API 936 ICP Exam Study Guide | Monolithic Refractories • Brick Systems • Fiber Linings

API INDIVIDUAL CERTIFICATION PROGRAM

EXAM STUDY GUIDE

API 936
Refractory Installation Quality Control
Inspection and Testing of Monolithic Refractory Linings and Materials

Exam Coverage Edition Date

API Standard 936 — Monolithic Refractories 5th Edition March 2024
API Standard 975 — Refractory Brick Systems 1st Edition November 2021

API Standard 976 — AES/RCF Fiber Linings 1st Edition March 2018

📋 HOW TO USE THIS GUIDE

This guide targets the API 936 ICP exam (valid for April 2025 through December 2026 sittings). Content is
based on the effectivity sheet (EKS April 2025). Study all three API standards — exam questions draw from
936, 975, and 976 equally. ASTM standards are referenced where relevant.

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API 936 ICP Exam Study Guide | Monolithic Refractories • Brick Systems • Fiber Linings

SECTION 1
API Standard 936 — Monolithic Refractory Linings

1.1 Scope & Purpose

API 936 provides installation Quality Control (QC) procedures for monolithic refractory linings. It may supplement
owner specifications and covers: materials, equipment, personnel qualification, and applied refractory quality
monitoring.

💡 KEY CONCEPT
"Monolithic" = formed by ramming, casting, gunning, or sintering into place — NOT pre-fired brick units. The
standard applies to the PROCESS side of process equipment lining systems.

⚠ EXAM TIP — VERBAL FORMS

Shall = mandatory minimum requirement. Should = recommendation (not required). May = permissible. Can
= statement of capability.

1.2 Key Definitions

These definitions are directly exam-tested — memorize all of them.
Term Definition
Refractory grain + bonding agent; becomes rigid by chemical action after
Castable
liquid addition

Cold Crushing Strength (CCS) Resistance to compressive load at room temperature after drying/firing

Cold Wall Insulating lining where metal shell temperature < 500°F (260°C)

Hot Wall Thin lining where metal shell temperature > 500°F (260°C)

Conventional Refractories Castables containing > 2.5% CaO (calcium oxide)

Bond formation in newly installed monolithic refractory (chemical process,

Curing
not heat)

Initial controlled heating to safely remove retained water and form

Dryout
shrinkage crack network

Execution Plan Written contractor document approved by owner BEFORE work starts

Green Refractory Newly installed refractory before dryout or initial heating

Gunning Application of monolithic refractories by air placement guns

Hammer Test Subjective test using audible resonance to gauge soundness of lining

Metallic anchoring system forming hexagonal enclosures; typically 3/4 in.

Hexmetal
or 1 in. thick

Monolithic Lining Lining formed by ramming, casting, gunning, or sintering into place

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Term Definition
PLC (Permanent Linear
% dimensional change after initial heating to a specific temperature
Change)

Workability Index Measure of plastic refractory moldability per ASTM C181

Biscuit Refractory piece formed within an area enclosed by the anchoring system

Aggregate/cement bouncing away from surface during gunning — shall

Rebound
NOT be reused

Shelf Life Maximum time a material may be stored and remain usable

Low-melting fibers (e.g., polypropylene) that burn out during dryout,

Organic Fibers
increasing permeability

Metal Fiber Reinforcement Austenitic SS fibers (3/4–1 in. long) improving toughness; up to 1 vol%

1.3 Quality Control Key Elements (Table 1)

QC Element Action Objective
Owner spec + contractor
Documentation Define job-specific work scope
execution plan

Testing at Confirm materials meet physical property

Material Qualification
independent/manufacturer lab standards

Contractor demonstration
Applicator Qualification Confirm equipment & personnel capability
(simulated installation)

Inspector monitors contractor Confirm specs and procedures are

Installation Monitoring
work followed

Inspector coordinates
As-Installed Testing Confirm installed materials meet standards
sampling/testing

Pre-Dryout Inspection Visual/hammer test Confirm lining meets specification

Monitor heating rates and hold

Dryout Monitoring Confirm agreed procedure is followed
times

Post-Dryout Inspection Visual/hammer test Confirm lining meets specification

1.4 Responsibilities

Owner (Section 5.1)

• Prepare detailed specification: lining products/thickness/method, anchor details, fiber reinforcement, curing and
dryout procedures
• Provide quality requirements: physical property criteria, sampling frequency, lining thickness tolerances, hammer
test criteria
• Approve engineering drawings, execution plan, and dryout procedure BEFORE installation begins
• Resolve exceptions, substitutions, conflicts, and work deficiencies

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Contractor (Section 5.2)

• Prepare and submit execution plan for owner approval before work starts
• Plan must include: responsible parties, inspection hold points, surface prep/welding procedures,
material/applicator qualification procedures, curing/dryout procedures
• Schedule and execute qualification tests; notify owner of time/location
• Maintain inspector-verified installation records: products applied, pallet codes, crew members, equipment,
fiber/water %, mixing details, sample locations, shell temps, weather conditions, dryout records
• Accountable for installed refractories meeting specified standards

Inspector (Section 5.3)

• Ensure material and applicator qualification results are fully documented
• Monitor qualification, production work, and dryout for compliance
• Notify owner and contractor of deficiencies WITHIN ONE WORKING DAY
• MAKE NO ENGINEERING DECISIONS unless approved by owner
• Inspect and hammer test linings before and after dryout
• Record all nonconformances

Manufacturer (Section 5.4)

• Provide compliance datasheet (per Annex B) for each product
• Provide material meeting the compliance datasheet
• For plastics: provide minimum acceptable workability index per ASTM C181

⚠ EXAM TRAP — INSPECTOR LIMITS

Inspector has NO engineering authority. Any engineering decision must be elevated to the owner. Inspector
deficiency notifications must be made within ONE working day.

