Low Cement Castables

Transcription

SUGGESTED HEATING PROCEDURES
for RESCO LOW, ULTRA-LOW, AND NO CEMENT CASTABLES
The following schedule is recommended for Resco Products' Low, Ultra-Low, and No Cement Castables. Controlled release of water in
the castable is necessary to prevent possible build-up of steam pressure and potential steam spalling. Heating can be done before or
during unit start-up.
The following schedule is recommended FOR SINGLE COMPONENT LININGS UP TO 9” THICK.
1.
At anytime following the initial 24 hour curing period, raise the temperature to 300 oF (149oC).
2.
Hold at 300oF (149oC) for 1½ hours per inch (25 mm) of lining thickness up to a maximum period of 8 hours.
3.
Raise temperature at a rate of 50ºF (28oC) per hour to operating temperature or 1000oF (540oC), whichever is less.
If the operating temperature is above 1000oF (540oC), then heat at a rate of 100ºF (56oC) per hour from 1000oF (540oC) to operating
temperature if the lining is up to 6” thick (152 mm); heat at a rate of 50ºF (28oC) per hour from 1000oF (540oC) to operating temperature if the lining is 6” to 9” thick (152 mm to 229 mm).
If the unit is not going into operation, but will be cooled down, hold at the operating temperature for a minimum period of 1½ hours per
inch (25 mm) of lining thickness up to a maximum period of 8 hours.
The following schedule is recommended FOR SINGLE COMPONENT LININGS OVER 9” THICK.
1.
At anytime following the initial 24 hour curing period, raise the temperature to 300 oF (149oC) at a rate of 50ºF (28oC) per hour.
2.
Hold at 300oF (149oC) for one hour per inch (25 mm) of lining thickness.
3.
Raise temperature at a rate of 50ºF (28oC) per hour to 450oF (232oC).
4.
Hold at 450oF (232oC) for one hour per inch of lining thickness.
5.
Heat at a rate of 25ºF (14oC) per hour to 600oF (315oC).
6.
7.
Heat at a rate of 50ºF (28oC) per hour to 1000oF (540oC).
8.
If the unit is not going into operation, but will be cooled down, hold at the operating temperature for a minimum period of 1½ hours per
inch (25 mm) of lining thickness up to a maximum period of 8 hours.
NOTES:
If, for any reason, the heating schedule is interrupted by a loss of heat and/or power into the unit, Resco Products recommends
that the heating schedule be initiated from the beginning once power and/or heat is restored. At the end user or contractor’s
discretion, they may elect to attempt to restart the cycle and “stabilize” the lining temperature at the point of interruption. After the lining has been stabilized, the heat up cycle may be resumed as scheduled from that point on. Resco assumes no
liability for this procedure, as it is difficult to determine that point at which the entire lining is stable to prevent the possibility of
a steam spall.
Temperatures shown are measured at the hot face of the lining for in place heating.
Allow the lining to cool down naturally; do not exceed 100ºF (56oC) per hour.
The dry out of refractory entails more than just following a heating schedule. Issues such as burner sizing and location, exhaust
location, air volume and velocity, etc need to be addressed. Resco recommends that an experienced dry out company be
consulted.
Temperatures should be monitored at the refractory surface at several locations in the unit.
If steaming is observed at any time during the schedule, the temperature should be held constant until the steaming subsides.
The schedule can resume when steaming ends.
This schedule is recommended for situations where proper heating equipment and air circulation are used, weep holes
are present and unclogged, and the ambient temperature ranges from 60 o to 90oF. If all of these parameters are not
met, a more conservative dry out schedule is needed. Consult your Resco Products, Inc salesman, the RESCO website
(www.rescoproducts.com), or call 888.283.5505.
Kricon
EZ Cast
EZ Cubed
Vibrocast
Vibrocast PC
Permacon
ProCast
Vibrocast EZ
Furnacubed
Kricon
EZ Cast
EZ Cubed
Vibrocast
Vibrocast PC
Permacon
ProCast
Vibrocast EZ
Low Cement
Castables
Page 15
Page 2
INDEX
Brand
Page
Brand
®
®
Page
EZ CAST 3000 .........................................
15
KRICON 28 ......................................... 14
®
®
EZ CAST 3200 .........................................
15
KRICON 30 ......................................... 14
®
®
EZ CAST 3250 .........................................
15
KRICON 32 ......................................... 14
®
®
EZ CAST 3400 .........................................
15
KRICON 32-70........................................14
®
®
EZ CAST 3400-SP .........................................
12
KRICON 34.............................................14
3®
®
EZ 34 ZLC .........................................
8-9
KRICON 34-10.............................................
12
3®
®
EZ 70PC .........................................
8-9
PERMACON 95 .........................................
13
3®
®
EZ 75PC .........................................
8-9
ProCAST 80 ......................................... 13
3®
®
EZ 80PC .........................................
8-9
VIBROCAST 2800 .........................................
3
3®
®
EZ AZS .........................................
8-9
VIBROCAST 3000 .........................................
3
3®
®
EZ 20-60 .........................................
10
VIBROCAST 50 .........................................
3
3®
®
EZ 3000 .............................................
8-9
VIBROCAST 50 PC .........................................
3
3®
®
EZ 3200 .........................................
8-9
VIBROCAST 56SC .........................................
10
3®
®
EZ 3200 .........................................
8-9
VIBROCAST 56SCHP .........................................
10
3®
®
EZ 60 LQY .........................................
8-9
VIBROCAST 60 .........................................
3
3®
®
EZ 60-M ............................................
8-9
VIBROCAST 60 PC .........................................
3
3®
®
EZ 80-15............................................
11
VIBROCAST 70 .........................................
4
3®
®
EZ 85............................................
8-9
VIBROCAST 70M .........................................
4
3®
®
EZ FS-6LC...............................................
5
VIBROCAST 75 .........................................
4
3®
®
EZ FS-6PC...............................................
5
VIBROCAST 80SC .........................................
