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Pallet

Batch

Testing Procedure

Sample

When a sample fails to meet the required specifications in accordance with API Std 936, any retesting must maintain strict consistency with the original conditions to ensure validity and comparability of results.

API 936 states:

“If a sample fails to meet any requirement, resampling shall be permitted. However, retesting shall be performed using specimens from the same batch, pallet, and sample as the original test. The same testing procedure must be used.”

— API Std 936, Section 6.2.3​

Explanation of Matching Terms:

Pallet: To ensure material consistency.

Batch: Revalidates results without introducing variability from a new production lot.

Testing Procedure: Methodology must not change to avoid skewed comparison.

Sample: Must be the original sample to confirm initial findings.

Therefore, all of these factors must remain the same. The only item in your provided list that is not required to match is “Inspection methods” — it is not part of the retesting condition clause.

Chemically bonded refractories, such as phosphate-bonded or acid-bonded types, develop strength through chemical reactions that requireexposure to ambient air. These materials must remainuncovered and dry during curing, as moisture or covering may inhibit the required chemical bonding or lead to improper set.

Covering chemically bonded linings (e.g., with plastic sheeting or wet burlap) — practices appropriate forhydraulic bonded(cement-based) refractories — would trap moisture and interfere with the chemical reaction process in chemical bonds.

The term "rebound" is officially defined in API Std 936 as follows:

“Rebound: That portion of a refractory that does not adhere to the surface and falls away when a material is applied by gunning.”

— API Std 936, Section 3, Definitions​

This makes "rebound" the precise and correct term describing the material that fails to adhere during gunning. The other options, such as “slurry,” refer to different material states or applications, and “trimmings” or “overspray” are not used with this specific meaning in the standard.

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API 936 establishes quality assurance testing frequencies based on usage, service condition, and criticality of application. Forerosion service refractory, which is subject to high-velocity particle impingement (e.g., in FCCU units), the standard testing frequency isone sample per 2 tons or less. This ensures that each significant quantity used in fabrication is represented by a test sample to verify compressive strength, density, and abrasion resistance.

Failure to meet this frequency may risk undetected variability in raw material batches or mixing inconsistencies.

The manufactureris responsible for specifying the exactdimensions, type, concentration, and metallurgical propertiesof metal fiber reinforcement in castable refractories. These fibers are often integral to the formulation and performance of the material and are introduced during manufacturing (not field mixing), with characteristics tailored to improve thermal shock resistance and crack propagation control.

API 936 defers to the manufacturer’s technical data for the design and quality control of any material component, including reinforcement. The contractor is responsible for verifying that materials match the manufacturer’s documented specification.