1.5 Inspector Qualifications (Section 6 & Annex C)

Inspector must have NO commercial affiliations with the contractor or manufacturer. Must possess and have
working knowledge of: this standard, owner specs, execution plan, and the inspection/test plan.
General
Inspection-Specific
Education Level Refractory Total Minimum
Experience
Experience
BS in Engineering/Technology 0 years 1 year 1 year

2-year degree/certificate 1 year 1 year 2 years

High school diploma 2 years 3 years 5 years

No diploma 3 years 3 years 6 years

1.6 Materials (Section 7)

Storage Requirements

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• Store in weather-protected area, elevated ventilated platform

• Temperature: 40°F to 100°F (5°C to 38°C)
• Shelf life set by material test time limits (8.2.3); manufacturer's more stringent requirements govern

Discard Criteria
• Exceeded shelf life
• Broken seals or damp/wet packages
• Plastics with workability index below manufacturer minimum
• Hard lumps that cannot be broken by hand

Packaging
• Hydraulic bonded castables: sealed, moisture-proof bags
• Chemical-setting refractories: heat-sealed plastic (vapor-tight) + outer mechanical protection

Marking Requirements
• Product name, batch number, hazard ID, date of manufacture
• Actual weight must not deviate from marked weight by more than ±2%
• Each pallet: unique pallet number and code date

Anchors (Section 7.4)

• Must be stamped/laser etched or in sealed traceable packaging to identify alloy
• Unmarked anchors: 100% PMI (Positive Material Identification) before installation

1.7 Testing and Test Procedures (Section 8)

8.1 Tests Performed

Test Standard Key Notes
Cold Crushing Strength Fire to 1500°F (815°C); spherical bearing block;
ASTM C133 (modified)
(CCS) cardboard shims

Fire to 1500°F; SiC used only once; report volume

Abrasion Resistance ASTM C704 (modified)
loss in cc

Fired specimens; measure dimensions to 0.02 in.,

Density Section 8.1.4
weight to 0.002 lb

PLC (Permanent Linear Measure at 4 edges; report as avg % shrinkage to

ASTM C113 (modified)
Change) ±0.05%

Workability Index ASTM C181 5 specimens per sample; plastics ONLY

Testing Machine Sensitivity (Table 2)

Castable Density Min Sensitivity Max Loading Rate
> 100 lb/ft³ (1600 kg/m³) 500 lbf (2222 N) 2500 psi/min

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Castable Density Min Sensitivity Max Loading Rate

60–100 lb/ft³ 100 lbf (444 N) 300 psi/min

< 60 lb/ft³ (960 kg/m³) 25 lbf (111 N) 250 psi/min

8.2 Preshipment (Material) Qualification Testing

• Tests required: density, PLC, CCS or abrasion resistance, workability index (plastics)
• Sampling Frequency:
◦ Erosion service: 1 sample per pallet per production run
◦ Other service: 1 sample per 3 pallets per production run
• Application period: refractory must be applied within 4 months of initial qualification tests
• Requalification permits usage for additional 3 months
• Retesting: ONE retest permitted using new sample from same pallet/batch; if retest fails → reject material

8.3 Applicator (Installer) Qualification

Pneumatic Gunning (8.3.1)
• Test panel: min 24 in. × 24 in. (600 × 600 mm), actual installation thickness
• Panel inclined at 45° above horizontal, midpoint ~6 ft (1.8 m) above grade
• Inspect at least 24 hours after completion; section/break panel to inspect for voids, laminations, rebound
• Test specimens cut from CENTER of panel

Casting (8.3.2)
• Mock-up simulates most difficult piece of installation
• Cure minimum 12 hours before stripping forms
• Lining must be homogeneous and free of voids/segregations

Thin-layer Abrasion-resistant (8.3.3)

• Test panel: 12 in. × 12 in. × 3/4 or 1 in. (300 × 300 × 19/25 mm)
• Tests: density, PLC, abrasion resistance

Thick-layer Plastic (>2 in.) (8.3.4)

• Test panel: 24 in. × 12 in. (600 × 300 mm); pneumatic ramming
• Remove forms immediately after installation; inspect from backside
• Workability index check required; physical property testing NOT required

8.4 Production (As-Installed) Testing

Method Minimum Sampling Frequency
Gunning 1 sample per crew per material per shift; at least 1 per lined item

Casting 1 sample per mixing crew per material per shift; at least 1 per lined item
Plastics/Thin erosion-resistant 1 sample per applicator per material per shift; at least 1 per lined item

• Gunning samples: wire mesh basket ~12 in. × 12 in., ≥ 4 in. deep (no deeper than lining thickness)
• Production samples remain in same environment as installation for first 24 hours
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8.4.4 Acceptance/Rejection Criteria (Table 3)

Physical Property Acceptable Minimum Acceptable Maximum
Abrasion Loss None 110% of datasheet value

Cold Crushing Strength 90% of datasheet value None

–5 lb/ft³ (–80 kg/m³) from +5 lb/ft³ (+80 kg/m³) from

Density
datasheet datasheet

Zero (0.00% — no expansion

PLC 110% of datasheet value
allowed)

• Failure → rejection of area represented by sample

• Disputes → core samples from questionable area; if retest fails → replace that area

⚠ EXAM TRAP — ACCEPTANCE CRITERIA

PLC minimum is ZERO — refractories that EXPAND (positive PLC) shall NOT be used. CCS must be ≥90%
of datasheet. Abrasion loss must be ≤110% of datasheet.

