Castable lining installation procedure

4.2013

What is AGC Plibrico
Pioneer of Monolithic Refractories

CONTENTS
What is AGC Plibrico ....................................................... 1

Refractory Products ......................................................... 2

Makes Walls Tough and Economical ............................. 4
Company Operation ........................................................ 5
Plastic Refractories .......................................................... 6

Patching Refractories ...................................................... 6

High Strength Castable Refractories .............................. 6
Pumping Castable............................................................ 6

Dense Castable Refractories ........................................... 8
Free Flow Castable Refractories ..................................... 8
Silicon Carbide Castables ............................................... 8

Insulating Castable Refractories ................................... 10
Acid Resistant Refractories ........................................... 10
Mortar ............................................................................. 10

Gunning Castable Refractories ..................................... 12

Wet Gunning Castable Refractories ............................. 12
Injection Refractories..................................................... 12

How to Install PLIBRICO ................................................ 14

How to Install PLICAST ................................................. 16

"Monolithic Refractory", developed in the

chemical and power generation sectors.

U.S.A. at the beginning of the 20th century as

Taking advantage of its know-how acquired in

an innovative alternative to fire brick, was first

the refractory business over the years, AGC

introduced in Japan by AGC Plibrico, leading to

Plibrico has also been developing the environ-

an epoch-making revolution in the refractory

mental business, providing high performance

field. As the pioneer of monolithic refractories,

incinerators and related equipments.

Plibrico Japan has since been engaged in the

AGC Plibrico keeps its basic stance of the con-

production, development of installation meth-

tinual improvement and advancement for the

ods and designing of furnace walls for various

full reliance and satisfaction of the customers.

facilities. AGC Plibrico enjoys a high reputation

As a "system engineer of fire and heat protec-

as a unique company with comprehensive tech-

tion", AGC Plibrico contributes widely to the so-

nical capabilities, in a vast range of fields includ-

ciety by offering products and services that

ing key industries such as steel, cement, oil,

meet the needs of our customers.

Corporate Philosophy
1. Contribute extensively to the society through system engineering of fire and heat protection.
2. Build up high-spirited and active company based on reliance.
3. Pursue one's own growth and happiness through job execution.
4. Contribute environmental protection as global citizen.

Quality Statement
Re-build-up slim and robust quality assurance system and enhance reliance of our customers.

Environmental Statement
Compliance with laws and regulations, and all employees work on environmental conservation.
ISO 9001: 2000 = JISQ 9001:2000
Scope of Applicable Products and Services
1. Design and production of monolithic refractories.
2. Production and sales of incinerators and accessory equipment.
3. Design and construction of refractory linings for industrial furnace.

ISO 14001: 2004 = JISQ 14001:2004
This Certificate is valid for the following product or service ranges:
Research & Development, Design & Product Development, Engineering,
Purchase & Logistics, Production, and Sales & Marketing of following products:
Ceramics and Industrial Furnaces.
1

4.2013

Refractory Products
AGC Plibrico has been developing various prod-

customers as well as our employees to promote

ucts, installation methods and machinery to en-

developments and improvements that are in

hance its total product leadership in the field of

line with the times. We will continue to make

m o n ol it h ic r e fr a c t o r y . W e h a v e a l w a y s

unlimited efforts to provide the best possible

responded promptly to the feedbacks from our

quality to our customers.

1954

Plastic

1960

1970

Accomplishing the impossible!
Leading the world with its unique
technology and products
AGC Plibrico’s technical capabilities and
creativity has brought various innovative
developments. Let us introduce two of our
outstanding developments:
HyRATE (product and installation method)
has successfully realized the gunning installation of plastic refractories, which was
thought to be impossible. The HyRATE installation method is several times faster than
conventional ramming installation. It is a

unique installation method with many advantages such as easy installation of complex
shaped furnace walls and longer service life
of linings.
PLIFLOW is a free-flow castable refractory that
generates flowability with low water content.
Being among the first in the industry to develop this product, we have realized an effective
installation of high-strength furnace walls.
Both developments are highly acclaimed as
innovative products and installation methods
pioneered by Plibrico Japan.

1980

1990

2000

PLIRAM
CYCLONE MIX
Plastic refractories
with high abrasion
resistance. Ideal for
cyclones and transfer
pipes of the FCC unit.

PLASTIC REFRACTORIES
Furnace walls are built using
formwork by carefully air ramming each slice.

PATCHING
REFRACTORIES

Gunning Plastic

Easy-to-use soft clay-like
refractories used for repairs.

Castable

PLICAST
Castable refractories that can be
mixed with water and poured into
formwork at the site to construct
furnace walls. Wide range of
products including basic, oxidation-resistant, SiC and heat-resistant types are available.

Gunning Castable

Innovative gunnable plastic refractories and installation method developed by AGC Plibrico, allowing
short installation period, which is
3-8 times faster than the standard
ramming installation.

PLICAST
SUPER HyMOR
Plibrico’s unique and
highstrength castable
refractories for vibration installation.

PLIFLOW
Free-flow castable refractories
that generate flowability with low
water content. Excels in strength
and abrasion resistance.

PLIGUN

PETGUN

Gunning castable refractories for
dry and semi-dry gunning installation.

Gunning castable refractories for PET (wet gunning
method) that generate minimal dust, achieve low
rebound loss and higher
compressive strength.

Wide range of products including
basic, oxidation-resistant, SiC and
heat-resistant types are available.

2

PLIBRICO HyRATE

3

4.2013

Makes Walls Tough and Economical

In arch section, the failure
of a single fire brick will
cause falling down of all
bricks.

Company Operation

PLIBRICO wall is supported
by hangers and never falls
down.

Refractories must not only withstand heat but

application.

also have enough strength and resistance to

Supported by elite Engineering, Research, Tech-

chemical corrosion. Various factors must there-

nical Development and Construction Divisions,

fore be reviewed from different perspectives,

AGC Plibrico supervises comprehensive serv-

such as operation conditions and gas atmos-

ices from design to construction. Here are some

phere inside the furnace, in order to select the

of our approaches in various industrial fields.

type of refractories that best meet the particular

Oil and Pertrochemical
Gas cannot escape through
jointless walls.

