Calcium Aluminate Cement CAC 50
Calcium Aluminate Cement CAC 50, also known as High-Alumina Cement (HAC), is a specialized hydraulic cement where the primary active components are calcium aluminates (CA, C₁₂A₇, etc.) rather than the calcium silicates (C₃S, C₂S) found in Ordinary Portland Cement (OPC).
The 50% grade refers to the typical Al₂O₃ content (approximately 50% to 55%). This cement is widely used in refractory castables and construction applications where resistance to heat, aggressive chemical environments, and rapid strength development are required.
Main Function and Characteristics
CAC 50% acts as the hydraulic binder in refractory castables, providing quick setting, high strength, and maintaining refractoriness up to moderate temperatures.
| CHARACTERISTIC | VALUE RANGE | PRIMARY REFRACTORY FUNCTION |
|---|---|---|
| Alumina (Al₂O₃) Content | ~50% to 55% | Determines the refractoriness of the final castable. |
| PCE (Refractoriness) | >1550°C | Allows for general-purpose use in medium-heat environments. |
| Setting Time | FAST | Essential for rapid installation and de-molding. |
CLASSIFICATION
- Binding Focus: Hydraulic Refractory Binder – Forms stable crystalline hydrates upon mixing with water.
- Primary Application Focus: Conventional Castables, Repair Mortars, and Corrosion-Resistant Concrete.
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
|---|---|---|
| Early Strength | HIGH | Achieves load-bearing strength rapidly (e.g., in hours), accelerating construction. |
| Abrasion/Corrosion | EXCELLENT | Resistant to chemical attack from acids (to a degree) and sulfur compounds. |
| Thermal Stability | GOOD | Maintains mechanical strength at elevated temperatures compared to OPC. |
Calcium Aluminate Cement CAC 50
- The Hydration and Conversion Mechanism
When CAC is mixed with water, it forms crystalline hydrate phases (CAH₁₀, C₂AH₈, etc.), which lock the aggregate grains together and provide the initial hydraulic bond (green strength).
- Thermal Conversion (Danger Zone): As CAC is heated in service, these hydrate phases decompose around 100°C to 300°C, causing a temporary loss of physical strength (known as the “conversion” or “red hardness” phase). However, as temperatures rise further (above ~800°C), the CAC reacts with the fine refractory aggregates to form a ceramic bond that restores and often exceeds the original strength.
- Refractoriness: The CAC 50% grade is sufficient for conventional castables (those using 15% to 30% cement) in general medium-duty applications. For higher service temperatures, CAC grades with 70% or 80% Al₂O₃ (used in LCC/ULCC castables) are required.
- Comparison with Other Binders
- Ordinary Portland Cement (OPC): CAC has far superior heat resistance. OPC melts/softens below 1200°C due to its high SiO₂ content, making it unusable for most refractory applications.
- Chemical Binders (e.g., Phosphates): CAC offers the convenience of a water-mix hydraulic set, avoiding the need for strong acids or complex chemical reactions.
- Technical Guidance
- Heat of Hydration: CAC releases a significant amount of heat during setting. Proper curing (keeping the castable cool and moist) is vital to prevent rapid water evaporation and explosive spalling during the dry-out process.
- Water Ratio: Precise control of the water-to-cement ratio is essential. Too much water compromises the final strength and density.
✨ 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. |