8.5 Test Specimen Requirements (Table 4)

No. of
Service Test Size
Specimens
Erosion Abrasion resistance 2 4½ × 4½ × 1 in.

Erosion PLC 1 2 × 2 × 9 in.

Other (non-erosion) CCS 3 2 × 2 × 2 in. cubes

Other (non-erosion) PLC 1 2 × 2 × 9 in.

Drying and Firing Protocol:

• Oven dry: 12 hrs min at 220°F–230°F (104°C–110°C) in forced air convection dryer
• Oven fire: heat at max 300°F/h (170°C/h) to 1500°F (815°C), hold 5 hours, cool at max 500°F/h (280°C/h)

1.8 Installation / Execution (Section 9)

Surface Preparation (9.1)

• Must meet SSPC SP-7/NACE No. 4 (Brush-Off Blast Cleaning) before lining
• SSPC SP-3 (Power Tool Cleaning) only acceptable for limited spot repair areas
• After blast, vacuum clean; do NOT wash with water unless it contains a suitable inhibitor

Water Quality (9.2)

• Water must be potable

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• Chloride content: max 200 ppm general; max 50 ppm when applied on stainless steel surfaces
• The 50 ppm limit does NOT apply when SS is limited to anchoring system or fibers only

Application Temperature (9.5)

• Air and shell temperature: 50°F to 90°F (10°C to 32°C) during installation and for 24 hours after
• Mix water temperature (absent manufacturer limits): 60°F to 80°F (16°C to 27°C)

Gunning Rules (9.6)

• Begin at LOWEST elevation, build gradually over area ≤ 10 ft² (1 m²)
• DOWNHAND GUNNING BEYOND 30° BELOW HORIZONTAL IS PROHIBITED
• Stoppages > 20 minutes or initial set → retain only full-thickness lining
• Cutback typically 15–20 minutes after placement; must be before initial set
• Rebound material SHALL NOT be reused

Curing (9.13)
• Min 24 hours at 50°F to 90°F (10°C to 32°C) before moving, stripping forms, or heating
Hydraulic bonded castables:
◦Apply membrane curing compound before surface dries; or wet mist every ~2 hours; or cover with
polyethylene/damp cloth within 1 hour
◦ No part of lining may air dry more than 1 hour before curing compound is applied
◦ Curing compound must burn off at 150°F–200°F (65°C–95°C)
Chemical-setting:
◦ Leave uncovered, free from moisture
Plastic refractories:
◦ Keep dry and protected from freezing
◦ SHALL NOT have field water addition — reconditioning only at manufacturer under controlled conditions

Repairs (9.14)
• Sections below minimum thickness → CUT OUT ENTIRELY and REPLACED — no overlay allowed
• Removed area must expose at least 1 anchor; recommended to expose 3 noncontinuous anchors
• Surface bubble defects → repair with phosphate-bonded castable (no metal fibers)
• Hexmetal lining defects → complete removal and replacement of ALL affected biscuits
• Contractor must prepare a map of all repaired/rejected areas

⚠ EXAM TRAP — REPAIRS

Overlay to build up thickness is NEVER allowed. Sections below minimum thickness must be fully removed
and replaced. Hexmetal biscuit defects = replace the entire affected biscuit(s), not just patching.

1.9 Dryout (Section 10)

The contractor develops the dryout procedure and submits it to the owner for approval. Thermocouples must be
within ½ in. (13 mm) of the refractory surface. Maximum cooldown rate is 100°F/h (56°C/h).
Complex vessels (>1 burner, >2 flue gas exits, or ≥8 thermocouples) → must be reviewed by an experienced
engineer.

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Dryout Schedule — Conventional Castables (Table 5)

Applies to castables with > 2.5% CaO and density ≤ 140 lb/ft³. Initial temperature shall not exceed 200°F (94°C).

Density Rate to Dryout

1st Hold 2nd Hold Rate to 3rd 3rd Hold
Range 2nd Index
100°F/h to
250–300°F;
< 75 lb/ft³ 100°F/h — operating — 23 hrs
1 hr/in.
temp

75°F/h to
250–300°F; 600–700°F;
75–100 lb/ft³ 75°F/h operating — 31 hrs
1 hr/in. 1 hr/in.
temp

1000–1050°F; 1
101–140 250–300°F; 600–700°F;
50°F/h 50°F/h hr/in. then 75°F/h 40 hrs
lb/ft³ 1 hr/in. 1 hr/in.
to operating temp

Dryout Index based on 5 in. thick lining, operating temp 1300°F, heating from refractory side only.

1.10 Compliance Datasheet (Annex B)

Must Include:
• Bulk density (green + fired)
• CCS (minimum value after firing to 1500°F)
• PLC (upper/lower limits, green-to-dried and dried-to-fired)
• Abrasion resistance (maximum cc loss) — for abrasive service materials
• Workability index (minimum) — for plastics
• Chemical analysis
• Water content range (±10% of optimum is suggested)
• Installation method for which data is valid
• Manufacturer-defined shelf life

Available on Request:
• Modulus of rupture
• Apparent porosity
• Thermal conductivity

1.11 Critical Numbers — API 936 Quick Reference

Memorize every value in this table. Multiple exam questions come directly from here.