AGC Plibrico also has an extensive track record in the oil and petrochemical
industry at home and abroad, with many products nominated in the specifications of process licensers. Our group of knowledgeable engineers provides lining design and installation optimum to each facility. We also contribute to reduce workloads and total cost of the customers through blanket services from product supply to design and construction work.

Gas easily escapes through
joints.

There is no worry for bulging as the wall is supported
by hook anchors.
There is nothing to prevent
fire bricks from bulging.

Fire bricks falls due to spalling, and requires troulbesome repair works.

Especially in special shaped
places,it requires long time
for repairs.

Spalling easily takes
place.Ashes and oil go in
through joints.

Iron and Steel
As the materials are supported by anchors, the
walls can be endurable
against bulging and spalling. Repair, if necessary,
can be done easily.

Plibrico products can be
formed to any shape at job
site. Installation period can
be shortened.

Excellent spalling resistance. Nothing goes in and
no troubles at all.

Plicast
Castable
Refractory

Plicast
Insulating
Castable

Plibrico
Plastic
Refractory

Plisulate
Insulating
Ceramic
Fibers

OTHER MERITS
In addition to advantages shown in the picture, Plibrico refractory materials offer following merits.
* As the materials are ready for use to any shape, there is no need for customers to stockpile fire bricks.
* It requires less time for baking and makes the job faster and economical.
* Prompt delivery.
* No need to be worried about breakage during transportation than fire brick.
* Easy to install and less skill is required. 
* If required, the materials can be precasted to designed shapes beforehand for ready to install at job site.
4

Our approach to the steel industry is field-oriented. By comprehending the
customer's facilities and focusing on their needs from various angles, we
provide optimum products, design, and installation to achieve total cost
reduction for the customer's benefit. We respond to our customer's needs
through prompt development of new products that meet the requirement
of each facility.

Cement
AGC Plibrico boasts high-quality products with proven track records in the
cement industry. We support our customer's operations in various ways by
providing well thought out and field-oriented services such as carrying out
lining inspections and installation supervision during the shutdown period.
We are prepared for prompt response to our customers through quick
product delivery.

Municipal Incinerator
AGC Plibrico boasts an extensive track record also in the municipal incinerator field inside and outside Japan. Our reliable product lines enable us to
respond promptly to our customer's needs with short delivery time. We
support our customers comprehensively throug propositions of efficient
designs and installation methods of furnace linings.

5

1

4.2013

PLASTIC REFRACTORIES/PATCHING REFRACTORIES/HIGH STRENGTH
MAXIMUM
SERVICE
TEMPERATURE(℃ )

MINIMUM
TIME BEFORE
FIRING

1920

IMMEDIATELY AFTER
REMOVAL OF FORM

HEAT

3.00

PLIRAM #90AB

1850

ANYTIME AFTER
INSTALLATION

AIR AND HEAT

PLIRAM #85AB

1800

〃

PLIRAM #80AB

1750

〃

1700

IMMEDIATELY AFTER
REMOVAL OF FORM

PLIBRICO SUPER ALX AB ※1

      ITEM
PRODUCT

PLASTIC REFRACTORIES
PATCHING
REFRACTORIES
CASTABLE
REFRACTORIES

WEIGHT TO
PLACE
(t /㎥ )

MODULUS OF RUPTURE(MPa)

Al2O3

SiO2

110℃
(350℃ )

110℃

500℃

1000℃

PACKING

AMOUNT
OF WATER
(%)

STORAGE
LIFE
(MONTH)

INSTALLATION

-0.1

9.0

1.512

1.686

25kg
CARTON

―

6

RAMMING

10

-1.3

-1.3

8.0

1.279

1.419

〃

―

6

〃

80

15

3.43 3.92 5.88 4.91

-0.9

-1.0

-1.1

9.0

1.279

1.419

〃

―

6

〃

75

16

2.45 2.94 3.92 3.43

-0.9

-0.9

-1.0

8.5

1.023

1.151

〃

―

6

〃

(350℃ )

-0.8

-0.3

9.5

1.279

1.419

〃

―

2

〃

-1.3

-1.4

8.0

1.023

1.151

〃

―

6

〃

3.05

87

〃

2.95

2.85

〃

2.80

2.70

HEAT

2.85

(350℃ )

1750

ANYTIME AFTER
INSTALLATION

AIR AND HEAT

PLIBRICO SUPER AL AB ※1

1700

〃

PLIBRICO SUPER F AB ※1

1600

PLIBRICO SUPER AB ※1

1550

PLIRAM #720

1000℃ 1300℃ 1500℃

THERMAL CONDUCTIVITY
（W/m.K）(FIRED BASE)

-0.1

―

(350℃ )

THERMAL
EXPANSION
( × 10-6PER ℃ )
1000℃ 1300℃ (FIRED BASE)

LINEAR CHANGE(%)

29.4 24.5 21.6 21.6 -0.1
5.39 5.88 9.32 7.85 -1.1

92

(350℃ )

(350℃ )

73

15

2.70

2.70
2.60

73

16

6.86 7.85 11.8 11.8 -0.8
3.0 3.5 4.5 5.0 -1.2

〃

2.50

2.35

58

30

2.0

3.0

4.5

5.5

-1.5

-1.7

-2.0

6.5

0.788

0.986

〃

―

6

〃

〃

〃

2.30

2.15

40

49

2.5

3.0

5.0

5.5

-1.4

-1.5

-1.8

5.7

0.766

0.958

〃

―

6

〃

〃

〃

2.20

2.10

39

51

2.0

2.5

4.5

5.0

-1.4

-1.5

-2.0

5.7

0.744

0.930

〃

―

6

〃

―

5.5∼6.5

12

HAND-PACKING
OR RAMMING

PLIRAM CYCLONE MIX

1700

24 HOURS

CHEMICAL

2.90

2.85

89

1

20.0 30.0 40.0

PLITAB SR MIX

1900

IMMEDIATELY AFTER
RAMMING

HEAT

3.00

2.90

(350℃ )

90

5

2.85

(350℃ )

2.75

80

10

(350℃ )

(350℃ )

-0.2

-0.5

-1.6

9.0

1.977

2.209

25kg
BAG

(350℃ )

