May 2005

Process Industry Practices

Refractory

PIP RFSM2000
Installation of Monolithic Refractories
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these technical
requirements into a single set of Practices, administrative, application, and engineering
costs to both the purchaser and the manufacturer should be reduced. While this Practice
is expected to incorporate the majority of requirements of most users, individual
applications may involve requirements that will be appended to and take precedence
over this Practice. Determinations concerning fitness for purpose and particular matters
or application of the Practice to particular project or engineering situations should not
be made solely on information contained in these materials. The use of trade names
from time to time should not be viewed as an expression of preference but rather
recognized as normal usage in the trade. Other brands having the same specifications
are equally correct and may be substituted for those named. All Practices or guidelines
are intended to be consistent with applicable laws and regulations including OSHA
requirements. To the extent these Practices or guidelines should conflict with OSHA or
other applicable laws or regulations, such laws or regulations must be followed.
Consult an appropriate professional before applying or acting on any material
contained in or suggested by the Practice.

This Practice is subject to revision at any time by the responsible Function Team and will
be reviewed every 5 years. This Practice will be revised, reaffirmed, or withdrawn.
Information on whether this Practice has been revised may be found at www.pip.org.

© Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3925 West Braker Lane (R4500), Austin,
Texas 78759. PIP member companies and subscribers may copy this Practice
for their internal use. Changes, overlays, addenda, or modifications of any
kind are not permitted within any PIP Practice without the express written
authorization of PIP.

PIP will not consider requests for interpretations (inquiries) for this Practice.

PRINTING HISTORY

May 2005 Issued

Not printed with State funds

 May 2005

Process Industry Practices

Refractory

PIP RFSM2000
Installation of Monolithic Refractories
Table of Contents
4.6 Water-Contaminated Refractory........ 5
1. Introduction................................. 2 4.7 Preparation for Lining Installation...... 6
1.1 Purpose ............................................. 2 4.8 Application Conditions ....................... 7
1.2 Scope................................................. 2 4.9 Mixing of Castable Refractory ........... 8
4.10 Dry Gunning .................................... 11
2. References .................................. 2 4.11 Wet Gunning.................................... 15
2.1 Process Industry Practices (PIP)....... 2 4.12 Casting ............................................ 18
2.2 Industry Codes and Standards.......... 2 4.13 Ramming ......................................... 20
4.14 Interruption of Application................ 22
3. Definitions ................................... 3 4.15 Curing .............................................. 23
4.16 Heat Dryout ..................................... 25
4. Requirements.............................. 4 4.17 Repairs ............................................ 26
4.1 General .............................................. 4 4.18 Shipping and Storage ...................... 27
4.2 Monolithic Refractory Lining Appendix A – Lining Thickness
Anchors.............................................. 4 Tolerance......................................... 29
4.3 Surface Preparation and Coating ...... 4 Appendix B – Dryout Guidelines for
4.4 Prequalification of Materials and Monolithic Castable and Plastic
Installation Personnel ........................ 5 Refractories (Notes 1 and 2) ........... 30
4.5 Water Quality and Testing ................. 5

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PIP RFSM2000
Installation of Monolithic Refractories May 2005

1. Introduction

1.1 Purpose
This Practice provides the requirements for the installation of monolithic refractory
linings.

1.2 Scope
This Practice provides the requirements for the installation of monolithic refractory
linings in process equipment and piping. Installation methods include preparation,
application, curing, and repair of the linings. This Practice also covers heat dryout of
newly installed or repaired linings.

2. References
Applicable parts of the following Practices, industry codes and standards, and references shall
be considered an integral part of this Practice. The edition in effect on the date of contract
award shall be used, except as otherwise noted. Short titles will be used herein when
appropriate.

2.1 Process Industry Practices (PIP)

– PIP CTSL1000 – Application of Internal Coatings
– PIP RFEG2000 – Refractory Design (under development)
– PIP RFIA1000 – Installation of Anchors and Accessories (under development)
– PIP RFSA1000 – Requirements for Refractory Anchors and Accessories (under
development)
– PIP RFSM1000 – Certification and Prequalification of Monolithic
Refractories
– PIP RFTA1000 – Qualification, Inspection, and Testing of Anchors and
Accessories (under development)
– PIP RFTM1000 – Qualification, Inspection, and Testing of Monolithic
Refractory Installations

2.2 Industry Codes and Standards

• American Society for Testing and Materials (ASTM)

– ASTM C71- Standard Terminology Relating to Refractory
– ASTM C309 – Standard Specification for Liquid Membrane-Forming
Compounds for Curing Concrete
– ASTM D4285 – Standard Test Method for Indicating Oil or Water in
Compressed Air

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 PIP RFSM2000
May 2005 Installation of Monolithic Refractories

• The Society for Protective Coatings (SSPC)

– SSPC-SP3 – Power Tool Cleaning
– SSPC-SP7/NACE No. 4 – Brush-Off Blast Cleaning
• American Petroleum Institute (API)
– API RP 936 – Refractory Installation Quality Control Guidelines – Inspection
and Testing Monolithic Refractory Linings and Materials

3. Definitions
With the exception of the terms listed in PIP RFSM1000 and PIP RFTM1000, terms used in
this Practice are defined in accordance with ASTM C71 and API RP 936 (Section 1.2 and
Appendix A). If a definition, as used in this Practice, differs from the one listed in the
reference documents, the modified definition is included in the following:

accelerant: See rigidizing agent

low cement: Refractory castable containing 1% to 2.5% total lime (CaO) on a calcined basis

lubricant: Bentonite clay or a polymer-based additive used to promote low friction flow of
refractory castables during wet gunning. The lubricants are water-based admixtures that have
minimal effect on the physical properties of the applied materials.

no cement: Refractory castable containing 0% to 0.2% total lime (CaO) on a calcined basis

owner: Party who owns the facility wherein the refractory lining is to be used

purchaser: Party who awards the contract to the supplier. The purchaser may be the owner or
the owner’s authorized agent.

purchaser’s inspector: Purchaser’s authorized representative with authority to act in the

interest of, and on behalf of, the purchaser in all quality assurance matters

retardant: Chemical compounds used to prevent flash setting of the material and possible
damage to the equipment or delivery system

rigidizing agent: Chemical compounds used to promote controlled rapid setting of wet gun
refractories. The rigidizing agent, also known as an accelerant, is delivered in a dry form,
mixed onsite in the original container, and added to the refractory at the wet gun nozzle.

