Castable Refractory

Castable Refractory is a sort of amorphous high temperature unshaped refractory material, dry refractory mix. It is also called refractory castable, which is a kind of mixture of granular and powdery material made of a certain amount of binder with refractory materials, and has a high fluidity. Castables are amorphous refractory formed by casting, They are flexible and adaptable for the construction or repair of the industrial kiln body. This Refractory material is commonly used in reheating furnace lining and some of high quality are even used in smelting furnace, like aluminate cement, high alumina cement and phosphate cement. If you are looking for Cheap Castables Refractory Supplier, please contact RS Refractory Kiln Refractory Group! Quote RS for the best price of refractory castables!

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What Is Castable Refractory

Castable is a kind of granular and powdery material made form refractory material with a certain amount of binder. As an amorphous refractory, castable has high fluidity and forms by pouring or spreading. The difference with other amorphous refractories is that the refractory castable has a certain setting and hardening time after construction. After finished casting, castable material needs to be removed after a certain period of maintenance, then castable material can be put into drying after a proper time of natural maintenance.

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Castable Composition

The castable refractories consist of refractory aggregate, binding material and admixture and castable comes into being by mixing with water or liquid binder.

As for the different chemical properties and composition of the aggregate, there are castables of clay, high alumina, silicon, magnesia, magnesia zirconia, magnesia chrome, silicon carbide,etc.

Based to the main crystalline phase of aggregate, the castable material can be divided into castable containing mullite, corundum, zirconium corundum, zirconium mullite, and so on.

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Castable Properties

• Simple preparation process, short production cycle and high labor productivity.
• Castable has strong flexibility and is not limited by the shape of industrial kin structure. It can be made into any shape you want.
• Good integrity, air tightness and thermal resistance which could reduce the heat loss of the industrial furnace and save the energy as well.
• Castable material makes the mechanized construction easy, saving labor and time.
• For the damaged industrial furnace lining, easy to repair.

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Castable Types & Classification

According to Working Performance

• Vibration castable refractory: this castable requires mechanical vibration to generate the flow and fill the model.
• Self-flow castable refractory: the refractory comes into being by self gravity and potential energy difference. This refractory castable can automatically fill the model and spread the surface.
• Pump pouring castable refractory: the material is pumped into the model with slurry pump, and can also automatically fill the model.

According to Volume Density of Aggregate

1. Dense castable refractory: volume density is greater than 2g/cm³
2. Medium weight castable refractory: volume density is between 1-2g/cm³
3. Lowweight castable refractory: volume density is between 0.4-1.0g/cm³

According to Chemical Properties

1. Acid Resistant Refractory Castable
   Acid castable products are acid resistant castables and phosphoric acid castables, mainly used in resistance to acid gas erosion, refractory castables are very critical to the construction environment. When we use acid resistant castables, the construction temperature must be between 5 degrees Celsius and 30 degrees Fahrenheit, if the temperature is 5 Celsius Degree, then we should store the dry materials in the room with suitable temperature. In the construction, we can keep the temperature of the acid resistant castable at ten degrees Celsius by heating the heating water or adding a proper amount of coagulant to the fire-resistant material technicians.
2. Alkali Proof Refractory Castable
   The alkali proof refractory castable is the granular and powdery material made from the refractory aggregate of Magnesium Oxide (MgO) as the main raw material. The castable material added with binder and admixture can be divided into magnesia castable, alumina magnesia castable, magnesia chrome castable, magnesia silicon castable, spinel castable and so on.

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Kinds of Castables Refractory Specifications

Calcium Aluminate Cement Bonded Castable

Types		SiO2	Al2O3	CaO	Fe2O3	Phase composition
Ordinary calcium aluminate cement	1	3~4	62~66	24~27	<1.5	CA2, CA, C2AS
	2	4~5	58~62	23~31	<2.0	CA2, CA, C2AS
	3	5~7	53~56	33~35	<2,0	CA2, CA, C2AS
Pure calcium aluminate cement	CA-70	<0.1	71~73	20~23	<0.1	CA, CA2
	CA-75	<0.1	75~76	23~26	<0.1	CA2,CA
	CA-80	<0.1	79~81	18~20	<0.1	CA, CA2,AL2O3