Parameter Value
Storage temperature 40°F – 100°F (5°C – 38°C)

Application temperature (air/shell) 50°F – 90°F (10°C – 32°C)

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Parameter Value
Mix water temperature (default) 60°F – 80°F (16°C – 27°C)

Water chloride limit — general 200 ppm max

Water chloride limit — SS surfaces 50 ppm max

Packaging weight tolerance ± 2%

Cold Wall shell temp < 500°F (260°C)

Hot Wall shell temp > 500°F (260°C)

Conventional refractory CaO content > 2.5% CaO

Max gunning downhand angle 30° below horizontal

Max gunning area per buildup 10 ft² (1 m²)

Initial set / stoppage limit 20 minutes or dry to touch

Curing duration minimum 24 hours

Max air dry before curing compound 1 hour

Curing compound burn-off temp 150°F – 200°F (65°C – 95°C)

220°F – 230°F (104°C – 110°C) for 12 hrs

Oven dry: temperature / duration
min

Oven fire temperature 1500°F (815°C), hold 5 hrs

Max heating rate to fire 300°F/h (170°C/h)

Max cooling rate from fire 500°F/h (280°C/h)

Max dryout cooldown rate 100°F/h (56°C/h)

Initial dryout temp limit 200°F (94°C) max

Application period before requalification 4 months

Requalification extension 3 months

CCS acceptance (as-installed) ≥ 90% of datasheet value

Abrasion loss acceptance (as-installed) ≤ 110% of datasheet value

PLC acceptance minimum Zero — expansion NOT permitted

Thermocouple distance from surface (dryout) Within ½ in. (13 mm)

Ceramic fiber density in nozzle packing ≥ 8 lb/ft³ (128 kg/m³)

Gunning test panel inclination 45° above horizontal

Gunning test panel midpoint above grade ~6 ft (1.8 m)

Wire basket for gunning samples (mesh size) ½ in. square mesh

Wire basket for gunning samples (dimensions) ~12 × 12 in., ≥ 4 in. deep

Metal fiber reinforcement — max vol% 1 vol%

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1.12 Common Exam Topics & Traps — API 936

# Topic Correct Answer
1 "Shall" vs "Should" "Shall" = mandatory; "Should" = recommendation

2 Refractory application window 4 months after initial qualification; +3 months after requalification

3 Downhand gunning limit 30° below horizontal is PROHIBITED

4 Failed as-installed sample Reject area; one retest from same pallet allowed

5 Hexmetal defects ALL affected biscuits must be replaced — no patching

6 Inspector engineering authority NONE — all decisions go to owner

Plastic workability index below

7 Must be requalified or discarded — no field water addition
minimum

8 Thickness overlay NEVER allowed — cut out and replace

9 Gunning panel inclination 45°; midpoint ~6 ft above grade

10 PLC expansion Products with positive PLC (expanding) shall NOT be used

11 Plastic refractory water addition No field addition — reconditioning only at manufacturer

12 Curing compound burn-off 150°F–200°F (65°C–95°C)

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SECTION 2
API Standard 975 — Refractory Brick Systems

2.1 Scope
API 975 provides QC procedures for aluminum silicate dense fire brick and insulating fire brick (IFB) refractory
systems. It may supplement owner specifications and defines: qualification methods for materials, equipment, and
personnel; acceptance criteria for installed refractory quality; and inspection responsibilities.

2.2 Key Definitions

Term Definition
Requires only air to gain green strength; bonds brick strongly before
Air Set Mortar
furnace heating

Bulk Density Ratio of weight (or mass) to volume in a specific condition

CCS (Cold Crushing Strength) Ability to resist compressive failure at room temperature after drying/firing

Compliance Data Sheet Manufacturer-warranted list of mechanical and chemical properties

Fins Fin-shaped manufacturing defects along the outer surface of a brick

Dense High-Alumina Firebrick Contains 45%–99% alumina

Insulating Firebrick (IFB) Characterized by low thermal conductivity and low heat capacity

Fireclay Brick Manufactured substantially or entirely from fireclay

Heat Setting Mortar Requires heat to gain significant strength; joints are usually thin

ITP (Inspection and Test Written checklist plan; each step requires acceptance by all responsible
Plan) parties

Key The uppermost or closing brick of a curved arch or ring

Lipping Overlapping of brick rows due to insufficient plumbing/tapping of brick

MTC (Material Production Test results verifying actual manufactured material meets specified
Test Certificate) properties

PMI (Positive Material

Non-destructive test detecting chemical composition of a metallic alloy
Identification)

QA (Quality Assurance) Monitor, audit, and spot-check installation quality; typically by third-party

Monitor installation quality for conformance with standards; typically by

QC (Quality Control)
contractor

Permanent dimensional change of a refractory as a result of heating to a

Reheat Change
specific temperature

Fireclay Brick Classifications (ASTM C27):

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• Medium-duty: PCE ≥ Cone 29, ≤ 31½

• High-duty: PCE ≥ Cone 31½, ≤ 32½ to 33
• Super-duty: PCE ≥ Cone 33 (meets additional requirements)

2.3 Responsibilities

Owner
• Provide detailed specification covering: lining products, brick thickness, installation method, anchor/support type,
layout
• Approve engineering drawings and project execution plan PRIOR TO any installation
• Approve the ITP
• Assign responsibility for ITP development (may develop it or delegate)
• Resolve exceptions, substitutions, deviations, conflicts, and deficiencies

