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DESCO N ENG INEERJ NG

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REFRACTORY APPLICATION PROCEDURE

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QC/M / R EF/001

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Da te:
Paoe:

09-Ju n-12

I of I 0

REFRACTORY APPLICATION PROCEDURE

FOR
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/IESCIIN

DESCON ENG INEE RING

REFRACTORY APPLICATION PROCE D URE

Doc No:

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Rev. No:

Date :

09-Jun-12

Page:

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TABLE OF CONTENTS

1.0

SCOPE & GENERAL COMMENTS

2.0 PRE-INSTALLATION REQUIREMENTS FOR THE

INSTALLING CONTRACTOR
3.0

REFRACTORY MATERIALS AND STORAGE

4.0

GENERAL REQUIREMENTS

5.0

APPLICATORS'S QUALIFICATION

6.0

APPLICATION OF POURED REFRACTORIES (CASTING)

7.0

TOLERANCES

8.0

CURING OF CASTABLE REFRACTORIES

9.0

SAMPLING AND TESTING DURING INSTALLATION

10.0 INSPECTION
11.0 REPAIRS TO REFRACTORY LINING

DESCO N ENGINEERING
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3ofl0

1. S COPE AND GENERAL COMMENTS

2.0

1 .1

This procedure shall be used in accordance with GASCO General Specifkation

DGS-6531-020_0_001 0.

1.2

AMBHertel shall perform all refractory installation work

1 .3

All units shall be in S.l (metrk)

1.4

The purpose of this Procedure is to define the requirements for refractory

Materials, handllng, installation, dryjng, curing, testing, inspection and
repair work if any.

1.5

The refractory installation contractor AMBHertel is responsible for providing a

finished refractory lining to the specified density, thickness, and uniform
composition that will perform in service to the ability proven in previous use
and test data.

1.6

The general guidelines of this procedure are mm1mum care and quality
requirements. The installation contractor is expected to utilize his expertise in
refractory installation, if and where conditions require, to exceed these
minimums or take additional steps to insure a satisfactory, serviceable lining is
provided.

1 .7

The contractor shall be responsible for the maintenance of records of the

refractory used (by manufacturer's batch number and date) and, when
required, for the arrangements of independent lab tests and recording of the
results.
PRE-INSTALLATION REQUIREMENTS FOR THE INSTALLING CONTRACTOR

2.1 AMBHertel shall check all materials upon receipt at the site of installation for
damage such as broken bags, moisture infiltration, etc., to assure the refractory
containers (bags, drums, etc.) as marked are material specified on the
arrangement drawing, and that the refractory is the specific mix for the intend
method of applkation (Casting).
2.2 Prior to starting refractory installation, Descon shall verify that 5% random bend
test of the anchors has been performed and recorded.

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2.3 When castable tie back has been installed by a party other than the AMBHertel,
AMBHertel shall assure by hammer or bend test, that the tieback is suitabl y
welded to the shell before starting work.
2.4 Bagged refractory shall have the batch date checked prior to mixing to confirm
that the material has not passed the manufacturer 's recommended shelf life.
2.5 Castables which show signs of having set (lumps or hardness throughout) prior to
mixing shall be rejected, regardless of shelf life expiration date.
3.0

REFRACTORY MATERIAL AND STORAGE

The material MANUFACTOR'S instructions for storage, handling, and shipment of
materials shall be met. Shipment of refractory should be scheduled to ensure that it is
installed within its specified shelf life. Material which has been longest in storage
shall be used first.
Refractory materials hall be stored with protection from extreme weather conditions
and exposure to sun. In winter, plastic mouldable refractory materials may freeze and
must be thawed before use. This is done by removing only the outside packaging, not
the foil, and storing in a warm place. Thawing may take several days; the material is
ready when it can easily be formed by hand.
All hydraulic setting refractory materials shall be protected from moisture absorption
during shi pment and storage. Air-tight, moisture-tight polyethylene bags shall be
used when specified by the CONTRACOR.
Refractory that shows signs of having set, ie. Hard or unbreakable lumps in the dry
mixture prior to installation shall be rejected and be removed from the job site.
Fractional part from previous jobs as well as damaged bags shall also be removed
from the job site.
Refractory materials, except dated castable refractory materials, shall be protected
to withstand ocean transit and extended periods of storage at the jobsite for a
minimum period of 18 months. Materials shall be protected to safeguard against all
adverse environments, such as humidity, moisture, rain, dust, dirt, sand, mud, salt
air, salt spray, and sea water.

