Vermiculite Granules
Vermiculite Granules are the highly porous, lightweight material produced by heating raw vermiculite ore to high temperatures (exfoliation). Vermiculite is a naturally occurring hydrated magnesium-aluminum-iron silicate mineral that dramatically expands (or exfoliates) upon heating, resulting in accordion-like, golden-brown, lightweight granules. This material is used as a loose-fill, high-temperature insulation, a lightweight aggregate in refractories and mortars, and a medium for fire protection.
Main Components and Structure
The lightweight and insulating nature comes from the internal structure created by the rapid removal of chemically bonded water during exfoliation.
| COMPONENT | COMPOSITION | PRIMARY ADVANTAGE |
| Exfoliated Granules | Hydrated Magnesium-Aluminum-Iron Silicate | Highly porous, lightweight structure with low density. |
| Form | Loose, free-flowing, granular aggregate | Ideal for filling irregular voids and use in pumpable/castable mixes. |
| CLASSIFICATION | MAXIMUM SERVICE T | PRIMARY USE |
| Industrial Grade | ~1100°C (2012 F) | Loose-fill insulation and refractory aggregate. |
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Bulk Density | VERY LOW | Reduces the weight of refractory castables and mortars. |
| Thermal Conductivity (k) | LOW | High volume of trapped air within the structure provides good insulation. |
| Fire Resistance | EXCELLENT | Non-combustible; does not shrink or degrade up to its MST. |
| Flowability | HIGH | Easily poured or blown into irregular or inaccessible cavities. |
Advantages and Key Characteristics
Vermiculite Granules are the choice material for cost-effective, high-temperature insulation and for formulating lightweight refractory materials.
- Loose-Fill Insulation: Its free-flowing nature allows it to be poured or blown into furnace cavities, ovens, or between double-walled chimneys, creating a seamless, uniform thermal barrier in areas where rigid or blanket insulation is impractical.
- Lightweight Refractory Aggregate: When mixed with cement or other binders, vermiculite granules produce insulating concrete or mortars that are significantly lighter than conventional dense refractories. These vermiculite-based mixes are used for insulating furnace backup layers, oven linings, and chimney renders.
- Fire Protection: Due to its non-combustible nature and high MST, loose vermiculite is widely used as a fire-resistant fill and packing material in fire-stopping assemblies.
- Chemical Inertness: Vermiculite is generally stable and resistant to most mild acids and alkalis, enhancing the durability of the refractory mixes it is used in.
Typical Industries and Applications
Vermiculite Granules are used in various thermal, refractory, and fire protection contexts:
- Chimneys and Flues: Poured down the cavity between the metal liner and masonry stack as a high-temperature insulating fire stop.
- Furnace and Oven Construction: Used as lightweight backup insulation fill in the walls, hearth, and arch of industrial kilns and high-temperature ovens.
- Refractory Mixes: Used as an aggregate in pre-mixed insulating castables and gunning mixes.
- Horticulture (Supplementary Use): Used in potting mixes to aerate soil and retain moisture (though this is a non-refractory application).
Key Data Sheet Properties to Consider
Selection is typically based on grade and particle size:
- Maximum Service Temperature (MST): CRITICAL VALUE. Standard industrial grades are rated to 1100°C.
- Particle Size (Grade): Available in various grades (e.g., fine, medium, coarse). Finer grades are used for dense packing or refractory mortars; coarser grades are used for loose-fill insulation where maximum air void volume is desired.
- Bulk Density: This low value (e.g., 100-160 kg/m3) determines the final weight of the insulating mix or the structural load of the loose fill.
Technical Guidance: When mixing vermiculite granules with cement to form insulating concrete, the ratio of water to cement is critical to ensure the granules remain intact and the mix is properly cured.
✨ 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. |
