CASTABLES

Definitions and classifications:

There are many different ways of classifying castables. One of the more useful
method is by density and bonding system.
Another method of classifying calcium aluminate bonded castables is in relation to
the total cement content or overall lime content. According to ASTM C401-91,
Standard Classification of Alumina and Alumina Silicate Castable Refractories the
following classification exists regarding chemistry and lime content. This can be seen
in following table.

ASTM Classification
CASTABLE CLASSIFICATION LIME CONTENT
Regular Castable Refractory CaO > 2.5%
Low Cement Castable Refractory 1.0% < CaO < 2.5%
Ultra Low Cement Castable Refractory 0.2% < CaO < 1.0%
No Cement Castable Refractory CaO < 0.2%

Conventional Castables:
Regular refractory castables are also called traditional, classical or conventional
castables.
Cement content for these types of products is often greater then 15%. A
conventional castable is composed of a binder phase containing calcium aluminate
cement with a content range of 15 - 40%, aluminosilicate materials and aggregates.
Conventional castables are placed with water, usually 8 to 20% . This water
content is required to ensure placement by casting. The combination of the water and
cement to form calcium aluminate hydrates results in the hardening of the castable
ensuring sufficient strength at low and intermediate temperatures. A small portion of
the water is absorbed by the aggregate and does not contribute to the hydraulic bond.
The majority of water is concentrated the matrix between the fine particles and reacts
with the cement to form the hydraulic bond.
In conventional castables, dried open porosity is contributed to significantly by the
excessive quantity of water added during the mixing and placing stage. Upon heating
the hydraulic bond is destroyed and new mineral phases are formed. It is during this
change that open porosity increases by about 15%. This porosity is dependent on
cement content and type. The amount of water for mixing and the quantity of
porosity at temperature are dependent on one another. Therefore, if water quantities
can be reduced a lowering of porosity is also possible. With the careful selection of a
calcium aluminate cement optimized in mineralogical content, conventional castables
can be formulated and placed at low water additions. These castables exhibit stable
rheological properties of successful placement which in turn ensures good mechanical
properties.

Low Cement Castables:

In the LCC system, the CAC cement is part of an interdependent binder system.
This system can be viewed as an interdependent triangle as seen in fallowing Figure.

CAC

Aggreg

Fillers Additives