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
- Service temperature
- Weight and collision from usage
- Abrasive and gas used inside the combustion area
- How rapid Temperature change suddenly
- 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 |