11
3
®
FURNA ™ 65 .........................................
7
VIBROCAST 80SCHP .........................................
11
3
®
FURNA ™ 70 .........................................
7
VIBROCAST 85 .........................................
4
3
®
FURNA ™ 75 .........................................
7
VIBROCAST 85ULM .........................................
12
3
®
FURNA ™ 85 .........................................
7
VIBROCAST 87 AS .........................................
4
3
®
FURNA ™ FS .........................................
5
VIBROCAST ASC-7LTPC .........................................
12
®
FURNACON™ 3000 .........................................
6
VIBROCAST ASC-8LT(C-C) .........................................
12
®
FURNACON™ 50W .........................................
6
VIBROCAST EZ 3250 .........................................
13
®
FURNACON™ 70W. .........................................
6
VIBROCAST EZ 80 .........................................
13
®
FURNACON™ 70W. .........................................
6
VIBROCAST FS-6 .........................................
5
FURNACON™ 95 .........................................
6
Resco Products, Inc
Phone: 888.283.5505
Penn Center West
Phone: 412.494.4491
Building 2, Suite 430
Fax:
Pittsburgh, PA 15276
www.rescoproducts.com
412.294.1080
EZ CAST® 3000 is
EZ CAST 3000 EZ CAST 3000 EZ CAST 3200 EZ CAST 3200
a self-flowing, low
Self Level
Vib Cast
Self Level
Vib Cast
iron, 56% alumina,
o
F
Maximum Service Temp.
3000
3000
3200
3200
low cement castaTypical Water Required
ble designed to
%
5.5-6.8
4-5.5
5.5-6.5
4.0-5.0
for Mixing
provide high
Bulk Density
lb/Ft3, 1500oF 147 to 151
153 to 157
164 to 170
170 to 174
strength and good
2
o
thermal shock and Cold Crushing Strength lb/in , 1500 F 4000 to 8000 11000 to 15000 5000 to 9000
10000 to
abrasion reModulus of Rupture
lb/in2, 1500oF 1000 to 1600 1400 to 2200 1100 to 1500 1700 to 2200
sistance. It offers
Apparent Porosity
%
13-17
10-14
15-17
11-14
good slag rePermanent Linear
%, 1500oF
-0.4 to 0
-0.2 to 0.2
-0.2 to 0
-0.4 to 0
sistance for severe
Change
applications up to
Al2O3
56.0
56.0
76.2
76.2
3000°F. In the laSiO2
38.4
38.4
19.2
19.2
boratory, this prodFe2O3
1.0
1.0
0.9
0.9
uct has shown exChemical Analysis, %
TiO2
1.8
1.8
2.1
2.1
cellent resistance
CaO
1.3
1.3
1.2
1.2
to CO atmosMgO
0.0
0.4
0.0
0.0
pheres found in
Alkalies
1.1
1.1
0.2
0.2
coke ovens and
®
blast furnaces. Large volumes of
EZ CAST 3200 is a self-flowing, resistance. In laboratory testing
this castable have been used suc- 76% alumina low cement castable this product has shown excellent
cessfully in a wide variety of appli- designed to provide longer service resistance to CO atmospheres
cations. This product can be
life and superior performance in
found in coke ovens and blast furpumped.
steel applications with temperanaces. This product can be
tures up to 3200°F. It also has out- pumped.
standing strength and abrasion
EZ CAST® 3250 is a low cement EZ CAST® 3400 is a self-flowing, thermal shock resistance. This
castable with an alumina content 99% alumina, low cement casta- product is not recommended for
of 78%. It has excellent abrasion ble for applications up to 3400°F. pumping, but it can be installed
resistance and superior hot
It has low porosity and low perwith or without vibration.
strength to as high as 2700ºF.
meability without a sacrifice in
These properties combined
EZ CAST 3250 EZ CAST 3250 EZ CAST 3400
with excellent thermal shock
Self Level
Vib Cast
Self Level
resistance have resulted in
o
F
many successful installations Maximum Service Temp.
3250
3250
3400
in bottoms and lip rings of
Typical Water Required
%
5.0-6.5
3.5-4.5
4.8-5.3
for Mixing
steel ladles. This proven prodBulk Density
lb/Ft3, 1500oF 165 to 171
uct has been successfully
169 to 173
187 to 191
used in a wide variety of appli- Cold Crushing Strength lb/in2, 1500oF 6900 to 12900 15000 to 20000 2000 to 4000
cations, often substituted for
Modulus of Rupture
lb/in2, 1500oF 1300 to 2300 1900 to 2900
700 to 1100
higher alumina content prodApparent Porosity
%
15-19
11-14
--ucts, making it a highly costPermanent Linear
%, 1500oF
-0.4 to 0.2
-0.6 to -0.2
-0.2 to 0.0
effective and versatile compoChange
sition. Its combination of
Al2O3
77.7
77.7
98.7
strength, toughness, alumina
SiO2
18.2
18.2
tr
content, and other composiFe2O3
0.8
0.8
tr
Chemical Analysis, %
tional features make it an exTiO2
1.7
1.7
tr
cellent product for many appliCaO
1.2
1.2
1.1
cations.
