Revamp Job

I.P.C.L-
Vadodara
GUJARAT,
INDIA

LINING INSTALLTION INSTRUCTIONS

FOR
CRACKING UNIT-
RADIANT SECTION,

TRANSITION ZONE,
COLLECTOR, DUCT AND
STACK,
CONTENTS
1. SCOPE

2. REFERENCE DOCUMENTS

3. TYPE OF LINING

4. LINING INSTALLATION SEQUENCE

5. LINING INSTALLATIN DETAIL

6. QA-PLAN FOR SITE INSTALLATION ACTIVITY

1.

SCOPE:

This document covers the installation sequence and modalities for

Installation of Refractory Lining materials viz. CFB Modules, Pyro
module, Ceramic Fiber blankets, Castables, and Bricks, etc. for
cracking furnace radiant section, Transition zone, collector, shadow
boxes, ducts & stack. The document also describes the storage
requirements of the materials & Quality Control requirements during
installation.

2. REFERENCE DOCUMENTS:

Lining arrangement and relevant details are shown in the drawings

made for the subject job. The List of Drawing & documents is attached
along with this document as an Annexure- A1.

3. TYPE OF LINING:

The various parts of furnace shall be lined as indicated in the relevant

detailed drawings. And listed in Annexure- A2 (Tabulate Detail of
Lining Description).

4. LINING INSTALLATION – SEQUENCE:

The sequence of installation of refractory for various parts of the

subject unit is shown as bellow.
4.0 LINING INSTALLATION - SEQUENCE:

• Radiant lower walls brick lining

• Wall burner blocks installation
• Upper walls Module lining
• Radiant Arch module lining
• Transition Zone wall module lining
• Transition floor lining with bottom bull nose lining
• Radiant floor lining
• Castable lining of Collector, Duct & Stack are to be lined at ground
• Trough CFB lining is to be done at ground and its erection will be done
at last.
• Shadow boxes ceramic fiber blanket lining

5.0 LINING INSTALLATION - DETAILS:

While executing refractory linings extreme care shall be taken to install

the right materials in the proper way and manner for attaining the best
properties and life of linings. The installation and its requirements may
be broadly classified as,

5.1 Anchor Layout and Welding.

5.2 Surface Preparation.
5.3 Lining Installation.
5.4 Equipments, Tools and Tackles for Installation.
5.5 Drying out.

5.1 Anchor Layout and Welding

Anchor layout is the first process in refractory lining installation

and is very critical in some areas like Ceramic fiber Module
installation where the dimensional tolerances for anchors are kept
to the minimum. Anchor pitch and layout are given in the relevant
 drawings. The drawings are laid out and orientation of the plates
is checked to establish the correctness of the grid lines. Initially
the out line and cut outs like openings for the doors, peepholes,
burner blocks etc are marked out. Then lines parallel to both
length and width of the panel as per anchor spacing are marked
and intersecting points are punched to give the anchor positions.
Locations of any special anchors around openings or objects are
also marked out as per drawing thus completing the anchor lay
out.

Prior to welding of anchors, initially spot grinding of the area

around the anchor position is carried out to ensure that the anchor
has welded on clean (steel) surface. Welding is done under
carefully controlled conditions and care taken to ensure
undercutting of anchors does not happen. Care should also be
taken to prevent threads of studs being damaged by any welding
flux. Also prior to welding the type of anchor and location should
be verified to prevent welding of incorrect anchors.
5.2 Surface Preparation

Surface preparation shall be as per CIRIA standards wherever it is

applicable / as per drawings. At other areas the surface to be
refractory lined shall be cleaned of heavy rust or mill scale, dust,
loose particles oil etc., by wire brushing.

5.3 Lining Installation.

The lining installation for this furnace basically consists of the

following lining combinations, which has to be meticulously
followed in addition to the specific requirements of each locations
described along with.
5.3.1 Corrosion resistance coating
5.3.2 Ceramic fiber Modules (Z Blok-3, Pyrofold M, Pyro M module
&Pyro T Bar Module) with CF Blanket as back up. (for typical
detail of Modules refer drawing No.VD-8668.)
5.3.3 Ceramic Fiber Blanket Lining.
5.3.4 Brick with back up Block Lining.
5.3.5 Castable with backup block lining.
5.3.6 Castable Lining.

5.3.1 Corrosion resistance coating

Corrosion resistance paint (Shalikote) to be applied wherever the shell

plate is in contact with ceramic Fibre blanket. 3mm layer is be built up
uniformly on the shell plate either by hand or by a soft brush and allowed
 to dry. Precautions should be taken to avoid damage to the coating in the
form of mechanical damage, rain etc.

5.3.2 Ceramic Fiber blanket as back up for CF modules

A) Locations Used : Radiant Upper Walls, Radiant Arch and
Transition zone Arch & side walls.

