Ceramic Fiber Blanket
A Ceramic Fiber Blanket is a lightweight, highly flexible insulation product made from fine, long, spun or blown Aluminum Silicate fibers. The blanket is produced by mechanically needling the bulk fibers together to create a continuous, strong, and highly resilient mat. It is the primary insulation material used for hot-face furnace linings and high-temperature backup insulation due to its extremely low thermal conductivity and low thermal mass.
Main Chemical Compositions & Categories
The material is a high-purity blend of Alumina (Al2O3) and Silica (SiO2). The Al2O3 content dictates the temperature rating.
| CATEGORY | Al2O3 Content | TYPICAL MST | PRIMARY USE |
| Standard Grade | 45% to 50% | ~1260°C to 2300°C | General furnace lining, backup insulation. |
| High Alumina Grade | 50% to 60% | ~1430°C to 1540°C | For higher heat flux and more severe chemical environments. |
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Thermal Conductivity (k) | EXTREMELY LOW | High volume of trapped air minimizes heat transfer through conduction and radiation. |
| Thermal Mass/Heat Storage | VERY LOW | Absorbs minimal heat; enables rapid heat-up/cool-down cycles (crucial for batch furnaces). |
| Thermal Shock | EXCELLENT | Flexible structure resists cracking or spalling during rapid temperature changes. |
| Erosion Resistance | GOOD (Density Dependent) | Needling provides fiber orientation and strength to resist the abrasive effects of high-velocity gases. |
Advantages and Key Characteristics
The blanket form is the workhorse of high-temperature insulation, providing a superior combination of thermal efficiency and ease of installation compared to rigid refractories.
- Energy Efficiency: The primary benefit is the dramatic reduction in heat loss due to low k, and the massive fuel savings due to low heat storage, especially in intermittent (batch) operations where the furnace is frequently heated and cooled.
- Ease of Installation: The blanket is highly flexible, allowing it to be easily cut, wrapped, and molded to fit complex shapes, around pipes, and over curved surfaces. It is installed by mechanical anchoring systems, often in the form of pre-compressed modules.
- Lightweight Construction: The low density of the blanket significantly reduces the structural load on the furnace casing, allowing for lighter, less expensive steel construction.
- Corrosion Resistance: Chemically stable in most furnace atmospheres, resisting attack by common combustion products.
Typical Industries and Applications
RCF Blankets are used universally across all high-temperature processes:
- Furnace Linings: Hot face and backup insulation for heat-treating furnaces, forging furnaces, kilns (ceramic and firing), and dryers.
- Kiln Cars: Used to insulate the surface of kiln cars to prevent heat loss and ensure a uniform temperature profile for the products.
- Duct and Pipe Wrapping: High-temperature insulation for large industrial ducts, flues, and steam piping.
- Emergency Repair: Used as a fast, temporary patch or insulation upgrade during short-term outages.
Key Data Sheet Properties to Consider
Selection is crucial based on the operating environment:
- Maximum Service Temperature (MST): CRITICAL VALUE. Must always be checked against the highest anticipated furnace temperature to prevent premature shrinkage and failure.
- Density: Typically available in 6 lb/ft3 (96 kg/m3) or 8 lb/ft3 (128 kg/m3). Higher density provides slightly better mechanical strength and reduced shrinkage at the hot face.
- Thickness: Ranges from 1/4 in to 2 in (6 mm to 50 mm). Multiple layers are used to achieve the target insulation value.
Technical Guidance: For the most severe environments (e.g., direct flame impingement or high gas velocity), the blanket is often protected by a rigidizing coating or installed in a folded, pre-compressed module form for enhanced durability and hot-face stability.
✨ 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. |
