Castables and Dry M ortars

Installation Instructions for Castables & Dry Mortars

M ix ing Instructions for

General Mixing Instructions
There are 2 types of Castables, Low Cement Castables (TufDura S600, TufDura S300, C-SIC 300,
C-SIC 500, C95, C82, C70A, C60A, C40A, UltraCast M60, NEOCAS1450, NEOCAS1550,
NEOCAS1650, NEOCAS1750, NEOCAS1800, and etc), and Conventional & Lightweight Castables
(CAST13, CAST13ES, CAST15, CAST15ES, CAST11LW, CAST13LW, CAST14LW, and etc). The
main differences in these 2 types of Castables in mixing aspect are the required mixing water amount
and binder separated/ not separated.

Low Cement Castables (TufDura S600, TufDura S300, C-SIC 300, C-SIC 500, C95, C82, C70A, C60A,
C40A, UltraCast M60, NEOCAS1450, NEOCAS1550, NEOCAS1650, NEOCAS1750, NEOCAS800,
and etc) will require amount of water approx. 4.5 -5.5% of Castables weight for mixing. Also, the binder
is packed separately (to improve the storage life), one pack of binder is to be mixed with one pack of
Castables (Mixing ratio of Castables: Binder is 1:1). Conventional Castables & Lightweight Castables

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(CAST13, CAST13ES, CAST15, CAST15ES, CAST11LW, CAST13LW, CAST14LW, and etc) will
require amount of water approx. 10.0 – 55.0 % of Castables weight for mixing. The binder has already
mixed in the Castables bag. There is no need to add binder.

Generally, dry mixing is required for all Castables types for app. 1 minute in order to make
homogeneous mixing between Castables and binder. Then water is slowly added in accordance with
the required amount of water for each type of Castables, this process may take 2-3 minutes. After the
Castables becomes shiny, it can be used for casting right away.

Installation Instructions for Low Cement Castables: C40A, C60A, C70A,

C-SIC500, TufDura S300, and TufDura S600

FAX: +66 2 587-2149 or +66 2 586-2982 e-mail: sricexp@cementhai.co.th

1. Prepare each approx. 1 square meter wooden former, with 5 mm. thick cardboard or plywood for
expansion joints deep at least 2/3 of castable thickness from hot surface to allow the castable
expand during preheating process.

2. Prepare the necessary equipment such as 10,000-15,000 vpm vibrators with 1-2 inches diameter,
buckets and a pan mixer.

3. Strictly recommend to use a 40-45 rpm pan mixer driven by 5-7 HP motor. The gap between mixer
base and its paddle should be not over than 3 mm in order to prevent the material segregation.

4. Before mixing the first batch of castable, be sure that a pan mixer is clean (partially hydrated
castable of the old batch or other contamination materials will act as an accelerator for the new
castable batch, which is not desired).

5. Fill the castable 100 kgs (4 bags) and fill the binder 4 bags into the pan mixer.

Note: the quantity of castable for mixing in each batch is depending on the capacity of pan
mixer, it can be increased but the mixing ratio must be varied proportionally, i.e. 200 kgs: 8
bags and fill the binder 8 bags

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 Castables and Dry M ortars
6. Strictly continue dry mixing process for 1.0 minute in order to homogenize the castable material

M ix ing Instructions for

with the binder and Retarder powder (if needed).

7. Then, slowly pour clean, drinkable water approx. 4.5- 5.5 litres, for 100 kgs batch (or 4.5- 5.5% of
castables weight in the batch mixing) into the castable in the mixer.

Note: the temperature of the water for mixing must not exceed 300C. The water should be
kept in the shaded area.

8. Wet mixing for another 2-3 minutes and could adjust by pouring some more water approx. 0.5-1.0
litre if the mix is too dry.

9. When the mixed castable becomes shining, drain it from the mixer to the buckets.

10. Put the mixed castable into only one side (left side or right side) of the prepared former.

11. Vibrate mixed castable. The castable will flow by itself to another side of former. The attention

THE SIAM REFRACTORY INDUSTRY CO., LTD. 1 SIAM CEMENT ROAD, BANGSUE, BANGKOK 10800 THAILAND
during vibrating stage is needed, not to leave vibrator too long in castable as it would cause
segregation easily. Besides, the pulling out motion of vibrator from castable must make it as slow as
possible, so that there will not be any air pocket left in the castable section. This can be observed by
seeing the castable surface flow and the hole was closed perfectly.
12. Finally, the castable becomes shining because the water comes out from its internal porosity.
13. Within 5-8 hours, the castable will be set from hydraulic reaction.

