Aluminum Silicate Fiber Cloth Needle Blanket
Aluminum Silicate Fiber Cloth Needle Blanket are high-temperature insulating materials, often referred to by the trade name Refractory Ceramic Fiber (RCF). They are manufactured by melting a blend of Alumina (Al2O3) and Silica (SiO2) and blowing or spinning the liquid into fine, flexible fibers. These fibers are the foundation for a range of lightweight, highly effective thermal insulation products.
Main Chemical Compositions & Categories
RCF is classified by its Al2O3 content, which determines its maximum service temperature (MST).
| CATEGORY | Al2O3/SiO2 Content | TYPICAL MST | PRIMARY ADVANTAGE |
| Standard RCF | 45% Al2O3 / 55% SiO2 | ~1260°C | Good thermal performance, most economical. |
| High Alumina RCF | $50\%$ to $60\%$ $\text{Al}_{2}\text{O}_{3}$ | ~1430°C to 1540°C | Higher MST, reduced shrinkage at heat. |
| Low Bio-Persistence (LBP) | Various | Similar to RCF | Engineered to be less durable in biological systems (for health/safety). |
Key Forms and Applications
The base fiber is converted into various formats for specific uses:
| PRODUCT FORM | TYPICAL DENSITY | PRIMARY APPLICATION |
| Fiber/Bulk | Loose fibers | Used as furnace packing, gunning mix aggregate. |
| Needle Blanket | 46 to 168 kg/m3 | Primary furnace lining (hot face or backup), kiln cars, module fabrication. |
| Cloth/Tape/Rope | Woven/Braided | Gaskets, seals, flexible thermal barriers, pipe wrapping. |
Aluminum Silicate Fiber Cloth Needle Blanket
Advantages and Key Characteristics
Ceramic Fiber products are fundamentally different from dense firebrick or castables. Their strength lies in their high porosity and extremely low thermal mass, making them indispensable for energy-efficient furnaces.
- Extremely Low Thermal Conductivity (k): The high volume of trapped air within the fiber matrix provides exceptional insulating power, minimizing heat loss.
- Low Thermal Mass/Heat Storage: RCF products absorb very little heat. This is a crucial advantage for intermittent furnaces (batch operations), allowing the furnace to be heated and cooled quickly, saving tremendous amounts of fuel and cycle time.
- Thermal Shock Resistance: The flexible, low-mass structure allows the material to absorb rapid temperature changes without cracking or spalling, unlike rigid refractories.
- Flexibility and Ease of Installation: Blankets, ropes, and cloth can be easily cut, molded, wrapped, and installed without complex masonry skills, allowing for fast, customized repairs or lining construction.
Typical Industries and Applications
RCF is used across nearly all industries that require high-temperature insulation:
- Furnace Linings: Used as the primary hot-face lining (often as pre-compressed modules) or backup insulation behind dense brick/castables in annealing furnaces, forging furnaces, kilns, and heat-treating ovens.
- Sealing and Gasketing: Cloth, rope, and braided packing are used to seal furnace doors, lids, vents, and expansion joints, preventing heat leakage.
- Kiln Cars: Used to insulate the surface of kiln cars in continuous kilns to prevent heat loss into the car structure.
- Acoustic and Fire Protection: Used in high-temperature environments to absorb sound and as a fire-blocking material.
Key Data Sheet Properties to Consider
Selection is highly dependent on the maximum temperature and required density:
- Maximum Service Temperature (MST): CRITICAL VALUE. Must exceed the maximum operating temperature of the furnace. Overheating causes crystallization and shrinkage.
- Density (for Blankets): Higher density (128 kg/m3 vs. 96 kg/m3) provides better mechanical erosion resistance but slightly higher thermal mass.
- Shrinkage: Look for low Permanent Linear Change (PLC) at the MST to ensure the blanket maintains its dimensions over time.
- Fiber Index: The percentage of usable fibers (low shot content is desirable).
Technical Guidance: While RCF is chemically stable against many gases, contact with acidic fumes or basic oxide vapors (like Na2O or K2O) can cause fluxing and premature failure. Safety Note: RCF is classified as a potential respiratory irritant; modern installations often favor Low Bio-Persistence (LBP) fiber alternatives where available.
✨ 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. |