B) Procedure

The lining of both the Radiant and Transition zone arch are to be
carried out after erection of the same and in position. Walls lining
are to be lined after erection of burner block as insitu.
As described above, the stud welding has to be completed as per
the layout shown in the drawing and painting as per CIRIA
Specification furnished, prior to commencing the lining installation.
Stud welding and painting can be done in at ground or insitu.

Back up blanket lining is a simple installation; however care

should be taken to ensure that tight compression joints are
obtained between adjacent blanket butt joints. Blanket lining
can be held in place using rubber bands.
The lining is to be done as followings:-

Lining has to commence from the Side wall. One layer of

blanket is impaled on the studs starting from a bottom end
corner with the blanket length vertical. While installing the
adjacent blanket, care to be taken to ensure that joints are
tight. Typical compression joint detail has given bellow in the
sketch. Back up blanket is laid completely including one
blanket on the end wall from where module lining is to start.
Similarly prior to lining of each wall, the back-up blanket
lining has to be completed.

Once the back-up lining is completed Module lining can commence.

 Note:
The anchor for vacuum formed peephole block should be
welded simultaneously along with the installation of vacuum
formed peephole block in the trough.

The detail of module installation has given in

the Installation Manual.
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5.4

5.5
 5.6

5.6.1
5.6.2
5.6.3

5.6.4
5.3.3

Ceramic Fibre Module Lining Systems

CONTENTS

Introduction
Ceramic fiber products are extensively used in the lining of
furnaces. And products are used basically due to its light weight,
low thermal conductivities and thermal shock resistance etc.
A General

• Design Considerations

• Design Check List

 • Surface Preparation

• Installation Sequence

B Installation

• Equipment Check List

• Installation Procedure of Z-Blok 3 modules:
Step 1 - Marking out the anchor pattern
Step 2 - Grinding anchor positions
Step 3 - Anchor welding
Step 4 - Application of coating / painting
Step 5 - Starting a row of modules
Step 6 - Installation of a module
Step 7 - Completion of the module installation
Step 8 - Packer details
Step 9 - The module installation is built up in rows
Step 10 - The plastic bands are removed
Step 11 - Finishing process
Step 12 - Completion of module lining installation

• Installation Procedure of Pyrofold M modules:

• Installation Procedure of Pyro M & Pyro T- Bar corner
modules.
Detail of procedure is attached at last

A GENERAL

Design Considerations

Z-Blok 3 Modules are designed to be installed in a soldier course

fashion with packing strips between each row of modules. Figure 1
shows the layout of a typical Z-Blok 3 Module installation. When
using the soldier course system in overhead applications packing
retaining staples (U-Pins) may be used.
 Figure 1 - Typical Z-Blok 3 Module Lining and Anchor Layout

Prior to installing the Z-Block 3 Modules, it is necessary to lay out

the anchor pattern and weld the anchors in place. At this point
coating / painting & blanket backup can be applied. While installing
the back-up blanket the butt joints should be tight compression
joints as shown in drawing.
Once the anchors and backup materials are in place, the Z-Block 3
Modules can be installed.
The Z-Block 3 Module is easy to cut or trim to allow for obstructions
such as burners or inspection doors. Best results will be achieved if
the module is trimmed, so that the anchor tubes will remain in line
with the pre-determined anchor pattern. It is best to cut less than
necessary and compress the module into place to ensure the
tightest possible joint.
Design Check List
 When planning to carry out a modular lining a simple checklist of
items required to ensure a trouble free installation.

• Required Ceramic Fiber Modules as per drawing.

• Check: Temperature grade, Density & thickness of the
modules, to ensure that the correct modules are being installed.
• Ceramic Fibre blanket packing is 128Kg/M3 X 25mm thick, of the
same temperature grade as the module, cut into strips with L
shaped edges as described in this document.
• Anchor sets of the correct length depending on backing lining.
Note one anchor set extra is required per row of modules.
• T Bar yokes. Note one T-Bar yoke extra is required per row of
modules.
• Packing retaining staples, necessary for overhead applications.
Suggested centers are one staple at 600mm to 900mm centers
depending on lining thickness and application.
• For casing coatings, check the thickness of coating required and
quantities of material. The coating shall be as per CIRIA painting
standards.
Surface Preparation (The steel surface to be lined should be free
of heavy rust or scale, non-conductive paints, dried refractory
cements or oil. Wire Brushing will be required to clean the surface.
Local cleaning is recommended at each anchor location prior to
welding. Set up good scaffolding so there will be easy access to the
areas to be lined. Also, make arrangements for the material to be
as close to the work area as possible without being in the way, so it
can be efficiently delivered to the working crews.
Installation Sequence
A furnace with four fixed walls and a roof should be lined in
sequence to ensure an open face during the installation.

