Silica Ramming Mixes
Silica Ramming Mixes SiO2 is made predominantly of high-purity Quartz or fused Silica sand (SiO2 ≥ 98.5%) with a precisely controlled grain size distribution. The binder is typically a low percentage of an inorganic chemical, such as Boric Acid (H3BO3), which acts as a sintering agent to promote the formation of a durable glassy bond at the hot face.
| COMPONENT | CONTENT | CHEMICAL BASE | PRIMARY ADVANTAGE |
| Aggregate | SiO2 ≥ 98.5% | Quartz / Fused Silica | Acidity, excellent volume stability |
| Binder | Boric Acid (B2O3) | Inorganic Sintering Agent | Forms a low-temperature glassy phase for hot face strength |
| VARIANT | B2O3 Content | APPLICATION NOTE |
| Wet/Dry | 0.5% to 2% | Content must be tuned to the operating temperature and campaign length. |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Chemical Resistance | EXCELLENT (Acid) | Highly stable against iron oxide and metallic charge, suitable for grey and ductile iron melting. |
| Volume Stability | EXTREME | Silica undergoes minimal volume change at high T compared to other oxides, providing lining stability. |
| Installation Density | VERY HIGH | Vibration/ramming achieves minimal porosity, inhibiting metal penetration. |
| Hot Strength | MODERATE-HIGH | Sintered hot face is strong; cold face remains unfired, creating an engineered wear-out profile. |
Advantages and Key Characteristics
Silica Ramming Mixes SiO2 is the standard, most economical choice for melting iron and low-alloy steels in CIFs, offering a unique wear mechanism for safety and longevity.
- Controlled Sintering and Safety: Upon initial firing, the B2O3 binder promotes the sintering of the inner working face, creating a strong, dense crucible. Crucially, the material further away from the hot face remains unsintered (“loose”). This loose layer acts as a safety barrier; if the hot face is worn through, the molten metal is rapidly chilled by the cold induction coil and solidifies against the loose, unsintered SiO2, preventing catastrophic failure.
- Cost-Effective: As Silica sand is abundant and inexpensive, SiO2 Ramming Mass provides a very low-cost lining solution compared to basic MgO or neutral Al2O3 ramming masses.
- Monolithic Crucible: The material is packed around a metal former, creating a seamless, joint-free crucible that precisely fits the induction coil, maximizing melting efficiency and eliminating the weak points found in brick linings.
- Chemical Affinity: The acidic SiO2 is chemically compatible with the iron/steel melt and FeO-rich slag generated, providing adequate resistance in the intended application range.
Typical Industries and Applications
This product is specialized for iron and general foundry operations:
- Foundry/Ferrous Industry: Working lining of Coreless Induction Furnaces (CIF) used for melting grey iron, ductile iron, malleable iron, and certain non-aggressive grades of steel.
- Smelting: Used in small, non-ferrous induction furnaces for melting Cu or Zn alloys.
Furnace Areas and Service Zones
They are specified for the metal-contact working lining:
- CIF CRUCIBLE: The entire inner working lining containing the molten metal and slag.
Key Data Sheet Properties to Consider
Selection criteria focus on purity, density, and binder:
- SiO2 Purity: CRITICAL VALUE. Must be high (SiO2 ≥ 98.5%) to ensure maximum refractoriness and controlled sintering.
- B2O3 Content: The percentage must be confirmed and matched to the furnace size and operational cycle (higher percentage for lower operating T).
- Installation Density: Look for the required Rammed/Vibrated Bulk Density (BD) (e.g., > 1.8 g/cm3) which is vital for performance and safety.
- Mineralogy: Should confirm the material is quartz (or fused silica) which ensures the correct sintering and volume stability profile.
Technical Guidance: Successful installation requires strict density control achieved through specialized vibrating tools. The initial sintering procedure (heat-up with a plug or charge) is critical to forming the working face and must be precisely followed to prevent lining washout. SiO2 ramming mass is not suitable for highly basic (CaO-rich) slags or for high-manganese steel melting, as these cause rapid fluxing and failure.
✨ 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. |
