Castable refractory cement recipe

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Castable refractory cement recipe

I am descended from 5, generations of tool-using primates. Also, I went to college and stuff. I am a long-time contributor to MAKE magazine and makezine. The cast lid is reinforced with a grid of steel wires to increase tensile strength. Castable refractories can be mixed with water, formed, and solidified like cement, but the process of drying the solid before full-temperature use is critical.

When working with castable refractory, be mindful of the hazard of heating trapped water too rapidly and causing a steam explosion. Lionel has been experimenting with and writing about home foundry work online for more than a decade, now, and his recipe uses no hard-to-find materials. By volume, it is Portland cement:perlite:silica sand, mixed together thoroughly, then combined with 4 parts fireclay.

You will need about 1 part by volume of Furnace Cement for each 4 parts by volume of Perlite so for a two gallon bag of Perlite you will need a half gallon of Furnace Cement. If you use much less than four volumes of Perlite for each volume of Furnace Cement all of the passages between Perlite beads will be sealed and it will take a long time for the cement to set it needs contact with air.

If you use much more than five volumes of Perlite for each volume of Furnace Cement the resulting material will be quite weak. You will also want to have some Furnace Cement to use as a sealing coat on your lining. The Furnace Cement has about the consistency of roofing tar and is very sticky. It is MUCH easier to work with if you add about 2 cups of water per gallon of cement. This makes it more like a thin plaster.

Latest Sean Michael Ragan. Related Stories from Make:. Send this to a friend Your email Recipient email Send Cancel. Thanks for signing up. Please try again.By easilyconfusedAugust 2, in Alchemy and Formulas.

I've been reading about used oil burners for casting and trying to come up with a recipe for some homemade refractory for the burner. I have portland cement and perlite kicking around the farm and some hard firebrick. I was wondering if, while it will be a fair bit of work, crushing up the firebrick would work for the refractory or will I still need new fireclay or benntonite clay?

castable refractory cement recipe

I'm pretty sure that won't work. You could use crushed firebrick instead of the perlite, but you stiil need the clay, I think? The cheepest unsented kitty litter you can find will be bentonite clay.

Or you can be lazy like meand just dump it in a bucket of water and let it set for about a week, stirring well a couple of times a day to turn it into slip. But the question on my mind is If you have firebricks already, why not just use them for the insulation? I tried a DIY refractory made of perlite, fireclay, and portland cement once. Both the perlite and cement melt at high forging temperatures and I ended up with a real nifty-looking glassy substance.

But it was real soft in the forge at temp. Oh, ok. I was misunderstanding what you wanted to use it for. I belive you it is recomended that you don't use cement, as it can spall violently from thermal expansion. Basically the same as not using river rocks to build a fire ring.

If all you need is enough for a burner, Ace hardware sells quart sized buckets of furnace cement for under ten bucks that will work for what you want, I think. I have to agree that the bentonite will degrade and crumble fairly quickly. I've done some more thinking and am leaning to a square urtuze, or however you spell it, style burner so that I could use the whole hard fire bricks.

I was just wondering if they would protect a layer of the recipe on melting metal in a home foundry, backyard metalcasting, metal casting if I used it as a thick layer of mortar behind the bricks, for support and insulation? I'd like to use the stuff up since it's been sitting in the shed taking up room for a long while but don't want it burning out after the first couple runs.

Cheap is definately good since I'm a student and, since I'm learning, don't feel the need to spend money on high-end refractory during my learning curve.

That being said, I also don't want to waste my time with really poor stuff that won't last a burn or too.

castable refractory cement recipe

Hmm- my propane forge has a liner made of portland cement, clay dirt from the yard, silica sand, and perlite. The proportions were aboutif I recall correctly. I use a layer of half inch kaowool inside a two inch layer of the above refractory, and have never had problems in many hours of operation. It is similar to adobe and should be put on in layers as one thick layer will crack as it dries.

I live in northern Florida and have access to a white clay that is found in most of the natural springs around here. I have done bronze cast for several years with home made furnaces of varying size made from fire brick and fire clay or from fire clay, silica sand and Portland cement.

