has
become lumpy.
Processing
Placing of refractory concretes by dry gunning has
become a standard installation method. The used
gunning machine should operate on the rotor princi-
ple or be a two-chamber machine.
Like any method of application, this process cannot

be applied to all cases, and success depends on the
skill of the operator, correct handling, suitable equip-
ment, and the material itself.
If the dense dry gunning concrete is placed in

a formwork or a mould, good stable bracing is
42 Dense dry gunning concretes (G-MCG-LCG-ED G) Dense dry gunning concretes (G-MCG-LCG-ED G) 43
required. The formwork has to be clean, made of may range between 2.0 and 4.5 bar. For ensuring a
water-repellent material, and well covered with mould homogeneous conveying of the refractory concrete
oil. Any connection to existing brickwork must be and an optimum gunning result, a hose length or
properly sealed off. a conveying distance of 40-60 m is recommended.
The water pressure provided must be ≥ 12 bar.
The dry gunning equipment consists of a gunning
machine, a high-pressure water pump, a gunning Do only use clean water (of potable quality) for gun-
nozzle, a water hose, and a material hose. During ning. The water temperature should range between
gunning, the dry refractory material is fed via a 12 and 25 °C, but must never fall below 5 °C. During
sieving hopper and stirring star to the rotor, which processing, the temperature of the materials to be
is fixed between two packing washers and trans- mixed should range between 15 °C and 25° C at
ports the gunning material to the blow-off socket, maximum. For to accelerate the setting process at
from where it is blown by means of compressed air low processing temperatures, the bagged material
through a material hose to the nozzle. The water and the water should be preheated. It is advisable
is added through a separate hose connected to to preheat the bagged material 1 to 2 days before
the nozzle. In dependency of the adjusted gunning use in a warm storage place or in a covered area.
parameters, the used gunning material and the flow Dry gunning concretes do not need the addition of
rate, the wear parts, like packing washers, friction any setting accelerator. The required water amount
discs and gunning nozzle, are subjected to normal is determined as per the type of refractory concrete
wear. The extreme hardness of the raw materials used, the gunning behaviour and the installation
used for high alumina and silicon carbide contain- conditions prevailing, and is varied at the nozzle by
ing gunning concretes may contribute to an earlier a control valve.
wear. We therefore recommend to check these wear
parts and the conical connecting pieces after 40 to During gunning, a certain amount of material always
80 hours of operation. rebounds. The amount of rebound material depends
on the skill of the gunning crew, the position of the
The gunning machine requires a constant supply lining (e.g. a ceiling or wall), the anchor spacing,
of water and air at adequate pressure by an air and the type of refractory concrete to be gunned
compressor and a water pump. The water and air (strictly observe chapter on “Basis for calculation of
pressure depend on the distance between gunning material requirement – Dry gunning concretes”). It
machine and nozzle, the used nozzle size, the height is not advisable to prewet the dry gunning concrete
above ground level of the part being gunned, and the in a forced-action mixer to reduce the formation of
nature and quality of the material to be applied. The dust during gunning, since along with the addition
air compressor should supply an air flow rate of min. of water, some reaction processes will start that
8-12 m3/minute and an air pressure of 6-8 bar. The lead to the formation of granulates which, with a
gunning pressure being adjusted at the dry gunning changed grain distribution, normally cause increased
machine must not generate any pulsating conveying of rebound/material losses. Do neither reuse any
the refractory concrete. In dependency of the con- rebound material nor any dry gunning concrete that
veying distance (20-100 m), the gunning pressure has been scraped off.
Hoses must be kept clean to avoid any clogging. Setting and hardening
Low ambient and setting temperatures (< 10 °C)
For dry gunning, the nozzle should be held at a right prolong the setting time significantly. For to shorten
angle to the surface in case of a vertical surface, the setting time, the ambient air should be preheat-
and at a slightly inclined angle in case of a horizon- ed above 10 °C (using for instance a radiant burner).
tal surface. This technique, in conjunction with a During hardening, the refractory concrete must
circular movement, gives minimum rebound, uniform not freeze at any rate. Temperatures above 25 °C
material structure and minimum risk of formation of accelerate the setting time significantly.
layers, which may result in subsequent spalling. For
to achieve an optimum gunning result, a distance of Cement-containing refractory concretes generate
0.5-1.0 m between wall and gunning nozzle should heat during the setting process. As a result of this
be kept. It is of special importance to build up the heat being generated, some of the moisture con-
material to full lining thickness gradually. In general tained in the lining evaporates, causing an incom-
it is advisable to gun marked-out panels or zones. plete setting and hence reduced strength of the
If necessary, the panels should be divided by stag- refractory concrete. For to reduce the heat being
gered shuttering joints. generated and thus the evaporation of the moisture,
the surface of the lining must be kept damp and cool
Always gun bottom surfaces before the top surfaces by slightly and regularly spraying water on the sur-
so that the anchors do not become covered with face, which may be covered with jute for example.
rebound material. If this happens, the anchors must
be cleaned before further gunning. The formwork must not be removed before the
refractory concrete has reached its full dimensional
When material is applied to a hot surface, it is stability. Contrary to cement-containing vibration
advisable to gun a thin intermediate layer at first. castables, dry gunning concretes may show a typi-
The water can rapidly dry in this area before further cally lower structural strength or may not have any
material is applied. This step prevents the formation striking sound (sound test). For hardening and until
of vapour pores, which would otherwise prolong the first heating-up, the refractory concrete requires
setting process of the material. at least 24-48 hours. Any processing of the built-in
refractory concrete must be avoided during that
Once the material is gunned, i.e. before the setting period. Once the hardening process has been
process starts, the surface is to be finished by completed, drying and heating-up can be started,
scraping off or drawing off with a straight-edge, but according to the instructions.
without smoothening the surface. For relatively large
batches of refractory concrete, shuttering areas Drying and heating-up
provided with corresponding expansion joints are Evaporation holes of 3 to 4 mm in diameter being
to be placed. For more details, please refer to the placed at a distance of approximately 100-150 mm each,
respective drawing. depending on the application conditions, have to be
provided, particularly in case of wall thicknesses/lin-
ings exceeding 230 mm and linings without any insu-
lation layer (independently of the wall thickness), in Personnel protection and safety
order to support evaporation of water during heating- Always wear your personal protective equipment
up. During the setting process, the evaporation (respiratory protection, tightly sealed safety goggles,
holes should be driven as far as the back lining, at safety gloves and tightly fitting protective clothing).
least to a depth of 80% of the lining thickness. This Wash thoroughly after processing of refractory
should not be done too soon after installation of the concretes. Always refer to the material safety
refractory concrete, as otherwise the holes will close data sheet.
again. Evaporation holes can be formed, for example,
by insertion of greased steel pins or rods (which are
observed.
Drying and heating-up process depend on the

