PT.

PUSPETINDO
GRESIK-INDONESIA
Job. No. : JE-010600

CASTABLE LINING
PROCEDURE

Sheet No. : 4 of 8
Doc. No. :
010600 ECL 01

2. REPAIREMENT PROCEDURE
2.1 PRE INSTALATION
2.1.1 Storage
The material should be stored in dry well ventilated area and held off the floor on pallets.
If stored outside the bags must be protected from rain or dripping water by a fixed cover.
If they are protected from rain by a plastic cover, ensure that there is sufficient ventilation
underneath the plastic sheet to prevent water condensing on the bags should there be a
sudden change ambient temperature.
Pallets should be stacked no more than three high to prevent consolidation and caking of
material on the bottom rows of the pallets.

2.1.2 Preparation Prior to Castable Placement

The work surface should be substantially free of dust, scale, oil, water, dirt and loose
foreign material. Cleaning by sandblasting may be necessary if the shell is badly
oxidized.

2.1.3 Formwork
Formwork may be constructed in either steel or wood of a design strong enough to resist
distortion when subject to hydrostatic pressures produced during casting. Distortion of
the formwork during costing is inadmissible. Generally construction in steel is favored
because of its inherent strength and non absorbent nature.
The surface of the formwork in contact with the castable must be lightly and thoroughly
oiled or greased to prevent water absorption during casting and to facilitate removal after
casting. The surface of formwork gives characteristic face of casting and therefore should
be as smooth as possible.
Formwork, when assembled must be water tight, so all joints and holes must be sealed.
The used of vibrators during casting will caused liquid s and fines to bleed through
cracks in the assembly. These liquids will be rich in cement and can thus leave a weakly
bonded material adjacent to leak and therefore cracks must be sealed on assembly in such
a way to prevent leakage under additional stress of vibration.

2.1.4 Anchors
Anchors specified for the installation should be installed prior to placing formwork. If
metallic anchors are specified they should be inspected prior to installation to
ensure that they meet specification and welding involved in anchor
construction is sound and free from cracks. Anchor position should be clearly
marked to give the specified anchor pattern and the anchors oriented before
welding so as to avoid the production of shear planes within the finished
refractory.
Prior to welding, the marked position should be lightly ground to remove surface
oxidation and thereby ensure a sound weld.

PT. PUSPETINDO
GRESIK-INDONESIA
Job. No. : JE-010600

CASTABLE LINING
PROCEDURE

Sheet No. : 5 of 8
Doc. No. :
010600 ECL 01

After welding the anchors should be hammer tested to guarantee a sound weld and any
defective welding repaired.
After welding the anchor should be coated with tape or bituminous paint to give 2 mm
burn off surface coating which will accommodate the expansion differences between the
anchor and the castable.

2.2 INSTALATION
2.2.1 Water
The water used for mixing shall be clean and of drinkable quality. Since the amount if
water added to the castable does more to affect the properties than any other factor it
must be accurately measured.
As the exact water requirement of the castable is dependent on a number of factors which
are site specific such as design of mixer, size of the mixer ambient temperature,
humidity, age of the refractory etc., its necessary to evaluate the water requirement for a
particular site with the first mix.
Kast O Lite 23 LI, in a tropical environment, normally requires water within the range 15
% W so as a start point the first cast should be mixed with 15 % water (7 litres / 25 kgs
castable), and so Greencast 94 requires 2.35 liters water / 25 kgs bag.
The water should be carefully measured out using a measuring cylinder and one the
correct water is established a container should be calibrated to give exactly this amount of
water.
(See the Instruction for Mixing and Using for both products for more detail).

2.2.2 Temperature
The water requirement of the mix is dependent on the temperatures of the mix and
therefore every effort must made to keep the mix as cool as possible. Bags of material
must be kept in shaded area with adequate ventilation and the kiln shell and mixer cooled
with water spray before installation. Some temperatures rise in the mixer will occur due
to frictional effect and this must be observed and if necessary the mixer sprayed with
water between casts. If the temperatures rises through the day and working time of the
mix decreases or water requirement rises throughout the duration of the installation then
it may necessary to add ice to additive water to regulate the temperature.

2.2.3 Mixing
The objective of mixing is to combine the dry materials with a minimum amount of water
into homogenous mass. Mixing shall be done in high intensity paddle mixer.
Hand mixing or barrel mixing is not suitable for this material and must not be
used. The amount in the mixer must not exceed the height of the centre shaft.
Paddle must be adjusted to be as close to the mixer shell as possible without
fouling to ensure efficient mixing and minimum carry over between mixes.

PT. PUSPETINDO
GRESIK-INDONESIA
Job. No. : JE-010600

CASTABLE LINING
PROCEDURE

Sheet No. : 6 of 8
Doc. No. :
010600 ECL 01

2.2.4 The MIXER AND TOOLS used in casting must be clean

Some materials found in dirty mixers can cause flash setting or otherwise reduce strength
of the material so all tools and mixer parts must be thoroughly cleaned before used. The
mixer should be cleaned down between mixes and material from the cleaning discarded.
On the commencement of mixing discharge at lease two bucket full through the
discharge gate and discard. This action cleans the discharge gate. Attention to this area is
required between mixes as this is an area where materials builds up and hardens.
Do not mix more material than can be cast within 10 mins.
Commencement of mixing should involve placing the materials ( usually four bags )
into the mixer and then adding 3 / 4 of the total water requirement and mixing four
minutes.
The remainder of water should them be added until good casting mix is derived ( which
will probably not occur until all measured water is added ). If the mix is sampled as a
4 diam sample ball and consolidated in the hand. There should be no surface cracks in
the ball and the surface should be moist and shiny.
If the material flows between the fingers then too much water has been added and the mix
should be discarded. If the mix is too dry after all the water has been added and mixing
has been done at least for 5 mins then small amount of water ( measured amount ) should
be added incrementally until the casting characteristic are correct. The water requirement
should be then be corrected and all other mixes carried out with this water content.
A check on water content versus castability should be carried out as casting progresses
and the water content modified as required. It is good practice to record these changes. It
is also a good practice to record the number of bags installed for a given volume as this
can be used to record cast density which is good indication of ultimate strength.

