Monolithic
concept
solutions for
Aluminium
Innovative refractory concepts
for the Aluminium Industry
Our role in the Aluminium Industry is to bring the best value-
in-use to our customers by continuous improvements of our
prod-ucts. Based on this approach, we have started for a long
time ago, research & development programs to improve not
only the performance of our products, but also facilitate their
placement and general properties.
As a consequence, we enjoy successful activity and partnership
with the Aluminium Industry worldwide for more than 50 years.
Our offer includes a full range of commodity and speciality
materials for new lining or maintenance of any equipment on
the Aluminium Industry. Moreover, based on our long term
and multinational experience we can suggest lining concepts
and provide full service including installation.
Our main product ranges:
ALKON® PHLOCAST BASACAST
PLICAST SPRAYCAST BASAGUN
PLIBRICO
Solutions for
Tank Melting and Holding Furnaces
1 BATH LINING melting PLICAST BL 80 B3 furnaces ALKON® cast Optimum 204
SPRAYCAST BL 85 B3 (wall)
holding ALKON® cast Optimum 206 furnaces PLICAST HyMOR 80 AL
high purity ALKON® cast Super 208
aluminium
2 BATH SAFETY
LAYER
PLICAST FM 40 AT
ALKON® cast Classic 202
3 BATH INSULATION &
SAFETY LINING
ALKON® cast iso 122
PLICAST 18 CG
4 ROOF & UPPER WALLS
PLICAST HyMOR 2800
PHLOCAST M 28
SPRAYCAST FL 50 B6
5 INSULATION roof BASACAST iso 09-110
wall BASACAST iso 09-110 PLISTIX isogun 125
6 LINTEL & PILLARS
GIBRAM
PLICAST LX 58
PHLOCAST M 32
7 BURNER BLOCKS
PLIBRICO 85 S
KERPLAST P 85
Solutions for
Scrap Melting Furnaces
1 BATH LINING
ALKON® cast Optimum 204
PLICAST HyMOR 80 AL
ALKON® cast Maximum 209
SPRAYCAST BL 85 B3 (walls)
2 SAFETY LAYER PLICAST FM 40 AT
ALKON® cast Classic 202
3 BATH INSULATION &
SAFETY LINING
ALKON® iso 135
PLICAST 18 CG
4 UPPER WALLS
LINING
PLICAST LX 58
PLIBRICO 85 S (plastic)
SPRAYCAST FL 60 B3
ALKON® cast Robust 203
5 UPPER WALL
INSULATION
BASACAST iso 13-135
PLICAST Strong-Lite
Insulating bricks (if plastic)
6 LINTEL & PILLARS
GIBRAM
PLICAST LX 58
PHLOCAST M 32
7 ROOF LINING
PLICAST HyMOR 2800
8 ROOF INSULATION
BASACAST iso 09-110
PLICAST LW Mix 123
9 DOOR LINING
PLICAST FM 40 AT
ALKON® cast Robust 203
Solutions for
Barrel Melting Furnaces
1 BATH LINING
PLICAST BL 80 B3
ALKON® cast Optimum 204
ALKON® cast Maximum 207
2 SAFETY & INSULATION
ALKON® iso 122 (gun)
PLISTIX isogun 125
3 ROOF LINING
PLIGUN 75 AL
ALKON® gun Maximum 402
4 BURNER BLOCK LINING
PLIBRICO 85 S
KERPLAST P 85
Solutions for
Shaft Melting Furnace with Side Well
1 BATH LINING
PLICAST HyMOR 80 AL 4 ROOF LINING
ALKON® cast Optimum 204
ALKON® cast Maximum 207 PLIGUN 75 AL
(holding chamber) ALKON® gun Robust 401
ALKON® cast Robust 203
2 BATH SAFETY &
5 ROOF INSULATION
INSULATION
ALKON® iso 135 PLISTIX isogun 123
PLICAST 18 CG BASACAST iso 09-110
3 CHARGING SHAFT 6 BURNER BLOCKS
PLICAST FM 50 PHLOCAST M 32 PHLOX 1560
PLIBRICO 85 S PLICAST 039 KK KERPLAST P 85
Solutions for
Bi-Chamber Shaft Melting Furnace
1 BATH LINING PLICAST HyMOR 80 AL
ALKON® cast Optimum 204
ALKON® cast Maximum 207 (holding chamber)
2 BATH SAFETY &
INSULATION
ALKON® iso 135
PLICAST 18 CG
3 TRANSITION VAULT
PLICAST BL 80 B3
ALKON® cast Maximum 209
GIBRAM
4 CHARGING SHAFT
PLICAST FM 50
PHLOCAST M 32
5 ROOF LINING
PLIGUN 75 AL
ALKON® gun Robust 401
6 ROOF INSULATION
