Ceramic Fiber Board
A Ceramic Fiber Board is a rigid, high-density, vacuum-formed insulation product made from a blend of Aluminum Silicate Fibers (RCF) and an inorganic binder. Unlike flexible blankets, the board maintains a self-supporting, structurally stable shape with defined dimensional tolerance. It is used for high-temperature lining applications that require the low thermal conductivity and low heat storage of ceramic fiber, combined with high compressive strength, rigidity, and resistance to high-velocity gas erosion.
Main Chemical Compositions & Categories
The chemical composition mirrors Ceramic Fiber Blanket, but the board’s key features are density and rigidity, achieved through vacuum forming and baking.
| CATEGORY | Al2O3 Content | TYPICAL MST | PRIMARY ADVANTAGE |
| Standard Grade | 45% to 50% | ~1260°C to 2300°C | Rigid and load-bearing insulation. |
| High Alumina Grade | 50% to 60% | ~1430°C to 1540°C | Higher MST and improved structural integrity at heat. |
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Compressive Strength | HIGH | Maintains shape and resists deformation under mechanical load or compressive stress from lining anchors. |
| Erosion Resistance | SUPERIOR | High density and smooth surface resist the abrasive effects of high-velocity gases (e.g., in ducts or flues). |
| Thermal Mass | LOW | Retains the energy-saving benefits of RCF for fast cycling furnaces. |
| Dimensional Stability | EXCELLENT | Maintains tight geometric tolerances, crucial for flat surfaces, doors, and module facings. |
Advantages and Key Characteristics
Ceramic Fiber Board is chosen when the insulating benefits of RCF are required but the mechanical demands (erosion, light load, rigidity) exceed the capability of a flexible blanket.
- Rigidity and Structural Integrity: The primary benefit. The board can be used to construct furnace parts (like doors, covers, or baffle walls) that are self-supporting and require handling without losing their shape.
- Resistance to Hot Gas Velocity: The smooth, dense surface resists the peeling and tearing associated with flexible blankets in zones of high gas turbulence (e.g., burner ports, exhaust flues, duct linings).
- Precise Installation: Boards can be machined, cut, and installed using standard anchoring systems, providing a uniform and joint-tight hot-face surface superior to hand-cut blanket installation.
- Backup Insulation: Used behind dense brick or castables to provide stable, load-bearing thermal backing without adding excessive weight or heat storage.
Typical Industries and Applications
This product is critical in demanding insulation and structural applications:
- Furnace Linings: Hot face for small, high-velocity furnaces, electric resistance furnaces, and induction furnace coil protection.
- Furnace Doors and Covers: Used to create rigid, lightweight insulation for furnace doors, lids, and kiln car tops.
- Baffles and Partitions: Used to create flow controls, radiant heat shields, or separation walls within the furnace chamber.
- Burner Blocks: Boards are often cut and stacked around burner ports for a rigid, erosion-resistant seal.
- Backup Insulation: Used behind refractory castables to insulate the steel casing.
Key Data Sheet Properties to Consider
Selection is highly dependent on density and thermal performance:
- Maximum Service Temperature (MST): CRITICAL VALUE. Must be verified based on the Al2O3 content.
- Density: Ranges from 230 kg/m3 to 480 kg/m3 (15 to 30 lb/ft3). Higher density provides better erosion resistance and compressive strength but slightly higher thermal conductivity.
- Cold Crushing Strength (CCS): Measures the material’s ability to withstand compressive loads without crushing, essential for load-bearing areas.
Technical Guidance: Boards can be treated with a surface rigidizer or hardener (often alumina-based) to further increase their surface hardness and resistance to erosion/dusting, which is recommended for the hot face of gas-fired furnaces. Boards must be properly vented during initial heat-up to allow the burnout of any residual organic binder.
✨ 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. |
