AGC Plibrico Monolithic Refractories

AGC Plibrico Monolithic Refractories
Since starting out as the ﬁrst company in Japan to manufacture monolithic refractories in 1954,
AGC Plibrico has developed into a specialized monolithic refractory manufacturer.
The company name Plibrico is an acronym of the words Pliable Firebrick Company (pliableﬁrebricks = monolithic refractories).
Characteristics of Monolithic Refractories
In contrast with shaped refractories, which are formed into a particular shape before shipping, monolithic

refractories are shipped in a powdered or granular clay-like product, and can be shaped on site to match thespeciﬁc needs of customers.

No Need for Skilled Workers

Reduced Workload

Application of monolithic refractories does not require
skilled workers, as in the refractory lining application
using shaped refractories.

With monolithic refractories there is no need to carryheavy bricks.

Shorter Construction Period

Complex Shapes

The refractory lining applications can be completed fasterusing monolithic refractories than using shaped refractories.

Monolithic StructureWith monolithic refractories it is possible to form
complex shapes, such as a boiler walls and aroundburners.

Using monolithic refractories it is possible to reduce thenumber of joints in comparison with shaped refractories,
thereby minimizing falling oﬀ and joint corrosion.

Characteristics of AGC Plibrico Monolithic Refractories
AGC Plibrico delivers superior quality to customers by conducting strict raw material acceptanceinspections and traceability management.
AGC Plibrico caters to small-lot production orders and short-term delivery deadlines and promises greater
security and peace of mind for customers.
AGC Plibricoʼs Chigasaki Plant has Manufacturing and Product Development divisions that cater tocustomer needs in a timely manner, and help to resolve customer issues.

AGC Plibrico Gunning Materials
AGC Plibrico considers the gunning application method to be the most economical application method formonolithic refractories, and has a particular preference for this method. Through the development ofmethods that were conventionally considered impossible, such as dry gunning of low cement castablerefractories (THERVEK AD) and gunning of plastic refractories (THERVEK HR), AGC Plibrico is pursuing
greater eﬃciency in refractory application methods.

（THERVEK）
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AGC Plibrico Monolithic Refractory Lineup
Contents
AGC Plibrico Monolithic Refractories ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1
AGC Plibrico Monolithic Refractories Lineup ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2Classiﬁcation
Refractory
castables
Cementcastables

Light weight
insulating castables
Refractory
castables
Light weight
insulating castables

BondingsystemInstallation method

Product name３

Casting/ trowelling
Hydration
bonding
Dry gunning

３

Vibration casting

４

Free-ﬂow casting
Low cement castables
Wet gunning

４

Coagulation
bonding

４
５

Dry gunningRamming
Plastic refractories

Page

Plastic gunning
Patching

５

Claybonding５

Phosphatebonding6

Acid resistant castable refractories

6

Abrasion resistant castable refractories

6

Abrasion resistant plastic refractories

7

Specialized castables

7〜8

Other monolithic refractories

Points for Attention in Applying Castable Refractories
Points for Attention in Applying Plastic Refractories

2・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 9〜11・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 12〜13

Cement castables（Casting / Trowelling）

Easy installation and excellent general-purpose characteristics

Refractory castables■■■

Powdered product consisting of carefully selected refractory aggregate and alumina cement.

Can be prepared simply by adding an appropriate amount of water and mixing using a mixer, and applied easily by either
casting or trowelling. When applying by casting, prepare suitable forms.
The requisite degree of strength can be achieved through hydration bonding of the alumina cement by curing for 24hours at normal temperature.

Characteristics• Enables easy application of refractory lining walls with superior refractoriness.
• Has low thermal conductivity in comparison with shaped refractories, and can contribute to energy saving. Also oﬀers
greater resistance to thermal spalling than shaped refractories.
• Oﬀers an extensive lineup of products with maximum service temperatures ranging between 1350℃ and 1800℃, andcan be used for all manner of equipment.

Light weight insulating castables■■■

Powdered product consisting of carefully selected light weight aggregate and cement.

Can be prepared simply by adding an appropriate amount of water and mixing using a mixer, and applied easily by either
casting or trowelling. When applying by casting, prepare suitable forms.

The requisite degree of strength can be achieved through hydration bonding of the cement by curing for between 24
and 48 hours at normal temperature.

Characteristics• Enables easy application of refractory lining walls with superior thermal insulation.
• Oﬀers an extensive lineup of products with thermal conductivity ranging between 0.1W/m K and 1.2W/m K, and cancater to all manner of energy-saving requirements.

