Greencast94 Mixing and Dryout Instructions

The following is given in good faith for Guidance only.

**Before attempting to mix refractory, be sure to wear proper personal protective equipment such as eye protection, appropriate dust mask, and disposable gloves. Mix outdoors or in a well ventilated area. When mixing add water to the refractory, and stir slowly as not to generate dust plume. 

Below is the manufacturers instructions for mixing and dryout

Material should be stored in a dry place. For best results, material should be maintained at
50°f - 69°f prior to casting.

Porous back-up materials or wood forms should be waterproofed. Absorption of water can result in reduced flow or affect setting of the product. Forms must be stout and water tight.

This product is designed to be mixed with water and poured or handcast into place. It can also be placed by vibration at a lower water addition. All equipment used to mix this product must be

 Add only clean water suitable for drinking, for best results, water
should be maintained at 50 - 69°f

Water Addition and Mixing Requirements

Water addition: 1.5 OUNCES of water per 1 lb of Greencast94

Mix well for at least five minutes (very important step). For best results, wet mix temperature should be maintained at 59 - 77°f.

Minor adjustments to the amount of water are permissible to achieve desired flow.

To maximize strength and density the castable should be placed using the minimum water addition consistent with satisfactory placement and removal of air pockets.

Over vibration or over vigorous placement of very fluid mixes should be avoided to minimize segregation of the castable.

Excess water lowers strength and increases time to set.

Place material within 20 minutes after adding water. Do not trowel to slick finish. At
temperatures above 59°f, air cure, keeping surfaces damp and / or covered, for 24 hours typically, or until a hard set has developed.

Lower temperatures will increase the time before a hard set develops.

The best results are achieved at curing temperatures of 86°f - 113°f.

Keep material from freezing during air cure and preferably until a dryout can be initiated.

Freezing of this product prior to water removal can cause structural damage.


Dryout Schedule


Heating and cooling refractory structures can be a complex procedure every effort must be made to adhere to the dryout schedule listed below.  Please note Pro tips have been added to help simplify the dryout of the refractory coating. The following is given in good faith as guidance only. 

Working with high temps is dangerous. Be sure to follow common sense safety procedures before beginning work. Always wear the proper personal protective equipment appropriate for the task. Keep a functioning fire extinguisher near by at all times. 

Step 1 

**Pro Tip** After application of refractory has been applied. Cover the forge with plastic sheeting or a card board box and let it air cure to a hard coat for 24hrs or until cured. Once this has been completed, remove the plastic sheeting or cardboard box used during air cure, once removed the following dry out instructions for Step 1 and Step 2 can be completed by placing an incandescent light bulb within the forge on one end for a period of 24hrs. Do not place any part of the lamp or light fixture with in tbe forge other than the bulb. Be sure forge burner is NOT installed on forge, as well as no plastic lamp parts, electrical cords, or other flammable materials are within the forge. 

Ambient to 248°f  (raise temp by 62°f per hour)

Hold at 248°f for 60 mins per inch of thickness (1/8"thickness=15 minutes, 1/4" thickness=30 min and so on)

Step 2

248°f to 500°f  (raise temp by 62° per hour)
Hold at 500f for 60 mins per 1" of thickness (1/8"thickness=15 minutes, 1/4" thickness=30 min and so on)

Step 3
500°f to 1022°f (raise temp by 62°per hour
Hold at 1022ºf for 60 mins per 1" of thickness (1/8"thickness=15 minutes, 1/4" thickness=30 min and so on)

**Pro Tip** If you used an incandescent light bulb to complete Steps 1 and 2, then at this point you will need to install the forge burner and secure it and double check all connections for leaks as it will be used for forging. It will be required to complete the remaining steps and will not need to be removed**

Step 4 

**Pro Tip**Light your forge burner on its lowest setting that it will operate steadily, correctly, and without blowing out to complete the following step**

                                                                          Heat your forge slowly until your forge chamber reaches 1022ºf once this temp had been reached continue to increase the temp to 1472ºf (raise temp by 62º per hour)
Hold at 1472ºf for 60 mins per 1" of thickness (1/8"thickness=15 minutes, 1/4" thickness=30 min and so on)

Step 5

Shut down heat source and let forge cool down to ambient temps 100%. Now your forge is ready to use. Always remember to bring forge temps up slowly to avoid thermal shock damage to the refractory. 

Never enclose a castable in a air tight enclosure a dangerous steam explosion may