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Instructions for Handling And Installing

Plibrico Plastic Refractories

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INSTRUCTIONS FOR HANDLING AND INSTALLING PLI BRICO PLASTIC REFRACTORIES

To assure a completed installation that will be reliable and lasting, we recommend that you read these instructions through before proceeding. Pre-Installation Considerations Material Consistency & Characteristics Plibrico plastic refractories are stiff, moist, putty-like materials. Upon leaving the factory, they have the proper workability and are ready for installation without the addition of water. To preserve the proper workability, Plibrico plastic refractories are protected by moisture retaining wrappers, and packed in cartons. Before using a Plibrico plastic, test it for workability by forming a small handful of material into a ball. It should be sufficiently pliable to mold and knit into a homogeneous monolith when rammed with a hand rammer or pneumatic tool Grouped according to setting characteristics, Plibrico plastic refractories fall into 3 general categories heat-setting, air-setting, and chemical setting. Material Storage Until installed, all Plibrico plastic refractories should be stored indoors in a cool, frost-free location. Under these conditions, the materials can be kept to the limit of their storage life. The average storage life of air & heat-setting Plibrico plastic products extends up to 12 months. The average storage life of chemical-setting refractories extends from 3 to 6 months. Since there are variations in the storage life of individual products, please note the exact storage life for the product(s) you store. When heat-setting and air-setting Plibrico plastic refractories are stored for too long and/or under hot conditions, the material may become unworkable. Reconditioning may be possible if no fresh material is directly available. Consult the Plibrico Technical Department for the proper procedures. Chemically bonded plastic refractories cannot be reconditioned. Reconditioning Frozen Material When Plibrico plastic refractories have frozen in the cartons, the material should be relocated to an

environment where the temperature is 60 degrees F or more. Material must then be thawed slowly, not quickly, as fast thawing results in a soft, non-uniform consistency. The cubes of refractory should be taken from their cartons, leaving the protective wrappers intact, and should be positioned so that warm air can circulate around them. The plastic refractory product is usable when it has fully thawed and the original workability is restored. Normally, the thawing process requires 2 to 3 days. Equipment Requirements In addition to the tools normally required for masonry construction, the installation of Plibrico plastic refractories requires:

A reciprocating pneumatic rammer with a steel or hard rubber ramming head operating at approximately 1200 strokes per minute. The shape of the ramming head depends upon the material applied, the shape of the lining, and the users experience. Bench rammers are recommended for most jobs, but floor rammers can be used where space permits.

Sufficient air hose to connect the rammer with the air supply.

An air manifold with multiple connections if more than one rammer is used. (The recommended pressure for pneumatic rammers is 80-90 psi). Sufficient air volume must be provided to maintain this pressure on all rammers being used.

A 2.5# hammer for hand ramming in small sections. A short handled spade for trimming the lining

surface. A hand tool for cutting expansion joints.

While installing plastic refractories, workers should follow normal construction safety procedures. Also refer to Material Safety Data Sheet (MSDS) for special instructions.

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Site Preparation Before beginning the installation of Plibrico plastic refractory, these precautions should be taken.

1. The site where the Plibrico materials will be installed must be clean so nothing can contaminate the refractory. The back-up surface, against which the Plibrico plastic refractory will be placed, must be smooth, without wide gaps or cracks, and thoroughly cleaned.

2. Care must be taken to prevent rain or water from contacting the refractory during installation and before bake-out takes place.

3. Care must also be taken to insure that the material does not freeze in the unfired state. Forming & Anchoring Provisions While Plibrico plastic refractories can usually be installed without forms, the use of forms and/or false anchoring is necessary in some cases. Forms are necessary for arches, suspended roofs, and walls which slope inward. Forms are recommended where it is desirable to achieve maximum compaction of the plastic in vertical walls exposed to severe mechanical load. It can also be economical to use forms for walls of large size and thickness. The forms must be braced and made of strong material to prevent movement, bending, or vibration when the material is installed. False anchoring is necessary when installing chemical setting plastics overhead. Contact the Plibrico Engineering department for specific information on forming and false anchoring methods. Depending upon the dimensions and position of the Plibrico refractory lining, it must be provided with special anchors and supports. These hold and secure the lining to the outer wall or steel structure and make it possible to remove or repair one section without affecting the stability of adjacent sections. Anchors are not to be used in molten metal contact situations. A wide range of Plibrico anchors and supports provide for all kinds of positions, temperature, and process conditions. Plibrico does not recommend the use of round bar type metallic anchors. The type and quality of anchors and supports as well as their position are given on the Plibrico drawing. If no drawing is available, contract Plibricos Engineering Department and ask for further advice before proceeding. Anchor hooks and support brackets must be securely fastened by an appropriate method to the outer

surface or steel structure prior to installation of the refractory lining. CAUTION: When forms are used, ceramic anchor tiles in their fully extended position should be to away from the inside face of the form to allow for trimming. In no case, should the plastic refractory protrude past or on top of the ceramic tile anchor after trimming.