The ones that have lasted the longest have been the ones out of fire brick.Login or Sign Up. DIY castable refractory. Posts Latest Activity.

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Search Forum. Page of 3. Filtered by:. Previous 1 2 3 template Next. DIY castable refractoryPM. I am sure this question has been asked and answered many time, but I have done many searches and forum reviews without any luck. I am interested in a mix design for home made castable refractory concrete. Interested in casting some panel sections for a wood oven project. Any help would be great.

Tags: None. Re: DIY castable refractory I've cast an oven with the following recipe. Mix well dry.

What sort of lime is it? Hydrated Lime?

Add minimum amount of H2O. Cast away. Comment Post Cancel. Re: DIY castable refractory.

LOUCAST 3000 Degree Dense Castable Refractory Mortar

Originally posted by michelevit View Post. I've cast an oven with the following recipe. Last edited by david s ;PM. Re: DIY castable refractory I think for a pizza oven you want calcium aluminate cement instead of portland, and firebrick grog instead of clay as aggregate. I think most instructions call for SS needles for strength as well. Re: DIY castable refractory If you are going through the effort of making good forms, don't waste your time with homebrew castable It is not that expensive--my entire dome only took kg bags of castable for a 80mm thick mm inside diameter dome.

I'd never screw around with a homebrew under any circumstances Re: DIY castable refractory how much was kg bags?You add water, mix and pour into your form to create a dense high-temperature firebrick.

The finished product is rated at F. This material is often used in furnaces and boilers. It is often used to create forges and for the floor of pizza and bread ovens. For wood kiln building this a great product as it allows you to cast any shape you need.

When casting larger monoliths it is recommended to add stainless steel refractory needles or other or stainless wire reinforcement. We also carry Litewate which is a similar product but with Litewate you can cast insulating firebrick forms. Often a forge will utilize a dense Loucast or hard-fire brick floor, with walls made of or insulated with Litewate, soft insulating fire brick IFBor kaowool blanket. All of these materials are available in pallet quantities at special pricing for large scale projects.

Please call or email us for a quote. This refractory mortar is designed to successfully withstand high sulphur fuel, reducing atmospheres, carbon deposition, erosion and abrasion. This castable refractory cement can be used for gunning, casting, troweling, or extruding.

It is equivalent to Mizzou. Yield : Pounds dry yields 1 cubic foot. With proper supervision, relatively unskilled labor can be used and still achieve excellent structural and thermal properties in the finished refractory lining.

castable refractory cement recipe

Mixing Castable refractories or refractory concretes, as they are sometimes called, can be installed by one of several methods: 1 pouring into forms, 2 tamping into place or 3 pneumatic gunning.

When the installation is by pouring or tamping, the mixing is done in a concrete mixer or preferably in a paddle type mixer. Mixing can be done in a mortar box by hand but this is not recommended. Only good clear water, suitable for drinking, should be used because there could be mineral or chemical contaminants in process water or dirty water, which could completely destroy the effect of the bonding agent in the refractory.

The mixer must be free of dirt and set-up concrete from previous mixes because if this material were to flake off into the new castable, it could have a radical effect on the setting characteristics of the new material. The time of mixing, after the addition of water, should be sufficient to insure that all of the dry material is thoroughly wetted but in no case should exceed five minutes. The proper water to cement ratio is of extreme importance when mixing a castable refractory mortar.

Enough water has to be used to hydrate the cement but an excessive amount of water will create shrinkage and a considerable loss of strength. There is a natural tendency for workmen to make the castable refractory mortar mix too wet because it will work and flow more easily in this state. As a result it is important to maintain careful supervision over the mixing process and there should be little variation in the water to material ration from the batch to batch.

There is a simple test, called the ball-in-hand test, to determine the proper consistency. Take a large handful of the castable refractory mortar mix and squeeze it between the hands as if making a snowball.

The material should form compactly and have a light film of water on the surface. When the ball is thrown about 12 inches into the air and caught with an open hand, the material should slump only enough to just begin to penetrate between the fingers.