dimensions of the lining, the refractory concrete,
and the processing technique chosen.
The refractory concrete expands during heating-up

and within the process. Therefore it is necessary to
provide expansion joints at regular distances (see
installation instructions in the drawings). A panel
size of 0.8-1.0 m2 with a maximum edge length of
1 m is commonly chosen.

in accordance with the heating-up recommendation,
as otherwise damages to the structure of the refrac-
tory concrete are to be expected. Once started, the
rupted. For instance in case of a possible breakdown
of a burner, the lining will have to be kept warm. If
cooling down is inevitable, heating-up is to be done
very carefully once again, beginning with the first
heating-up step.
In order to achieve optimum product properties, the

processing instructions and heating-up recommen-
dations must be strictly followed.

48 Insulating dry gunning concretes (G-Iso.) 49
Insulating dry gunning concretes
(G-Iso.)
All types with the designation:

REFRALITE® … G
The optimum amount of water required is to

be adjusted directly at the gunning nozzle.
Shelf life
Do not use any insulating dry gunning concrete
that has become lumpy.
Processing
Placing of insulating refractory concretes by dry
gunning has become a standard installation method.
The used gunning machine should operate on the
rotor principle or be a two-chamber machine.
Like any method of application, this process cannot

be applied to all cases, and success depends on
the skill of the operator, correct handling, suitable
equipment, and the material itself.
If the insulating dry gunning concretes are placed

in a formwork or a mould, good stable bracing is
required. The formwork has to be clean, made of
water-repellent material, and well covered with
mould oil. Any connection to existing brickwork
must be properly sealed off.
The dry gunning equipment consists of a gunning

