Insulating castables are a type of refractory material used to provide thermal insulation and protect the surrounding structures from heat. They are mainly composed of lightweight aggregates like perlite, exfoliated vermiculite, or lightweight chamotte, insulating grog etc. These aggregates contribute to the low density and excellent insulating properties of the castable.
Features:
- Low Thermal Conductivity: Our Insulating castables have a low thermal conductivity, which means they have excellent insulation properties. This property helps to reduce heat transfer and minimize heat loss thus serve as either hot face or back-up insulating refractory lining.
- Low Density: Our Insulating castables are typically lightweight (density being between 600 to 1600 kg/m3 ) due to the use of porous and lightweight aggregates like expanded perlite or vermiculite. The low density minimizes the load on the supporting structure.
- Thermal Stability: Our Insulating castables are designed to withstand high temperatures without significant structural degradation. They exhibit good thermal stability and maintain their insulation properties even under prolonged exposure to heat.
Below are the range of insulating castables that HRW cater to its customers
| Brand Name: – | HR INSULCAST 4 | HR INSULCAST 7 | HR INSULCAST 9 | HR INSULCAST 11 | HR INSULCAST 13 | ||||||
| Type | Low Density Insulating Castable | Low Density Insulating Castable | Medium density insulating Castable | Medium density insulating Castable | Moderate density insulating Castable | ||||||
| Nature of Bond | Hydraulic | Hydraulic | Hydraulic | Hydraulic | Hydraulic | ||||||
| Installation | Tamping | Tamping | Tamping | Tamping | Tamping | ||||||
| Raw Material Base | Exfoliated Vermiculite | Exfoliated Vermiculite | Insulating Aggregate | Insulating Aggregate | Insulating Aggregate | ||||||
| Max Service Temp. | 1000 0C | 1100 0C | 1200°C | 1300°C | 1350°C | ||||||
| Max Grain Size | 6 mm | 6 mm | 6 mm | 6 mm | 6 mm | ||||||
| Water Required for Casting | 70-100 % | 40-70 % | 35-40% | 25-35% | 25-30% | ||||||
| Chemical Analyses: -(%) | Typical | Specification | Typical | Specification | Typical | Specification | Typical | Specification | Typical | Specification | |
| Al2O3 : | 30.4 | — | 33 | — | 33 | – | 34.5 | – | 39 | – | |
| Fe2O3 : | 10.5 | 11.0 Max | 7.5 | 8.5 Max | 4.7 | 6.00 Max | 3.3 | 3.50 Max | 3 | 3.50 Max | |
| CaO : | 13.5 | — | 16 | — | 11 | – | 10.3 | – | 11 | – | |
| Physical Properties: – | |||||||||||
| B. D (gm/cc) | 0.53 | 0.55 Max | 0.82 | 0.85 Max | 0.98 | 1.00 Max | 1.23 | 1.25 Max | 1.43 | 1.45 Max | |
| Drying at 110°C/24 hrs. | |||||||||||
| Cold Crushing Strength (Kg/cm2): | |||||||||||
| Drying at 110°C/24 hrs. | 6 | 4 Min | 15 | 12 Min | 20 | 15 Min | 40 | 35 Min | 55 | 50 Min | |
| Fired at 800°C/3hrs. | 4 | 2 Min | 9 | 4 Min | 10 | 6 Min | 35 | 25 Min | 40 | 30 Min | |
| Fired at 1100°C/3hrs. | — | — | 12 | 6 Min | — | — | 30 | 25 Min | 35 | 30 Min | |
| Fired at 1200°C/3hrs. | — | — | — | — | 15 | 10 Min | — | — | — | — | |