Cement castables（Dry gunning）

Superior gunning performance and excellent general-purpose characteristics

Gunning refractory materials■■■

Powdered product consisting of carefully selected refractory aggregate and alumina cement.

Prepare a Need Gun or other gunning machine, supply the powdered product using compressed air, and apply to therefractory lining walls with the addition of water at the nozzle. Dry gunning does not require forms or mixing.
The requisite degree of strength can be achieved through hydration bonding of the alumina cement by curing for 24hours at normal temperature.

Characteristics• Dry gunning castable refractory material with superior gunning performance (superior adhesion and low rebound loss).
• Signiﬁcantly increases installation eﬃciency in comparison with casting, since no forms or mixing are required.
• Oﬀers an extensive lineup of products with maximum service temperatures ranging between 1300℃ and 1800℃, andcan be used for all manner of equipment.

Gunning light weight insulating materials■■■

Powdered product consisting of carefully selected light weight aggregate and cement.

Prepare a Need Gun or other gunning machine, supply the powdered product compressed air, and apply to the refractory lining walls with the addition of water at the nozzle. Dry gunning does not require forms or mixing.

The requisite degree of strength can be achieved through hydration bonding of the cement by curing for between 24
and 48 hours at normal temperature.

Characteristics• Dry gunning insulating castable material with superior gunning performance (superior adhesion and low rebound loss).
• Signiﬁcantly increases installation eﬃciency in comparison with casting, since no forms or mixing are required.
• Oﬀers an extensive lineup of products with thermal conductivity ranging between 0.2W/m K and 0.5W/m K, and cancater to all manner of energy-saving requirements.

3

Low cement castables（Vibration casting）

Low cement castable refractory with density that surpasses that of shaped refractories■■■

Powdered product consisting of carefully selected refractory aggregate, ultraﬁne powdered materials and a small
amount of alumina cement.

Can be prepared by adding an appropriate amount of water and mixing using a mixer, and applied by casting under suitable vibration. When applying by vibration casting, prepare suitable forms.

The prescribed degree of strength can be achieved through coagulation bonding of the ultraﬁne powder within 24 hours
at normal temperature.

Characteristics• By using ultraﬁne powdered raw materials, low cement castable refractories succeed in dramatically reducing theamount of alumina cement and mixing water required, thereby achieving drastic improvements in corrosion resistanceand heat resistance in comparison with cement castable refractories.
• By reducing the amount of mixing water, low cement castable refractories achieve greater density and drastic
improvements in strength and abrasion resistance in comparison with cement castable refractories.
• Although conventionally the performance of monolithic refractories has been considered inferior to that of shaped
refractories, the performance of low cement castable refractories is not inferior to that of shaped refractories.

Low cement castables（Free-ﬂow casting）

Low cement castable refractory that does not require the use of a vibrator■■■

Powdered product consisting of carefully selected refractory aggregate, ultraﬁne powdered materials and a small
amount of alumina cement.

Can be prepared by adding an appropriate amount of water and mixing using a mixer, and applied by casting without
vibration. When applying by free-ﬂow casting, prepare suitable forms.

The prescribed degree of strength can be achieved through coagulation bonding of the ultraﬁne powder within 24 hours
at normal temperature.

Characteristics• By optimizing the combination of ultraﬁne powdered raw materials and dispersants, and oﬀers improved the ﬂuidity andfree-ﬂow casting.
• These refractories enable the application of refractory lining walls oﬀering excellent corrosion resistance, heat resistance,
strength, abrasion resistance and performance on par with shaped refractories without using a vibrator.These
refractories display their eﬀectiveness in narrow spaces and places where the use of a vibrator is not possible.

Low cement castables（Wet gunning）

Low cement castable refractory that increases eﬃciency of installation using wet gunning■■■

Powdered product consisting of carefully selected refractory aggregate, ultraﬁne powdered materials and a small
amount of alumina cement.

The development of low cement castable refractories (free-ﬂow casting) has enabled pumping of low cement
castable refractories. Wet gunning is a method of application in which mixed castable refractories are delivered
under pressure via a pump system, injected into the gun nozzle together with compressed air and setting agent.

The prescribed degree of strength can be achieved through coagulation bonding of the ultraﬁne powder within 24 hours
at normal temperature.

Characteristics• The enabling of wet gunning has eliminated the need to set forms, and oﬀers improved installation eﬃciency incomparison with vibration casting.These refractories enable the application of refractory lining walls oﬀering
performance on par with shaped refractories using the gunning application method.

4

Low cement castables（Dry gunning）

Low cement castable refractory that further increases eﬃciency of installation using dry gunning■■■

Powdered product consisting of carefully selected refractory aggregate, ultraﬁne powdered materials and a small
amount of alumina cement.