Comment: Sodium nitrate (a common rigidizing agent) is considered an oxidant and is

flammable if mixed with certain chemicals.
supplier: Party responsible for furnishing and/or installing the monolithic refractory lining

ultra-low cement: Refractory castable containing 0.2% to 1% total lime (CaO) on a calcined
basis

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PIP RFSM2000
Installation of Monolithic Refractories May 2005

4. Requirements

4.1 General
4.1.1 Conflicts, Exceptions, Substitutions, and Deviations
4.1.1.1 All conflicts between the referenced documents and this Practice
shall be submitted in writing to the purchaser for clarification and
resolution before proceeding.
4.1.1.2 All exceptions, substitutions, and deviations to the requirements of
this Practice and in referenced documents shall be approved by the
purchaser.
4.1.2 Regulations and Material Safety Data Sheets (MSDSs)
4.1.2.1 Refractory materials shall comply with all applicable federal, state,
and local codes and regulations on storage, handling, safety, and
environmental requirements.
4.1.2.2 Latest issue of the refractory manufacturer's product data sheets,
application instructions, and MSDSs shall be available at the
installation site and complied with during the installation of
monolithic refractory linings.
4.1.3 Notification
Purchaser’s inspector(s) shall be given adequate notice before the start of all
work and hold points, so the inspector(s) can witness the work.
4.1.4 Preinstallation
A refractory installation procedure including surface preparation, curing, and
heat drying of the completed lining system shall be submitted to the
purchaser for review and approval before the start of installation. This
procedure shall constitute an inspection hold point in accordance with
PIP RFTM1000-F.

4.2 Monolithic Refractory Lining Anchors

Selection, installation, and inspection and testing of anchors shall be in accordance
with PIP RFSA1000, PIP RFIA1000, and PIP RFTA1000, respectively.

4.3 Surface Preparation and Coating

4.3.1 Requirements for Coated Surfaces
All inspections and tests that are necessary to assure that surface preparation
and coating application comply with the requirements of PIP CTSL1000
shall be completed before refractory installation. This completion of surface
preparation and coating application shall each constitute an inspection hold
point in accordance with PIP RFTM1000-F.

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 PIP RFSM2000
May 2005 Installation of Monolithic Refractories

4.3.2 Requirements for Uncoated Surfaces

4.3.2.1 Immediately before refractory installation, all surfaces to be lined
shall be cleaned to meet SSPC SP7/NACE No. 4 standards for grit
blasting if either of the following occur:
a. Rust, weld slag, oil, dirt, or other foreign materials are present on
the surface to be lined.
b. Hydrotesting was performed after the grit blast cleaning for
anchor installation.
4.3.2.2 If grit blast cleaning is required, anchor caps (if present) shall be
removed before the grit blast cleaning. After grit blast cleaning, the
surfaces to be lined shall be vacuum cleaned to remove all debris.
Water shall not be used for washing unless it contains a suitable
inhibitor.
4.3.2.3 Use of SSPC-SP3 shall be acceptable only for limited areas such as
spot grinding for repairs.
4.3.2.4 Completion of cleaning before refractory application shall constitute
an inspection hold point in accordance with PIP RFTM1000-F.

4.4 Prequalification of Materials and Installation Personnel

4.4.1 Materials
All monolithic refractories to be installed shall be certified and prequalified
in accordance with PIP RFSM1000.
4.4.2 Installation Personnel
All refractory installation personnel shall be prequalified in accordance with
PIP RFTM1000. This prequalification shall constitute an inspection hold
point in accordance with PIP RFTM1000-F.

4.5 Water Quality and Testing

4.5.1 Mixing water shall be clean and potable (suitable for drinking), with a
pH between 6 and 8.
4.5.2 Water from the fire fighting system shall not be used.
4.5.3 Water shall contain less than 200 ppm chlorides (or less if specified by the
refractory material manufacturer) and shall be free from deleterious
impurities. When used for installation on stainless steel equipment, the
chloride content of water shall not exceed 50 ppm.
4.5.4 Equipment used for storing and handling of the water shall be clean, so that
no contaminating material is introduced.

4.6 Water-Contaminated Refractory

4.6.1 Any refractory or pallets of refractory exhibiting evidence of water
contamination shall be retested in accordance with PIP RFSM1000 before
use, regardless of the results of the prequalification (or requalification)
testing.

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PIP RFSM2000
Installation of Monolithic Refractories May 2005

4.6.2 Any individual container of refractory material containing hard lumps

resulting from moisture penetration shall be discarded.

4.7 Preparation for Lining Installation

4.7.1 Timing
4.7.1.1 Refractory installation shall not begin until after completion of
welding, postweld heat treatment, and pressure testing.
4.7.1.2 If the refractory installation must take place before pressure testing,
all pressure retaining weld seams shall remain unlined, i.e., exposed
to the testing medium.
4.7.2 Lining Penetrations
Structural members, nozzle extensions, and other items within the limits of
the lining shall be wrapped with 1/8 inch (3 mm) thickness of a nonabsorbent
paper (not cardboard or ceramic fiber paper) to prevent moisture absorption
from, or bonding to, the refractory lining. Paper shall be taped smoothly into
place.
4.7.3 Openings
4.7.3.1 Openings shall be closed by means of a removable sealed wood or
metal-jacketed plugs, slightly tapered (smaller toward the shell), and
of such dimensions to fit snuggly into the openings.
4.7.3.2 Surfaces of the plugs shall be lightly coated with heavy grease or
covered with plastic to prevent binding.
4.7.3.3 Plugs shall not be removed from the openings or disturbed until the
refractory lining has developed the final set.
4.7.4 Obstructions
Obstructions (e.g., scaffolding) that could interfere with the satisfactory and
continuous application of the refractory lining shall be avoided.
4.7.5 Nozzle Necks
4.7.5.1 Refractory in the nozzle neck shall be cast or hand packed to within
1 inch (25 mm) of the inside of the shell or head to which it is
attached. The remaining 1 inch (25 mm) shall be installed
monolithically with the shell lining.
4.7.5.2 If specifically shown on the approved drawings, any voids or spaces
to be packed with ceramic fiber blanket insulation (e.g., annular
space in nozzles equipped with inner sleeves) shall be completed
before the installation of refractory. Nozzles shall be packed to a
point flush with the inside face of the shell. After nozzle packing, the
ceramic fiber density shall be at least eight pounds per cubic foot
(64 kilograms per cubic meter).

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 PIP RFSM2000
May 2005 Installation of Monolithic Refractories

4.7.6 Overspray
4.7.6.1 All anchors shall be cleaned of spatter and overspray before
refractory is installed.
4.7.6.2 For multilayer linings, anchors for the hot-face layer shall be
protected and free of all backup refractory material before
application of the hot-face layer.
4.7.7 Anchor Tips
If anchor tip coverings as defined in PIP RFSA1000 are required, placement
of the coverings shall be confirmed immediately before refractory placement.
This shall constitute an inspection hold point in accordance with PIP
RFTM1000-F.
4.7.8 Equipment Cleaning
4.7.8.1 Mixers, guns, conveyors, hoses, and all other equipment shall be
thoroughly cleaned before use.
4.7.8.2 Equipment shall be cleaned at each material change, shift change,
and more often if buildup of castable takes place.
4.7.8.3 Cleaning is required between each mix of Type 9 refractory
(PIP RFSM1000, Appendix A).
4.7.8.4 For low-moisture (low-cement) mixes and other refractories sensitive
to water content, the mixer shall be thoroughly washed and excess
water removed after each batch. For other mixes, the cleaning
interval shall be such as to prevent buildup of refractory materials on
the mixer internals (including the drum).
4.7.8.5 All tools used in mixing, transporting, and applying the refractory
lining shall be cleaned after each batch and kept free of all
deleterious materials.
4.7.9 Site
Work area shall be kept clean and protected to ensure that lining installation
can proceed in an orderly manner without incorporating dirt, debris, rain, or
other deleterious material into the lining.