A mixture of this consistency would be correct for what is normally called a pouring mix. A tamping mix, by the same test as described above, should have just enough water to form a compact ball with no water film on the surface.

When thrown as above it should remain intact and not penetrate between the fingers at all. The temperature during mixing and casting is mainly of importance due to its effect on the working time.

Castables are stronger when cast in the warm weather, 70 degrees Fahrenheit or above, but casting at temperatures as low as 40 degrees Fahrenheit generally gives good results if the castable is not allowed to freeze before it cures. In cold weather it is advisable to keep the castable stored in a warm place and even to use warm water for mixing so that the temperature of the mixture at the time of the pouring is around 70 degrees.

Placement and Working Time The castable refractory mortar mixture should be poured into place immediately upon completion of the mixing cycle.

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The use of a pencil vibrator is recommended to consolidate the material and to help remove entrapped air.What to Do Mix Perlite and Fire cement using the above measurements Allow it to try for several days at room temperature 68F 72F Bake at F for several hours until no steam or smoke is coming out of it Allow it to cool completely Repeat at a slightly.

Full tutorial on how to make refractory cement three different recipes This is part one of a much requested three part tutorial that shows the viewer how to safely cut and fabricate a small foundry from a discarded propane tank.

Sep 18 Not sure if this is the right forum to post this someone let me know Ill delete it and post in the correct forum if needed I built a small knife charcoal forge my first one ever and I was wondering about what the best homemade refractory recipe I have seen a couple that use portland cement a.

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Jun 07 How to build a small foundry Stand a 4inch plastic pipe centered in a large metal bucket or stainless steel stock pot Mix sodium silicate also known as waterglass or liquid glass Pour the Perlite mixture into the bucket and around the plastic pipe Once the mixture hardens remove the.

Homemade Refractories This page will detail some of the refractory formulas that I experiment previous furnaces were all made from a clay form surrounded with regular concrete or mortar The 2 bucks furnace was my first use of an actual refractory formula Jan Apr 05 Lionel has been experimenting with and writing about home foundry work online for more than a decade now and his recipe uses no hardtofind materials By volume it is Portland cementperlitesilica sand mixed together thoroughly then combined with 4 parts fireclay.

Nov 15 I wouldnt use cement or concrete or mortar unless it is a fire place one or fire rated Portland cement will break down at forge temperatures and may spall Chunks flying out of the forge doesnt sound like fun to me For years I just used wood ash as the lining in a solid fuel forge made from and old barbq grill It works fine.

Home Foundry This instructable will take you step by step how to make a home foundry so you can make quick and efficient aluminum melts for casting Its propane fueled so its easy to set up and easy clean I hope its informative and allows you to make casting. This way if a crucible fails and dumps molten metal into the foundry it will stay in the foundry instead of dangerously flowing out of the pipe The blower tube is really easy to make Start with a 1 steel pipe This is the business end that will sit next to the hot coals in the foundry.

Oct 29 Also super cheap casting material You will be surprised at the detail you can get with concrete and cement Cement is the limestone part of the concrete Concrete has the agglomerates such as rock or gravel in it The cement by itself wont be as strong as the concrete.

Refractory concrete mixture ingredients recipe for mixing by hand and concrete in building pizza ovens How to make heat resistant concrete type for buildig wood fired pizza ovens and similar applications where heat and heating is present Heat differences in materials Temperature differences in material heat expansion and contraction shrinkage of edges with cooling downwards.

Making your own concrete stepping stones is a fun summertime activity that adds a personal touch to your garden Once youve selected concrete and have an idea of what you want your cement stepping stones to look like you might think its smooth sailing from there but concrete can be tricky to work with Here are some tips on how to use concrete for stepping stones.


Mix one 94lb bag of cement with 6 gallons US all the water in your container first and add the cement while you are mixing to avoid clumping When the cement and water are well mixed turn on the Little Dragon and add foam to the mixture Add enough foam to make a total of 45 gallons of AirCrete Thats about 30 high in a standard 55 gallon drum.