-1.2

-1.4

9.0

1.279

1.419

25kg
CARTON

―

3

PATCHING

-1.4

-1.3

9.0

1.198

1.360

〃

―

3

〃

―

3

〃

※2

1600

〃

〃

2.10

2.00

44

47

9.81 17.70 27.50 27.50 -1.1
(350℃ )
(350℃ )
6.86 6.86 11.80 10.80 -1.4
(350℃ )
(350℃ )
5.88 7.85 10.80 10.80 -1.0

-1.8

6.5

0.744

0.930

20kg
CARTON

PLICAST SUPER Hy MOR 1800 KK

1800

24 HOURS

HYDRAULIC

3.05

3.10

92

6

15.7 17.7 19.6 24.5 -0.05 -0.15 -0.15

9.6

1.977

2.209

25kg
BAG

4.0∼5.5

9

VIBRATING

PLICAST SUPER Hy MOR 1700 KK

1700

〃

〃

2.85

2.90

82

10

16.7 16.7 16.7 13.7 -0.05 -0.20 -0.10

7.9

1.744

1.977

〃

5.0∼6.5

9

〃

PLICAST SUPER Hy MOR 1650 KK

1650

〃

〃

2.55

2.60

62

32

12.8 14.7 17.7 17.7 -0.05 -0.25 -0.25

7.0

1.454

1.628

〃

4.5∼6.0

9

〃

PLICAST SUPER Hy MOR 1600 KK

1550

〃

〃

2.40

2.45

48

47

14.7 14.7 16.7 14.7 -0.05 -0.25 -0.20

5.5

1.279

1.454

〃

5.0∼6.5

9

〃

PLICAST SUPER Hy MOR 1500 KK

1450

〃

〃

2.25

2.30

40

55

11.8 10.8 10.8

―

6.0

1.163

1.454

〃

5.0∼6.5

9

〃

MAXIMUM
SERVICE
TEMPERATURE(℃ )

MINIMUM
TIME BEFORE
FIRING

SETTING
CHARACTERISTICS

WEIGHT TO
PLACE
(t/㎥ )

BULK
DENSITY
(g/㎤ )
110℃

CHEMICAL
COMPOSITION
(mass%)

MODULUS OF RUPTURE(MPa)

Al2O3

SiO2

110℃

PECO 1700

1700

24 HOURS

HYDRAULIC

2.55

2.58

83

10

6.0

10.0 11.0 10.0 -0.10 -0.60 -0.60

8.2

1.70

1.90

25kg
BAG

8∼9

9

PM-1

POMPING

PECO 1650

1650

〃

〃

2.33

2.36

62

33

5.0

15.0 18.0 18.0 -0.10 -0.60 -0.70

7.0

1.40

1.60

〃

8∼9

9

〃

〃

PECO 1600

1600

〃

〃

2.08

2.10

46

47

3.0

2.5

3.5

6.5

0.68

0.825

〃

12∼14

9

〃

〃

PECO TUFF MIX D

1400

〃

〃

1.88

2.00

47

41

7.0

4.5

7.0

―

-0.10 -0.35 -0.20

6.0

0.68

0.83

〃

14∼17

12

PM-3

〃

PECO HYDRO MIX

1370

〃

〃

1.90

2.05

33

44

6.0

3.5

6.0

―

-0.10 -0.40 -1.00

6.0

0.66

0.81

〃

17∼19

12

〃

〃

PECO #27

1370

〃

〃

1.85

2.00

36

51

4.0

2.0

5.0

―

-0.10 -0.20 +0.10

6.0

0.65

0.80

〃

17∼20

12

〃

〃

PECO LW-1600

1600

〃

〃

1.38

1.48

43

48

0.5

1.0

2.0

4.0

-0.30 -0.50 -1.50

8.4

0.535

0.58

〃

28∼32

9

PM-10

〃

PECO LW-1400

1400

〃

〃

1.35

1.44

48

42

3.0

1.5

2.0

―

-0.20 -0.50 -0.80

6.0

0.47

0.54

〃

33∼39

9

PM-1

〃

PECO LW-1350

1350

〃

〃

1.25

1.40

40

40

3.0

1.5

2.0

―

-0.10 -0.50 -1.50

5.5

0.36

0.42

〃

36∼44

12

PM-3

〃

1.5

1.5

―

―

0.27

(800℃ )

0.305

〃

36∼44

12

〃

〃

0.5

(800℃ )

―

―

(800℃ )

20kg
BAG

85∼105

12

〃

〃

1.4

(800℃ )

―

―

85∼105

12

PM-4

〃

0.2

(800℃ )

―

―

120∼150 12

PM-3

〃

PLIRAM #515
PLIRAM #187A

※2
※2

      ITEM
PRODUCT

PECO LW-1200
PECO VERILITE S
PECO VERILITE
PECO AIRLITE S

1700

1200
1000
820
1000

〃

〃
〃
48 HOURS
24 HOURS

〃

〃
〃
〃
〃

1.20
0.75
0.75
0.45

※1 The data represent typical properties of Plibrico (Dalian) Industries Co., Ltd.'s product.
※2 The data represent typical properties in consistency when test pieces are formed.
＊ PLITAB, PLIRAM, PLIBRICO, PLICAST, PECO are registered trademark of AGC Plibrico Co., Ltd.
6

BULK
DENSITY
(g/㎤ )
110℃

2.95
2.95

PLITAB RAM MIX

PUMPING CASTABLE

SETTING
CHARACTERISTICS

CASTABLE REFRACTORIES/PUMPING CASTABLE

CHEMICAL
COMPOSITION
(mass%)

1.31
0.85
0.85
0.53

29
―
―
―

50
―
―
―

1000℃ 1300℃ 1500℃

0.4
0.8
0.2

-1.2

-0.05 -0.20 -0.30

THERMAL THERMAL CONDUCTIVITY
EXPANSION （W/m.K）(FIRED BASE)
PACKING
( × 10-6PER ℃ )
(FIRED
BASE)
1000℃ 1300℃
500℃
1000℃

LINEAR CHANGE(%)
110℃

10.0 -0.10 -0.30 -0.20

-0.20 -1.00
(800℃ )

-0.40 -1.5
(800℃ )
-0.40 -2.00
(800℃ )

