better installation practices for best campaign life · burner blocks, kiln car blocks, large...
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DESKILL REFRACTORY INSTALLATION BY CONFORMANCE TO SOP
SHARADAA
BETTER INSTALLATION PRACTICES... FOR BEST CAMPAIGN LIFE
SHARADAA CERAMICS PVT LTD
(for other type of Monolithics please ask for guide)Sharadaa provide Installation Support for Discplined castable Installation
Do not use HooksBy Hand
Do not use Dirty WaterUse Clean Water of PH 7Do not use Uncleaned Mixer
Use Cleaned Mixer
Material Stacking on FloorOutside under Hot Climates
Material Stacking on PalletInside covered Ware House
Avoid Floor / Hand Mixing
Mixing Done by Mixer only
Paddle Mixer Without Top Cover - Open toSky
Use Paddle Mixer with Top Cover - Under covered Shed
Uncleaned ShutterUse Recommended Oil on the Shutter before Casting
Avoid HDPE Bag for Mixed Material Handling
Use Clean Container for Mixed Material Handling
MATERIAL HANDLING
WATERMIXER
MATERIAL STACKING
MIXING BY MIXER 33RPMPADDLE MIXER
CLEANED SHUTTER MIXED MATERIAL HANDLING
1. 2.
3. 4.
5. 6.
7. 8.
Unmeasured JarUse Measuring JarAdd water specified bythe manufacturer
Do not measure water temp. by hand
Use thermometer to measure water temp. Use 20°C water by adding ICE
Mixing:Dry - 2 mts.Wet - 3 mts.
Mixing Time Monitored by Stopwatch Excess WaterCorrect WaterLow Water
0
100
200
300
400
500
600
700
0 8 16 24 32 40 48 57 64 72 81 90 94 104 114 118 123 136 147 159 160 184
Hrs. after casting
Tem
p. °
C
1. Deshutter After 8 Hrs. 2. Carry out Air Curing 3. Heat Curing as per Manual
Check Type / Chemistry / Space / Welding of Studs & Anchors / Type of Electrodes
Check Shutter Size / Thickness / Support / Lubrication
Preferred Segment Size 600 x 600 mmProvide construction / Expansion joints
Do not add Water during casting
Use Needle / External Vibrator for Casting
SHARADAA REFRACTORY MONOLITHICS
MEASURING JAR WATER TEMPERATURE 20°C
MIXING TIME CHECK BALL IN HAND
HEAT CURING CURVE (TYPICAL)
CHECK ANCHORS CHECK FORM WORK SIDE WALL & ROOF PANEL
NEEDLE VIBRATOR FOR CASTING
9. 10. 11.
12. 13.
14. 15.
16.
CHECK LINING FOR SOUND, CRACKS, CORNERS, COMPACTION AND DO REPAIR IF WANTED18.
17.
Conventional Castables(Medium Purity Group)
Trowelling, Patchingand Vibrocasting
1300°C MaxNon Metal contact areas, Flue gas transfer
Flue gas DuctsCyclone areas
Conventional Castables(High Purity Group)
Hand casting, patchingand Vibration
Typical Range : 1300-1700°CMaintenance ofMetal contact areas
Ladle maintenance, General Maintenance in Cement Kilns
Rodding Castables(Medium Cement)
Rodding / Vibrocasting Typical Range: 1000-1500°CAbrasion / Thermal Shock areas
Maintenance Lining in Rotary equipment.Cement and DRI KilnsCFBC Boilers
Low CementCastables
Vibrocasting Typical Range : 1000-1500°CAbrasion areas
Original Equipment Lining.Cement and DRI KilnsCFBC Boilers
Insulation Castables(Medium Purity Group)
Pouring / Vibration Max 1100°CLower Thermal Conductivity
Back up lining for Gas DuctsFurnaces and Kilns
Plastics / Ramming Mass Ramming Abrasion Resistance upto 1500°C
Repair of Brick / CastablesCFBC Boilers Lining ofAbrasion areas
Insulation Castables(High Purity Group)
Vibration Typical Range : 800 -1400°C
Lower Thermal ConductivityHigher chemical resistance
Working lining in Coke Oven DoorsRadiant section of Heaters and reformers
Gunning CastablesConventional / Low Cement / Insulating Type
Gunning Typical Range: 800-1400°CFast JobNo form workLess rebound loss
Maintenance repair of Non Critical areas in Standard Furnaces, Rotary Kilns, Reheat Furnaces
Shotcreting/Pump ableCastables
Shotcreting /Pumping
Typical Range: 800-1700°CFast JobNo dust during Shotcreting.Equivalent strength to LCC
Maintenance and repair
No Cement GelBondedCastable
Self Flow/Vibration
Typical Range: 1300-1800°CThermal Shock resistanceMetal Contact areasCorrosion resistance
Burner Blocks, Kiln CarBlocks, Large Blocks,Ladle Bottom,Precast blocks
Product Group
Application Techniques
Temperature / ConditionRecommendations
Recommended Areas
APPLICATION GUIDANCE
387, 388 SIDCO Industrial Estate, Ambattur, Chennai-600098Tel : +91 44 26254365 / 26254366Fax : +91 44 42189355Mobile : +91 9600095559 / 9600095574 / 8754530681Email : [email protected] www.sharadaceramics.com
SHARADAAC E R A M I C S P V T. LT D.