Installation

Module from the Refractory and Insulation Curriculum curriculum.

Module 3 - Refractory Installation · Learning Objectives · 1. Select installation method: pumped, gunited, hand-packed · 2. Install V-anchors, hex mesh, or needles per manufacturer spec · 3. Follow controlled water additions (no more than spec) · 4. Apply dry-out/cure schedule (critical to avoid explosive spalling) · 5. Hold-point QC: density, thickness, anchor spacing · Installation Method Comparison

Method	Water %	Productivity	Cost	Best For	Notes
Gunite (dry)	6-8%	High (fast)	Low	Large area, walls	Can bounce
Wet shotcrete	10-12%	High	Moderate	Surface coverage	Better adhesion
Pump cast	10-14%	Moderate	Moderate	Enclosed forms	Controlled
Hand pack	10-12%	Low	High labor	Small area, repair	Touch-up
Vibration cast	9-12%	Low	Moderate	Critical shapes	Minimize voids
Dry vibration (ram)	0-5%	Low	High skill	Taphole, plasma	Wear applications
Typical Dry-Out Schedule (Castable Refractory)
Stage	Temp	Duration	Function	Rate	Notes
Stage 1: Room T to 250F	Amb-250F	Hold 24 hr at ambient	Chemical water removal	25 F/hr	Slow
Stage 2: 250F to 500F	250-500F	Hold 24 hr at 250F	Remove free water	25 F/hr	Critical
Stage 3: 500F to 1000F	500-1000F	Hold 12 hr at 500F	Dehydrate hydrates	50 F/hr	Moderate
Stage 4: 1000F to service	1000-service	Hold 8 hr at 1000F	Final dry	50-100 F/hr	Ramp
Service soak	Service T	Hold 24 hr	Normal ops	-	Stable

Source: Refractory_Insulation_Curriculum_v1.xlsx · Sheet: Installation

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