1. SCOPE………………………………………………………………………………….2. REFERENCES
3. DEFINITIONS
4. MATERIALS …………………………………………………………………………..4.1
Castable
4.2
Anchors
4.3 Waterproof Membrane ………………………………………………………..4.4
Curing Compound
5. DOCUMENTATION
6. STORAGE AND HANDLING OF MATERIALS…………………………….
7. SURFACE PREPARATION
7.1 General
7.2
Coal-Tar Epoxy Corrosion-Proof Membrane …………………………..
8.
INSTALLATION
8.1 General
8.2
Environmental Conditions ……………………………………………………
8.3 Working Points
8.4
Attachment Welds
8.5 Mixing of Refractory Castables …………………………………………….8.6
Castable Retainer Forms, Shot Boards and Construction Joints
8.7
Dual-Layer Linings
8.8
Tolerances…………………………………………………………………………
8.9
Application
8.10 Expansion Joints
9. INSTALLATION OF ANCHORS ………………………………………………..10. APPLICATION BY PNEUMATIC GUN
11. APPLICATION BY CASTING
11.1 Mixing……………………………………………………………………………….11.2 Application of Castable
12. CURING AND DRYING OUT
12.1 Moist Curing ………………………………………………………………………
12.2 Air Drying
12.3 Heat Drying (Initial Heat-Up)
13.
INSPECTION AND TESTING …………………………………………………..
13.1 Supervision
13.2
Inspection of Anchors
13.3 Procedure and Crew Qualification Testing …………………………….13.4 Acceptance Testing of Castable Materials
13.5 Testing Installed Castable
14. REPAIRS……………………………………………………………………………….15. CONFLICTS AND DEVIATIONS
FIGURE
1 Type 740 V-S Anchor
TABLE
I
Anchor Materials …………………………………………………………………….
II
Corrosion-Proof Membranes
1. Scope
1.1 This specification describes general requirements for materials, installation, and inspection of
hydraulic-setting castable refractory linings for the interior of furnaces, waste heat boilers, process
vessels, incinerators, ducts and piping.
1.2 Casting, vibratory casting and pneumatic gunning application methods are described.
1.3 This specification covers new installations and repairs to existing linings.
2. References
Reference is made in this specification to the following documents. The latest issues, amendments and
supplements to these documents shall apply unless otherwise indicated.
American Society of Mechanical Engineers (ASME)
Boiler and Pressure Vessel Code Section IX. Welding and Brazing Qualifications
American Society for Testing and Materials (ASTM)
C 133 Test Methods for Cold Crushing Strength and Modulus of Rupture of Refractory Brick and Shapes
C 134 Test Method for Size and Bulk Density of Refractory Brick and Insulating Firebrick
C 860 Standard Practices for Determining and Measuring Consistency of Refractory Concretes
C 962 Practice for Preparing Refractory Concrete Specimens by Casting
Steel Structures Painting Council (SSPC)
SP 6 Commercial Blast Cleaning
SP 7 Brush Blasting
3. Definitions
For the purpose of understanding this standard, the following definitions apply.
Castable. A hydraulic-setting castable refractory, applied by casting, vibratory casting and pneumatic
gunning methods.
4. Materials
4.1 Castable
4.1.1 Castable shall be specified by manufacturer and trade name in the individual job specification.
4.1.2 Manufacturer’s latest published materials data sheets and material safety data sheets for the
castable used shall become part of this SES.
4.1.3 Castable shall meet the acceptance testing requirements of 13.4.
4.2 Anchors
4.2.1 Anchor material shall be based upon maximum hot face temperature as listed in Table I.
4.2.2 Anchor materials which are subject to corrosive condensed gases, shall be specified by SABIC.
4.2.3 Anchor recommendations shall be specified or approved by SABIC.
4.2.4 Metal anchors for use above 538 °C (1000 °F) shall be coated with a 20-mil thickness of cellulose
acetate polymer, unless otherwise specified.
4.2.5 Metal anchors shall be Type 740 (V-S) (see Figure 1). Other types of anchor require SABIC
approval.
4.2.6 The length of the metal anchor shall extend through 70 percent of the castable lining thickness
rounded off to the nearest 13 mm (1
/2 in) increment. Diameter of the anchor shall be based on weight of
castable lining and spacing between anchors. Anchor layout pattern and attachment design shall be
approved by SABIC.
