Today, I wanna talk about something that’s been keeping me busy lately – mixing refractory concrete. You know, the stuff that can handle the heat in furnaces and kilns and whatnot. I got into this because I needed to build a small forge in my backyard. It’s been a journey, let me tell you.
First off, I had to figure out what this refractory concrete actually is. Turns out, it’s a mix of special cement and some other things that can take a serious amount of heat without crumbling. Now, I’m no expert, but I like to get my hands dirty and try things out. So, I decided to mix my own batch. A lot of folks online were talking about making their own mix of clay and refractory cement as a cheaper alternative, and that sounded right up my alley.
Getting Started
I started by gathering all the stuff I needed. The main thing is the refractory cement, which I managed to find at a local supplier. Then, there’s the aggregate – that’s the stuff that gives the concrete its body. Some people use sand, some use gravel, and others use special heat-resistant materials. I went with a mix of sand and some firebrick grog I had lying around.
Mixing It Up
- The first step was getting all my ingredients measured out. I used a simple ratio I found online: one part cement to three parts aggregate. Seemed straightforward enough.
- Then, I dumped everything into a big bucket. I’ve seen people use wheelbarrows, but a bucket worked fine for the amount I was making.
- Next, it was time to add water. This is where it gets tricky. You don’t want it too soupy, but you don’t want it too dry either. I started with a little bit of water and mixed it in with a shovel.
- I kept adding water bit by bit, mixing as I went, until I got a consistency that looked like thick oatmeal. It was a real workout, let me tell you.
Forming the Bricks
Once I had the mix ready, I had to get it into shape. Since I was building a forge, I needed bricks. I made a simple wooden mold for this. Nothing fancy, just some scrap wood nailed together. I greased up the inside of the mold with some old motor oil so the concrete wouldn’t stick. Then, I shoveled the mix into the mold, making sure to pack it down tight. I used a trowel to smooth out the top and get rid of any air pockets.
Letting It Cure
After filling the mold, it was time to wait. Refractory concrete needs time to cure, just like regular concrete. I covered the mold with a damp cloth to keep it from drying out too fast. The waiting was the hardest part. I kept checking on it every few hours, making sure the cloth was still damp.
It took a couple of days for the concrete to set up properly. I could tell it was ready when it felt hard to the touch. I carefully removed the bricks from the mold, and there they were – my homemade refractory bricks. They weren’t perfect, but they were mine.
Putting It to the Test
Of course, the real test was whether they could handle the heat. I used the bricks to build my little forge, fired it up, and waited with bated breath. To my relief, the bricks held up just fine. They got hot, sure, but they didn’t crack or crumble. Success!
So, that’s my story of mixing refractory concrete. It was a bit of a learning curve, but I’m glad I did it. It’s always satisfying to make something with your own hands, especially when it works as intended. If you’re thinking about trying it yourself, I say go for it. Just be prepared to get a little messy and do some heavy lifting. It’s all part of the fun!