PT.

OSBELINDO MEGA
Jl. Pulau Menjangan I, Komp. Medan Industrial Centre Blok C No.5 KIM II Medan - Sumatera Utara,
Tel : +6261 – 77813338

INSTALLATION INSTRUCTION
(Including STORAGE, MIXING, CURING, DRYING, & FIRING)
for
ECOCAST DENSE REFRACTORY CASTABLES

ECOKAST are standard grade castables designed for installation by light poker vibration or rodding.
ECOKAST "C" are coarse-grained castables designed for installation by poker vibrators.
ECOKAST "G" are gunning grade castables designed for installation by pneumatic gunning machine or by trowelling.

STORAGE:
The ECOKAST range is supplied in 25kg bags, shrink-wrapped on pallets and the following should be observed.
1. Do not store where the bags are exposed to raining or wetting by other means.
2. Do not place pallets in standing water and keep away from wet areas.
3. It is possible for the material in the bottom bags of the pallets to become compacted. This is due to the pressure on the bags
during storage, but these lums can easily be broken down by hand.

MIXING:
1. Equipment should be thoroughly clean to ensure that no contaminants lead to dificulty in casting the material and
a reduction in quality e.g. portland cement can accelerate or retard setting time.
2. Clean drinking water should be used.
3. Padlle or pan type mixers should be used. Under no cirmumstances use drum type mixers.
4. Always mix the material dry for a few minutes before adding water to give an even consistency.
"BALL IN HAND" test is a good guide to the ammount of mixing water.
5. Always mix the full contents of a bag, as segregation can occur during storage and handling. DO NOT MIX PART BAGS.
6. Do not add further dry material after the batch has been mixed.
7. Material should be installed within 20 - 30 minutes after mixing. Do not leave a mix standing for longer than the above
period as stiffening or setting can occur. NEVER remix a batch, which has stiffened or started to set.
To prevent this, do not mix more than can be placed in the above time.
8. Mixing should be kept to a minimum 5-10 minutes during which time the total water addition should be made.

SHUTTERING & MODULS:

For all type of castables, shutter and moduls should be strong enough to withstand pressure of vibration and weight of
castables. Shutter should be oiled and the joint taped to ensure fine material is not allowed to leak.

INSTALLATION of ECOKAST "C" & STANDARD GRADE CASTABLES:

1. These castables should be placed immidiately after mixing.
2. "C" grade castables should be placed using high frequency poker vibrators of 60-76 mm diameter depending on the thickness
to be cast.
3. Standard grade castables should be placed using high requency poker vibrators of 38 mm diameter or by rodding to remove
entrapped air.
4. Most constructions are designed in sections with expansion joints and it is important to cast each section continuously to
avoid laminations.
5. It is not necessary to trowel to a smooth finish as this causes the fine cement to rise to the surface.
INSTALLATION of ECOKAST "G" GRADES:
1. Aplication is normally carried out by means of a pneumatical operated gun.
2. The material is fed to the gun and water is added at the nozzle. The water addition is controlled by the nozzle operator and
this is usually the maximum the material can tolerate without slumping; it is therefore necessary for only competent
operators to control the nozzle.
3. Pre-damping allows the material to accept water additon at the nozzle and helps to reduce rebound.
4. On no acount should rebound material be used again.
5. Where event thickness is required, the surface should be scraped with a trowel as soon as possible after gunning is complete.

CURING:
1. The evolution of heat, wich accompanies the hydration of high alumina cements, can evaporate some of the moisture
required for full hydration to take place and thus a drop in optimum strength can occur. To prevent this, the material must be
cured properly. This can be done
a) by covering with wet sacks, which should be kept wet, or
b) by sprying the surface with a fine spray of water once partial setting has occured.
2. 24 hours is usually sufficient to alow for full curing.
3. Gunned or trowelled material should be cured by method b)

DRYING:
Drying of castables is important to ensure that the material gives optimum performance.
The ECOKAST range of material should be heated up for the first time in accordance with the following schedule:
1. The temperature should be raised at 10 deg. C per hour until the surface of the material is at 150 deg C and held for a
minimum of 12 hours.
2. The temperature should then be raised at 25 deg. C per hour until the surface of the material reaches 450 deg C and then held
for 1 hout per 25mm lining thickness.
3. The temperature should then be raised at 50 deg. C per hour until the surface temperature of the material reaches 650 deg. C
and then held for 1 hour per 25mm of lining thickness.
4. The temperature should then be raised at 50 deg. C per hour until working temperature is reached.
5. It should be noted that the direct flame impingement should be avoided until after the soak at 650 deg. C.
6. It is necessary to ensure a good airflow throughout the furnace heating, in order to facilitate the removal of moisture.