| Fired at 1300°C/3hrs. | — | — | — | — | — | — | 45 | 40 Min | 60 | 50 Min | |
| Fired at 1350°C/3hrs. | — | — | — | — | — | — | — | — | |||
| Thermal Properties: – | |||||||||||
| Refractoriness, Orton / 0 C | — | — | 12 | 12/1337 Min | 14 | 14/1398 Min | 14 | ||||
| PLC (%) | ± 0.20 Μαξ | 0.05 | ± 0.20 Μαξ | ||||||||
| Fired at 800°C/3hrs. | -0.25 | ± 0.40 Μαξ | -0.25 | ± 0.80 Μαξ | -0.3 | ± 0.60 Μαξ | 0.15 | ||||
| Fired at 1000°C/3hrs. | -0.5 | ± 0.60 Μαξ | -0.56 | ± 1.20 Μαξ | — | — | — | — | — | — | |
| Fired at 1100°C/3hrs. | — | — | — | — | -0.5 | ± 1.00 Μαξ | 0.5 | ± 1.00 Μαξ | 0.5 | ± 0.80 Μαξ | |
| Fired at 1300°C/3hrs. | — | — | — | — | — | — | — | — | — | — | |
| Fired at 1350°C/3hrs. | — | — | — | — | — | — | — | — | — | — | |
| Thermal Conductivity , K Cal/m/hr/0C | |||||||||||
| @300 0C | 0.07 | — | 0.15 | — | 0.24 | — | 0.27 | — | 0.3 | — | |
| @500 0C | 0.09 | 0.10 Max | 0.17 | 0.18 Max | 0.26 | 0.28 Max | 0.3 | 0.31 Max | 0.32 | 0.33Max | |
| @800 0C | 0.12 | — | 0.19 | — | 0.28 | — | 0.32 | — | 0.35 | — | |
| Water requirements indicated are based on laboratory test conditions. Actual water requirement may vary subject to site conditions. The properties shown are for vibratory cast material only unless specified otherwise. All values are based on test results on standard bars of size 160x40x40 mm. Test methods are guided by and based on various Indian Standards (IS). | |||||||||||
| Brand Name: – | HR INSULCAST 15 | HR POURABLE INSULATION | HR INSULCAST 11 Li | HR INSULCAST 11 Liz | HR INSULCAST 13 Li | |||||
| Type | Moderate density insulating Castable | Insulating Castable Used By Pouring | Medium density insulating Castable | Medium density insulating Castable | Moderate density insulating Castable | |||||
| Nature of Bond | Hydraulic | Hydraulic | Hydraulic | Hydraulic | Hydraulic | |||||
| Installation | Tamping | Pouring | Tamping | Tamping | Tamping | |||||
| Raw Material Base | Insulating Aggregate | Exfoliated Vermiculite | Insulating Aggregate | Insulating Aggregate | Insulating Aggregate | |||||
| Max Service Temp. | 1350°C | 900°C | 1350°C | 1300°C | 1400°C | |||||
| Max Grain Size | 6 mm | 6 mm | 6 mm | 6 mm | 6 mm | |||||
| Water Required for Casting | 23-28% | 55-70% | 30-35% | 40-45% | 25-30% | |||||
| Chemical Analyses: – (%) | Typical | Specification | Typical | Specification | Typical | Specification | Typical | Specification | Typical | Specification |
| Al2O3 : | 39.5 | — | 20.8 | — | 44.2 | – | 45.8 | — | 44.2 | – |
| Fe2O3 : | 2.5 | 3.20 Max | 7.5 | 9.0 Max | 1.3 | 1.50 Max | 1.1 | 1.20 Max | 1.3 | 1.50 Max |
| CaO : | 11 | — | 26 | — | 8.1 | – | 10 | — | 8.1 | – |
| Physical Properties: – | ||||||||||
| B. D (gm/cc) | 1.58 | 1.60 Max | 0.65 | 0.70 Max | 1.23 | 1.25 Max | 0.98 | 1.00 Max | 1.43 | 1.45 Max |
| Drying at 110°C/24 hrs. | ||||||||||
| Cold Crushing Strength (Kg/cm2): | ||||||||||
| Drying at 110°C/24 hrs. | 100 | 90 Min | 20 | 15 Min | 50 | 45 Min | 20 | 15 Min | 90 | 80 Min |
| Fired at 800°C/3hrs. | 70 | 60 Min | 15 | 12 Min | 40 | 30 Min | 14 | 10 Min | 50 | 40 Min |
| Fired at 1100°C/3hrs. | 65 | 60 Min | — | — | 35 | 30 Min | 12 | 8 Min | 45 | 40 Min |