-0.30 -0.50

―
―
―
―

6.0
6.0
6.0
6.0

0.20

0.22

0.20

(800℃ )

0.22

〃

0.15

(800℃ )

10kg
BAG

0.17

AMOUNT STORAGE
PRECEDING INSTALLALIFE
OF WATER
MORTAR
TION
(MONTH)
(%)

Note: All figures are "averaged" results of laboratory tests and reasonable variations can be expected.
※Test pieces are formed in the workability suitable to make specimen.
7

2

4.2013

DENSE CASTABLE REFRACTORIES/FREE FLOW CASTABLE REFRACTORIES/
MINIMUM
TIME BEFORE
FIRING

SETTING
CHARACTERISTICS

WEIGHT TO
PLACE
(t /㎥ )

BULK
DENSITY
(g/㎤ )
110℃

Al2O3

SiO2

110℃

1000℃ 1300℃ 1500℃

110℃

PLICAST #40

1800

24 HOURS

HYDRAULIC

2.60∼2.70

2.75∼2.85

95

―

8.34 6.86 5.88 10.8

-0.1

-0.2

-0.3

PLICAST #38

1750

〃

〃

2.75∼2.85

2.80∼2.95

94

―

7.00 7.00 8.00 10.0

-0.1

-0.2

PLICAST #36

1700

〃

〃

2.35∼2.45

2.35∼2.50

70

22

5.88 4.41 3.92 8.83

-0.1

PLICAST KL MIX

1650

〃

〃

2.10∼2.20

2.20∼2.30

56

37

6.37 3.92 4.91 9.81

PLICAST #34

1650

〃

〃

2.00∼2.10

2.05∼2.15

51

43

3.43 1.96 1.96 5.88

PLICAST ABREST KK

1600

〃

〃

2.35

2.37

56

36

9.81 6.86 9.81

PLICAST TP MIX #55

1600

〃

〃

2.10∼2.30

2.20∼2.40

54

39

6.37 4.41 6.37 9.81

PLICAST #33

1580

〃

〃

2.10∼2.20

2.15∼2.25

57

34

4.91 2.94 3.92

PLICAST #31

1540

〃

〃

1.95∼2.05

2.05∼2.15

48

40

4.0

PLICAST #31TROWL

1540

〃

〃

1.65∼1.80

1.80∼1.95

42

PLICAST #27

1370

〃

〃

1.95∼2.05

2.05∼2.20

PLICAST TUFF MIX A

1420

〃

〃

1.90∼2.05

PLICAST TUFF MIX D

1400

〃

〃

PLICAST TUFF MIX

1320

〃

PLICAST HYDRO MIX

1370

PLICAST HYDRO MIX TROWL

FREE FLOW CASTABLE
REFRACTORIES

DENSE CASTABLE REFRACTORIES

PRODUCT

SILICON CARBIDE
CASTABLES

MODULUS OF RUPTURE(MPa)

MAXIMUM
SERVICE
TEMPERATURE(℃ )

      ITEM

THERMAL
EXPANSION
( × 10-6PER ℃ )
1000℃ 1300℃ (FIRED BASE)

LINEAR CHANGE(%)

THERMAL CONDUCTIVITY
（W/m.K）(FIRED BASE)

PACKING

AMOUNT
OF WATER
(%)

STORAGE
LIFE
(MONTH)

