Firecrete Super Refractory Castables

Product Description

Description and Key Properties

Firecrete Super is primarily used in less critical zones of industrial equipment to provide a cost-effective, durable lining.

• Maximum Service Temperature: Up to 1450C.

• Chemical Composition: Contains approximately 70% Alumina ($Al_{2}O_{3}$) and a maximum of 5.5% Iron Oxide ($Fe_{2}O_{3}$).

• Nature of Bond: Hydraulic, allowing it to set like standard cement after the addition of water.

• Physical State: Supplied as a greyish-white dry powder, typically in 25kg or 50kg bags.

• Performance: It offers excellent mechanical strength and resistance to thermal shocks, maintaining its structural integrity under intense heat.

• Common Uses: Ideal for boiler linings (especially in the sugar industry), ovens, baking furnaces, and flue gas or hot air ducts.

Directions for Use

Proper installation is critical to ensure the longevity of the refractory lining and prevent issues like cracking or "spalling" (explosive steam release).

1. Preparation

• Surface Cleaning: The application area must be free of dust, oil, and grease.

• Formwork: Use watertight and rigid forms (usually mild steel or plywood). Coat them with a release agent like mold oil to ensure easy removal after setting.

• Anchors: If using steel anchors, coat them with a thin layer of bitumen or plastic to allow for metal expansion during heating.

2. Mixing

• Water Quality: Use only clean, potable (tap) water.

• Water Ratio: Add 10% to 11% water by weight (approximately 2.52.75 liters per 25kg bag).

• Process: * Dry mix the powder for about 1 minute.

  • Add water incrementally and mix for 35 minutes until uniform.

• Consistency Test: Perform a "ball-in-hand" test. Toss a ball of the mix 1530 cm into the air; it should adapt to the shape of your hand when caught without crumbling (too dry) or flowing through your fingers (too wet).

3. Installation (Casting)

• Timing: The mixture must be placed within 20 to 30 minutes of adding water.

• Compaction: Use a high-frequency mechanical vibrator to ensure high density and remove air pockets.

• Surface Finish: Trowel only enough to level the surface. Do not create a slick, polished finish, as this can trap moisture.

4. Curing and Drying

• Curing: Keep the castable covered with wet gunny bags or plastic sheets for at least 24 hours after the initial set to maintain moisture for proper bonding.

• Air Drying: Allow the material to air dry for an additional 24 hours after removing the forms.

• Initial Heat-up: Follow a controlled heating schedule. Raise the temperature slowly (e.g., 25C per hour) to 110C and hold until all steaming ceases before proceeding to higher temperatures.