Ultra Low Cement Castable (ULCC)
Main Chemical Compositions & Categories
ULCCs are composed of the highest-purity aggregate (e.g., Tabular Alumina, White Fused Alumina, or high-grade Mullite) and an advanced, minimalist binding system. The extreme reduction in CAC binder is balanced by incorporating large amounts of highly active ultra-fine reactive powders (fumed SiO2 and/or reactive Al2O3) and high-performance dispersants to maintain fluidity and achieve maximum packing density.
| COMPONENT | CONTENT | KEY FEATURE | PRIMARY ADVANTAGE |
| Aggregate | 85% to 99% | Highest purity refractory grains | Maximum refractoriness and wear resistance |
| CAC Binder | < 1.0 CaO | Minimum Lime Content | CRITICAL: Virtually no low-melting liquid phases |
| Reactive Fines | Ultra-fine SiO2/Al2O3 | Promotes dispersion and densification | Superior final strength and low porosity |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Hot Strength/Creep | MAXIMUM | Near-zero CaO means negligible formation of detrimental glassy phases, providing brick-like performance under load. |
| Refractoriness (RUL) | HIGHEST | Maintains structural integrity up to 1800°C depending on the aggregate type. |
| Density/Porosity | MAXIMUM DENSITY | Ultra-fine particle packing and minimal mixing water achieve very low apparent porosity (AP). |
| Chemical Resistance | SUPERIOR | High purity and low porosity provide excellent resistance to penetration and chemical attack. |
Advantages and Key Characteristics
ULCC technology is used for the most severe, high-stress applications, providing a performance level comparable to ZCC (Zero-Cement Castables) but with the benefit of an initial hydraulic set.
- Near-Elimination of Creep: The primary function of ULCC. By reducing the CaO content to trace amounts, the formation of the CaO–Al2O3–SiO2 glassy phase, which is the main cause of high-temperature deformation (creep), is essentially eliminated. This allows the ULCC lining to maintain its structural dimensions under the highest thermal and physical loads.
- Maximum Purity and Stability: The low flux content makes ULCC highly resistant to chemical attack by acidic and neutral slags, as well as molten aluminum and other non-ferrous metals. The purity makes it ideal for applications sensitive to contamination.
- Superior Abrasion Resistance: The high packing density and use of the hardest aggregates (like Tabular or Fused Alumina) result in exceptional resistance to erosion and mechanical wear.
- Monolithic Reliability: ULCC allows users to replace complex, expensive high-performance brick shapes with a seamless, monolithic lining that offers comparable, and often superior, performance and longevity.
Typical Industries and Applications
ULCCs are reserved for the most critical, highest-temperature zones in industrial furnaces:
- Ferrous Industry (Steel): Critical load-bearing zones, ladle bottoms and safety linings, runners, and high-heat EAF/Ladle Furnace hot spots.
- Non-Ferrous Industry: Continuous casting funnels, high-wear launders, and refractory contact zones in primary aluminum smelting.
- Petrochemical & Chemical: Linings in severe service FCC (Fluid Catalytic Cracking) regenerators and high-temperature gasifiers.
Furnace Areas and Service Zones
They are specified for structural, high-wear, and maximum heat zones:
- HOT-FACE WORKING LINING: Used where service temperature and load are at their limits.
- TAP-HOLE AND RUNNERS: Areas exposed to high-velocity molten metal and severe thermal shock.
- STRUCTURAL SUPPORTS: Load-bearing piers and sections where dimensional stability is non-negotiable.
Key Data Sheet Properties to Consider
Selection criteria focus intensely on chemical and high-temperature mechanical properties:
- CaO Content: CRITICAL VALUE. Must be verified as < 1.0% to classify as ULCC.
- Creep in Compression (CISC): CRITICAL VALUE. Must demonstrate an extremely low creep rate at the peak service temperature (e.g., 1550°C to 1650°C).
- Cold Crushing Strength (CCS): Should be exceptionally high, often > 100 MPa, confirming maximum density.
- Mixing Water: Typically requires very low and precise water content, which is essential for maximizing density and flow (often achieved via Self-Flow technology).
Technical Guidance: ULCCs are highly specialized and sensitive materials. The mixing procedure must be exact, as the dispersants are sensitive to the mixing time and water amount. Crucially, due to their very high density and low permeability, ULCCs have the most stringent and slow dry-out and heat-up schedule of any castable. Failure to follow this schedule precisely is the leading cause of catastrophic spalling failure.
✨ 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. |
