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 : admin@sharadaamonolithic.com www.sharadaceramics.com

SHARADAAC E R A M I C S P V T. LT D.