High Alumina Castable and Clay Refractory Castable

Specifications	Clay refractory castable	High alumina castable 1	High alumina castable 2
Al2O3 SiO2          % CaO	40~45 35~40 5~6	60~65 23~30 5~6	70~75 15~20 5~6
Volume density 110℃，24h g/cm³   1350℃，3h	2.0~2.1 2.1~2.15	2.4~2.5 2.5~2.6	2.7~2.8 2.7~2.85
Cold flexible strength/MPa 110℃，24h 1350℃，3h	4.5~6 6~7	5~6 6.5~7.5	5.5~6 7~8
Cold compressive  strength/MPa 110℃，24h 1350℃，3h	30~35 45~50	40~45 50~60	45~50 55~65
Change of post firing line at 1350℃	+（0.1~0.3）	-（0.1~0.3）	-（0.1~0.5）
Water consumption %	10~12	10~12	10~12
End-use temperature	1350	1450	1550

Steel Fire Castable

	ME430	ME304	ME446	ME310	ME330
Cr	14~18 %	18~20 %	23~27 %	24~26 %	17~19 %
Ni	0	8~12	0	19~22	34~36
Melting temperature℃	1480/1530	1400/1455	1425/1510	1400/1455	1345/1425
Thermal cycle temperature	850	870	1205	1040	1050
Continuous use temperature	815	980	1100	1150	1165
Coefficient of linear expansion870℃	13.7/10⁶	20.2/10⁶	13.1/10⁶	18.5/10⁶	17.6/10⁶
Thermal conductivity W/m*K 540℃	26.5	20.1	24.8	18.0	21.5
Tensile strength of fiber MN/㎡ 870℃	47	124	53	152	193
Modulus of elasticity GN/㎡ 870℃	83	124	97	125	134

Silicon Aluminum Castable

	NM-1	NM-2	NM-3	NM-4
Al2O3 %	≧70	>70	≧80	≧85
CaO %	≦2.5	≦2.5	≦2.5	≦2.5
Volume density   g/cm³	>2.6	>2.75	>2.8	>2.9
Compressive strength/MPa110℃，24h 1000℃，3h 1400℃，3h	>60 >75 >90	>65 >80 >95	>70 >85 >105	>75 >90 >110
Flexible strength/MPa110℃，24h 1000℃，3h 1400℃，3h	>8.50 >10.5 >13.0	>9.30 >11.5 >13.5	>10.0 >12.0 >15.0	>11.5 >13.0 >16.0
Ambient temperature wear /cm³	<9.6	<8.5	<7.3	<6
RUL Refractoriness under load ℃	>1450	>1490	>1530	>1560
Thermal shock resistance/times900℃-0	>20	>20	>20	>20
Maximum operating temperature/℃	1550	1550	1600	1600
Linear change on reheating %	<-0.3	<-0.3	<-0.2	<-0.2

Mullite Lowweight Castable

	MK-60	MK-65	MK-70
Al2O3 %	59~61	64~65	68~70
Volume density   g/cm³	1.25~1.40	1.45~1.50	1.50~1.60
Flexible strength/MPa (after burning at 1350℃)	1.25~2.5	2.5~3.5	3.0~4.5
Linear change on reheating %	-(0.2~0.3)	0~ -0.2	-0.2- +0.2
Thermal conductivity W/m*K 800℃	0.40~0.45	0.45~0.50	0.50~0.55
Using temperature ℃	1250	1350	1450

Applications of Castable Refractory

Castable Refractory materials are used as insulation layers in the kiln, thermal equipment, chimney and flue lining of metallurgical, mechanical, petrochemical, electric and building. However, with the improvement of the quality of the refractory material and the improvement of refractory technology, in many occasions, castables are directly used as the refractory lining of atmosphere furnace.

Castable Refractory Manufacturer

RS Kiln Refractory Group, as one of the professional castable refractory manufacturers, specializes in producing high alumina castable, corundum mullite castable, silica refractory castable, silicon carbide castable, steel fiber castable and other various refractory castables with low price. If you need any kind of castable, please contact RS to get the free quote! RS will offer you the satisfying price!