When should I specify a conventional castable instead of LCC?

Use conventional castable for backup safety linings behind a working LCC or brick lining, boiler walls and roofs (non-hot-face zones), industrial waste incinerator general body, cement preheater meal chutes, foundry trough backup, and any minor repair work where the new material does not need premium hot-strength. Total cost of ownership is lower because the cheaper material is replaced more often but each replacement is cheap.

What grades of conventional castable do you supply?

We supply Conventional 40 (38–42% Al₂O₃, rated to 1300°C) for boiler back walls, Conventional 50 (48–52% Al₂O₃, 1400°C) for general furnace linings, Conventional 60 (58–62% Al₂O₃, 1500°C) for higher duty backup, and Conventional 70 (68–72% Al₂O₃, 1550°C) for moderate hot-face zones in incinerators and small foundry furnaces. Insulating LD-1.5 (1.50 g/cc bulk density) for backup insulation behind dense linings.

Why is the water demand higher for conventional castables than LCC?

More cement means more water needed to wet the cement particles for hydration — typically 8–12% water by weight versus 4.5–5.5% for LCC. The trade-off is higher porosity in the cured castable (cement hydration leaves micro-pores). For non-critical applications this porosity is acceptable; for slag-line and impact zones it is not, which is why LCC dominates those zones.

How fast can I install a conventional castable lining?

Conventional castables tolerate faster installation than LCC. Cast in 200–250 mm layers, vibrate for 20–30 seconds per layer, demould after 12–18 hours, and dry out at 25°C/hour to 110°C with an 8-hour soak — versus the 24-hour cure and 12-hour soak typical for LCC. A mid-size boiler sidewall job that takes 5 days with LCC can be done in 3 days with conventional castable.

Which brands of conventional castable do you supply?

Mahakoshal Refractories conventional grades 40 to 70, Calderys India conventional and budget castables, CUMI Super Refractories range, and Crown Ceramics for acid-proof variants. Stocked at our Delhi warehouse with pan-India dispatch and full export documentation for GCC and ASEAN customers.

Conventional Castables (Fireclay-Based) | Mahakoshal & Calderys

PRODUCT OVERVIEW

Conventional castables are the workhorse monolithic refractories for general industrial applications — fireclay-based or low-purity high alumina aggregates bonded with 15–25% calcium aluminate cement. They cost roughly half what an equivalent LCC costs and install faster (no special vibration or extended cure required), making them the right specification for backup linings, low-wear zones, and repair work where premium hot-strength is not required. Indian foundries, boiler plants and cement preheater backup zones still consume large volumes of conventional castables every year.

KEY PROPERTIES

Al₂O₃ Range

38 – 72% (fireclay → mid-alumina)

Cement Content

15 – 25% (high cement)

Water Addition

8 – 12% by weight

Cost vs LCC

Roughly 40 – 55% lower per tonne

De-mould Time

12 – 18 hrs at ambient

Installation

Vibro-cast, gunning or hand-pack

APPLICATIONS

Backup linings behind LCC / dense brick working linings

Boiler furnace front and rear walls (non-hot-face)

Industrial waste incinerator general lining

Heat treatment furnace walls and roof

Soaking pit backup and chimney bottom

Brick-cast hybrid lining where minor repairs and adjustments are needed

Foundry ladle backup and trough lining

Cement preheater bottom and meal chute

TECHNICAL SPECIFICATIONS

Grade	Al₂O₃	Cement	Bulk Density	CCS (110°C)	CCS (1200°C)	Max Temp
40% Al₂O₃ Castable	38-42%	20-25%	2.20 g/cc	20 MPa	35 MPa	1300°C
50% Al₂O₃ Castable	48-52%	18-22%	2.30 g/cc	25 MPa	45 MPa	1400°C
60% Al₂O₃ Castable	58-62%	15-20%	2.45 g/cc	30 MPa	60 MPa	1500°C
70% Al₂O₃ Castable	68-72%	15-18%	2.55 g/cc	35 MPa	70 MPa	1550°C
Insulating LD-1.5	45-50%	20-25%	1.50 g/cc	—	—	1300°C

* Test conditions: IS 1528 (India) / ASTM C-133 / EN 1402. Values are typical — exact data sheets available on request.

AVAILABLE GRADES

40% Al₂O₃ Conventional Castable50% Al₂O₃ Conventional Castable60% Al₂O₃ Conventional Castable70% Al₂O₃ Conventional CastableInsulating Castable (LD-1.5)

INSTALLATION NOTES

1
Pre-wet steel formwork to prevent cement-water absorption from the castable mix
2
Mix with measured water (8–12% by weight) for 4–6 minutes in a pan or paddle mixer
3
Cast in 200–250 mm layers and vibrate using a 25 mm needle vibrator for 20–30 seconds per layer
4
Cover with polythene sheet for 24 hrs ambient cure before form removal
5
Standard dry-out: 25°C/hr to 110°C, hold 8 hrs; then 30°C/hr to operating temperature
6
For thin sections (< 100 mm): consider hand-pack or gunning instead of casting

WHY BUY FROM SHANKER AGENCIES

Conventional castables are not glamorous — but they save Indian plants money where premium LCC offers no measurable benefit (backup linings, low-wear zones, repair work). Shanker Agencies stocks Mahakoshal Refractories conventional grades 40–70 ready-to-ship from Delhi, alongside Calderys and CUMI variants. Our engineers will recommend conventional vs LCC based on actual zone duty, not blanket spec.

PARTNER BRANDS

Mahakoshal Refractories Calderys India CUMI Super Refractories

FREQUENTLY ASKED QUESTIONS

A conventional castable is a fireclay or low-purity high alumina aggregate bonded with 15–25% calcium aluminate cement — the original castable formulation that has been used in industrial linings for over 50 years. It is roughly half the price of an equivalent low cement castable (LCC at 3–5% cement) and one-third the price of ULCC. The trade-off: lower hot strength, higher porosity, and lower slag resistance. Right product for backup linings and low-wear zones; wrong product for steel ladle hot face.

QUICK INFORMATION

Max Temperature

1500°C

MORE IN UNSHAPED REFRACTORIES

Low Cement Castables (LCC)

High-strength castables with 3–5% cement — the industry standard for steel ladles

Ultra Low Cement Castables (ULCC)

Premium monolithics with <1.5% cement for the most demanding high-wear zones

Ramming Masses

Dense dry/moist masses for jointless induction furnace linings

Gunning Materials

Pneumatically applied repair mixes — minimise downtime with in-situ hot repairs

READY TO ORDER OR NEED A SAMPLE?

Our engineers can recommend the exact grade for your application. Sample kits available for trials. No minimum order on standard grades.

Get a Quote Call +91 98999 57888

CONVENTIONAL CASTABLES (FIRECLAY-BASED)