| Fired at 1200°C/3hrs. | — | — | — | — | — | — | — | — | — | — |
| Fired at 1300°C/3hrs. | 80 | 70 Min | — | — | 55 | 50 Min | 18 | 15 Min | — | — |
| Fired at 1350°C/3hrs. | — | — | — | — | — | — | — | — | 60 | 50 Min |
| Thermal Properties: – | ||||||||||
| Refractoriness, Orton / 0 C | 15 | 15/1430 Min | — | — | 14 | 15/1398 Min | 14 | 15/1398 Min | 15 | 15/1430 Min |
| PLC (%) | ||||||||||
| Fired at 800°C/3hrs. | — | — | -1.2 | ± 1.50 Μαξ | — | — | — | — | — | — |
| Fired at 1000°C/3hrs. | — | — | — | — | — | — | — | — | — | — |
| Fired at 1100°C/3hrs. | 0.05 | ± 0.20 Μax | — | — | -0.1 | ± 0.20 Μax | -0.2 | ± 0.20 Μax | -0.1 | ± 0.20 Μax |
| Fired at 1300°C/3hrs. | 0.5 | ± 1.00 Μax | — | — | -0.7 | ± 1.00 Μax | -0.9 | ± 1.00 Μax | — | — |
| Fired at 1350°C/3hrs. | — | — | — | — | — | — | — | — | -0.6 | ± 0.80 Μax |
| Thermal Conductivity , K Cal/m/hr/0C | ||||||||||
| @300 0C | 0.39 | — | 0.18 | — | 0.3 | — | 0.19 | — | 0.35 | — |
| @500 0C | 0.42 | 0.44Max | 0.19 | 0.20 Max | 0.32 | 0.34Max | 0.21 | 0.22Max | 0.38 | 0.40Max |
| @800 0C | 0.45 | — | 0.2 | — | 0.36 | — | 0.23 | — | 0.41 | — |
| Water requirements indicated are based on laboratory test conditions. Actual water requirement may vary subject to site conditions. The properties shown are for vibratory cast material only unless specified otherwise. All values are based on test results on standard bars of size 160x40x40 mm. Test methods are guided by and based on various Indian Standards (IS). | ||||||||||
| Brand Name: – | HR INSULCAST 15 Li | HR INSULCAST 8 S | HR INSULCAST 10 S | HR CAST 97 L | HR INSULCAST 9 HS | |||||
| Type | Moderate density insulating Castable | Low density insulating Castable | Medium density insulating Castable | Insulating Castable For 18000 C Temp. | Medium density insulating Castable (High Strength) | |||||
| Nature of Bond | Hydraulic | Hydraulic | Hydraulic | Hydraulic | Hydraulic | |||||
| Installation | Tamping | Tamping | Tamping | Tamping | Tamping | |||||
| Raw Material Base | Insulating Aggregate | Insulating Aggregate | Insulating Aggregate | Bubble Alumina | Insulating Aggregate | |||||
| Max Service Temp. | 1400°C | 1300°C | 1100°C | 1800°C | 1200°C | |||||
| Max Grain Size | 6 mm | 6 mm | 6 mm | 6 mm | 6 mm | |||||
| Water Required for Casting | 23-28% | 46-50% | 40-46% | 13-18 % | 35-40% | |||||
| Chemical Analyses: – (%) | Typical | Specification | Typical | Specification | Typical | Specification | Typical | Specification | Typical | Specification |
| Al2O3 : | 45.7 | — | 43.5 | 40 Min | 33.8 | – | 94.3 | 94.0 Min | 40.5 | 40.0 Min |
| Fe2O3 : | 1.3 | 1.50 Max | 0.9 | 1.0 Max | 3.5 | 6.0 Max | 0.2 | 0.3 Max | 2.6 | 3.0 Max |
| CaO : | 8 | — | 11.2 | – | 15 | – | 4.8 | 5.0 Max | 7.8 | 8.0 Max |
| Physical Properties: – | ||||||||||
| B. D (gm/cc) | 1.58 | 1.60 Max | 0.88 | 0.900 Max | 1.05 | 1.10 Max | 1.6 | 1.65Max | 0.98 | 1.00 Max |
| Drying at 110°C/24 hrs. | ||||||||||
| Cold Crushing Strength (Kg/cm2): | ||||||||||
| Drying at 110°C/24 hrs. | 140 | 130 Min | 25 | 25 Min | 25 | 20 Min | 80 | 70 Min | 25 | 20 Min |