4.3 Waterproof Membrane
A waterproof membrane of paper, plastic film, paint, or spray shall be used between castable and fibrous
insulating material to prevent absorption and migration of water.
4.4 Curing Compound
A SABIC approved organic resin concrete curing compound, containing a dye so that 100 percent
coverage can be verified, shall be used.
5. Documentation
5.1 Required reference drawings and specifications (including metal structure) shall be assembled and
understood by installers prior to installation. These shall include the following:
a. Refractory design drawings
b. Method of castable installation
c. Castable refractory to be used
d. Manufacturer’s data sheets
e. Thickness of castable (if not shown on drawings)
f. Anchors
(i) Material, length, diameter
(ii) Spacing
(iii) Orientation
(iv) Attachment to shell
g. Whether a corrosion-proof membrane is required (as detailed in 7.2)
h. Location of construction joints
i. Crew qualification in conformance with 8.1.3 and 13.3
j. Expansion joint details
6. Storage and Handling of Materials
6.1 Materials shall be received in weatherproof containers, covered and kept dry. This includes protection
from condensation. Materials shall be stored off the ground, and shall not be set on ground or concrete that
is damp.
6.2 Indoor storage of materials is required if storage exceeds one week.
6.3 Materials which may be damaged by freezing or overheating shall be stored in temperature controlled
areas, or otherwise suitably protected. Maximum hot or cold storage temperature shall be as defined in the
manufacturer’s data sheets.
6.4 The contractor shall be responsible, in accordance with 6.1 to 6.3, for the protection of SABIC
purchased materials which he has moved to the job site. Contractor shall replace at his expense materials
damaged by his negligence.
7. Surface Preparation
7.1 General
7.1.1 Cleaning shall be done by the contractor and approved by SABIC before any castable refractory is
installed.
7.1.2 Interior surfaces to be lined shall be free of loose rust and mill scale, dirt, grease, oil and other
contamination.
7.1.3 Cleaning may be done by one of the following:
a. Scraper and wire brush
b. Grit blasting in accordance with SSPC SP 6
c. Brush blasting with abrasive, in accordance with SSPC SP 7, followed by solvent wipe if
required and approved
7.2 Coal-Tar Epoxy Corrosion-Proof Membrane
7.2.1 Use. The application of coal-tar interior surface coatings for the purpose of protecting the casing
from corrosion by condensed gases shall be used only on metal surfaces which will operate at 110 °C
(230 °F) or less.
7.2.2 Surface Preparation. Surfaces to be coated shall be thoroughly cleaned of all foreign material in
accordance with 7.1.3.
7.2.3 Installation. Membrane materials shall be chosen from the list in Table II and applied according to
manufacturer’s instructions. The coating shall be applied to the prepared surface as quickly as possible, to
avoid rusting after blasting. Anchors shall be installed prior to surface preparation. Anchors shall be
protected to within 25 mm (1 in) of the base during membrane application.
8. Installation
8.1 General
8.1.1 Installation shall be in accordance with the job specification, required reference drawings (as
detailed in section 5), and the provisions of this specification. The contractor shall meet with SABIC at a
pre-installation meeting to discuss their method of installation; to ensure that they understand the
drawings; and can fulfill the requirements of this specification. A qualified supervisor who understands this
specification and the individual job specification shall be present at all times that work is in progress.
8.1.2 Method of installation; cast, vibratory cast or pneumatic gunning, shall be in accordance with the job
specification.
8.1.3 Installation shall be done by personnel experienced in industrial refractory construction.
Qualification of crew in accordance with 13.3 shall be required when specified by SABIC.
8.1.4 The requirements of this specification refer to shop and field installed linings.
8.1.5 The contractor shall conform to SABIC and plant site safety regulations. Before starting work, the
contractor shall obtain the SABIC safety instructions in writing.
8.2 Environmental Conditions
8.2.1 Castable shall not be installed when the ambient temperature, is below 11 °C (50 °F) or above 50 °C
(122 °F).
8.2.2 Refractory materials shall be warmed to at least 11 °C (50 °F) but not exceeding 38 °C (100 °F) in
winter prior to installation. In winter, precautions shall be taken to hold the temperature of the castable and
surfaces being lined above 11 °C (50 °F) for at least 24 hours after the lining is applied.
8.2.3 The vessel temperature shall not exceed 38 °C (100 °F). The exterior of the area to be lined shall be
kept cool by shading, casting indoors or at night, spraying with water, or a combination of these. Care shall
be taken that water does not run onto the castable.
