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    Application Procedure - Castocrete Super

    Uploaded by

    RAJKUMAR
    This document provides instructions for installing Castowel Industries' Castocrete Super refractory material. Key steps include: [1] Storing refractory materials covered and off the ground; [2] Using a paddle mixer and vibrator for installation; [3] Thoroughly cleaning and drying surfaces before application; [4] Mixing castable with 12-15% water by weight and vibrating for compaction within 30 minutes of mixing.

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    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd

    Application Procedure - Castocrete Super

    Uploaded by

    RAJKUMAR
    202 views3 pages
    This document provides instructions for installing Castowel Industries' Castocrete Super refractory material. Key steps include: [1] Storing refractory materials covered and off the ground; [2] Using a paddle mixer and vibrator for installation; [3] Thoroughly cleaning and drying surfaces before application; [4] Mixing castable with 12-15% water by weight and vibrating for compaction within 30 minutes of mixing.

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    Application procedure_Castocrete Super

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    This document provides instructions for installing Castowel Industries' Castocrete Super refractory material. Key steps include: [1] Storing refractory materials covered and off the ground; [2] Using a paddle mixer and vibrator for installation; [3] Thoroughly cleaning and drying surfaces before application; [4] Mixing castable with 12-15% water by weight and vibrating for compaction within 30 minutes of mixing.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    202 views3 pages

    Application Procedure - Castocrete Super

    Uploaded by

    RAJKUMAR
    This document provides instructions for installing Castowel Industries' Castocrete Super refractory material. Key steps include: [1] Storing refractory materials covered and off the ground; [2] Using a paddle mixer and vibrator for installation; [3] Thoroughly cleaning and drying surfaces before application; [4] Mixing castable with 12-15% water by weight and vibrating for compaction within 30 minutes of mixing.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    of 3

    CASTWEL INDUSTRIES

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


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

    APPLICATION PROCEDURE FOR CASTOCRETE SUPER

    A) Storage of refractory materials :

    All the refractory material should be stored under the 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 type castable mixer of 100 to 150 kg capacity, needle vibrator
    (25 to 40 mm dia) depending upon lining thickness. Measuring cylinder of 1000 ml
    capacity for measurement of water. Shovel / spades, 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) Installation :

    a) Water : Clean drinking water shall be used for mixing of castable. Water
    temperature should be 18 – 200C. 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 CASTOCRETE SUPER is 12 – 15 % by wt. of dry
    powder for vibrocasting)

    b) Shuttering : For required places (e.g. roof areas), 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. If the application is to be done
    by toweling / rodding, shuttering is not required.
    CASTWEL INDUSTRIES
    C-18/6, M.I.D.C. AREA, NAGPUR - 440 028
    PH. No.:- 07104 – 234128, 646241 to 53
    c) Castable Mixing & placement : Should be done as close to site as possible.
    Add the 100 to 150 kg material in mixer pot and dry mix the castable for about 1
    minute. Add correct quantity of water & allow it to mix the for 5 to 7 minutes
    minimum. The consistency of mixture shall be checked by means of Ball in hand
    test.
    The batch should be placed within 30 minutes of mixing. It should be vibrated for
    1 to 2 minutes to take the entrapped air & for better compaction. The cycle should
    be repeated to achieve the required thickness. The shuttering should be tightly
    fitted / fixed so that they can withstand the vibrations of the needle.

    d) Deshuttering : Should be done after material is properly set, say after 10 to 12


    hrs. for vertical surface & 24 hrs for overhead position.

    e) Wet Curing : Wet hessian / jute bags to be placed over the refractory applied
    area after the 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.

    E) Precautions to be taken while casting:


    1. Wooden formwork should be thoroughly wetted.
    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. Expansion joints may be provided for sections larger than 1 meter X 1
    meter. This may be done by inserting a 2 mm thick cardboard strip between
    each such section. Ceramic fiber may also be used.
    5. Where reinforcement or anchors are used they should first be coated with
    pitch, tar, paper or any burn-out material to about 1-2 mm thickness to allow
    space for steel expansion.
    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. When the castable is placed by hand tamping spading or rodding, a plastic
    but not too “sloppy” a mix is desirable.
    8. Contamination with Portland cement should be avoided at all costs.

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