Self-Flow Castable (SFC)
Main Chemical Compositions & Categories
SFCs are premium LCC or Ultra Low Cement Castable (ULCC) systems, consisting of high-purity aggregate (e.g., Tabular Alumina or Mullite) and a low-content Calcium Aluminate Cement (CAC) binder. The critical components are advanced dispersants or superplasticizers that temporarily deflocculate the fine particles, achieving high fluidity with minimal mixing water.
| COMPONENT | CONTENT | KEY FEATURE | PRIMARY ADVANTAGE |
| Aggregate | 80% to 90% | High-purity refractory grains | High hot strength and refractoriness |
| Binder | CAC (< 2.5% CaO) | Low CaO content | Superior hot strength and creep resistance |
| Dispersants | Polycarboxylate/Naphthalene | Superplasticizing agents | CRITICAL: High fluidity with low water content |
| VARIANT | FLUIDITY/WATER USE | KEY APPLICATION BENEFIT |
| SELF-FLOW (SFC) | Requires minimal water (typically low W/C ratio) | Eliminates vibration, faster installation. |
| SELF-LEVELING (SLC) | Ultra-high flow index | Achieves perfect horizontal surface and fill. |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Installation | NO VIBRATION REQUIRED | Dispersants create a highly fluid suspension that flows easily into complex molds and tight spaces. |
| Density/Porosity | VERY HIGH DENSITY | Minimal mixing water and flow packing achieve maximum particle density and minimal apparent porosity (AP). |
| Hot Strength/Creep | EXCELLENT | Inherits the superior hot strength and creep resistance of its LCC/ULCC base formulation. |
| Surface Finish | SMOOTH | Self-leveling action eliminates air pockets and vibration marks, yielding a near-perfect surface. |
Advantages and Key Characteristics
SFCs are premium castables designed for applications where difficult access, complex geometry, a superior surface, and maximized density are critical performance requirements.
- Elimination of Vibration (No-Vib): This is the core advantage. By removing the need for mechanical vibration, the installation process is simplified, labor costs are reduced, noise pollution is eliminated, and the risk of worker-induced defects (like segregation or excessive fines buildup) is minimized.
- Superior Fill and Density: SFCs can flow and fill intricate molds and tight areas where vibration is impractical or impossible (e.g., deep under-cuts or narrow anchor gaps). The dense, homogeneous packing results in very low porosity, greatly enhancing resistance to slag and molten metal penetration.
- Reduced Permeability and Improved Corrosion Resistance: The low porosity and high packing density translate into low permeability, making the final lining highly resistant to the infiltration and destructive chemical attack by aggressive liquids and gases.
- Improved Hot Strength Reliability: As a specialized LCC, SFCs combine the benefits of low CaO content (suppressed liquid phase) with superior installation quality, ensuring maximum RUL and minimal creep in service.
Typical Industries and Applications
SFCs are used for high-value, critical installations across various industries:
- Ferrous Industry (Steel): Ladle bottoms and safety linings, runners and trenches with complex curves, and pre-cast blocks where high precision is required.
- Non-Ferrous Industry: Aluminum melting furnace bottoms and critical tap-hole areas where superior density is needed to prevent metal penetration.
- Boilers & Power Generation: Burner tile systems and cyclone bottoms that have complex geometries and require a perfect surface for aerodynamic flow.
Furnace Areas and Service Zones
They are specified for structural, high-density, and hard-to-access areas:
- MONOLITHIC FLOORS/BOTTOMS: Used where the castable needs to level itself to form a perfect horizontal plane.
- COMPLEX PRECAST SHAPES: Used to create highly precise, dense components (e.g., baffles, flow control devices).
- TIGHT REPAIR ZONES: Used to fill narrow gaps or areas with high rebar/anchor density.
Key Data Sheet Properties to Consider
Selection criteria focus on fluidity and hot strength:
- Flow Value (Self-Flow Index): CRITICAL VALUE. Measured by a standard test (e.g., using a flow table) to confirm the material’s ability to flow and level (> 100% spread is common).
- CaO Content: Must be in the LCC or ULCC range (< 2.5%) to ensure high hot strength.
- Bulk Density (BD) and Apparent Porosity (AP): BD should be maximized and AP minimized (< 15%) to confirm the effectiveness of the self-flow process.
- Hot Modulus of Rupture (HMOR): Required to confirm mechanical strength at service temperatures.
Technical Guidance: Due to the sensitivity of the dispersants, the mixing water content is extremely critical and must be controlled within a very narrow range. The casting time (time window for pouring) can be short. As with all dense LCC formulations, a very strict, slow, and monitored dry-out and heat-up schedule is mandatory to prevent steam spalling.
✨ 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. |
