Monolithic float glass forming chamber and method of construction

A method for the construction of a monolithic float glass forming chamber which comprises:

• forming a first refractory structure by mixing a castable and pumpable refractory material comprising from about 40 to about 90% by weight of Al2O3, and an insulation material selected from carlite, thermolite, perlite, verelite or mixtures of the same;
• and, forming a second refractory structure of the castable and pumpable refractory material comprising from about 40 to about 90% by weight of Al2O3, said structures are formed on the construction site, and wherein the forming of the first and second refractory structures are carried out by a sol-gel process;
• wherein the monolithic float glass forming chamber includes a bottom refractory wall characterized by:
• forming on a bottom metal casing, a first bottom wall by mixing the castable and pumpable refractory material and an insulation material;
• placing two vertical parallel plates, which are separated one from the other on two lateral sides of the first bottom wall;
• filling the two vertical parallel plates with the mixture of the castable and pumpable refractory material and the insulation material to form first side walls;
• separating the two vertical parallel plates once the mixture of the castable and pumpable refractory material and the insulation material have been cast and the first side walls have been formed;
• forming a second bottom wall with a castable and pumpable refractory material on said first bottom wall;
• placing parallel plates separated from the first side walls forming a space between said first side walls and the plates;
• filling the space with the castable and pumpable refractory material to form second side walls;
• and
• separating the parallel plates once the castable refractory material has been cast and the second side walls have been formed.