Ceramic fiber Module lining of side walls shall be done first after
that end walls lining. Top most one or two row of walls ceramic fiber
Modules shall be installed after completing the arch lining and then
the left out one or two row of walls lining shall be completed.

Figure 2 - Installation Sequence for a Four Fixed Wall Application.

B INSTALLATION
 Equipment Check List

The following list details the basic equipment required to carry out
a typical Z-Blok 3 Module installation.

• Welding equipment suitable for welding of studs

• Hand Tools.
• Measuring Tape
• Chalk line
• Angle Grinder
• Long sharp knife suitable for cutting Ceramic Fiber.
• A means of cutting SS tubes in the modules and T Bar arms.
• Slip plates (approx 1mm) sheet steel or plastic (lining
thickness x 600mm) to allow modules to slide into position
during installation.
• 10mm socket and extension bar suitable to access the
locking nut, through the thickness of the lining.
• Tools to adjust welder; screwdriver, pliers, hexagonal keys
etc.
• Tamping tool to finish the surface. This can be formed in
wood or expanded metal (300x 250mm).

Installation Procedure of Z-Blok 3 Modules

The Z-Blok 3 Modules are installed in a soldier course layout
with a packing strip between rows. (Figure 1). The Z-Blok 3
Module requires a pre-determined anchor pattern so the first
step is to establish the layout.
Step 1
Measure the correct distance vertically and horizontally and
mark with a chalk line. Typically, the soldier course anchor
spacing is 290mm horizontally and 430mm vertically, as
shown in the drawing.

Step 2
At the points where the chalk lines cross it is good practice to spot
grind an area approximately 10mm diameter to ensure that the weld
is made onto clean steel. This is especially important on old steel
casings.
 Step 3
At the points where the chalk lines cross, weld a T Bar anchor
onto the steel casing

Step 4
If coating / painting is being used it is a good idea to protect
the threads of the anchors by installing plastic covers over the
anchors. If a coating is not being used, plastic covers for the
anchors are not needed. At this point, back-up layers of
 blanket and Aluminium or Stainless Steel foil vapour barriers
should be installed if being incorporated into the lining of the
furnace.

Step 5
When the necessary backing coatings and or linings have been
installed the Z-Blok 3 Modules can be installed. The modules
are installed in rows therefore at the start of a row remove the
arms from one side of a T Bar yoke. Locate the T Bar yoke onto
the anchor, which has been welded to the wall previously, fixing
it into position with a locking nut.
Step 6
The tubes in the module are then located onto the arms of the
T Bar yoke, another T Bar yoke is located into the tubes in the
opposite end of the module. The module is then compressed
into position.
 Step 7
The sequence is completed by fitting the T Bar yoke onto the
anchor and securing with the locking nut.

Step 8
 The procedure mentioned above is repeated until the row is
completed. Before commencing the installation of another row
of modules a packing strip of Ceramic Fibre blanket should be
installed (folded & compressed as per lining arrangement &
detail drawing). This blanket packer should be jointed using a
staggered joint and not exceed 2 metres in length.

Step 9
When the packing strip is in place the next row of modules can
be installed. The anchor positions will ensure that the modules
are compressed during installation. The use of thin steel or
plastic plates allows the modules to be slid into position
making the task of obtaining the necessary compression
easier.

Step 10

The lining is carried out as described above till the end of the row is
reached. For the last but one module a half split yoke is used to complete
the Z-Blok 3 lining with one module space at the end left vacant. Because
of this the split yoke can be easily fixed. For the last module a center
fixing module Pyrofold M Module is used which can be easily installed
and fixed to the prewelded shell as described below under stop end
fixing.
Step 11

When the installation is complete, remove the plastic retaining

bands from the module. This is carried out with the aid of a
sharp knife.
 Step 12
The procedure mentioned in steps 5 to 10 are repeated until the area to be lined is completed.  The 
final task is to tamp the face of the lining to tighten all the joints, close any small superficial openings 
on the face of the lining and to improve the overall appearance. The tamping shall be done using a 
wooden Board or plywood kept on the surface to be tamped and then a wooden mallet shall be used 
for tamping. Limited force only can be applied while using a wooden mallet and since the applied 
force is distributed, extent of force may be described as force generated by a normal human being 
using a wooden mallet. Excess force will only cause the mallet to break.

• Installation Procedure of Pyrofold M modules:

The general lining installation procedure of PyroFold M-module

is as follows:
(i) Remove the thread cover from the stud.
(ii) Lift the module and push the module against the backup
blanket.
(iii) Insert a hexagonal nut into the end of the nut driver and
thread the nut by hand on to the stud and tighten.
(iv) Remove the nut driver and the collapsible access tube
from the module.
(v) Pinch the fiber together to eliminate the hole.
(vi) Repeat the process until all the adjacent modules have
been installed.
 (vii) Install batten strips.
(viii) When all the modules have been installed, the lining
should be tamped out to further tighten all the joints and
close any gaps that may exist.