machine, a high-pressure water pump, a gunning
nozzle, a water hose, and a material hose. During
50 Insulating dry gunning concretes (G-Iso.) Insulating dry gunning concretes (G-Iso.) 51
gunning, the dry refractory material is fed via a mixed should range between 15 °C and 25° C at
sieving hopper and stirring star to the rotor, which maximum. For to accelerate the setting process at
is fixed between two packing washers and trans- low processing temperatures, the bagged material
ports the refractory material to the blow-off socket, and the water should be preheated. It is advisable to
from where it is blown by means of compressed air preheat the bagged material 1 to 2 days before use
through a material hose to the nozzle. The water in a warm storage place or in a covered area. Dry
is added through a separate hose connected to gunning concretes do not need the addition of any
the nozzle. In dependency of the adjusted gunning setting accelerator.
parameters, the used gunning material and the flow
rate, the wear parts, like packing washers, friction The required water amount is determined as per the
discs and gunning nozzle, are subjected to normal type of refractory concrete used, the gunning be-
wear. We therefore recommend to check these wear haviour, and the installation conditions prevailing,
parts after 40 to 80 hours of operation. and is varied at the nozzle by a control valve.
The gunning machine requires a constant supply of During gunning, a certain amount of material always
water and air at adequate pressure by an air com- rebounds. The amount of rebound material depends
pressor and a water pump. The water and air pres- on the skill of the gunning crew, the position of the
sure depend on the distance between the gunning lining (e.g. a ceiling or wall), the anchor spacing, and
machine and the nozzle, the used nozzle size, the the type of refractory concrete to be gunned (strictly
height above ground level of the part being gunned, observe chapter on “Basis for calculation of material
and the nature and quality of the material to be requirement – Dry gunning concretes”).
applied. The air compressor should supply an air flow
rate of min. 8-12 m3/minute and an air pressure of It is not advisable to prewet the insulating dry gun-
6-8 bar. The gunning pressure being adjusted at the ning concrete in a forced-action mixer to reduce the
dry gunning machine must not generate any pulsat- formation of dust during gunning, since along with
ing conveying of the refractory concrete. At short the addition of water, some reaction processes will
conveying distance of approx. 40 m, a gunning pres- start that lead to the formation of granulates, which,
sure of 0.5 up to 2.0 bar can be adjusted, depending with a changed grain distribution, do normally cause
on what is required. If possible, larger conveying increased rebound/material losses. Do neither reuse
distances should be avoided, since for achieving a any rebound material nor any insulating dry gunning
constant conveying behaviour, the gunning pressure concrete that has been scraped off.
can then be up to 3.5 bar. This in turn will result in
an unwanted increased material consumption. The Insulating materials tend to compact during gunning.
water pressure must be ≥ 12 bar. This may result in a higher material consumption and
in a higher density of the applied material than speci
Do only use clean water (of potable quality) for gun- fied by the manufacturer (strictly observe chapter on
ning. The water temperature should range between “Basis for calculation of material requirement – Dry
12 and 25 °C, but must never fall below 5 °C. During gunning concretes”).
processing, the temperature of the materials to be
52 Insulating dry gunning concretes (G-Iso.) Insulating dry gunning concretes (G-Iso.) 53
Hoses must be kept clean to avoid any clogging. concrete must not freeze at any rate. Temperatures
above 25 °C accelerate the setting time significantly.
For dry gunning, the nozzle should be held at a right
angle to the surface in case of a vertical surface, Cement-containing insulating dry gunning concretes
and at a slightly inclined angle in case of a horizon- generate heat during the setting process. As a result
tal surface. This technique, in conjunction with a of this heat being generated, some of the moisture
circular movement, gives minimum rebound, uniform contained in the lining evaporates, causing an
material structure and minimum risk of formation of incomplete setting and hence reduced strength of
layers, which may result in subsequent spalling. For the insulating dry gunning concrete. For to reduce
to achieve an optimum gunning result, a distance of the heat being generated and thus the evaporation
0.5-1.0 m between wall and gunning nozzle should of the moisture, the surface of the lining must be
be kept. It is of special importance to build up the kept damp and cool by slightly and regularly spraying
material to full lining thickness gradually. In general water on the surface, which may be covered with
it is advisable to gun marked-out panels or zones. jute for example.
Always gun bottom surfaces before the top surfaces The formwork must not be removed before the
so that the anchors do not become covered with insulating dry gunning concrete has reached its full
rebound material. If this happens, the anchors must dimensional stability. Contrary to cement-containing
be cleaned before further gunning. vibration castables, insulating dry gunning concretes
may show a typically lower structural strength or
When material is applied to a hot surface, it is do not have any striking sound (sound test) after
advisable to gun a thin intermediate layer at first. installation. For hardening and until first heating-up,
The water can rapidly dry in this area, before further the insulating dry gunning concrete requires at least
material is applied. This step prevents the formation 24-48 hours. Any processing of the built-in insulating
of vapour pores, which would otherwise prolong the dry gunning concrete must be avoided during that
setting process of the material. period. Once the hardening process has been com-
pleted, drying and heating-up can be started, accord-
Once the material is gunned, i.e. before the setting ing to the instructions.
process starts, the surface is to be finished by
scraping off or drawing off with a straight-edge, but Drying and heating-up
without smoothening the surface. Drying and heating-up process depend on the
dimensions of the lining, the insulating dry gunning
Setting and hardening concrete, and the processing technique chosen.
Low ambient and setting temperatures (< 10 °C)
prolong the setting time significantly. For to shorten In case of one-layer wall constructions with insu-
the setting time, the ambient air should be preheat- lating dry gunning concretes, the latter also expand
ed above 10 °C (using for instance a radiant burn- during heating-up and within the process. Therefore
er). During hardening, the insulating dry gunning it is necessary to provide expansion joints at regular