With wet gunning method of low cement castable refractories, the task of mixing the product in a mixer was a limiting
factor for application eﬃciency. With its development of a specialized gun nozzle, AGC Plibrico has achieved the same
mixing performance as a mixer with in-nozzle mixing, and perfected wet gunning method for low cement castablerefractories. Prepare a PLIMATE-Ⅱ and Need Gun, supply the powdered product using compressed air, and apply to therefractory lining walls with the addition of water at the nozzle. The PLIMATE-Ⅱ is equipped with a built-in setting agent
mixing quantitative supply system.

The prescribed degree of strength can be achieved through coagulation bonding of the ultraﬁne powder within 24 hours
at normal temperature.

Characteristics• Dry gunning of low cement castable refractories does not require forms or mixing, and greatly improves applicationeﬃciency in comparison with vibration casting. These refractories enable the application of refractory lining walls oﬀering
performance on par with shaped refractories easily and conveniently using the dry gunning method.

Plastic refractories（Ramming）

Clay bonded ramming refractory with superior resistance to thermal spalling■■■

Plastic ramming refractory consisting of carefully selected refractory aggregate and highly-pliable clay, adjusted intoa workable form with the addition of moisture. The product is supplied in 50mm-thick slices.
Place slices of the product in the form, and apply to the refractory lining walls by ramming them ﬁrmly into place with apneumatic rammer. Prepare forms for ramming application.

Clay bonded plastic refractories maintain their shape after ramming due to the adhesive power of the clay. After ﬁring,gives the refractories their strength (i.e. heat setting).

Characteristics• Plastic refractories do not require mixing, and can be rammed as they are.
• Clay bonded plastic refractories oﬀer superior resistance to thermal spalling.

Plastic refractories（Plastic gunning）

Clay bonded plastic gunning refractory with superior resistance to thermal spalling■■■

Plastic gunning refractory consisting of carefully selected refractory aggregate and highly-pliable clay, adjusted into aworkable form with the addition of moisture. The product is supplied in granular clay-like form.

Using AGC Plibricoʼ s independently developed specialized gunning machine (HyRATE unit), it is now possible toapply plastic refractories by gunning (HyRATE method), achieving a drastic improvement in installation eﬃciency incomparison with ramming.

Clay bonded plastic refractories maintain their shape after ramming due to the adhesive power of the clay. After ﬁring,gives the refractories their strength (i.e. heat setting).

Characteristics• Gunning signiﬁcantly increases application eﬃciency in comparison with ramming.
• Clay bonded plastic refractories oﬀer superior resistance to thermal spalling.

5Plastic refractories（Patching）

Patching repair material with superior adhesive properties■■■

Plastic refractory for patching use, consisting of a combination of carefully selected refractory aggregate and phosphate binder, adjusted into a workable form.

Patching refractories are adjusted to a softer consistency than ramming plastic refractories, and used for repairing small-scale
damaged sections of refractory lining walls by patching (i.e. manual ﬁlling).
After application, patching refractories are ﬁxed in place by the strong adhesive power of phosphate. When theserefractories are heated to temperatures in excess of 350℃, a phosphate condensation reaction occurs, signiﬁcantly
improving the strength of the refractory (i.e. heat setting).

Characteristics• These refractories are aﬃxed ﬁrmly to the repair area by the strong adhesive power of phosphate.
• After heating, patching refractories display extremely strong adhesive strength in their adhesion to the base material.
• Patching in this way enables you to prolong the service life of your refractories by performing easy repairs.

Acid resistant castables

AGC Plibrico s acid resistant castable refractory series: AR Series■■■

AR Series are powdered products consisting of carefully selected refractory aggregate and binders, combined according
to the application of use.

These refractories can be applied by casting, trowelling or dry gunning.

The prescribed degree of strength can be achieved within 48 hours at normal temperature.

Characteristics• Alumina cement (which is typically used as the binder for monolithic refractories) exhibits poor resistance to acids, andcannot be used in applications where refractories will be exposed to strong acids.
• AR900 is a chemically (water glass) bonded castable refractory with superior acid resistant characteristics.
• AR800 utilizes a special alumina cement as its binder, enabling it to display superior performance in terms of resistanceto both acids and alkalis.
• AR500 utilizes a special cement as its binder, oﬀering superior resistance to acids.