Installer
• Prepare detailed execution and quality plan; submit and get agreement BEFORE work starts
• Develop and issue ITP to owner for approval prior to any work
• Provide inspector-verified documentation of all installation records
• Ensure compliance data sheet is available prior to work

Inspector
• No commercial affiliations with installer or manufacturer
• Notify owner of deficiencies WITHIN ONE WORKING DAY — notifications to owner in writing
• Monitor compliance with the approved ITP
• SHALL NOT make engineering decisions unless approved by owner
• Check MTC availability

Manufacturer
• Provide compliance data sheet per Annex A for each product
• Provide MTC (Material Production Test Certificates)
• Provide product data sheet and installation guidance

2.4 Materials (Section 5)

Dimensional Tolerances (5.2.2)

Dimension Tolerance
Length and width — High-alumina grades ±1.0%, max ±3 mm

Length and width — Fireclay grades ±2%

Thickness ±1.0 mm

Taper (length < 155 mm) ±1 mm

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Dimension Tolerance
Taper (length > 155 mm) ±1.5 mm

Warpage (diagonal) ±1.5 mm

Max lipping tolerance ±1.5% or 1.5 mm of brick thickness

Defect Criteria — Dense Firebrick ([Link])

Defect Type Acceptance Limit
Laminations Shall be FREE of internal laminations

Fins Shall NOT exceed 3.0 mm height at corners/edges

Cracks Shall NOT exceed 19 mm length, 2 mm depth, 0.25 mm width

No more than 2 defects; max 19 mm total dimension each.

Edge/Corner Damage
REJECT if > 3 defects.

Defect Criteria — Insulating Firebrick / IFB ([Link])

Defect Type Acceptance Limit
Laminations and Voids Free of laminations; voids NOT larger than 10 mm diameter
Cracks Shall NOT exceed 35 mm length, 4 mm depth, 1.5 mm width

Edge/Corner Damage No more than 3 defects; max 40 mm total dimension each

Anchors (Section 5.9)

Anchor Material Max Temp (°C) Max Temp (°F)
Carbon Steel 455 850

TP 304 Stainless Steel 760 1400

TP 316 Stainless Steel 760 1400

TP 309 Stainless Steel 815 1500

TP 310 Stainless Steel 927 1700

TP 330 Stainless Steel 1038 1900

Alloy 601 (UNS N06601) 1093 2000

Ceramic Components >1093 >2000

• Marked/traceable components: PMI at 5% or per owner requirements

• Unmarked/non-traceable anchors: 100% PMI required
• Surface cleaned to SSPC SP 6/NACE No. 3; spot cleaning per SSPC SP 3

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2.5 Pre-Shipment Testing

Minimum AQL of 4% applies to physical attributes testing. Testing conducted for each lot.
Lot Size (Bricks) Sample Size (Bricks) Reject/Re-test if Defective ≥
< 50 8 2

51–90 13 3

91–150 20 4

151–280 32 6

281–500 50 8

501–1200 80 11

1201–10,000 125 15

> 10,000 200 22

💡 DEFINITION TO MEMORIZE
"Lot" = group of hard bricks identified and produced under the same manufacturing process; pressed, fired,
and finished at the same time.

2.6 Installation — Key Rules (Section 7)

Installer Qualification
• Installer must provide list of all installers with previous project references BEFORE work starts
• Workers must have work history for all types of brick construction
• A mock-up may be required by owner

Anchor and Support Requirements

• Horizontal shelf supports: width ≥ 1/3 of hot-face lining thickness
• Support shelf vertical spacing: typically 1.8 m (6 ft), NOT to exceed 3 m (10 ft)
• Flat walls: > 15% of bricks shall be tied back
• Tie-backs: extend into at least 1/3 of hot-face brick layer thickness

Workmanship — Critical Rules

Rule
Requirement
#
1 Handle firebrick without causing physical damage

2 Damaged bricks: NOT used without owner approval

3 Wet/water-damaged IFB: NOT used without owner approval

4 Bricks must be laid PLUMB and TAPPED TIGHT; max lipping: ±1.5% or 1.5 mm

5 METALLIC HAMMERS shall NOT be used to tamp any brick

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Rule
Requirement
#
6 Firebricks shall be SAW CUT — no hammer cutting or chipping

7 Remove excessive mortar from face so joints can be visually inspected

8 Cut firebrick: not less than 50% of nominal dimensions in any direction

9 Key/ring closure brick: adjacent brick may be cut, but not less than 2/3 of any nominal dimension

10 Cut brick: NOT in 12 o'clock position; ring closure bricks staggered from adjacent rings

11 Cracked or damaged bricks during installation: SHALL be replaced

12 Firebrick ties/supports: installed through DRILLED HOLES — not driven with a hammer

Gravity Wall Construction Limits

• Max gravity wall height: 7.3 m (24 ft)
• Minimum brick: high-duty fireclay brick
• Base width ≥ 8% of total wall height
• Height-to-width ratio: max 5:1

Mortar Rules
Rule Requirement
Opened/mixed mortar Used within usable life; no partial bag mixing

Extra water NOT allowed to extend mortar life

Mixing mortars Different manufacturers shall NOT be mixed

Mixing method Mechanical mixer with clean, dry paddle; potable water

Hard lumps in dry mortar DISCARD if lumps cannot be broken by hand

Water chloride limit (general) < 200 ppm

Water chloride limit (SS surface) ≤ 50 ppm

Mixing temperature range (default) 5°C (40°F) to 38°C (100°F)

2.7 Critical Numbers — API 975 Quick Reference

Parameter Value
Carbon steel anchor max temp 455°C / 850°F

Alloy 601 anchor max temp 1093°C / 2000°F

Dense firebrick max crack length 19 mm (¾ in.)