Feb 26 I did a mixture of Portland cement and sand as Exoray recommended and so far it seems better than the mortar though it hasnt fully cured yet so it is too soon to tell Right now I am just making the bucks the first of which I used mortar to shape a rock texture and I could tell then that it wouldnt work well for the casting process.

This is my first post here but Ive been looking around the forum for a while Ive definitely learned a lot here Ive been looking into oil burner technology for a while since charcoal can get expensive my budget is almost nil For an oil burner I needed a decent refractory but Im not going to buy 50 worth of commercial formula in the event that I could find some.

LOUCAST Degree Castable Refractory is a dense castable refractory mortar rated for F It is low iron content with high purity This refractory mortar is designed to successfully withstand high sulphur fuel reducing atmospheres carbon deposition erosion and abrasion. Recipes for Lightweight Concrete Recipe 1 1 quart of water 2 quarts portland cement 3 quarts sand 3 quarts perlite In a mixing container bucket mix all dry ingredients together Next in a seperate bucket add 34 of your water next slowly mix in your dry ingredients until you have good workable consistantcy.

This is a formula for making excellent refractory material to use to line the walls of a melting furnace I am routinely melting aluminum and brass and I have been looking for a formula that is strong and lasts a long time All of the formulas that I have seen that use Portland cement need replacing pretty often because Portland does not hold up under heat.

Mar 29 How to Make Foam Concrete Blocks Foam concrete also known as foamed concrete or foamcrete is a versatile cement based and porous lightweight building material that can be used for a wide range of building applications around your. Ive seen a recipe turn up several times for refractory cement both on here and on sites for metal castingkiln building etc Perhaps in the bonding process while curing the.

Bos Easy Mixes For Small Projects Mixes for handbuilt projects and for noncritical uses are described Generally it can be preferable to use pure Portland cement powder and add locally found sands or aggregates Some suppliers include all ingredients prepackaged just add water but these prevent tailoring mixes for your specific requirements. Mixing molding sand greensand Based on some of the emails I get there are plenty of people having trouble with their molding sandI put this page together to illustrate just how easy it is to make a small batch of greensand for your personal foundry.

Lightweight cement is a cement mixture using lightweight aggregates such as Styrofoam beads or pumice stones as a replacement for heavier gravel aggregate The replacement material is applicable using the same methods as traditional stone aggregatebased cement The problem with lightweight cement is in its strength.

Aug 30 Let me show you some of my Tips and Tricks for Concrete Crafting so you too can make it all the time like baking a cake What is concrete The term concrete is for a material that is created from a mix of aggregates with a cement that is activated with water.

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Jun 09 Casting molds are a pretty handy thing to have around especially if youre in the habit of playing with resin or liquid polymer clays If youve ever longed for a custom mold of your own this easytofollow molding putty recipe is a great place to start.

Another important factor in achieving a quality concrete casting is to make sure all of the air pockets are eliminated as the mold is filled with wet concrete To do that the concrete should be added slowly and shaken down or tamped into the mold.

Please feel free to contact us to get the price of our foundry cement recipe. Our professional engineer will customize a solution for you according to your specific requirements.Refractory —Resistant to high temperatures. Soft Fire Bricks —Insulating Fire Bricks IFB are made from refractory clays and various other ceramic materials along with an organic filler that is burnt out, leaving small voids in the brick that help it to insulate.

They are lightweight and absorb about half the energy of hard bricks. Hard Fire Bricks —Refractory brick that can withstand and hold heat without fusion. Used in ceramics kilns, lining furnaces, and fireboxes.

They are hard and durable, have good thermal shock resistance and can withstand various firing atmospheres. These can only be cut with a tile saw or brick saw.

They absorb a lot of heat which adds to firing costs.

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The percentage of alumina in the bricks for ceramic kiln use varies. Hard Castable Dense Castable —Castable refractory with similar properties of hard-fire bricks.

Ceramic Fiber —Fibers of molten materials are stretched and collected to form a blanket or pressed into other products such as fiber board, fiber paper, ropes or custom shapes. Ceramic fiber comes in a variety of weights densitytemperature ratings, and thicknesses.