| Fired at 800°C/3hrs. | 90 | 75 Min | 23 | 20 Min | 18 | 15 Min | 70 | 60 Min | 15 | 8 Min |
| Fired at 1100°C/3hrs. | 80 | 75 Min | — | — | — | — | 55 | 40 Min | — | — |
| Fired at 1200°C/3hrs. | — | — | — | — | 15 | 12 Min | — | — | 20 | 15 Min |
| Fired at 1300°C/3hrs. | 110 | 90 Min | 34 | 30 Min | — | — | — | — | — | — |
| Fired at 1550°C/3hrs. | — | — | — | — | — | — | 75 | 60 Min | — | — |
| Thermal Properties: – | ||||||||||
| Refractoriness, Orton / 0 C | 15 | 15/1430 Min | 15/1430 | 14/1398 Min | 13/1350 | 12/1337 Min | 38 | 38/1835 Min | 14 | 14/1398 Min |
| PLC (%) | ||||||||||
| Fired at 800°C/3hrs. | — | — | -0.18 | ± 0.30 Μax | -0.06 | ± 0.80 Μax | -0.03 | ± 0.20 Μax | -0.3 | ± 0.60 Μax |
| Fired at 1100°C/3hrs. | -0.1 | ± 0.20 Μax | -0.3 | ± 0.50 Μax | -0.6 | ± 1.20 Μax | -0.06 | ± 0.20 Μax | -0.55 | ± 1.00 Μax |
| Fired at 1350°C/3hrs. | -0.5 | ± 1.00 Μax | — | — | — | — | — | — | — | — |
| Brand Name: – | HR INSULCAST 15 Li | HR INSULCAST 8 S | HR INSULCAST 10 S | HR CAST 97 L | HR INSULCAST 9 HS | |||||
| Type | Moderate density insulating Castable | Low density insulating Castable | Medium density insulating Castable | Insulating Castable For 18000 C Temp. | Medium density insulating Castable (High Strength) | |||||
| Nature of Bond | Hydraulic | Hydraulic | Hydraulic | Hydraulic | Hydraulic | |||||
| Installation | Tamping | Tamping | Tamping | Tamping | Tamping | |||||
| Raw Material Base | Insulating Aggregate | Insulating Aggregate | Insulating Aggregate | Bubble Alumina | Insulating Aggregate | |||||
| Max Service Temp. | 1400°C | 1300°C | 1100°C | 1800°C | 1200°C | |||||
| Max Grain Size | 6 mm | 6 mm | 6 mm | 6 mm | 6 mm | |||||
| Water Required for Casting | 23-28% | 46-50% | 40-46% | 13-18 % | 35-40% | |||||
| Chemical Analyses: – (%) | Typical | Specification | Typical | Specification | Typical | Specification | Typical | Specification | Typical | Specification |
| Al2O3 : | 45.7 | — | 43.5 | 40 Min | 33.8 | – | 94.3 | 94.0 Min | 40.5 | 40.0 Min |
| Fe2O3 : | 1.3 | 1.50 Max | 0.9 | 1.0 Max | 3.5 | 6.0 Max | 0.2 | 0.3 Max | 2.6 | 3.0 Max |
| CaO : | 8 | — | 11.2 | – | 15 | – | 4.8 | 5.0 Max | 7.8 | 8.0 Max |
| Physical Properties: – | ||||||||||
| B. D (gm/cc) | 1.58 | 1.60 Max | 0.88 | 0.900 Max | 1.05 | 1.10 Max | 1.6 | 1.65Max | 0.98 | 1.00 Max |
| Drying at 110°C/24 hrs. | ||||||||||
| Cold Crushing Strength (Kg/cm2): | ||||||||||
| Drying at 110°C/24 hrs. | 140 | 130 Min | 25 | 25 Min | 25 | 20 Min | 80 | 70 Min | 25 | 20 Min |
| Fired at 800°C/3hrs. | 90 | 75 Min | 23 | 20 Min | 18 | 15 Min | 70 | 60 Min | 15 | 8 Min |
| Fired at 1100°C/3hrs. | 80 | 75 Min | — | — | — | — | 55 | 40 Min | — | — |
| Fired at 1200°C/3hrs. | — | — | — | — | 15 | 12 Min | — | — | 20 | 15 Min |
| Fired at 1300°C/3hrs. | 110 | 90 Min | 34 | 30 Min | — | — | — | — | — | — |
| Fired at 1550°C/3hrs. | — | — | — | — | — | — | 75 | 60 Min | — | — |
| Thermal Properties: – | ||||||||||
| Refractoriness, Orton / 0 C | 15 | 15/1430 Min | 15/1430 | 14/1398 Min | 13/1350 | 12/1337 Min | 38 | 38/1835 Min | 14 | 14/1398 Min |
