Electric Furnace Gunning Mix (Non-Basic)
Main Chemical Compositions & Categories
This mix is composed predominantly of acidic/neutral oxides, primarily High Alumina (Al2O3), Mullite, or Alumina-Silicate to ensure chemical compatibility with the existing lining (e.g., clay brick or high-alumina castable). The binding system is typically a high-purity chemical bond (e.g., phosphates, colloidal silica, or clay) designed for fast setting and strong adhesion to the hot lining.
| COMPONENT | CONTENT | CHEMICAL BASE | PRIMARY ADVANTAGE |
| Aggregate | Al2O3 (70% to 90%) | Bauxite, Tabular Alumina, Mullite | High refractoriness, chemical resistance to acidic slags |
| Binder | Chemical Bond | Phosphate / Colloidal Silica | Fast, reliable setting and high adherence to the existing lining |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Chemical Compatibility | EXCELLENT | Neutral or acidic composition ensures stability against acidic slags and prevents fluxing of the Al2O3/SiO2 lining. |
| Adhesion | VERY GOOD | Chemical bonds are formulated to achieve a tenacious, fast-setting patch on the hot substrate. |
| Application Method | Gunning (Dry or Wet) | Allows for quick, remote, large-volume repairs with good density and minimal dust. |
| Refractoriness Under Load (RUL) | HIGH | High Al2O3 content maintains structural stability at peak operating temperatures. |
Advantages and Key Characteristics
Non-Basic Gunning Mixes are essential for industrial operations where refractory downtime must be minimized, offering a fast, monolithic, and chemically compatible repair solution.2
- Rapid Turnaround Time: Applied via gunning, this mix allows for repairs to be performed quickly between operational cycles or during short outages, significantly improving equipment uptime and overall process efficiency.
- Chemical Match: Used exclusively for repairing non-basic (acidic or neutral) linings, the high-alumina or alumina-silicate composition prevents the chemical reaction and degradation that would occur if an incompatible basic mix were used.
- Structural Patching: The mix is formulated to pack densely, creating a low-porosity, high-strength layer that resists chemical infiltration and provides structural integrity to the repaired zone.
- Cost-Effectiveness: Gunning is a flexible and economical maintenance method for patching isolated zones of wear or erosion, extending the campaign life of the lining without requiring a full, expensive reline.
Typical Industries and Applications
This mix is used in various industries where neutral/acidic linings are prevalent:
- Glass Industry: Crowns, checker walls, and forehearth sections of glass melting furnaces.
- Cement & Chemical Industry: Flue gas ducts, incinerator linings, and structural repairs on calcining furnaces.
- Specialty Steel/Foundry: EAF roofs and non-basic ladles/tundishes, as well as coreless induction furnace linings where silica/alumina linings are used.
Furnace Areas and Service Zones
They are specified for high-wear areas in the hot zone:
- EAF ROOF: Areas prone to erosion and thermal shock above the electrodes.
- HOT SPOTS/CORNER WEAR: Localized wear areas in the furnace walls or roofs where flame impingement or turbulence is concentrated.
- GENERAL PATCHING: Used for repairing lining cracks, eroded joints, and minor structural damage in high-alumina or fireclay zones.
Key Data Sheet Properties to Consider
Selection criteria focus on refractoriness, chemical composition, and application properties:
- AL2O3 Content: CRITICAL VALUE. Must be high (> 70%, often 80%) for high refractoriness and chemical stability in most heavy-duty applications.
- Rebound Loss: The percentage of material bouncing off during application (lower is better, typically < 15%$ to 20%).
- Bonding Type: Verify the bond is compatible with the operating temperature and if it is designed for hot (chemical bond) or cold (hydraulic/air set) application.
- Slag Resistance: Must show good resistance to the specific acidic or neutral slag expected in the application.
Technical Guidance: Due to the risk of chemical attack, ensure the gunning mix used is chemically compatible with the base refractory lining and the operating slag. Non-basic mixes should never be used in a highly basic (Magnesia/Dolomite) furnace environment as this will lead to immediate fluxing and failure of the repair.
✨ 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. |