4.8 Application Conditions

4.8.1 Shell/Surface
4.8.1.1 Temperature of the refractory lining and the surface to which it is
applied shall be kept above 50°F (10°C) during application and
curing.
4.8.1.2 If an increase in temperature is required, suitable means for heating
and/or exterior insulation shall be provided.
4.8.1.3 Refractory shall not be exposed to live steam.
4.8.1.4 Temperature of the refractory lining and the surface to which it is
applied shall not exceed 95°F (35°C) during application.

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PIP RFSM2000
Installation of Monolithic Refractories May 2005

4.8.1.5 If temperature reduction is required, the exterior surface of the vessel

can be cooled by spraying the shell with cold water before and
during the refractory lining application.
Comment: Shading may also be required with water spraying. Air
conditioning or installation at night may also be an
effective approach.
4.8.1.6 After refractory application, forced cooling of the shell is no longer
required.
4.8.1.7 Shell surface temperature shall be continuously and locally
monitored at the installation location before and during installation
and, if low temperatures are possible, after installation.
Comment: Significant shell temperature variation can occur because
of the presence or lack of radiant heat from the sun.
4.8.2 Ambient Conditions
Comment: Ambient conditions influence the mix and shell temperatures and
the refractory water content. Shielding workstations from wind,
rain, sun, etc., minimizes the effect of ambient conditions.
Refractory materials shall be protected from detrimental ambient conditions,
including the following:
a. Elevated temperature or exposure to sunlight causing evaporation of
mixing water
b. Windy conditions drying the mix and/or removing fines
c. Exposure to rain or high humidity conditions increasing the water
content
d. Dusty environments causing entrainment of foreign materials into the
mix

4.9 Mixing of Castable Refractory

4.9.1 General
4.9.1.1 Full contents of each bag of premixed refractory material shall be
used.
4.9.1.2 Bags of refractory material that have been wet, opened, or damaged
shall not be used.
4.9.1.3 Refractory lining materials from one manufacturer shall not be
mixed with those from other manufacturers.
4.9.1.4 No cement, lime, or other admixtures of any kind (other than metal
fiber) shall be added to the premixed refractory materials as received
from the manufacturer, unless approved by the manufacturer.

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May 2005 Installation of Monolithic Refractories

4.9.2 Mixing Temperatures

4.9.2.1 Manufacturer’s temperature recommendations for the specific
material and placement conditions shall be followed for mixing,
transportation, and installation.
Comment: Proper mix temperatures for monolithic refractory
materials allow linings to develop the intended physical
properties. Optimum properties develop if cement is
allowed to crystallize in a predictable manner.
4.9.2.2 Mix temperature requirements shall be met by cooling or heating the
material, cooling or heating the water, and/or providing a controlled
environment for mixing.
4.9.2.3 If a manufacturer’s temperature recommendation is not available, the
temperature of the wet-mixed refractory shall be maintained between
60°F (15°C) and 80°F (27°C).
4.9.2.4 Water temperature shall be between 40°F (5°C) and 80°F (27°C).
4.9.3 Mixing Equipment and Procedure
4.9.3.1 Aluminum tools or equipment shall not be used.
4.9.3.2 Stainless steel and carbon steel tools and equipment shall be used in
contact with the refractory.
4.9.3.3 All mixing shall be performed in a horizontal shaft, rotating blade,
paddle mixer except for castable ramming mixes, which shall comply
with Paragraph 4.13.1.2, Item 1.
4.9.3.4 Mixer shall be covered with a coarse grating to prevent entry of
tools, bags, and other large foreign materials.
4.9.3.5 Concrete mixers shall not be used.
4.9.3.6 For critical placements, where interruption in application cannot be
tolerated, at least one spare mixer shall be provided at the jobsite at
all times.
4.9.4 Mixing Procedure
4.9.4.1 Any bag of refractory material that exhibits lumps that cannot be
easily broken or can be attributed to water penetration shall be
discarded.
Comment: During transportation and storage, refractory materials
can compact into lumps. Such lumps are not detrimental
to the installation if easily broken by hand.
4.9.4.2 Metal Fiber Addition
1. Metal fiber reinforcement shall be used only if specified. If
specified, the fibers shall be in accordance with
PIP RFSA1000.
2. Metal fibers shall be introduced into the mixer immediately
following the introduction of the dry refractory material and

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PIP RFSM2000
Installation of Monolithic Refractories May 2005

before the addition of any mixing water other than

predampening.
3. Fibers shall be introduced into the refractory mix in a manner
that ensures uniform distribution, without agglomeration. To
accomplish this uniform distribution, preweighed lots of fibers
shall be introduced into the refractory mix (with the mixer
operating) through the use of a screen to assure that the fibers
fall in a manner similar to rain. The maximum opening
dimension for the screen shall not exceed 1/2 inch (13 mm)
square.
4. Mixer shall be operated for 30 seconds to 1 minute after the
metal fibers are added before the addition of water.
4.9.4.3 Water Addition
1. Water addition at the mixer shall be based on the actual weight
of refractory being used and shall be calculated according to
material prequalification data.
Comment: For dry gunning, this section applies to predampening
water only.
2. Water shall be measured accurately by volume (graduated
containers) or weight as specified in the approved installation
procedures.
3. Maximum total water content recommended by the manufacturer
and noted on the compliance data sheets for the material shall not
be exceeded.
Comment: High or low humidity, wind, and exposure to sunlight
can affect the total water content.
4. Approximately 90% of the calculated total water requirement
(for that individual batch) shall be added at one time. The
balance of the required water shall be added as deemed
necessary to produce a uniform mix.
5. Water shall be added at a slow, uniform rate similar to a rain
while the refractory is being blended, unless the manufacturer’s
procedure recommends otherwise.
4.9.4.4 Mix Time
1. Total mixing time, starting with initial addition of water, shall
not be less than 3 minutes or exceed 5 minutes, unless otherwise
specified by the material manufacturer.
Comment: With Low, Ultra Low, and No Cement castables, the
mix times become a major factor in the final physical
properties.
2. Batches that have mixed longer than 5 minutes after the initial
addition of water shall be discarded.

