Faik IŞIKÇI
General Manager
Remsan Refrakter
As REMSAN family, we are excited to introduce our REMFORCE UNIMIX concrete for use in iron, steel, cement, aluminum, foundry, chipboard factories, power plants and refineries, which will ensure you achieve successful performance by eliminating your stock problems even if you apply it by gunning or cast concrete method.
One of the most common problems in businesses is that it is not possible to apply the concrete purchased for casting purposes by gunning method or vice versa. Even if this is possible in MEDIUM CEMENT concretes, it is necessary to purchase separate concretes for gunning and casting in ULC concretes. This requires an extra stock load in businesses.
For example, it is not possible to convert a casting type ULC concrete to gunning type for any reason. Most importantly, casting performances of gunning concretes are not as successful as desired. However, you can get the same performance with REMFORCE UNIMIX concretes.
REMFORCE UNIMIX USAGE AREAS
• You can successfully use REMFORCE UNIMIX in any area where concrete will be applied by gunning or casting method. You can immediately return to gunning method, especially in areas where application is difficult and low cement concrete is required. Likewise, if desired the casting method can be applied in an area where gunning method was planned.
• REMFORCE UNIMIX is in ULC or LCC structure. It contains low CaO. It can be used successfully in any area with adhesion, chemical erosion, thermal shock and abrasion problems.
STRUCTURE OF REMFORCE UNIMIX
As with REMLOWGUN and REMFORCE, it is a ULC – LCC concrete. Our REMFORCE UNIMIX concrete does not contain clay or BENTONITE. For this reason, you will not experience raw material fermentation or low refractoriness problems. Thanks to its chemical binders, our concrete has a structure indistinguishable from very low cement (ULC) pouring or gunning type concretes.
REMFORCE UNIMIX GUNNING (GUN MIX)
We have so far reached solutions by using low cement or self-flow concretes against high wear resistance, high strength, chemical, physical, erosion and raw material fermentation in industrial furnaces, iron steel, cement, aluminum, foundries, chipboard factories, as well as all kinds of furnaces. But there are some areas where it is impossible or very difficult to mold and cast concrete. Moreover, casting the concrete with vibration is a time-consuming process. Preparing the molds is another challenge. In these cases, we have reached the solution by placing expansion joint Forms, applying template, template gunning instead of preparing molds.
As a result, we have seen that gunning applications have gained a large market share thanks to the fast and relative priming technique. Gunning concretes produced to date have been traditional medium cement concretes. Thanks to the structure of aggregates we use, we have created solutions that prevent chemical and physical wear with these concretes. We have achieved a certain level of performance in strength values of gunning concretes compressed under high pressure. As a result of our search for quality gunning to catch performance of Lowcement Castable and Selflow Castable concretes in some regions we produced REMLOWGUN – Low Cement Gunning (L.C.G.) concretes compressed under high pressure. In this way, we have also eliminated time losses caused by difficulties in mold making and applications in L.C.C. concretes. Moreover, we have solved the problems of explosion, scabbing and cracking that may occur during Dry Out, arising from the dense structure of Lowcement concretes.
REMFORCE UNIMIX GUNNING (GUN MIX) has the same properties as REMLOWGUN and at the same time, this concrete has the same properties with REMFORCE concretes. In other words, it can be applied both as cast and gunning concrete.
HOW TO APPLY REMFORCE UNIMIX CONCRETE AS GUNNING (GUN MIX)?
Gunning very low cement (ULC), high strength REMFORCE UNIMIX without molding and vibrating, and the problem is over.
OUR GAINS
• Less water addition
• Mortars wettable more easily. (Water cure while jetting)
• Reduced rebound loss
• Excellent adhesiveness
• Very fast solution (time saving)
• Adjustable working time for cutting, shaping, troweling, trimming and nailing on the open surface thanks to the additive level.
• Much less risks of bursting, scaling and cracking.
• Easy and fast drying (Dry Out)
APPLICATION METHOD
Necessary equipment to apply our REMFORCE UNIMIX concretes with GUNNING (GUN MIX) METHOD.
• One DRY PAL MIXER (for dry mix)
• Modified special gunning machine (it should have wide frequency range for speed) or gunning jet machine
• High flow compressed air
• High pressure controllable water tank with booster
• trimming, nailing, troweling equipment
• Potable water
• Expansion joint forms
• Degree
• BIG BAG or transport discharge bunker plastic bucket etc.
STRUCTURE
We have been using clay additives to give adhesiveness and plasticity to the gunning produced until today and we have used a medium amount of cement additive. In other words, they were not much different from conventional cement concrete. Although we achieved good results in strength under high pressure, we could only achieve results by using suitable aggregates in chemical erosion. However, we were using our Lowcement or Selflow concretes to prevent raw material fermentation and low refractoriness due to its high CaO and clay content. Well, now we have the solution. We have prevented this problem with 0 (zero) clay additive and very low cement additive in Remlowgun concretes. In other words, our REMFORCE UNIMIX concretes have a structure that is indistinguishable from low cement cast concretes thanks to their chemical binders and there is no clay additive. Moreover, it has a less dense structure than cast type concretes. Since there is no mold in front of it, the concretes can be shaved without setting and skewered, allowing easy water discharge. Due to easy wetting, it shows less exothermic reaction during setting.
