Calcium Silicate Board
Calcium Silicate (CS) Board is a rigid, lightweight, and high-strength inorganic insulation product made from a blend of silica, lime (CaO), and reinforced fibers (historically asbestos, but modern products use cellulose or inorganic fibers). It is formed under high pressure and temperature in an autoclave process. CS board is primarily used as structural, load-bearing backup insulation behind the hot face of refractory linings or as high-temperature pipe and vessel insulation, where its combination of high compressive strength, low thermal conductivity, and moisture resistance is essential.
Main Components and Structure
CS board’s physical strength and low k value come from its micro-porous structure, often based on hydrothermally grown Calcium Silicate Hydrates (CSH) phases.
| COMPONENT | COMPOSITION | PRIMARY ADVANTAGE |
| CSH Phases | CaO / SiO2 / H2O | Provides rigidity and a highly porous, insulating structure. |
| Reinforcement | Non-asbestos fibers (cellulose, synthetic) | Increases mechanical strength and handling durability. |
| CLASSIFICATION | MAXIMUM SERVICE T | PRIMARY USE |
| High-Density CS | ~650°C to 1000°C | Structural insulation for vessels and as a fire stop/barrier. |
| Low-Density CS | ~850°C | Pipe and vessel insulation, lower k value. |
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Compressive Strength | HIGH | Can support the weight of linings, pipes, or personnel (load-bearing insulation). |
| Thermal Conductivity (k) | LOW | Highly porous microstructure minimizes heat transfer. |
| Moisture Resistance | GOOD | Chemically stable against water; resists fungal growth and rot. |
| Non-Combustible | EXCELLENT | Purely inorganic composition does not burn or produce smoke. |
Advantages and Key Characteristics
CS Board is the most common rigid, structural insulation for medium to high temperatures, where its stability and safety characteristics are paramount.
- Load-Bearing Capability: The primary advantage over soft insulation like blankets or mineral wool. It can bear the weight of heavy refractory linings (e.g., brick) without crushing, making it ideal for the floors and lower walls of furnaces.
- Fire Safety: Due to its inorganic nature, CS board is non-combustible and does not contribute fuel to a fire, making it a key component in passive fire protection and industrial fire barrier walls.
- Corrosion Protection (5$\text{CUI}$): The material is non-corrosive to steel and aluminum, and its ability to wick moisture away from the metal surface helps to mitigate Corrosion Under Insulation.
- Ease of Installation: Boards and pre-formed pipe sections are rigid, lightweight, and easily cut with standard tools, simplifying installation in large industrial settings.
Typical Industries and Applications
CS board is widely used in high-temperature process equipment and building materials:
- Industrial Furnaces: Backup insulation for the shell behind dense firebrick or castable linings, particularly on the hearth (floor) where loads are heaviest.
- Power Generation: Insulation for boilers, flues, breechings, and precipitator casings.
- Oil and Gas/Chemical: Sectional insulation for large-diameter piping, vessels, and reactors up to 1000°C.
- Passive Fire Protection: Used as fire-rated barriers, sheathing, and fire stops in industrial facilities and commercial construction.
Key Data Sheet Properties to Consider
Selection is based on the required mechanical strength and maximum temperature:
- Maximum Service Temperature (MST): CRITICAL VALUE. Must match or exceed the cold-face temperature of the hot-face lining.
- Compressive Strength: CRITICAL VALUE. Look for the minimum strength (e.g., 3.0 MPa) required to support the weight of the overlying refractory lining and any mechanical stress.
- Thermal Conductivity (k): Check the k value at the required mean operating temperature to ensure the necessary insulation value is achieved.
Technical Guidance: CS board loses its chemically bonded water upon initial heat-up, which must be vented. For furnace applications above 1000°C, a layer of higher-temperature insulation (like RCF or microporous insulation) may be required as an intermediate layer to protect the CS board from overheating.
✨ Customization Services
We offer product customization services, allowing you to tailor the appearance, dimensions, or specific markings of items like refractory shapes or bricks. This includes options for incorporating specific geometric requirements to ensure seamless integration into your process systems.
🔬 Sampling for Testing & Validation
Free product samples are available for thorough testing and validation. This allows you to confirm the quality, compatibility, and performance of our materials—such as specific bricks, castables, or raw materials—before committing to a full order.
💡 Expertise in Refractory Solutions
Leverage our deep expertise to receive detailed, application-specific refractory solutions. We move beyond just selling products by providing comprehensive plans that encompass material selection, installation guidance, and performance optimization to maximize the lifespan and efficiency of your high-temperature processes.