8.2.4 No admixtures shall be used except with SABIC approval.
8.2.5 Water and dry materials of linings shall be maintained at temperatures between 11 and 32 °C (50 to
90 °F) so as not to adversely accelerate or retard the rate of set of the lining materials when hydrated.
8.2.6 Installed refractory shall be kept from freezing before initial heat-up. It shall not be subjected to rain,
condensation, or other forms of moisture until fired.
8.3 Working Points
Working points shall be established by the contractor to provide a continuous dimensional check for
installation of rings, courses, or panels. This is necessary to ensure proper location and support of
compression rings, skews, nozzle openings, expansion joints, special shapes and construction joints.
Refractory shall be installed so that openings match metal nozzle holes within 3 mm (1
/8 in) unless
otherwise specified. All working points shall be checked and approved by SABIC.
8.3.1 The contractor shall check the vessel for roundness, straightness, and fit-up of welds, and be
satisfied that the vessel is in suitable condition to be refractory lined. If not, he shall notify SABIC in writing
prior to starting the job. All heat-treating, pressure testing, and inspection of the equipment to be lined shall
be completed before installation of refractory lining.
8.3.2 Piping and equipment shall be adequately supported to prevent distortion during lining.
8.3.3 Castable installation shall not be started until the contractor is certain the lining can be completed
with the materials available.
8.3.4 Removable internals which interfere with, or prevent, proper installation of the refractory lining shall
not be installed until the lining has been completed, unless expressly excepted in the scope of work.
8.3.5 When welding is required on ASME code boilers or pressure vessels, written SABIC approval shall
be obtained prior to the start of welding.
8.4 Attachment Welds
The welding specifications for attachment welds associated with the lining shall be compatible with the
vessel welding specifications. All welding procedures require SABIC approval.
8.5 Mixing of Refractory Castables
8.5.1 Job site mixing of bulk components, to meet manufacturer’s formulation of castable, is not
acceptable.
8.5.2 Premixed castables are subject to material segregation during shipment, therefore the full contents
of each bag shall be charged to the mixing or gunning machine. Dry premixing is required. Castable
containing hard lumps shall not be used. This does not include castable which has been stacked in high
piles and become compacted in the bottom bags. This readily breaks down to the original grain size with
the fingers, and the material has not set up. Hard lumps mean the material has set up, and the whole bag
shall be discarded. See also 8.3.3.
8.5.3 Water addition, mixing time and temperature shall be in strict accordance with the manufacturer’s
printed instructions. If material cannot be applied when mixed according to the manufacturer’s instructions,
the manufacturer shall be contacted and written approval shall be obtained before modifying water
requirements. Suitable equipment shall be available to accurately measure water.
8.5.4 Only clear, clean, drinking quality water shall be used. Steam may be injected into the water stream
for heating to the required temperature.
8.5.5 When polymer or steel fibres are added to the castable, they shall be added to the mixer through a
12 mm (1
/2 in) wire screen mesh to achieve good distribution.
8.6 Castable Retainer Forms, Shot Boards and Construction Joints
8.6.1 Location of construction joints shall be as shown in the reference drawings (based upon curing
shrinkage and thermal expansion of the castable, and not for installer’s convenience).
8.6.2 Forms shall be installed by the contractor.
8.6.3 Form materials shall be non-absorptive and be of adequate cross-sectional area to provide a rigid
form.
8.6.4 Forms shall be constructed and finished to provide a reasonably smooth uniform surface in contact
with the refractory.
8.6.5 Forms shall be designed so their removal will not damage the lining.
8.6.6 The form surface in contact with the refractory shall be well oiled to afford easy removal.
8.6.7 All openings shall be closed by hardwood plugs or sheet metal sleeves, slightly tapered, and long
enough to extend beyond the final thickness of the lining. These plugs or sleeves shall be coated with
grease, snugly fitted into openings, and not disturbed until the castable has set.
8.6.8 Metal nozzles and structural members that project through the lining are to be coated with, for
example, asphalt, grease or wax, prior to lining application. Coating thicknesses of about 0.002 mm/mm
(0.002 in/in) of steel thickness is usually sufficient.
8.6.9 If castable is to be installed in sections prior to their being welded, a minimum 100 mm (4 in) gap
shall be left at the end of each section until they are welded.
8.7 Dual-Layer Linings
8.7.1 Linings shall be gunned or cast in successive layers; the second layer being applied only after
proper cure of the first layer.