• Pyro-Bloc M & Pyro T Bar corner module

See Pyro-Bloc M module Design and installation
Manual as attached

5.3.4 Ceramic Fiber Blanket Lining.

A) Location : Arch cover plate

B) Procedure : Inner surface lined with Ceramic Fiber

shall have Acid Proof Coating.
The arch cover is to be lined in several pieces with
compression joints between the ceramic fiber linings. For
blanket lining, the cold face blanket is cut with excess width
so that it can be wrapped over the hot face layer as shown in
drawing. The intermediate layers are cut to the exact
required width so that the wrap over of the cold face layer
would be protruding out and will form a tight compression
joint when fixed to the next piece already lined. Also when
lining the backup blanket layers, compression joints of 10mm
has to be achieved as detailed in the drawing. Care should
be taken to ensure that the blankets are tight around the
tube sleeves if any.

5.3.5 BRICK LINING

A) Location: BRICK & BLOCK: Lower Radiant Section

B) Procedure:

Lower Radiant Section is lined with a combination of 2

layers of insulating blocks and one layer of hot face
insulating bricks anchored to the casing.
 The blocks are then laid out starting from one corner.
Blocks are supplied in standard size of 1000 x 600mm.
The first layer of blocks are cut and laid out in between
the anchor plates for b/w. Bricks hooks are inserted
through the Cleat slots and kept in position. The gaps
between adjacent boards if any and at brick hook
locations are filled with block mix (block powder mixed
with water to paste consistency). When the second layers
of blocks are installed necessary cuts are done on the
blocks to allow for the brick hook anchors. The gaps so
formed are again filled with the block mix. While laying
the second layer of blocks, care should be taken to ensure
that the joints of second layer are staggered by a
minimum of 50mm from the joints of the first layer. At the
top, the blocks are cut tight against the bottom of the
shelf plates.
 To commence the brickwork, first the corner bricks are
laid with expansion joint blanket strip between them.
Then the bricks are laid along end wall and sidewalls as
shown in drawing using blakite mortar mixed to proper
consistency. Mortar joints are between 1.5 to 2mm in
thickness (horizontal nominal joint thickness of 1.8mm
and nominal vertical joint thickness of 1.4mm). Layer as
shown in drawing is followed for each course. In the
fourth course on each brick, after marking the anchor
location insitu, a small hole of 6mm dia and 35mm deep is
drilled and then a saw cut 6mm deep x 6mm wide is made
to enable the anchor snug fit with the bricks it is holding.
Same procedure is continued to complete the brick work
as in drawing. The anchors are located on various courses
as shown in drawing. At the top of brickwork and below
the shelf plate a folded blanket is introduced to enable the
vertical expansion of brickwork as indicated in drawing.

While installing expansion joint bricks great care should

be taken to ensure that the central joint between the two
expansion joint bricks are dry laid and not with mortar to
assist movement between them.

During brick lining in lower radiant wall, the shelf plate

bricks and expansion joint bricks have to be cut / shaped
at site as shown in drawings.

General points to be followed for brick work-

• Each brick should be checked, prior to installation, for

defects, cracks etc.

• The mortar for bricks is supplied in drums on ready to

use wet blend form and would harden when it comes in
contact with air. So drums should be opened only
when its necessary and required quantity taken out,
mixed and supplied to the mason.
 • The layout should be first marked out and expansion
joint positions fixed.

• The brick lining should be in plumb and in straight line.

• The anchor positions should be properly marked and

holes drilled in it. Anchors should not be inserted into
the brick by hammering it in. It would create cracks in
the bricks.

• Mortar should be evenly applied over the bricks face.

Trowelling excess mortar on the edges should be
avoided.

5.3.5 CASTABLE WITH BACKUP BLOCKS:

A) Location i) Radiant Floor

ii) Transition Floor
iii) Bull Nose

B) Procedure:

As in brickwork, for Castable also blocks are lined

initially, with care taken to ensure that adjacent joints are
offset by at least 50mm. In case of walls, the blocks are
first placed in location and pressed slightly against the
studs for making the impressions of the studs on to the
blocks. Holes are then drilled into the blocks at these
points. After lining the blocks the gaps are filled tightly
with block mix and V anchors are installed along with the
washer to hold the boards in position. Once the back up
lining is completed, formworks are fixed on alternate
panels and Castable lining carried out by pouring the
mixed Castable into forms. Formwork is removed after 24
hours and curing carried out Panel sizes are determined
based on the shuttering dimensions and expansion joint
locations in the drawing. At expansion joints, blanket
strips wrapped in polythene sheets are placed prior to
 casting. The general construction considerations detailed
below has to be adhered to strictly.

