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Xintai Group would like to share with everyone how to properly handle calcined bauxite in the construction of refractory castables.

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Company News

2022-08-24

Alumina-based refractory castables are unshaped refractory materials made by mixing calcined bauxite clinker and fine refractory powders with a refractory binder in specific proportions. Xintai Group summarizes: The seven key operational steps involving calcined bauxite clinker during the construction of refractory castables are crucial and correct—these serve only as a reference!

Alumina-based refractory castables are unshaped refractory materials made by mixing calcined bauxite clinker and fine refractory powders with a refractory binder in specific proportions. Xintai Group summarizes: The seven key operations involving calcined bauxite clinker during the construction of refractory castables are crucial and correct—this information is for reference only!

Xintai Group stated that the seven key operational procedures for alumina clinker in the construction of refractory castables are as follows:

1. The materials, specifications, and models of the anchor bolts used for welding anchor bolts shall be selected in accordance with the design standards. The distribution of anchor devices and the quality of welding shall be completed according to the design standards.

2. The mold frame dimensions must be accurate and meet the design requirements. Support points should be firm, joints tightly fitted, and no slurry leakage allowed. For casting materials with strong corrosivity or adhesiveness, an isolation layer should be provided in the mold. Wooden strips reserved for expansion joints must be securely fixed to prevent displacement during vibration compaction.

3. During the construction of castable materials, the amount of castable material mixed should be used up within 30 minutes. Before pouring the castable material, the formwork should be coated with a release agent. The pouring process must be completed continuously. The next layer of castable material should be poured before the previous layer begins to set. If the construction schedule exceeds the initial setting time, the pouring should still be completed continuously. The next layer of castable material should be poured before the previous layer begins to set.

4. When using an insert-type vibrator, the thickness of the concrete layer being poured shall not exceed 1.25 times the length of the vibrator’s vibrating section. When using a flat-bar vibrator, the layer thickness shall not exceed 200 mm.

5. The curing of castables: Silicate refractory castables are suitable for water curing, particularly when using flat-column vibrators. The thickness of such castables should not exceed 200 mm, especially for high-alumina cement castables.

6. Water-glass-based casting materials should be allowed to cure naturally in a dry, well-ventilated environment without adding any water. Do not use water or steam to cure the molds; instead, allow them to cure naturally in a dry, mild environment. If the ambient temperature is low, ensure that the curing process takes place under low-temperature drying conditions.

7. Non-load-bearing formwork should be removed only when the strength of the cast material is sufficient to ensure that its surface and edges are not damaged during demolding. Load-bearing formwork may be removed only after the strength of the cast material has reached at least 70%.

Xintai Group has learned that refractory castables are characterized by low bulk density, high strength, excellent air tightness, minimal linear change after firing, low thermal conductivity, and high operating temperatures. They also exhibit outstanding on-site performance and are particularly well-suited for lining walls with complex shapes. Once installed, the furnace walls demonstrate exceptional structural integrity. These materials are widely used as thermal insulation layers in industrial furnace linings or as inner linings for high-temperature industrial furnaces. When selecting bauxite raw materials for refractory castables, both Al2O3 content and refractoriness are crucial indicators; therefore, it is essential to choose the appropriate bauxite product for your specific application. To learn more about calcined alumina clinker, Xintai Group—our company—with years of experience in this industry—is happy to provide further information. Please feel free to contact us for more details.

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