8.7.2 Construction joints shall be located so that those in one layer do not coincide with those in the other
layer.
8.7.3 A waterproof membrane as specified in 4.3 shall be placed between each layer to prevent water
migration.
8.7.4 The heads of anchors projecting through an intermediate layer shall be completely clean before
proceeding with the next layer.
8.8 Tolerances
The tolerance on the thickness of single-layer lining shall be minus zero mm plus 13 mm (-0 in +
/2 in).
For multiple-layer lining, the tolerance shall be ± 6 mm (±
1
1
/4 in) for each layer.
8.9 Application
The full layer thickness of the single or multiple-layer lining shall be applied in a single operation. In
cylindrical vertical vessels, the lining shall be applied circumferencially in narrow bands, starting at the
bottom, and working upward. The full thickness shall be developed as the work progresses in each band.
‘Flash coats’ are not acceptable. In no case shall a thickness of castable less than specified be applied
and allowed to develop its initial set. As a general rule, a band shall be completed within one hour.
8.10 Expansion Joints
Expansion joints shall be constructed according to the details shown on the reference drawings, and shall
be placed only at the locations shown.
9. Installation of Anchors
9.1 Anchors shall meet the requirements of 4.2.
9.2 Metal anchors, studs or clips for refractory anchors shall be installed by certified welders using an
ASME qualified manual metal arc or manual stud gun welding procedure. The anchors, studs, or clips
shall be installed by the contractor.
9.3 Spot grinding of anchor weldment areas shall be done to obtain acceptable welds if anchors are
installed prior to the surface preparation detailed in 7.1.3.
9.4 Anchors shall be placed on centers as shown in the specific reference drawings. It is not essential that
the anchors be located exactly, and variations of 13 mm (
1
/2 in) in any direction of the centers, as called
for, are allowed. In no case shall anchors be located closer than 50 mm (2 in) to any main vessel weld
seam. In, for example, piping, no anchors shall be located on any weld seam.
9.5 Orientation of metal anchor lines shall be 90° to each adjacent anchor.
9.6 Stud threads shall be protected, for example by plastic caps, after welding and during application of
the insulating layer, to avoid thread damage.
9.7 If equipment is to be post weld heat treated, anchors shall be welded prior to heat treatment.
10. Application by Pneumatic Gun
10.1 Only qualified personnel, thoroughly familiar and experienced with pneumatic application of castable
refractory, shall be employed for this work.
10.2 Only ‘dry nozzle’ type mixing guns shall be used. Equipment and tools shall be in good working
condition, well maintained and clean of any foreign material, for example previously used hard castable.
10.3 The castable specified shall be pre-wet before gunning, to obtain proper in-place density. Pre-wetting
is accomplished by placing dry castable in a paddle-type mortar mixer and adding 10 to 20 percent of the
total water required. The pre-wet castable is then charged to the gunning machine. The castable shall be
used within 15 minutes of pre-wetting in the mixer.
10.4 The compressed air, free of oil and water, shall be supplied at a steady pressure; indicated by
properly installed and operating instrument gages.
10.5 The flow of water and air shall be adjusted in accordance with the refractory manufacturer’s printed
instructions. The lining contractor shall ensure that the equipment delivers proper material consistency. The
air pressure required for pneumatic application will vary for various aggregates, nozzle sizes, and length of
delivery hose. The optimum pressure shall be determined by test before proceeding with the actual work;
however, the pressure should be kept to a minimum to prevent loss of cement and still produce a dense
lining. The amount of water used shall be sufficient to produce proper hydration, but excessive water shall
be avoided, to prevent sagging of the applied castable.
10.6 SABIC shall be present during placement of castable against construction joints. Baffles or
bulkhead-type construction shall not be utilized to accomplish this operation. Material shall be gunned past
the termination point and then cut back normal to the hot face.
10.7 The nozzle operator shall make every effort to shoot normal to the surface being covered. Material
impinging on support places, for example, falls back (rebounds) and builds up excessively dry areas.
Shooting angle shall be varied to prevent voids behind anchors on the side away from the gun. Rebound
and loose material shall be removed from the surface of a completed band or panel before proceeding with
the next. No rebound materials shall be allowed to accumulate at any point where the lining has already
been applied. Rebound material shall be removed ahead of the nozzle operator to prevent its inclusion in
the lining.