Dense firebrick max crack depth 2 mm

Dense firebrick max crack width 0.25 mm

Dense firebrick max fin height 3.0 mm

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Parameter Value
Dense firebrick max corner defects 2 (reject if > 3)

IFB max crack length 35 mm

IFB max void diameter 10 mm

IFB max corner defects 3

High-alumina dimensional tolerance (L&W) ±1.0%, max ±3 mm

Fireclay dimensional tolerance (L&W) ±2%

Thickness tolerance ±1.0 mm

Warpage tolerance (diagonal) ±1.5 mm

Max lipping tolerance ±1.5% or 1.5 mm

Min cut brick size 50% of nominal dimensions

Key/closure adjacent brick min 2/3 of any nominal dimension

Max gravity wall height 7.3 m (24 ft)

Gravity wall base width min 8% of total wall height

Gravity wall height-to-width max 5:1

Shelf support vertical spacing (typical) 1.8 m (6 ft), max 3 m (10 ft)

Min tie-back on flat walls > 15% of bricks

Tie-back penetration depth ≥ 1/3 of hot-face brick layer

Shelf support width min ≥ 1/3 of hot-face lining thickness

Mortar water chloride (general) < 200 ppm

Mortar water chloride (SS surfaces) ≤ 50 ppm

Mortar mixing temperature (default) 5°C (40°F) to 38°C (100°F)

Target wall mortar min rating 1540°C (2800°F)

Target wall expansion joint fiber min rating 1430°C (2600°F)

Pre-shipment testing minimum AQL 4%

PMI — marked/traceable components 5% (or per owner, whichever greater)

PMI — unmarked/non-traceable 100%

API 936 / 975 / 976 — Effective April 2025

API 936 ICP Exam Study Guide | Monolithic Refractories • Brick Systems • Fiber Linings

SECTION 3
API Standard 976 — AES/RCF Fiber Linings

3.1 Scope
API 976 covers installation QC procedures and lining system design requirements for AES/RCF fiber linings. It
applies to INTERNAL refractory linings on the process side of equipment. It does NOT cover external insulation or
jacketing.

3.2 Key Definitions

Term Definition
AES (Alkaline Earth Silicate) MMVF with ≥18% alkali earth oxides; bio-soluble/low bio-persistence;
Fiber exempt from EU carcinogen classification

RCF (Refractory Ceramic

MMVF predominantly alumina and silica
Fiber)

PCW (Polycrystalline Wool) >70 wt% Al₂O₃; used above 1426°C (2600°F)

Manmade vitreous fiber — includes fiberglass, mineral wool, AES, and

MMVF
RCF

Temp at which MMVF has ≤4% linear shrinkage (blanket/paper) or ≤2%

Classification Temperature
(vacuum form/boards) after 24-hr treatment

Hot-face Layer Layer exposed to highest temperatures

Cold-face Surface against the metal casing

Batten Strip Single or folded fiber blanket compressed between module courses

Fibrous refractory in stacked/folded blankets or monolithic form with

Module
integrated attachment system

Rigidizer Liquid applied to AES/RCF to produce a rigid surface when dried

Metallic foil placed between layers to block flue gas and protect steel shell
Vapor Barrier
from acid corrosion

Module lining design where anchoring is PERPENDICULAR for adjacent

Parquet
modules

Module lining design where anchoring is PARALLEL for all modules in a

Soldier Course
row

Un-fiberized sphere-shaped material in MMVF — does NOT contribute to

Shot
insulation

Wet Blanket Flexible RCF blanket saturated with wet binder; sets rigid on heat exposure

Staples Anchor hooks to secure batten strip to module (MANDATORY in arches)

API 936 / 975 / 976 — Effective April 2025

API 936 ICP Exam Study Guide | Monolithic Refractories • Brick Systems • Fiber Linings

Fiber Grade Temperature Ranges

Grade Max Classification Temperature Typical Continuous Use Temp
AES 1450°C (2642°F) ~1283°C (2342°F)

RCF 1426°C (2600°F) ~1259°C (2298°F)

PCW > 1426°C (2600°F) Above RCF range

💡 KEY RULE — FIBER TEMPERATURE OFFSET

Continuous application temperature is typically 167°C (300°F) BELOW the classification temperature.

3.3 Responsibilities

Owner/EM
• Provide detailed specification: lining products, construction, coatings/vapor barriers, anchor/pin materials, PMI
requirements
• Approve engineering drawings and project execution plan BEFORE any installation
• Resolve exceptions, substitutions, deviations, and work deficiencies

Installer
• Prepare detailed execution and quality plans; designate inspection HOLD POINTS
• Prepare and submit ITPs for owner approval
• Give advance notification of all work times/locations
• Provide inspector with verified documentation: products applied, pallet codes, crew members, weather
conditions
• Store materials per manufacturer's recommendations

Inspector
• Monitor production work for compliance with specifications
• Notify owner and contractor of any deficiencies AS SOON AS POSSIBLE
• SHALL NOT make engineering decisions unless approved by owner
• Prior to installation: check materials are properly stored and damaged materials are identified

Manufacturer
• Provide Safety Data Sheets (SDS)
• Provide compliance datasheets per Annex A
• Provide materials meeting the approved compliance datasheet

3.4 Materials

Physical Property Requirements (per ASTM C892)

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API 936 ICP Exam Study Guide | Monolithic Refractories • Brick Systems • Fiber Linings

Property Required on Compliance Datasheet?