14. After casting, it is highly recommended that the setting refractory material should be covered with
plastic sheet or damp sack to prevent surface moisture lost. The mould or former can be removed
after the first 8 hours to ensure completing reaction. However, castable curing by WATER SPRAYING
is PROBIBITED. The air setting should be continued for 24 hours. With the cover removed, the refractory
material may be air dried for another 24 hours.

FAX: +66 2 587-2149 or +66 2 586-2982 e-mail: sricexp@cementhai.co.th

Notes:
To avoid the false set (immediately set in the pan mixer) of castable, the pan mixer must be clean
every time when the mixer is idle for long period. In addition, the pan mixer must be clean when
there is a mixing change from one type of castable to another type of castable.
Water required for above mentioned Castables is approx. 4.5- 5.5% by weight. If the ambient
temperature is high, water might be reached to 6.0% by weight, or Retarder must be added
additionally with appropriate amount to slow down the setting time.

Installation Instruction for Conventional Castables: CAST13ES, and CAST15ES

1. Prepare each approx. 1 square meter wooden former, with 5 mm. thick cardboard or plywood for
expansion joints deep at least 2/3 of castable thickness from hot surface to allow the castable
expand during preheating process.

2. Prepare the necessary equipment such as 10,000-15,000 vpm vibrators with 1-2 inches diameter,
buckets and a pan mixer.

3. Strictly recommend to use a 40-45 rpm pan mixer driven by 5-7 HP motor. The gap between mixer
base and its paddle should be not over than 3 mm in order to prevent the material segregation.

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 Castables and Dry M ortars
4. Before mixing the first batch of castable, be sure that a pan mixer is clean.

M ix ing Instructions for

5. Fill the castable around 100 kgs (4 bags of 25 kgs package) into the pan mixer.

Note: the quantity of castable for mixing in each batch is depending on the capacity of pan
mixer.

6. Strictly continue dry mixing process for 0.5-1.0 minute in order to homogenize the castable
material (and Retarder if needed).

7. Then, slowly pour clean drinkable water approx. 10.0 litres (10.0% of Castables weight) into the
castable in the mixer.

Note: the temperature of the water for mixing must not exceed 300C. The water should be
kept in the shaded area.

8. Wet mixing for more 2-3 minutes and could adjust by pouring some more water approx. 1.0-4.0
litres if the mix is too dry or do not have enough flowability.

THE SIAM REFRACTORY INDUSTRY CO., LTD. 1 SIAM CEMENT ROAD, BANGSUE, BANGKOK 10800 THAILAND
9. When the mixed castable become homogeneous, drain it from the mixer to the buckets.

10. Put the mixed castable into one side (left-hand side or right-hand side) of the prepared former.

11. Curing for 6-10 hours, the castable will be set as a result of hydraulic reaction.

12. After casting, it is highly recommended that the setting refractory material should be covered with
plastic sheet or damp sack to prevent surface moisture lost. The mould or former can be removed
after the first 12 hours to ensure completing reaction. However, castable curing by WATER
SPRAYING is PROBIBITED. The air setting should be continued for 24 hours. With the cover removed, the
refractory material may be air dried for another 24 hours.

FAX: +66 2 587-2149 or +66 2 586-2982 e-mail: sricexp@cementhai.co.th

Notes:

To avoid the false set of castable, the pan mixer must be clean all times when the mixer is left for
long period. In addition, the pan mixer must be clean when there are changes from one type of
material to the other types.

Water required for above mentioned Castables is approx. 10-12% by weight. If the ambient
temperature is high, water might be reached to 15% by weight, or Retarder must be added
additionally with appropriate amount to slow down the setting time.

Too much mixing water causes castable crack during curing time.

Installation Instruction for Lightweight Castables: CAST11LW, CAST13LW, and

CAST14LW

1. Prepare each approx. 1 square meter wooden former, with 5 mm. thick cardboard or plywood for
expansion joints deep at least 2/3 of castable thickness from hot surface to allow the castable
expand during preheating process. (in practical, lightweight castable for backup lining, it does
not need to provide the expansion joint)

2. Prepare the necessary equipment such as 10,000-15,000 vpm vibrators with 1-2 inches diameter,
buckets and a pan mixer.

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 Castables and Dry M ortars
3. Strictly recommend to use a 40-45 rpm pan mixer driven by 5-7 HP motor. The gap between mixer

M ix ing Instructions for

base and its paddle should be not over than 3 mm in order to prevent the material segregation.

4. Before mixing the first batch of castable, be sure that a pan mixer is clean.

5. Fill the castable around 60 kgs (3 bags of 20 kgs package) into the pan mixer.

Note: the quantity of castable for mixing in each batch is depending on the capacity of pan
mixer.