10.8 Hand packing of castable to prevent voids shall precede pneumatic installation of the surrounding
lining.
10.9 If the application stops for more than 15 minutes, the applied castable shall be cut back to the shell
with a steel trowel. This cut shall be made at right angles to the shell at locations where the full thickness of
castable has been applied. Castable outside the cut shall be discarded. Before continuing lining
application, the castable surface at the construction joint shall be moistened. Care shall be taken to avoid
damage to the membrane, if applied.
10.10 On projects where the application of refractory castable is not a continuous operation, work shall not
be terminated until a unit or section is finished. In other words, work shall cease only at designed stopping
points. If unscheduled work interruption occurs, the requirements of 10.9 shall be met.
10.11 Gunned castable shall be finished to the final thickness by scraping with the edge of a steel trowel.
This leaves a rough grainy surface which is desirable and correct. Do not trowel the surface to a smooth
finish.
11. Application by Casting
11.1 Mixing
See 8.5 for general requirements.
11.1.1 Only a paddle-type mortar mixer shall be used for mixing castable. Equipment and tools shall be in
good working condition, well maintained and clean of foreign material, for example previously mixed hard
castable.
11.1.2 Do not mix more than can be applied immediately after mixing.
11.1.3 Empty dry material into mixer. Pour total contents of bag into mixer. Briefly dry mix before adding
water (30 seconds maximum).
11.1.4 Measure the water carefully using marked containers to ensure that only the required amount is
used.
11.1.5 Do not add water to make the mix more pourable.
11.1.6 The ASTM C 860 ‘ball in hand’ test shall be used to determine the correct consistency.
11.1.7 Do not overmix. Follow manufacturer’s instructions for mixing time.
11.1.8 Transport and place the material as quickly as possible after it leaves the mixer.
11.1.9 Rinse off any build-up in the mixer and transport equipment before the next batch.
11.2 Application of Castable
11.2.1 Mixed castable shall be applied as close to its final position as possible. Free fall is to be limited so
as not to exceed 1.2 m (4 ft).
11.2.2 Vibrate, spade, or puddle by rodding the mix into place, ensuring that all voids are eliminated.
11.2.2.1 For thicker sections of castable, use an electric internal high-frequency concrete vibrator, or
follow manufacturer’s recommendations if special equipment is required.
11.2.2.2 Vibrate placed castable in passes 0.2 to 0.3 m (8 to 12 in) deep. Move vibrator continuously,
slowly and steadily through the mix. A void will result if vibrator is withdrawn too quickly from the mix.
11.2.2.3 Caution: Do not over vibrate, or segregation will occur. Use vibrator very sparingly with insulating
type refractory castable.
11.2.2.4 Material for external vibration in a form shall be manufactured specifically for vibratory casting,
and be fine grained and uniform. Any additives for enhancing flow properties shall be used according to
manufacturer’s instructions.
11.2.3 Excess material shall be screeded off at the top of the form with the edge of a board or steel trowel.
This produces a rough and grainy surface which is desirable and correct. Do not trowel the surface to a
smooth finish.
11.2.4 If casting stops for more than 15 minutes, the castable shall be cut back at right angles to the shell
where there is full lining thickness. Castable outside this cut shall be discarded. Before continuing, the cut
surface shall be moistened. Care shall be taken to avoid damage to the membrane, if applied.
12. Curing and Drying Out
The following instructions for proper curing and dryout are essential for refractory lining success, and shall
be followed.
12.1 Moist Curing
12.1.1 An organic curing compound as specified in 4.4 shall be applied, either by spraying or with a very
wet brush, to the hot face of gunned castables and the exposed surfaces of cast castables in sufficient
thickness to provide a continuous, pinhole-free film. One hundred percent coverage shall be required, the
dye in the compound providing visual affirmation.
12.1.2 The organic curing compound shall be applied within 30 minutes of installation of the castable.
12.1.3 The refractory shall remain undisturbed for 24 hours to complete its moisture cure.
12.1.4 Linings shall not be steamed prior to drying.
12.2 Air Drying
After the castable has completed its moisture curing, the castable shall be ambient air dried for a minimum
of 24 hours before applying heat.
12.3 Heat Drying (Initial Heat-Up)
12.3.1 Linings to be used in services above 93 °C (200 °F) shall be dried by heating from the normal hot
face side of the lining at a controlled rate to the process operating temperature of the lining. Heat shall not
be applied to the outside of equipment.
