Kaolite Super Lightweight Insulating Castables

1 Super Lightweight Kaolite Castables reduce both the quantityof heat storage and heat transfer through the lining producing significant savings in furnace fuel lower densities of these vermiculite based Kaolite Castables reduce the amount of supporting furnace steelwork required and provide more insulation with a thinner lining. These products can be cast, poured, or 1600is a Super Lightweight , low thermal conductivityvermiculite based castable designed for backup insulation upto 1600 F.

2 Kaolite 1600 contains portland cement which limits use temperature to 1600 F; however, this makes it aneconomical product based on cost per cubic 1800is a Super Lightweight , low thermal conductivityvermiculite castable designed for both backup insulation andsome hot face applications up to 1800 F. Kaolite 1800 contains a calcium-aluminate cement which gives it betterhigh-temperature stability when compared to Kaolite applications would be low-temperature lining forovens and ductwork For UsingCastingHighest strength is obtained with castable refractory by usingthe least amount of clean mixing water.

3 This will allow thorough working of material into place by lightly vibrating orrodding. A mechanical mixer is required for proper placement(paddle-type mortar mixers are best suited). After achievinga ball-in-hand consistency, mix for 6 minutes. Place materialwithin 20 minutes after suitable gunite equipment. Material should be predamp-ened uniformly with approximately 10 - 12% by weight ofclean water in mechanical mixer before placing into gun. Thiswill reduce rebound and dust. Add required water at nozzlefor effective placement.

4 Suggested air pressure at the nozzle is between 15 and 25 bagged Castables in a dry place, off the ground and,when possible, with the original shrink wrapping forms must be used when placing material. Allporous surfaces that will come into contact with the materialmust be waterproofed with a suitable coating or maximum strength, cure 24 hours under damp conditionsbefore initial heat-up. Keep freshly placed castable warmduring cold weather, ideally between 70 F and 80 F.

5 Newcastable installations must be heated slowly the first timeFreshly placed Lightweight Castables are prone to a deterio-rating condition called alkali hydrolysis when they are kept ina non-dried state for a sustained period of time in a warm,humid environment. Under these conditions, the castablesshould be force dried soon after placement or coated withKao-Seal to resist the possible deterioration mor information on castable placement, consult yourThermal Ceramics Properties316001800 Recommended use limit, F ( C)1600 (871)1800 (982)Pounds per bag (kg)50 (23) 50 (23)

6 Method of installation2C, G, PC, G, PShelf life, months1212 Kaolite SuperLightweight InsulatingCastablesProduct 14-705 Kaolite Super LightweightInsulating CastablesProduct InformationPhysical Properties316001800 Recommended Method of Application, cast, gunnedcast, gunnedAverage lb required to place one cubic ft1(kg)23, 36* (10,16)23, 35* (10,15)Recommended water ranges, % by weightCasting (by vibrating)120 - 145 145 - 165 Pouring150 - 180 175 - 190 Recommended Temperature Use Limit, F ( C)1600 (871)1800 (982)Melting Point, F ( C)2300 (1260)2400 (1316)Density, pcf (kg/m3)fired @ temp.

7 Use limit20 - 25, 31 - 3920 - 25, 29 - 38(320-400, 496-625)(320-400, 464-609)Modulus of rupture, psi (Mpa)ASTM C 133 dried 18-24 hrs. @ 220 F (104 C) cast45 - 75 ( - )25 - 40 ( - )gunned70 - 120 ( - )50 - 100 ( - )fired 5 hrs. @ 1500 F (816 C)cast25 - 40 ( - )30 - 50 ( - )gunned35 - 55 ( - )40 - 60 ( - )fired 5 hrs. @ temp. use limit, cast 25 - 40 ( - )25- 40( - )gunned35- 50( - )35 - 55 ( - )Cold Crushing Strength, psi (Mpa)dried 18-24 hrs. @ 220 F (104 C) cast80 - 120 ( - )35 - 50 ( - )gunned125 - 175 ( - )70 - 120 ( - )fired 5 hrs.

8 @ 1500 F (816 C)cast50 - 70 ( - )50 - 80 ( - )gunned90 - 120 ( - )80 - 110 ( - )fired 5 hrs. @ use limit, cast50- 70( - )40 - 60 ( - )gunned90 - 120 ( - )60 - 80 ( - )Perm. Linear Change, %, ASTM C 1134fired 5 hrs. @ 1500 F (816 C) to to 5 hrs. @ temp. use limit to to ChemicalAnalysis, %, Weight basis after firingAlumina, Al2O31129 Silica, SiO233 32 Ferric oxide, Titanium oxide, Calcium oxide , CaO 30 14 Magnesium oxide, MgO 12 Alkalies, as, Conductivity, Btu ft2 F (w/m k),ASTM C 417 Mean temperaturecast, gunnedcast, gunned@500 F (260 C) ( ), ( ) ( )

9 , ( )@1000 F(538 C) ( ), ( ) ( ), ( )@1500 F (816 C) ( ), ( ) ( ), ( )*Note: For overhead gunning applications, pounds required to place one ft3should be increased to 40-50 pcf. Does not includerebound Gunite installation may require 10-30% overage due to rebound and on-site Installation key: C-cast, G-gun, P-pour3. Properties indicated are for vibratory cast materials unless specified Fired linear change values reflect samples taken from a dried to fired data sheets for specific applications or job requirements are available upon request.

10 The values given herein are typical average values obtained in accordance with accept-ed test methods and are subject to normal manufacturing variations. They are suppliedas a technical service and are subject to change without notice. Therefore, the data con-tained herein should not be used for specification purposes. Check with your ThermalCeramics office to obtain current Ceramics is a trademark of The Morgan Crucible Company and Kao-Seal are trademarks of Thermal Ceramics Communications OfficesThermal Ceramics AmericasT: +1 (706) 796 4200F: +1 (706) 796 4398 Thermal Ceramics Asia PacificT: +65 6733 6068F: +65 6733 3498 Thermal Ceramics EuropeT: +44 (0) 151 334 4030F:+44 (0) 151 334 1684 North America - Sales OfficesCanadaT: +1 (905) 335 3414 F: +1 (905) 335 5145 MexicoT: +52 (555) 576 6622F.