DURING REMFORCE UNIMIX APPLICATION
Measure the temperature of air, material and water with a thermometer. Air temperature should be min. + 5 ° C / max. + 28 ° C. It is more convenient that the temperature of material and water is preferably 20-27 ° C.
Preliminary Preparation
Boil sufficient amount of stainless anchoring materials in the areas where our REMFORCE UNIMIX concretes will be applied. These can be made of V, Y, Helical or expanded metal. Determine stainless quality according to the oven temperature. Preferably, it should be 310 S quality. The top of the anchors and the jacket must be very clean. And painting the anchors would be good for expansion. Install the Expansion Joint forms in a fibrous structure beforehand. Gunning templates should be 50×50 cm or max 80×80 cm. If isolated concrete is to be applied, apply the REMLITE insulation concretes with a conventional gunning machine. After isolated concrete has completed its setting period, clean the concrete burrs on the anchors. Anchors should be clean.
Gunning
Our REMFORCE UNIMIX concretes are stored in 25 kg paper bags with film inside. Before applying, determine the dry material requirements according to density of concrete to be applied. Bring a dry mixing clean mixer and modified gunning or special gunning gunning machine to the application area. If it is to be applied with a modified gunning machine, adjust the speed of gunning machine according to density of concrete and install special nozzle tip. Gunning compressed metered water through continuous dry material and pressure water pipe to fill template. According to the type of concrete used, water need is up to max. 9% / 12%.
Each bag of REMFORCE UNIMIX is 25 to 250 kg. In each bag, there is GUNNING ADDITIVE MATERIAL in one 250 gr special paper bag (Reads GUNMIX on the bag and there is an application recipe. Beside, there is CASTING ADDITIVE MATERIAL in a 250 gr special paper bag (Reads CASTMIX and includes and application recipe on the bag.) You will only use the gunning additive material.
First open the REMFORCE UNIMIX Bag, put minimum 4 or more (depending on the homogeneous mixing power of your mixer) bags of dry material into dry mixer. Add GUNMIX additive in the bag (from the package of 250 g). Put 24,750 kg material at first, then add 250 g of GUNMIX by tearing special paper package.
For example, for 100 kg of mixture, add 4 bags of REMFORCE UNIMIX and 4 GUNMIX additives.
Mix your dry mixer for 2 or 3 minutes. Never use extra CASTMIX ADDITIVE MATERIAL in the bag (remove from the area so that it does not mix). Then, prepare appropriate amount of material depending on application area and transfer it to the BIGBAG or transport unloading bunker. This is necessary in order not to interrupt your gunning process.
Pour the prepared mixture into chamber of gunning machine and gun with addition of 7-12% of pressure water supplement.
Do not switch to another template before gunning process of one template is completed. After application area starts absorbing the water, perform trimming and rodding process. In order to prevent exothermic reaction that may occur while setting, make sure wetting it while setting through water inlet of gunning or cover it with an airtight stretch film, nylon, wet cover. Leave the material to rest for at least 24 hours (preferably 48 hours). The furnace must be activated with the heat curing program.
Issues to be considered during application
1- Use pressurized (6-7 bar) water and air at high flow (min. 4-5 m min / dry air).
2- Modified gunning machine (it should have wide frequency range for speed) or gunning jet machine
3- The water should be potable water and its proportion to dry material should be min. 7% / max. 12% by weight.
4- Apply our concretes at an air temperature between +4 and +28 °C.
5- Application templates should be min. 50×50, max. 80×80 in size and expansion joint forms should be placed around it.
6- Do not stop or pause for a long time gunning application before filling a template. Provide continuous gunning.
7- Gunning surface and anchors must be clean.
8- When the material starts absorbing the water after the gunning process, perform trimming and rodding process.
9- When material starts setting, wet the material or cover it with an airtight nylon or wet cloth to prevent exothermic reaction.
10- Activate it with a suitable drying program.
REMFORCE UNIMIX MAIN USAGE AREAS
Our REMFORCE UNIMIX concretes can be used at any area where gunning method will be applied.
• In low cement bulk concrete application and other areas where application is difficult, • In iron and steel plants, torpedo cars, coke batteries, nozzle and snorkel repairs, tundish and melting pot repairs,
• In cement factories, transfer ramp, furnace entrance belt, cooling ceiling and goose neck, tertiary pipes etc.
• In the friction zone of fluidized bed boilers,
• Chipboard mills, chip dust friction areas.
