Jamb spray mixes including fused silica and methods of utilizing the mixes

Abstract

A dry composition formulated to be combined with water to form a jamb spray mix, the dry composition comprising, by weight: 0.1% to 10% phosphate by weight based on total weight of the dry composition; 5% to 15% plasticizer by weight based on total weight of the dry composition; and the balance including fused silica particles and impurities.

We claim: 
     
         1 . A dry composition formulated to be combined with water to form a jamb spray mix, the dry composition comprising, by weight:
 0.1% to 10% phosphate by weight based on total weight of the dry composition;   5% to 15% plasticizer by weight based on total weight of the dry composition; and   the balance including fused silica particles and impurities.   
     
     
         2 . The dry composition of  claim 1 , wherein the fused silica particles content is 60% to 95% by weight based on total weight of the dry composition. 
     
     
         3 . The dry composition of  claim 1 , wherein the fused silica particles content is 70% to 90% by weight based on total weight of the dry composition. 
     
     
         4 . The dry composition of  claim 1 , wherein the fused silica particles content is 80% to 90% by weight based on total weight of the dry composition. 
     
     
         5 . The dry composition of  claim 1 , wherein the fused silica particles comprise at least two fused silica particle fractions with different particle size distributions. 
     
     
         6 . The dry composition of  claim 5 , wherein the fused silica particle fractions include at least two fused silica particle fractions selected from a first fused silica particle fraction sized −30 mesh to +50 mesh, a second fused silica particle fraction sized −50 mesh to +100 mesh, and a third fused silica particle fraction sized −120 mesh. 
     
     
         7 . The dry composition of  claim 1 , wherein the fused silica particles include a first fused silica particle fraction sized −30 mesh to +50 mesh, a second fused silica particle fraction sized −50 mesh to +100 mesh, and a third fused silica particle fraction sized −120 mesh. 
     
     
         8 . The dry composition of  claim 1 , wherein the composition includes, by weight based on total dry weight of the composition, at least one fused silica particle fraction selected from:
 15% to 30% of fused silica particles sized −30 mesh to +50 mesh;   25% to 45% of fused silica particles sized −50 mesh to +100 mesh; and   18% to 35% of fused silica particles sized −120 mesh.   
     
     
         9 . The dry composition of  claim 1 , wherein the composition includes, by weight based on total weight of the dry composition, at least one fused silica particle fraction selected from:
 18% to 28% of fused silica particles sized −30 mesh to +50 mesh;   28% to 40% of fused silica particles sized −50 mesh to +100 mesh; and   21% to 31% of fused silica particles sized −120 mesh.   
     
     
         10 . The dry composition of  claim 1 , wherein the composition includes, by weight based on total weight of the dry composition, at least one fused silica particle fraction selected from:
 20% to 25% of fused silica particles sized −30 mesh to +50 mesh;   32% to 38% of fused silica particles sized −50 mesh to +100 mesh; and   24% to 28% of fused silica particles sized −120 mesh.   
     
     
         11 . The dry composition of  claim 1 , wherein the phosphate comprises sodium phosphate. 
     
     
         12 . The dry composition of  claim 1 , wherein the phosphate content is 2% to 5% by weight based on the total weight of the dry composition. 
     
     
         13 . The dry composition of  claim 1 , wherein the plasticizer comprises a refractory clay selected from a ball clay and bentonite. 
     
     
         14 . The dry composition of  claim 1 , wherein the composition further comprises boric acid. 
     
     
         15 . The dry composition of  claim 1 , wherein the composition further comprises 0.1% to 10% of powdered boric acid by weight based on total weight of the dry composition.