Alkalies
0.2
0.2
0.1
Page 14
Page 3
Maximum Service
Temp.
o
F
KRICON 28
KRICON 30
KRICON 32
KRICON 32-70 KRICON 34
Vib Cast
Vib Cast
Vib Cast
Vib Cast
Vib Cast
2800
3000
3200
3200
3400
Typical Water Required for Mixing
%
4.5-5.5
4.5-6.0
4.5-5.5
4.5-6.0
4.6-5.2
Bulk Density
lb/Ft3, 1500oF
140 to 146
143 to 150
157 to 163
170 to 174
190 to 194
Cold Crushing
Strength
Modulus of Rupture
Apparent Porosity
Permanent Linear
Change
lb/in2, 1500oF 4800 to 10800 6700 to 12700 4900 to 10900
8000 to 16000 6000 to 9000
lb/in2, 1500oF 1500 to 2500 1100 to 2100
1400 to 2200 1500 to 1800
%
1700 to 2700
8-12
10-14
11-15
16-18
14-16
%, 1500 F
-0.6 to 0.1
-0.5 to 0.1
0 to -0.1
-0.3 to -0.1
-0.1 to 0
Al2O3
45.2
46.5
63.4
77.0
98.7
SiO2
48.4
45.4
31.7
18.2
0.1
Fe2O3
1.2
1.2
1.1
1.0
0.1
TiO2
CaO
MgO
Alkalies
1.8
1.4
0.3
1.6
1.9
1.2
0.3
0.7
2.2
1.2
0.2
0.2
2.2
1.2
0.2
0.2
Tr
1.0
Tr
0.1
o
KRICON® 28 is a good general purpose, 45% alumina, low iron, low cement castable for service temperatures up to 2800°F. It should be installed using vibration casting methods.
KRICON® 30 is a low iron, 46% alumina castable with good
slag resistance up to 3000°F, and is installed using vibration
casting methods.
KRICON® 32 is a low cement 60% alumina castable that is
designed for service temperatures up to 3200°F. It has low
iron content with excellent hot strengths and is installed using
vibration casting methods.
KRICON® 32-70 is a very popular 77% alumina, low iron
castable with a 3200°F temperature limit. It offers improved slag resistance and positive reheat
expansion at steel making temperatures to insure tight, crack-free linings in cast ladles and tundishes. This castable should be installed using vibration casting methods.
KRICON® 34 is designed for service temperatures up to 3400°F. It is a high purity alumina, low
cement castable featuring low porosity and low permeability while maintaining good thermal
shock resistance. This mix is very pure at 99% alumina with a very low content of total impurities, and is installed using vibration casting methods.
Data and descriptions for QuikTurn and R-Max low cement Castables can be found in RESCO’s QuikTurn and R-Max brochures
VIBROCAST® 2800 is an economical 2800 o F low-cement vibratable castable designed to yield
high fired strengths at maximum density with low porosity and linear change. This material will
withstand high temperature corrosion and erosion.
VIBROCAST® 3000 is a 3000oF low-cement vibratable castable which will give high fired strength at
maximum density with minimum porosity and linear change. This material will withstand the severe high
temperature corrosion and erosion that are common in today’s Lime and Cement applications.
VIBROCAST ® 50 is a 3000 o F, low-cement vibratable castable that offers excellent resistance
to alkalies. This product is designed to give minimum porosity and low linear change with maximum density and high fired strengths, and can withstand severe high temperature corrosive
environments.
VIBROCAST ® 50PC is a pumpable, 3000 o F, low-cement castable that offers excellent resistance to alkalies. In addition to being pumpable, VIBROCAST ® 50PC requires substantially
less vibration than standard low cement castables. Light vibration should be used to de -air the
castable. This pumpable castable can also be shotcreted using RESCO’s shotcrete activator.
VIBROCAST® 60 is a 60% alumina, mullite based, 3100oF, low-cement castable which is designed to
give minimum porosity and low linear change with maximum density and high fired strengths. This material will withstand severe high temperature corrosive and erosive and erosive environments and installed using vibration casting methods.
VIBROCAST® 60PC is a 60% alumina, mullite based, pumpable, 3100oF low-cement castable designed to
provide minimum porosity and low linear change with maximum density and high fired strengths. This material will withstand severe high temperature corrosive and erosive environments. This pumpable castable
can also be shotcreted using RESCO’s shotcrete activator.
for Mixing
Bulk Density
Vibrocast
2800
Vib Cast
Vibrocast
3000
Vib Cast
F
2800
3000
3000
3000
3100
3100
%
6.0-6.5
5.3-5.8
5.4-6.0
5.4-6.0
5.0-6.0
6.2-6.7
lb/Ft3, 1500oF
137
4500 to
8000
143
9000 to
11000
148
9000 to
11000
1200 to
1700
15
156
10000 to
14000
2000 to
2400
16
160
10000 to
14000
1400 to
2000
17
o
Vibrocast 50
Vib Cast
Vibrocast
Vibrocast
Vibrocast 60
50PC
60PC
Pump Cast Vib Cast Pump Cast
Modulus of Rupture
lb/in2, 1500oF
---
1200 to 1700
Apparent Porosity
Permanent Linear
Change
%
16
16
145
9000 to
11000
1200 to
1700
16
%, 1500 F
-0.3 to +0.2
---
0 to -0.3
0 to -0.3
0.0 to -0.4
-0.1 to -0.3
Al2O3
40.0
48.9
45.0
45.9
60.8
60.8
SiO2
56.1
46.9
50.9
50.0
34.5
34.5
Fe2O3
0.8
0.9
0.7
0.9
1.0
1.0
TiO2
CaO
Alkalies
1.2
1.7
0.0
1.6
1.5
0.0
1.1
2.0
0.0
1.4
1.5
0.0
1.8
1.6
0.3
1.8
1.6
0.0
Cold Crushing Strength lb/in2, 1500oF
o
Page 13
Page 4
for Mixing
Bulk Density
Vibrocast 70
Vib Cast
Vibrocast 70M
Vib Cast
Vibrocast 75
Vib Cast
Vibrocast 85
Vib Cast
Vibrocast 87
AS
Vib Cast
F
3200
3200
3200
3200
3200
%
5.1-5.6
5.5-6.0
5.8-6.3
4.9-5.4
5.5
lb/Ft3, 1500oF
164
164
168
176
180
o
8500 to 12500
8500 to 12500 10000 to 13000 10000 to 15000
lb/in2, 1500oF
%
2400 to 2800
17
2400 to 2800
17
2700 to 3100
---
1300 to 1800
---
-----
%, 1500oF
---
---
-0.1 to -0.4
---
-0.3 to 0.0
Al2O3
71.5
70.8
79.1
83.0
87.0
SiO2
22.5
23.4
14.4
11.3
7.5
Fe2O3
1.2
1.3
1.4
1.5
1.1
TiO2
CaO
MgO
Alkalies
2.8
1.6
0.0
0.0
2.6
1.5
0.0
0.0
2.9
1.5
0.0
0.0
2.4
1.6
0.0
0.0
3.4
0.8
0.1
0.1
Modulus of Rupture
Apparent Porosity
Permanent Linear
Change
4000 to 8000
VIBROCAST® EZ 80 is a low cement 80% alumina castable that features improved flow characteristics
during casting. This product should be installed using vibration casting methods only.
