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In the modern industrial and construction fields, castables, which are unshaped refractory materials that can harden without heat treatment, are gradually becoming the preferred choice for refractory engineering. Among them,calcium aluminate concrete, with its unique properties and wide range of applications, has become a leader in the castable field. This article will delve into the properties, classifications, and excellent performance ofcalcium aluminate concrete in different scenarios.
Calcium aluminate concrete, as the name suggests, is a refractory material that uses calcium aluminate cement as the main binder, mixed with aggregates and powders in specific proportions, and formed through casting, vibrating, and moist curing. Based on porosity,calcium aluminate concrete can be divided into dense and insulating types to meet different insulation and refractory needs in various conditions.
Classified by binder type, calcium aluminate concrete can be further subdivided into bauxite cement castables, aluminum-60cement castables, low-calcium aluminate cement castables, and purecalcium aluminate concrete. Each type occupies a niche in the refractory materials market based on its unique hardening mechanisms and performance advantages.
Bauxite cement castables
Bauxite cement castables primarily feature the CAmineral, characterized by rapid setting and hardening, and fast strength growth. During summer construction, water spraying is required for cooling, while winter construction requires insulation covering to keep the product or lining surface moist. The initial and final setting times are only 1–3h and 6–8h, respectively. After curing for 1 day, it can achieve about 75% of its ultimate strength, making it an ideal choice for those pursuing construction efficiency.
Aluminum-60cement castables
Aluminum-60cement castables are primarily based on CA2mineral. Compared to bauxite cement, its hardening speed is slightly slower, but the heat release is more uniform. Steam curing can accelerate its hardening process while reducing strength loss caused by the transformation of hydrates. Aluminum-60cement castables exhibit a smaller drop in medium-temperature strength and a higher usage temperature than bauxite cement castables of the same material, making it an ideal choice for high-temperature environments.
Pure calcium aluminate concrete
Pure calcium aluminate concrete, with its high-purity chemical composition and selected refractory aggregates, exhibits extremely high physical and chemical performance. Its mineral composition mainly includes CA2 and a small amount of CA. With precise proportioning and preparation processes, high-quality castables with a compressive strength of up to 4050 MPa can be produced. After heat treatment, both its cold and hot tensile strengths are significantly improved, with the maximum usage temperature reaching 1700-1800℃, making it the go-to choice for extreme refractory performance.
Calcium aluminate concrete, as a bright star in the field of castables, is leading the innovative development of the refractory materials industry with its diverse types, excellent performance, and broad application prospects. Whether it is the fast-hardening bauxite cement castables, the medium-temperature strength-stable aluminum-60cement castables, or the superior performance of purecalcium aluminate concrete, each plays an irreplaceable role in their respective fields. With continuous technological advancements and increasingly diverse engineering demands, calcium aluminate concrete is bound to display even broader development prospects and infinite possibilities in the future.
