Monolithics · Castables & Mortars
Castables and mortars — the monolithic backbone
Castables let you cast complex shapes in place. Mortars hold brickwork together. Both are routine high-volume consumables on every running plant, and both are stocked at our Chakan warehouse in standard 25 kg sealed bags ready for same-day dispatch.
LCC/ULCC
Low & Ultra-Low Cement
Self-Flow
Vibration-Free Pour
25 kg
Sealed Bag Standard
Stocked
Same-Day Dispatch
Overview
Castables & Mortars — what they are, when to specify
Refractory castables are dry mixes of refractory aggregate, calcium-aluminate cement (or alternative bond) and additives that you add water to and pour or vibrate into formwork on site. The cement family (conventional 15-30%, low-cement 4-8%, ultra-low-cement 1-3%, no-cement / sol-gel) sets the strength, drying schedule and high-temperature performance.
Grades
Stocked grades — pick by service condition
Indicative properties only. Final specification is set per application after we review your operating envelope.
| Grade | Composition | Service Limit | Typical Application |
|---|---|---|---|
| Conventional Castable (CC) | 40-60% | 1450-1550 °C | General lining, repair work, low-stress areas |
| Low-Cement Castable (LCC) | 60-85% | 1550-1700 °C | Furnace floors, ladle bottoms, kiln transition zones |
| Ultra-Low-Cement Castable (ULCC) | 75-90% | 1650-1800 °C | Petrochemical reformers, glass-tank superstructure, hot-spot inserts |
| Self-Flow Castable (SFC) | 70-90% | 1650-1750 °C | Congested areas, anchor-rich linings, no-vibration pours |
| SiC-Bonded Castable | 40-60% (with SiC 25-40%) | 1500 °C | Aluminium runners, incinerator floors, abrasive zones |
| Insulating Castable | 35-50% | 1100-1300 °C | Backup linings, casing thermal-bridge breaks |
| Air-Set Mortar | 40-70% | 1450-1650 °C | Brick jointing — sets at room temperature |
| Heat-Set Mortar | 60-80% | 1550-1750 °C | Brick jointing — sets only at operating temperature |
Supplied dry-mixed in 25 kg moisture-barrier bags. Shelf life 6-9 months from manufacture. Air-set mortars in plastic pails (25 kg) ready to use.
Datasheets available on request — email punesales@chaneyco.com with your specification and we will send the matching PDF.
Applications
Where castables & mortars are specified
Aluminium
Furnace runners, holding-furnace floors, dross cooling
Steel & Foundry
Ladle bottoms, EAF roof delta, runner systems
Cement & Lime
Kiln nose-ring, preheater cyclones, cooler grates
Power & Energy
AFBC/CFBC bed linings, cyclone separators
Petrochemicals
Reformer floors, FCC regenerator standpipes
Why Chaneyco
Three reasons buyers source castables & mortars from us
Stocked at Chakan, dispatched fast
Castables & Mortars are held at our Chakan plant in Pune. Standard grades dispatch same-day to plants in the Pune industrial belt and within days pan-India by road or rail.
Spec advice before quote
Choosing the right grade for the operating envelope makes a much bigger lifecycle-cost difference than haggling on the cheapest grade. Our technical team will recommend by zone before quoting.
ISO 9001:2015 audit-ready
Every batch ships with composition and dimensional QC records, supported by our ISO 9001:2015 certification (Cert. 11553, AQSR / USAC accredited, valid through 17 Sept 2027).
Frequently Asked
Castables & Mortars questions, answered
LCC vs ULCC vs conventional — which do I use?
Rule of thumb: conventional for non-critical and repair work; LCC for steady-state hot-face linings under 1700 °C; ULCC where you need maximum hot strength and minimum porosity (refractoriness-under-load). Cost goes up as cement comes down. We will recommend by zone after reviewing operating conditions.
Do I need to vibrate the cast?
Conventional and LCC need vibration to release entrained air. Self-flow castables are formulated to flow under their own weight and self-deair — useful in congested anchor-rich linings where a poker can't reach. ULCC is normally vibrated unless you specifically order the SFC variant.
How important is dry-out schedule?
Critical. Castables hold both physical water (up to ~110 °C boil-off) and chemically bound water (up to ~600 °C release). Skip the controlled dry-out and you trap steam, blow off the hot face, or crack the entire lining. We supply the dry-out schedule with every cast and can arrange supervised dry-out from our Chakan crew.
Talk to a Refractory Engineer
Tell us about your application
Share the basics — furnace type, operating temperature, atmosphere, the lining zone you are specifying. Our technical team responds within one working day with grade recommendation, indicative quote and lead time.