Steel fiber castables are composite refractory materials that incorporate high-grade bauxite clinker as the aggregate, high-quality bauxite clinker and corundum fine powder as the matrix, and various composite materials, including ultrafine powders, as binders and additives. Stainless steel heat-resistant fibers (typically constituting 0.6% to 2.5% by weight) are also included in the formulation.
These castables introduce steel fiber reinforcement into refractory materials. Through the synergistic effect between steel fibers and the refractory matrix, the comprehensive properties of the material are significantly improved, especially in terms of impact resistance, thermal shock resistance, and toughness.
Core Components
Refractory Matrix: Composed of refractory aggregates (such as corundum, mullite, high-alumina bauxite, silicon carbide, etc.) and fine powders, it provides basic refractory properties such as high-temperature strength and erosion resistance.
Binders:Include aluminates cement, phosphates, sodium silicate, etc., ensuring plasticity during construction and structural strength after hardening.
Steel Fibers: Typically made of stainless steel (e.g., 304, 310S, etc., resistant to high-temperature oxidation) or heat-resistant alloy fibers, with a diameter of 0.2–0.8 mm and a length of 15–50 mm. They function through the "bridging effect" and "crack deflection mechanism," inhibiting the initiation and propagation of cracks in the matrix, thereby enhancing the material's toughness.
characteristic
| Performance Dimension | Characteristics of steel fiber refractory castables |
| Thermal Shock | Steel fibers alleviate thermal stress caused by sudden temperature changes, significantly reducing the risk of cracking. They are suitable for kilns with frequent start-stops or large temperature fluctuations. |
| Impact and abrasion resistance | Steel fibers enhance toughness, resist mechanical impacts (such as material scouring and gas flow impact), and reduce wear, thereby prolonging service life. |
| High Temperature Strength |
The composite structure formed by steel fibers and the refractory matrix maintains structural stability at high temperatures, surpassing that of ordinary refractory castables. |
| Anti-cracking | The pores between fibers can release the vapor pressure generated by water evaporation, reducing the risk of bursting during construction and baking. |
Physical and Chemical Specifications
| Grade / Specifications |
NDL-60G |
NDL-70G |
NDL-75G |
NDG-80G |
NDG-90G |
|
|
Al2O3 % ≥ |
60 |
70 |
75 |
80 |
90 |
|
|
Bulk Density (g/cm3) ≥ |
110℃ x 24 hr |
2.30~2.40 |
2.40～2.50 |
2.50~2.60 |
2.60~2.80 |
2.90~3.10 |
|
Linear Change (%) |
1100℃ x 3 hr |
±0.5 |
±0.5 |
±0.3 |
±0.3 |
±0.3 |
|
Crushing Strength (Mpa) ≥ |
110℃ x 24 hr |
35 |
45 |
50 |
55 |
70 |
|
1100℃ x 3 hr |
50 |
60 |
70 |
80 |
100 |
|
|
HMOP Hot Modulus of Rupture (Mpa) ≥ |
110℃ x 24 hr |
6 |
7 |
8 |
9 |
>11 |
|
1100℃ x 3 hr |
8 |
10 |
11 |
>11 |
>11 |
|
|
Classification Temperature (℃) |
1350 |
1400 |
1500 |
1500 |
1600 |
|
Applicationss
Metallurgical Industry: Blast furnace stacks, hot blast stove pipelines, converter tapping holes, etc., to resist scouring by high-temperature molten steel and thermal shock.
Ladle and Tundish Linings: Withstand frequent charging and abrupt temperature changes.
Building Materials and Ceramic Industry: Cement kiln decomposing furnaces, tertiary air ducts, tops of ceramic tunnel kilns, high-temperature sections of roller kilns, to resist wear from dust-laden gas flows and high-temperature corrosion, and to adapt to periodic temperature variations.
Chemical and Energy Industry: Gasifier linings, incinerator combustion chambers, glass kiln charging ports, flow channels, to withstand high temperatures, acidic gases (e.g., SO₂, HCl), and scouring by solid particles, and to resist erosion by glass melt and mechanical impact.
Construction Points
Fiber Dispersion: Use a forced-action mixer. First, pre-mix the refractory aggregates with the binder, then add steel fibers in batches. Extend the mixing time by 2–3 minutes compared to ordinary castables to ensure uniform distribution of fibers and avoid agglomeration.
Vibration Process: Steel fibers may increase the viscosity of the material, requiring appropriate enhancement of vibration to ensure compactness. However, over-vibration should be avoided to prevent fiber settlement or single-directional orientation.
Curing and Baking: During normal-temperature curing, direct watering should be avoided; instead, moisturize with plastic sheeting. Follow a stepped temperature-rise curve during baking: slowly drain water in the low-temperature stage (<300°C) to prevent excessive vapor pressure from causing delamination between fibers and the matrix.
By combining rigidity and flexibility, steel fiber refractory castables address the defects of traditional refractory materials, such as high brittleness and poor thermal shock resistance. They have become key materials for the development of modern industrial kilns toward high efficiency and long service life. The technical core lies in the stress transfer mechanism at the fiber-matrix interface. Future development directions include developing fibers with higher temperature resistance (such as ceramic fibers and cermet composite fibers) and optimizing fiber distribution technology to further expand application scenarios.
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By collaborating with ZINFON, we ensure that customers enjoy the ex-factory price of Steel Fiber Refractory Castables, reducing costs from middlemen or distributors. This allows customers to obtain the most cost-effective pricing directly from the source.
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ZINFON is surrounded by abundant mineral resources. With these high-quality materials, customers can obtain products that are both affordable and excellent in performance.
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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 Monolythic Refractory from ZINFON, quality, reliability, and technical support are equally important considerations.
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