| PLC (%) | ||||||||||
| Fired at 800°C/3hrs. | — | — | -0.18 | ± 0.30 Μax | -0.06 | ± 0.80 Μax | -0.03 | ± 0.20 Μax | -0.3 | ± 0.60 Μax |
| Fired at 1100°C/3hrs. | -0.1 | ± 0.20 Μax | -0.3 | ± 0.50 Μax | -0.6 | ± 1.20 Μax | -0.06 | ± 0.20 Μax | -0.55 | ± 1.00 Μax |
| Fired at 1350°C/3hrs. | -0.5 | ± 1.00 Μax | — | — | — | — | — | — | — | — |
| Fired at 1550°C/3hrs. | — | — | — | — | — | — | 0.5 | ± 1.00 Μαξ | — | — |
| Thermal Conductivity , K Cal/m/hr/0C | ||||||||||
| @300 0C | 0.38 | — | 0.19 | — | 0.19 | — | 0.9 | — | 0.24 | – |
| @500 0C | 0.42 | 0.44Max | 0.21 | 0.22 Max | 0.21 | 0.22 Max | 0.95 | 1.10 Max | 0.26 | 0.28 Max |
| @800 0C | 0.44 | — | 0.22 | — | 0.22 | — | 1.02 | — | 0.28 | – |
| Water requirements indicated are based on laboratory test conditions. Actual water requirement may vary subject to site conditions. The properties shown are for vibratory cast material only unless specified otherwise. All values are based on test results on standard bars of size 160x40x40 mm. Test methods are guided by and based on various Indian Standards (IS). | ||||||||||
| HR INSULCAST 11 Liz | ||||
| ( AS PER MIDREX Specification) | ( AS PER MIDREX Specification) | |||
| Type | Medium density Insulating Castable | Light Weight Insulating Castable(Low Iron) | ||
| Nature of Bond | Hydraulic | Hydraulic | ||
| Installation | Tamping | Tamping | ||
| Raw Material Base | Insulating Aggregate & Perlite | Insulating Aggregate & Perlite | ||
| Max Service Temp. | 1093°C | 1260°C | ||
| Max Grain Size | 6 mm | 0 – 6 mm | ||
| Water Required for Casting | 40-50% | 55-65 % | ||
| Chemical Analyses: – (%) | Typical | Specification | Typical | Specification |
| Al2O3 : | 49.6 | 45 to 50 | 42.5 | 40-43 |
| Fe2O3 : | 0.9 | 0.5 to 1.3 | 1.2 | 0.9-1.3 |
| SiO2 : | 32 | 30 to 40 | 35.3 | 35-37 |
| Physical Properties: – | ||||
| B. D (gm/cc) | 1.1 | 0.96 to 1.12 | 0.88 | 0.83-0.93 |
| Drying at 105°C/24 hrs. | ||||
| Cold Crushing Strength (Kg/cm2): | ||||
| Drying at 105°C/24 hrs. | 97 | 80-100 | 35 | 30-37 |
| Fired at 500°C/3hrs. | 65 | 60-70 | 30 | 29-32 |
| Fired at 800°C/3hrs | 64 | 60-63 | 30 | 28-35 |
| Fired at 1100°C/3hrs | 55 | 53-56 | —- | —- |
| Fired at 1200°C/3hrs | — | — | 35 | 28-35 |
| Thermal Properties: – | ||||
| Refractoriness, Orton / 0 C | 14 | Service Temp. 10930C | 14 | Service Temp. 12600C |
| PLC (%) | ||||
| Fired at 800°C/3hrs. | -0.1 | -0.9 Max | -0.30 | – 0.5 to -0.7 |
| Fired at 1100°C/3hrs. | -0.53 | -1.10 Max | — | — |
| Fired at 1200°C/3hrs | —- | —- | -1 | -1.7 to –1.9 |
| Thermal Conductivity , K Cal/m/hr/0C | ||||
| @260 0C | — | — | 0.1 | 0.161 – 0.164 |
| @538 0C | 0.24 | 0.24-0.25 | 0.13 | 0.174-0.177 |
| @815 0C | 0.28 | 0.27-0.30 | 0.17 | 0.198-0.205 |
| Water requirements indicated are based on laboratory test conditions. Actual water requirement may vary subject to site conditions. The properties shown are for vibratory cast material only unless specified otherwise. All values are based on test results on standard bars of size 160x40x40 mm. Test methods are guided by and based on various Indian Standards (IS). | ||||