5.3.6 Castable Lining:

A) Location : Collector, Duct and Stack

B) Procedure :

Castable Lining procedure is similar to as explained

above. Initially the casing plate is cleaned and side
formworks fixed for Castable lining. Mixed Castable is then
poured, ramming and then discard the access material from
the top of the side forms to attain the casing contour. After
lining and once the Castable start setting, the surface is
covered with wet gunny bags for proper curing or cover it
with polythene sheet properly for self curing.

In horizontal position, the castable lining shall be carried in

alternate / staggered panels (each panel / segment should
not be more than 0.9sq.m area but not larger than 1.44sq.m.
Segments shall be made of plywood templates along with the
wooden strips, which are useful for construction joints. And
templates for curved surfaces shall match the contour of the
surface.
 Note : The collector’s duct and the stack are to be lined at
ground.

The stack is lined in three parts, circumferentially, by

rotating the stack segments. Initially the stack pieces are
kept horizontally on supports and side forms fixed. Then the
bottom 1/3rd, i.e. from 4 'O' Clock to 8 'O Clock position is line
by pouring and ramming. Once the entire segment has been
lined at this position, the stack segment is rotated to bring
the upper 1/3rd to ground level (i.e. 12 'O Clock to 4 'O Clock
position is now in 4 O' Clock to 8 'O Clock position after
rotating). Same process as above is carried out to complete
the lining activity of the subject segment. The stack is made
available for lining in two segments.

SPECIAL CARE TO BE TAKEN ON:

(i & ii) Radiant Floor and Transition Floor:

Radiant Floor refractory lining is installed in the end after the
completion of arch / wall lining and radiant tube erection.
Lining is carried out in-situ.

The back up insulation board is initially laid out. Towards the

wall side the blocks are laid out tightly against the insulating
Fire Bricks already lined on the walls. Next course is then laid
similarly. Care should be taken to ensure that the joints are
offset by a minimum of 50mm between adjacent layers.
Balance layers of blocks are also similarly laid out to
complete the back up board insulation.

A strip of 19mm thick Cerachem blanket of required width,

covered with polythene sheet is laid against the insulating
Brick lined on the walls. Side forms for Castable is then laid
out in line with the construction joints and alternate panels
are poured. After few hours when the Castable has set, the
said forms can be removed. Care should be taken to ensure
that lining is not disturbed or damaged while removing the
side forms. Intermediate panels are then poured to complete
the lining of the subject layer.

Final layer of Castable is poured similar to the first layer,

after ensuring that the joints are offset by a minimum of
100mm between the bottom layer Castable. Relevant
drawing gives the necessary guidance regarding expansion
joint locations. In case additional construction joints are
required, care to be taken to ensure that the joint is 'Z'
shaped similar to the expansion joints. The installed
Castable can be cured by either intermittent spraying of
water or wet gunny bags laid out over the Castable lining.

The bottom nose castable is also to be lined as above

described method. Area around De-Cocking connections shall
be lined with castable after laying two layers of block 607 as
back up. All the expansion joints of floor are to be covered
with JM 26 STD brick and mortared one side as shown in the
relevant dwg.
During castable lining, the instrument connections should be
wrapped with Ceramic Fibre Blanket and then covered with
polythene sheet, before pouring the Castable. In case
instrument connections are not fitted, a PVC tube of similar
diameter is placed in position after wrapping it with blanket
to ease removal after casing.

Expansion Joints & construction joints if any shall be

staggered as shown in drawing. At the bottom of the wall
lining a recess of 38mm is kept to enable the floor lining to
extend inside the wall by 25mm. The installed Castable to be
cured by using wet gunny bags or intermittent spraying of
water.

(iii) Bull Nose along Radiant wall (Radiant to Transition):

The lining is carried out in-situ after erection.

As in walls initially the blocks are lined and secured in place

with washer & 'V' anchor. The watertight formwork is then
fixed, properly supported from the bottom. Castable is then
poured from the top. Formwork can be removed only after a
minimum of 24 hours as it is in overhanging position.

The convection section is lined at ground in shop.

As in other areas, initially the blocks are lined and then
secured with 'V' anchor. Castable lining is carried out by
pouring castable into watertight side forms in alternate
panels. After removing the side forms once the castable has
set, in-between panels are cast after an interval of one day
from the previous casting. Pockets, as shown in drawing,
have to be left for intermediate tube supports. In ETS the
next row of tubes shall be filled with castable. Instrument
connection nozzles are wrapped with Ceramic Fibre Blanket
19mm thick compressed and covered with polythene sheet
prior to pouring.

(iv) : Collector Duct

In ducts Castable lining as explained above has to be carried

out. Ducts should be lined at ground level by rotation.

