Reference Table for Construction Consumption of Different Types of Castables
| Castable Types | Bulk Density Range (t/m³) | Reference Value of Common Density (t/m³) | Typical Application Zones | Recommended Loss Factor | Consumption Calculation Formula | Application Description |
| Clay Bonded High Alumina Castable | 2.25-2.45 | 2.35 | Flue Ducts, Low-Temperature Kiln Lining | 1.05-1.10 | Consumption = Construction Volume × 2.35 × Loss Factor | Suitable for neutral or weakly oxidizing environments with temperature ≤1300°C. It features good thermal shock resistance and moderate cost. |
| CA-50 Cement Bonded High Alumina Castable | 2.30-2.60 | 2.45 | Kiln Transition Zone, Hot Air Ducts | 1.06-1.12 | Consumption = Construction Volume × 2.45 × Loss Factor | Bonded by calcium aluminate cement, it has high strength and is suitable for load-bearing or stressed sections below 1400°C. |
| Low Cement High Alumina Castable | 2.40-2.70 | 2.55 | Kiln Outlet, Cooling Zone, Feed Pipe | 1.08-1.15 | Consumption = Construction Volume × 2.55 × Loss Factor | Cement content ≤8%, low apparent porosity, good wear and erosion resistance, suitable for high-temperature areas with material abrasion. |
| Ultra Low Cement High Alumina Castable | 2.30-2.60 | 2.45 | Heating Furnace Roof, Soaking Zone Lining | 1.07-1.13 | Consumption = Construction Volume × 2.45 × Loss Factor | Cement content ≤3%, good high-temperature volume stability, suitable for long-term service at around 1500°C. |
| CA-70 Cement Bonded Corundum Castable | 2.70-3.00 | 2.85 | Combustion Chamber, Burning Zone, Tapping Hole | 1.10-1.15 | Consumption = Construction Volume × 2.85 × Loss Factor | High corundum content, refractoriness above 1700°C, excellent slag resistance and erosion resistance, suitable for extreme high-temperature environments. |
| Water Glass Bonded Clay Castable | 2.10-2.35 | 2.25 | Low-Temperature Flues, Chimney Lining | 1.05-1.10 | Consumption = Construction Volume × 2.25 × Loss Factor | Good acid resistance, low cost, suitable for non-load-bearing low-temperature sections ≤1000°C. |
| Phosphate Bonded High Alumina Castable | 2.30-2.70 | 2.5 | Aluminum Electrolytic Cell, Roasting Furnace Lining | 1.08-1.14 | Consumption = Construction Volume × 2.50 × Loss Factor | Hardens at ambient temperature, no preheating required, resistant to electrolyte erosion, suitable for non-ferrous metal smelting equipment. |
| Lightweight Insulating Castable | 1.00-1.80 | 1.4 | Outer Kiln Insulation, Flue Insulation Layer | 1.05-1.12 | Consumption = Construction Volume × 1.40 × Loss Factor | Low density, low thermal conductivity, mainly used to reduce heat loss; not suitable for load-bearing or direct flame contact. |
| Corundum Castable (97% Al₂O₃) | 3.40-3.60 | 3.5 | High-temperature Core Zones of Special Kilns, Laboratory Kilns | 1.10-1.15 | Consumption = Construction Volume × 3.50 × Loss Factor | Made of high-purity corundum, refractoriness above 1800°C, suitable for special industrial scenarios with extremely high performance requirements. |
Description and Application Guide
Density Selection Principle
The "typical reference density values" in the table represent generally accepted industry ranges. For actual calculations, the product test report or datasheet issued by the castable manufacturer shall prevail. A density deviation of 10% may result in a material consumption calculation error of more than 10%.
Basis for Loss Factor Adjustment
The base value refers to the *Quota for Refractory Material Engineering*. The baseline wastage rate for cast-in-place refractory concrete is 6%.
Take the lower limit for simple flat surfaces (e.g. straight walls, floors).
Take the upper limit for complex irregular structures (e.g. holes, corners, curved surfaces).
When pump casting is adopted, add an extra 3%–5% to the loss factor.
Self-flowing casting may use the mid-to-lower range.
Calculation of Construction Volume
For regular shapes (rectangular, cylindrical), calculate directly using geometric formulas:
Rectangle: Length × Width × Height
Cylinder: π × Radius² × Length
For irregular sections, split the shape into multiple regular geometric bodies, calculate each part separately and sum up the results. On-site measurement verification is recommended when necessary.
Correction for Special Conditions
If ambient temperature is below 5°C, increase the loss factor by 2%–3%.
If ambient temperature exceeds 30°C, reduce the loss factor by 1%–2% and implement cooling measures.
Where the thickness of layered casting exceeds 100 mm, vibration shrinkage shall be considered; an additional allowance of 1%–2% may be added in volume calculation.
Example: Low cement high alumina castable is to be applied at the kiln outlet of a rotary kiln (subject to long-term high-temperature erosion; the structure requires spalling resistance). The measured construction volume is 12 m³. Calculation based on parameters in the table: Actual material quantity = 12 m³ × 2.60 t/m³ × 1.20 = 37.44 tons. It is recommended to place the purchase order for 37.5–38.0 tons.
The following are industry standards and specifications for calculating the required quantity of castables for construction:
SH/T 3115-2024, Technical Specification for Lining Engineering of Lightweight Castables for Petrochemical Tube Furnaces
This standard specifies the basic requirements for lightweight castable lining materials, construction, quality inspection, curing, drying, furnace baking and project acceptance for petrochemical tube furnaces. It applies to hydraulic lightweight castable lining works with a bulk density of 500 kg/m³ ~ 1300 kg/m³, constructed by mechanical spraying or manual ramming methods for petrochemical tube furnaces and flue & duct systems. Although the standard does not provide detailed formulas for material consumption calculation directly, it defines various parameters and requirements during construction, which serve as critical references for accurate castable quantity estimation.
YB/T 4921-2021, Code for Construction and Acceptance of Castables for Blast Furnace Trough
This code applies to construction quality acceptance of castables for blast furnace troughs in new, reconstructed and expanded ironmaking projects. It elaborates on the construction procedures of blast furnace trough castables, including formwork erection, mixing, casting and vibration, curing and other stages. Requirements for these procedures are closely related to castable consumption calculation. For example, dimensions of erected formwork affect the construction volume of castables and consequently the material quantity calculation.
Shaanxi Installation Engineering Consumption Quota – Furnace and Kiln Masonry Works
It stipulates that the quantity of refractory spray coatings shall be measured in "m²". The formula for the rebound rate of spray coatings (including shaping loss) is V₀ = P × (1 + K), where V₀ stands for total consumption, P is net consumption, and K is rebound rate. Meanwhile, if embedding steel bars or installing wire mesh is required by design for refractory castables, the overlapping length or area may be included in the measured quantity.
Shandong Installation Engineering Quantity Calculation Rules (Furnace and Kiln Masonry)
These rules specify that the quantity of refractory spray coatings shall be calculated in the unit of "10 m²", and the rebound loss of spray coatings is already incorporated into the quota material consumption. Refractory plastics and refractory ramming mixes are quantified based on actual volume. Where embedding steel bars or laying wire mesh is specified in the design for refractory castables, the overlapping length or area can be counted into the engineering quantity.