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 PIP RFSM2000
May 2005 Installation of Monolithic Refractories

4.9.4.5 Post Mixing

1. Quantity of refractory material mixed at one time shall not be
greater than can be placed before the initial set begins.
2. Total time between the addition of water and the placement of
refractory shall not exceed 20 minutes. Batches that have not
been placed within 20 minutes of the initial addition of water
shall be discarded.
3. In transporting the mix, precautions shall be taken to prevent
separation of aggregate, cement, and water.
4. Mixer shall be discharged directly into a clean metal, plastic, or
sealed or lined wood container.
5. After being placed in the container, the refractory shall be
immediately conveyed or moved to the installation site.
6. Refractory shall not be discharged onto the ground.
7. Refractory that misses the container shall not be used.
8. Any batch of refractory material that has been dumped from the
mixer shall not be placed back into the mixer and remixed for
any reason.

4.10 Dry Gunning

4.10.1 General
4.10.1.1 Dry gunning is the pneumatic conveyance of dry (but normally
dampened) monolithic refractory material, including metal fibers (if
required) through a hose to the installation site where the required
hydrating water is added, mixed at the nozzle, and sprayed onto the
surface being lined.
4.10.1.2 Dry-gun application shall be made by pneumatic placement
equipment. The size and style of the equipment, and the operating
procedure shall be as required for the specific refractory lining
application.
4.10.1.3 Only qualified installation personnel who are thoroughly familiar
and experienced with pneumatic application of refractory lining and
who have been prequalified in accordance with Paragraph 4.4.2
shall be employed for this work.
4.10.2 Materials
Refractory materials shall be designed and intended for dry-gun application.
4.10.3 Equipment
4.10.3.1 Dry-Gunning Machines
1. Dry-gunning machines shall be either double-chamber air feed or
rotary feed.

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PIP RFSM2000
Installation of Monolithic Refractories May 2005

2. A double-chamber, air-feed machine shall be used for critical

applications or if metal fibers are included in the mix.
Comment: The double-chamber pot is complicated to operate;
however, the material delivery rate to the nozzle is
consistent.
3. Rotary-feed machines can be used for services not included in
the previous paragraph.
Comment: Rotary-feed machines are easy to set up and operate
but result in a variable, pulsating flow at the nozzle.
4. On critical placements, where interruption in application cannot
be tolerated, at least one spare dry-gun machine shall be at the
jobsite at all times.
4.10.3.2 Air Compressors
1. Air compressor shall be a dependable, oil-free machine (to
prevent the introduction of oil into the refractory). The oil
content of the air stream shall be checked by passing the
discharge air stream through a clean cloth for a minimum
of 1 minute and checking for oil deposits in accordance with
ASTM D4285.
2. Optimum air pressure required to apply the refractory mix shall
be determined during prequalification testing. Optimum density
shall be obtained to maximize physical properties.
Comment: Air pressure is difficult to optimize without
significant testing. Uniformly consolidated linings
can be produced with low air pressures, however,
physical property development is reduced.
3. Pressure shall be kept steady at the optimal value to prevent loss
of binder, produce a uniform lining, and minimize rebound.
4. On critical placements, where interruption in application cannot
be tolerated, at least one spare air compressor shall be provided
at the jobsite at all times.
4.10.3.3 Hose
Hose length from the gunning machine to the gunning nozzle shall
be constant throughout the refractory installation.
4.10.3.4 Gun Nozzle
Gun nozzles shall be suitable for the refractory material being
applied including any metal fibers.
4.10.3.5 Hydration Water
1. Hydration water shall be added at the gunning nozzle.
2. Water supply shall be uniform and at a minimum pressure
of 100 psi (7 kg/cm2).

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 PIP RFSM2000
May 2005 Installation of Monolithic Refractories

3. Amount of water shall be sufficient to produce proper hydration

and within the limits set by the installation personnel
prequalification in accordance with
Paragraph 4.4.2.
4.10.4 Dry-Gunning Application
Comment: The experience, skill, and technique of the installation personnel
are extremely important factors influencing the quality of the final
lining product. Optimum water content, gunning angle, and
nozzle distance from the work area are important aspects of
gunning. Dry-gunning variables include feed rate, air
pressure/volume, and hydration at the nozzle. Improper feed rates
produce high rebound, poorly consolidated material and/or a
laminar structure. Many other variables such as ambient
temperature, mix (material) temperature, water temperature,
humidity, predampening water content, and mixing time
contribute to lining quality. It is important that the purchaser’s
inspector and the installation personnel know how these variables
affect performance and make quick adjustments in the application
process to minimize the effect.
4.10.4.1 Preparation
1. Shell and refractory anchors shall be inspected to confirm
cleanliness and that all anchor caps or coating (if required) are in
place in accordance with PIP RFSA1000 before the lining is
installed.
2. Lining application procedure shall not dislodge any of the anchor
caps or coatings.
3. Previously installed lining and areas yet to be lined shall be
protected to prevent adherence of rebound or overspray
materials.
4.10.4.2 Gunning
1. Full refractory thickness shall be placed at each location as a
single application.
2. A limited area shall be gunned at once, using a small, circular
motion.
3. The following and any other application methods that may create
laminations in the lining shall not be permitted:
a. Using a “painting” motion
b. Building up the lining thickness in layers
4. Gunning shall be into the just-applied refractory and
approximately perpendicular to the lined surface.
5. Gunning nozzle shall be 2 feet to 4 feet (600 mm to
1200 mm) from the shell.

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PIP RFSM2000
Installation of Monolithic Refractories May 2005

6. Upward gunning angle shall be minimized except if gunning

overhead (e.g., the top head).
7. Downward gunning angle shall be minimized, with a maximum
downward angle of 30 degrees.
8. Joining surface of cold joints shall be cleaned, roughened and
prewet before the placement of adjacent refractory.
4.10.4.3 Vertical Equipment
1. Surface to be lined shall be in the vertical during the lining
installation.
2. Refractory lining shall be applied in horizontal, circumferential,
bands generally between 4 feet (1200 mm) and 6 feet (1800 mm)
high.
3. Each band shall be installed continuously (without interruption)
to minimize the number of joints.
4. Initial band shall be at the bottom, with successive bands
working upward.
5. Edges of each band shall be cut perpendicular to the shell.
6. Longitudinal joints shall be staggered.
7. In large diameter vessels, two crews may be used beginning
simultaneously at the same point and working in opposite
directions until meeting.
Comment: This procedure avoids the creation of excess vertical
joints.
8. Within each band, the refractory shall be installed in vertical
columns, always working upward, to minimize the rebound
material that falls into or otherwise becomes entrained into
freshly placed refractory.
4.10.4.4 Thickness
1. Lining thickness shall be measured by means of a small diameter
insertable gauge.
2. Measurement of the installed refractory thickness shall be taken
continuously and as close as possible behind the nozzleman.
3. Edges shall be cut to full thickness perpendicular to the shell.
4. Refractory lining thickness shall be within the design tolerances
(see Appendix A).
5. Thin areas shall be marked and brought to full thickness
immediately.
6. If over the specified thickness, the material shall be immediately
cut away without pulling or damaging the underlying material.
7. Trowel finishing of the cut-off surface shall not be permitted.