General instructions for Castable Lining

Work Planning

Work planning is very important for a smooth and quality

lining work. The day prior to the planned casting activity, all
parameters associated with lining activity should be checked
for adequacy like cleanliness of the casing, availability of
sufficient Castable material and potable quality water at site,
manpower etc.
Ambient Conditions
Castable lining is ideally carried out in temperatures between
10 to 32°C. If the ambient temperature exceeds 32°C,the
mixing water can be cooled down by using ice made of
potable quality water. A rough shade over the castable lining
area shall also help in preventing direct sunlight falling on
wet installed castable. In hot weather direct sunlight shall be
avoided on out side casing where castable refractory is
applied.
Surface preparation
The work surface shall be completely free of dust, scale, oil,
water dirt and loose foreign material. (Wire brush cleaning to
be applied).

Formwork
Formwork should be constructed from strong materials.
Generally 3/4 inch plywood or steel forms are favored for this
job because of their inherent strength and non-absorbent
nature. The surface of the formwork must be cleaned, lightly
and thoroughly oiled or greased to facilitate easy removal
from the face of the casting after completion of lining activity.

The surface of the formwork should be uniform and smooth

to give a goods surface finish to the casting. It also aids in
formwork release. Formwork must be as watertight as
possible, so all joints and holes must be sealed. The
formwork should also be properly supported, especially in the
case of vertical wall casting, to prevent collapsing of the
system when loaded with wet concrete.
Water:
The water used for mixing should be clean and of potable
quality, of low acidity, free from salt, sugar and other foreign
matter. Should quality of water be uncertain, it should be
analyzed and ensured that it complies with the following
specification advised by Thermal Ceramics.

PH : 6.5 to 8.35
Ca2+ : < 300 PPM
Mg2+ : < 300 PPM
K++Na+ : < 150 PPM
Cl- : < 200 PPM
Fe3+ : < 300 PPM
SO42- : < 200 PPM
Residue after
Evaporation at 180 Dg C : 1500 PPM

In case the available water does not conform to the above

specification, de-mineralized water should be used.

The amount of mixing water added to the Castable plays a

very important role in the strength and quality of Castable.
Hence the ratio of mixing water has to be determined initially
using the date provided in the date sheet as guidance, it has
to be adhered to strictly.

Water amounts shown on the back of the monolithic bags are

intended as a guide only. Actual amounts will depend upon
field conditions.

Mixing –
Mixing combines the dry materials and water into a
homogenous mass. Mixing must be done in paddle type
mixer of sufficient capacity to ensure through mixing of the
Castable.

The mixer and tools used in casting must be clean. Some

substances like lime or Portland cement, found in dirty mixers
can cause flash setting or otherwise lower the ultimate
strength of the Castable. The mixer should also be washed
periodically during the course of mixing to prevent buildup of
material.

Do not mix more material than can be placed within 15

minutes from the start of mixing and do not combine
different type of materials. In no circumstances should be
Castable be remixed after they have stiffened or started to
set.

The moisture content in Castable is critical for dense

concretes where maximum strength with optimum density is
required. Insulating concretes by nature are weaker than
dense concretes and thus it is important that they too should
be mixed properly with correct amount of water.
Too much water will reduce density and strength while too
little water will decrease the yield and may cause difficulty in
proper placing of Castable / working with the Castable.

Because of the possibility of segregation of the various

components of the Castable within the bag during shipment,
it is essential that only full bags should be used for mixing. If
any a small quantity of material is required for some reason,
then the full be bag should be dry mixed and then required
material from it taken for mixing. The balance should be
packed in bags immediately for further use preferably in the
next immediate requirement.

To mix the Castable, it is recommended to add first 80 ≅90%

of the water specified by Thermal Ceramics Data Sheet and
then to gradually add water till required consistency is
obtained. Guidance for consistency is as follows:

-For insulating Castable water addition should be as specified

in the latest technical data sheet of the Castable.
For dense Castables the water quantity will be the minimum
required to install the material properly. Ball in Hand test can
also be used to gauge the consistency of the Castable.

Add the minimum quantity of water in the mixer while mixing

the Castable and then scoop out sufficient mixed Castable in
the palm of the hand to make a ball. The ball is then
bounced in the hand. Too dry a mix will break up and too wet
a mix will slump through the fingers. If the bouncing imparts
a wet glistening look to the ball without any appreciable
transfer of water and cement to the palm, the water quality
is the optimum.

The mixing time is normally around 3 minutes and should be

controlled Excessive mixing may lead to crushing of
aggregates and changes the properties of the materials.
The discharge gate should be cleaned out after every mix to
prevent build-up of old material in the region.

