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If you are a manufacturer of pre-cast refractory shapes, and you might be screening out the fines of your castable for use as a patch or a cover, so your shapes look good for your customer. The fines you are using are in large portion the cement out of the castable mix, so you get good adhesion in your patches, but you also get a concentration of calcium aluminate cement, which can act as a flux at high temperatures. Westmoreland Advanced Materials manufactures ready made High Temperature Cover mixes that perform the same esthetic function, but are not subject to fluxing at high temperatures. HTC SA mixes can be blended with water to a consistency similar to latex paint for application by brush or roller. HTC AA mixes can be mix to a spackling consistency for patching corners and edges without worryies about shrinkage cracks. HTC CAM is a 70% alumina mix that is based on mullite, and utilizes a cement bond for higher green strength. AA and SA mixes are water based for easy mixing and easy clean-up, and each can be smoothed or feathered into your pre-cast shape with 100 grit sand paper after air drying.
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There is an industry standard for the feel and trowelability of refractory mortars. Westmoreland Advanced Materials dry mortars meet that standard (some have said we've exceeded the standard). WAMŪ mortars are designed to feel creamy and smooth, they don't roll up around the edge of your trowel, they stay in susension indefinitely after mixing with the amount of water you deem to be "troweling consistency", or "dipping consistency". Available in air setting or heat setting versions, they are suitable for laying ladle liners or IFBs. These dry mortars have an indefinite shelf life when stored properly.
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