Installation Methods: Part 2: Types of Installation Methods of Monolithics/Castables

Types of Refractory Castables

• Conventional, High Cement
• Low Cement
• Ultra-Low Cement
• No Cement (Colloidal Silica, Phosphate Bonded)
• Basic Castables (Magnesite – Chrome)
• Insulating (20pcf to 90 pcf categories)

Castable Refractory Classifications

• Conventional / Regular Castable =>2.5% CaO
• Low Cement = 1.0% to 2.5% CaO
• Ultra-Low Cement = 0.2% to 1.0% CaO
• No Cement Castables = up to 0.2% CaO

No Cement

• Castables and gun mixes based on colloidal silica and phosphate-based binders

Brands Names: EZ EST (Colloidal Silica Bonded) and Rescobond (Phosphate Bonded)

Basic Castables and Gun Mixes

• 95 to 97% MgO-based; Dead Burned Magnesia
• Chrome Ore-Based
• Fused magnesia-Chrome Grain-Based
• Chemically Bonded
• Phosphate Bonded
• Silicate Bonded

Brand Names: Permanente, Rescomag, Permagun, Permacast, CP-40

Lightweight or Insulating Castables

• Can be cast, gunned, or pumped
• Cement bonded
• Contain lightweight aggregate
• Densities range 20 pcf to 90 pcf
• Gunned densities higher than cast density

Brand Names: Rescocast, Rescolite, Quiklite

Precast Shapes

• Cast into molds and shipped as a shape
• 45% to 98% alumina, alumina resistant
• Cement bonded
• Many different shapes

Brand Names: Uniform, Furnaform, Mighty Fibre, Mighty Agg

Plastic Moldables

• Phosphate bonded (50% to 90% Alumina)
• Air Setting (45% to 90% Alumina)
• Fine-Grained for Patching

Brand Names: Rescoram, Ref Ram, Ref Patch, Corpatch

Gunning Mixes

• Sprayable” using compressed air
• 45% to 94% Alumina
• Magnesite, Fused Magnesia-Chrome
• Phosphate Bonded, Colloidal silica Bonded
• Cement Bonded: High Cement, Low Cement

Brand Names: HM, Progun, Rescobond G, Permacast, Permagun, Rescocast, QuikTurn G, EZ EST

Wet Mortars in Pails

• Air setting and phosphate bonded
• 60% to 90% silica
• 45% to 90% alumina, alumina-chrome

Brand Names: Ladlelock – Rescoset, Adament – Adacore – Adaphos

Dry Mortars in Bags

• Air setting, 40% to 85% alumina
• Heat setting, 33% to 60% alumina
• Basic (Magnesite or Chrome Ore)

Brand Names: Lo Set – Alutab– Metaldam (Alumina)