General purpose castables
The MAC CRETE range of conventional
castables is suitable for moderate and high heat duty applications. These are calcium
aluminate bonded refractory concrete for application in temperatures upto 1400° c. These
can be either vibration cast or poured. The grading of these products is formulated such
that they can be gunned if required.
High alumina High purity Conventional
The MACHEAT range of high alumina
conventional castables is made with aluminus aggregate and high purity high alumina
refractory cement. These are suitable for use in
critical applications upto 1800° c. They exhibit high volume stability, good thermal
shock resistance and excellent hot strength. These castables are installed by both
vibration and hand placement.
Low Cement Castables
The MACVIB range of low cement castables
are available in 45% to 90% Al2O3 content. They are made with
aluminus and mullite aggregates and high purity high alumina cement. These are suitable for extreme service
conditions and have application temperatures upto 1800° c. These products are
distinguished by their high volume stability, low porosity, better corrosion and erosion
resistance, good thermal shock resistance and excellent hot strength. Installation of
these castables is by vibration only.
Large aggregate Low
Maithan also manufactures large aggregate
(upto 10mm) based low cement castables. They exhibit excellent volume stability, spalling
resistance and high temperature mechanical properties. Application of these castables is
recommended in severe service conditions where the thickness exceeds 75mm. The castables
are most suitably installed by vibration casting.
Self flow castables
The MACFLOW range is a set of tailor made
self flow castables. Depending on the end use, these could be either silicate bonded or
alumina bonded. This range is available in a wide range of alumina content. Their
installation is recommended by pouring against the form work. Extreme purity of the bond
system and easy placement make them highly acceptable for various applications.
The MACLITE range of insulating castables
is based on high purity insulating grog manufactured in-house. The service temperature
goes upto 1800° c for bubble alumina based 95% Al2O3 castable and
bulk densities achieved are as low as 500 gms/dm3. This prolific range of
castables find use as both hot face and backup refractory lining.
The process of supplying precast shapes
starts with a close interaction of our technical staff with the customers to understand
their operational and design requirements. These shapes are designed around specialized
castable formulations, each developed by the
development group for specific conditions. The shapes are cast in a modern precast
shop which has the capability to process shapes from 2 kgs to 1000 kgs. The experts in
this shop are responsible for the development of innovative techniques in piece and mould
design, forming, curing and drying. Maithan possesses a hot floor and chamber drier and
firing capability upto 1700° c for large shapes. For more intricate shapes which require
embedded steel or mating framework, a vendor base of high quality refractory steel
fabrication manufacturers is in place.
Maithans precast shapes have found
wide acceptance in the steel, foundry, glass and carbon black industries as a technically
superior alternative for conventional products. Successful precast products include
ladle wear pads, seating and well blocks for steel,
bottom blocks and feeder channels for glass, and
Fireclay gunning mixes
Fireclay gunning mixes are dense products
similar to conventional fireclay castables designed around our calcium aluminate cement
and calcined aggregate. These are formulated for speedy application, cold or hot gunning
and very low rebound losses. MACGUN range of mixes find use in cement preheaters,
incinerators, boilers and blast furnaces.
High Alumina gunning
This range of products is formulated with
high purity calcium aluminates and synthetic refractory aggregates. They are characterized
by a high refractoriness, good abrasion and corrosion resistance and high volume
stability. These products can be applied through hot or cold gunning. This range finds
application in steel ladles, LRF, EAF, petrochemical and fertilizer plants.
MCL GUN95 is a highly successful
gunning mix for EOF hot repair. This product was
initially developed as an import substitute but it has outperformed established and
expensive imports in the same application in all the existing EOFs in India. Further this
material is a multi-utility monolithic which can be used as a ramming mass if need arises.
High Alumina ramming
Maithan manufactures a wide range of air
and ceramic setting ramming masses. On setting, these products form a dense monolithic
mass displaying strong resistance to molten metal and high volume stability. An
indigenously developed import substitute, MCL COREMAG SP-DRM has found increasing
acceptability for non-ferrous melting via the induction furnace route. Alumina ramming
masses find application in
EAF roofs, burner blocks and aluminum melting furnaces.
For glass melter sub paving and hot and
cold repairs, Maithan manufactures high purity Zircon based ramming masses. These are
manufactured using fused AZS grains and zircon grog. These products are designed to sinter
at a relatively low temperature and provide a high degree of alkali resistance at elevated
Basic ramming masses
The wide range of basic ramming masses
are produced using a blend of indigenous DBM and imported fused/sea water magnesia. Basic
ramming masses find acceptance in
EAF hearth, cold and hot
The PLASTOCAST range of Fireclay and High
alumina refractory plastics is an indigenously developed product suitable for economical
and emergency repairs. Maithan has shipped a substantial tonnage of this product to
leading steel plants in the past year. The plastics are shipped in slices to be rammed
into place without any further processing.
To complement its range of shaped
products, Maithan manufactures compatible heat and air setting mortars. The mortar lineup
ranges from the economical fireclay mortar to premium high purity zircon, mullite and
magnesite mortars. Mortars are designed to have comparable volume stability to the shaped
products and form a strong bond with the bricks until otherwise desired.
It is an unshaped product with
a highly controlled granulation used for filling
taphole. This is manufactured using a blend of imported and indigenous DBM.
BOF TAPHOLE MASS
It is a specialized product for taphole repair
for BOF. This is made with a selected blend of
high purity fused/sea water magnesia.