DOCUMENT NO.: CALDERYS/PAS/IM/001 REVISION NO.: 0 INSTALLATION MANUAL FOR DENSE CASTABLE

Transcription

1 INSTALLATION MANUAL

2 Index 1. Installation of Dense Castable. 2. Storing of Dense castable. 3. Anchor Welding 4. Preparation for Installation 4.1 Surface Preparation. 4.2 Shuttering Preparation. 4.3 Tool and Tackles. 4.4 Shuttering Fixing. 4.5 Fixing Water Percentage. 5. Method of Installation. 6. Curing.

3 1 Installation of Dense Castable 1.1 Making preparation as per Procedure. 1.2 Check anchor height from back-up layer / from shell. 1.3 Inspect back-up layer. 1.4 Inspect formwork. 1.5 Place formwork as per given in drawings. 1.6 Fix water percentage as per Product Specification. 1.7 Fix mixing time as per ISO procedure. 1.8 Take one batch of material and mix it in service pan and fix the mixing schedule as per requirement. 1.9 Discharge and start casting as per requirement Continue mixing / casting as per requirement Allow the castable to set after casting is over. Check setting intermittently Allow the castable to set after the casting is over. Check the setting intermittently Remove the former after castable has set Inspect and dress if required Do air and wet curing as per procedure Inspect again after curing Complete documentation work. Use format for records.

4 2 Storing of Dense Castable 2.1 Always store under covered space. Never in open area. 2.2 Protect from moisture. Keep dry. 2.3 Stack away from the walls on wooden pallets. 2.4 First In First Out (FIFO) is must. 2.5 Must be used within the self life period.

5 3 Anchor Welding 3.1. Check the anchor dimensions (randomly) Clean the surface of the shell thoroughly with wire brush Mark the location in the shell as specified in the drawing as per decided spacing. Ensure marking orientation of the anchors as per drawing Put a punch mark in the anchor welding location Grind the surface all around the punch mark. This will ensure the better welding of anchor with shell Weld one anchor (ensure services of qualified welder only). Check the quality of welding rods Check the projection (dimension) of anchor in the shell and ascertain coverage of intended lining thickness Hammer test the welded anchor If satisfactory, continue welding of other anchors Check the perpendicularity of anchor with respect to shell and parallel of the anchors with respect to base reference anchor Hammer test randomly to ensure proper welding Fill the welding inspection report after inspection with client or any other inspection party.

6 4 Preparation for Installation 4.1 Surface preparation Clean the shell with wire brush / compressed air thoroughly (if there is no back up layer), before going to apply refractory. The surface must be free from grease, oil, dust and any other foreign material Clean the anchor with wire brush thoroughly If there is any backup layer, provide a plastic sheet or bituminous paint coating above the back up layer as mentioned in the drawing If there is no back up layer, apply one coat of bituminous paint on the shell Provide one coat of Bituminous Paint for anchor to take care of expansion of anchor Wrap tips of the anchors with insulation tape or provide plastic cap for expansion allowance. 4.2 Shuttering Preparation Make plan for casting as per site condition Prepare shuttering as per casting plan Decide the panel size, if not already decided. Panel size normally should not exceed 800x Plan staggered panels as far as possible to ensure staggered joints.

7 Stopper plate has to be designed in such a way that, it should have a step of minimum 25 mm with a slope of 25mm at the middle of stopper. Avoid straight stopper plate Shuttering materials can be either wooden or metal. But ensure shuttering has to be strong enough to bear the load of material, vibration, ramming and etc., if required give further supports. Ensure shuttering material is having holes for making vent holes at an interval of mm Ensure orientation of shuttering for casting suitability Apply Grease / oil at shuttering surface for easy removal and prevention of water absorption Ensure number of shuttering available at site to avoid want of shuttering for casting. 4.3 Tools and Tackles Pan Mixer Machine should be located as close as possible to the installation site. Check the mixer condition (RPM, gap between scraper and bottom plate, discharge door, gear oil, DOL starter and etc.) Check the working of Needle Vibrator and ensure the availability of adequate needle size with spare Ensure easy availability of portable water Verify capacity of water measuring jar Ensure availability on ice if, intended to be used Ensure availability of following items: Carpentry Tools

8 Masonry Tools Measuring jar for measuring water Hand lamps First aid box with necessary medicine Drums for storing Potable water Pulley and Rope for lifting castable bags, water and other materials required at higher elevation Welding machine, electrode etc Thermometer for measuring water temperature. 4.4 Shuttering Fixing Ensure the proper shuttering with required tools & tackles and supports Ensure the required numbers of shuttering and stopper plate at site to avoid stoppage of work to want of shuttering / stopper plate Ensure separate manpower for fixing the shuttering, while many fronts are available for casting Apply a coat of grease / oil over the from work. Check it before placement. 4.5 Fixing Water Percentage Clean the mixer thoroughly. Charge known quantity of castable in the mixer.

9 4.5.2 Mix dry for about one minute Add specified quantity of water Mix for 3-5 minutes, in case of Conventional Castable, 5-7 minutes, in case of Low Cement Castable Check the mix material with ball in hand method If the mix is too dry, add small quantity of water Mix again for 1-2 minutes, if required From the above experience, fix the water % and mixing time for rest of the mixing. The mixing time should not exceed 10 minutes and water % should not exceed specified limits.

10 5. Method of Installation 5.1 The mixed castable should be cast as early as possible. In any case it should not exceed 15 minutes after mixing. 5.2 Fill the mixed castable in the shuttering and vibrate thoroughly (check needle size) 5.3 Draw back the needle slowly in running condition. 5.4 Ensure proper filling of shuttering. 5.5 Ensure providing vent holes in the cast panel before setting. 5.6 Check the surface for proper setting. 5.7 Remove shuttering carefully after material has set.

11 6. Curing 6.1 Practice wet curing using wet gunny bag for clothes. Sprinkle water on the gunning bag clothes as specified in the procedure on case to case basis. 6.2 Allow air-drying for minimum 12 hours. 6.3 The specified heating schedule should be followed strictly. 6.4 Keep records of material batch no. water % mixing time, etc.