Abrasion resistant castables
AGC Plibrico s abrasion resistant castable refractory, for parts of FCC reactors
subjected to abrasive wear by catalysts■■■

Powdered product consisting of carefully selected refractory aggregate, light weight aggregate, and a special binder.
This series oﬀers a lineup of products that can be applied by vibration casting, free-ﬂow casting or dry gunning.
The prescribed degree of strength can be achieved within 24 hours at normal temperature.

Characteristics• Refractories used in FCC reactors (ﬂuid catalytic cracking reactors, a type of apparatus used at oil reﬁneries) are
subjected to intense abrasive wear caused by the circulation of the catalyst inside the reactor. While this requires them
to be resistant to abrasion, they must also have insulating properties in order to protect the reactor shell. The ABR ofabrasion resistant castable refractories achieves the conﬂicting properties of both abrasion resistance and insulating
performance.

6Abrasion resistant plastic refractories
AGC Plibrico s abrasion resistant plastic refractory, for parts of FCC reactors
subjected to abrasive wear by catalysts■■■

Powdered product consisting of carefully selected refractory aggregate and a special phosphate binder.

The refractory is prepared by adding an appropriate amount of water and mixing in a mixer, and applied by ramming using apneumatic rammer. If the amount of mixing water is increased, CYMIX can also be applied by hand packing.

The prescribed degree of strength can be achieved within 24 hours at normal temperature. On additional heating, aphosphate condensation reaction occurs, producing an extremely strong refractory installation.

Characteristics• Refractories used in the cyclone sections of FCC reactors (ﬂuid catalytic cracking reactors, a type of apparatus used atoil reﬁneries) are subjected to particularly intense abrasive wear by the catalyst. This requires them to be highly
resistant to abrasion. CYMIX is an abrasion resistant plastic refractory that is ideal for use in such locations.

Other monolithic refractories
High-strength joint packing and bond■■

PX-BD is a paste-type product consisting of refractory aggregate and water glass binder. It can be delivered in plastic
tube, caulking tube or pail can form.

PX-BD is a high-strength joint packing and bond.

• PX-BD can be used to ﬁll joints by inserting a tube into the open space between brick joints and ﬁlling them
directly with the product.

• When performing patching repairs, a thin underlay coating of PX-BD can be applied to the surface of the basematerial using a trowel or similar tool. Doing so increases the adhesive strength of the bond between the basematerial and the patching material, increasing the eﬀectiveness of the repair.

■

When PX-BD is heated to temperatures in excess of 500℃, chemical bonding occurs, increasing the strength of therefractory (i.e. heat setting).

Other monolithic refractories
AGC Plibrico s coating refractory■■

PX-CO is a powdered product consisting of refractory aggregate and a special binder.

The refractory is prepared by adding an appropriate amount of water (or other dedicated ﬂuid) and mixing in amixer. A coating is then applied to the surface of refractory lining walls or metal surfaces using a trowel or pastingbrush.

Characteristics• PX-CO1700 (2P) is a highly corrosion resistant, high-strength coating material that can extend the service life ofincinerators when used as a coating for incinerator walls.
• PX-CO1100 is an elastic, impact-resistant and abrasion resistant coating material, which improves abrasion resistantcharacteristics when applied to parts of FCC reactors that are subjected to abrasive wear by catalysts.
• PX-CO900 is an acid resistant coating material for application to metal surfaces.

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Other monolithic refractories
AGC Plibrico s injection refractory■■■

PX-IJ is a powdered product consisting of carefully selected refractory aggregate and water glass.

The refractory is prepared by adding an appropriate amount of water and applied by injection. It can also be
applied by hot injection.

When PX-IJ is heated at working temperature, chemical bonding occurs, resulting in hardening (i.e. heat setting).

Characteristics• PX-IJ can be used to repair localized hot spots of equipment by injection.
• PX-IJ1600 is an injection repair refractory for blast furnaces.

Other monolithic refractories
AGC Plibrico s heat setting mortar■■■

PX-DM is a joint mortar for alumina and alumina-silica bonding bricks. It is a powdered product consisting of carefully
selected refractory aggregate and water glass.

The refractory is prepared by adding an appropriate amount of water and applied by trowelling.
When PX-DM is heated, chemical bonding occurs, resulting in hardening (i.e. heat setting).

Characteristics• PX-DM oﬀers a lineup with refractoriness ranging from 30 to 40, and is used according to the quality of refractory
bricks.

[P] indicates that the product can be pumped under pressure.

[T] indicates that the product is designed for application by trowelling.

[K] indicates that an anti-explosive additive has been added to the product.

[S] indicates that the product is a high strength.

[A] indicates that the product contains low levels of iron.
[H] indicates that the product is a high heat resistance.

[L] indicates that the product is a light weight refractory.

