Low Cement Castable (LCC)
Main Chemical Compositions & Categories
LCCs consist of high-purity aggregate (e.g., Alumina, Mullite, Bauxite, or SiC) and a specially formulated, low-content binding system. The reduction in CACĀ is compensated by incorporating ultra-fine reactive powders (SiO2Ā fume or reactive Al2O3) to ensure effective dispersion, mixing, and high final density.
| COMPONENT | CONTENT | KEY FEATURE | PRIMARY ADVANTAGE |
| Aggregate | 70% to 85% | High-purity refractory grains | Refractoriness and wear resistance |
| CAC Binder | 1% to 2.5% CaO | Reduced Lime Content | CRITICAL: Minimizes low-melting liquid phases |
| Reactive Fines | Ultra-fine SiO2/Al2O3 | Promotes dispersion and densification | High strength development at lower T |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Hot Strength/Creep | SUPERIOR | Reduced CaO minimizes fluxing agents that form liquid phases, maximizing the Refractoriness Under Load (RUL) and minimizing creep. |
| Refractoriness (RUL) | VERY HIGH | Allows the castable to maintain structural integrity at higher service temperatures than conventional castables. |
| Abrasion Resistance | EXCELLENT | Dense packing and high final bond strength provide superior resistance to erosion and wear. |
| Water Requirement | LOW | Typically requires a lower water-to-cement ratio than conventional castables. |
Advantages and Key Characteristics
LCC technology represents a major leap in castable performance, allowing refractory users to utilize castables in applications previously reserved for high-performance refractory bricks.
- Enhanced Hot Strength and Creep Resistance: The principal benefit. In traditional castables, the CaO from the cement reacts with Al2O3 and SiO2 to form a glassy, low-viscosity liquid phase at high temperatures. LCC minimizes CaO, thereby suppressing this liquid phase formation, which allows the castable to maintain strength and resist sagging (creep) under load at extreme temperatures.
- Higher Service Temperature: By eliminating the temperature-limiting liquid phase, the refractoriness and maximum service temperature of the castable are significantly increased, often by 100Ā°CĀ or more compared to conventional counterparts.
- Low Porosity and High Density: The use of ultra-fine reactive powders enables dense packing of particles, leading to very low apparent porosity (AP) and high bulk density (BD). This improves resistance to both slag and molten metal penetration.
- Cost-Effective Monolithic Lining: LCCs provide brick-like performance with the installation versatility of a castable (poured, pumped, or gunned), allowing for seamless, joint-free linings that often offer a better service life-to-cost ratio than complex brick shapes.
Typical Industries and Applications
LCCs are used extensively across all high-temperature industries for critical applications:
- Ferrous Industry (Steel): Ladle linings (bottom and impact zones), EAF delta sections, runners, high-wear zones in reheating furnace hearths, and tundish working linings.
- Non-Ferrous Industry: High-wear launders, contact zones in aluminum holding furnaces, and anode baking furnace floors.
- Cement & Chemical Industry: Cyclone separators, kiln burner pipes, and chemical reactor linings where high T and abrasion are factors.
Furnace Areas and Service Zones
They are specified for structural, high-wear, and hot zones:
- LOAD-BEARING ZONES: Areas under compressive stress at maximum operating temperature.
- SLAG/MOLTEN METAL CONTACT: Areas requiring maximum resistance to chemical infiltration.
- CRITICAL THERMAL ZONES: Areas where traditional castables would fail due to excessive hot deformation.
Key Data Sheet Properties to Consider
Selection criteria focus heavily on the chemical purity and hot mechanical properties:
- CaO Content: CRITICAL VALUE. Must be checked to be in the 1% to 2.5% range.
- Creep in Compression (CISC): Must demonstrate a superior, low creep rate at the peak service temperature (e.g., 1500Ā°C).
- Abrasion Resistance Index: High resistance index is preferred for wear zones.
- Water Requirement: Note the mixing water requirement; LCCs typically require very precise, often low, water content for optimal performance.
Technical Guidance: Due to the dense packing and hydraulic nature of the bond, LCCs require a very strict, slow, and monitored dry-out and heat-up schedule.Ā The low permeability makes water removal difficult, and rapid heating can easily cause catastrophic steam spalling. Precise control over mixing water is also critical, as excess water significantly degrades the final performance.
āØ 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.
š¬ 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 materialsāsuch as specific bricks, castables, or raw materialsābefore committing to a full order.
š” 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.
š¦ 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 absorptionāespecially 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 placardingāespecially for any items classified as Dangerous Goodsāto ensure full compliance with international and domestic transport regulations.
ā 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 materialsāfrom Alumina-Silicate Bricks to high-performance Silicon Carbide Bricksāthe 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 materialāsuch as our Refractory Castables or Alumina-Silicate Bricksāin 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. |