Chemical composition Required

Maximum continuous use temperature Required

Tensile strength (fiber) Required

Density Required

Thermal conductivity at mean use temperature Required

Shrinkage On request only

Anchors (same table as API 975 — see Section 2.4)

Anchor Material Max Temp (°C) Max Temp (°F)
Carbon Steel 455 850

TP 304 / 316 SS 760 1400

TP 309 SS 815 1500

TP 310 SS 927 1700

TP 330 SS 1038 1900

Alloy 601 (UNS N06601) 1093 2000

Ceramic studs and washers > 1093 > 2000

• 100% visual inspection and physical testing required for all individual anchors
• Open/unstamped packaging → 100% PMI required before installation
• Fiber with rating other than 1260°C (2300°F) — at least one visible surface must show classification temperature

3.5 Lining Design (Section 6)

Key Prohibitions — What Fiber CANNOT Do

Condition Prohibition
Design temp > 704°C (1300°F) AND Na+V
Ceramic fiber SHALL NOT be used as hot-face
in fuel > 100 ppm

Gas velocity > 12 m/s (40 ft/s) Fiber BLANKET NOT for hot-face

Wet blanket, fiberboard, or modules normally NOT for hot-

Gas velocity > 30 m/s (100 ft/s)
face
Floors with maintenance traffic/scaffolding Full-thickness fiber linings NOT for floors

Convection sections with soot blowers /

Fiber NOT used
steam lances / water wash

Any application Mineral wool block SHALL NOT be used

API 936 / 975 / 976 — Effective April 2025

API 936 ICP Exam Study Guide | Monolithic Refractories • Brick Systems • Fiber Linings

Layered Construction Requirements

Requirement Value
Hot-face layer material Needled blanket

25 mm (1 in.) for overlap or butt joint

Hot-face blanket min thickness
construction

Hot-face blanket density 128 kg/m³ (8 lb/ft³)

Blanket lengths in layered system Min 1219 mm (4 ft), max 3810 mm (12.5 ft)

Fiberboard as hot-face — min thickness 38 mm (1.5 in.)

Fiberboard as hot-face — min density 240 kg/m³ (15 lb/ft³)

Backup blanket behind fiberboard — min density 96 kg/m³ (6 lb/ft³)

Backup blanket max width 600 mm (24 in.)

Module Installation Rules (6.6)

• Support hardware must span ≥ 80% of module width
• Installed in soldier-course with batten strips (parquet ONLY acceptable on flat arches)
• Two adjacent modules must NOT be edge-on-edge — must be separated by compressed batten strip
• Batten strips must be same grade as hot-face material
• Batten strips cut at regular intervals: 1.2–2.5 m (4–8.33 ft) depending on temperature
• Anchors attached to casing BEFORE modules are installed
• Blankets SHALL NOT be stretched

Protective Coatings & Vapor Barriers (6.7)

Condition Requirement
Sulfur content > 200 mg/kg (200 Casing and carbon steel anchors below acid dew-point must be
ppm) coated; coating max continuous use temp ≥ 175°C (350°F)

Sulfur content > 500 mg/kg (500 Add 2 mil (50 micron) austenitic SS foil vapor barrier; installed in
ppm) soldier course

Vapor barrier exposed temp Must be ≥ 55°C (100°F) above calculated acid dew point

Vapor barrier edge overlap ≥ 175 mm (7 in.)

Edge/puncture sealing Sodium silicate, fiber cement, mortar, or moldable

3.6 QA/QC, Examination & Testing

Anchor Bend Test Frequency (Section 9.1)

Anchor Count (per type/installation/welder) Required Test Frequency
< 25 100%

API 936 / 975 / 976 — Effective April 2025

API 936 ICP Exam Study Guide | Monolithic Refractories • Brick Systems • Fiber Linings

Anchor Count (per type/installation/welder) Required Test Frequency

25 to 50 50%

50 to 500 25%

> 500 5%

Anchor Stud Welding (Section 9.2)

• Start of each shift: each welder performs sample test welds (prequalification)
• Prequalification: stud weld 5 anchors on plate similar to anchor location or on prepared shell
• Excess anchors from shell testing removed BEFORE refractory installation
• Bend test: bend anchor tine 15 degrees from vertical and BACK — no cracking
• All equipment settings checked and noted PRIOR TO each work shift

Fiber Lining Inspection & Testing (Section 9.3)

Quantity Samples Required
> 1000 pieces 3 samples

< 1000 pieces 1 sample

• For AES fiber: manufacturer must provide evidence of exemption from carcinogenic classification per Note Q of
EU Commission Directive 97/69/EC

Installation Workmanship Checklist (Section 9.4)

Check Item Requirement
Drawings/procedures Available and reviewed at job site BEFORE work starts

Anchor layout Plumb, level, and compliant with specification tolerances

Hot-face layer overlap In direction of gas flow

Prepared before coating; coating applied promptly to avoid flash

Shell surface prep
rusting

Anchor threads Protected from overspray

Blankets SHALL NOT be stretched

Butt joints Must have specified compression

Tightly installed before banding removed; tamped with no gaps at

Module installation
joints

Irregular openings Filled with blanket or pumpable AES/RCF fiber

3.7 Rigidized and Surface-Treated Fiber

• Rigidizer SHALL be colloidal silica/alumina based

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API 936 ICP Exam Study Guide | Monolithic Refractories • Brick Systems • Fiber Linings