[W] indicates that the product has wire added to it (the number indicated the percentage amount added).

8

Points for Attention in Applying Castable Refractories
1. Storage of castable refractories■

Please pay attention to the following points when storing castable refractory products.
• Store castable refractories in a dry location. Pay particular care to rain and moisture from the ground.
• In summer, avoid direct sunlight, high temperatures and high humidity. Store castable refractories in a cool indoor location
and avoid temperature changes wherever possible.
• In winter, store castable refractories in a warm indoor location wherever possible.
• In some cases, where products have expired their storage life, it may not be possible to achieve the prescribed ﬂuidity
and/or hardness characteristics. Please use castable refractories as soon as possible.

2. Casting of cement castable refractories(1) Forms(2) Mixing• Use strong frame boards for forms to prevent loosing or
deformation due to side pressure when from poured castablerefractories, and use reinforcing materials as needed.
• Apply oil or other suitable coatings to the surface of the forms
that are in direct contact with the castable refractory toensure smooth removal of the forms after hardening.

• Prepare a mixer (the standard equipment is a mortar
mixer).

(3) Adjustment of working time and setting time
• Working time of castable refractories (i.e. the amount of time
for which the mixed product retains enough ﬂuidity to beuseable before setting) are designed to be around 60 minutes
at an outside temperature of 20℃.
• Setting times for castable refractories are designed to bewithin 24 hours (or 48 hours for some products) at an outside
temperature of 20℃. (Please check the Standard setting
times column of the product information.)• The working time of cement castable refractories decreases
with increasing temperature. On the other hand, setting time
tends to be longer at less than 10℃ and around 30℃.

• Feed the entire contents of the paper bag or container
bag into the mixer. Do not divide the contents of suchbags into smaller portions.

• First, mix the product as it is for around 1 minute before
adding water.

• Next, mix the product while adding around 1/2 of thestandard amount of mixing water. Add the remaining
amount of water a little at a time while checking thestate of the mixture, until you obtain the desired level of
ﬂuidity.
・Use pure water for mixing (ideally, use drinkable waterwherever possible).
・Use an amount of mixing water that is within thestandard amount of mixing water, and the smallest
possible amount with which application is possible.
・The standard mixing time is 3 minutes.
・Ensure that the mixer, scoops, trays, buckets and anyother tools that you use are clean before mixing.
・After mixing is completed, clean the mixer and othertools thoroughly before placing other materials in themixer, to ensure that none of the previously mixed
castable refractories remain.

・To ensure working time for ambient temperatures inexcess of 30℃, lower the temperature of the materials, oruse ice to cool the mixing water.
・To adjust setting time for ambient temperatures below
10℃, raise the temperature of the materials or the mixing
water.

(4) Casting• Mixed castable refractories lose their ﬂuidity as time passes. Please complete casting work as soon as possible.
• When carrying out casting work, use a rod or other tool when ﬁlling the form to prevent the formation of surface voids in thecasting. Where the product has been mixed with a small amount of water, a vibrator may be used.

(5) Curing and removal of forms• After application, it is necessary to leave castable refractories without the application of external forces, until they have
hardened and set. Only remove forms once the standard setting time has elapsed.
• Where the forms must be removed after a shorter period of time than the standard setting time for some unavoidable reason,check carefully to ensure that the refractory has hardened and set properly.
• Even in cases where the forms have been removed after a shorter period of time, leave the refractory in an untouched state forthe remainder of the standard setting time.
• At temperatures of 5℃ and below, the hardening process for castable refractories slows to almost a complete stop. When
applying castable refractories in winter, even where the mixing water has been warmed, there are cases in which temperatures
fall rapidly overnight and forms cannot be removed in 24 hours. In such cases, warm the surrounding area using a heater, or
use other heated curing measures.
• If castable refractories freeze during the curing process, they may not harden and set, or they may set but with an extremely
degraded level of strength. When casting refractories during winter, take care to ensure that they do not freeze.
• Because the hardening of the cement used in cement castable refractories is an exothermic (i.e. heat-producing) reaction, thetemperature of castings increases during the curing process. During summer, it is possible that moisture may evaporate alongwith the increase in temperature, leaving a shortage of the moisture required for the cement hydration reaction and leading to
insuﬃcient level of strength in the ﬁnished casting. In such cases, sprinkle water on the work surface, or cover the work surface
with wet cloth or paper (water curing).
• In their undried state, castable refractories undergo a carbonation reaction (eﬄorescence) when they are in contact with air.
This phenomenon is particularly likely to occur with insulating castable refractories. When applying an insulating castablerefractoires layer on the operating side, drying as quickly as possible after it has been applied.