VIBROCAST® EZ 3250 is a 75% alumina low cement castable that is installed by vibration casting. This
product has been formulated for improved service life in steel ladle applications
ProCAST® 80 is an 84% alumina, ultra-low cement castable. This vibration mix performs well in steel
ladles, EAF deltas, and other applications requiring high strength, good thermal shock resistance, and
good abrasion resistance. This product should be installed by vibration casting.
PERMACON® 95 is an ultra-low cement, 95% alumina castable, designed for severe service conditions
at temperatures up to 3300°F. It offers superior resistance to spalling, cracking, impact, and abrasion;
and greater resistance to chemical attack than low cement or conventional castables. This product
should be installed by vibration casting.
VIBROCAST ® 70 is a low-cement vibratable castable which is designed to give minimum
porosity and linear change with maximum density and super high fired strengths.
VIBROCAST ® 70M is a low-cement vibratable castable which is designed to give minimum porosity and linear change with maximum density and super high fired strengths.
These materials are designed to withstand the severe high temperature corrosion and
erosion in today’s steel applications.
VIBROCAST® 75 is a high alumina, 3200oF service limit, low cement vibratable castable used in
a wide variety of applications including forging furnace floors, heat treating furnace floors, crematory furnace floors, precast burner blocks, gas fired non-ferrous melting furnaces and incineration
chambers.
VIBROCAST 85 is a low-cement, 85% alumina vibratable castable designed to give
minimum porosity and linear change with maximum density and super high fired
strengths. This material will withstand the severe
high temperature corrosion and erosion that are common in today’s Steel appliations.
VIBROCAST® 87 AS is an 87% alumina, ultra-low cement
castable. This product should be installed using vibration
casting methods only. This product has been used to
manufacture precast shapes for steel applications, but can
be used for a variety of different high temperature applications.
Vibrocast EZ
3250
Vib Cast
ProCast 80
Vib Cast
Permacon 95
Vib Cast
F
3200
3250
3200
3300
%
5.0-5.5
4.5-5.0
4.0-6.0
3.0-4.0
lb/Ft3, 1500oF
168
170
182-188
189-195
10000 to 13000
15,000
5800 to
6100 to 12100
lb/in , 1500 F
%
2700 to 3100
---
2,000
---
1100 to 2100
13-17
2100 to 3100
11-15
%, 1500oF
-0.4 to 0.1
-0.4 to 0.0
-0.4 to 0.2
-0.4 to 0.3
Al2O3
79.1
75.7
84.0
94.1
SiO2
14.4
20.2
10.2
4.9
Fe2O3
1.4
0.8
1.2
0.2
TiO2
CaO
MgO
Alkalies
2.9
1.5
0.0
0.0
1.7
1.2
0.2
0.2
3.0
1.1
0.3
0.2
0.2
0.3
0.1
0.2
o
for Mixing
Bulk Density
®
Vibrocast EZ 80
Vib Cast
Modulus of Rupture
Apparent Porosity
Permanent Linear
Change
2
o
Page 5
Page 12
Spinel and Chromia Containing Castables
Fused Silica Castables
®
KRICON 34-10
Vib Cast
o
F
3400
%
3.7-4.7
for Mixing
Bulk Density
lb/Ft3, 1500oF
217 to 221
Cold Crushing Strength lb/in2, 1500oF 9000 to 13000
Modulus of Rupture
lb/in2, 1500oF 2000 to 2400
Apparent Porosity
%
8-12
Permanent Linear
o
%, 1500 F
0 to 0.4
Change
Vibrocast
85ULM
Vib Cast
Vibrocast Vibrocast ASC- EZ CAST 3400
ASC-7LTPC
8LT (C-C)
SP
Pump Cast
Vib Cast
Self Level
3200
3400
3400
3400
5.2-5.7
7.8-8.3
4.5-5.2
4.7-5.7
185
5000 to 8000
--20
180 to 184
5000 to 8500
1350 to 1800
19-23
171
175
6000 to 12000 1500 to 3000
------18
-0.3 to 0.0
---
---
-0.2 to 0.2
Al2O3
88.4
80.7
95.7
94.0
91.1
SiO2
0.1
15.0
0.1
0.2
0.4
Fe2O3
0.1
0.9
0.1
0.0
0.2
TiO2
CaO
MgO
Cr2O3
Alkalies
0.0
1.2
0.0
2.4
0.6
0.0
0.0
1.4
2.3
0.0
1.6
4.0
0.8
1.8
5.6
10.0
0.2
0.0
0.1
0.0
0.0
0.0
0.0
0.0
<0,1
VIBROCAST FS-6 is a fused silica, low cement vibratable castable. VIBROCAST ® FS-6
offers high strength, very good resistance to abrasion, and low reversible thermal expansion, resulting in a highly thermal shock resistant material.
EZ3® FS-6LC is a low cement, self-leveling, fused silica castable that offers high strength,
excellent resistance to abrasion, and low reversible thermal expansion. This product
may be cast or pumpcast.
EZ3® FS-6PC is a pumpable, low cement, fused silica castable that offers high strength,
excellent resistance to abrasion, and low reversible thermal expansion. This product
may be cast or pumpcast.
FURNA3™ FS is a non-wetting, fused silica-based castable for aluminum contact. It has excellent
strength and low porosity with good abrasion resistance. It possesses excellent thermal shock resistance because of a very low reversible coefficient of thermal expansion. The product provides extremely good dross resistance and outstanding resistance to spalling at a reasonably low density.

