Refractory castable refers to a mixture composed of refractory aggregate, binder and admixture, which can be mixed with water (or liquid binder) to form a slurry that can be constructed by pouring method. The difference with other amorphous refractories is that the refractory castables have a certain setting and hardening time after construction. Therefore, the castables can be demoulded only after a certain period of curing, and then can be put into use after a proper period of natural curing.

The manufacturer of castable shall share the construction details of refractory castable:

1. Preparation of refractory castables

The first thing to be considered in the construction rules of refractory castables is that the preparation of refractory castables before construction should first check the integrity and cleanness of mixing equipment, transportation tools, vibrating tools and parts to be poured; check the water loss prevention measures of formwork, surrounding refractory bricks and thermal insulation layer; Check the derusting of the equipment, the form, size, layout, welding quality of the anchor and the expansion compensation measures of the metal anchor; check whether the quality of the castable and the construction water meet the requirements. In addition, during the castable construction, it is necessary to ensure that there is no power failure and construction interruption.

Among them, the formwork for castable construction is made of non absorbent materials. If wooden formwork is used, waterproof coating shall be applied to prevent water loss of castable. After the loss of water, the fluidity of the castable decreases, so it is difficult to remove the bubbles and vibrate the castable. Steel formwork shall be coated with release agent to prevent adhesion between formwork and castable. When reusing, the formwork shall be cleaned first, then applied with oil, and then used.

2. Mixing of refractory castables

① Forced mixers shall be used for mixing. The mixer shall be cleaned in advance and washed with water, and shall not be mixed with lime, silt, Portland cement and other sundries. If the amorphous material is mixed with superphosphate, the equipment must be thoroughly cleaned before it can be used to mix the cement bonded castables.

② According to the specifications and construction conditions of the mixer, the mixing amount shall not exceed 200kg each time. Under the condition of specified water consumption, sufficient fluidity of the mixed castable must be achieved.

③ Pour each component of the castable into the mixer, dry mix for 3min, and then add clean tap water. When adding water, first add 90% of the reference water content of the castable, then slowly add the remaining water to make the fluidity of the slurry meet the requirements, and the wet mixing time shall not be less than 5min.

④ Castables must be used in a whole barrel and bag. The mixed castables shall be poured quickly, and shall be used up within 30 minutes from the time of adding water. The wet materials that have been initially set shall not be formed by force, and shall not be mixed with water again for reuse, and must be discarded.

3. Vibration of refractory castable

① The model shall be tight to prevent leakage. The castables poured into the mold frame shall be vibrated in layers as soon as possible with a vibrating rod. The thickness of each layer shall not exceed 300 mm, and the vibration interval shall be about 250 mm. Do not vibrate the compacted part repeatedly to avoid segregation.

② During vibration, avoid touching the anchor and damaging the heat insulation layer, and slowly pull out the vibrating rod after the pouring material surface is ooze and most bubbles are discharged.

③ Pouring shall be carried out continuously. Before the initial setting of the previous layer of castable, the construction of the next layer of castable shall be carried out in time. If the construction interval exceeds the initial setting time, it shall be treated according to the construction joint requirements.

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