Used Aluminum Silicate Refractories
USING INSTRUCTIONS FOR KNITTED MORTARS
The Production Technology of Lattice Mortars is the refractory clay addition which binds to the powdered sintered refractory material and is packed ready for use in 25 or 50 Kg kraft paper bags.
CONSIDERATIONS IN USE:
It should be thoroughly mixed dry before adding water. Mixing should be continued at the same time while the water is slowly added to the brick surface at a thickness of max. 2 mm until the consistency is reached so that the two bricks will stick together.
APPLICATION METHODS:
The most common methods of application are;
Mala Method: Mortar is applied with malting so that the thickness of the bricks does not exceed 2 mm, and it is ensured that the other brick to be glued is brought on top of this brick without any loss of time.
Immersion Method: In this method, one of the bricks to be adhered must be immersed in the mortar prepared in a reservoir or a boat and placed on the knitted wall.
Monolithic Refractories
OPERATING INSTRUCTIONS
The mixture consisting of sinter and special binding materials is very well mixed and bagged during production. Often the binders and additives are in the same bag.
If monolithic materials (Ready Fire Concrete) need to be stockpiled for a long time, the binder and sinter material should be placed in separate bags, but two separate bags should be placed in another bag so that the materials in the mixture in the bag are not affected by the medium. Two bags in one single bag should be mixed very well to make mortar.
PREPARATION
The amount of water to be used during the preparation of the cast monolithic materials varies according to the properties of the material.
Water Excess Mixture: The use of excessive water will increase the settling and freezing times of the refractory materials and will have a very negative effect on the porosity and therefore the strength during drying and baking. The most important of these problems is the big cracks.
Less Water Mixture: If the water is used less than necessary, a homogenous mixing will not be achieved and the early freezing will start.
During the preparation of monolithic materials (Fire Concretes), water should be continuously checked manually when adding water, try to get proper consistency and care should be taken to avoid lumps. This process should be completed within 3-5 minutes, otherwise the water and cement reaction will result in mortar pitting, which will shorten the time to freeze and cause difficulties both in terms of application and failure to obtain the expected performances from the refractory at the place of application.
PLACING
Monolithic material (Fire Concrete) is poured rapidly into the molds after the molds are wetted according to the place to be applied.
The application is inserted into the mold according to the shape.
In the placed material;
Within 3-5 minutes,
Start freezing within 3-5 hours,
Min for 24 hours. It should be kept at 95% relative humidity (at 35 ° C). This can be achieved by covering the nylon over 24 hours.
Or; this can also be done by sprinkling water on the material.
However, if it can not be kept moist, the heat will come into play as a result of the reaction and the increased heat will cause cracking of the concrete.
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ANCHORAGE SYSTEM
Anchorage system suitable for gravity and shape should be applied on moving or flat walls or floors. Stainless steel is designed as Y and V. The thickness of the concrete is about 2/3 of its thickness and the thickness of the concrete is 6 , 8,10,12, etc., and so on. Anchorages can also be made in the environment where the temperature is lower.
Each anchor is 200 to 300 mm in distance, one of which is mounted on the opposite side of the other and with hair or mantle welds, which will be surprising to each other. The following illustration shows the anchoring method.
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THE DILATATION
It is necessary to leave a dilatation share in order to be able to easily obtain the extensions to be welded during the pouring of the monolithic material (Fire Concrete). For a application area of 1 to 2 m2, it is necessary to leave a dilution interval of 3 - 25 mm. In this range, ceramic blanks, cardboard etc. should be put in place.
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DRYING AND COOKING
Once the concrete is completely hardened and formed, the molds are removed. The access to drying and usage temperature program is given in the table below.
The cooking regime can be increased for temperatures above 800 degrees Celsius. But; It is always very risky to go above 400 centigrade degrees / hour.
Low Cement Monolithic Materials
OPERATING INSTRUCTIONS
Low Cement Castables have to be applied with vibration. They are very difficult to apply because of the low water content inside.
Vibrating Materials;
* Porosites are low,
* Their strength is high,
* Their volume weights are high and therefore their performances are quite high. Depending on their usage status, their performances can be further increased. In poor conditions, the performance may become low. the mixing should be homogeneous, a good mixer should be used and the mixers should be very clean. Mixing time max. Prepared mortars should be stocked in dry environment and this environment should be artificially ventilated.
The water used should be very clean, even the temperature should be careful and the temperature should be 5-25 oC.
The amount of water to be used in the materials to be vibrated is 5.5-6.5%. With this ratio, the mixture is close to dryness. If water is collected on the surface as a result of applying the vibration, the amount of water should be reduced in other applications.
Vibration application time should be about max. 5 minutes. If air bubbles are seen in the mold during application, vibration should be stopped immediately. Long vibrations can also disrupt the homogeneity of the mixture. If vibration application is applied with vibrating method, the vibration device should be pulled very slowly through the concrete,
After 4 hours of mixing, freezing starts and lasts for 48 hours. The mold should be dismantled after 12 - 14 hours and thus the concrete should be well contacted with the air for continued curing in freezing.
