In high-temperature industries such as glass, metallurgy, aluminum processing, power generation, and ceramics, effective insulation is essential for equipment safety and energy efficiency. In recent years, high-density calcium silicate board has emerged as a popular choice thanks to its outstanding heat resistance, low thermal conductivity, mechanical strength, and eco-friendly composition.
Calcium silicate board is a porous material made from siliceous materials (e.g., quartz powder), calcareous materials (e.g., lime), and reinforcing fibers (e.g., glass fiber, carbon fiber) through a high-temperature, high-pressure hydrothermal reaction that typically forms a tobermorite crystal structure. Based on its density, it is classified into:
Low-density type (200–500 kg/m³)
Medium-density type (500–800 kg/m³)
High-density type (850–1000 kg/m³ and above)
The High-Density Calcium Silicate Board, made from xonotlite-based calcium silicate, is designed for high-temperature applications requiring excellent insulation, strength, and resistance to molten non-ferrous metals like aluminum. Reinforced with glass or carbon fibers, it offers superior machinability and stability for critical industrial processes.
With a service temperature up to 1000°C, this board ensures energy efficiency through low thermal conductivity and heat capacity, while its non-wetting properties minimize maintenance and downtime.
Meantime, our CNC-equipped workshop enables us to deliver custom components with precision and efficiency.
Non-Wettability: Prevents molten aluminum from sticking, reducing maintenance and cleaning time.
Low Thermal Conductivity: Minimizes heat loss and improves energy efficiency in high-temperature processes.
High Mechanical Strength: Withstands thermal and mechanical stress, offering durability and long service life.
Excellent Machinability: The board’s homogeneous, fine-pored structure allows precise CNC machining into custom shapes for specific applications.
Thermal Shock Resistance: Resists cracking during rapid temperature changes, ensuring stable performance.
Dimensional Stability: Maintains shape and structural integrity at temperatures up to 1000°C.
The product is available in glass fiber-reinforced (comparable to Marinite-A, N-14, M1) and carbon fiber-reinforced versions (comparable to Marinite AHP, N-17, M1A, G34) to meet various aluminum processing needs. Common applications include:
Launders: For transferring molten aluminum with optimal heat retention.
Spouts and Floats: Ensuring precise control of molten metal flow during casting.
Hot-Top Ring Headers: Enhancing insulation and energy efficiency in holding furnaces.
End Dams and Pouring Spouts: Custom-machined for efficient metal handling.
Baffles, Headers, and Distribution Boxes: Essential components used to manage molten metal during casting processes.
Hot-face Linings for Dosing/Holding Furnaces
When selecting high-density calcium silicate boards, the following factors should be considered to ensure optimal performance:
Operating Temperature: For long-term use, temperatures below 850°C are recommended. For conditions approaching the 1000°C limit, reinforced grades are preferred.
Mechanical Load: For areas requiring structural strength—such as furnace doors, bases, or support frames—choose boards with higher compressive strength.
Machining Requirements: For CNC machining or components with complex shapes, select boards with a fine, compact structure and good machinability, such as glass fiber-reinforced types.
Contact Environment: For direct exposure to molten aluminum or other non-ferrous metals, carbon fiber-reinforced boards with non-wetting properties are recommended.
Installation Conditions: In humid environments, boards must be fully dried and preheated before use to prevent moisture-related cracking.
FCS-85IG Board: A cost-effective insulation product reinforced with organic and glass fibers, ideal for aluminum holding furnaces, steel ladles, tundishes, and glass furnace bottom insulation.
FCS-80C: Carbon fiber-reinforced, suitable for direct contact with molten aluminum, ideal for demanding applications.
FCS-100G: Glass fiber-reinforced, offering high strength and good high-temperature performance as a more economical option than FCS-80C.
FCS-95GC: An enhanced version of FCS-100G with added carbon fiber, significantly improving thermal shock resistance.
Moisture Control: The board can absorb moisture. If damp, it must be thoroughly dried before exposure to high temperatures to avoid cracking.
Gradual Heating: During initial use or after long shutdowns, heat the board gradually to prevent thermal shock.
Proper Machining: Use appropriate tools for cutting and drilling. Always wear protective equipment and manage dust effectively.
Gentle Handling: Although structurally strong, the board is brittle. Handle with care to avoid impact, edge chipping, or over-tightening.
Regular Inspection: Inspect periodically for cracks or damage. Replace promptly if thermal insulation performance is compromised.
If you’re looking for an industrial-grade insulation material that offers both safety and durability, high-density calcium silicate board is a reliable choice. Contact us today to request samples, technical specifications, or tailored recommendations.
