CASTWEL INDUSTRIES

C-18/6, M.I.D.C. AREA, NAGPUR - 440 028

PH. No.:- 07104 – 234128, 646241 to 53

APPLICATION PROCEDURE FOR INSULCAST 1500

A) Storage of refractory materials :

All the refractory material should be stored under covered shed above
ground level to avoid contact with water.
Shelf life or Expiry date of castable is to be verified.

B) Machinery & Equipments required :

Mechanical paddle/pan mixer of 100 to 200 kg capacity, mold release agent,

measuring cylinder of 1000 ml capacity for measurement of water.
Shovel/spades, wooden rods, saucer container to carry the material etc.

C) Surface Preparation :

Surface to be refractory lined shall be thoroughly cleaned with wire brush.

No water shall be used for cleaning. Surface should be free from rust, oil, or
any greasy material.

D) Anchor welding :
Soundness of welding of anchors shall be checked for type, grade, spacing
(pitch) as per drawing.
Soundness of the welding of anchors shall be checked with the help of light
hammer by ringing sound & by bending 45 degree both ways. Defective
anchors shall be rewelded /replaced.
All anchors shall be provided with plastic caps / burnout coating at tip.

E) Installation :
a) Water : Clean drinking water shall be used for mixing of castable. Water
temperature should be 180C ± 20C. If required ice may be used for cooling of
water, but direct addition to water shall be avoided. Water should have
chloride content less than 200 ppm and pH around 6 – 8. Quantity of water
shall be as per Material Test Certificate or manufacturers guidelines.
(Recommended water addition for Insulcast 1500 is 22–28 % by wt. of dry powder.)
However at site water requirement may vary slightly depending on site
conditions.
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 CASTWEL INDUSTRIES
C-18/6, M.I.D.C. AREA, NAGPUR - 440 028
PH. No.:- 07104 – 234128, 646241 to 53
b) Shuttering : Suitable plywood shuttering should be placed which are
watertight, working face to be coated with oil / grease for quick release. In
case of porus working surface, cover with poly line sheet or paint to prevent
the absorption water from the mix.

c) Castable Mixing & placement : Mixing should be done as close to sites

as possible . Mixer shall be thoroughly cleaned before use. Add 100-150 kg
material . Dry mix the material for 1 minute. Add specified quantity of water
& allow it to mix for 2 to 3 minutes . The consistency of mixture shall be
checked by means of Ball in hand test. Temperature of mix refractory
should be between 25–300C. The batch should be placed within 30 minutes
of mixing.
Meanwhile thoroughly wet all wooden formwork where the castables are to
be placed. A light coating of oil or grease may also be given on all
formwork. Place the castable by rodding . Rodding is to be done properly
to avoid pockets etc.If the placement is done by needle vibrator it should be
vibrated only for achieving proper placement and not for compaction. After
placement, cover all exposed surfaces with hessian and keep it wet.
Periodically keep wetting the hessian. Care should be taken to see that it
does not dry. After allowing the castables to set, it should be wet cured.

d) Deshuttering : Should be done after material is properly set . Strip non

load bearing formwork after 12 hrs. of placement, and all other formwork
may be removed after 24 hrs.

e) Wet Curing : Keep the castable wet and cool by covering with wet
hessian / jute bags. to be placed over the refractory applied area after
removal of shuttering for next 24 hrs.
After wet curing , wet gunny bags shall be removed and allow the castable to
air dry for minimum 24 Hrs.

f) Heating (Hot Drying) : After air drying castable applied should be heated
for moisture removal and strengthening as per dryout schedule.

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 CASTWEL INDUSTRIES
C-18/6, M.I.D.C. AREA, NAGPUR - 440 028
PH. No.:- 07104 – 234128, 646241 to 53
F) Precautions to be taken while casting:
1. Wooden formwork should be thoroughly coated with grease or oil.
2. Water used should be clean and potable. On no account should sea
water or similar water be used for gauging curing, etc.
3. All tools, mixers and receptacles should be free from soluble salts,
Portland cement, plaster, etc.
4. Construction joints may be provided at every 600 mm height and
every 1000 mm length.. This may be done by casting alternate panels
with step joint. These construction joints serve as expansion joints.
5. Where reinforcement or anchors are used they should first be coated
with pitch, tar, paper or any burn-out material to allow space for steel
expansion. Anchor tips should be provided with plastic caps.
6. Even when less than one bag of material is used, all material should
be tipped out and remixed before necessary quantity is taken.
7. Contamination with Portland cement should be avoided at all costs.
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