Refractory Storage Policy for Monolithics
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Effective Date: Mar. 16th, 2020

General Guidelines for Ideal Refractory Storage Conditions

1. Refractory monolithics (dry castables and gun mixes, basic castables and gun mixes, plastics, wet and dry mortars, liquid seals, precast shapes) should be stored in a dry, covered, weather-protected location, such as a permanent warehouse, and placed on a concrete slab, asphalt pad, or other impermeable surfaces. The product should be stored on the original pallets (with stretch wrap or original packaging intact, when applicable) but elevated from the surface to allow air circulation. Care should be taken to avoid high humidity locations where moisture can collect under the plastic pallet wrapping.
2. Refractory monolithics should NOT be stored on grass, soil, or other non-compacted surface or any area where moisture can collect, stand, or come in contact with the refractory or refractory packaging.
3. Refractory bags or containers showing evidence of damage, or being previously opened, should not be used and should be discarded. Bags containing dry refractory that is agglomerated, containing hard lumps, or have evidence of water stains should not be used and should be discarded. Hard lumps indicate that the dry refractory has come into contact and reacted with water.
4. The ideal air and material temperature range during storage is 50°F (10°C) to 80°F (27°C) for all refractory monolithic products.

Guidelines for DRY Monolithic Refractories

(Dry Castables and Gun mixes, Basic Castables and Gun Mixes, Dry Mortars)

1. Dry monolithic products should be stored in unopened bags or containers and on the original shipping pallets. Bags or containers showing evidence of damage or being previously opened should NOT be used and should be discarded. Bags containing dry refractory that is agglomerated, containing hard lumps, or that have evidence of water stains should NOT be used and should be discarded. Hard lumps in the bag indicate that the dry monolithic refractory has come into contact with moisture.
2. If exposed to freezing temperatures during storage, dry monolithic products should be heated to a temperature between 50°F (10°C) and 80°F (27°C) prior to installation for best results. Measure material temperature for best results. An immersion thermometer is a good method to measure the refractory monolithic temperature.
3. In hot weather conditions, dry monolithic products should be placed in shady, cool areas; out of direct sunlight. Measure material temperature for best results. Refrigerated truck vans have been successfully used to cool dry monolithics to within the ideal temperature range prior to installation.

Guidelines for WET Mortars and Plastics

(Air Setting, Phosphate Bonded)

1. Wet mortars and plastics can be affected by storage temperatures more than that of dry monolithic products and should be stored at temperatures between 40°F (4°C) and 80°F (27°C) to minimize premature hardening of the product. Long-term storage at hot temperatures can, prematurely, accelerate the wet product’s dryout, setting, and, subsequently, hardening.
2. Do not store wet mortars and plastics close to high heat sources, such as operating furnaces.
3. In cold / freezing air temperatures, wet mortars and plastics should be stored in a heated area prior to use. Winterized wet mortars should be considered for winter conditions. Winterized wet mortars have depressed freezing points but can still freeze if the air temperatures become very low.
4. For wet mortars, some product separation and settling might occur during long-term storage. Evidence of this separation and settling would be a thin liquid layer on the top of the mortar when the container is first opened. If this liquid layer is noticed, mix the liquid back into the mortar prior to use. The preferred method for mixing is a “paint-type” mixer attached to a power drill.

Guidelines for Liquid Coatings and Seals

(Air Setting, Phosphate Bonded)

1. The preferred method for storing liquid coating and seals is in air temperatures ranging from 40°F (4°C) TO 80°F (27°C) in the original packaging.
2. Liquid coating and seals can be negatively affected by cold storage temperatures. In cold or freezing air temperature, liquid coatings and seals should be stored in a heated area prior to use. Winterized versions of liquid coating and seals, with lower freezing points, are available but can still freeze if air temperatures are extremely cold. If regular liquid coatings or seals are exposed to freezing temperatures during storage, a gel phase might develop. The liquid product can be reconstituted if the liquid is thawed and vigorously mixed.
3. In hot weather conditions, liquid coatings and seals should be stored in cool, shaded areas prior to use. Hot air temperatures can promote dehydration and a surface “skin” might form.
4. Liquid coatings and seals should be stirred prior to use, especially if the product has been in storage for a period of time.

Guidelines for Precast Shapes

(Cement Bonded; Dried)

1. The preferred method for storing precast shapes is in a dry, covered, weather-protected location such as a permanent warehouse in minimum air temperatures of 40°F (4°C) on the original packaging.
2. Refractory precast shapes should NOT be stored on grass, soil, or other non-compacted 
   

Best Practices for Storing RESCO Monolithics

Dense Castables & Gun Mixes

Insulating Castables & Gun Mixes

HPI Specific Castables & Gun Mixes

(*) = When transported and/or stored, the product should not be exposed to freezing temperatures

Basic Castables, Ram Mixes, & Gun Mixes

Alumina-Silica Mortars (Wet & Dry)

Basic Castables - Ram Mixes