INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
Index
1. Installation of Gunning Refractory.
2. Storing of Gunning Refractory.
3. Anchor Welding
4. Back-up layer Fixing & Inspection
4.1 Ceramic Paper / Ceramic Blanket
4.2 Calcium Silicate Block
5. Preparation for Installation
5.1 Surface Preparation
5.2 Template Preparation
5.3 Tools and tackles
5.4 Fixing water percentage
5.5 Fixing setting time and shuttering removal time
6. Template Fixing
7. Mixing and Transport
8. Gunning Installation Procedure
9. Removal of Template
10. Inspection
11. Air Drying and Wet curing
12. Inspection Report
13. Thermal Dryout
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
1. Installation of Gunning Refractory
1.1 Make preparation as per 4.
1.2 Check anchor height from back-up layer / from shell.
1.3 Inspect back-up layer
1.4 Inspect form work
1.5 Place form work as per 5
1.6 Fix air pressure and material feed
1.7 Fix nozzle water control
1.8 Fix the setting time and shuttering removal time as per.
1.9 Take one batch of material and mix it in service pan mixture
(predampning).
1.10 Discharge and feed in gunning machine
1.11 Install as per procedure
1.12 Allow the castable to set after gunning. Check setting intermittently.
1.13 Remove the stopper after castable has set as per
1.14 Inspect and dress if required as per
1.15 Do air and wet curing as per
1.16 Inspect again after curing
1.17 Complete documentation work. Use format for records.
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
2. Storage of Gunning Refractory
2.1 Always store under covered space. Never in open area.
2.2 Protect from moisture. Keep dry.
2.3 Stack away from the walls on wooden pallets.
2.4 First In First Out (FIFO) is must.
2.5 Must be used within self life period.
3. Anchor Welding
3.1. Check the anchor dimensions (randomly).
3.2. Clean the surface of the shell thoroughly with wire brush.
3.3. Mark the location in the shell as specified in the drawing as per
decided spacing. Ensure marking orientation of the anchors as per
drawing.
3.4. Put a punch mark in the anchor welding location.
3.5. Grind the surface all around the punch mark. This will ensure the
better welding of anchor with shell.
3.6. Weld one anchor (ensure services of qualified welder only). Check
the quality of welding rods.
3.7. Check the projection (dimension) of anchor in the shell and
ascertain coverage of intended lining thickness.
3.8. Hammer test the welded anchor.
3.9. If satisfactory, continue welding of other anchors.
3.10. Check the perpendicularity of anchor with respect to shell and
parallel of the anchors with respect to base reference anchor.
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
3.11. Hammer test randomly to ensure proper welding.
3.12. Fill the welding inspection report after inspection with client or any
other inspection party.
4. Back-up Layer Fixing & Inspection
4.1 Ceramic Paper / Ceramic Blanket
4.1.1. Check thickness of ceramic paper / ceramic blanket.
4.1.2. Cut into pieces as per site requirement, so that it can be
easily fixed in between two anchors and it will also avoid a
gap around the anchors.
4.1.3. Fix it with any adhesive.
4.1.4. Ensure proper fixing of ceramic paper / ceramic blanket (i.e.,
without any gap formation).
4.1.5. Make Installation report as per the format.
4.1.6. In the case of castable lining adjacent to ceramic blanket,
then provide thin polyethylene sheet / tar paper etc., to avoid
the absorption of water in to the ceramic blanket. In the case
of dry layer is coming like calcium silicate block / insulation
brick then there is no need to provide any polyethylene
sheet.
4.2 Calcium Silicate Block
4.2.1 Check thickness of calcium silicate block.
4.2.2 Cut into pieces as per site requirement, so that it can be
easily fixed in between two anchors.
4.2.3 Fix it tightly with GI wire, it will also prevent the falling of
calcium silicate block from it position.
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
4.2.4 Fill the gap with fine calcium silicate mixed with sodium
silicate solution.
4.2.5 Near the anchor, fill the gap with loose ceramic wool / loose
ceramic blanket.
4.2.6 Check the thickness of the calcium silicate block after fixing.
4.2.7 Make Installation Report as per the format.
4.2.8 Provide one coat of bituminous paint above the calcium
silicate block, if there is any additional insulation back-up
layer has to be provided.
5 Preparation for Installation
5.1 Surface preparation
5.1.1. Clean the shell with wire brush / compressed air thoroughly
(if there is no back –up layer), before going to apply
refractory. The surface must be free from grease, oil, dust
and any other foreign material.
5.1.2. Clean the anchor with wire brush thoroughly.
5.1.3. If there is any backup layer, provide a plastic sheet or
bituminous paint coating above the back up layer as
mentioned in the drawing.
5.1.4. If there is no back up layer, apply one coat of bituminous
paint on the shell.
5.1.5. Wrap tip of the anchors with insulation tape or provide plastic
cap for expansion allowance.
5.2 Template Preparation
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
5.2.1. Make a plan for gunning as per site condition (template
details, panel length, from which area gunning has to be
started, and etc).
5.2.2. Prepare template as per gunniting plan.
5.2.3. Decide the panel size, if not already decided. Panel size for
Insulating castable as backup layer should not be more than
1000 x1000 mm. In case of Dense castable as hot face layer
it should not be more than 800 x 800.
5.2.4. Plan staggered panels as far as possible to ensure
staggered joints.
5.2.5. Template has to be designed in such a way that, it should
have a step of minimum 25 mm with a slope of 25 mm at the
middle of stopper. Avoid straight template.
5.2.6. Template can be either wooden or metal. But ensure
template has to be strong enough to bear the load of
material, force due to gunning and etc., if required provide
further supports.