At the end of every day or at the end of casting activity on

each working day, the mixer shall be thoroughly cleaned.
Similarly the mixer should be thoroughly cleaned with water
whenever a different type of Castable is mixed.

Placement:
The Castable shall be installed immediately after mixing.
The aim should be to position and consolidate freshly mixed
material within 15 minutes of it leaving the mixer. The
location of mixer machine and manpower required to shift
the mixed Castable and for placing should be adequate for
fast placement. This has to be taken care of while planning
the Castable lining. Also the time between pouring of
consecutive batches must be such that the setting of the first
batch should not begin before the second batch is poured.
The Castable must be installed in a manner, which minimizes
material segregation. It should be poured slowly into
position, taking care that every undercut or profile is
completely filled up and the lining is devoid of any air
pockets. For insulating Castables rodding or tamping is
sufficient to remove voids and to consolidate the material
without excess compaction. Excessive rodding is also not
advisable for lightweight Castables as it will crush the
materials and increase the density. Striking the formwork
from outside with hammer will also help to avoid formation of
air pockets.
Once the installation has started, it should proceed without
interruption until the lining of the part or section concerned is
completed. In case of any unavoidable interruption in lining
activity, the wet edge of the lining shall be cut back at right
angle to the surface of lining and all material ahead of the
cut shall be removed and discarded.
Each batch from the mixer shall be installed so that the full
thickness of the lining is produced, rather than building up
the thickness in layers. When doing vertical casting as in
walls, the Castable shall be spread evenly along the length of
the shuttering and tamped in order to obtain a homogeneous
lining.
Joints
Construction joints are designed the break the job up into
conveniently sized panels. Adjoining panels are cast against
each other without leaving any gaps using the set face of
previously cast section as the formwork edge. Typical joint
details are as shown in relevant drawings. At expansion
joints, Ceramic fiber blanket strips covered with thin
polythene sheet (to prevent absorption of water) are used.
Finishing
When finishing the exposed surface of the refractory
Castable lining, it is important to avoid smooth / excessive
trowelling of the surface. Excessive working draws water to
the surface along with the fines and cement binder and
produces a fine finish rich in cement which is easily dislodged
by peeling on curing and certainly on exposure to elevated
temperature / alternate heating and cooling. Thus the lined
Castable surface only needs to be leveled with a screed or
wood float and not to be trowelled to a smooth finish.

Curing
Curing prevents the loss of moisture from freshly cast
refractory concrete. Loss of water from the surface of the
cast before the bond is fully hydrated results in a weaker
lining. To prevent this, various methods of moist curing can
be used. Formwork should be left in place for a minimum of
24 hours and exposed refractory concrete either sprayed
with water, covered with plastic sheeting or with wet gunny
bags. This is called moist curing. Moist curing can start
immediately after the initial setting when the lining surface is
hard enough to prevent impinging water from washing out
the surface cement and shall proceed for a minimum of 24
hours. During the curing process the refractory lining and
casing temperature shall be maintained between 10 to 32°C,
if the lining is done in open air, the surface of lining should be
 protected from direct sunlight by shading until the wet curing
process is complete.

After the initial 24 hours of moist curing, formwork can be

stripped away, being careful not to damage the lining as this
could possibly occur. A further 24 hours air curing should be
allowed before the lining is fired to further increase the final
strength.

Refractory lined equipments or panels should not move at all

from its place of lining on
site, until the curing operation (wet curing + air curing) is
completed.

Besides general guidelines regarding the castable application

shall be followed as detailed above.

5.4 Equipments, Tools and Tackles for Lining Installation:

Welding

• Welding equipment suitable for welding of various

anchors:
• Angle Grinder with discs
• Wire Brush
• Measurement Tape
• Chalk Lines
• Punch
• Hammer

Ceramic Fiber / Module Lining

• Measurement Tape
• Long Bladed Knife
• Hack Saw for cutting SS Tubes in Modules
• Lubricators / Slip Plates
• Socket with extension arm for tightening nuts to fix
modules
 • Hand Tools like Screw Driver, Pliers etc.
• Tamping Tool (small flat piece of ply wood / wood or
expanded metal Approx.300 x 250mm with a handle for
tamping modules after installation.

Castable Lining:
• Paddle Mixer
• Water Tank
• Wooden tray with GI or Aluminium facing
• Rubber / GI Buckets for transporting mixed castable.
• Formwork, Supports and hand tools for fixing formwork /
supports.
• Pans
• Tamping Rods
• Electric or Diesel Vibrator
• Thermometer
• Trowel
• Gunny Bags for curing
• Wooden Hammer
• Binding wire.
• Spirit Level / water level.
• Measuring Jar
• Moulds for sample preparation.

