Castable

Castable

In general, Castable can be grouped into 3 types which are Conventional castable, Low Cement Castable (LCC), and Ultra Low Cement Castable (ULCC).

Type of Castable

 

Conventional Castable

Low Cement Castable (LCC) Ultra Low Cement Castable (ULCC)
 

NORMAL

 

ES SERIES

 

LW SERIES

 

CG SERIES

 

TUFF SERIES

Other Special Application Castable Other Special Application Castable
 

STRENGHTS

 

 

 

 

 

Strengths

Used for general casting Used for casting that required extra strength to hold the weight Used for casting that prevent the heat loss and help reducing the energy loss Used for casting that required extra strength, excellent for high mechanical strength, abrasive resistant Used for casting that required high resistant to change of temperature Used for casting especially for Cement plant, non-ferrous plant (Non-Wetting Castable) Used for casting with temperature higher than 1700 Degree Celsius and high resistant for slag penetration and abrasive resistance
Product Name Castable 13 Castable 13 ES Cast 10 LW CAST 13 CG TUFF C50 Alka60 UL80
Castable 15 Castable 15 ES Cast 11 LW CAST 15 CG TUFF C60 SPHERE B UL80 S
Castable 16 Castable 16 ES Cast 13 LW CAST 17 CG TUFF C70 SPHERE B6
Castable 18 TUFF C80
Castable 13 MJ (Patching)
Castable 15 MJ (Patching

 

Criteria of choosing the most appropriated castable for usage

  1. Service temperature
  2. Weight and collision from usage
  3. Abrasive and gas used inside the combustion area
  4. How rapid Temperature change suddenly
  5. Chemical corrosion from slag and alkaline

 

Applications

  • Casting an alternative to fireclay and high alumina brick for application such as glass furnaces, EAF, reheating furnace, tapping spout, aluminum and jewelry kiln.
  • Application for cyclone preheated of cement kiln, ceramic kiln, ash coal hoppers coal and incinerators.
  • Casting an alternative to high alumina brick at EAF roof core, burner block, nose ring and kiln load.

 

 

 

 

 

 

 

 

 

 

 

 

 

1.1 Conventional Castable (Normal Series)

Conventional castable suitable for general casting, high mechanical and abrasive resistance.

PRODUCTS

PROPERTIES

UM C13 C15 C16 C18 C13 MJ
Quality Fireclay Fireclay High Alumina Tabular Alumina Fireclay
Max. Allowable Temp. (°C) °C 1300 1500 1600 1800 1300
Max. Grain Size of Aggregates (mm.) mm 5 5 5 5 3
Approx Weight Required for Casting kg/m3 1900-2000 2150-2200 2200-2250 2750-2800 2050-2100
Approx. Amount of Water Required for Casting (%) % 12-13 11-12 12-12.5 9 13-15
Setting Time (Hrs) Hour 2-3 2-3 2-3 2-3 2-3
Bulk Density After Drying at 110 °C kg/m3 2000-2010 2150-2200 2200-2250 2750-2800 2050-2100
Modulus of Rupture After Drying at 110 °C kg/cm2 55-65 70-80 60-70 110-130 45-55
Cold Crushing Strength After Heating at 110 °C kg/cm2 350-400 300-350 350-400 650-750 220-250
Modulus of Rupture After Heating kg/cm2 45-55

(1260 °C)

80-90

(1400 °C)

100-110

(1400 °C)

120-140

(1400 °C)

35-40

(1260 °C)

Cold Crushing Strength After Heating kg/cm2 300-350

(1260 °C)

420-450

(1400 °C)

450-500

(1400 °C)

450-550

(1400 °C)

220-250

(1260 °C)

Permanent Linear Change After Heating kg/cm2 +0.5

(1260 °C)

-0.2

(1400 °C)

+0.5

(1400 °C)

-0.4

(1400 °C)

-0.5

(1260 °C)

Thermal Conductivity at 400°C (W/m.K) 1.10 1.18 1.20 1.87 1.13
Thermal Conductivity at 600°C (W/m.K) 1.12 1.23 1.25 1.87 1.16
Thermal Conductivity at 1000°C (W/m.K) 1.16 1.38 1.40 1.90 1.28
Alumina (Al2O3) %   30 52 60 95 36
Silica (SiO2) %          60 38 34.3 1.0 55
Iron Oxide (Fe2O3) % 3.0 1.2 1.6 0.1 2.5
Lime (CaO) % 4.2 6.6 4.3 4.2 4.8