54 Insulating dry gunning concretes (G-Iso.) Low cement wet gunning concretes (LC-JC) 55
distances (see installation instructions in the draw- Processing instructions

ings). A panel size of 0.8-1.0 m2 with a maximum Low cement wet gunning concretes
edge length of 1 m is commonly chosen.
(LC-JC)
in accordance with the heating-up recommenda- All types with the designations:
tions, as otherwise damages to the structure of the JC, JC AR, and JC Z AR
insulating dry gunning concretes are to be expected.
Once started, the heating-up process must not (Also refer to classification in the data sheet.)
be stopped or interrupted. For instance in case of
a possible breakdown of a burner, the lining will Amount of water to be added
have to be kept warm. If cooling down is inevitable, See respective data sheet,
heating-up is to be done very carefully once again, data printed on respective bag or big bag.
beginning with the first heating-up step.
Shelf life
In order to achieve optimum product properties, the Big bags: 6 months,
processing instructions and heating-up recommen- bagged material (25 kg/bag): 12 months
dations must be strictly followed. (see data sheet).
Do not use any refractory concrete that
Personnel protection and safety has become lumpy.
Always wear your personal protective equipment
(respiratory protection, tightly sealed safety goggles, Processing
safety gloves and tightly fitting protective clothing). For preparing the refractory concrete always use a
Wash thoroughly after processing of refractory clean gunning equipment and a clean mixer. There
concretes. Always refer to the material safety must not be any impurities (i.e. concrete remainder),
data sheet. neither in the gunning equipment nor in the mixer.
The water is added continuously, while emptying the
big bag or the bags into the mixer. Do only use clean
water (of potable quality) for mixing. The whole wet
mixing procedure should last at least 5 minutes. The
correct and suitable consistency of deflocculated
refractory concretes is often only achieved at the
end of the wet mixing time. That is why the refrac-
tory concrete may seem to be too dry and crumbly at
the beginning of the mixing process.

consistency of the refractory concrete. A ball formed
out of refractory concrete slips through the fingers
56 Low cement wet gunning concretes (LC-JC) Low cement wet gunning concretes (LC-JC) 57
without having to shake it or by only slightly having has to be finished by drawing off with a straight-
to shake it by hand at first. edge or by smoothing.
The water temperature should range between For larger batches of refractory concrete, shuttering
12 and 25 °C, but must never fall below 5 °C. During areas provided with corresponding expansion joints
processing, the temperature of the materials to be should be placed. For more details, please refer to
mixed and the finished mix should range between the respective drawing.
15 and 25 °C at maximum. Lower or higher tempera-
tures either reduce or accelerate the setting process Strictly observe chapter on “Basis for calculation of
significantly. material requirement - Wet gunning concretes”.
For to accelerate the reaction behaviour at low pro- Setting and hardening
cessing temperatures, the big bags/bagged material Low ambient and setting temperatures (< 10 °C)
and the water should be preheated, but not above prolong the setting time significantly. For to shorten
25 °C. It is advisable to preheat the big bags/bagged the setting time, the ambient air should be preheat-
material 1 to 2 days before use in a warm storage ed above 10 °C (using for instance a radiant burner).
place or in a covered area. There must never be add- During hardening, the refractory concrete must
ed any powdery setting accelerator to wet gunning not freeze at any rate. Temperatures above 25 °C
concretes during the mixing process. If a prolonged accelerate the setting time significantly.
period of time is required for processing at elevated
processing temperatures, cool the big bags/bagged Even low cement concretes generate heat during the
material and the water (place the pallets in the setting process. Elevated outside temperatures may
shade), and protect the gunning equipment and the additionally make some of the moisture contained
pipes/hoses from direct solar radiation. in the lining evaporate prematurely, resulting in
an incomplete setting and hence reduced strength
During the gunning process of wet gunning con- of the refractory concrete. In order to reduce the
cretes, the required special liquid accelerator has to heat being generated and thus the evaporation of
be added at the gunning nozzle. Since the consistency/ the moisture, the surface of the lining must be kept
pumpability of the accelerator is temperature-depen damp and cool by slightly and regularly spraying
dent, a preheating at low processing temperatures water on the surface, which may be covered with
(< 10 °C) is indispensable. jute for example.
The processing time of the refractory concrete is For hardening and until first heating-up, the refrac-
temperature-dependent and should therefore not tory concrete requires at least 24-48 hours. Any
take more than 20 minutes. During installation by processing of the built-in refractory concrete is to be
gunning, the refractory concrete hardens rapidly and avoided during that period. Once the hardening pro-
becomes stable within a few seconds. Once having cess has been completed, drying and heating-up can
placed the refractory concrete, the surface therefore be started, according to the instructions.