93. Application of cement castable refractories by trowelling■

The procedure for application of cement castable refractories by trowelling is essentially the same as for casting.
However, please pay attention to the following additional points that are speciﬁc to application of cement castablerefractories by trowelling.

(1) Forms(2) Mixing• Forms are not required for the application of cement castablerefractories by trowelling.

• In order to produce a good consistency for application of
cement castable refractories by trowelling, it is necessary
to mix the product suﬃciently. Please mix for around 5
minutes.

(3) Trowelling• Install a lath (wire mesh, etc.) or other supporting material on the refractory lining walls. Push the
castable refractories in using a trowel (or by hand) to ensure that it ﬁlls the back part of the
supporting material, and ﬁnish the surface using a trowel.
• The standard thickness for application of cement castable refractories by trowelling is 50mm.

4. Vibration casting of low cement castable refractories■

The procedure for application of low cement castable refractories by vibration casting is essentially the same as for
casting. However, please pay attention to the following additional points that are speciﬁc to application of low
cement castables by vibration casting.

(1) Forms(2) Mixing• Vibration casting requires the use of morerobust forms than for standard casting.

• Mixing times for low cement castable refractories tend to be longer thanfor standard cement castable refractories. Please mix for around 5 minutes.

(3) Adjustment of working time andsetting time
• Working time and setting time of low cement
castable refractories become shorter as
temperature rises. Especially in summer,
working time may become shorter, presenting
an obstacle to work. Therefore, add a setting
retarding additive during mixing. Please checkthe product information for the particular
product that you are using with regard to theamount of setting retarding additive to be
added.

• Adding excessive amounts of mixing water to low cement castablerefractories causes signiﬁcant degradations in their physical properties.
Please observe the standard amount of mixing water to be added. In
particular, low cement castable refractories for vibration casting aredesigned to only exhibit ﬂuidity when vibration is applied to them. Pleasetake care to avoid adding excessive amounts of mixing water, since thesecastable refractories appear to have no ﬂuidity during mixing.

(4) Casting• When applying low cement castablerefractories by vibration casting, vibrate thecastable refractories directly using apole-shaped vibrator or similar tool, or
attach a vibrator to the form and vibrate theform as it is being ﬁlled.

5. Free-ﬂow casting of low cement castable refractories■

The procedure for application of low cement castable refractories by free-ﬂow casting is essentially the same as forvibration casting, although neither a rod nor vibrator are required. Vibration the mixture may cause the castablerefractories to separate.

6. Dry gunning of cement castable refractories
■

■

■

■

Dry gunning of cement castable refractories is a method of
application in which the powdered product is supplied to a Need
Gun or other gunning machine using compressed air, and applied
by gunning, with the addition of water at the nozzle.

Dry gunning method
Powdered product

The PLIMATE system improves the quality of the gunningapplication and suppresses dust during gunning by adding acertain percentage of water to the powdered product in advance.

When gunning, hold the gun nozzle perpendicular to the work
surface, and at a distance of between 0.5m and 1.0m from thesurface generally.
Request for application of cement castable refractories by dry
gunning to be carried out by AGC Plibrico or another specialist
service provider.
10

PLIMATE-Ⅱ(premoist / quantitative powdered
product supply device)
Need Gun 400(gunning machine)
Mixing water

Compressed air
Gun nozzle

7. Wet gunning of low cement castable refractories
Wet gunning of low cement castable refractories is a method of
application in which mixed castable refractories are delivered underpressure via a squeeze pump or other pump system, injected into thegun nozzle together with compressed air and setting agent, andapplied to the refractory lining walls.
■ In wet gunning of low cement castable refractories, a setting agent is
added in the nozzle. The Q-Gun system supplies a measured quantityof powdered setting agent.
■ When gunning, hold the gun nozzle perpendicular to the work surface,and at a distance of between 0.5m and 1.0m from the surface generally.
■ Request for application of low cement castable refractories by wet
gunning to be carried out by AGC Plibrico or another specialist service
provider.
■Wet gunning method
Mixingwater

Powderedproduct

Q-Gun（quantitative setting
agent supply device）

Mixer

Setting agent

Compressed air

Squeeze pump (pump device)
Gun nozzle

8. Dry gunning of low cement castable refractories
Dry gunning of low cement castable refractories is a method of
application in which the powdered product is supplied to a Need Gunor other gunning machine using compressed air, and applied to therefractory lining walls with the addition of water at the nozzle.
■ The adoption of a specialized gun nozzle has enabled in-nozzle mixingof low cement castable refractories.
■ The PLIMATE system improves the quality of the gunning construction
and suppresses dust during gunning by adding a certain percentage ofwater to the powdered product in advance. It is also equipped with asystem for supplying a ﬁxed quantity of setting agent.
■ When gunning, hold the gun nozzle perpendicular to the work surface,and at a distance of between 0.5m and 1.0m from the surface generally.
■ Request for application of low cement castable refractories by dry
gunning to be carried out by AGC Plibrico or another specialist service
provider.
■Dry gunning method
Powderedproduct