INSTALLATION

500℃

1000℃

8.5

1.256

1.500

25kg
BAG

9.5∼10.5

9

POURING

-0.4

8.5

1.260

1.500

〃

8.5∼10.0

9

〃

-0.2

-0.3

7.0

0.744

0.930

〃

9.5∼10.5

9

〃

-0.1

-0.3

-0.3

6.0

0.686

0.837

〃

10.0∼12.0

9

〃

-0.2

-0.3

-0.3

6.0

0.686

0.837

〃

13.0∼15.0

9

〃

-0.1

-0.4

-0.1

6.5

1.140

1.360

〃

8.0∼9.0

9

VIBRATING

-0.1

-0.2 +0.4

6.5

0.744

0.930

〃

9.0∼13.0

9

TROWELLING

―

-0.1

-0.2

-0.4

6.0

0.686

0.837

〃

11.5∼12.5

12

POURING

4.0

―

-0.1

-0.3

-0.5

6.0

0.686

0.837

〃

13.0∼15.5

12

〃

50

2.45 1.47 2.45

―

-0.1

-0.3

-0.6

6.0

0.686

0.837

〃

17.0∼21.0

12

TROWELLING

36

51

6.0

4.5

―

-0.1

-0.3

-0.6

6.0

0.651

0.802

〃

12.5∼15.0

12

POURING

1.95∼2.10

45

46

6.86 6.37 7.85

―

-0.1

-0.3

-0.9

6.5

0.686

0.837

〃

10.0∼13.0

9

〃

1.80∼1.95

1.90∼2.05

47

41

6.86 3.92 6.86

―

-0.1 -0.35 -0.2

6.0

0.686

0.837

〃

13.0∼16.0

12

〃

〃

1.90∼2.00

1.95∼2.10

38

42

5.39 2.45 4.41

―

-0.1

-0.3

-0.8

6.0

0.686

0.837

〃

14.0∼16.0

12

〃

〃

〃

1.95∼2.05

2.00∼2.15

33

44

5.88 2.94 4.41

―

-0.1

-0.3

-1.5

6.0

0.651

0.802

〃

14.0∼16.0

12

〃

1350

〃

〃

1.80∼1.95

1.90∼2.05

32

43

4.90 2.45 4.90

―

-0.1

-0.3

-1.5

6.0

0.651

0.802

〃

16.0∼18.0

12

TROWELLING

PLICAST PETRO MIX

1370

〃

〃

1.95∼2.05

2.00∼2.20

45

40

5.39 2.94 7.36

―

-0.1

-0.2 +0.2

6.0

0.651

0.802

〃

13.0∼17.0

12

POURING

PLICAST TROWL MIX

1350

〃

〃

1.60∼1.70

1.75∼1.85

40

45

2.45 1.47 3.92

―

-0.1

-0.5

-0.9

6.0

0.651

0.802

〃

18.0∼22.0

12

TROWELLING

PLIFLOW 1700 KK

1700

24 HOURS

HYDRAULIC

2.80

2.82

83

10

10.8 12.8 11.8 11.8 -0.05 -0.3

-0.2

―

1.744

1.977

25kg
BAG

7.0∼8.0

9

POURING

PLIFLOW 1650 KK

1650

〃

〃

2.45

2.48

62

33

9.81 17.7 19.6 19.6 -0.05 -0.4

-0.4

―

1.454

1.628

〃

6.5∼8.0

9

〃

PLIFLOW 1600 KK

1600

〃

〃

2.35

2.37

52

44

8.83 12.8 14.7 14.7

-0.3

-0.3

―

1.279

1.454

〃

7.0∼8.0

9

〃

PLIFLOW ABREST SUPER KK

1650

〃

〃

2.50

2.55

60

33

14.0 12.0 14.0 14.0 -0.05 -0.5

-0.5

―

1.455

1.628

〃

5.7∼6.7

9

〃

PLIFLOW ABREST KK

1600

〃

〃

2.35

2.40

51

42

13.7 10.8 14.7 14.7 -0.05 -0.4

-0.4

―

1.209

1.442

〃

6.2∼6.7

9

〃

PLICAST SIC 80 KK

―

24 HOURS

HYDRAULIC

2.50

2.54

9

80

SiC

7.36 11.8 14.7 24.5

-0.1

-0.2

-0.2

5.5

5.035

8.012

25kg
BAG

6.0∼7.5

9

VIBRATING

PLICAST SIC 60 KK

―

〃

〃

2.35

2.43

18

60

SiC

7.36 5.88 6.37 11.8

-0.1

-0.4

-0.4

5.5

2.704

4.186

〃

7.0∼8.5

9

〃

PLICAST SIC 50 KK

―

〃

〃

2.25

2.37

19

50

SiC

9.32 5.88 5.39 11.8

-0.1

-0.4

-0.4

5.5

2.587

4.070

〃

11.5∼13.5

9

〃

PLICAST SIC 40 KK

―

〃

〃

2.20

2.32

25

40

SiC

9.32 6.37 5.39 11.8

-0.1

-0.3

-0.3

6.0

2.529

4.012

〃

9.5∼11.0

9

〃

PLIFLOW SIC 60 KK

―

〃

〃

2.27

2.30

16

57

12.0 11.0 11.0 18.0

-0.1

-0.5

-0.5

―

3.459

4.942

〃

10.0∼11.0

9

POURING

PLIFLOW SIC 50 KK

―

〃

〃

2.25

2.28

20

48

13.0 12.0 12.0 20.0

-0.1

-0.4

-0.5

―

3.277

4.709

〃

10.0∼11.0

9

〃

＊ PLICAST, PLIFLOW are registered trademark of AGC Plibrico Co., Ltd.

8

SILICON CARBIDE CASTABLES

CHEMICAL
COMPOSITION
(mass%)

2.5
3.5

―

-0.1

Note: All figures are "averaged" results of laboratory tests and reasonable variations can be expected.

9

3

4.2013

INSULATING CASTABLE REFRACTORIES/ACID RESISTANT REFRACTORIES
MINIMUM
TIME BEFORE
FIRING

SETTING
CHARACTERISTICS

WEIGHT TO
PLACE
(t /㎥ )

BULK
DENSITY
(g/㎤ )
110℃

Al2O3

SiO2

110℃

1000℃ 1300℃ 1500℃

110℃

PLICAST LWI-606

1700

24 HOURS

HYDRAULIC

1.45∼1.60

1.55∼1.70

95

―

3.92 3.43 3.92 5.39

-0.1

-0.3

-0.4

PLICAST LWI-26

1400

〃

〃

1.30∼1.40

1.35∼1.45

48

42

1.96 1.47 1.96

―

-0.1

-0.4

PLICAST LWI-24

1350

〃

〃

1.20∼1.30

1.30∼1.45

40

40

2.45 1.47 3.43

―

-0.1

PLICAST LWI-24 TROWL

1350

〃

〃

1.20∼1.30

1.30∼1.40

39

42

1.77 1.08 2.94

―

PLICAST LWI-24A

1350

〃

〃

1.30∼1.40

1.35∼1.45

48

42

1.96 1.47 2.45

PLICAST TUFFLITE

1320

〃

〃

1.35∼1.45

1.40∼1.55

30

45

2.94 1.77 3.43

INSULATING CASTABLE REFRACTORIES

PRODUCT

PLICAST LWI-22
PLICAST LWI-22 TROWL
PLICAST LWI-20
PLICAST LWI-20A
PLICAST LWI-20S
PLICAST VERILITE S
PLICAST VERILITE
PLICAST AIRLITE

ACID RESISTANT
REFRACTORIES

PLICAST AIRLITE TROWL

MORTAR

MODULUS OF RUPTURE(MPa)

MAXIMUM
SERVICE
TEMPERATURE(℃ )

      ITEM

1200
1200
1100
1100
1100
1000
820
BACK UP
980
820
BACK UP
980
820
BACK UP
980

〃
〃
〃
〃
〃
〃
48 HOURS

〃

〃
〃
〃
〃
〃
〃
〃
〃

1.05∼1.15
1.05∼1.20
0.85∼0.95
0.85∼0.95
1.05∼1.15
0.70∼0.80
0.70∼0.80
0.30∼0.36

1.10∼1.25
1.15∼1.30
0.90∼1.00
0.90∼1.00

35
39
26
50

44
42
50
37

1.15∼1.25

30

44

0.75∼0.85

―

―

0.75∼0.85

―

―

0.33∼0.40

―

―

THERMAL CONDUCTIVITY
（W/m.K）

PACKING

AMOUNT
OF WATER
(%)

STORAGE
LIFE
(MONTH)

INSTALLATION

1000℃

7.5

1.081

1.221

25kg
BAG

14.0∼18.0

9

POURING

-1.3

6.0

0.384

0.442

〃

33.0∼38.0

9

〃

-0.4

-0.8

5.5

0.360

0.419

〃

35.0∼40.0

12

〃

-0.1

-0.5

-0.8

5.5

0.360

0.419

〃

34.0∼40.0

12

TROWELLING

―

-0.1

-0.4

-1.1

6.0

0.384

0.442

〃

32.0∼37.0

9

POURING

―

-0.1

-0.4

-1.1

6.0

0.384

0.442

〃

35.0∼40.0

12

〃

0.267

(800℃ )