12.3.2 When the outside shell temperature reaches 66 °C (150 °F) the lining is moisture-free. If external
insulation is installed to promote dryout, metal shell temperature during dryout shall not exceed 121 °C
(250 °F).
12.3.3 During the heat drying procedure, the equipment shall be ventilated, or a circulating medium shall
be used to remove all moisture.
12.3.4 After the drying is complete, the castable lining may be cooled or put directly into process service.
12.3.5 Thermocouples shall be installed in the incoming and outgoing gas stream. Process thermocouples
may be used to measure the temperatures. Thermocouples shall be connected to a multi-point
temperature recorder, and readings taken continuously throughout the drying period.
12.3.6 The heating rate shall not exceed 24 °C/h (75 °F/h) with 10 °C/h (50 °F/h) as the preferred rate.
12.3.7 There shall be a minimum of two holds, one at 99 ° C (210 °F) and the other at 260-288 °C
(500-550 °F). The lengths of the hold times are 12 min/cm (30 min/in) of thickness of the refractory. Then
heat-up to process operating temperature shall be continued at normal operating warm-up rate.
Temperatures referred to are those of the circulating medium and not those of the refractory.
12.3.8 Paragraphs 12.3.6 and 12.3.7 can be modified by using castables with polymer fiber additions
which permit a much more rapid initial heat-up. The rate of heat-up shall be approved by SABIC.
12.3.9 The use of vendors specializing in refractory dryout is acceptable and especially encouraged when
equipment is being put into service for the first time, or where process burners lack adequate controls to
provide the proper heat-up rate.
13. Inspection and Testing
13.1 Supervision
SABIC will be present during all phases of construction of major lining installations. They will review all test
results and will reject any part of the work which does not conform to the specifications contained herein, in
the reference drawings, or the individual job specification.
13.2 Inspection of Anchors
13.2.1 Welders doing manual welding for the construction of the lining shall be qualified in accordance with
ASME Boiler and Pressure Vessel Code, Section IX.
13.2.2 A bend test shall be used for the first ten anchors welded in any particular position or with any
particular machine setting. The bend test shall consist of bending the anchor through a 45° angle and
straightening. The anchor weld will be acceptable if no cracks are visible in the weld zone.
13.2.3 After the bend test demonstrates that acceptable welds are being obtained, subsequent anchors
shall be given a good visual inspection and shall be tested by striking sharply with a hammer to secure a
ring, thereby proving that the anchor is securely welded. If the ring produced by striking sounds slightly off,
the weld at the base of the anchor shall be examined on the entire periphery. If the weld is incomplete, it
shall be finished by hand welding. If the weld is undercut, it shall be removed and rewelded.
13.2.4 The visual inspection and testing of anchors shall proceed along with their installation, so that if a
faulty welding procedure is being employed, it will be discovered with a minimum of time and material loss.
13.3 Procedure and Crew Qualification Testing
13.3.1 When specified, SABIC shall conduct procedure and crew qualification tests to certify the
procedure and crew prior to beginning the application of any lining. The test procedure shall consist of
placing a representative thickness of the specified castable lining on a panel which is a minimum 1.2 m by
1.2 m (4 ft by 4 ft) in size. Within this panel, at least one horizontal construction joint shall be made, and
core samples taken in two places. These cores shall be free of included rebound and any sign of
significant cleavage. They shall also be tested for specified density and cold crushing strength in
accordance with ASTM C 133, C 134 and C 962 by an independent testing laboratory. Castables
containing fibres shall be cut into four pieces and also examined for uniform fibre distribution.
13.3.2 The ability of the crew, and quality of workmanship shall also be judged by SABIC. The
qualification samples shall be suitably identified and kept at the job site until the closing out of
construction. In the event of failure to pass this test, a crew and procedure may be changed and retested.
Procedure and crew qualification are the responsibility of the contractor.
13.3.3 In the case of pneumatic gun placement, a crew is defined as the nozzle operator and the gunite
machine operator. If either operator is changed then the crew shall requalify. When refractory is placed by
casting, the crew is defined as the mixer and vibrator operators.
13.3.4 If problems arise during the job, SABIC reserves the right to requalify the crew.
13.4 Acceptance Testing of Castable Materials
13.4.1 Acceptance testing of castable materials shall be required to ensure materials meet the specified
properties. If the requirements of 13.4 are waived, the contractor shall assume all responsibility for
installed properties of castable. Acceptance testing of castable materials shall be performed by an
independent laboratory.