Ceramic fiber is a dust hazard. Castable Refractory —A refractory mixture with heat resistant hydraulic cement and binders that can be cast in place. Castable refractory has many applications in industry as well as studio ceramics. It is often used in kiln construction because it is easy to use and mix, and reasonably priced.

Castable refractory has many benefits over traditional bricks because it can be mixed on site and poured into molds of almost any shape. The forms are also relatively easy to construct.

This leaves fewer joints that can leak heat or air. This material is often used by potters in kiln building to cast the kiln floor both car and standard kilns. This is easy because you just make a square or rectangular form, seal it with something like Vaseline, and pour in the castable, giving you a level and smooth floor for your kiln.

It is also commonly used to form the key block in standard sprung arch and anagama kilns. This eliminates the need to make complicated and precise cuts, which saves time and reduces mistakes. The key block is cast in place by sealing the top of the arch form and pouring in the castable.

The walls and gravity hold everything in place while it cures. Some people cast the entire kiln, including the door made of cast brick shapes.

Foundry Cement Recipe

Others only cast portions of the kiln—for example, building a kiln body with standard bricks and then casting just the sprung arch to save the expense of buying specialized arch bricks. It can be bought commercially or homemade. All you have to do is add water. Getting the water ratio right is the most difficult part; too much water may cause it to shrink and crack. High-alumina castable can be used to make the trough in the bottom of a salt kiln fire box. This helps contain the salt that is poured into the kiln and preserves the floor from its destructive effects.

Knowing the properties of the materials allows us to exploit their positive characteristics. The downside of using castable is making a form for everything that needs to be cast. Although wooden forms can be used repeatedly for multiple bricks and arch forms, you may only make one kiln. Many potters are already familiar with the mold-making and slip-casting process; this type of building is similar, being either enjoyable or tedious depending on how you feel about the process.Mix recipe and ingredients of refractory concrete.

Mixing your heat resistant concrete by hand with pictures. There are two ways; two types of heat resistant concretes that can be prepared. Cheaper and more expensive - stronger and weaker under a heat. The first one is the high heat refractory concrete. This type will survive in real high heat and can be used for hot-face applications. What is hot face? Hot face is any surface facing the main heat generated by a heat source e. Internal walls, floor and arches made from firebricks inside a pizza oven is hot-face.

Firebricks face the heat, the hot flames from wood fire and the red hot embers. Refractory concrete can face the heat therefore applied as a hot face.

Homemade Refractory Ceramic - Blowtorch Demonstration

Refractory or heat resistant concrete may be mixed with heat resistant cement, or, can be purchased ready in bags as pre-mix product. The packed one is most often referred to as castable. It is different to fill holes and awkward spaces with castables. Large blocks tend to crack as a result of something called heat differences in material, or temperature differences in material in other words, which is a very powerful natural phenomena.

But hey no worries Mate, we still have firebricks here luckily firebricks those nice little fragments for making the dome part properly read more about heat differences in materials - basically it deals with shrinking of cooled down edges and also surfaces while middle is still hot and expanded. A wise idea is to mix the heat resistant cement, e. Calcium Aluminate cement, with firebrick grog.

Companies who manufacture refractory material like Claypave Pty. There are many different refractory cement types, some of them allowed to mixed in lime, plaster, or fireclay, but others cannot be mixed with these because their chemical properties don't allow it, rather they get contaminated by similar additives.

Because they differ, read the usage instruction printed on a particular cement bag, also its producer will gladly give you print out on -it will tell you exactly how to or what can be done. Now, the second one heat resistant concrete type.

It is a lower grade heat resisting concrete, lower grade in withstanding heat but still it can be applied successfully in many areas whose get pretty heated too. For instance layers such as those on the other side of firebricks, on the outside of firebricks, the slab under the heated floor made from fire bricks or cladding around the firebrick dome, chimney parts, etc.

Into this concrete type the common Portland cement goes in the Portland is often also referred to as GP cement and this type is already a bit refractory and of course lime. Both lime and Portland are bonding agents and are described more further below.


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