58 Low cement wet gunning concretes (LC-JC) Low cement wet gunning concretes (LC-JC) 59
Drying and heating-up inevitable, heating-up is to be done very carefully

Evaporation holes of 3 to 4 mm in diameter being once again, beginning with the first heating-up step.
placed at a distance of approximately 100-150 mm
each, depending on the application conditions, have to In order to achieve optimum product properties, the
be provided, particularly in case of wall thicknesses/ processing instructions and heating-up recommen-
linings exceeding 230 mm and linings without any dations must be strictly followed.
insulation layer (independently of the wall thickness),
in order to support evaporation of water during Personnel protection and safety
heating-up. REFRA JETCRETE® (JC) types, which are Always wear your personal protective equipment
not installed by gunning, but by pumping, casting or (respiratory protection, tightly sealed safety goggles,
vibratory compaction, must be provided with evap- safety gloves and tightly fitting protective clothing).
oration holes, too. During the setting process, the Wash thoroughly after processing of refractory
evaporation holes should be driven as far as the back concretes. Always refer to the material safety
lining, at least to a depth of 80% of the lining thick- data sheet.
ness. Evaporation holes can be formed, for example,
by insertion of greased steel pins or rods (which are
followed.

dimensions of the lining, the refractory concrete, and
the processing technique chosen.
The refractory concrete expands during heating-up

and within the process. Therefore it is necessary to
provide expansion joints at regular distances (see
installation instructions in the drawings). A panel
size of 0.8-1.0 m2 with a maximum edge length of
1 m is commonly chosen.

in accordance with the heating-up instructions, as
otherwise damages to the structure of the refractory
concrete are to be expected. Once started, the heating-
up process must not be stopped or interrupted. For
instance in case of a possible breakdown of a burn-
er, the lining must be kept warm. If cooling down is