Insulation Block and Brick Lining:

• Measurement Tape
• Drill Machine with 6mm & 12mm drill bits for bricks and
blocks
• Hand Saw for cutting
• Pans for mortar / block mix
• Heavy Duty Drill Machine with spatula for mixing mortar
• Wooden / Robber Hammer
• Plumb Bob
• Trowel
• Straight Edge
• Angle
• Water Level
 5.5 Drying Out

The process of curing of castable does not end with wet

curing. After wet curing for 24 hours, the castable should be
air dried for a minimum of 24hours. Subsequently it has to
be dried out gradually by using Flue Gas to remove the water
content inside the castable as detailed in Ciria Doc. No. 205-
1522. Drying out has to be done meticulously and carefully.

6.0 QUALITY ASSURANCE PLAN - SITE INSTALLATION

ACTIVITY:

A successful refractory lining owes equally to good

application practices as to the quality of material. As
refractory linings are applied manually, it is essential that the
applicator should be aware of the various quality control
requirements and its impact on the life of installed linings.
Thus it is advisable that the applicators are tested to check
their awareness of the various requirements and given
proper instruction on good working practices.

Equipment's used for the various lining activities should be

thoroughly checked to ensure that they are in proper working
condition before they are brought to site.

Proper quality control of installation can be segregated as

• Installation Pre Cautions
• Inspection and Test Plan

Installation Pre Cautions:

Only sufficient quantity of the correct type of material should

be brought near the equipment to be lined, prior to lining
activity.

Storage requirements and precaution against inclement

weather should be met at the installation site for the material
stocked.
 Care should be taken while shifting the material to avoid
damages.

Different type of blankets and boards should be stored

separately to enable identification at work site also.

Installers should be properly instructed by qualified persons

prior to all types of installation activity on good working
practices and the requirements of the job.

While mixing mortar for brickwork only sufficient quantity

should be mixed. In case of any excess the same should be
covered with a thin layer of water on top to prevent contact
with air. The same may be drained off prior to use of the
mortar.

All equipment's and hand tools should be properly cleaned at

the end of working shift.

Batch No. of castable used should be noted down along with

the location of installation of castable.
Inspection and Test Plan for Site Installation Activity
Anchor Welding
Anchor welded to the casing must be securely attached
without any weld undercut. Any anchor properly welded shall
be capable of withstanding being bent upto 15 degrees from
its initially welded plane to the direction o greatest resistance
and back without evidence of any weld failure. The anchor
weld should be inspected by hammer test wherein striking of
the anchor would give a good ringing sound when hit with a
hammer. The inspection of anchors can be random. Visual
inspection of welding is also done.

Castable Lining:
The main objective of physical testing of samples made at
site is to assess and judge the quality of installed lining to
some extent without disturbing the lining. Thus the essence
of sampling is to ensure that the sample represent the
installed lining in all aspects, including the material batch,
method of installation etc and is marked properly to correlate
the sample to the installed portion of the unit.
Sampling for application by casting:
One sample per section of the lining for each quality and
batch of castable being installed is made during the actual
installation.
Each sample consists of 3 nos. 50mm ± 4mm cubes, which
are cast in metal moulds. The metal moulds are cleaned,
slightly oiled and kept ready for sampling. When the
installation work / castable lining is ongoing the cubes are
cast with the same material. The cubes are then cured,
carefully coded and marked. The codes are then mentioned
on the lining drawing to indicate the location where the
parent material, from which sample was cast, is lined. The
batch number of the castable is also noted while sampling to
enable correlation of the sample with the batch of the
material.
The cubes per batch of Castable are then kept together and
randomly 3 cubes are selected for testing. 3 cubes per lot
(supplied batches of each type of Castable material) of
Castable material are then sent for testing (Bulk Density and
Cold Crushing Strength). The cubes after wet curing of 24
hours are allowed to air dry for 24 hours before being sent to
testing to an approved laboratory or the laboratory specified
by the customer/client. The cubes are tested for bulk density
and cold compressive strength after oven drying at 105°C,
B.D. as per ASTM C 134 & CCS as per ASTM C 133 standards.
The results are then compared with the acceptance criteria
with an additional tolerance of 10% of the material. Ie for
Cold Compressive strength, the permissible value shall be the
minimum value as per acceptance criteria less 10% and no
limit for the maximum value. Similarly for Bulk Density, the
permissible value shall be the maximum value as per
acceptance criteria + 10% and no limit for the minimum
value. Thus permissible values are
Bulk Density : Max of (Acceptance Criteria
Value + 10%)
Cold Crushing Strength : Minimum (Acceptance Criteria
Value – 10%)

In case of any significant variation in test results, another set

of 3 bars from the same lot is sent for testing. All other
sample shall be preserved with their tag nos. for future use if
any. An inspection checklist as detailed below shall be used
at site to ascertain the quality maintained during installation
of materials.
 EIL Job No. : 6569
LHT Job
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