Silica Brick Zero Expansion
Silica Brick Zero Expansion are true Silica refractories composed of high SILICA (SiO2) purity (94% to 98%), with very low levels of fluxes. The key distinction is the advanced, specialized firing process designed to fully convert all quartz to Cristobalite and Tridymite before the brick is shipped.
| CATEGORY | SiO2 CONTENT | KEY FEATURE | PRIMARY ADVANTAGE |
| ZERO EXPANSION | 94% to 98% | Pre-converted SiO2 phases | Eliminates installation expansion risk |
| STANDARD SILICA | 94% to 98% | Unconverted Quartz | Requires a complex, slow initial heat-up |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | VARIATION WITH PRE-CONVERSION |
| Installation Expansion | ZERO | CRITICAL: Standard Silica expands up to 3% during initial heat-up; this product is already stabilized. |
| Temperature Under Load (TUL) | MAXIMAL (Excellent) | IMPROVES with SiO2 purity, resisting deformation almost up to the fusion point. |
| Thermal Shock | POOR | Sensitivity remains due to the Cristobalite phase inversions occurring at 270°C and the Tridymite inversions at 163°C/117°C. |
| Volume Stability | EXCEPTIONAL at high temperatures | GUARANTEED by the complete conversion of quartz to the stable high-temperature polymorphs. |
Silica Brick Zero Expansion
Advantages and Key Characteristics
Zero Expansion Silica bricks are premium products that offer the superior high-TUL performance of Silica without the catastrophic risk of uncontrolled expansion during initial firing, significantly simplifying installation and commissioning.
- Eliminates Initial Expansion: Standard Silica bricks swell by 1.5% to 3.0% during the first firing due to the conversion of quartz to cristobalite/tridymite. This product, having completed the conversion, allows for immediate, precise installation without the need for large expansion allowances.
- Simplified Heat-Up Schedule: The initial slow, complex heat-up phase required below 600°C for standard Silica (to manage expansion) is drastically simplified or eliminated, saving significant time and risk during commissioning.
- High Load Bearing (TUL): Retains the core benefit of Silica, offering maximum structural rigidity under load at temperatures approaching the melting point (700°C), critical for large crowns.
Typical Industries and Applications
This brick is used in all major applications requiring Silica, but where the operational risks associated with initial firing are a major concern:
- Glass Industry: Crowns of large glass melting furnaces, where precise arch geometry and minimal stress are vital.
- Coke Ovens: Walls and roofs of new coke oven batteries, where expansion must be tightly controlled to prevent damage to the steel framework.
- Large Arch/Dome Construction: Any structure where the mass and rigidity of the arch demand volume-stable components from day one.
Furnace Areas and Service Zones
They are used in zones demanding the highest structural stability and simplest installation:
- FURNACE CROWNS: The main application, ensuring immediate arch stability without the need for crushable expansion joints.
- HOT ZONES (Structural): Used in any structural high-temperature area where the consequences of uncontrolled expansion are severe.
Key Data Sheet Properties to Consider
Selection criteria focus entirely on the degree of pre-conversion:
- QUARTZ CONTENT: THE CRITICAL VALUE. Must be reported as near zero or below 0.5% to confirm the “Zero Expansion” claim.
- CRISTOBALITE/TRIDYMITE CONTENT: Should be high, confirming that the SiO2 polymorphs are stable for the operating range.
- Permanent Linear Change (PLC): Should be near zero when re-tested at high temperatures, confirming stability.
- Refractoriness Under Load (TUL): Must be high, matching the required structural limit.
Technical Guidance: Zero Expansion Silica bricks are the ultimate safety measure for STRUCTURAL SILICA INSTALLATIONS. While they eliminate the risk of initial quartz conversion expansion, they DO NOT eliminate the risk of thermal shock from the Cristobalite and Tridymite inversions. A slow cool-down and careful low-temperature cycling (100°C to 300°C) are still mandatory during operation to prevent spalling.
✨ Customization Services
We offer product customization services, allowing you to tailor the appearance, dimensions, or specific markings of items like refractory shapes or bricks. This includes options for incorporating specific geometric requirements to ensure seamless integration into your process systems.
🔬 Sampling for Testing & Validation
Free product samples are available for thorough testing and validation. This allows you to confirm the quality, compatibility, and performance of our materials—such as specific bricks, castables, or raw materials—before committing to a full order.
💡 Expertise in Refractory Solutions
Leverage our deep expertise to receive detailed, application-specific refractory solutions. We move beyond just selling products by providing comprehensive plans that encompass material selection, installation guidance, and performance optimization to maximize the lifespan and efficiency of your high-temperature processes.