0.302

〃

40.0∼45.0

12

〃

0.267

(800℃ )

0.302

〃

40.0∼44.0

12

TROWELLING

0.233

(800℃ )

20kg
BAG

46.0∼53.0

12

POURING

0.244

〃

50.0∼54.0

9

〃

0.244

(800℃ )

0.267

25kg
BAG

40.0∼44.0

12

〃

0.198

(800℃ )

0.221

20kg
BAG

70.0∼85.0

12

〃

0.198

(800℃ )

0.221

〃

70.0∼85.0

12

〃

0.128

(800℃ )

0.151

10kg
BAG

150∼170

12

〃

(800℃ )

〃

80.0∼110

12

TROWELLING

0.122

〃

210∼240

12

POURING

(500℃ )

25kg
BAG

NOZZLE
MIXING

9

GUNNING

〃

NOZZLE
MIXING

12

〃

12

〃

―

―

1.47 0.78

―

―

1.18 0.88

―

―

1.18 0.88

―

―

1.96 1.37

―

(800℃ )

-0.15 -0.8

―

-0.15 -0.8

―

-0.15 -1.2

―

-0.2

-1.5

―

―

-0.15 -1.0

―

―

―

-0.3

(800℃ )

(500℃ )

-0.8

―

―

―

-0.3

(500℃ )

(500℃ )

-1.0

―

―

―

-0.3

(500℃ )

(500℃ )

-1.2

―

―

―

-0.4

(500℃ )

-1.2

―

6.0

0.151

(500℃ )

―

―

-0.6

-1.0

(500℃ )

―

6.0

0.106

(500℃ )

―

―

-0.1

-0.4

(500℃ )

―

9.5

0.640

(500℃ )

―

―

-0.1

-0.2

(500℃ )

―

9.5

0.640

0.686

(500℃ )

―

―

-0.2

(500℃ )

-0.5

―

6.0

(300℃ )

0.355

(500℃ )

0.366

〃

NOZZLE
MIXING

1.68 0.78
1.96 1.18
0.29

THERMAL
EXPANSION
( × 10-6PER ℃ )
1000℃ 1300℃ (FIRED BASE)

LINEAR CHANGE(%)

500℃

1.28 0.98

0.2

〃

〃

0.45∼0.55

0.45∼0.55

―

―

0.49 0.29

PLICAST ASTROLITE

800

〃

〃

0.29∼0.32

0.29∼0.33

―

―

0.10 0.08

PLIGUN AR-500

500

48 HOURS

HYDRAULIC

1.80∼1.95

1.85∼2.00

15

58

10.8 5.88

PLIGUN AR-941

500

〃

〃

1.80∼1.90

1.85∼2.00

9

66

7.85 2.94

6.0
5.5
5.3
5.5
5.5
6.0
6.0
6.0

0.221

(300℃ )

(300℃ )

(300℃ )

0.256
(800℃ )

0.174
(500℃ )

0.686
(500℃ )

500

〃

〃

0.90∼1.05

0.95∼1.10

―

―

1.47 1.18

DEMON AIR SET #40 (D)

1800

24 HOURS

HEAT AFTER AIR
DRYING

―

―

78

16

2.94 3.92 3.92 3.92

―

―

―

―

―

―

25kg
BAG

16.0∼23.0

6

TROWELLING

DEMON AIR SET #36 (D)

1700

〃

〃

―

―

49

40

2.94 2.45 3.92 3.92

―

―

―

―

―

―

〃

20.0∼30.0

6

〃

DEMON AIR SET #34 （D）

1500

〃

〃

―

―

35

53

2.45 2.94 2.94

―

―

―

―

―

―

―

〃

20.0∼30.0

6

〃

DEMON AIR SET #30 (D)

1400

〃

〃

―

―

5

85

2.45 1.96 2.45

―

―

―

―

―

―

―

〃

18.0∼25.0

6

〃

PLIGUN LAR-500

＊ PLICAST, PLIGUN, DEMON are registered trademark of AGC Plibrico Co., Ltd.

10

/MORTAR

CHEMICAL
COMPOSITION
(mass%)

Note: All figures are "averaged" results of laboratory tests and reasonable variations can be expected.

11

4

4.2013

GUNNING CASTABLE REFRACTORIES/WET GUNNING CASTABLE

MODULUS OF RUPTURE(MPa)

MAXIMUM
SERVICE
TEMPERATURE(℃ )

MINIMUM
TIME BEFORE
FIRING

SETTING
CHARACTERISTICS

WEIGHT TO
PLACE
(t /㎥ )

BULK
DENSITY
(g/㎤ )
110℃

Al2O3

SiO2

110℃

1000℃ 1300℃ 1500℃

110℃

PLIGUN #80

1800

24 HOURS

HYDRAULIC

2.50∼2.60

2.55∼2.65

78

13

8.83 9.32 10.8 14.8

-0.1

-0.4 +0.1

PLIGUN MIX #901

1700

〃

〃

2.25∼2.40

2.35∼2.50

65

26

9.81 5.88 8.83 12.8

-0.1

-0.2

PLIGUN TP MIX #55

1600

〃

〃

2.20∼2.40

2.20∼2.40

54

39

6.37 4.41 6.37 9.81

PLIGUN ABREST KK

1400

〃

〃

2.15∼2.25

2.25∼2.40

58

27

9.81 6.37 7.85

PLIGUN MIX #932

1400

〃

〃

1.90∼2.10

1.90∼2.10

32

55

PLIGUN PETRO MIX

1370

〃

〃

1.85∼2.05

2.00∼2.20

34

PLIGUN HYDRO MIX

1350

〃

〃

1.95∼2.05

1.95∼2.10

PLIGUN BF MIX

1300

〃

〃

1.90∼2.05

PLIGUN LWI-26

1400

〃

〃

PLIGUN LWI-24

1350

〃

PLIGUN LWI-24A

1350

PLIGUN TUFFLITE

1320

      ITEM
PRODUCT

GUNNING CASTABLE REFRACTORIES

REFRACTORIES/INJECTION REFRACTORIES

CHEMICAL
COMPOSITION
(mass%)