Jambs & Lintel
– Pechiney – Ravenswood,
WV
• Two 220,000 lb. round
top charge melters.
• One 220,000 lb. tilting
holding furnace.
KRICON® 34-10 is a low cement castable with a 10% chromia content for extremely corrosive environments. The high chromia content can also offer improvement in thermal shock resistance when
compared to high alumina products of similar density.
VIBROCAST ® 85ULM is an ultra low cement castable designed to have maximum slag
and hot metal resistance for use in LMF ladles and related steel -making applications.
®
VIBROCAST ASC-7LTPC is a high purity, low-cement, alumina-spinel castable designed to provide maximum resistance to molten steel and steelmaking slags. VIBROCAST ASC-7LTPC is designed for pumping or shotcreting placement in steel ladles and
related steelmaking applications.
®
VIBROCAST ASC-8LT(C-C) is a high purity, low-cement, alumina-spinel castable designed to provide maximum resistance to molten steel and steelmaking slags.
VIBROCAST ASC-8LT(C-C) is designed for production of cast shapes or monolithic placement in steel ladles and related steelmaking environments and should be installed by vibration casting.
for Mixing
Bulk Density
EZ3 FS-6LC
Vib Cast
EZ3 FS-6PC
Pump Cast
FURNA3 FS
Self Level
FURNA3 FS
Vib Cast
F
2000
2000
2000
2200
2200
%
5.9-6.5
6.3-7.0
6.0-6.5
7.8-8.8
6.8-7.8
lb/Ft3, 1500oF
o
131
136
130 to 134
118 to 122
122 to 126
7000 to 10000
8000 to 11000
8000 to 11000
4000 to 7000
7000 to 10000
lb/in2, 1500oF
%
1300 to 1700
17
1300 to 1700
13
1300 to 1700
13
1000 to 1600
12-14
1200 to 1600
9-11
%, 1500oF
0 to -0.3
0 to -0.2
0 to -0.3
-0.4 to 0
-0.4 to 0
Al2O3
20.2
28.5
22.5
11.0
11.0
SiO2
77.5
69.3
74.9
87.8
87.8
Fe2O3
0.4
0.1
0.3
tr
tr
TiO2
CaO
MgO
Alkalies
0.4
1.6
0.0
0.0
0.1
1.8
Tr
0.2
0.3
1.7
0.1
0.2
tr
1.1
0.0
0.1
tr
1.1
0.0
0.1
Modulus of Rupture
Apparent Porosity
Permanent Linear
Change
EZ CAST® 3400-SP is a tabular alumina-based castable containing magnesium aluminate spinel.
This self-flowing product is a good alternative to chromia-containing materials where slag and corrosion resistance are essential. This product is not recommended for pumping.
Vibrocast FS-6
Vib Cast
Page 6
Page 11
Aluminum Contact Castables
FURNACON FURNACON
FURNACON 70
3000
50 W
Vib Cast
Vib Cast
Vib Cast
for Mixing
Silicon Carbide Containing Castables
FURNACON
70 W
Vib Cast
FURNACON
95
Vib Cast
o
F
3100
2800
3000
3000
3200
%
4-4.8
4.5-6.0
4.0-5.5
4.0-5.5
4.0-5.5
lb/Ft3, 1500oF 197 to 201
143 to 146
167 to 173
167 to 172
189 to 194
Cold Crushing Strength lb/in2, 1500oF 5500 to 9500 7000 to 11000 11000 to 17000 12000 to 16000 15000 to 19000
Modulus of Rupture
lb/in2, 1500oF 1750 to 2150 1500 to 1900 2800 to 3800
2700 to 3900 4000 to 4500
Apparent Porosity
%
--7-13
11-15
10-13
10-13
Permanent Linear
o
%, 1500 F
-0.1 to 0.0
0 to -0.4
-0.4 to +0.2
-0.2 to +0.2
-0.3 to -0.1
Change
VIBROCAST ® 80SC is an 80% SiC castable that uses low cement binder technology. Its
low porosity, excellent abrasion resistance and high heat transfer value make this product an excellent choice for the tube walls in the combustion zones of power generating
units. The high heat transfer characteristic of the SiC reduces surface slagging and alkali build-up, thereby improving the operating efficiency of your unit. VIBROCAST 80SC
is best applied by vibration casting.
Bulk Density
Al2O3
92.8
45.6
72.4
70.9
93.8
SiO2
0.1
47.8
21.6
23.2
5.0
Fe2O3
Tr
1.3
1.0
1.1
Tr
TiO2
CaO
MgO
Alkalies
Tr
1.1
Tr
0.1
1.8
1.5
0.3
1.8
2.1
2.5
0.2
0.2
2.1
2.5
0.1
0.1
Tr
1.1
Tr
0.1
FURNACON™ 3000 is a high purity alumina low cement
castable designed for installation at or above the dross line
of aluminum-melting furnaces. It will resist molten aluminum penetration and reaction after exposure to temperatures as high as 3000°F, such as occur with thermiting of
magnesium containing drosses or overheating of the sidewalls.
FURNACON™ 50W is designed as a low cost refractory
to resist mild alloys. It is cost-effective in metal contact areas and where salt fluxes are used. FURNACON™ 50W is
available only in a winterized version for faster setting at
lower temperatures.
FURNACON™ 70 resists the most aggressive alloys, especially magnesium-containing aluminum alloys. It is a
cost-effective refractory for severe operating conditions. In
addition to its non-wetting properties, it has exceptional
strength and toughness to resist thermal and mechanical
abuse. It is one of the most widely used castables for lower sidewalls and aluminium furnace hearths. A winterized
version, FURNACON™ 70W, is available for fast-setting
at low temperatures.
FURNACON™ 95 resists spalling and cracking from thermal and mechanical abuse. Its high purity, high alumina
base makes it ideally suited for troughs and tapholes.
