Carbon Brick – Resin Bonded
Main Chemical Compositions & Categories
Resin-Bonded Carbon Bricks are composed of high-purity CARBON (C) materials (e.g., natural or synthetic graphite) held together by a SYNTHETIC RESIN binder. They are typically subjected to a low-temperature bake (curing) rather than high-temperature firing, preserving the carbon structure.
| COMPONENT | CONTENT | KEY FEATURE | PRIMARY ADVANTAGE |
| CARBON (C) | 90% to 99% | High non-wetting property | Superior slag/metal adhesion resistance |
| RESIN BINDER | 3% to 8% | Forms a strong carbon char upon curing | Low porosity and high mechanical strength |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Non-Wetting | OUTSTANDING | High carbon content prevents molten metal and slag from adhering to the surface. |
| Density/Porosity | VERY HIGH DENSITY, LOW POROSITY | Resin binder creates a strong, dense matrix upon curing, inhibiting infiltration. |
| Thermal Shock Resistance | EXCELLENT | High thermal conductivity and low expansion coefficient of carbon provide stress resilience. |
| Purity | EXCELLENT | Synthetic resin binders often contain fewer impurities than coal tar pitch. |
Advantages and Key Characteristics
Resin-Bonded Carbon Bricks are favored for applications requiring the chemical benefits of carbon combined with a cleaner, denser bond and superior handling strength compared to pitch-bonded types.
- High Mechanical Strength: The phenolic resin forms a dense, strong carbon char during the initial cure, giving the brick exceptional Cold Crushing Strength (CCS), which is vital for handling and installation.
- Low Porosity and Permeability: The resin fills the intergranular voids efficiently, resulting in a dense structure that significantly reduces the penetration of corrosive slag and metal.
- Reduced Impurities: Synthetic resins introduce fewer metallic impurities and potentially less harmful organic substances than coal tar pitch, leading to a cleaner final refractory product.
- Wider Application: The resin binder is widely used in high-performance Magnesia-Carbon (MgO-C) bricks for steel ladles and converters, where its strength enhances composite performance.
Typical Industries and Applications
This brick is used in critical lining applications where non-wetting and erosion resistance are paramount:
- Ferrous Industry (Steel): Ladle slag lines, Electric Arc Furnace (EAF) tapholes, and main linings for Basic Oxygen Furnaces (BOF) and Vacuum Degassers (VD).
- Non-Ferrous Industry: Troughs and linings for continuous casting equipment.
Furnace Areas and Service Zones
Resin-bonded types are specified for the permanent structures in contact with the melt:
- SLAG LINE: The primary zone for MgO-C variants, leveraging the resin bond for high resistance to chemical wear and thermal stress.
- TAPHOUSE AND RUNNER: Used where metal flow is high-velocity and the non-wetting property is required to maintain a clean channel.
- PERMANENT LINING: Can be used in the hearth of submerged arc furnaces.
Key Data Sheet Properties to Consider
Selection focuses on the strength and density imparted by the binder:
- Cold Crushing Strength (CCS): CRITICAL VALUE. Must be very high to ensure structural integrity.
- Bulk Density (BD): Must be high (e.g., > 1.7 g/cm3) to maximize material mass and conductivity.
- Apparent Porosity (AP): Must be extremely low (e.g., < 8%) due to the dense char formation.
- Resin/Carbon Yield: The percentage of the binder that successfully converts to solid carbon (char yield) indicates the final material density.
Technical Guidance: Like all carbon products, Resin-Bonded bricks are susceptible to OXIDATION (burning). When used in non-sealed environments, they must be protected by a sacrificial material or carefully placed to avoid exposure to air at high temperatures. The curing process for resin-bonded materials is less temperature-dependent than pitch-bonded materials, leading to faster, more reliable manufacturing.
✨ 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. |