BESCDII

4.0

DESCON ENGINEERING
REFRACTORY APPLICATION PROCEDURE

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GENERAL REQUIREMENTS
4.1

The recommended procedures from a manufacturer of a proprietary material

for water rates, mixing, placing and curing shall be followed unless:
3.1.1 Site conditions dictate some modifications to obtain the desires results.
3.1.2 The installations contractor
has demonstrated through previous
experience that his recommended changes will produce a superior in
place product.
3.1.3 Deviations in the manufacturer's recommended procedures shall be
submitted to client in writing. Acceptance of the contractor's
recommended changes by client do not relieve the contractor of his
responsibility and liability for the completed lining.

4.2

5.0

Clean Water used for mixing or preparation of the refractory components

Wetting of surfaces to be lined and for water spray during curing shall be
potable and shall have low chloride content (50 ppm maximum)

APPLICATOR'S Qualification
1. Each team of mixer operations and APPLICATORS shall prepare either a standard
shape (230 X 114 X 64 mm minimum dimensions) of a box specimen (280 X 180 X 75
mm minimum dimensions) in a hardwood box.
2. The box should contain the same anchor system (type and spacing) as to be using in
the actual installation.
3. The specimen shall be placed by hand in approximately 25 mm thick layers,
subsequently poked to achieve accurate filling and good workmanship.
4. Vibrators shall not be used with castables having a bulk density of less than 1750
kg/ m3.
5. During installation of dense and medium weight refractory materials, the APPLICATOR
shallcheck the consistency of the ready mixed refractory material using the "Ball-in
Hand" method (ASTM C860). In the cast of a viibra cast installation, a similar form and
vibration system should be modelled with a similar anchor system.

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ENGINE
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APPLICAT
OR'S test
samples
shall be
stored to
set and
dry.
6.0
APPLICATION
OF POURED
REFRACTOY
(CASTING)
6. 1
Preparat
ion
a.
(
a
s

table refractory are normally supplied in moisture proof

bags and are mixed with water on site and poured in
place. The amount of water to be added depends on the
type of the castable and the consistency required during
installation. The minimum amount of castable to be
mixed shall be one bag and larger mixes shall be made
using a whole number of bags. No partial bag should be
used.
b. Where the steelcasing does not completely surround
the refractory surface, forms are necessary. Forms
should have a relatively rigid, stable, smooth surface,
be water resistant, and be greased or coated with
concrete mould release agent.
c. Forms shall be kept in place for the curing period to
provide support and retain moisture within the castable.
Their design shall allow removal without damage to the
refractory. Forms shall be sealed when jointed to prevent
loss of water
or material.

d. The preferred mixer for poured castable is a paddle type

mixer (mortar mixer )
to separate unwanted matter such as paper.
e. Temperature of mix shall be maintained between 5C-30C.
f. During mixing, the consistency shall be checked by the
"Ball-in-hand" method in accordance with ASTM C860
Ferrules to be fixed in the tube sheet before the starting
the castable works.
g.

After fixing the ferrules shuttering should be done for

casting.
h.

6.2

Installation
a. The lining shall be applied in narrow areas,
starting at the bottom and working upward.

DESCO N ENGINEERING

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b.
Eac

h batch of the mixer shall be

cast over the full thickness and
evenly distributed.

1.
Surfa
ce
tempe
rature
s
must
be
maint
ained
betwe
en
1030C
for 36
hours
during
curing
. If
ambie
nt
tempe
rature
s
above
30C
are
antici
pated
during
the
cure,
AMBH
ertels
hall
provid
e the
coolin
g
metho
d by
sprayi
ng the
water
on the
surfac
e to
maint
ain
the
temp
eratur
e.

c. Once application has started it

shall proceed without intervals
until
the entire
scheduled
lining has been completed.

d. If an unavoidable interruption
occurs, the wet ending of the
lining shall be cut back at an
angle to the surface to provide
a slight "keyed" effect when the
final material is cast.
All material ahead of the cut
shall be discarded.
e. Care should be taken that no
castable materials
should
protrude inside the tube sheet
or ferrules. If it happens, then
the same to be cleaned.
f.

