Monolithic
Category:
Castable Refractory
Keyword:
- Describe
-
Refractory castable is the most mainstream type of monolithic refractories. It is prepared by mixing refractory aggregates, powders, binders and additives in a specified ratio. After mixing with water (or liquid), it is cast and vibrated to form, then cured and baked to form an integral furnace lining.
II. Core Characteristics
- Good integrity: No brick joints; air tightness, erosion resistance and penetration resistance are far better than brick masonry.
- Flexible construction: Can be cast into any shape, suitable for complex structures, repair and integral lining.
- Complete product range: Covers low temperature to ultra-high temperature, wear resistance, slag resistance and thermal insulation.
- Short construction period: Fast on-site installation, ideal for maintenance and emergency repair.
- High strength: Stable medium and high temperature strength, adjustable thermal shock resistance.
III. Classification by Binder (Most Critical)
Cement-bonded castable (Most commonly used)水泥结合浇注料
- Binded by aluminate cement (high alumina cement)
- Typical products: Low cement castable, ultra-low cement castable, ordinary cement castable
- Advantages: Easy construction, high strength, moderate cost
- Applications: Ladle, heating furnace, rotary kiln, blast furnace trough, etc
Water glass-bonded castable
- Good acid resistance, moderate high temperature strength
- Applications: Chimneys, flues, acid working conditions
Phosphoric acid / phosphate-bonded castable
- Extremely high medium and high temperature strength, excellent wear resistance
- Applications: Wear-resistant linings, burners, impact zones
Sol-bonded castable (High performance)
- Ultra-low impurities, excellent high temperature stability
- Applications: Clean steel production, glass furnace, high-end furnace linings
IV. Classification by Material / Chemical Composition
Fireclay / High alumina castable
- Al₂O₃: 40%~80%
- General-purpose, service temperature 1300~1500℃
- Applications: Heating furnaces, flues, hot air ducts, general kilns
Corundum castable
- Al₂O₃ ≥ 90%, high-purity corundum aggregateAl₂O₃≥90%
- High temperature resistance, strong slag resistance, good wear resistance
- Applications: Ladle walls, slag line, burners, gasifiers
Magnesia / Magnesia-alumina spinel castable
- Basic material, extremely strong alkaline slag resistance
- Applications: Ladle slag line, converter repair, cement kiln burning zone
Lightweight thermal insulation castable
- Porous structure, low thermal conductivity
- Applications: Back insulation, insulation layer, not in direct contact with molten slag
Wear-resistant castable
- High density, high hardness
- Applications: Iron trough, launder, coal powder pipeline, cyclone cylinder
V. Classification by Cement Content (Important Industrial Grade)
- Ordinary cement castable: Cement content ≥15%
- Low cement castable (LCC): Cement 3%~8% (Most mainstream)
- Ultra-low cement castable (ULCC): Cement ＜3%
- No cement castable (NCC): 0 cement, sol / colloid bonded
Lower cement content → better high temperature performance, better thermal shock resistance, smaller shrinkage
VI. Typical Applications (Full coverage in metallurgy /building materials /chemical industry)
- Iron & steel: Ladle, tundish, iron trough, slag trough, heating furnace, walking beam
- Cement: Preheater, calciner, cooler, kiln inlet
- Petrochemical / Coal chemical: Gasifier, cracking furnace, heating furnace tube lining
- Waste incineration: Incinerator, flue
- Industrial furnaces: Heat treatment furnace, soaking furnace, chimney lining
VII. Key Performance Indicators (Essential for Bidding Documents)
- Refractoriness
- Cold modulus of rupture / Cold compressive strength
- Permanent linear change on firing
- Apparent porosity / Bulk density
- Thermal conductivity (for insulating castables)