2.2.5 Joints
There are two type of joints used in casting
1. Construction Joints : are used to anticipate any potential cracking in the
complete structure and thereby divide the construction into section which can
move independently. They also used to provide a useful stopping points in the
progression of installation where additional formwork needs to be constructed.
Commonly a medium such as P.E. sheet is used for joint construction.
2. Expansion Joints : are to accommodate the reversible thermal expansion which
will take place in refractory during use. The size and positioning depends entirely
on the refractory design.

2.2.6 Curing
The purpose of curing is to prevent the lost of moisture form freshly coat concrete during
the chemical change associated with the hydration of the Calcium Aluminate binder.
Although KS4V and Kast O Lite 30 procedures are initially set with 5-7 hrs of casting,
its full strength is not developed until 24 hours after casting and during this time it must
not be allowed to dry out, as otherwise the chemical reaction involved in its strength
development stops and full strength is not realized.

PT. PUSPETINDO
GRESIK-INDONESIA
Job. No. : JE-010600

CASTABLE LINING
PROCEDURE

Sheet No. : 7 of 8
Doc. No. :
010600 ECL 01

Form work should be left in a place for 24 hrs and all open cast surfaces should be
maintained in a damp condition by covering with hessian sacks.
After 24 hrs the form work can be stripped and the casting allowed to air dry for a further
24 hrs. It is best to arrange for good air circulation during this time.

2.2.7 Commissioning
The heating up (commissioning) of the finished casting should follow the attached
heating schedule as closely as possible. The schedule is designed to prevent the
possibility of steam generation and consequent bursting stresses and therefore if any
deviation from the schedule is necessary then slower is the only acceptable deviation.

3. SITE INSPECTION TEST

3.1 ANCHOR TEST
Prior to application of castable material, all anchors shall be hammer tested to ensure
sound welding. A light hammer shall be used to tap each anchor end sharply without
bending it. Each anchor having a dull, flat sound shall be replaced.

4. PRODUCTION QUALIFICATION
4.1 Water Test
For Al SiO2 Monolithic refractory water condition must be pH = 6.5 to 7, at 15 0 C to
250 C. to avoid any contamination.
Water contain for GREENCAST-94 is 2.35 liters / 25 kgs bag
Water contain for KAST-O-LITE 23 LI is 7 liters / 25 kgs bag
Above information should be reported every shift.
4.2 Production Sample.
For each shift production of lining installation one set of sample shall be taken
approximately two hours after the start of the shift.
One set consist of a 50 x 50 x 50 mm (2 x 2 x 2 in) cubes casted in water-proof mold, for
Bulk Density test. Typically this test will represent material strength and homogeneity of
lining.

PT. PUSPETINDO
GRESIK-INDONESIA

CASTABLE LINING

Sheet No. : 8 of 8

Job. No. : JE-010600

PROCEDURE

Doc. No. :
010600 ECL 01

4.2 Thickness Test

During installation, the lining thickness shall be verified as a specified lining thickness
requirement from the Vendor. The tolerance on installed lining thickness shall not exceed
+ 13 mm (+0.5 in) or 6mm (- 0.25 in) of the specified lining thickness.
Measurement shall be taken after casted 1 section and before move to next section.
4.4 Sound Test
Following initial 24 hours curing but before heat drying, the castable lining shall be
tested by striking with a 0.5 kg (1 lb) hammer at about 300 mm (12 in) intervals over the
entire surface. Any void or dry-filled space will emit a dull sound.
All test shall be performed in strict accordance with the requirement specified in the
applicable ASTM procedure.

PT. PUSPETINDO
GRESIK-INDONESIA

CASTABLE LINING

Sheet No. : 3 of 8

Job. No. : JE-010600

PROCEDURE

Doc. No. :
010600 ECL 01

1. CASTABLE LINING ARRANGEMENT.

1.1 General Arrangement for Wall Lining.
Dual Layers,
1st layer ( hot face ) 76.2 mm thick Greencast 94 ( casting grade ).
2nd layer ( back-up ) 114.3 mm thick Kast O Lite 23 LI / VSL 50 ( able for
Casted or Gunned ).
Metal Y anckor SS-310 type, (1/8t x 5/8w x 7 1/2l ) inch at 254 mm centers.
1.2 Tubesheet ( Heat Exchanger ) wall lining.
Single layer 76.2 mm thick Greencast 94 ( casting grade ).
Metal V anchor SS-310 type, ( 1/8t x 5/8w x 2 1/2l ) inch.
Metal Ferrule SS-310 w/ Asbestos tape.
1.3 Main Door,
1st layer ( Hot face ) 76.2 mm thick Greencast 94 ( casting grade ).
2nd layer ( Back-up ) 267 mm thick Kast O Lite 23 LI ( Casted or Gunned ).
Metal Y anchor SS-310 type, ( 1/8t x 5/8w x 16l ) inch as shown in drawing.
Note :
Attach Ceramic Fiber Paper around the Main Door prior to installed the castables,
then casted the Main Door into 2 ( two ) sections.