FURNA3™ 70 is a 74% alumina, non-wetting to aluminum,
low cement castable that can be vibration cast, self-flow
cast, or shotcreted. This product has excellent thermal
shock resistance to 2000ºF. It has been used for preformed blocks in an aluminum furnace and has been shotcreted in aluminum furnace upper and lower walls. Unlike
other FURNA3™ products, this product is recommended
for use only in aluminum furnace applications. Therefore,
its maximum non-metal contact use temperature is
2500ºF.
FURNA3™ 75 is a self-flowing, 76% alumina castable designed for non-wetting applications up to 2200°F. It can be
used for other applications up to 3000°F where increased
strength and abrasion resistance are needed.
FURNA3™ 65 is a self-flowing, 64% alumina castable designed for non-wetting applications up to 2200°F. It can be
used for other applications up to 3000°F where increased
strength and abrasion resistance are needed.
FURNA3™ 85 is an 85% alumina, non-wetting to aluminum, low cement castable designed to replace 85% alumina brick in aluminum furnaces. This product has exceptional strength and abrasion resistance particularly at
1500°F. It is also very strong and thermal shock resistant
at 1500ºF. It can be placed by vibration casting, self-flow
casting, or shotcreting. Its high strength and toughness
after shotcreting are ideal for aluminum furnace maintenance gunning or as an easy-to-install initial working lining.
VIBROCAST ® 80SCHP is an 80% SiC refractory material that uses low cement binder
technology. Its low porosity, excellent abrasion resistance and high heat transfer value
make this product an excellent choice for the tube walls in the combustion zones of power generating units. The high heat transfer characteristic of the SiC reduces surface
slagging and alkali build-up, thereby improving
the operating efficiency of your unit.
VIBROCAST ® 80SCHP is best applied by hand
packing.
EZ3® 80-15 is a corrosion resistant 75% alumina
castable, nominally containing 17% silicon carbide,
that can be poured as a self-leveling mix, pumped,
shotcreted, or vibrated. It is an ultra-low cement mix
developing excellent green and dry strengths. It offers high hot strength and excellent thermal shock
resistance.
Vibrocast 80SC Vibrocast 80SCHP
Vib Cast
Hand Pack
for Mixing
Bulk Density
o
EZ3 80-15
Shotcrete
EZ3 80-15
Vib Cast
F
2800
2800
3100
3100
3100
%
4.5-5.1
5.9-6.3
5.5-6.0
4.5-5.0
3.5-4.5
178 to 182
182 to 186
lb/Ft3, 1500oF
155 to 160
Modulus of Rupture
lb/in2, 1500oF 2300 to 3300
Apparent Porosity
%
--Permanent Linear
o
%, 1500 F
-0.1 to -0.4
Change
EZ3 80-15
Self Level
160 to 165
182 to 186
14000 to 18000
6000 to 10000 8000 to 13000
12000 to 17000
5000 to 6000
---
1500 to 2000 20000 to 2500
15-19
14-18
2500 to 3000
13-17
-0.1 to -0.3
-0.3 to 0.1
-0.3 to 0.1
-0.3 to 0.1
Al2O3
8.7
11.3
75.5
75.5
75.5
SiO2
9.2
7.5
5.0
5.0
5.0
Fe2O3
0.2
0.1
0.3
0.3
0.3
TiO2
CaO
SiC
MgO
Alkalies
tr
2.0
79.8
0.0
0.0
0.0
1.7
79.2
0.1
0.1
1.5
1.2
16.3
0.7
0.1
1.5
1.2
16.3
0.7
0.1
1.5
1.2
16.3
0.7
0.1
Page 10
Page 7
Aluminum Contact Castables
Silicon Carbide Containing Castables
EZ3 20-60
Self Level
o
F
3000
%
5.5-6.5
for Mixing
Bulk Density
lb/Ft3, 1500oF
156 to 162
Modulus of Rupture
lb/in2, 1500oF 600 to 1600
Apparent Porosity
%
15-19
Permanent Linear
o
%, 1500 F
-0.3 to 0.3
Change
EZ3 20-60
Shotcrete
EZ3 20-60
Vib Cast
3000
3000
2700
2700
4.8-5.8
4.0-5.5
4.5-5.0
5.8-6.1
156 to 159
11500 to 13500
800 to 1500
15-17
Vibrocast 56SC Vibrocast 56SCHP
Vib Cast
Hand Pack
161 to 167
157 to 162
9800 to 15800 10000 to 15000
1100 to 2100 2500 to 3500
11-15
17
157 to 162
10000 to 15000
2500 to 3500
17
-0.1 to 0
-0.3 to 0.3
-0.1 to -0.4
-0.1 to -0.4
FURNA3 70
Self Level
o
for Mixing
Bulk Density
FURNA3 75
Vib Cast
F
2500
2500
3000
3000
3000
%
5-6
4-5
5.5-6.5
5-6
4.5-5.5
166 to 170
155 to 161
168 to 172
158 to 161
169 to 174
3000 to 7000
5000 to 9000
6000 to 9000
10000 to 16000
700 to 900
18-22
1100 to 1500
15-17
1200 to 1500
18-20
1700 to 2200
11-14
-0.4 to 0.2
-0.5 to 0.0
-0.3 to -0.1
-0.4 to 0.0
lb/Ft3, 1500oF
2
o
Cold Crushing Strength lb/in , 1500 F 5500 to 10000
Modulus of Rupture
lb/in2, 1500oF 1100 to 2800
Apparent Porosity
%
15-18
Permanent Linear
%, 1500oF
-0.4 to 0.2
Change
Al2O3
74.0
74.0
75.6
75.6
75.6
Al2O3
22.3
22.3
22.3
19.8
19.8
SiO2
17.6
17.6
18.3
18.3
18.3
SiO2
14.9
14.9
14.9
21.5
21.5
Fe2O3
0.9
0.9
1.1
1.1
1.1
Fe2O3
0.5
0.5
0.5
0.3
0.3
TiO2
CaO
SiC
Alkalies
0.4
1.4
60.3
0.1
0.4
1.4
60.3
0.1
0.4
1.4
60.3
0.1
0.3
1.7
56.2
0.0
0.3
1.7
56.2
0.0
TiO2
CaO
SiC
MgO
Cr2O3
2.0
1.2
0.0
0.0
2.0
1.2
0.0
0.0
2.3
2.5
0.0
0.0
2.3
2.5
0.0
0.0
2.3
2.5
0.0
0.0
0.0
0.0
0.0
0.0
0.0
ZrO2
Alkalies
0.0
0.2
0.0
0.2
0.0
0.1
0.0
0.1
0.0
0.1
EZ3® 20-60 is a self-flow, pumpable, shotcretable mix that has excellent corrosion resistance and contains 60% silicon carbide. It has developed into a premium product to resist alkali buildup in cement kiln
preheaters and coolers. Its great ability for adherence has made EZ3® 20-60 the mix of choice when
shotcreting overhead is necessary.