Rabatec products are exclusively manufactured in facilities that have achieved rigorous ISO certifications across Quality (ISO 9001), Environmental Management, and Occupational Health & Safety. This commitment ensures every product, from refractory bricks to specialized equipment, meets the highest global benchmarks for performance, sustainability, and workplace safety.
📦 Logistics Excellence: Shipping, Packaging, and Marking
Minimizing Risk: We manage all logistics to minimize handling touchpoints and transit shock. Our carriers are pre-vetted for their experience in transporting heavy, fragile, and sensitive industrial materials.
Traceability: Every shipment includes comprehensive documentation and tracking information, providing end-to-end visibility and ensuring precise delivery coordination for your site.
Protection is Paramount: Our packaging strictly follows industry standards to prevent damage, corner chipping, and moisture absorption—especially critical for materials like Basic Refractory Bricks and Refractory Mortars & Mixes.
Robust Palletization: Products are secured on fumigated, high-strength export pallets (e.g., 1100x950mm or similar sturdy dimensions) using heavy-duty strapping and durable protective wrapping (polyethylene sheeting, cardboard, etc.) to withstand long-distance travel and multiple loadings.
Moisture Control: Sensitive materials are protected with appropriate sealing and, where necessary, desiccants or moisture-vapor proof enclosures to maintain the product's integrity until installation.
Clear Identification: All outer packaging is clearly marked on multiple sides with large, legible text for immediate identification and safe handling.
Full Traceability: Markings include all essential data points: Product Name, Quality Grade, Batch Number, Quantity, Net/Gross Weight, Order Number, and the Final Destination/Construction Area. This ensures every pallet can be accounted for and correctly staged upon arrival.
Safety & Compliance: We adhere to all regulatory requirements for marking, labeling, and placarding—especially for any items classified as Dangerous Goods—to ensure full compliance with international and domestic transport regulations.
❓ Frequently Asked Questions (FAQ)
Question | Elaborated Answer |
Q: What is the Refractoriness Under Load (RUL) of your refractories? | A: Refractoriness Under Load (RUL) is a critical property that defines the maximum temperature our materials can withstand while under compressive stress before deforming (softening). Since we offer a wide range of materials—from Alumina-Silicate Bricks to high-performance Silicon Carbide Bricks—the RUL varies significantly. For specific product data, please refer to the product data sheet or submit a quote request for the material you are interested in. |
Q: Where are the Rabatec refractories and materials produced? | A: Our products are primarily sourced from specialized manufacturing plants in China. Crucially, these facilities have all undergone rigorous audits and achieved comprehensive ISO certifications (Quality, Environment, and Safety), ensuring that production adheres to the highest global standards for consistency and performance. |
Q: What refractory materials does the company offer? | A: We supply a comprehensive portfolio of advanced refractory solutions, including: Shaped Products: Alumina & Silica Bricks, Basic & Specialized Bricks (e.g., Magnesia), SiC & Structural Ceramics, and Precast Shapes. Monolithic Products: Refractory Castables, Mixes & Mortars. Insulation: Insulation Fibre and High-Performance Insulation Products. |
Q: How should I choose the appropriate refractory material for my application? | A: Selecting the correct refractory is paramount to process efficiency. The choice depends on three key factors: 1. Operating Environment: Maximum process temperature and thermal cycling (shock). 2. Chemical Attack: Type of slag, molten metal, or corrosive gas being handled (acidic, neutral, or basic). 3. Mechanical Stress: Abrasion, erosion, and static load requirements. We recommend utilizing our detailed refractory solutions service to consult with our engineers for an optimized, application-specific recommendation. |
Q: Which monolithic material should I choose when patching an existing lining? | A: For patching and minor repairs, the ideal monolithic material depends on the parent lining material, the patching depth, and the need for a rapid return to service. Common choices include: Refractory Mortars & Mixes (for minor joints/surfaces) or Plastic Refractories (for areas requiring physical compaction). Always choose a patch material chemically compatible with the existing lining to ensure proper bonding and service life. |
Q: Can I receive product samples before placing a major order? | A: Yes. We gladly provide product samples for your internal testing and validation purposes. This ensures you can confirm the quality, composition, and fit of the material—such as our Refractory Castables or Alumina-Silicate Bricks—in your specific operational environment before committing to a bulk purchase. |
Q: Do you provide certifications to verify material quality? | A: Absolutely. We provide product-related inspection certificates and quality assurance documentation upon request. This verifies that your order has passed all internal quality control checks and meets the required material specifications and industry standards. |
Q: What measures are taken for product protection during transport? | A: We ensure quick, reliable transport by using robust, industrial packaging that strictly follows industry standards. This includes high-strength palletization, heavy-duty strapping, and weather-resistant wrapping to protect fragile items like bricks and mixes from corner chipping, mechanical damage, and moisture during transit. |