PLIGUN LWI-22
PLIGUN LWI-20
PLIGUN LWI-20A
PLIGUN LWI-20S
PLICAST VERILITE S

1200
1100
1100
1100
1000

PLICAST VERILITE

820
BACK UP980

PLICAST AIRLITE

820
BACK UP980

THERMAL
EXPANSION
( × 10-6PER ℃ )
1000℃ 1300℃ (FIRED BASE)

LINEAR CHANGE(%)

THERMAL CONDUCTIVITY
（W/m.K）(FIRED BASE)

PACKING

AMOUNT
OF WATER
(%)

STORAGE
LIFE
(MONTH)

INSTALLATION

500℃

1000℃

8.0

1.256

1.500

25kg
BAG

NOZZLE
MIXING

9

GUNNING

-0.2

7.0

1.256

1.442

〃

〃

9

〃

-0.1

-0.2 +0.4

6.0

0.744

0.930

〃

〃

9

〃

―

-0.1

-0.2

-0.6

6.7

0.988

1.186

〃

〃

9

〃

9.81 6.86 9.81

―

-0.1

-0.3 +0.2

6.5

0.744

0.907

〃

〃

9

〃

48

4.90 2.94 5.88

―

-0.1

-0.3 +0.2

6.0

0.686

0.837

〃

〃

12

〃

30

52

5.88 4.90 7.85

―

-0.1

-0.3 +1.0

6.5

0.744

0.907

〃

〃

12

〃

1.95∼2.15

36

48

5.88 3.43 4.91

―

-0.1

-0.4

-1.0

6.0

0.744

0.907

〃

〃

12

〃

1.40∼1.55

1.42∼1.57

43

47

2.45 1.96 2.45

―

-0.15 -0.4

-1.3

6.0

0.465

0.523

〃

〃

9

〃

〃

1.30∼1.40

1.40∼1.50

40

40

2.94 2.45 3.92

―

-0.1

-0.3 +0.3

6.5

0.407

0.465

〃

〃

12

〃

〃

〃

1.35∼1.50

1.35∼1.55

43

46

2.94 1.77 2.45

―

-0.1

-0.5

-1.4

6.0

0.465

0.523

〃

〃

9

〃

〃

〃

1.35∼1.50

1.45∼1.60

35

40

3.92 2.45 3.43

―

-0.1

-0.3

-0.8

6.0

0.465

0.523

〃

〃

12

〃

0.349

(800℃ )

0.384

〃

〃

12

〃

(800℃ )

20kg
BAG

〃

12

〃

0.291

〃

〃

9

〃

(800℃ )

25kg
BAG

〃

12

〃

(800℃ )

20kg
BAG

〃

12

〃

〃
〃
〃
〃
〃
48 HOURS

〃

〃
〃
〃
〃
〃
〃
〃

1.10∼1.20
0.98∼1.13
1.00∼1.15
1.15∼1.30
0.75∼0.90
0.95∼1.10
0.50∼0.60

1.10∼1.25
1.00∼1.15
1.05∼1.18

24
23
45

54
57
42

1.20∼1.35

29

45

0.85∼1.00

―

―

1.00∼1.15

―

―

0.55∼0.65

―

―

1.57 1.37

―

―

1.18 0.88

―

―

1.47 0.98

―

―

2.16 1.47

―

(800℃ )

(500℃ )

(500℃ )

(500℃ )

1.96 1.28
2.45 1.28
0.49 0.39

-0.15 -1.0

―

-0.15 -1.2

―

-0.2

-1.3

―

―

-0.15 -0.9

―

―

―

(800℃ )

―

―

―

-0.2

(500℃ )

-0.9

―

―

―

-0.3

(500℃ )

-1.0

―

―

―

-0.4

(500℃ )

-0.8

―

-0.1

-0.3

-0.2 -0.75

6.0
5.3
5.5
5.5
6.0

0.267
0.267
0.291

0.291
(800℃ )

0.326

0.244

0.267

0.244

(800℃ )

0.267

〃

〃

12

〃

6.0

0.198

(800℃ )

0.221

10kg
BAG

〃

12

〃

―

6.0

(300℃ )

-0.166

(500℃ )