refractory castable series ：
Castable1 1:
HIGH ALUMINA BASE BRAND HD-LJ50 HD-LJ55 HD-LJ60 HD-LJ65 HD-LJ70 HD-GJ75 Al2O3(%) ≥ 50 55 60 65 70 75 BD 110℃× 24 h 2.2 2.2 2.3 2.3 2.5 2.6 （g/cm3）≥ MOR 110℃× 24 h 6 7 7 8 8 9 （MPa） ≥ 1350℃× 3 h 8 8 10 10 11* 11* CCS 110℃× 24 h 25 30 35 40 45 50 （MPa） ≥ 1350℃× 3 h 30 40 45 50 60* 65* PLC 1350℃× 3 h ±0.5 ±0.5 ±0.5 ±0.5 ±0.5* ±0.5* (%) ≤ REF（℃） 1350 1400 1450 1500 1550 1600 Castable 2:
CORUNDUM BASE MULLITE BASE BRAND HD-GJ80 HD-GJ90 HD-GJ95 HD-MJ55 HD-MJ60 HD-MJ65 HD-MJ70 Al2O3 (%) ≥ 80 90 95 55 60 65 70 BD（g/cm3）≥ 110℃× 24 h 2.7 2.8 3.0 2.2 2.3 2.4 2.5 MOR（MPa）≥ 110℃× 24 h 9 10 11 7 7 8 9 1350℃× 3 h 12* 12* 12* 9 10 10 12* CCS（MPa）≥ 110℃× 24 h 60 60 60 30 35 40 45 1350℃× 3 h 70* 75* 80* 40 50 50 60* PLC(%) ≤ 1350℃× 3 h ±0.5* ±0.5* ±0.5* ±0.5 ±0.5 ±0.5 ±0.5* REF （℃） 1650 1700 1800 1450 1500 1550 1600 Castable 3:
CORUNDUM - CR - ZR BASE ITEM HD-CH1 HD-CH2 HD-CH3 CHEM（%）≥ Al2O3+Cr2 O3 90 — 90 Al2O3+Zr O2 — 93 — Al2O3+Cr2O3+Zr O2 - 95 - BD（g/cm3）≥ 110℃× 24h 3.2 3.3 3.0 MOR（MPa）≥ 110℃× 24 h 10 10 10 1500℃× 3 h 12 12 12 CCS（MPa）≥ 110℃× 24 h 40 40 30 1500℃× 3 h 100 100 80 PLC（%）≤ 110℃× 24 h ±0.1 ±0.1 ±0.1 1500℃× 3 h +0.3～-0.5 +0.3～-0.5 +0.3～-0.5 Castable 4:
AL-MG-CR BASE HD-DYZ1 HD-DYZ2 HD-DYZ3 HD-DYZ4 chem Al2O3+MgO(%) ≥ 80 90 ---- ---- Al2O3+ MgO +Cr2O3(%) ≥ ---- ---- 85 90 BD (g/cm3) ≥ 110℃×24h 2.8 2.8 2.9 3.0 MOR (MPa) ≥ 110℃×24h 7 8 7 8 1500℃× 3 h 10 10 10 12 CCS (MPa) ≥ 110℃×24h 40 45 40 54 1500℃× 3 h 50 60 60 70 Castable 5:
ASC BASE RAMMING MASS CASTABLE SELF FLOW CASTABLE CHEM（%）≥ Al2O3 50 65 60 70 80 55 65 SiC+C 10 10 10 8 15 25 17 BD（g/cm3） ≥ 110℃ ×24 h 2.2 2.4 2.5 2.6 2.8 2.5 2.6 CCS（MPa）≥ 110℃ ×24 h 10 10 15 15 15 25 25 1450℃ ×3 h 13 15 35 35 50 35 35 Castable 6:
Clay base
ITEM CLAY BASE HIGH ALUMINA BASE HD-12N HD-13N HD-12NL HD-13NL Al2O3 (%) ≥ 40 48 40 48 BD(g/cm3)≥ 110℃ ×24h 2.1 2.2 2.1 2.2 MOR (MPa) ≥ 110℃ ×24 h 5 5 7 8 1000℃ ×3 h 2.5 2.5 7 8 CCS (MPa) ≥ 110℃ ×24 h 40 40 60 70 1000℃ ×3 h 20 20 70 80 PLC (%) ≤ 1000℃ ×3 h ±0.5 ±0.5 ±0.5 ±0.5 REF （℃） 1200 1300 1200 1300 gunning repair mass series ：
High alumina Refractory gunning mass:
HIGH ALUMINA BASE Al2O3 (%) ≥ 50 55 60 65 70 75 REF （℃） 1350 1400 1450 1500 1550 1600 Mgo base Refractory spraying mass or dry repair mass :
MGO BASE ITEM DB-1 DB-2 DB-3 DB-4 MgO ≥ 38 45 55 70 CaO ≥ 10 8 8 5 C ≥ / / / / BD（g/cm3）100℃ 2.4 2.2 2.5 2.55 CCS（MPa）≥ 30 25 35 30 Mgo base Refractory gunning mass:
Mgo base ITEM HD-BPB85 HD-BPB70 HD-BPB60 HD-BPB50 MgO （%）≥ 85 70 60 50 MOR（MPa）≥ 200℃×3h 3 3 2.5 2 1550℃×24 3 3 3 3 BD（g/cm3）≥ 200℃×3h 2.2～2.5 2.2～2.4 2.0～2.3 2.0～2.1 ramming mass series ：
Quartz Refractory ramming mass:
Sio2 base SIO2 (%) ≥ 99 98 99 B (%) ≥ 2 2 - Cr2o3(%) ≥ - 2 - Zro2 (%) ≥ - 1 - REF （℃） 1750 1750 1750 BD ( AFTER HEATING ) 1.85 1.86 1.86 High alumina Refractory ramming mass:
HIGH ALUMINA/ CORUNDUM BASE Al2O3 (%) ≥ 85 90 85 Mgo (%) ≥ 12 - - Cr2o3(%) ≥ - 8 6 Zro2 (%) ≥ - 6 REF （℃） 1850 1850 1850 BD 3.0 3.1 3.15 Mgo base Refractory ramming mass:
Mgo base ITEM HD- MFC-1 HD- MFC-2 HD- MFC-3 MgO （%） ≥ 70 68 65 CAO（%） ≥ 24 18 15 MOR（MPa） ≥ 200℃×3h / / / 1550℃×24 8 7 7 BD（g/cm3）≥ 1600℃×3h 3.2 3.15 3.1 Mgo base Refractory ramming mass:
Mgo base ITEM HD-RX1 HD-RX2 HD-RX3 HD-RX4 BINDER TYPE PITCH PITCH RESIN RESIN MgO（%） ≥ 65 70 75 80 C（%） ≥ 10 12 8 5 BD（g/cm3）≥ 1500℃×3h 2.2 2.2 2.1 2.1 CCS（MPa） ≥ 1500℃×24 5 6 5 6 REF（℃） 1750 1750 1750 1750 Mgo base Refractory ramming mass:
Mgobase ITEM HD-JZ80 HD-JZ70 HD-JZ60 HD-JZ50 MgO （%） ≥ 80 70 60 50 MOR（MPa） ≥ 200℃×3h 3 3 2.5 2 1550℃×24 3 3 3 3 BD（g/cm3）≥ 200℃×3h 2.2～2.5 2.2～2.4 2.0～2.3 2.0～2.2
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HENAN SINO INDUSTRIAL REFRACTORY NEW MATERIAL CO. LTD
Factory Address:
Mazhai, Zhengzhou, China
Nanlou, Dashiqiao, China
Xinmi, Zhengzhou, China
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