60 No cement wet gunning concretes (ED-JC) 61
No cement wet gunning concretes
(ED-JC)

ED JC, ED JC AR, and ED JC Z AR

data printed on respective bag or big bag.
Shelf life
Big bags: 6 months,
bagged material (25 kg/bag): 12 months
(see data sheet).
Do not use any refractory concrete that
has become lumpy.
Processing
For preparing the refractory concrete always use a
clean gunning equipment and a clean mixer. There
must not be any impurities (i.e. concrete remainder),
neither in the gunning equipment nor in the mixer.
ing. Never use any type of liquid binder. The water
is added continuously, while emptying the big bags
or the bagged material into the mixer. For preventing
the mixer from possibly reaching its limits at low
processing temperatures, the big bags should be
emptied with some delay. At recommended process-
ing temperatures, the whole wet mixing time should
last up to 5 minutes; at low processing and refrac
tory concrete temperatures (< 10 °C) it may be extend-
ed accordingly. The correct and suitable consistency
of deflocculated refractory concretes is often only
achieved at the end of the wet mixing time. That is
62 No cement wet gunning concretes (ED-JC) No cement wet gunning concretes (ED-JC) 63
why refractory concretes may seem to be too dry cretes), the accelerator added at the gunning nozzle
and crumbly at the beginning of the mixing process. requires a much finer dosage and a smaller quantity
of the same being added due to its high reactivity.
consistency of the refractory concrete. A ball formed The processing time of the refractory concrete is
out of refractory concrete slips through the fingers temperature-dependent and should therefore not
without having to shake it or by only slightly having take more than 20 minutes. During installation by
to shake it by hand at first. gunning, the refractory concrete hardens rapidly and
becomes stable within a few seconds. Once having
The water temperature should range between placed the refractory concrete, the surface therefore
15 and 35 °C, but must never fall below 10 °C. Dur- has to be finished by drawing off with a straight-
ing processing, the temperature of the materials to edge or by smoothing.
be mixed and the finished mix should range between
15 and 30 °C. Lower or higher temperatures either For larger batches of refractory concrete, shuttering
reduce or accelerate the setting process significantly. areas provided with corresponding expansion joints
should be placed. For more details, please refer to
For to accelerate the reaction behaviour with the the respective drawing.
special accelerator being added at the nozzle and
for a faster setting process at low processing tem- Strictly observe chapter on “Basis for calculation of
peratures, the big bags/bagged material and the material requirement - Wet gunning concretes”.
water have to be preheated, but not above 25 °C. It
is advisable to preheat the big bags/bagged mate- Setting and hardening
rial 1 to 2 days before use in a warm storage place Low ambient and setting temperatures (< 10 °C)
or in a covered area. During the mixing process, prolong the setting time significantly. For to shorten
there must never be added any powdery setting the setting time, the ambient air should be preheat-
accelerator to wet gunning concretes. If a prolonged ed above 10 °C (using for instance a radiant burner).
period of time is required for processing at elevated A higher compressed air amount being added at the
processing temperatures, cool the big bags/bagged nozzle or a higher compressor power may possibly
material and the water (place the pallets in the lead to a quicker hardening of the gunned deeper
shade), and protect the gunning equipment and the refractory concrete layers. During hardening, the
pipes/hoses from direct solar radiation. refractory concrete must not freeze at any rate.
Temperatures above 25 °C accelerate the setting
During processing of wet gunning concretes, the time significantly.
required special liquid accelerator has to be added
at the gunning nozzle. Since the consistency/pump- No cement ED-JC concretes do not generate any
ability of the accelerator is temperature-dependent, heat during the setting process. However, elevated
preheating at low processing temperatures (< 10 °C) outside temperatures may additionally make some
is indispensable. In case of no cement wet gunning of the moisture contained in the lining evaporate
concretes (contrary to low cement wet gunning con- prematurely, resulting in an incomplete reaction and
64 No cement wet gunning concretes (ED-JC) No cement wet gunning concretes (ED-JC) 65
hence reduced strength of the refractory concrete. the holes will close again. Evaporation holes can be
In order to reduce the evaporation of the moisture, formed, for example, by insertion of greased steel
the surface of the lining must be kept damp and cool pins or rods (which are removed before the end of
at increased setting temperatures by slightly and the setting process) or by drilling etc. Installation
regularly spraying water on the surface, which may instructions are to be strictly followed.
be covered with jute for example.
Contrary to cement-containing vibration castables, dimensions of the lining, the refractory concrete,
no cement concretes show a typical lower structural and the processing technique chosen.
strength and a not that pronounced sound (sound
test) after installation or demoulding. After having The refractory concrete expands during heating-up
reached its full dimensional stability, or after having and within the process. Therefore it is necessary to
completed the hardening process, drying and heating- provide expansion joints at regular distances (see
up can be started, according to instructions. At low installation instructions in the drawings). A panel
processing temperatures and for obtaining a higher size of 0.8-1.0 m2 with a maximum edge length of
structural strength, it is particularly recommended to 1 m is commonly chosen.
extend the hardening time of the refractory concrete
until the first heating-up (e.g. 24-48 hours). Any Heating-up of the lining is to be carried out strictly
processing of the built-in refractory concrete is to be in accordance with the heating-up instructions, as
avoided during that period. otherwise damages to the structure of the refractory
concrete are to be expected. Once started, the heating-
Drying and heating-up up process must not be stopped or interrupted. For
Evaporation holes of 3 to 4 mm in diameter are to be instance in case of a possible breakdown of a burn-
placed at a distance of approximately 100-150 mm er, the lining must be kept warm. If cooling down is
each, for supporting evaporation of water during inevitable, heating-up is to be done very carefully
heating-up. Particularly in case of wall thicknesses/ once again, beginning with the first heating-up step.
linings exceeding 230 mm, linings without any insu-
lation layer (independently of the wall thickness), In order to achieve optimum product properties, the
and in case of projects, where the lined refractory processing instructions and heating-up recommen-
concrete panels will for instance only be dried dations (ED: Easy Dry) must be strictly followed.
after 4 weeks or more, evaporation holes must be
provided. REFRA JETCRETE® (JC) types, which are Personnel protection and safety
not installed by gunning, but by pumping, casting Always wear your personal protective equipment
or vibratory compaction, must be provided with (respiratory protection, tightly sealed safety goggles,
evaporation holes, too. During the setting process, safety gloves and tightly fitting protective clothing).
these evaporation holes must be driven as far as the Wash thoroughly after processing of refractory
back lining, at least to a depth of 80% of the lining concretes. Always refer to the material safety
thickness. This should not be done too soon after data sheet.
installation of the refractory concrete, as otherwise
66 Poured insulating concretes (Iso.) 67
Poured insulating concretes
(Iso.)
All types with the designation:

REFRALITE®…, e.g. REFRALITE® 32,
REFRALITE® 30, REFRALITE® 20

Shelf life
Do not use any insulating concrete that has
become lumpy.
Processing
If the insulating concrete is placed in a formwork
or a mould, good stable bracing is required. The
formwork has to be clean, made of water-repellent
material, and well covered with mould oil.
The insulating concrete should be mixed by means

of a clean mechanical gravity mixer. A forced-action
mixer could also be used for mixing, but one should
observe that a too high mixing power or mixing of
the insulating concrete for more than 2 minutes may
cause crushing of the lightweight raw materials and
hence possibly changes in process/product proper-
ties. There must not be any impurities (i.e. concrete
remainder) in the mixer. The ideal mixing batch
may come up to 100 kg. Before adding water, the
insulating concrete must be mixed in dry state for a
short time (about 30 seconds) to avoid any segrega-