When casting horizontal areas

without
molds, the finished
surface shall be levelled
off
with a scraper or screed only;
slurry shall not appear after
finishing the surface.

g. As the work progresses, the

refractory shall be checked
for final thickness and any
deficiencies
shall
be
corrected
immediately.
A
screened finish is all that is
required; smoothing, floating or
trowelling shall be avoided.
7 TOLERANCES
6.1Thickness
1. The refractory castable thickness
shall be within +12mm,-O
measured from the steel plate.
8 CURING OF CASTABLES REFRACTORIES
The purpose of curing a castable refractory
is to prevent the loss of water through
evaporation needed by the refractory binder
to develop its strongest hydraulic bond.

2.

Surface temperatures shall be

measured and recorded every 4
hours.

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3. Direct sunlight is not permitted on any refractory within 36 hours of

installation.
4. The castable must be allowed to partially set up before start of spraying to
prevent washing out the binder.
5. Frequency of spraying is determined by factors such as ambient
temperature, humidity, air circulation, etc. In
the surface must not
genera,l
be allowed to dry during the first 24hours after refractory placement.
6. After the 24hour cure period, an additional 24hours of air drying is
mandatory before handling or application of any heat to the refractory.
7. In excessively hot weather, the forms, steel sections, and refractory face
may be sprayed with cold water to cool the refractory.
9 SAMPLING AND TESTING DURING INSTALLATION
1. At randomly selected times during each shift, the APPLICATOR shall prepare
a number of samples (panels) using the same refractory materials being
installed.
2. The minimum number of samples shown in Table A2-2 of DGS- 6531020_0_0010
3. Preparation of the samples shall be witnessed by the CONTRACTOR.
Depending on the type of refractory material, samples shall be either
(Figure A2-1) DGS-6531-020_0_0010:
Standard shape : 230 X 114 X 64 mm (see Note below)
Box
: 280 X 280 X 75 mm, for ramming and
poured castables;
Panels
: 500 X 500 X 114 mm, for gunned refractory
materials.
NOTE: Filling shall be done with dimension of 114 mm upright.
Each sample shall be clearly marked with APPLICATOR'S code numbers for that
Day/shift/crew and for sequence of production. Each code shall be unique, and
traceable to the locations where refractory has been applied by that crew during
that shift.

DESCO N ENGINEERING
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4. The APPLICATOR is responsible to ensure that the samples are regularly

delivered for testing to the test laboratory. Test specimens shall be cut
from the samples at the laboratory, after being prepared, cured and air
dried at the work site.
5. For each sample, the following properties shall be tested:
Bulk Density
Water Content (1 per shift)*
Cold Crushing Strength;
*for information purposes only, not subject to acceptance
criteria. The acceptance criteria for these tests shall be as stated in Table
A2-3.
If the test values do not meet the specification, new samples from the same panel
or, if necessary, from the related lining section, shall be retested for:
Bulk Density
Cold Crushing Strength
If the retest results do not meet the specification, the lining section related to the
tested samples shall be rejected.
10 INSPECTION
10.1 Visual
1. After air drying, the lining shall be inspected for cracks.
2. Random surface cracking up to 2 mm wide, not more than Y2 the full refractory
thickness in depth, and not exceeding an average spacing of 300 mm is
acceptable.
3. Areas containing cracks wider than 2 mm or any criss-cross (intersecting) cracks
are considered defective and shall be repaired.
4.
Visua,l

dimensional, and quality inspection of expansion joints shall be made.

DESCON ENGINEERING
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Hammer Testing
1. The type of inspection is generally referred to as a Hammer test. It involves the
practice of striking the lining over its entire area with a ball point machinist
hammer having a recommended weight of 450grams.
2. Hammer testing will indicate whether or not a lining is homogeneous. An
experienced ear will determine, in more detail, faults which might cause a lining
to collapse such as voids eliminations etc.

11.

REPAIRS TO REFRACTORY LINING

1. If inspection reveals defective areas as previously defined greater than 150 mm x 150
mm, the full thickness of the defective concrete layer must be removed for a
minimum area that include 3-4 anchors.
2. Care must be taken in the removal of the faulty material that the surrounding sound
lining is not damaged
3. The removal of the refractory concrete should progress at a small angle to the shell
and the periphery of any repair be located mid-way, between anchors.
4. The area being repaired should be cleaned of all loose concrete and debris and the
adjacent sound material thoroughly wetted before any new concrete is installed.
5. Only the same concrete as originally employed should be used for replacement and
wherever possible, especially in large areas the same installation method as was
originally used.