Product family

Refractory Castables & Monolithic Refractories

Monolithic refractories are unshaped refractory materials — castables, plastics and ramming mixes, gunning mixes and mortars — installed in place to build, maintain or repair a furnace lining instead of being laid as individual bricks. RISING REFRACTORY publishes 17 monolithic products in four groups; the castables are the largest group.

17 products

$RISING monolithic refractory materials$

What is a refractory castable?

A refractory castable is a monolithic refractory supplied as a dry mix and placed by casting, either in position or as precast shapes. In the RISING catalogue, castables differ by their bond — calcium aluminate cement, low or ultra-low cement, phosphate, hydration-and-coagulation or aluminium sulfate bond — and by their main material: clay, high alumina, corundum, fused silica, hollow alumina spheres, alumina–magnesia or alumina–silicon carbide–carbon.

The bond changes how the material behaves in service. Unlike conventional cement-bonded castables, whose strength drops significantly between 800 and 1200 ℃, low- and ultra-low-cement castables gain strength as the temperature rises; phosphate-bonded castable has a higher cold crushing strength and better thermal shock resistance than calcium aluminate cement-bonded castable. Each product page publishes the specification table the comparison is made from.

Product groups in this family

Four groups, each with its own installation form. Every product named below has a page with its published specification.

Castables
Dense low- and ultra-low-cement castables in clay, high alumina and corundum types; phosphate-bonded castable; wear-resistant and steel-fiber-reinforced castables for abrasion and thermal cycling; lightweight insulation castable and alumina bubble castable for insulating and permanent layers; acid-resistant, alkali-resistant, alumina–magnesia, Al₂O₃-SiC-C and fused silica castables for specific service conditions.
Plastics and ramming mixes
Clay and high alumina refractory plastics, wear-resistant refractory plastic in high alumina, silicon carbide and zircon chrome corundum types, and dry ramming mass in acidic (quartz), neutral (spinel, corundum, mullite) and alkaline (magnesia) types.
Gunning mixes and coatings
Semi-lightweight and lightweight alumina silicate gunning mixes for insulating linings and low- to medium-temperature working linings, and a nano ceramic wear-resistant coating applied to severely worn areas below 1300 ℃, such as in large CFB boilers.
- Alumina Silicate Gunning Mix
- Nano Ceramic Wear-Resistant Coating
Mortars
Jointing mortars for brick masonry in four material systems — silica, alumina-silicate, magnesia and silicon carbide / carbon — each matched to the brick lining it joins and specified with its own grades.
- Refractory Mortar

How to choose a monolithic refractory

Selection starts from the service conditions, not from the product list. These are the points the technical team reviews, each with the published products it leads to.

01
Equipment and lining zone
A lining is built in layers. Dense castables, plastics and ramming mixes are specified in the industry matrices for working-layer positions; lightweight insulation castable, alumina bubble castable and the lightweight gunning mixes for the insulating and permanent layers behind them.
02
Operating temperature
The published tables state a maximum working temperature where the specification gives one — for example 1450, 1600 and 1800 ℃ for the clay, high alumina and corundum low-cement castables — and the operating temperature is the first service condition reviewed.
- Low & Ultra-Low Cement Castable
03
What the lining is in contact with
Molten iron and slag point to the Al₂O₃-SiC-C castable for iron and slag runners and to alumina magnesia castable for ladle and tundish linings; abrasion to the wear-resistant and steel-fiber-reinforced castables and the wear-resistant plastic; acids to the acid-resistant castable; alkali metal oxides and their compounds to the alkali-resistant castable.
04
Installation form
Castables are cast in place or as precast shapes; plastics and ramming masses are rammed; gunning mixes are gunned; mortars joint the bricks. The form follows the equipment and the repair or new-lining situation.
Dimensions and drawings
For monolithic materials a drawing is optional; the lining zone and the lining thickness help the technical team size the quotation.

Where monolithic refractories are specified

Taken from the refractory selection matrices of the published industry pages: each industry with the products of this family its source names.

Industry	Products named by the source
Steel & Iron	Wear-Resistant Refractory Castable Alumina Silicate Gunning Mix Refractory Mortar Al₂O₃-SiC-C Castable Dry Ramming Mass Alumina Magnesia Castable Low & Ultra-Low Cement Castable Fused Silica Castable
Power & CFB Boilers	Wear-Resistant Refractory Castable Wear-Resistant Refractory Plastic Nano Ceramic Wear-Resistant Coating Steel Fiber Reinforced Castable Lightweight Insulation Castable
Nonferrous Metals	Refractory Mortar Lightweight Insulation Castable Low & Ultra-Low Cement Castable Clay & High Alumina Refractory Plastics
Glass	Lightweight Insulation Castable Refractory Mortar
Chemical & Petrochemical	Lightweight Insulation Castable Alumina Bubble Castable
Cement	Alkali-Resistant Refractory Castable Low & Ultra-Low Cement Castable Wear-Resistant Refractory Plastic Steel Fiber Reinforced Castable Wear-Resistant Refractory Castable Lightweight Insulation Castable Refractory Mortar

What to send for a castable quotation

A complete enquiry covers the six items below. Send what you have; the rest is asked for during technical review.

01Product / material requirement
02Application / equipment
03Quantity
04Dimensions / drawings
05Technical specification / TDS
06Destination country / port

Mixing-water percentages, curing and dry-out schedules, anchor spacing and installation procedures are not published on this site; the technical team provides them for the product and lining zone you specify.

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Furnace & Kiln Lining

A refractory lining is not one material. It is built in layers: a working layer against the process, a permanent layer behind it, an insulation layer behind that, and the steel shell outside. Each layer is supplied from a different product family, and the material in each changes with the equipment and the operating zone.

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