 

 

 

 

 

 

1.2 Special Application Conventional Castable (ES and CG Series)

Castable ES series is used for casting that required extra strength to hold the weight

Castable CG series is used for casting that required extra strength, excellent for high mechanical strength, abrasive resistant

 

PRODUCTS

PROPERTIES

UM C13ES C15ES C13CG C15CG C17CG
Quality Extra Strength Extra Strength Coarse Grain Coarse Grain Coarse Grain
Max. Allowable Temp.  (°C) °C 1300 1500 1350 1500 1700
Max. Grain Size of Aggregates (mm.) mm 5 5 8 5 5
Approx Weight Required for Casting kg/m3 2150-2180 2200-2250 2110  2200-2250 2650-2700
Approx. Amount of Water Required for Casting (%) % 11-12 12-13 10-11 9-10 8-9
Setting Time (Hrs) Hour 2-3 2-3 1-2 1-2 1-2
Bulk Density After Drying at 110 °C kg/m3 2150-2180 2200-2250 2150 2160 2680-2700
Modulus of Rupture After Drying at 110 °C kg/cm2 70-80 100-110 80-90 75-80 90-100
Cold Crushing Strength After Heating at 110 °C kg/cm2 430-470 550-570 500-550 450-500 700-800
Modulus of Rupture After Heating kg/cm2 60-70

(1200 °C)

70-80

(1400 °C)

60-70

(1200 °C)

80-90

(1400 °C)

120-130

(1400 °C)

Cold Crushing Strength After Heating kg/cm2 300-350

(1200 °C)

400-450

(1400 °C)

350-400

(1200 °C)

550-600

(1400 °C)

900-1000

(1400 °C)

Permanent Linear Change After Heating kg/cm2 +0.05

(1200 °C)

-0.5

(1400 °C)

+0.2

(1200 °C)

-0.2

(1400 °C)

-0.5

(1400 °C)

Thermal Conductivity at 400 °C (W/m.K) 1.15 1.22 1.14 1.18 1.85
Thermal Conductivity at 600 °C (W/m.K) 1.18 1.27 1.20 1.23 1.85
Thermal Conductivity at 1000 °C (W/m.K) 1.30 1.42 1.35 1.38 1.87
Chemical Composition (Approx)
Alumina (Al2O3) % 43 50 43.5 50 80.0
Silica (SiO2) % 45 37 45.0 40 12.0
Iron Oxide (Fe2O3) % 1.6 2 1.5 1.2 1.2
Lime (CaO) % 7.0 6.6 4.0 5.5 2.4

 

 

1.3 Light Weight Castable

 

GRADES AND CODES

PROPERTIES

UM  

10LW

 

11LW

 

13LW

Max. Service Temperature °C 1000 1100 1300
Max. Grain Size of Aggregates mm 3 3 3
Approx Weight Required for Casting kg/m3 600 860 1300
Approx. Amount of Water Required for Casting % 110 50-60 30-35
Setting Time Hour 3-4 3-4 3-4
Bulk Density After Drying kg/cm3 570

(925 °C)

900

(110 °C)

1350

(110 °C)

Modulus of Rupture After Drying kg/cm2 15

(925 °C)

10-15

(1040 °C)

20-30

(1340 °C)

Cold Crushing Strength After Drying kg/m2 30

(925 °C)

40

(1040 °C)

80-100

(1260 °C)

Permanent Linear Change After Heating % -0.5

(925 °C)

-0.5

(1040 °C)

-0.05

(1260 °C)

Thermal Conductivity at 400 °C (W/m.K) 0.14 0.25 0.36
Thermal Conductivity at 600 °C (W/m.K) 0.16 0.30 0.38
Thermal Conductivity at 800 °C (W/m.K) 0.18 0.40 0.42
Alumina (Al2O3) % 24.0 37.0 43.0
Silica (SiO2) % 44.0 36.0 44.5
Iron Oxide (Fe2O3) % 1.0 0.5 1.4
Calcium Oxide (CaO) % 27 14 9.30