Refractory Silica Fume
High-Temperature Refractory Castable Cement
A refractory castable is a heat-resistant building material predominantly used to manufacture industrial metallurgical furnaces or kilns for companies specializing in the production of building materials, chemicals, and the oil industry. Adding silica fume to refractory-grade cement is extremely beneficial due to its excellent thermal resistance, enhanced strengths, superfine particle size, and reduced water storage capacity.
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Undensified silica fume has the same chemical characteristics as densified fume. However, the compaction is far less and makes the actual particles lighter and more readily available in the mix to chemically bond. In lower dosage rates, silica fume can improve workability, thus reducing the overall water requirements while maintaining the same flow characteristics. Silica fume also promotes low-temperature sintering and can increase mullite formation; resulting in lower permeability to gas, slag, and metal penetration. Castables made with undensified silica fume tend to be stronger than non-silica fume castables, especially at high temperatures and higher density. By using undensified silica fume, the cement will have porosity and be more volume stable.
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R-E-D Industrial Products undensified refractory silica fume has a stable pH and a low impurity level and is perfectly adapted to the unique requirements of refractory castables. Its use improves the flow, mechanical properties (especially hot strength), and durability (via permeability reduction). In addition to offering premium silica fume for refractory use, R-E-D Industrial Products also serves customers in the industrial concrete as well as the oil and gas industry. Contact our experienced team anytime to learn more about our silica fume for oil and gas applications or to receive a quote.
Benefits of Silica Fume for Refractory Castables
Adding silica fume to cement for refractory castable production significantly benefits mechanical properties, thermal performance, longevity, and permeability. Improving cement composition with undensified silica fume makes the final material far more suitable for high-performance industrial applications and extreme conditions. Some specific benefits of refractory silica fume are listed below.
Improved Strength:
When added to cement for refractory applications, the extremely fine silica fume particles fill the interstitial spaces between the cement particles. By filling these gaps, the microstructure of the cement becomes much stronger and resists bending or possible deformation with higher compressive strength.
Enhanced Thermal Performance:
Refractory castables must perform at extreme temperatures above 1,000℉, so silica fume helps create an improved heat-resistant structure. Additionally, silica fume provides better resistance to the continual fluctuation or thermal cycling within these end components and reduces the chances of cracking.
Enhanced Workability:
When used in refractory cement, silica fume enhances the workability of the mixture. This is particularly useful for placing and shaping cement, resulting in more uniform and consistent performance throughout the specific cast.
Reduced Permeability:
A reduction in permeability is critical to the overall performance of refractory castables. By filling the gaps in the cement structure, silica fume makes castables more impermeable to the gases and liquids that could ultimately lead to degradation. By improving the permeability of cement with silica fume the material will last longer and require less continual maintenance.
Silica Fume & Sustainability
R-E-D Industrial Products undensified silica fume for refractory applications provides a premier combination of function and sustainability. This is how our silica fume product line can make a difference in longevity and viability. See the information below to find out how silica fume can provide confidence that you are making a sustainable choice for your next project. R-E-D Industrial Products' core values of reliability, efficiency, and dependability are all key components linked to our pursuit of sustainability and environmentally conscious distribution.
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Applicability for Sustainability:
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Increased strength in concrete structures
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Longer durability means less frequent replacement
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Resistance to alkali-silica reaction (ASR)
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Low permeability to intrusion from corrosives such as water, salt, chloride, and other natural elements in challenging environments
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Reduction of life cycle costs
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Abrasion and impact resistance to withstand continuous traffic or loads
Implementations:
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Low permeability makes it well suited for structures that are immersed or near oceans, rivers, and water sources such as bridges, dams, and tunnels.
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The ability to protect from abrasion and impact resistance provides a boost in protection for rebar from deterioration and replacement.
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Increased strength for use in more wear-and-tear concrete structures that need to reach the standard life cycle span of 50 years.
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Why Silica Fume?
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Increase sustainability in concrete projects
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Lower life cycle costs of infrastructure and building projects
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An ethically sourced product that can boost your green initiatives
Sustainability Fact: 39% of infrastructure in America is older than its designed lifetimes, while nearly 10% are structurally deficient and 14% are characterized as functionally obsolete [1].
Creating structures with sustainable solutions such as silica fume are paramount to promoting your project's vitality into the future.
[1] “The State of U.S. Infrastructure.” Council on Foreign Relations, Council on Foreign Relations, https://www.cfr.org/backgrounder/state-us-infrastructure