PLISTIX isogun 123
BASACAST iso 09-110
7 MINERAL FIBRE
8 BURNER BLOCKS
PLIBRICO 85 S
PLICAST 039 KK
Solutions for
Dosing (Holding) Furnace
1 BATH LINING
ALKON® cast Optimum 206
PLICAST HyMOR 80 AL
SAFETY & INSULATION
2 INSULATING BRICKS
3 DENSE FIBRE BOARD
4 CALCIUM SILICATE 6 ROOF SCREEN
CHARGING ZONE
5 MICROPOROUS PANELS
PLICAST FM 40 AT ALKON® cast Robust 203
Solutions for
Coreless Induction Furnaces
1 CRUCIBLE LINING
ALKON® dry Maximum 505
TV 200
PLIRAM 24 S pre-shaped ALKON® cast Super 208
crucible
2 COIL PROTECTION Coil cement
Mica sheet (M 40)
3 POURING SPOUT
LINING
PLICAST FM 40 AT
ALKON® cast Classic 202
4 UPPER RING
LINING
BASACAST iso 13-135
PLICAST Strong-Lite
5 COVER LINING
ALKON® iso 122
PLICAST XL-25
Solutions for
Channel Induction Melting Furnaces
1 BATH LINING
PLICAST BL 80 B3
ALKON® cast Optimum 204
ALKON® cast Maximum 209
2 UPPER BATH LINING &
METAL LINE
PLICAST HyMOR SIC 85
4 WALL SAFETY &
ALKON® cast Optimum 204
INSULATION LINING
PLICAST 18 C/G
3 BOTTOM SAFETY
ALKON® iso 135 (gun)
LINING
PLICAST 18 C/G
5 CALCIUM SILICATE
ALKON® iso 135
Solutions for
Channel Induction Holding Furnaces
1 BATH LINING PLICAST HyMOR 80 AL
ALKON® cast Super 206
4 INDUCTOR LINING
2
SAFETY &
ALKON® dry Maximum 504
INSULATION LINING
ALKON® ram Optimum 600
ALKON® iso 122 (gun) PLICAST AL 65 B3 (castable)
PLIGUN XL-25
INDUCTOR TOPPING
5
3 CALCIUM SILICATE RODAROX coat 953 PJ
Solutions for
Road Transport Ladles
1 MAIN WORKING
LINING
PLIFLOW AL 65 B3
ALKON® flow Optimum 303
2 SAFETY &
INSULATION
PLIGUN XL-25
ALKON® iso 122
3 INSULATION
Microporous
insulation panels
4 COVER LINING
PLICAST Strong Mix AT
ALKON® cast Classic 202
Products
Technical Information Product name
Chemical analysis (%) Material Permanent
Max grain size Main Mixing water linear CCS 800°C
required
(mm) component (l/100kg) change (MPa)
Al2O3 Fe2O3 CaO (t/m3)
800°C (%)
Dense anti-wetting castables
PLICAST BL 80 B3 10 Bauxite 81 1.1 2.2 3.08 4.4 - 4.8 -0.2 150
ALKON® cast Optimum 204 5 Bauxite 79.5 1.1 4.2 2.82 4.5 - 6.0 -0.2 > 140
ALKON® cast Optimum 206 6 Bauxite 81 1.1 3.6 3 7.0 - 7.5 0 60
PLICAST HyMOR 80 AL 6 Corundum 80 0.25 4.6 3.05 5.2 - 6.0 -0.15 130
ALKON® cast Super 208 6 Tabular alumina 90 0.1 3.4 3.1 5.5 - 6.0 0 80
ALKON® cast Maximum 209 5 Corundum 92 0.2 2.2 3.15 4.0 - 5.0 0 140
ALKON® cast Maximum 207 6 Corundum 87 0.2 3.6 3.2 5.5 - 6.0 0 95
ALKON® flow Optimum 303 5 Bauxite 84.5 1 2.7 2.9 5.5 - 6.5 -0.1 120
PLIFLOW AL 65 B3 6 Andalusite 65 0.5 2.4 2.69 6.0 - 6.4 0 95
ALKON® cast Robust 203 6 Mullite 61 0.9 3 2.6 5.5 - 6 0 80
PLICAST FM 40 AT 6 Chamotte 40 2.4 3.1 2.12 8.8 - 9.6 -0.3 60
ALKON® cast Classic 202 5 Chamotte 44.6 1 4.2 2.25 6.0 - 7.5 -0.25 90
PLICAST Strong-Mix AT 6 Chamotte 41 4.9 11 2 12 - 14 -0.1 45
Insulating anti-wetting castables
ALKON® iso 135
8
Light weight
40
3.1
14
1.3
25 - 35
-0.2
6
chamotte
ALKON® iso 122 4 Light weight
40 3.4
11.5 1.2
32 - 38 -0.3
6
chamotte
Dry & Ramming Mixes
ALKON® dry Maximum 504
6
Corundum
90.5
0.4
5.7
2.9
dry mix,
-0.2
30
heat setting
ALKON® dry Maximum 505 6
Corundum
92.4
0.2
1.1
3
dry mix, -0.1
40
heat setting
TV 200 6
Chamotte 51
0.6 40
2.7 dry mix, -0.15
12
heat setting
ALKON® ram Optimum 600 6
Bauxite
84
0.9
3.02
phosphatic 0
45
(humid)
PLIRAM 24 S 6
Chamotte 48
0.7 7.5
2.3 phosphatic -0.15
60
(humid)
Plastics
PLIBRICO 85 S
6
Bauxite
85
0.9
