Steel Fiber Reinforced Castable
Main Chemical Compositions & Categories
SFRC is a composite material. The matrix is a standard refractory castable formulation (e.g., 60% AL2O3 or LCC 85% Al2O3) to which 300-series or 400-series stainless steel fibers are added, typically composing 1% to 5% of the castable’s weight.
| COMPONENT | CONTENT | KEY FEATURE | PRIMARY ADVANTAGE |
| Matrix | High Alumina, Mullite, etc. | Refractoriness | Determines Tmax and chemical resistance |
| Steel Fibers | 1% to 5% by weight | Stainless Steel (SS 304/310) | CRITICAL: Bridges cracks, improves post-cracking strength |
| FIBER TYPE | SS Alloy (Example) | Tmax Limit | KEY APPLICATION NOTE |
| Standard | SS 304/316 (Ni/Cr) | ~1250°C | For moderate temperatures and good oxidation resistance |
| High-Temp | SS 310 (High Ni/Cr) | ~1400°C | For higher temperatures where oxidation is severe |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Flexural Strength | SIGNIFICANTLY INCREASED | Fibers bridge micro-cracks, dramatically increasing resistance to bending (Modulus of Rupture). |
| Thermal Shock/Spalling | EXCELLENT | Fibers absorb and distribute thermal stresses, preventing micro-cracks from propagating into catastrophic failures. |
| Impact Resistance | HIGH | Provides toughness and ductility, resisting damage from mechanical impact or rough handling. |
| Abrasion Resistance | IMPROVED | The cohesive, dense matrix resists surface erosion better than non-reinforced material. |
Advantages and Key Characteristics
The addition of steel fibers transforms the brittle nature of refractory ceramics into a tougher, more ductile material, significantly enhancing the life and reliability of the lining, especially in demanding structural and thermal environments.
- Enhanced Spalling Resistance: This is the primary benefit. During thermal cycling, temperature gradients create stress that leads to micro-cracks. The steel fibers act as internal anchors, holding the matrix together, preventing these micro-cracks from linking up into large, failure-inducing cracks.
- Increased Post-Cracking Strength (Toughness): Unlike brittle unreinforced castable, which fails completely when the maximum bending stress is exceeded, SFRC maintains a substantial portion of its load-bearing capacity even after cracking, often allowing the lining to continue functioning until a scheduled shutdown.
- Improved Abrasion/Erosion Resistance: By increasing the cohesion and density of the castable surface, the fibers help the lining resist erosion from high-velocity particles and mechanical scouring.
- Control of Shrinkage: The fibers restrict the initial shrinkage that occurs during the drying and firing process, resulting in a lining with better volume stability and fewer large shrinkage cracks.
Typical Industries and Applications
SFRC is used in high-wear, high-impact, and thermally stressed environments:
- Ferrous Industry (Steel): Ladle lips and slag zones (high impact/thermal shock), Electric Arc Furnace (EAF) roofs, coke oven charging hole sleeves, and high-wear reheating furnace hearths.
- Cement & Chemical Industry: Kiln discharge areas, pre-heater cone tips, and incinerator floors where high abrasion and thermal cycling are common.
- General Furnace Linings: Any lining requiring higher mechanical integrity, such as large monolithic sections and door linings.
Furnace Areas and Service Zones
They are specified for critical, exposed, and structural areas:
- IMPACT ZONES: Areas where raw material or slag is poured or dropped onto the refractory surface.
- LADLE RIMS: Used to resist mechanical damage from charging and scraping.
- MONOLITHIC ROOFS: Used to provide structural integrity and prevent large-scale cracking and collapse.
Key Data Sheet Properties to Consider
Selection criteria focus on the fiber properties and the mechanical enhancement:
- Fiber Material: CRITICAL VALUE. Must verify the grade of stainless steel (SS 310 is required for maximum temperatures > 1250°C) to prevent premature oxidation and failure of the fiber.
- Fiber Loading: Typically 1% to 5%$ by weight. Higher loading increases strength but also cost and can complicate mixing.
- Residual Cold Crushing Strength (CCS): Look for data showing the material’s CCS after thermal cycling to confirm durability.
- Modulus of Rupture (MOR) / Toughness Index: The flexural strength and post-cracking performance are the best indicators of the fiber’s benefit.
Technical Guidance: The maximum operating temperature of the SFRC is often dictated by the oxidation limit of the steel fiber, not the refractory matrix. For example, using SS 304 in a 1400°C furnace will lead to rapid fiber oxidation, loss of reinforcement, and potential FeO fluxing. The fibers must be thoroughly and evenly dispersed during mixing to be effective; balling or clumping will negate the benefits.5
✨ 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. |