• Sodium silicate or potassium silica SHALL NOT be used

• Other rigidizers subject to owner approval

3.8 Critical Numbers — API 976 Quick Reference

Parameter Value
AES fiber max classification temp 1450°C (2642°F)

RCF fiber max classification temp 1426°C (2600°F)

Continuous use temp offset below classification 167°C (300°F)

Hot-face ceramic fiber Na+V fuel limit 100 ppm at > 704°C (1300°F)

Gas velocity limit — fiber blanket hot-face 12 m/s (40 ft/s)

Gas velocity limit — wet blanket/fiberboard/modules 30 m/s (100 ft/s)

Hot-face blanket density 128 kg/m³ (8 lb/ft³)

Min fiberboard hot-face thickness 38 mm (1.5 in.)

Min fiberboard density 240 kg/m³ (15 lb/ft³)

Successive blanket joint stagger Min 50 mm (2 in.)

Module hardware span ≥ 80% of module width

Batten strip cut intervals 1.2–2.5 m (4–8.33 ft)

Backup blanket joint offset from module joint ≥ 1 in. (25 mm)

Sulfur threshold — casing coating required > 200 mg/kg

Sulfur threshold — vapor barrier required > 500 mg/kg

Vapor barrier foil thickness 2 mil (50 micron) austenitic SS

Vapor barrier edge overlap ≥ 175 mm (7 in.)

Vapor barrier temp above acid dew point ≥ 55°C (100°F)

Patch repair typical size limit < 0.465 m² (5 ft²)

Anchor bend test angle 15 degrees from vertical

Stud welder prequalification count 5 anchors

Sample count (> 1000 pieces) 3 samples

Sample count (< 1000 pieces) 1 sample

API 936 / 975 / 976 — Effective April 2025

API 936 ICP Exam Study Guide | Monolithic Refractories • Brick Systems • Fiber Linings

SECTION 4
Master Exam Quick Reference — All Standards

4.1 Verbal Form Hierarchy (All Standards)

Word Meaning Exam Significance
Mandatory minimum
Shall Failure = nonconformance
requirement

Recommendation — advised but

Should Not a violation if not followed
not required

May Permissible action Optional — at party's discretion

Statement of possibility or
Can Physical ability statement only
capability

4.2 Cross-Standard Comparison Table

Topic API 936 (Monolithics) API 975 (Brick) API 976 (Fiber)
Water chloride — general 200 ppm max < 200 ppm N/A

Water chloride — SS
50 ppm max ≤ 50 ppm N/A
surface

No engineering No engineering No engineering

Inspector authority
decisions decisions decisions

Deficiency notification Within 1 working day Within 1 working day As soon as possible

Execution plan approval Before work starts Before work starts Before installation

Unmarked anchors 100% PMI 100% PMI 100% PMI

Carbon steel anchor max

N/A (not specified) 455°C / 850°F 455°C / 850°F
temp

Alloy 601 anchor max

N/A 1093°C / 2000°F 1093°C / 2000°F
temp

4.3 Common Exam Traps — Across All Standards

Trap Standard Correct Rule
Overlay of thin refractory to meet
936 NEVER — cut out and replace
thickness

Inspector makes a repair decision

936/975/976 NEVER — escalate to owner
on the spot

API 936 / 975 / 976 — Effective April 2025

API 936 ICP Exam Study Guide | Monolithic Refractories • Brick Systems • Fiber Linings

Trap Standard Correct Rule

Rebound material reused in
936 Prohibited — shall not be reused
gunning

Metallic hammer used to tamp

975 Prohibited — use rubber/plastic mallet
brick
Hammer-cut firebrick used 975 Prohibited — saw cut only

Cut brick placed at 12 o'clock in

975 Prohibited — stagger ring closure bricks
arch

Fiber blanket used on a high-

976 Prohibited if velocity > 12 m/s
velocity hot-face

Mineral wool block used 976 Prohibited (shall NOT be used)

Na+V > 100 ppm and ceramic

976 Prohibited — must use monolithic or brick
fiber hot-face > 704°C

Sodium silicate used as rigidizer 976 Prohibited — colloidal silica/alumina only

Plastic refractory field water

936 Prohibited — reconditioning at manufacturer only
addition

Two modules edge-on-edge with

976 Prohibited — batten strip required
no batten strip

4.4 ASTM References Summary

ASTM Standard Subject API Standard Context
ASTM C113 Reheat Change of Refractory Brick (PLC) 936, 975

Cold Crushing Strength and Modulus of

ASTM C133 936, 975
Rupture

ASTM C181 Workability Index — Plastic Refractories 936

ASTM C704 Abrasion Resistance at Room Temperature 936, 975

Classification of Fireclay and High-Alumina

ASTM C27 975
Brick

Size, Dimensional Measurements, and Bulk

ASTM C134 975
Density (Brick)

ASTM C155 Classification of Insulating Firebrick 975

ASTM C210 Reheat Change of Insulating Firebrick 975

High-Temperature Fiber Blanket Thermal

ASTM C892 976
Insulation

ASTM C177 / C201 Thermal Conductivity Test Methods 976

Wavelength-Dispersive X-Ray (Chemical

ASTM E1172 976
Analysis)

API 936 / 975 / 976 — Effective April 2025