Setting
agent

PLIMATE-Ⅱ(premoist / quantitative powdered
product supply device)
Need Gun 400(gunning machine)
Mixing water

Compressed air
Gun nozzle

9. Drying of castable refractories■

Refractory lining walls constructed using castable refractories are dried, through a process called dryout, in order togradually remove internal moisture. When doing so, if the temperature is raised too rapidly, there is a risk of causing
explosive spalling as a result of massive steam pressure arising inside the refractory lining walls, which could damage therefractory lining walls themselves. Please carry out dryouts according to the prescribed speed of temperature increase. In
addition, please raise the temperature carefully in the following cases.

・ When castable refractories (especially low cement castable refractories) are applied with an amount of low water, maintain aretention time of 350℃ because of the refractory lining wall with density at the curing temperature is lower 10℃.
・ The temperature of chemically bonded (water glass) castable refractories is increased at a moderate speed because
dehydration is diﬃcult to proceed.
■

In case of entering operation directly from dryout

Max.50℃/h
500℃■

In case of lowering the temperature after dryout(for inspections inside the furnace, etc.)

Raise to operating
temperature

Temperature (°C)

Temperature (°C)

Raise to operating
temperature

350℃

Max.30℃/h

Min.350℃

Max.100℃/h

Max.30℃/h
Lower temperature(natural cooling)

Setting timeMin.24h■

In case of refractory lining wall with density

Max.50℃/h
Min.350℃

Min.24h■

Max.30℃/h
Setting timeMin.24h( ) time maintained( ) time maintained Repeat increasing temperature

Time (h)Maintain for 1 hour per
lining thickness of 10mm

In case of chemically (water glass) bonded castables

Temperature (°C)

Temperature (°C)

Raise to operating
temperature

350℃

Setting time

Time (h)Raise to operating
temperature

Max.50℃/h
500℃
350℃

Max.20℃/h

Setting time

Time (h)Min.24h

Maintain for 1 hour per
lining thickness of 10mm

11Max.30℃/h

Time (h)Points for Attention in Applying Plastic Refractories
1. Storage of plastic refractories■

Please pay attention to the following points when storing plastic refractory products.

・ Store plastic refractories in a dry location. Pay particular care to rain and moisture from the ground.
・ In summer, avoid direct sunlight, high temperatures and high humidity. Store plastic refractories in a cool indoor location andavoid temperature changes wherever possible.
・ In winter, store plastic refractories in a warm indoor location wherever possible to prevent them from freezing.
・If plastic refractories are removed from their packaging and left out they will harden and lose the suitable viscosity required for
application. Do not remove plastic refractories from their packaging until immediately before application.
・ Always use new materials. Do not use plastic refractories that have expired their storage life, or have dried out.

2. Ramming of plastic refractories(1) Forms■■

Use forms that are strong enough to suﬃciently withstand the force of ramming.

Take care to use suﬃcient reinforcement to prevent deformation of forms when building the framework, and ensure thatthe shape and dimensions of forms do not change during the ramming process.

(2) Ramming■

Since the product is in clay-like form, mixing is not required. The product can be rammed
immediately after opening.

• Please prepare and use a pneumatic rammer.
■

■

■

■

Lay out slices of plastic refractory to the full thickness of the refractory lining wall, and ram
them into place evenly with the pneumatic rammer.

When ramming, hold the pneumatic rammer as perpendicular to the ramming surface aspossible. Move the pneumatic rammer backwards and forwards in the direction of the wall
thickness, and shift it sideways as you proceed with ramming.
When a single ramming thickness is greater than 50mm, the force of impact from thepneumatic rammer is not transmitted all the way to the bottom, and each slice layer will
not be in suﬃciently close contact with the others. Be sure to carefully ram each slice
thickness thoroughly into place. As a guide, suﬃciently ram each slice such that a slice withthickness of around 50mm is compressed to a thickness of around 25mm.

After ramming, the rammed surface will be smooth and ﬂat. Use a scraper or other tool toscrape the surface into a rougher texture before laying the next piece of material on top of it.