Rabatec products are exclusively manufactured in facilities that have achieved rigorous ISO certifications across Quality (ISO 9001), Environmental Management, and Occupational Health & Safety. This commitment ensures every product, from refractory bricks to specialized equipment, meets the highest global benchmarks for performance, sustainability, and workplace safety.
📦 Logistics Excellence: Shipping, Packaging, and Marking
Minimizing Risk: We manage all logistics to minimize handling touchpoints and transit shock. Our carriers are pre-vetted for their experience in transporting heavy, fragile, and sensitive industrial materials.
Traceability: Every shipment includes comprehensive documentation and tracking information, providing end-to-end visibility and ensuring precise delivery coordination for your site.
Protection is Paramount: Our packaging strictly follows industry standards to prevent damage, corner chipping, and moisture absorption—especially critical for materials like Basic Refractory Bricks and Refractory Mortars & Mixes.
Robust Palletization: Products are secured on fumigated, high-strength export pallets (e.g., 1100x950mm or similar sturdy dimensions) using heavy-duty strapping and durable protective wrapping (polyethylene sheeting, cardboard, etc.) to withstand long-distance travel and multiple loadings.
Moisture Control: Sensitive materials are protected with appropriate sealing and, where necessary, desiccants or moisture-vapor proof enclosures to maintain the product's integrity until installation.
Clear Identification: All outer packaging is clearly marked on multiple sides with large, legible text for immediate identification and safe handling.
Full Traceability: Markings include all essential data points: Product Name, Quality Grade, Batch Number, Quantity, Net/Gross Weight, Order Number, and the Final Destination/Construction Area. This ensures every pallet can be accounted for and correctly staged upon arrival.
Safety & Compliance: We adhere to all regulatory requirements for marking, labeling, and placarding—especially for any items classified as Dangerous Goods—to ensure full compliance with international and domestic transport regulations.
❓ Frequently Asked Questions (FAQ)
Question | Elaborated Answer |
Q: What is the Refractoriness Under Load (RUL) of your refractories? | A: Refractoriness Under Load (RUL) is a critical property that defines the maximum temperature our materials can withstand while under compressive stress before deforming (softening). Since we offer a wide range of materials—from Alumina-Silicate Bricks to high-performance Silicon Carbide Bricks—the RUL varies significantly. For specific product data, please refer to the product data sheet or submit a quote request for the material you are interested in. |
Q: Where are the Rabatec refractories and materials produced? | A: Our products are primarily sourced from specialized manufacturing plants in China. Crucially, these facilities have all undergone rigorous audits and achieved comprehensive ISO certifications (Quality, Environment, and Safety), ensuring that production adheres to the highest global standards for consistency and performance. |
Q: What refractory materials does the company offer? | A: We supply a comprehensive portfolio of advanced refractory solutions, including: Shaped Products: Alumina & Silica Bricks, Basic & Specialized Bricks (e.g., Magnesia), SiC & Structural Ceramics, and Precast Shapes. Monolithic Products: Refractory Castables, Mixes & Mortars. Insulation: Insulation Fibre and High-Performance Insulation Products. |
Q: How should I choose the appropriate refractory material for my application? | A: Selecting the correct refractory is paramount to process efficiency. The choice depends on three key factors: 1. Operating Environment: Maximum process temperature and thermal cycling (shock). 2. Chemical Attack: Type of slag, molten metal, or corrosive gas being handled (acidic, neutral, or basic). 3. Mechanical Stress: Abrasion, erosion, and static load requirements. We recommend utilizing our detailed refractory solutions service to consult with our engineers for an optimized, application-specific recommendation. |
Q: Which monolithic material should I choose when patching an existing lining? | A: For patching and minor repairs, the ideal monolithic material depends on the parent lining material, the patching depth, and the need for a rapid return to service. Common choices include: Refractory Mortars & Mixes (for minor joints/surfaces) or Plastic Refractories (for areas requiring physical compaction). Always choose a patch material chemically compatible with the existing lining to ensure proper bonding and service life. |
Q: Can I receive product samples before placing a major order? | A: Yes. We gladly provide product samples for your internal testing and validation purposes. This ensures you can confirm the quality, composition, and fit of the material—such as our Refractory Castables or Alumina-Silicate Bricks—in your specific operational environment before committing to a bulk purchase. |
Q: Do you provide certifications to verify material quality? | A: Absolutely. We provide product-related inspection certificates and quality assurance documentation upon request. This verifies that your order has passed all internal quality control checks and meets the required material specifications and industry standards. |
Q: What measures are taken for product protection during transport? | A: We ensure quick, reliable transport by using robust, industrial packaging that strictly follows industry standards. This includes high-strength palletization, heavy-duty strapping, and weather-resistant wrapping to protect fragile items like bricks and mixes from corner chipping, mechanical damage, and moisture during transit. |