68 Poured insulating concretes (Iso.) Poured insulating concretes (Iso.) 69
tions that may have occurred in the bag. Do only use If water accumulates on the surface during process-
clean water (of potable quality) for mixing. ing and compaction, the insulating concrete is too
wet. Any formation of layers due to surplus water
Add about 80% of the water amount required to has to be avoided by all means.
the insulating concrete, and mix for about 1 minute.
Then the remaining 20% of water are to be added Setting and hardening
and mixed for 1 minute more. The whole mixing time Low ambient and setting temperatures (< 10 °C)
should ideally not exceed 2 minutes. prolong the setting time significantly. For to shorten
the setting time, the ambient air should be preheat-
The water temperature should range between ed above 10 °C (using for instance a radiant burner).
12 and 25 °C, but must never fall below 5 °C. During During hardening, the insulating concrete must not
processing, the temperature of the materials to be freeze at any rate. At temperatures above 25 °C the
mixed and the finished mix should range between setting time is accelerated significantly.
10 and 25 °C. Lower or higher temperatures either
reduce or accelerate the setting process significantly. Cement-containing insulating concretes generate
heat during the setting process. As a result of
For to accelerate the setting process at low process- this heat being generated, some of the moisture
ing temperatures, the bagged material and the water contained in the lining evaporates, causing an
should be preheated. It is advisable to preheat the incomplete setting and hence reduced strength of
bagged material 1 to 2 days before use in a warm the insulating concrete. In order to reduce the heat
storage place or in a covered area. Regular cement being generated and thus the evaporation of the
insulating concretes do not need the addition of moisture, the surface of the lining must be kept
any setting accelerator. If a longer period of time damp and cool by slightly and regularly spraying
is required for processing at elevated processing water on the surface, which may be covered with
temperatures, cool the bagged material and the jute for example.
water (place the pallets in the shade) or add some
ice (water amount to be considered). The mixer is The formwork must not be removed before the
to be positioned as close as possible to the place of insulating concrete has reached its full dimensional
installation. stability. Contrary to cement-containing vibration
castables, insulating concretes may show a typically
After having placed the insulating concrete behind lower structural strength or do not have any striking
the formwork, it has to be slightly compacted sound (sound test) after demoulding. For hardening,
by pouring, rodding or ramming layer by layer the insulating concrete requires at least 24-48 hours.
(10-15 cm), or vibrating. Before preparing the next Any processing of the insulating concrete is to be
layer, the surface of the anterior layer is to be slight- avoided during that period. Once the hardening pro-
ly roughened. This will avoid any formation of layers. cess has been completed, drying and heating-up can
The time required for processing the insulating be started, according to the instructions.
concrete is temperature-dependent and should not
exceed 20 minutes.
70 Poured insulating concretes (Iso.) Setting accelerator 71
Drying and heating-up Setting accelerator

dimensions of the lining, the insulating concrete, Information
and the processing technique chosen. on the use of a special additive as setting
accelerator
In case of one-layer wall constructions with insu-
lating concretes, the latter also expand during To be added to
heating-up and within the process. Therefore it is all low cement vibration castables
necessary to provide expansion joints at regular (LCC, LCC AR, AR, Z AR)
distances (see installation instructions). A panel size
of 0.8-1.0 m2 with a maximum edge length of 1 m Not to be added to
is commonly chosen. wet gunning concretes (JC),
dry gunning concretes (G, MCG, LCG), and
Heating-up of the lining is to be carried out strictly no cement concretes (ED: Easy Dry)
in accordance with the heating-up recommenda-
tions, as otherwise damages to the structure of the Processing
insulating concrete are to be expected. Once started, The setting accelerator (packed in 10 g bags) is
the heating-up process must not be stopped or inter- added during the dry mixing process of low cement
rupted. For instance in case of a possible breakdown vibration castables on the plant site.
of a burner, the lining must be kept warm. If cooling
down is inevitable, heating-up is to be done very The indicated water amount is added subsequently
carefully, beginning with the first heating-up step. and mixed according to the processing instructions
given for low cement vibration castables on page 17.
In order to achieve optimum product properties, the
processing instructions and heating-up recommen- Since the additive is an extremely effective acceler-
dations must be strictly followed. ator, the castables have to be processed as fast as
possible!
Personnel protection and safety
Always wear your personal protective equipment
(respiratory protection, tightly sealed safety goggles,
safety gloves and tightly fitting protective clothing).
Wash thoroughly after processing of refractory
concretes. Always refer to the material safety
data sheet.