6. Strictly continue dry mixing process for 0.5-1.0 minute in order to homogenize the castable
material (and Retarder if needed).

7. Then, slowly pour clean drinkable water approx. 30.0 litres (50.0% of Castables weight) into the
castable in the mixer.

Note: the temperature of the water for mixing must not exceed 300C. The water should be
kept in the shaded area.

THE SIAM REFRACTORY INDUSTRY CO., LTD. 1 SIAM CEMENT ROAD, BANGSUE, BANGKOK 10800 THAILAND
8. Wet mixing for more 2-3 minutes and could adjust by pouring some more water approx. 1.0-4.0
litres if the mix is too dry or do not have enough flowability.

9. When the mixed castable become homogeneous, drain it from the mixer to the buckets.

10. Put the mixed castable into one side (left-hand side or right-hand side) of the prepared former.

11. Little vibrate with vibrator/ or Patch with Trowel of the mixed-castable. The good castable will flow
by itself to another side or able to adjust by Trowelling.

Note: Vibrator is not necessary for Lightweight Castables casting. If vibrator is used, do not
apply too long, because it will separate water from aggregate (segregation).

FAX: +66 2 587-2149 or +66 2 586-2982 e-mail: sricexp@cementhai.co.th

12. CAST11LW or Cast13LW or CAST14LW is an insulating castable for back up lining. Ramming or
hammering without vibrating can be applied.

13. Curing for 6-10 hours, the castable will be set as a result of hydraulic reaction.

14. After casting, it is highly recommended that the setting refractory material should be covered with
plastic sheet or damp sack to prevent surface moisture lost. The mould or former can be removed
after the first 12 hours to ensure completing reaction. However, castable curing by WATER
SPRAYING is PROBIBITED. The air setting should be continued for 24 hours. With the cover removed, the
refractory material may be air dried for another 24 hours.
Notes:

To avoid the false set of castable, the pan mixer must be clean all times when the mixer is left
for long period. In addition, the pan mixer must be clean when there are changes from one type
of material to the other types.

Water required for above mentioned Castables is approx. 50% by weight. If the ambient
temperature is high, water might be reached to 55% by weight, or Retarder must be added
additionally with appropriate amount to slow down the setting time.

Too much mixing water causes castable crack during curing time.

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 Castables and Dry M ortars
Installation Instructions for Dry Mortar: Mortar 30AM(D), 43AM(D), 70AM(D),

M ix ing Instructions for

and M80AM(D)

1. Before mixing first batch, ensure that the mortar buckets are clean.

2. Prepare 12.5 litres of clean, drinkable water in the bucket.

3. Fill one-third bag of mortar (one bag, 25 kgs) into the water in prepared bucket.

4. Agitate the mixed mortar until homogeneous.

5. Fill little by little the left mortar into the mix and continue agitating until finishing a bag of mortar.
At this stage, there are differences in instructions of Mortars between applied to Refractory
Bricks and to Insulation Bricks or Calcium Silicate Boards

Mortar 30AM(D), 43AM(D), 70AM(D): Air Setting Mortar for Refractory Bricks

THE SIAM REFRACTORY INDUSTRY CO., LTD. 1 SIAM CEMENT ROAD, BANGSUE, BANGKOK 10800 THAILAND
6. Reduce the viscosity by pouring some more water approx. 1.0-2.0 litres if the mix is too dry.

7. It is recommended to soak this mortar for 24 hours after mixed. Before using in the next day,
stir and add some more water if too dry.

8. Agitating mixed mortar is needed before use if it is left over from the previous day.

9. Too dry mortar is recommended to add some more water for liquidating without any quality dropped.

Mortar 43AM(D): Air Setting Mortar for Insulation Brick or Calcium Silicate Boards
Mortar M80AM(D): Air Setting Magnesia Mortar for Basic Bricks

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6. Fill 2.0-4.0 litres of Sodium Silicate (43 Be) Solution and agitate until homogeneous and
workability.

7. It is recommended to soak this mortar for 24 hours after mixed. Before using in the next day,
stir and add more sodium silicate solution or water if needed.

8. During the day, if the material becomes muff, the mortar can be adjusted by adding clean water into
it. Stirring before use.

9. Dry or muff mortar is recommended to add some more water for liquidating without any quality
dropped.

Notes:
Usually, please mix one bag of mortar for each batch in the mortar bucket.
Water required for Mortars is approx. 40-50% by weight. Mortar30AM(D), 43AM(D), 70AM(D) are
Dry Type- Air Setting Mortar. It is included Sodium Silicate Powder already. However, if not glued
enough, Sodium Silicate (43 Be) Solution is additionally required.

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