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May 2005 Installation of Monolithic Refractories

8. Shot Boards
a. Use of shot boards to define the extent and thickness of each
area to be lined (e.g., band) may be allowed if approved by
the owner.
Comment: Use of shot boards is to define the top of each
band (the previous band defines the bottom) and
the starting point for gunning. If shot boards are
used, proper gunning technique is critical to
avoid rebound entrapment or voids in the
difficult-to-gun areas of shot boards.
b. Shot boards shall be placed between anchors and held in
place to ensure that nothing (wire, bolts, etc.) projects into or
becomes embedded in the lining, and a smooth lining surface
is produced.

4.11 Wet Gunning

4.11.1 General
4.11.1.1 Wet gunning is the process of pumping a castable refractory that
has been mixed with the required hydrating water, a set retardant,
and metal fibers (if required), through a pump, then pneumatically
applying the product to the lining surface.
4.11.1.2The following general application steps shall be used:
a. Mixing of a pumpable/self-flow castable refractory, set retardant,
water, and metal fibers (if required)
b. Pumping of the castable refractory through a pipe/hose assembly
to the installation site
c. Applying the castable refractory to the surface to be lined
through a nozzle assembly that injects a rigidizing agent and
compressed air. The rigidizing agent causes the refractory
castable to gel on the application surface.
4.11.2 Castable Refractory Materials
Refractory materials shall be designed and intended for wet-gunning
application.
4.11.3 Equipment and Accessories
4.11.3.1 General
Application equipment and accessories shall be assembled and
tested before pumping the castable refractory.
4.11.3.2 Piping and Hose
1. Pipe/hose clamp gaskets shall be lubricated with vegetable oil or
light oil during the assembly.
2. All pipe/hose clamps shall have retainers for safety purposes.

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3. Pipe supports on vertical runs shall be used in lieu of rope or

wire ties.
4. Hose assembly shall be filled with water to wet all the interior
surfaces before use.
4.11.3.3 Nozzle Assembly
1. Nozzle assembly shall be cleaned before use.
2. All valves shall be in good condition and tested under operating
pressure.
4.11.3.4 Accelerant System
1. All components of the accelerant system shall be designed to
deliver accelerant at 100 psi to110 psi (7 kg/cm2
to 7.7 kg/cm2) at the gunning nozzle.
2. Accelerant shall be screened to 16 mesh (1190 microns) to break
lumps before use.
3. Accelerant supplied in a dry state shall be mixed a minimum of
10 hours before use.
4. Accelerant system shall be energized with air pressure and tested
before pumping of the refractory castable.
4.11.3.5 Lubrication
1. Pump and material delivery assembly shall be lubricated before
pumping of the refractory castable.
Comment: The pump/line lubricant is a temporary agent that is
replaced by the fines in the refractory castable as it is
pumped through the system. The lubricant is used to
seal the porosity in the material delivery system
during the initial charging of the system.
2. Lubricant may be either of the following:
a. Wet slurry of the castable refractory to be installed
b. Supplemental lubricant, if approved by the refractory
manufacturer
3. All lubricant shall be completely removed by pumping castable
through the system before commencing installation.
4.11.3.6 Compressed Air
1. Air compressor for wet gunning shall be a minimum
of 500 cfm (0.24 cms) at 120 psi (8.4 kg/cm2).
2. Air hose to the nozzle assembly shall be a minimum
of 1 inch (25 mm).
4.11.3.7 Pump
Pump shall be designed specifically for pumping of wet-gunning,
castable refractories.

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4.11.4 Wet-Gunning Setup

4.11.4.1 Refractory mixer shall be installed on level ground or a platform for
operation.
4.11.4.2 Area shall be accessible for material delivery to the mixer and
pump.
4.11.4.3 Mixer shall be installed in a manner to directly charge the refractory
pump.
4.11.4.4 Pump/mixer setup shall be in an area that allows discharging of the
material in case of an emergency clean out.
4.11.4.5 Piping shall be routed in a manner that provides the least amount of
turns necessary to reach the application area. Pipe sweeps shall be
used in lieu of elbows.
4.11.4.6 Hose shall be used for the last 50 feet to 75 feet (15 meters
to 23 meters) of the material delivery system.
4.11.5 Wet-Gunning Installation
4.11.5.1 General
1. Application procedures for dry gunning
(see Paragraph 4.10.4) shall also apply to wet gunning.
2. Only qualified installation personnel who are thoroughly familiar
and experienced with wet-gunning application of refractory
lining and prequalified in accordance with Paragraph 4.4.2 shall
be employed for this work.
3. Surface finish of the wet-gun material shall be as close to a
nozzle finish as possible. The applied materials shall not be
finished smooth.
4. Repairs or patching shall be performed immediately after
gunning of the lining and before the initial set takes place.
5. Use of castable with a rigidizing agent shall be permitted for
hand-applied repairs and patching. The material shall be
homogenized into the application area with a trowel or other
cement tool.
4.11.5.2 Pump Operation
1. During the initial stages of pumping activities, the pump shall be
operated at a low volume of material delivery to prevent
plugging during startup.
2. Pump operator shall monitor the pump pressure at all times.
3. First batch of material shall be at a maximum water content to
maintain lubrication of the material delivery assembly.
4. Water content of each successive batch shall be decreased to the
target water content range during pumping activities.

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5. Adjustments in the water content shall be made by the pump

operator based on weather and site conditions within the limits
set during prequalification in accordance with
PIP RFTM1000.
6. Pressure at the nozzle shall be in the range of 90 psi to 100 psi
(6.3 kg/cm2 to 7 kg/cm2).
7. Care shall be taken to keep the nozzle pressure a minimum of 10
psi (0.7 kg/cm2) less than accelerant pressure.
8. Wet-gunning activities shall be conducted in a continuous
manner. The mixer, pump, and associated pipe/hose shall be
cleaned out during delays, such as lunch breaks or work
stoppage.
Comment: Delays could result in the setting or hardening of
materials in the material delivery assembly.
9. Cut-back or rebound refractory materials shall not be used in the
finished application.
10. Cleanup of all items shall be required upon completion of wet-
gunning activities. Care shall be taken to completely clean out
the pump hopper and cylinders. All castable refractory shall be
removed from the hose and pipe assembly.

4.12 Casting
4.12.1 General
4.12.1.1 Amount of water used in casting applications shall be within ±5%
of the amount used in the prequalification mockup in accordance
with PIP RFTM1000, Paragraph 4.5.3.2, and shall be within the
water range described in PIP RFSM1000, Paragraph 4.1.5.
4.12.1.2 Water addition shall be based upon the nominal weight marked on
each refractory container. The nominal weight marked shall comply
with the requirements of PIP RFSM1000, Paragraph 4.4.2.3.
4.12.1.3 Refractory shall be deposited in a manner that minimizes the
segregation of materials. The refractory shall be deposited as nearly
as possible to the final position. The vertical free fall shall not
exceed 6 feet (2 meters).
4.12.1.4 Work shall continue until an entire section has been completed.
4.12.2 Forming
4.12.2.1Forms shall be required if installing refractories by casting, vibration
casting, and self-leveling methods.
4.12.2.2Forms shall be fabricated from steel or wood, rigidly constructed,
and watertight.