7.4
2.95
phosphatic,
-0.85
90
ready to use
KERPLAST P 85 6
Bauxite 82
1.3 7.5
3.1 phosphatic, -0.15
70
ready to use
Chemical analysis (%)
Material Mixing
Permanent
Product name Max grain size Main
linear CCS 800°C
required water
(mm) component
change (MPa)
Al2O3
Fe2O3
CaO
(t/m3) (l/100kg)
800°C (%)
Gunning castables
ALKON® gun Maximum 402
6
Corundum
84
0.2
6.5
2.9
added at
-0.2
40
the nozzle
ALKON® gun Robust 401 6
Chamotte 50
1 6.3
2.3 added at -0.1
40
the nozzle
PLIGUN 75 AL 7
Corundum 84
0.2 6.5
2.85 added at -0.1
80
the nozzle
PLIGUN 45 AL 6
Chamotte 48
0.7 7.5
2.3 added at -0.15
60
the nozzle
Low cement dense gunning
ALKON® gun Optimum 404
6
Bauxite
74
1
4.1
2.9
5 - 6% added
-0.2
100
at the nozzle
SPRAYCAST (low cement wet gunning)
SPRAYCAST BL 85 B3 6 Bauxite 85 0.9 1.8 2.93 5.2 - 6.0 -0.1 70
SPRAYCAST FL 60 B3 6 Syntetic mullite 60 0.7 1.9 2.68 5.6 - 6.4 -0.2 80
SPRAYCAST FL 50 B6 6 Chamotte 49 0.85 1.9 2.45 6.4 - 7.6 -0.1 80
Patching & repair mixes (for gunning and trowelling)
ALKON® patch Classic 701 3 Chamotte 44 1.1 4.2 2 16 - 18 -0.3 15
ALKON® patch Maximum 702 3 Corundum 80 0.9 4.7 2.6 11 - 13 -0.1 25
ALKON® coat Super 900
6 Tabular alumina 82 0.1 1.5 ready to use patching paste (heat setting)
Product name
Chemical analysis (%) Material Permanent
Max grain size Main Mixing water linear CCS 800°C
required
(mm) component (l/100kg) change (MPa)
Al2O3 Fe2O3 CaO (t/m3)
800°C (%)
Alternative castables for aluminium furnaces
PLICAST 18 C/G 6 Chamotte 33 2.3 6.2 1.85 14 - 16 -0.1 25
PLICAST HyMOR 2800 6 Chamotte 50 0.75 4.2 2.33 6.4 - 7.6 -0.2 135
PLICAST HyMOR SIC 85 3 Silicon Carbide 9.5 0.2 1.85 2.6 5.6 - 6.4 -0.15 95
PLICAST 039 KK 6 Alumina 69 0.7 1.5 2.51 7.0 - 8.0 -0.04 30
PHLOCAST M 28 5 Chamotte 45.5 1.3 3 2.2 6.0 - 7.5 -0.25 90
PHLOCAST M 32 SR 5
Bauxite 77.7
1 2.65
6.5 - 8.5 -0.3 110
(1200°C)
(1200°C)
PHLOX 1560 5
Andalusite 59
1.1 2.2
2.5 6.0 - 8.0 +0.1 70
(1200°C)
(1200°C)
PLICAST LX 58 6 Andalusite 57 1.1 2.3 2.53 5.6 - 6.0 -0.04 100
GIBRAM 5 Bauxite 82.5 1.5 1.2 2.9 5.0 - 6.0 -0.15 130
Alternative insulating castables
BASACAST iso 13-135 (cast)
5
Light weight
41
3.1
9.6
1.3
25 - 30
-0.1
8
chamotte
Light weight
BASACAST iso 09-110 8 chamotte; 25 9 13 0.9 45 - 60 -0.3 2
Vermiculite
PLICAST Strong-Lite 4
Light weight 40
5.5
13
1.43
22 - 24
-0.15
18
chamotte
PLICAST XL-25 5 Light weight
45 0.9
16 0.63
52 - 56 -0.05
2
aggregates
PLIGUN XL-25 5 Light weight
43 0.9
15.2 0.98 added at
-0.15 5
chamotte
the nozzle
PLICAST LW-mix 123 4 Vermiculite 25 10.5 17.5 1.02 38 - 42 -0.25 4.5
BASACAST iso 13-135 (gun) 5 Light weight
41 3.1
9.6 1.6 added at
-0.2 25
chamotte
the nozzle
Light weight added at
PLISTIX isogun 125 4
chamotte; 36
4 9
1.35 -0.4
5.5
the nozzle
Vermiculite
NOTES: CALDERYS does not warrant the accuracy, fi tness for purpose or update of any information disclosed herein. The recipient shall refer to instructions
and advice provided under any technical documentation. This document and the information contained herein are the exclusive property of CALDERYS.
Reproduction, alteration, copy, release, publication or distribution, in whole or in part, is not allowed. References, trademarks and specifi cations of the products may change according to the geographical area to be supplied. Please check the availability of the
products with the sales area manager.