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The cast, or pour, method is one in which the area is made completely watertight by use of forms (i.e. ladle walls and floor). The mix would contain more water than a trowel application mix. A cast refractory should be thoroughly worked into place, with internal air bubbles removed by rodding or vibrating. The best method is to use vibratory equipment, since it encourages the material to flow freely and completely fills the form or box. Vibrating also permits working with a stiffer mix (less water). However, hand rodding--with a shovel, rod, ice scraper or pole--will suffice if done thoroughly. Working out all the air strengthens the material and reduces porosity. The action of vibration or rodding sets the refractory particles in motion, reducing the friction between the particles and giving the mixture the texture of a thick fluid. Internal vibrating or rodding does the most consistent job, but external vibration is also effective. Although vibration equipment lasersightforchopsaw is available for refractories, it can often be improvised with equipment already on hand to vibrate the mass externally. An air hammer held against the form can do a good job in many cases. So may a nut runner or other pneumatic vibratory tool. Even hammering the form with a hand sledge will do if accompanied by hand rodding. In all cases, be sure the material is worked near the forms. That is where air bubbles collect.

[ILLUSTRATION OMITTED]Size matters. It''s easy to see why an SDS-max rotary hammer (the red Milwaukee) is the best tool for big holes and frequent use. The ample size reduces vibration, and stout motors can turn 2-inch spiral bits. The blue cordless Makita SDS-plus rotary hammer (bottom) is handy, but its smaller chuck and motor are meant only for bits up to 3/4 inch. The 1/2-inch DeWalt hammer drill (right) is versatile, but drilling in hard concrete is slow and the conventional chuck isn''t made for heavy pounding.

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