0.180

〃

〃

12

〃

-0.3

5.5

2.907

3.488

25kg
BAG

NOZZLE
MIXING

9

GUNNING

6.0

800

〃

〃

0.43∼0.47

0.42∼0.46

―

―

0.49 0.39

―

24 HOURS

HYDRAULIC

2.30∼2.40

2.35∼2.45

8

82

SiC

5.88 7.85 9.81

PLIGUN SIC 60

―

〃

〃

2.20∼2.30

2.25∼2.40

17

63

SiC

8.34 6.86 7.85 14.7

-0.1

-0.2 -0.15

5.5

2.326

3.140

〃

〃

9

〃

SiC

GUNNING CASTABLE
REFRACTORIES

PLIGUN SIC 80

WET GUNNING
CASTABLE REFRACTORIES

PETGUN 1800

―

〃

〃

2.25

2.28

22

52

9.0

8.0

9.5

17.0

-0.1

-0.4

-0.1

5.5

3.227

4.709

〃

9.0∼12.0

9

〃

INJECTION
REFRACTORIES

PLICAST ASTROLITE

PLISTIX BF MIX SUPER

1700

ANYTIME AFTER
INSTALLATION

HEAT

2.20∼2.40

―

81

13

―

―

―

―

―

―

―

―

―

―

25kg
BAG

15.0∼20.0

6

INJECTION

PLISTIX BF MIX

1700

〃

〃

2.15∼2.35

―

78

15

―

―

―

―

―

―

―

―

―

―

〃

16.0∼20.0

6

〃

PLISTIX BF MIX Ｆ

1600

〃

〃

1.70∼2.10

―

63

30

―

―

―

―

―

―

―

―

―

―

〃

28.0∼33.0

6

〃

PLIGUN SIC 50

―

〃

〃

2.00∼2.10

2.05∼2.20

19

50

6.86 5.39 4.91 11.8

-0.1 -0.25 -0.3

5.5

2.267

3.081

〃

〃

9

〃

PLIGUN SIC 40

―

〃

〃

2.00∼2.10

2.05∼2.20

24

41

SiC

6.86 5.39 4.91 11.8

-0.1 -0.25 -0.3

6.0

1.977

2.442

〃

〃

9

〃

1800

24 HOURS

HYDRAULIC

2.87

2.90

90

8

9.5

17.0 20.0 25.0

-0.1

-0.4

-0.5

9.6

1.977

2.209

25kg
BAG

6.5∼7.5

9

WET
GUNNING

PETGUN 1700

1700

〃

〃

2.78

2.80

80

14

9.0

12.0 12.0 10.0

-0.1

-0.4

-0.5

8.2

1.744

1.977

〃

7.0∼8.5

9

〃

PETGUN 1650

1650

〃

〃

2.43

2.46

62

33

10.0 18.0 18.0 18.0

-0.1

-0.5

-0.5

8.0

1.454

1.628

〃

7.0∼8.5

9

〃

PETGUN 1600

1600

〃

〃

2.25

2.27

54

41

9.0

12.0 16.0 16.0

-0.1

-0.5

-0.7

6.0

1.279

1.454

〃

7.5∼9.0

9

〃

18

SiC

60

9.0

8.0

11.0 17.0

-0.1

-0.4

-0.1

5.5

3.459

4.942

〃

8.5∼10.0

9

〃

SiC

PETGUN SIC 60
PETGUN SIC 50

―

〃

〃

＊ PLIGUN, PLICAST, PLISTIX are registered trademark of AGC Plibrico Co., Ltd.
12

2.30

2.32

Note: All figures are "averaged" results of laboratory tests and reasonable variations can be expected.
13

4.2013

How To Install PLIBRICO 【PLASTIC REFRACTORY】
Prior to installing PLIBRICO, hooks are welded to
the casing, and then the material is placed.
PLIBRICO is packed in a carton consisting of 5pcs of
50mm thick slabs for convenience to install.

3

When a first row of slabs is pounded, the surface is
trimmed by scraper.The next row of slabs is placed on
the first row of slabs, and then the pounding is continued in the same manner.

5

When the pounding is completes, frames are
removed, and the lining is trimmed down to a smooth
surface and the specified thickness.

2

Wooden frames are formed, and a row of PLIBRICO
slabs is placed with full thickness of the furnace wall in
wooden frames, and then material is pounded by air
rammer.

4

When PLIBRICO wall reaches to the height of hooks,
anchors are hooked to hooks, and then anchors are embedded into the PLIBRICO refractory wall by hammer.

6

After PLIBRICO wall has been trimmed, expansion
joints are cut into the surface of wall. This should be a
slight cut of about 30~50mm in depth and placed in
every 900 ∼ 1200mm pitch.

7

Finally, ventilation holes of 3~4mm φ are placed on
whole surface in 100 ∼ 150mm pitch.

8

The finished monolithic PLIBRICO lining and the
tools used are shown.

Plastic refractories are more porous than castable refractory.
Moreover, in plastic refractory, there is no water of crystallization due to hydration and most water is present as free
water. As a result, lining made of plastic refractory are not as
liable to vapor explosion as those made of castable refractory.
Therefore, plastic refractory lining allows somewhat faster
heating rate than castables and are easier to handle. However, a sudden rise in temperature will evaporate the water in
plastic refractory linings, causing it to collect at the surface
and weaken it. At times this causes the surface to fall
off.Considering this, heat up rates are maintained at 50 ℃/h
for plastic refractory linings( Fig. 1 ). Note that some plastic
refractories reqire heating immediately after installation and
some allow it to be carried out later. The minimum time
allowed before heating by the various varieties must not be
forgotten.

To operation temp.

Temperature

1

/h

0℃

5

Time
Fig. 1 Heat-up rate for a plastic refractory lining

GENERAL NOTES ON PLASTIC REFRACTORY INSTALLATION
1. Never allowed to contact with water (such as rain water) during or following installation of plastic refractory.
2. When temporarily halting work,cut the finished area at vertical against casing angles to the shell and cover with a
vinyl sheet to prevent from drying. If jointing the lining, trim the jointing surface of lining already formed.
3. When applying castable refractory on a plastic refractory lining already placed, waterproof the plastic lining adequately
like covering with a vinyl sheet or applying waterproof paint.
4. Remove ceiling forms to facilitate natural drying as much as possible from completion to apply plastic refractory to
start operation. However, at intervals of 1200~1500mm, place about 300mm wide plates which edges are on the
score lines, supported by square bars.

14

15

4.2013

How To Install PLICAST【CASTABLE REFRACTORY】
PLICAST is hydraulic castable refractory and
hardens at room temperature.

MEMO

As PLICAST contains alumina cement, similar
method of cement installation is applicable.
However, various grades of PLICAST for wide
applications are available and each grade has an
individual setting characteristics and proper conditions for installations. Therefore, please refer
details to our separate catalog, “How to install
PLICAST (CASTABLES)”.

1. Material needs to be stored under roof in dry condition.
2. Frames should be made solid and water-proofed to avoid
the leakage of material.

3. Only clean and correct amount of water shall be used for
mixing, and the material is well mixed before and after
adding water.

4. Material is placed immediately after being mixed with
water, and should not be used with any material which
has already started hardening.

5. As poured, it is puddled with a paddler or vibrator to prevent any void is made.

6. Proper expansion joints shall be placed.
7. PLIBRICO’s accessories designed and manufactured
based on our abundant experience shall be used.

8. For water curing, it is required to keep proper time. Material should be kept moist by either covering wet mats or
spraying water to prevent the surface from drying.

9. For heat drying, the temperature shall be raised slowly
according to our standard dryout curve.

16

17

Head Office: 6F Mita-NN Bldg., 1-23, Shiba 4-chome, Minato-ku,
Tokyo 108-0014 JAPAN
TEL :81-3-3455-1359 (East Japan Branch)
FAX:81-3-3455-1362
Branches: Osaka, Nagoya, Mizushima, Fukuoka, Hachinohe, Kashima, Kimitsu,
Keihin, Wakayama, Kakogawa, Fukuyama, Oita, Singapore
Factory:

Chigasaki

Subsidiary: Plibrico (Dalian) Industries Co., Ltd.

Form No.(1000)3.2013 KO