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4.12.2.3Forms shall be strong enough to resist deformation and movement

caused by the weight, buoyancy, and head pressure of the fluid
refractory material.
4.12.2.4Forms shall be designed for easy removal. Arc gouging or other
methods that can damage the refractory shall not be used unless
approved by the owner.
4.12.2.5Forms shall be constructed and installed to achieve lining thickness
within the tolerances shown in Appendix A.
4.12.2.6Forms shall be constructed so that joints between adjacent forms are
not located at nozzles or other critical areas.
4.12.2.7Drop chutes and watertight pouring ports through the form shall be
used for placement of the refractory material. The pouring ports
shall be large enough and arranged to allow observation of the free
refractory surface at the top of the casting throughout the refractory
placement.
4.12.2.8Forms shall be cleaned and waterproofed before use.
4.12.2.9Joints shall be sealed to prevent leakage.
4.12.2.10 Forms shall be coated with light oil, grease, or another parting agent
to prevent adherence to the refractory.
4.12.2.11 Completion of form installation shall constitute an inspection hold
point in accordance with PIP RFTM1000-F.
4.12.3 Vibration Cast
4.12.3.1 Vibrators shall be installed on the outside of the shell to consolidate
refractory, thereby eliminating voids.
4.12.3.2 Vibrators may be installed on the form if permitted by the owner and
demonstrated during mockup.
4.12.3.3 Immersion vibrators shall not be permitted.
4.12.3.4 Vibrators shall be attached to the shell using strapping or other
means without any welded connection to the shell.
4.12.3.5 Amount of vibration shall be determined during the mockup.
Vibration shall continue only until the voids have been consolidated
and water is starting to rise to the top of the refractory. Excessive
vibration shall not be permitted.
4.12.4 Self-Leveling
4.12.4.1 A self-leveling monolithic refractory is a castable that when poured,
seeks its level without the addition of any mechanical energy.
4.12.4.2 Use of vibrators for self-leveling applications is prohibited.
4.12.5 Handpacking
4.12.5.1 Handpacking is refractory placement by hand, and compaction
without the aid of a mechanical device such as a pneumatic rammer.

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4.12.5.2 Handpacking shall be permitted only for hydraulic-set monolithic

refractories.
4.12.5.3 Application by handpacking of the refractory shall be permitted only
in areas with a maximum dimension of 18 inches (450 mm) where
the following occurs:
1. Contouring is required
2. Space does not permit gunning or casting
4.12.5.4 A paddle-type mortar or reciprocating orbital mixer shall be used.
4.12.5.5 Installer’s prequalification panel preparation (in accordance with PIP
RFTM1000, Paragraph 4.5.6) shall be used to determine the actual
range of water content for each type of material at jobsite conditions.
4.12.5.6 Refractory shall be placed and compacted in a manner that ensures
complete filling of the area to be lined.
4.12.5.7 Smooth troweling of the surface shall not be permitted.

4.13 Ramming
4.13.1 Thin Erosion-Resistant Linings
4.13.1.1 Thin erosion-resistant linings shall be 1.5 inches (37 mm) thick or
less.
4.13.1.2 Castable
1. Refractories shall be mixed in a reciprocating orbital mixer (e.g.,
Hobart mixer). The mixer shall have stainless steel paddles and
bowls.
2. Metal fiber reinforcement shall be used only if specified, and the
fibers shall be in accordance with PIP RFSA1000.
3. Metal fibers shall be introduced into the mixer immediately
following the introduction of the dry refractory material and
before the addition of any mixing water other than
predampening.
4. Fibers shall be introduced in a manner that ensures uniform
distribution throughout the refractory mix without
agglomeration.
a. Preweighed lots of fibers shall be introduced into the
refractory mix (with the mixer operating) through the use of
a screen or other device to assure that the fibers fall as a rain.
b. If a screen is used, the maximum opening dimension for the
screen shall not exceed 1/2 inch (13 mm) square.
c. Mixer shall operate for 30 seconds to 1 minute after the
metal fibers are added before the addition of water.
5. Mixing shall be strictly in accordance with the manufacturer’s
recommended procedures using water levels determined during

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installation prequalification in accordance with PIP RFTM1000,

Paragraph 4.5.4.
4.13.1.3 Plastic
1. Plastic refractories shall be installed at the manufactured
consistency.
2. Water addition or reconditioning shall not be permitted.
3. Refractory shall be removed from the container/plastic wrap
immediately before application.
4. Refractory shall be placed on a clean surface for spading,
cutting, and/or separating into slices.
5. Work surface shall be cleaned and maintained to avoid
contaminating fresh refractory with material from previous
cutting or separating operations.
4.13.1.4 Application
1. Refractory shall be applied using a handheld, reciprocating
pneumatic rammer, mallet, and/or wood block as demonstrated
in the installation prequalification in accordance with PIP
RFTM1000, Paragraph 4.5.4.
2. Refractory shall be fully compacted in and around the anchor
supports to form a homogeneous lining structure free of voids
and laminations.
3. Once consolidated, overfill shall be removed flush with the tops
of the hexmesh or hexalt anchors using a trowel or currycomb.
4. Surface shall be tamped, as necessary, to remove imperfections
such as surface tearing and pull-away defects.
5. Water slicking of the lining surface shall not be permitted.
6. Water used to clean and lubricate tools shall be dried off before
use on the refractory. No lubricating agent shall be used.
7. Lining thickness tolerances shall be in accordance with
Appendix A.
4.13.2 Thick Plastic Lining
4.13.2.1 Thick plastic linings are those greater than 1.5 inches (37 mm) thick.
4.13.2.2 Material Preparation
1. Installation prequalification shall be in accordance with
PIP RFTM1000, Paragraph 4.5.5.
2. Plastic refractories shall be installed at the manufactured
consistency.
3. Water addition or reconditioning shall not be permitted.
4. Refractory shall be removed from the container/plastic wrap
immediately before application.

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5. Refractory shall be placed on a clean surface for spading,

cutting, and/or separating into slices.
6. Work surface shall be cleaned and maintained to avoid
contaminating fresh refractory with material from previous
cutting or separating operations.
4.13.2.3 Application
1. Refractory shall be ram packed in successive, handful-sized
pieces using a handheld, reciprocating pneumatic rammer.
2. Refractory shall be fully consolidated into a uniform mass,
compacting the material around the anchor supports.
3. Plastic shall be kneaded into the previously installed material to
form a homogeneous lining free of voids and laminations.
4. Lining shall be trimmed to the desired lining thickness using a
trowel or currycomb.
5. Cutback material can be reused if workability characteristics are
not diminished. Dry or crumbly material shall not be installed.
6. Trimmed surface shall then be tamped, as necessary, to remove
imperfections such as surface tearing and pull-away defects.
7. Water slicking of the lining surface shall not be permitted.
8. Immediately after trimming, 1/8 inch (3 mm) diameter weep
holes extending to three-fourths of the lining depth shall be
placed on a 1 foot (300 mm) square grid over the entire surface.
Comment: These holes are required for steam release during
firing and heat dryout.
9. Lining thickness tolerances shall be in accordance with
Appendix A.