5.2.7. Ensure orientation of template for gunning suitability.
5.2.8. Apply Grease / oil at stopper surface for easy removal and
prevention of water absorption.
5.2.9. Ensure number of template available at site to avoid want of
template for gunning.
5.3 Tools and Tackles
5.3.1. Gunning machine with required length of water hose pipe,
material feed pipe and air hose pipe and other consumable
spares.
5.3.2. Pan Mixer Machine should be located as close as possible
to the installation site. Check the mixer condition (RPM, gap
between scraper and bottom plate, discharge door, gear oil,
DOL starter and etc.)
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
5.3.3. Ensure easy availability of potable water with a pressure of 4
kg/cm2.
5.3.4. Ensure easy availability of air with a pressure of 7 kg/cm2.
5.3.5. Ensure availability of following items:
5.3.5.1. Carpentry Tools
5.3.5.2. Masonry Tools
5.3.5.3. Hand lamps
5.3.5.4. Measuring jar
5.3.5.5. First aid box with necessary medicine
5.3.5.6. Drums for storing Potable water
5.3.5.7. Welding machine, electrode etc.
5.4. Fixing water percentage
5.4.1 Take 100 kg of one batch of material in a pan mixer.
5.4.2 Dry mix for 1 minute.
5.4.3 Add 10 – 20% of specified requirement of water as per data
sheet.
5.4.4 Mix for 3-5 minutes (predamping)
5.4.5 Feed the material in the gunning machine.
5.4.6 Gun the material in the test panel.
5.4.7 Based on the trial, fix water percentage requirement, air
nozzle pressure and check for rebound losses.
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
5.4.8 If consistency is not obtained inform to HO and technical
department.
5.5 Fixing setting time and template removal time
5.5.1 Make a test panel size of 250x250x250, with side template.
5.5.2 Observe the setting time of the material.
5.5.3 Fix the setting time of the material and template removal
time.
6. Template Fixing
6.1. Ensure the proper template is available at site as per the
panel size with required tools & tackles and supports for
fixing the template.
6.2. Ensure the required numbers of templates available at site to
avoid stoppage of work due to want of templates.
6.3. Ensure separate manpower for fixing the templates for
continuous operation of gunning.
6.4. Apply a coat of grease / oil over the stopper plate. Check it
before placement.
6.5. Fix the template in position with sufficient number of side
supports to avoid the template movement from its position.
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
7. Mixing and Transport
7.1 Clean the mixer thoroughly. Charge known quantity of castable in
the mixer.
7.2 Mix dry for about one minute.
7.3 Add 10-20 % of specified quantity of water as determined by 4.4.
7.4 Mix for 3-5 minutes.
7.5 Discharge the mixed material from the pan mixer.
7.6 Predamped material is placed in the gunning machine via the
feeding hopper with sieve cover or manually as per site condition.
7.7 From the gunning machine, the material is transported to the nozzle
unit through high-abrasion resistant material hoses by means of
compressed air, via an agitator and a pocket of rotor.
7.8 At the nozzle unit, the required water quantity is added with a
manual valve which is operated by the nozzle operator, who may
only add as much water as required determined as per 4.4.
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
7.9 The water and air requirements strongly depend on the material to
be gunned.
8. Gunning Installation Procedure
8.1 The material should be gunned onto the prepared panels without
interruption, up to the upper edge of the templates.
8.2 For the horizontal surfaces, the gunning nozzle must be held at a
right angle to the surface and distance should not be more than
1.5 mts.
8.3 For the vertical surface, the gunning nozzle must hold at an angle
slightly inclined downwards in comparison to the impact surface.
Combined with circular movements, this techniques leads to a
regular material structure.
8.4 In order to avoid generation of spots or nests, each panel must be
gradually build up from bottom to top until the definite strength is
reached.
8.5 Fill the panel completely without any significant super elevations of
the surface. Each super elevation leads to additional time
expenditure and material loss.
8.6 In the case of roof gunning, with dimensions more than 100mm,
this will often prove impossible. In this case, the material is gunned
in layers one after the other. It is important that the interval between
the installation of the first layer and the installation of the final layer
is a short as possible. The first layer must still be in a plastic state.
8.7 The surface must be flushed until it is as rough as wood. Do not
flatten completely.
8.8 Put vent hole at a pitch of 250 x 250mm.
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
9. Removal of template
8.1 Check and ensure proper setting of castable.
8.2 Remove all the supports provided for fixing the template one by
one.
8.3 Don’t apply heavy force for removing the supports. If heavy force is
applied for removing the supports it will disturb the castable.
8.4 Remove the template slowly.
10. Inspection
10.1 Check the gunned area.
10.2 Make the gunning installation details.
10.3 If the thickness of the gunning is more, dress them as per
requirement.
11. Air Curing and Wet Curing
11.1 Allow air drying for minimum 8 hours after gunning.
11.2 Practice wet curing after normal air curing using wet gunny bag for
clothes. Cover the gunned area with plastic sheet and above that
put wet gunny bags or cloths. This will prevent the absorption of
water into the castable.
11.3 Sprinkle water on the gunny bags / clothes. Don’t allow the surface
to be dry.
11.4 Allow wet curing for 12 hours minimum.
12. Inspection Report
12.1 Complete the gunning installation details Report.
INSTALLATION MANUAL
FOR
GUNNING CASTABLE
DOCUMENT NO.: CALDERYS/PAS/IM/005 REVISION
12.2 Make a joint inspection along with client and any other third party.
12.3 Make the final protocol (drawing) report mentioning all dimensions
of each panel, gunning date and time.
13 Thermal Dryout
13.1 The specified heating schedule should be followed strictly. (if
specified heating schedule is not known, please seek help from
Customer Manager / Technical Service Department / R &D)