Special Weather Conditions Hot Weather Installation Plastic refractory installations in warm or tropical climates require extra precautions due to the high ambient temperatures normally encountered. Provisions for cool storage of the Plibrico plastic are essential, particularly if the product will not be sued soon after delivery. During installation, these steps should be taken:

The distance between the cut joints should be reduced to between 20 and 28.

The distance between vent holes should be 6. CAUTION: Phosphate-bonded plastics should be vented immediately before bake out.

Prevent condensation from forming on the surface of the unfired refractory (which normally results from high humidity and lower temperatures inside the furnace than outside) by opening access doors, combustion air dampers, and flue gas dampers to create a slight draft. This reduces the risk of surface condensation, as constant ventilation is the most efficient preventative measure. Take care to limit ventilation to prevent excessive surface drying. Cold Weather Installation Plastic refractory installations in cold weather also require extra precautions:

Store plastic refractories in a frost-free warehouse. Do not install frozen plastic refractories. Take steps to prevent the material from freezing

during installation. Take steps to prevent the installed Plibrico plastic

lining from freezing in the unfired state. If material is accidentally frozen in the cartons, see

the section on reconditioning frozen material. If the plastic refractory is frozen after installation and prior to firing see the section on bake-out instructions.

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Ramming Procedures Open the carton and the moisture proof packaging at all 4 corners of the cube (with the pre-cut slices in a vertical position). Separate the individual slices with a trowel or spade. Ramming - WALLS Lay a row of either complete or cut Plibrico slabs in place against the back-up wall, plate, or insulation, and along the length of the wall or section to be lined. Never place more than 1 layer, or a 2 thickness, at a time. With the pneumatic or hand ramming tool, ram the first layer of material thoroughly into a solid, monolithic mass. This ramming must be done uniformly and thoroughly. All ramming should be done by moving in a direction perpendicular to the length of the work. When thoroughly done, the plastic should be compacted to approximately one half the original unrammed thickness. Voids should not be present, and the slices should be molded into a monolithic mass. After ramming the first layer, proceed by placing the second layer directly on top. For this second layer, and all succeeding layers, stagger the placement of the slabs so that the joint between pieces is offset from the layer below, preventing continuous vertical joints from being formed. Ramming of subsequent layers must also be done thoroughly. Do not ram the next layer against a smooth surface, as the previous rammed layer must be roughened before the next layer is placed. This will give maximum coherence between the 2 layers. This practice is of great importance in metal contact applications. As soon as the Plibrico wall reaches the height of a row of anchor hooks or support brackets, the anchors or supports must be fitted to these hooks or brackets and then embedded into the Plibrico plastic refractory. This must be done carefully, fitting each anchor into the base of the hook, and each support into the base of the tapered portion of the bracket. In order to keep anchors flexible, it is recommended that the connection between the anchor and the hook be kept free of plastic refractory. All anchors must be installed in a fully extended position. To do this, insert a pair of non-metallic wedges between the anchor and the hook. When the anchor has been rammed in place, the wedges should be removed. CAUTION: Never ram directly on a ceramic anchor. When installing ceramic anchor tile, use a dummy or spare tile to make a full depth profile in the plastic refractory. Then set the ceramic anchor tile.

Ramming - ROOFS Ramming roofs/arches requires forming and the use of ceramic tile anchors. Chemically setting plastic refractories additionally require false anchoring provisions. Consult with your Plibrico representative or the Plibrico Engineering Department for details. Ramming - FLOORS No anchors are required in floor applications. Ramming should be carried out in a direction as close to perpendicular to the hot face as possible. Never face ram the outer surface of a lining. Trimming If the Plibrico plastic is not rammed behind forms, a wall lining may tend to bulge due to vertical ramming. Therefore, trim off the bulging portion to the required thickness using a sharp flat blade or a special pneumatic tool. The trimming must be done within a short time while the material is still workable. Trimmed material can be used again if it is not contaminated with foreign matter. A clean job site is beneficial. Joints During bake-out of a Plibrico installation, the plastic refractory has a tendency to first shrink and then expand. It is recommended that provisions be made for this to occur at preselected places rather than where cracks are not desired, such as at anchor locations. To accomplish this, the surface lining must be provided with cut joints. The depth of these cut joints should be about 1/5th of the wall thickness, with a maximum depth of 2 on walls over 12 thick. These joints can be made with a hand tool. The cut joints must be made in both horizontal and vertical directions. Position of cut joints may be given on the drawing of the refractory lining. Should no drawing be available, it is recommended that the joints be cut at distances of about 48. The prime consideration is to space cut joints between rows of anchors. If required, the Plibrico Engineering Department can supply special recommendations regarding distance between joints and their depths. CAUTION: Do not cut joints in molten metal contact areas. The joints must be cut within a short time after ramming, while the Plibrico material is still workable. Finishing During the bake-out of the lining, moisture in the Plibrico plastic refractory will evaporate. In order to