VIBROCAST ® 56SC is a 56% SiC castable that uses low cement binder technology. Its low porosity, excellent abrasion resistance and high heat transfer value make this product an excellent choice for the combustion zones of POWER GENERATION units and for the riser lines and preheater sections of
CEMENT PLANTS. The high heat transfer characteristic of
the SiC reduces surface slagging and alkali build-up, thereby, improving the operating efficiency of your unit.
VIBROCAST ® 56SC is best applied by vibration casting.
for Mixing
Bulk Density
FURNA3 65
Vib Cast
FURNA3 85
Self Level
FURNA3 85
Pump/Shotcrete
FURNA3 85
Vib Cast
o
F
3000
2800
2800
2800
%
5-6.5
4.5-5.5
4.0-5.0
4.0-5.0
170
176 to 182
176 to 182
180 to 185
lb/Ft3, 1500oF
2
o
2
o
Cold Crushing Strength lb/in , 1500 F
®
FURNA3 70
FURNA3 75
FURNA3 75
Pump/Shotcrete Self Level Pump/Shotcrete
VIBROCAST 56SCHP is a 56% SiC castable that uses low
cement binder technology. Its low porosity, excellent abrasion resistance and high heat transfer value make this product an excellent choice for the combustion zones of POWER
GENERATION units and for the riser lines and preheater
sections of CEMENT PLANTS. The high heat transfer characteristic of the SiC reduces surface
slagging and alkali build-up, thereby, improving the operating efficiency of your unit.
Vibrocast ® 56SCHP is best applied by hand packing.
Modulus of Rupture
Apparent Porosity
Permanent Linear
Change
16,790
lb/in , 1500 F 2500 to 3500
%
---
23500 to 29500 12000 to 19000 27000 to 33000
4600 to 6000
15-19
2950 to 3950
14-18
4200 to 6200
10-14
%, 1500oF
0.0 to +0.5
-0.4 to 0.2
-0.9 to -0.2
-0.5 to 0.1
Al2O3
64.3
83.5
83.5
83.5
SiO2
24.6
9.6
9.6
9.6
Fe2O3
1.0
0.8
0.8
0.8
TiO2
CaO
MgO
Alkalies
1.8
2.0
0.0
0.3
2.1
2.8
0.0
0.3
2.1
2.8
0.0
0.3
2.1
2.8
0.0
0.3
Page 8
3
Page 9
o
EZ 34ZLC is a 2910 F Zircon based low
cement castable which requires no vibration to install. Super high strengths and
abrasion resistance are achieved even
when the material is mixed to a “Free
Flowing” or “Self-Leveling” consistency.
3®
EZ 3000 is a self-flowing, low iron, 56%
alumina, low cement castable designed to
provide high strength, and good thermal
shock and abrasion resistance. It offers
good slag resistance for severe applications up to 3000°F. In the laboratory, this
product has tested well for resistance to
CO (carbon monoxide) disintergration encountered in coke ovens and blast furnaces.
This product can be vibrated,
pumped, or shotcreted.
EZ3® 3200 is a shotcretable or selfflowing, low iron, 76% alumina, low cement castable designed to provide longer
service life and superior performance in
steel applications with temperatures up to
3200°F. It also has outstanding strength
and abrasion resistance. In laboratory
testing this product has shown excellent
resistance to CO atmospheres found in
coke ovens and blast furnaces.
EZ3® 3200 Fine is a slightly finer grain
size version of EZ3® 3200. It can be used
in the same applications, and it is recommended when pumping for long distances, particularly long vertical runs.
Self-flowing, Pumpable. Shotcretable Castables
for Mixing
Bulk Density
EZ3® 85 is an 85% alumina, low cement
castable that exhibits superior physical
properties when vibrated, poured, or shotcreted. The excellent thermal shock, corrosion, and abrasion resistance attributes
combined with other excellent physical
properties make this a premium product.
Normally, very high alumina containing
products are more difficult to shotcrete
due to higher rebounds. EZ3® 85 is remarkably easy to shotcrete and adheres
well at low water levels yielding superior
physical properties.