3. Gunning of plastic refractories (HyRATE method)■■

For gunning of plastic refractories, a dedicated gunning machine (HyRATE unit) is used.

Since the product is granular clay-like product, mixing is not required. The product can be fed directly into the HyRATE
unit.
• With gunning plastic refractories there is no worry of explosive spalling. Drying is also completed in a shorter period of timethan in comparison with castable refractories.
• The compact, miniature-sized MIC unit is convenient for small-volume gunning.

■

■

■
■

When gunning, hold the gun nozzle perpendicular to the work surface, and at a distance of between 0.5m and 1.0m
from the surface generally.

To ensure that layers are not formed in the refractory lining walls in the direction of the thickness, perform the entire
gunning process for the prescribed thickness of refractory material in one go, without leaving any time in between.

Clean as you work to ensure that rebound losses do not build up inside the refractory lining walls as they are constructed.

It is necessary to pay continuous attention to the direction of the nozzle to ensure that voids are not formed in theshaded parts around the tile anchors.

Plastic gunning method
Granular clay-like productCompressed air

Granular clay-like product

HyRATE unit
(mill/grinder and gunning machine)

MIC unit

Compressed air
Gun nozzle

Gun nozzle

12Points for Attention in Applying Plastic Refractories
4. Finishing(1) Trimming■■■

After applying plastic refractories, perform trimming (i.e. ﬁnishing to roughen the surface) to make it easier for moisturefrom inside the refractory to escape.

Remove the forms before the refractory lining walls harden and trim them using a scraper or other such tool.

The purpose of trimming is not to form the shape of the refractory lining walls themselves. Assemble ramming forms as
precisely as possible to minimize the amount of excess trimming required by as much as possible.

(2) Score lines
■

■

■

■

After trimming the surfaces of the refractory lining walls, make score lines into them before they harden. The purpose ofthis is to concentrate contraction of the refractory lining walls due to drying and minimize the occurrence of irregularcracks.
Before making score lines, be sure to draw gridlines with chalk or some other writing implement, and make score lines
along those gridlines.

Position make score lines between anchors, and make shallow score lines using a hard bladed tool. As a guide, makescore lines around 3 to 4 lines per tile anchor interval.
The depth of score lines should be around 1/3 the thickness of the wall itself. Take care to score lines at the same
depth, and perpendicular to the wall surface.

(3) Venting holes■■

After making score lines in the wall surfaces, make venting holes across the whole surface of the plastic refractory walls.
This is eﬀective in allowing moisture inside the lining walls to which the plastic refractories have been applied to escapewhen the temperature of the furnace rises.
Make venting holes by poking a wire (of diameter φ3-4mm) perpendicular to the refractory lining walls, and opening
holes randomly at intervals of around 100-150mm. As a guide, open holes to a depth of around 2/3 the thickness of theplastic refractory layer that you have applied.

5. General points for attention after installation of plastic refractories■■■

During and after the installation of plastic refractories, take suﬃcient care to ensure that the refractory lining walls do not
become wet with rainwater or other water.
After the installation of plastic refractories, leave them without the application of external forces until initial ﬁring, inorder to promote the natural drying process.

If plastic refractories freeze after installation, there is a possibility of falloﬀ and other issues during initial ﬁring. For installations during winter, take suﬃcient measures to prevent freezing.

6. Drying of plastic refractories■■

If a rapid increase in temperature takes place during initial ﬁring, refractory lining walls constructed using plastic refractories can be weakened as a result of the collection of steam formed from moisture inside the walls collecting at the work
surface, resulting in material falloﬀ. Therefore, carry out the initial increasing temperature at the prescribed speed. Be
sure to check the minimum initial ﬁring time for each particular material.

In case of entering operation immediately
after initial ﬁring temperature increase

Max.50℃/h

In case of lowering the temperature after dryout(for inspections inside the furnace, etc.)
Raise to operating
temperature

Temperature (°C)

Temperature (°C)

Raise to operating
temperature

■

500℃

Min.500℃
Max.100℃/h
Max.50℃/h
Lower temperature(natural cooling)

Time (h)( ) time maintained Repeat increasing temperature
Maintain for 1 hour per
lining thickness of 10mm

13Time (h)Head Oﬃce・East Japan Branch
6F Mita-NN Bldg., 1-23, Shiba 4-chome, Minato-ku, Tokyo
108-0014 JAPANTEL +81-3-3455-1359（Overseas Sales） FAX +81-3-3455-1362

https://www.plibrico.co.jp
THERVEK™ is a trademark or registered trademark of AGC Plibrico Co., Ltd. in Japan and other countries.

Form No. (1000) 07.2019