72 Setting accelerator 73
Addition of 0.01 0.02 0.03 0.04 0.05

wt.% Additive
Batch weight
25 kg mix 2.5 g 5.0 g 7.5 g 10.0 g 12.5 g
50 kg mix 5.0 g 10.0 g 15.0 g 20.0 g 25.0 g
75 kg mix 7.5 g 15.0 g 22.5 g 30.0 g 37.5 g
100 kg mix 10.0 g 20.0 g 30.0 g 40.0 g 50.0 g
150 kg mix 15.0 g 30.0 g 45.0 g 60.0 g 75.0 g
200 kg mix 20.0 g 40.0 g 60.0 g 80.0 g 100.0 g
Amount of accelerator to be added during dry mixing
process depends on batch weight.
Dosage
At processing temperatures ≤ 15 °C, the amount of
additive required ranges from 0.01 wt.% up to max.
0.05 wt.%.
As a general rule, one should start adding the small-

est amount of additive and observe the flowability,
compaction and setting behaviour of the low cement
vibration castable. Make sure that the amount of
additive used does not impair the castable's flowa-
bility and compaction.
Dosage is therefore to be carried out very carefully,

because an overdosage (> 0.05 wt.%) will lead to
a very fast setting (in the mixer already) and to a
considerably impaired flowability of the castable.
The water added must not exceed the maximum

water amount stated in the data sheet.
Safety instructions
Strictly observe the attached material safety data
sheet when using setting accelerators. Always wear
your personal protective equipment (respiratory pro-
tection, tightly sealed safety goggles, safety gloves
and tightly fitting protective clothing) when using
setting accelerators. Valid as at: 03/2017
Refratechnik Cement GmbH
Rudolf-Winkel-Strasse 1
37079 Göttingen
Ce 1-084-05/2017
Germany
Phone +49 551 6941 0
Fax +49 551 6941 104
cement@refra.com

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REFRATECHNIK

Basis for calculation of material requirement

Regular cement vibration castables (RC-Vib.) 11

Low cement vibration castables (LC-Vib.) 17

No cement vibration castables (ED-Vib.) 23

Mixcrete vibration castables (Mix) 29

Basic vibration castables (MgO-Vib.) 35

Dense dry gunning concretes

Insulating dry gunning concretes (G-Iso.) 49

Low cement wet gunning concretes (LC-JC) 55

No cement wet gunning concretes (ED-JC) 61

Poured insulating concretes (Iso.) 67

• Store dry, well ventilated and cool, but frost-free.

• The packaging, a tarpaulin or a protective cover

• Big differences in temperature (e.g. in the

• Any improper storage or damaged packaging/bags

• The stated, product-specific shelf life will only be

• Liquid binders and accelerators always have to be

• In case of longer storage periods and processing

©Refratechnik Cement GmbH

Basis for calculation of

The calculation of material required depends on

The calculation of material required is based on the

Any deviations from these preconditions may cause

©Refratechnik Cement GmbH ©Refratechnik Cement GmbH

Higher material consumption or higher • prewetted, already granulated material

• the used gunning nozzle technology and the

• tight space conditions, increased or reduced

• subsurface conditions, such as uneven places and

©Refratechnik Cement GmbH ©Refratechnik Cement GmbH

Basis for calculation of • frequent and long interruptions

• loss of higher amounts of material that remain in

©Refratechnik Cement GmbH ©Refratechnik Cement GmbH

All regular cement types without any

(Also refer to classification in the data sheet.)

Amount of water to be added

For mixing the castable always use a clean mechani-

­ efore adding water, the castable is to be mixed in

©Refratechnik Cement GmbH ©Refratechnik Cement GmbH

©Refratechnik Cement GmbH ©Refratechnik Cement GmbH

Drying and heating-up process depend on the dimen-

©Refratechnik Cement GmbH ©Refratechnik Cement GmbH

All types with the designations:

(Also refer to classification in the data sheet.)

Amount of water to be added

For mixing the castable always use a clean mechan-

is often achieved at the end of the wet mixing time Vibrating

©Refratechnik Cement GmbH ©Refratechnik Cement GmbH

Drying and heating-up process depend on the dimen-

©Refratechnik Cement GmbH ©Refratechnik Cement GmbH

All types with the designations:

(Also refer to classification in the data sheet.)

Amount of water to be added

For mixing the castable always use a clean mechani-

only. That is why the castable possibly seems to Vibrating

REFRACLAY 40 LCC - REFRA-SiC 50 AR

REFRACLAY 40 LCC - REFRAZIRCON Z AR

* The mixing ratio is only applicable to the ­respective

Amount of water to be added

©Refratechnik Cement GmbH ©Refratechnik Cement GmbH

Vibrating The formwork must not be removed before the

©Refratechnik Cement GmbH ©Refratechnik Cement GmbH

The castable expands during heating-up and within Processing instructions

• The packaging, a tarpaulin or a protective cover

• Big differences in temperature (e.g. in the

• Any improper storage or damaged packaging/bags

• The stated, product-specific shelf life will only be

• Liquid binders and accelerators always have to be

• In case of longer storage periods and processing

• the used gunning nozzle technology and the

• tight space conditions, increased or reduced

• subsurface conditions, such as uneven places and

• loss of higher amounts of material that remain in

efore adding water, the castable is to be mixed in

* The mixing ratio is only applicable to the respective