Calderys Monolithic Refractories, Bricks, Gunning Mixes and Tap-Hole Clay

Selection and quotation of Calderys refractories: castables and mixes, bricks, precast shapes, CALDE SILICA MIX, tap-hole clay, ACCUTHERM fluxes and HYSIL insulation.

Monolithic Refractories: Castables, Plastics and Ramming Mixes

Calderys unshaped refractories serve non-ferrous metallurgy, steel, cement, petrochemical and waste disposal plants. The range covers plastic, ramming, patching and coating refractories, mortars and insulating castables. For a given dry-out time there are LCC, ULCC, QD and sol-gel grades.

Low cement LCC and ultra-low cement ULCC castables
Quick Dry (QD) and sol-gel no cement castables
Plastic, ramming, patching and coating mixes, mortars
Fast dry ranges CALDE FD and ALKON FD

Gunning Mixes for Lining Maintenance

The Calderys gunning product shows a low to high viscosity behavior at the point of impact. This gives good adherence to the deformed lining profile and a very low level of rebound. Layers can be built up one over another without significant spalling. CALDE GUN is developed for gunning in foundries.

Low to high viscosity behavior at the point of impact
Very low rebound and good adherence to the profile
Multi-layer build-up without significant spalling
Calderys gunning machines for EAF, BOF and ladles

Refractory Bricks: Alumina, Magnesia and Magnesia-Carbon

Calderys makes bricks through its subsidiary Haznedar Durer (Türkiye), its plant in Odisha (India) and the HWI brand (USA). The range covers high alumina, andalusite and mullite, corundum, insulation, fired magnesite, magnesia-spinel and chrome-magnesite bricks, plus resin bonded grades.

Resin bonded magnesia-carbon, alumina-magnesia, dolomite
CALDE MAG B MF bricks for the cement kiln burning zone
AUREX alumina-chrome bricks for copper refining
Andalusite and mullite basis bricks

Precast Refractory Shapes

Calderys precast shapes are made from its own monolithics, custom designed to fit the unit and cast at a Calderys site or on site. Dry-out is done off the production floor, which cuts installation time and shut down duration. Fireclay blocks serve glass furnace bottoms, doghouses and throats.

Any shape and thickness to the unit specification
Glass furnace fireclay slabs from 50 mm thick
Hearth flatness tolerance ±2 mm on pre-shipment mockup
Over 150 molds of various thickness and dimensions

CALDE SILICA MIX Linings and CALDE MICA Sheets for Induction Furnaces

CALDE SILICA MIX is an acidic dry vibration mix made from Dalsland quartzite processed at the Calderys Åmål plant in Sweden. It suits most coreless and channel induction furnaces. A boron-free version is available, and CALDE MICA sheets are installed between the coil and the refractory lining.

Boron-free SILICA MIX Q BF
CALDE MICA S sheet thickness 0.4 mm
CALDE MICA COMBI sheet thickness 2.4 mm
CALDE GUARD kit with a precast top ring

Tap-Hole Clay for Blast Furnaces

Calderys tap-hole clay is used mainly in the tapholes of blast furnaces. Its design targets three operations: plugging, opening and iron tapping. Calderys has made tap-hole clay for over 40 years and balances aggregates, additives and binders to the furnace practice.

Tap-hole clay manufacturer for over 40 years
Aggregates, additives and binders tuned to the furnace
Plugging, opening and tapping operations
Cleaner formulations ahead of the regulations

ACCUTHERM Mold Fluxes for Continuous Casting

ACCUTHERM casting fluxes in granular or powder form are used for continuous casting and bottom pouring of steel. Each flux is tailored by viscosity, thermal breakpoint, inclusion absorption and consumption rate. They serve billet, bloom, beam blank, slab and thin slab casters.

Granular and powder ACCUTHERM fluxes
Steel grades: ULC, peritectic, high carbon, TRIP
Quality control and flux development lab at each plant
Over 40 years of tailor-made casting fluxes

HYSIL Calcium Silicate and HT Regenspray Insulation

HYSIL hydrous calcium silicate pipe sections and blocks insulate pipes and back up refractory linings. They are made at the Dharuhera plant in India, part of Calderys since July 2020. HT Regenspray is a fiber-based spray insulation for glass furnace regenerators, for continuous use up to 950 °C.

HYSIL grades H-800, H-1000 and H-1100
Meets IS 8154, BS 3958 Part II and ASTM C 533
HT Regenspray applied 25 to 100 mm thick
Anchors, insulating blankets, boards and fibers

Choosing a Castable by Dry-Out Time

Dry-out largely sets how soon a lining returns to service. The Calderys range includes conventional and medium-cement castables, low cement LCC, ultra-low cement ULCC, Quick Dry QD and sol-gel no cement grades.

CALDE FD (boilers and energy) and ALKON FD (aluminum furnaces) are cement-bonded monolithics engineered to remove free water efficiently from the lining without compromising performance. No additional equipment or tools are required to install them.

Lining a Cement Rotary Kiln by Zone

For cement rotary kilns Calderys installs the established refractory design and offers its own solutions for the most critical areas. Tire positions often show strong shell deformations that make brick installation difficult, so a monolithic concept with CALDE MAG CAST K 85 SP is used there.

The burning zone takes CALDE MAG B MF magnesia-hercynite spinel bricks, the upper and lower transition zones take CALDE MAG B SP magnesia-spinel bricks; high-alumina bricks complete the range.

Induction Furnace Lining: Mix, Mica and Castables

The working lining of a coreless induction furnace melting and holding iron is rammed with the acidic CALDE SILICA MIX dry vibration mix; CALDE MAG covers neutral and basic conditions.

CALDE MICA sheets between the coil and the lining act as a barrier against zinc and carbon deposition and as a slip plane for push-out during relining. Ladles, cupolas, pouring and holding furnaces are lined with CALDE CAST and CALDE FLOW castables.

Molding Sand Additives

For molding and core sands Calderys supplies green sand additives, pure bentonite, bespoke bentonite mixtures, slag additives and protective coatings. ENVIBOND reduces sea coal use by 30% to 90% and emissions and odors by up to 95%.

IKOBOND blends bentonite with a small percentage of highly refractory clay for high-density molding, reducing the amount of bentonite burned out and minimizing thermal stress in the mold.

Calderys and model names are trademarks of their respective owners and are used only to identify the equipment for which we source parts. SpareX is not an official dealer, distributor or representative of Calderys and is not affiliated with the trademark owner. Origin, documents and warranty are stated for each item in the quotation.