Installation Methods: Part 1: Understanding Types of Refractories 

Types of Installation Refractory Methods

• Vibration casting using forms
• Pump casting using concrete pump and forms
• Shotcreting using a concrete pump and shotcreting activator
• Precast and dried shapes
• Pneumatic gunning using gunning mixed
• Pneumatic ramming using plastics

Installation of Refractory, Vibration Casting Using Forms

• Traditional installation method
• Mix castable in a paddle mixer, cast behind forms, and vibrate into place
• Water addition can be measured and consistent for consistent properties
• Slow, batch-type installation rate if installing high volume

Brands: Vibration Casting Using Forms

• Rescocast (conventional cement)
• Pacocast (conventional cement)
• Vibrocast (low cement, 45% to 85% alumina)
• Quikturn (low cement, rapid heat-up)
• EZ EST (no cement, 60% alumina to 70% alumina; colloidal silica-bonded)
• EZ Cast (low cement, 45% to 98% alumina)
• R-Max (abrasion-resistant)

Installation of Refractory, Pump casting using a concrete pump

• Double piston, swing valve pump most common
• Mix castable in paddle mixer on the pump and pump through hoses, behind forms
• Water content can be measured and consistent for consistent properties but higher water content needed to pump (compared to vibration casting)
• Higher installation rate when continuously mixing and pumping
• Best for high volume installation

Installation of Refractory, Shotcreting

• Double piston swing valve pumped used
• Mixed castable pumped through the hose
• Shotcrete nozzle attached on the end of the hose
• Shotcrete activator added at the nozzle
• Pumped castable sprayed onto the wall

Brands: Pump Casting and Shotcreting

• Vibrocast PC (low cement 45% to 60% alumina)
• Quikturn PC (low cement, rapid heat-up)
• EZ EST PC (no cement, 60% alumina to 70% alumina; colloidal silica-bonded)
• EZ Cubed (low cement; 45% to 85% alumina)
• R-Max PC (abrasion-resistant)