High Alumina Cement (CAC) Mortar
Main Chemical Compositions & Categories
CAC Mortar consists of a refractory aggregate (e.g., fine-ground chamotte, calcined fireclay, or bauxite) and Calcium Aluminate Cement (CAC) as the binder. The high Al2O3 content of the cement itself contributes to the overall refractoriness.
| COMPONENT | CONTENT | CHEMICAL BASE | PRIMARY ADVANTAGE |
| Binder | 20% to 40% | High Alumina Cement (CA / CA2) | Fast hydraulic set, initial strength development |
| Aggregate | 60% to 80% | Alumina-Silicate fines | Refractoriness, volume stability, and workability |
| VARIANT | Al2O3 Content | MAXIMUM SERVICE TEMPERATURE (MST) |
| Medium Duty | 45% to 55% | 1400°C to 1550°C |
| High Duty | 60% to 75% | 1600°C to 1700°C |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Setting Mechanism | HYDRAULIC | Sets chemically by reaction with water at ambient temperatures, unlike ceramic bonds. |
| Ambient Strength | HIGH | Achieves sufficient Cold Crushing Strength (CCS) quickly, allowing for fast lining completion. |
| Hot Volume Stability | GOOD | High Al2O3 ensures the fired bond is refractory and resistant to creep. |
| Shelf Life | LIMITED | Susceptible to aging and degradation by moisture, requiring careful storage and inventory control. |
Advantages and Key Characteristics
CAC Mortar is chosen when speed, initial strength, and water-based application are critical, making it a versatile tool for both bricklaying and quick structural repairs.
- Fast and Reliable Hydraulic Setting: Unlike air-setting or heat-setting mortars that require high temperature or air exposure to develop strength, CAC mortar develops high initial strength rapidly (often within hours) just by adding water. This speeds up construction and allows the lining to be put into service faster.
- Good All-Around Refractoriness: The high Al2O3 content in the cement contributes to a highly refractory bond once fired, making the mortar suitable for higher temperature zones than traditional Portland cement mortars.
- Structural Integrity: The high ambient strength allows the mortar to bear the weight of the overlying brickwork immediately after setting, which is a major advantage in tall furnace structures.
- Versatile Use: Used not only for joining brick but also for small patching and trowel-on repairs of refractory surfaces.
Typical Industries and Applications
This mortar is a standard joining compound across various high-temperature industries:
- General Refractory Bricklaying: Used for joining fireclay, high-alumina, and Mullite refractory bricks in zones not subjected to extreme slag attack.
- Structural Repairs: Small-scale patching and trowel repairs on general furnace walls, hearths, and flue linings.
- Kiln Car Construction: Used for joining the top layer bricks on kiln cars where a fast, strong ambient bond is critical before firing.
Furnace Areas and Service Zones
They are specified for structural and general lining joints:
- BRICK JOINTS: The gap between adjacent bricks in the working lining and backup layers.
- PATCHING: Filling small cracks, holes, and localized wear spots on castable or brick linings.
- FOUNDATIONS: Used for setting the first courses of brick on the furnace base.
Key Data Sheet Properties to Consider
Selection criteria focus on setting behavior and refractoriness:
- Al2O3 Content: CRITICAL VALUE. Check the overall Al2O3 content of the final mixed mortar (typically 45% to 75%).
- Maximum Service Temperature (MST): Must be confirmed; CAC Mortar is limited by the refractoriness of the cement phase, often 1400°C to 1700°C.
- Water Requirement and Workability: Must be controllable to ensure the mortar is not too thick (poor joint fill) or too thin (sagging).
- Shelf Life: CRITICAL NOTE. CAC is sensitive to moisture and must be used well before its expiration date to guarantee the hydraulic set.
Technical Guidance: CAC Mortar requires a controlled initial heat-up/dry-out schedule after the hydraulic set is complete. The removal of chemically bound water at 100°C to 300°C is necessary to avoid steam spalling. It is essential to use a thin, uniform joint to minimize the amount of lower-refractory cement in the total lining.
✨ 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. |
