Introduction
Self-flow castables are refractory materials that can flow and degas without the need for vibration (see refractory castables). Their key feature is that, with the appropriate addition of water, they can be cast into various shapes without significantly compromising their performance. Self-flowing castables are especially suitable for thin-walled or complex shapes where vibration molding is impractical.
These materials are developed from low-cement and ultra-low-cement castables. They consist of refractory aggregates, powders with specific particle size distributions, and high-efficiency dispersants. The key to their performance lies in the appropriate use of ultrafine powders and dispersants, which enable the castable to flow and spread automatically.
characteristic
Self-flowability
After adding an appropriate amount of water or binder, the material can flow automatically and spread evenly under gravity to fill thin walls, narrow joints, or complex structural parts, avoiding air holes or incomplete filling caused by insufficient vibration.
Flowability is achieved by adjusting the proportions of aggregate gradation, ultrafine powders (such as silica micropowder), and high-efficiency dispersants (such as polycarboxylates) to ensure "self-leveling" during construction.
Vibration-free construction
Eliminating the traditional vibration process reduces construction noise and equipment reliance. This is particularly suitable for situations where vibration is impossible (e.g., overhead work, construction near precision components) or vibration-sensitive structures (e.g., thin-walled linings, parts with complex embedded components).
High performance retention
After molding, the properties (e.g., strength, high-temperature resistance, erosion resistance) are comparable to or better than conventional vibrating castables because the material can spontaneously eliminate air bubbles during flow and form a dense structure.
Comparison with conventional castables
| Characteristics | Self-flowing castables | Conventional vibrating castables |
| Construction method | Vibration-free, self-flowing molding | Requires mechanical vibration to remove air bubbles |
| Applicable structures | Thin walls, complex shapes, narrow seams | Thick-walled, simple construction |
| Construction efficiency | High (elimination of vibration process) | Lower (requires vibration equipment) |
| Bubble control | Self-flowing degassing for a denser structure | Dependent on vibration effect, air holes may remain |
| Amount of water/binding agent | Lower (high dispersant efficiency) | High |
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Raw Materials
Core components
Refractory aggregates: Such as corundum, mullite, magnesia, providing high-temperature resistance and structural support.
Fine and ultrafine powders: Fill gaps between aggregates, optimize particle gradation, and improve fluidity (e.g., Al₂O₃ micro, SiO₂ micro).
High-efficiency dispersants: Reduce friction between particles, enabling high fluidity with low water/binder use while avoiding segregation.
Binders: Such as sodium silicate, aluminate cement, ensure hardening and shaping.
Principle of action
By optimizing particle gradation and using dispersants' deflocculation effect, the castable forms a uniform, low-viscosity slurry after mixing that flows under its own weight to fill molds. Ultrafine powders absorb water and form a lubricating layer, further enhancing fluidity.
Physical and Chemical Specifications
| Grade / Specifications |
ZL-G1 |
ZL-G2 |
ZL-G |
ZL-1 |
ZL-2 |
ZL-3 |
|
|
Al2O3 % ≥ |
65 |
75 |
85 |
65 |
70 |
80 |
|
|
Bulk Density (g/cm3) ≥ |
110℃ x 24 hr |
2.35-2.40 |
2.50-2.60 |
2.70-2.80 |
2.30-2.40 |
2.50-2.60 |
2.60-2.80 |
|
1100℃ x 3 hr |
2.45 |
2.60 |
2.70 |
2.35 |
2.55 |
2.70 |
|
|
Linear Change (%) |
1100℃ x 3 hr |
-0.5-0 |
-0.5-0 |
-0.3-0 |
-0.5-0 |
-0.5-0 |
-0.5-0 |
|
Crushing Strength (Mpa) ≥ |
110℃ x 24 hr |
30 |
45 |
50 |
30 |
40 |
45 |
|
1100℃ x 3 hr |
70 |
70 |
80 |
45 |
55 |
55 |
|
|
HMOP Hot Modulus of Rupture (Mpa) ≥ |
110℃ x 24 hr |
5 |
6 |
8 |
5 |
6 |
8 |
|
1100℃ x 3 hr |
10 |
11 |
>11 |
8 |
9 |
10 |
|
|
Refractoriness ℃ |
1750 |
1790 |
1790 |
1730 |
1770 |
1790 |
|
|
Classification Temperature (℃) |
1350 |
1450 |
1500 |
1350 |
1400 |
15 |
|
Applications
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01/Delivery cycle and logistics
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About 30 days, customized products delivery time depends on the actual situation.
02/Customized packaging
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03/Purchase ZINFON Monolythic Refractory at Reasonable Prices
We recognize that pricing is a critical factor in our customers' purchasing decisions. Leveraging our proximity to abundant mineral resources and advanced manufacturing technologies, we offer competitive pricing without compromising on quality. Our strategic location minimizes raw material costs, while economies of scale achieved through state-of-the-art processes further reduce unit production expenses.
Factory price
By collaborating with ZINFON, we ensure that customers enjoy the ex-factory price of Self-flow Castables, reducing costs from middlemen or distributors. This allows customers to obtain the most cost-effective pricing directly from the source.
Low raw material cost
ZINFON is surrounded by abundant mineral resources. With these high-quality materials, customers can obtain products that are both affordable and excellent in performance.
Mass production
ZINFON possesses advanced production equipment and technologies, enabling the factory to achieve economies of scale and reduce unit production costs. Meanwhile, it ensures a continuous supply of high-quality products at preferential prices.
It is worth noting that while price is an important factor, it should not be the sole determinant of your purchasing decision. When buying Self-flow Castables from ZINFON, quality, reliability, and technical support are equally important considerations.
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Provide professional after-sales protection
Our address
Qinghua Management Dist., Dashiqiao City, Yingkou City, Liaoning, China
Phone Number
+8613700131695
+8618540210631
By choosing ZINFON as your supplier, you can access high-quality refractory bricks, a wide range of other refractory materials, and comprehensive support. Contact ZINFON Refractories immediately to discuss your specific requirements and obtain customized solutions!
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