EZ3 3000
Shotcrete
EZ3 3000
Vib Cast
EZ3 3200
Self Level
EZ3 3200
Shotcrete
EZ3 3200
Vib Cast
2910
3000
3000
3000
3200
3200
3200
EZ3 3200 Fine EZ3 3200 Fine EZ3 3200 Fine
Self Level
Shotcrete
Vib Cast
3200
3200
3200
Modulus of Rupture
Apparent Porosity
Permanent Linear
Change
EZ3 60 LQY
Vib Cast
3100
5.7
157
11,050
4,510
---0.3
Al2O3
34.0
56.6
56.6
56.6
76.8
76.8
76.8
75.9
75.9
75.9
55.0
SiO2
41.5
36.1
36.1
36.1
18.5
18.5
18.5
19.2
19.2
19.2
40.6
Fe2O3
0.5
1.9
1.9
1.9
1.1
1.1
1.1
0.9
0.9
0.9
1.0
TiO2
CaO
ZrO2
Alkalies
0.8
1.4
2.2
1.3
2.2
1.3
2.2
1.3
2.3
1.1
2.3
1.1
2.3
1.1
2.1
1.5
2.1
1.5
2.1
1.5
1.7
1.5
21.5
0.3
0.0
0.8
0.0
0.8
0.0
0.8
0.0
0.1
0.0
0.1
0.0
0.1
0.0
0.1
0.0
0.1
0.0
0.1
0.0
0.2
EZ3 60-M
Self Level
EZ3 60-M
Shotcrete
EZ3 60-M
Vib Cast
EZ3 85
Self Level
EZ3 85
Shotcrete
EZ3 85
Vib Cast
EZ3 70PC
Pump Cast
EZ3 75PC
Pump Cast
EZ3 80PC
Pump Cast
EZ3 AZS
Self Level
EZ3 AZS
Vib Cast
F
3100
3100
3100
3250
3250
3250
3200
3200
3200
2800
2800
%
5.75-6.75
4.75-5.75
4-5
4.5-5.5
4.0-5.0
4.5-5.0
5.8-6.5
5.4-5.9
6.1-6.5
5.3
5.1
lb/Ft3, 1500oF
152 to 157
153 to 158
11000 to
17000
158 to 163
19000 to
25000
178 to 184
180
180
12,500
12,500
-----
-----
o
3®
EZ 60-M is a mullite-based 60% alumina castable that can be pumped, vibrated,
or shotcreted. It is recommended for applications requiring thermal shock resistance, wear resistance, and good refractoriness.
F
EZ3 3000
Self Level
%
4.3-4.8
6.5-7.0
5.5-6.0
4.8-6.8
5.5-6.5
5.0-6.0
4.7-5.5
5.5-6.5
5.0-6.0
4.5-5.5
for Mixing
Bulk Density
lb/Ft3, 1500oF
170
150 to 151
151 to 155
153 to 157
164 to 170 152 to 151
170 to 174
164 to 170
152 to 157
170 to 174
Cold Crushing Strength lb/in2, 1500oF 11000 to 16000 5200 to 11200 6000 to 12000 12000 to 16000 5000 to 9000 3700 to 8200 10000 to 16000 5000 to 9000 3700 to 8200 10000 to 16000
Modulus of Rupture
lb/in2, 1500oF
to
800 to 1800 800 to 1800 1500 to 2300 1100 to 1500 500 to 1500 1700 to 2200 1100 to 1500 500 to 1500 1700 to 2200
Apparent Porosity
%
15
15-19
15-19
10-14
15-17
20-24
11-14
15-17
20-24
11-14
Permanent Linear
%, 1500oF
0 to -0.3
-0.6 to 0
-0.2 to 0
-0.2 to 0.2
-0.2 to 0
-0.3 to 0
-0.4 to 0
-0.2 to 0
-0.3 to 0
-0.4 to 0
Change
3®
EZ 60 LQY is an alkali-resistant 60%
alumina castable that can be installed using vibration casting, pumping, or wet
shotcreting methods. This product has
been formulated to be resistant to alkali
attack.
o
EZ3 34ZLC
Self Level
7500 to 13500
176 to 182
11000 to
12500 to 16500
17000
181 to 187
160
170
167
14500 to
18500
10000 to 14000 9000 to 12000 9000 to 13000
lb/in2, 1500oF
%
1750 to 2750
15-19
%, 1500oF
-0.5 to 0.1
-0.3 to 0.3
-0.7 to -0.1
-0.1 to 0.1
-0.2 to 0.4
-0.1 to 0.1
-0.1 to -0.3
0 to -0.3
0.0 to -0.3
-0.2
-0.2
Al2O3
63.3
63.3
63.3
85.5
85.5
85.5
69.4
77.6
79.2
52.7
52.7
SiO2
32.3
32.3
32.3
9.8
9.8
9.8
25.7
16.2
15.4
19.5
19.5
Fe2O3
0.9
0.9
0.9
0.8
0.8
0.8
1.1
1.4
1.1
0.2
0.2
TiO2
CaO
SiC
MgO
ZrO2
Alkalies
1.7
1.5
0.0
0.0
1.7
1.5
0.0
0.0
1.7
1.5
0.0
0.0
2.2
1.2
0.0
0.0
2.2
1.2
0.0
0.0
2.2
1.2
0.0
0.0
1.9
1.5
0.0
0.0
2.6
1.5
0.0
0.2
2.3
1.5
0.0
0.0
0.3
1.5
4.9
0.2
0.3
1.5
4.9
0.2
0.0
0.2
0.0
0.2
0.0
0.2
0.0
0.4
0.0
0.4
0.0
0.4
0.0
0.0
0.0
0.5
0.0
0.5
20.5
0.2
20.5
0.2
2250 to 3250 3500 to 4500
13-17
10-14
2700 to 3200 2200 to 3200 3200 to 3800 1300 to 1700
15-19
14-18
12-16
17
1200 to 1700 1300 to 1800
18
---
EZ3® 70PC is a pumpable, low-cement castable which is designed to give minimum porosity and linear change with maximum density and super h igh fired strengths.
EZ3® 75PC is a pumpable, low-cement castable which is designed to give minimum porosity and linear change with maximum density and super h igh fired strengths. This material will
withstand severe high temperature corrosion and erosion.
EZ3® 80PC is a pumpable, low-cement, 80% alumina, vibratable castable designed to give minimum porosity and linear change with maximum den sity and super high fired strengths.
This material will withstand the severe high temperature corrosion and erosion that are common in today’s Steel Industry.
EZ3® AZS is a low cement castable, that contains an alumina-zirconia-silica (AZS) aggregate, that can be vibration cast, pumped, and shotcreted. This product was formulated specifically for cement preheater tower applications that require an abrasion-resistant monolithic refractory that resists dust build up.

Low Cement Castables

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