REMFORCE UNIMIX CASTING (CAST MIX): THE LAST POINT OF POWER TESTED ULC- LC – SELF FLOW CASTING CONCRETE
So far, we have produced solutions by using LOW CEMENT, SELFLOW, and REMLOWGUN against high abrasion resistance, high strength, chemical / physical interaction, erosion and raw material fermentation in industrial industrial facilities such as iron and steel, cement, power plants and chipboard factories. Our R & D studies led us to produce REMFORCE concretes in order to solve the problems of strength, high wear resistance, easy application and setting. Our REMFORCE concretes have long endurance period and thus, can be used in all industrial production facilities, especially in main industrial groups such as cement, iron-steel, petrochemistry, wood, and in all areas which require high strength and abrasion resistance, easy application, and setting time control. REMFORCE concrete provides an economic solution when its investment cost is compared to its long durability. REMFORCE UNIMIX CAST CONCRETE (CAST MIX) HAS THE SAME FEATURES AS REMFORCE.
CLASSIC PROBLEMS WITH LOW CEMENT AND SELF FLOW CONCRETE
• Need to vibrate too much or add water for good fluidity,
• Homogeneity challenges,
• Bleeding and rising of water during casting (desorption),
• Different setting problems in different parts of the mold,
• Control of setting time,
• Demoulding difficulties,
• Short shelf life.
STRUCTURE
Our REMFORCE UNIMIX concretes show better fluidity, better workability, increased mechanical properties at room temperature and fast setting properties thanks to the microsilica-bonded system anddominantcementadditivecontainedin REMLOWCASTconcretes produced until today. In other words, it is the most advanced class of conventional cement concrete. Although good results were obtained in strength under high pressure with conventional Low Cement concretes, theses could be obtained by using suitable aggregates in chemical erosion. However, providing fluency in narrow areas and most importantly controlling setting time were very difficult for the user. Now, we have reached the solution with REMFORCE UNIMIX, which shows LOW CEMENT, ULTRALOWCEMENT and SELFFLOW features. In the interior structure of REMFORCE Concretes a homogeneous crystal structure is obtained thanks to the interaction that occurs as result of integration of high strength aggregates that provide abrasion resistance with an intense chemical structure. All the structures and features described above are the features of our REMFORCE concretes. REMFORCE UNIMIX is the same concrete, but you can apply it both as gunning and casting with two separate additives included in REMFORCE UNIMIX Packages.
REMFORCE UNIMIX CAST CONCRETE (CAST MIX) CHARACTERISTIC PROPERTIES AND OUR GAINS
• Holding water without desorption
• Homogenized dissolving in mortar
• Preparation of mortar in less time
• Less water addition
• Easier spreading with less vibration
• Working time and setting time control
• Homogenized setting
• High strength with mullite phase formation
• Long shelf life
MATERIALS REQUIRED FOR APPLICATION AND APPLICATION METHOD
• A powerful mixer with high intensity and volume of 0.08-0.11 m
• REMPIPE (AVAILABLE ON REMFORCE UNIMIX PALLETS)
• Potable water facilities
• Dilatation forms
• Degree
• Water measuring cup
• 17000 – 18000 VPM immersion vibrator.
LET’S APPLY OUR REMFORCE UNIMIX CONCRETE BY THE CASTING METHOD:
Each Bag of REMFORCE UNIMIX 25 is 250 kg. Inside each bag, there is a 250 gr GUNNING ADDITIVE MATERIAL in a SPECIAL PAPER BAG (Reads GUNMIX on the bag and there is an application recipe). There is also a 250 gr CAST ADDITIVE MATERIAL in a SPECIAL PAPER BAG (Reads CASTMIX on the bag and it has an application recipe). You will only use the CASTING additive material. Never use the extra GUNMIX ADDITIVE in the bag (remove it from the area to avoid mixing).
First open the REMFORCE UNIMIX Bag, put minimum 4 or more (depending on the homogeneous mixing power of your mixer) bags of dry material into PAL mixer. Add CAST MIX additive in the bag (from the package 250 g). Put 24,750 kg material at first, then add 250 g of CAST MIX by tearing special paper package.
For example, for 100 kg of mixture, add 4 bags of REMFORCE UNIMIX and 4 CAST MIX additives.
• REMFORCE UNIMIX dry material is discharged into the PAL mixer after net weighing. Mixer is run dry for 3 minutes before adding water (to ensure a homogeneous mixture). The water to be added is preweighed; For 100 kg of material, 4.5 – 5.5 kg of water is poured into the mixer working slowly.
• Mixer is run for 3-5 minutes. You can see the fluidity gained by the concrete when you stop the mixer. Pour it into the mold without waiting and apply a small amount of vibration. While the concrete sets, cover the exposed surface with nylon or wet sheet.
MAIN USAGE AREAS
CEMENT: Furnace outlet, flame tube, furnace head, cooling, goose neck, transition ramp, calciner.
IRON AND STEEL: Tundishes, Cast Iron, Steel, Oxygen nozzles,
FOUNDRY: Melting pots, runners POWER PLANTS Coal friction zones
REFINERIES: Reactors.
WOOD INDUSTRY: Chip Wear Zones
FLUIDIZED BED BOILERS: And in every part of the industry where High Strength and High wear is required.