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facilitate the escape of water vapor and to prevent spalling of the lining, two measures must be taken during installation: surface roughening and venting. When the Plibrico lining is trimmed to the proper thickness, the surface of the material must be made rough This can be done by scraping it with a trowel or special roughening tool. Surface roughening must be done within a short time after ramming is completed. Do not finish the Plibrico lining to a smooth and slick surface. When trimming, joint cutting, and surface roughening are completed, vent holes must be made in the Plibrico lining. The distance between the vent holes should be about 8 inches, except in molten metal contact areas. A 3/16 diameter rod or nail

should be used to pierce the lining to a depth of approximately 50% of the lining thickness, up to a maximum of 6. In metal contact areas, only make the vent holes 2 deep and the vent holes should be 18 apart. Vent holes must be made while the lining can still be pierced, however not too soon because the vent holes may close due to external vibration from surrounding equipment or installation activities. The best time to make vent holes is immediately before bake-out, if possible.

THE EASIEST INSTALLATION INSTRUCTIONS:

1. LET US DO IT ALL FOR YOU!

Plibrico skilled installation crews will craft a refractory lining of superior quality. From tear-out of the worn lining to new lining bake-out, we offer service so extensive it makes it easy for you to plan and coordinate your project. Large job or small we can provide the best installation service, combined with the best refractory products. This results in bottom-line economy for you, due to our single source capabilities. Our nation-wide network of Plibrico Sales & Service offices is ready to provide you with a free estimate for performing every service needed to carry out your work. We also draw on the resources of the Engineering Department of Plibrico Company which, since 1914, has dealt with every phase of refractory enclosure configuration. We can give you refractory linings computer programmed for maximum thermal efficiency and cost effectiveness.

Start your work the right way call Plibrico today! For the name of your local Plibrico representative

Please call (312) 337 9000 Or fax (312) 337 9003

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Work Interruptions When the installation of a Plibrico plastic refractory lining is interrupted, as during a lunch break, overnight, or over a weekend, or for any reason, the working surface must be covered with plastic sheeting to prevent the lining from drying out. When work resumes, the dried material on the working surface must be scraped away and the new surface roughened before ramming begins. If possible, try to have work interruptions coincide with where a joint is to me made later. When any interruption will exceed 8 hours, the installed lining must be trimmed and provided with cut joints. Frozen Linings When an installed plastic refractory lining is frozen, it must first be thawed very carefully. Since both the freezing and thawing process can dry the surface of the lining excessively, it should be sealed with a plastic or a sealing compound before thawing to avoid the risk of surface spalling later. Then, the temperature of the lining must be increase no more than 25 degree F/hr, up to a maximum of 150 degrees F. This temperature should be maintained for at least 24 hours. Linings over 9 thick may require a longer holding time at 150 degrees F. Consult your Plibrico representative for special instructions. After that, normal bake-out procedure can be initiated. Frozen and thawed linings may show higher surface shrinkage, which does not always affect the quality of the lining.

For more information about bake-out procedures, contact Plibricos

Engineering Department for assistance.

Bake out Instructions Do not allow high drafts through the furnace, which may cause an undesirable rapid dry-out. A slight draft is necessary to prevent the formation of

condensation on the lining. However, do not leave the doors and dampers wide open. Refractory linings must also be protected from freezing prior to bake-out! The bake-out of a Plibrico plastic refractory lining is of great importance. During this procedure, the existing free water, which was necessary for the workability of the material, must evaporate. This bake-out procedure must take place with a prescribed temperature increase per hour, depending upon the amount and type of material installed. Various grades of Plibrico plastic refractories require different bake-out rates. Please refer to Plibricos bake-out schedules for the appropriate bake-out program. Also, advice is available from Plibricos Engineering Department on the proper bake-out procedure for installations that are very large, or complicated, or of multi-components, or which involve special processes. Linings constructed of chemical setting plastics should be baked out within 1 week after installation. Thus, you must take this requirement into consideration when scheduling the work. When bake-out is delayed beyond this time, the lining must be covered and carefully sealed with plastic sheeting or curing compound to prevent drying. Suspended roofs or chemical-setting plastic should also remain supported before-bake-out. Linings constructed of air-setting plastics need not be baked out immediately. Air bonded materials are designed to stand in their unfired state for a period of time, while developing a certain strength at room temperature. Flat arches of air-setting plastic require special curing procedures, ask your Plibrico representative for specific details.

PLIBRICO COMPANY

1010 N Hooker St Chicago, IL 60622

Phone (312) 337 9000 Fax (312) 337 9003 Rev02a

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