4.14 Interruption of Application

4.14.1 If application is interrupted before completion of the lining, the refractory
lining shall immediately be cut back to the shell between anchors with a steel
trowel.
4.14.2 Cutback shall be made at a right angle to the shell and at a location where the
full refractory thickness has already been applied.
4.14.3 All material beyond the cut and material left in the gun, hose, and/or mixer
for more than 20 minutes shall be discarded.
4.14.4 Anchors and plate surfaces shall be completely cleaned of all refractory
lining materials.
4.14.5 Dislodged anchor caps shall be replaced.
4.14.6 During the period of interruption in application, curing of the refractory
lining already applied shall be in accordance with Section 4.15.

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4.14.7 If installation is halted for the day, all openings in the item being lined shall
be covered, closed, and sealed.
4.14.8 Immediately before resuming refractory application, the exposed surface of
the refractory lining to which a bond must be made shall be cleaned of all
loose refractory material, roughened, and thoroughly wetted with water or
coated with a membrane curing compound. Alternatively, a bonding agent
such as a weak phosphoric acid solution or phosphate-bonded mortar may be
used.

4.15 Curing
4.15.1 Curing of Castable Linings
4.15.1.1 Hydraulic and chemically bonded castable linings shall be allowed
to cure at no less than 50°F (10°C) for a minimum of 24 hours
before the initial heating of the lining.
4.15.1.2 Chemically bonded castable refractory lining surfaces shall remain
uncovered and free from contact with moisture during the curing
period.
4.15.1.3 Curing of hydraulically bonded castables shall be performed in
accordance with one of the following methods as approved by the
owner:
1. Membrane-Curing Compound
a. Curing compound shall be a solution of resin and
hydrocarbon base, membrane-forming (nonreactive), and in
accordance with ASTM C309.
b. Curing compound shall be nonflammable and nontoxic, and
shall contain a factory-added pigmentation that allows for
complete visual inspection of coverage.
c. All curing compounds shall be approved by the owner.
d. Curing compound shall be applied to all exposed surfaces
before the surface is dry to touch. No part of the lining shall
be allowed to air dry more than
2 hours before the application of the curing compound.
e. A one-coat application of curing compound of sufficient
thickness to completely cover the exposed surfaces of the
lining shall be used.
f. Curing compound shall be allowed to dry tack free before
lining is installed in an adjoining area.
g. Adequate ventilation shall be provided during the
membrane-curing compound application and curing period.
2. Water Mist
a. Exposed surfaces of the lining shall be wetted with a fine
water mist. No part of the lining shall be allowed to air dry

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more than 2 hours before the application of the first water

mist.
b. Water-mist application shall be repeated at approximately
2-hour intervals.
c. All surfaces shall be maintained damp to the touch
throughout the curing period.
d. Wetting shall not disturb the lining or wash out components
(e.g., cement, aggregate).
e. Lining shall not be allowed to become dry or excessively
wet.
3. Surface Covering
a. Exposed surfaces shall be covered with polyethylene
sheeting or a damp cloth within 2 hours of installation.
b. All openings must be sealed, and the trapped air removed.
c. If a cloth is used, the cloth shall be kept wet continuously.
4.15.1.4 No curing treatments shall be required on formed surfaces as long
as the forms are retained for the full 24-hour curing time.
4.15.1.5 Refractory-lined equipment shall not be moved, and the forms shall
not be removed for at least 24 hours after casting.
4.15.1.6 Refractory shall not be exposed to steam until heat drying has been
completed.
4.15.1.7 The following steps shall be taken if it is anticipated that a delay
will occur between ambient-curing/air-drying and heating to final
dryout temperature, and that freeze-thaw conditions can occur:
a. Lining shall be cured at a temperature greater than
60°F (16°C) for 72 hours.
b. All openings shall be sealed to prevent the accumulation of
superficial water on the lining during the delay period. Moisture
in the form of water, snow, etc. shall not be permitted.
c. Castable temperature shall be raised to 60°F (16°C) through the
entire thickness and stabilized for 24 hours before the heating-to-
final-dryout temperature is started.
4.15.2 Curing of Plastic Lining
4.15.2.1 Plastic refractories do not require air curing but shall not be exposed
to moisture or freezing conditions before firing.
4.15.2.2Firing of plastic refractories shall commence as soon as practical but
shall not be delayed more than 2 weeks after completion of
installation.

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4.16 Heat Dryout

4.16.1 Initial heating of newly installed refractory linings shall be performed by
process heating devices or temporary equipment such as electric heating
elements or portable burners.
4.16.2 Cold-wall, refractory-lined components shall be dried out by heating from
the refractory hot face only.
4.16.3 Hot-wall, refractory-lined components shall be heat dried from either the
inside or outside surface or placed within an oven and heat soaked from both
sides.
4.16.4 Dryout plan shall be reviewed by the owner’s engineer experienced in dryout
of refractory-lined equipment. The dryout plan shall include one of the
following:
a. Heat-up/cool-down rates for all control temperature indicators and the
maximum difference between temperature indicators
b. General dryout schedule in accordance with Appendix B.
4.16.5 Heating shall be monitored using either process or temporary thermocouples
to monitor gas temperatures throughout the newly lined area(s).
4.16.6 Heating rates shall be controlled by thermocouples on the refractory surface
closest to the heat source and at the exit.
4.16.7 Hold temperatures and durations shall be achieved at the exit thermocouples.
4.16.8 Heat source and airflow shall be immediately removed upon completion of
the dryout schedule, all openings shall be closed, and equipment shall be
allowed to cool naturally to 400ºF (204°C).
4.16.9 Sections that do not have the fully required thickness of insulating refractory
lining or are otherwise not adequate for the maximum heat drying
temperature shall be sealed or otherwise protected from the drying
temperatures. The temperature of these areas and of the metal beneath the
refractory lining shall be monitored to ensure that allowable temperature
values are not exceeded.
4.16.10 Outer metal surface shall not be insulated.
4.16.11 Flow of heated air shall be controlled so that the entire surface of the
refractory is subjected to the full heat drying cycle. Dead or low-flow areas
shall not be permitted. Back pressure, throttling of the air flow, or other
means may be necessary.
4.16.12 During the drying period, adequate ventilation shall be provided for the
escape of moisture.
4.16.13 Heat drying shall be performed by personnel experienced in, and with the
equipment required for, heat drying of refractory-lined equipment.
4.16.14 Dryout procedure shall include a sketch showing the location of heat
source(s), blower arrangement, and thermocouple locations.
4.16.15 Flame shall not enter object being dried.

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4.16.16 If steaming is observed during any hold period, the hold period shall be
maintained until steaming ceases. The remainder of the heating schedule
shall be followed without any make up of the lost time.

