Ceramic Fiber Shaped Parts
Ceramic Fiber Shaped Parts are rigid, high-density, custom components manufactured by a vacuum-forming process using a slurry of Aluminum Silicate Fibers (RCF) and a specialized inorganic binder. These parts are then baked to create a precise, self-supporting shape. They are essential for applications requiring the excellent thermal insulation and low heat storage of ceramic fiber, but with superior structural rigidity, high compressive strength, and dimensional accuracy not achievable with flexible blankets.
Main Chemical Compositions & Categories
The material is chemically identical to Ceramic Fiber Blanket, classified by its Al2O3 content, but structurally defined by its density and binder content.
| CATEGORY | Al2O3 Content | TYPICAL MST | PRIMARY ADVANTAGE |
| Standard Grade | 45% to 50% | ~1260°C to 2300°C | Rigid insulation, most cost-effective. |
| 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 under mechanical load; ideal for self-supporting structures. |
| Dimensional Accuracy | EXCELLENT | Vacuum forming allows for tight tolerances, crucial for precise fittings like plugs and ports. |
| Erosion Resistance | SUPERIOR | High density and smooth, hard surface resist high-velocity gas flow and abrasion. |
| Thermal Mass | LOW | Retains the energy-saving benefit of fast thermal cycling for intermittent operations. |
Advantages and Key Characteristics
Shaped parts bridge the gap between flexible fiber insulation and rigid, dense refractories, providing the best of both in specific structural applications.
- Customized Rigidity: They provide a self-supporting structure that can be handled and installed without loss of shape, making them ideal for complex, prefabricated components.
- Reduced Gas Erosion: The high density and smooth surface created by the vacuum-forming process offer superior resistance to erosion from fast-moving combustion gases or process air, protecting the hot face in turbulent zones.
- Plug-and-Play Installation: Being pre-formed and accurate, they allow for rapid installation as plugs, gaskets, or burner components, minimizing downtime and guaranteeing a tight, consistent fit.
- Hot Spot Isolation: They are often used to surround or protect sensitive components (like heating elements or burners), ensuring maximum insulation right up to the working part.
Typical Industries and Applications
This product is specialized for critical, high-precision insulation areas:
- Burner Blocks: Pre-formed rings or blocks used to insulate and protect gas and oil burners, providing a rigid, erosion-resistant seal against the furnace wall.
- Sight and Access Ports: Custom shapes used as rigid plugs for thermocouple entry points, sight glasses, and inspection ports.
- Furnace Doors and Vents: Used as rigid inserts, gaskets, or insulation pieces for furnace door seals and flue lining.
- Electric Furnaces: Used as coil supports, electrical insulators, or structural elements in resistance-heated furnaces.
Key Data Sheet Properties to Consider
Selection is based on the required mechanical strength and thermal properties:
- Density: Measured in kg/m}=3 or lb/ft3. Higher density generally means higher strength and erosion resistance.
- Cold Crushing Strength (CCS): This measures the ultimate compressive load the part can bear, which is critical for load-bearing applications.
- Dimensional Tolerance: Ensure the manufacturing tolerance meets the requirements for the specific fitting (e.g., clearance around a burner tube).
Technical Guidance: For use on the immediate hot face, shaped parts are frequently treated with a surface rigidizing liquid (often alumina-based) to further harden the surface and lock down loose fibers, reducing dusting and increasing erosion resistance.
✨ 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. |
