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AnonymousSME facilitators -Damon McCrory, Harbison-Walker Refractories Co & Barry Robinson, Middough
- One of the most important steps in a refractory installation
- Proper curing & dry-out are required for monolithics to achieve maximum properties for best reliability
- Monolithics have multiple dehydration points to get rid of free and chemically combined water
- High pressure builds during dry-out and increases with steam which can overcome material strength
- Dry-outs must be done in a controlled process following prescribed ramp rates and hold points to further allow proper development of designed properties
Best Practices
- Assure proper air cure times and temperatures (60*F to 90*F)
- Assure proper air exchange during Dry-out for circulation and venting of gasses and steam
- Use weep holes when possible
- The conservative approach is always the best approach
Example
- Discuss Dry-Out of Phos Bonded Plastic Burner Throats of Furnace. It was done electrically without proper air exchange.
Installation
- Select the appropriate material for the job. Consider installation technique and orientation of the equipment
- Ensure material is within shelf life
- Store materials properly
- Maintain temperatures between 60*F and 90*F
- Keep it DRY
- Make sure proper equipment is used and it is in proper working order
- When forming, make sure forms are water tight and sturdy enough to support the load of the material being installed
- Assure proper accommodations for ambient temperatures. Remember that Monolithics have to go through a chemical reaction which is exothermic and that reaction is affected by ambient conditions.
- Get refractory contractor involved in T/A planning early, up to 1 year in advance
- Owner – Operators: make sure refractory installers have clean potable water sources for compressed air, welding machines, and plot space in unit for material storage, mixing equipment, gumming rigs, etc.
- Having a refractory coordinator to interface with installer works best
- Inspect linings as a team, and color code markups so refractory marks are distinguishable from mechanical.
- Refractory installers prefer to be responsible for anchor installations as well as for material installations.
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