4.17 Repairs
4.17.1 General
4.17.1.1 Areas deemed defective in accordance with PIP RFTM1000,
Section 4.7, shall be repaired.
4.17.1.2 Sections of the lining below the minimum thickness (in accordance
with the applicable lining design data sheets of PIP RFEG2000)
shall be cut out entirely and replaced.
4.17.1.3 In a multilayer lining, the hot face shall be removed without
removing or disturbing the backup.
4.17.1.4 Additional material shall not be placed over previously applied
material to build up to the required thickness.
4.17.1.5 Lining installed over a field joint shall follow the same procedures
as a repair.
Comment: If the refractory used for repair differs from the
refractory of the adjacent lining, the installation
procedure, curing, and dryout requirements also may
differ.
4.17.2 Repair Procedures
4.17.2.1 General
1. All proposed materials and methods of repair shall be approved
by the owners before the repair is made.
2. Immediately before placement of the new refractory, the sound
refractory material adjacent to the repair area shall be cleaned of
debris, roughened, and completely prewetted with potable water,
membrane curing compound, phosphate-bonded mortar, or a
weak phosphoric acid.
3. Anchors and shell shall be cleaned of refractory or other debris
and new caps installed on the anchor tips where applicable.
4. If the anchors or the attachment weld are damaged, the anchor
shall be replaced in accordance with PIP RFSA1000.
4.17.2.2 Monolithic Lining
1. With the exception of surface bubble defects, unacceptable
refractory lining shall be cut at a right angle to the shell and
laterally to the acceptable lining and removed. The shell shall not
be damaged.
2. Any areas removed for repair shall have at least one anchor
completely exposed. If not, a new anchor shall be installed. The

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recommended area to be removed for repair shall be sufficient to

expose three, noncontinuous anchors.
3. Corners shall be rounded to a smooth, generous contour
throughout the depth of the refractory.
4. Surface bubble defects shall be repaired by packing with a
phosphate-bonded castable. Metal fibers shall not be used in this
type of repair. The surface shall be screed flush with the adjacent
refractory surface.
4.17.2.3 Thin Erosion-Resistant Lining
1. Defective refractory in hexmesh lining shall require complete
removal and replacement of all affected biscuits.
2. Repair of defective areas of hexalt lining shall comply with
Section 4.17.2.2.
4.17.3 Dryout of Repaired Lining
4.17.3.1 Repaired areas of unfired lining shall be heat dried in conjunction
with the dryout of the overall lining.
4.17.3.2 Patched areas not larger than 5 square feet (0.5 square meter) in
previously dried-out linings of Type 1 through Type 5
(PIP RFSM1000, Appendix A) or less than 2 inches (50 mm) thick,
can be put into service after initial cure without dryout.
4.17.3.3 Patched areas in previously dried-out linings not in compliance with
Section 4.17.3.2 shall be cured and heat dried according to the
procedure of original lining.
4.17.3.4 Local heating can be used as an alternative if approved by the
owner.
4.17.3.5 Means shall be provided to vent steam from all areas of the
refractory repair.
4.17.3.6 Dryout of repairs in linings containing hydrocarbon or hydrocarbon
residues shall not exceed 700°F (370°C) at any location.
Comment: Hydrocarbon or hydrocarbon residues are combustible
and may ignite at elevated temperatures if oxygen is
present.

4.18 Shipping and Storage

4.18.1 Shop-installed refractory lining shall be prepared for shipment in a manner
that ensures delivery to the destination in the original lined, cured, and heat-
dried condition.
4.18.2 Equipment lined with insulating refractories Type 1 through Type 4, and
chemical setting plastic refractory Type 10 (PIP RFSM1000, Appendix A),
shall be heat dried in accordance with Section 4.16 before shipment.
Comment: Heat drying of all refractory-lined equipment before shipment or
storage exceeding 2 months is highly recommended.

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4.18.3 Equipment shall be reinforced using spiders, truing rings, braces, etc. to
maintain the equipment shape and prevent damage to the refractory linings
during handling and shipment.
4.18.4 All openings shall be sealed, and a means shall be provided to keep
refractory linings dry during shipping, storage, and post-erection before the
startup.
4.18.5 Proper supports, external bracing, rigging, and lifting techniques shall be
used to prevent flexing of the equipment during handling, shipping, and
erection.

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Appendix A – Lining Thickness Tolerance

Tolerance
Component
inch mm
Dry/Wet Gunned -0, +1/4 -0, +6

Cast Straight Section ±1/4 ±6

Cast Elbow Section/Irregular Shapes ±1/2 ±13

Maximum Offset at Adjoining Formed Sections ±1/16 ±1.5

Handpack ±1/4 ±6

Rammed Thin (Note 1) -0, +1/8 -0, +3

Rammed Thick (Note 2) ±1/4 ±6

Dual Layer (Gun or Cast)

Back-up Layer -1/4, +0 -6, +0
Hot-Face Layer -0, +1/4 -0, +6

Floor ±1/4 ±6

Notes:
1. Erosion-resistant linings 1.5 inches (37 mm) thick or less
2. Plastic refractory linings greater than 1.5 inches (37 mm) thick

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Appendix B – Dryout Guidelines for Monolithic Castable

and Plastic Refractories (Notes 1 and 2)

First Hold Second Hold Maximum

Refractory Material 300˚F (150˚C) 700˚F (370˚C) Temperature
PIP Type (Note 3) Heating Rate (Notes 4, 5) (Notes 4, 5) (Note 6)

Types 1, 2, 3, 3LI 75˚F (42˚C)

Yes None 1200˚F (650˚C)
Insulating Castables per hour

Type 4 50˚F (28˚C)

Yes None 1200˚F (650˚C)
Medium Weight Castable per hour

Types 5, 6, 7
Medium/Moderate Weight and 50˚F (28˚C)
Yes Yes 1200˚F (650˚C)
Fused Silica Erosion-Resistant per hour
Castables

Types 8, 9
25˚F (14˚C)
Erosion-Resistant Yes None 1200˚F (650˚C)
per hour
Dense Castables

Type 10 50˚F (28˚C)

Yes None 1200˚F (650˚C)
Plastic Refractory per hour

Type 11
25˚F (14˚C)
Chemically Inert Yes Yes 1200˚F (650˚C)
per hour
Dense Castable

Notes:
1. Dryout guidelines are for single-layer castable or plastic refractories up
to 5 inches (125 mm) thick. Multicomponent or thicker refractories may
require slower heating rates.
2. Dryout rates are based on refractory materials without organic fiber or other
agents that permit faster heating rates.
3. PIP Type refers to monolithic refractory types in accordance with
PIP RFSM1000, Appendix A.
4. All hold times are 1 hour per inch (25 mm) thickness of refractory.
5. If steaming is observed during any hold period, the hold period shall be
maintained until steaming ceases.
6. Use the operating temperature if less than 1200˚F (650˚C).

Page B-1 Process Industry Practices