To ensure optimum performance from our product,

it is essential to pay close attention to all the above instructions.
 PT. OSBELINDO MEGA
Jl. Pulau Menjangan I, Komp. Medan Industrial Centre Blok C No.5 KIM II Medan - Sumatera Utara,
Tel : +6261 – 77813338

INSTALLATION INSTRUCTION
(Including STORAGE, MIXING, CURING, DRYING, & FIRING)
for
ECOCAST INSULATION REFRACTORY CASTABLES

STORAGE:
The ECOKAST range of Insulation castables is supplied in 20kg or 25kg bags, shrink-wrapped on pallets and the followig should
be observed.
1. Do not store where the bags are exposed to raining or wetting by other means.
2. Do not place pallets in standing water and keep away from wet areas
3. It is possible for the material in the bottom bags of the pallets to become compacted. This is due to the pressure on the bags
during storage, but these lums can easily be broken down by hand.

MIXING:
1. Equipment should be thoroughly clean to ensure that no contaminants lead to difficulty in casting the material and a
reduction in quality e.g. portland cement can accelerate or retard setting time.
2. Clean drinking water should be used.
3. Padlle or pan type mixers shoukd be used. Under no cirmumstances use drum type mixers.
4. Always mix the material dry for a few minutes before adding water to give an even consistency.
5. Always mix the full contents of a bag, as segregation can occur during storage and handling. DO NOT MIX PART BAGS.
6. Always add the recommended amount of mixing water. The "BALL IN HAND" test is a good guide to the correct ammount of
mixing water.
7. Do not add further dry material after the batch has been mixed.
8. Mixing time should be made as short as possible compatible with complete distribution of water. Extended mixing can break
down insulation aggregates, wich are mostly soft or compressible.
9. The castables should be placed with the minimum of delay and centainly within 20 minutes of mixing,
since the absorbent nature of the aggregates can cause the mix to stiffen. NEVER remix a batch, hich has starded to set.

SHUTTERING & MODULS:

For all type of castables, shutter and moduls should be strong enough to withstand pressure of vibration and weight of
castables.
Shutter should be oiled and the joint taped to ensure fine material is not allowed to leak.

INSTALLATION
1. These castables should be placed immediately after mixing.
2. Rodding or tamping is usually sufficient to place insulation castables. If a vibrator is used to make sure that ta complicated
shape of shutter is completely filled or that the castables is in good contact with ceramic anchor then only a light poker
should be used to move the castables. Heavy vibraion will cause densification with a serious loss os insulation value or
cause a cement rich surface, which may peel off during use.
3. The ECOKAST range of insulation castables is designed to be able to be placed by casting, gunning or trowelling.
4. When aplication by gunning is required, this is normally carried out by means of a pneumatically operated gun.

The material is fed to the gun and water is added at the nozzle. The water addition is controlled by the nozzle operator and this
is usually the maximum the material can tolerate without slumping; it is necessary for t only competent operators to control
the nozzle.
Pre-damping allowa the material to accept water additon at the nozzle and helps to reduce rebound.
On no acount should rebound material be used again.
Where event thickness is required, the surface should be scraped with a trowel as soon as possible after gunning is complete.
CURING:
1. The evolution of heat, wich accompanies the hydration of high alumina cements, can evaporate some of the moisture
required for full hydration to take place and thus a drop in optimum strength can occur. to prevent this, the material
must be cured properly. This can be done
a) by covering with wet sacks, which should be kept wet, or
b) by sprying the surface with a fine spray of water one partial setting has occurred.
2. 24 hours is usually sufficient to alow for full curing.
3. Gunned or trowelled material should be cured by method b)

DRYING:
Drying of castables is important to ensure that the material gives optimum performance.
The ECOKAST range of material should be heated up for the first time in accordance with the following schedule:
1. The temperature should be raised slowly until the surface of the material is at 110 deg. C and held for a minimum of 12 hours.
2. The temperature should then be raised at 25 deg. C per hour until the surface of the material reaches 150 deg C and then held
for 1 hour per 25mm lining thickness.
3. The temperature should then be raised at 25 deg. C per hour until the surface temperature of the material reaches 650 deg. C
and then held for 1 hour per 25mm of lining thickness.
4. The temperature should then be raised at 50 deg C per hour until working temerature is reached.
5. It should be noted that the direct flame impingement should be avoided until after the soak at 650 deg C.
6. It is necessary to ensure a good airflow throughout the furnace heating, in order to facilitate the removal of moisture.

To ensure optimum performance from our prduct,

it is essential to pay close attention to all the above instructions.