13.4.2 Any batch of castable for which the average of the test results does not meet the minimum physical
properties guaranteed by the manufacturer shall be retested. Unsatisfactory retest shall be cause for
rejection.
13.4.3 Immediately on arrival of the castable at the site of installation, samples shall be taken and
forwarded to the laboratory. The laboratory shall immediately cast and test the specimens and report the
results prior to installation of castable. Samples for testing shall be prepared in accordance with
manufacturer’s recommendations and ASTM procedures. The minimum number of random samples for
castables shall be 3 per every 10 tons or less of each castable lot number.
13.4.4 The following testing shall be performed as a minimum:
a. Dry sieve analysis
b. Density after heating to 538 °C (1000 °F)
c. Permanent linear change after heating to 538 °C (1000 °F)
d. Modulus of rupture after heating to 538 °C (1000 °F)
e. Compressive strength after heating to 538 °C (1000 °F)
13.4.5 The responsibility and cost of this testing shall be the contractor’s if they supply the materials.
SABIC will be responsible if SABIC supplies the materials.
13.5 Testing Installed Castable
When specified by SABIC, installed castable shall be tested as follows:
13.5.1 Location and number of test samples to be taken while castable installation is in progress shall be
determined at the pre-installation meeting (see 8.1.1). Minimum number of samples taken shall be one per
working crew per shift.
13.5.2 Gunned samples shall be taken in a 230 x 230 x 115 mm (9 x 9 x 41
/2 in) form constructed of
12.7 mm (
1
/2 in) square hardware screen. Cast samples shall be taken in a 230 x 230 x 115 mm (9 x 9 x
4
1
/2 in) watertight form treated with a release agent. Contractor is responsible for providing these forms.
Samples shall be identified with date, time and location. Each sample taken shall duplicate as closely as
possible work being performed at that point (that is for example, form orientation and method of castable
placement) and be done in the presence of SABIC. SABIC also reserves the right to obtain core samples of
installed work.
13.5.3 SABIC will have these samples tested by an independent laboratory for density, permanent linear
change, modulus of rupture, and compressive strength after heating to 538 °C (1000 °F). Samples for
which the average of the test results does not meet the minimum physical properties guaranteed by the
manufacturer, shall be retested.
13.5.4 Unsatisfactory retest shall be cause for rejection of the installed castable represented by the test
sample. The castable shall be repaired as specified in section 14.
13.6 Castable mixtures which have been in storage for over one year shall not be used unless a new test
is made to ensure that the material has retained the required physical properties.
13.7 After the castable has moisture cured, the entire surface of the layer shall be hammer tested to detect
the presence of any voids or any areas which may be filled with dry materials. The hammer test shall
consist of striking the surface with sharp blows at about 300 mm (12 in) intervals with the flat surface of an
8-10 ounce hammer. A hollow sound indicates the presence of voids, honeycombs, or other defective
areas. These shall be repaired in accordance with section 14. Areas containing cracks wider than 3.2 mm
(1/8 in) are considered defective.
14. Repairs
14.1 Lining which is found to be defective by inspection in accordance with 13.7 or testing in accordance
with 13.5 shall be removed to the full thickness of the layer until sound material is found on all sides. A
minimum of 0.093 m2
(1 ft2
) shall be removed. If 25 percent of the lining area is defective, then the
complete section shall be judged defective.
14.2 Repair of defective linings is the responsibility of the contractor.
14.3 Method of repair is subject to approval by SABIC.
15. Conflicts and Deviations
Any conflict(s) between this specification, SES and industry standards, engineering drawings, and contract
documents shall be resolved at the discretion of SABIC before any installation proceeds.
FIGURE 1
Type 740 V-S Anchor
Guidelines:
1. Dimension A to be as specified from 4.2.6.
2. Dimension B shall be 25 mm (1 in) maximum.
3. Dimension C shall be 13 mm (1/2 in) minimum.
4. Dimension D shall be 25 mm (1 in) minimum.
5. Dimension E shall be:
a. 6 mm (1/4 in) for lightweight insulating castables up to 230 mm (9 in) thickness
b. 8 mm (5/16 in) for dense castables up to 230 mm (9 in) thickness
c. 10 mm (3/8 in) for dense castables above 230 mm (9 in) thickness
TABLE I
Anchor Materials
TABLE II
Corrosion-Proof Membranes
