Refractory castables, masses, and mortars

Our portfolio of refractory materials

We produce dense and insulating refractory concretes, mortars, and masses for applications ranging from 600 °C to 1700 °C.

All our products are based on high-quality raw materials, such as chamotte, bauxite, mullite, andalusite, and corundum. Refractory monolithic products are unique blends that maintain their properties while resisting high temperatures. They are used where the application of formed products (refractory bricks) is impossible.

We offer complete monolithic solutions, including dense and insulating concrete, tailored to various installation methods, such as casting, shotcreting, and ramming. We propose materials based on cement, silica, gel, or hybrid bonding systems depending on the customer's needs.

Produkty

Our products

Castable refractory Gunning mixes Insulating casting concrete Insulating gunning mixes Refractory ramming mass Refractory mortar

Castable refractory

Castable refractory

Casting concrete is a refractory material that is supplied in powder form. After mixing with a liquefier, most often water, it is poured into molds or casting forms to achieve a specific shape of refractory lining. Available mixes include traditional, vibrated, and self-leveling types, which do not require vibration. After drying and setting, such concretes acquire a solid structure, gaining resistance to mechanical factors and high temperatures. We supply these products in 25 kg paper bags or big bags with a 500 or 1000 kg capacity.

Conventional concrete

Pcocast BOS

See technical specifications

Conventional refractory concrete, with a high cement content (15-30%), is the easiest to install (correct mixing and drying) among casting concrete. Although they do not provide the highest performance in extreme conditions, they are a versatile and cost-effective choice for many standard operating conditions in refractory linings.

Medium-cement concrete

Pcocast BM
Mulcast BM

See technical specifications

Medium refractory mortars castable concretes (MCC) achieve binding with a cement content ranging from 5 to 15%. They bridge the gap between conventional and low refractory castable concretes in terms of performance and workability. Specialists appreciate the suitable parameters achieved at low temperatures (even before startup) and the more workable consistency than low-cement alternatives or cement-free systems.

Low-cement concrete

Pcocast BN
Mulcast BN

See technical specifications

Low cement castable concretes (LCC) require a minimal morstars content (from 3 to 10%) to achieve binding. As a result, they need more attention during installation than, for example, conventional concretes, but a well-made lining is characterized by improved parameters such as higher temperature resistance, lower porosity, resistance to corrosion and abrasion, and thermal shock resistance.

Low-cement concrete based on silicon carbide

BN SiC

See technical specifications

The BN SiC line includes low cement castable concretes for special applications in areas most susceptible to thermal shocks and corrosive factors.

No-cement castables

SOLCAST
GELCAST
NxGel

See technical specifications

Cement-free refractory concretes (NCC) do not contain cement, and binding is achieved through additives such as silicates, aluminates, or phosphates. They are intended for applications at very high temperatures, where traditional cementitious concretes could degrade. Linings made from cement-free concretes are characterized by, among other things, high resistance to thermal shocks and chemical corrosion.

Gunning mixes

Gunning mixes

Gunning mix is a product used in the method of pneumatically conveying the refractory mix through a hose. To this mix is added a liquefier, most often water. Then, the mix is sprayed onto the application surface at high velocity. Our portfolio includes materials based on binding systems that utilize both cement and special chemical additives.

Gunning mixes

Pcogun

See technical specifications

The PCOGUN line of masses is designed to be easy to apply and adhere well to the existing lining. The products are characterized by specially selected granulation and contain additives that minimize material loss during spraying (reduced rebound).

Insulating casting concrete

Insulating casting concrete

Light insulating concrete is a specially designed monolithic product that combines excellent insulating properties with the integrity of the refractory lining.

Thanks to its porous structure, it has a low density, which translates into lower thermal conductivity, making it harder for heat resistance to penetrate. As a result, it offers better insulation than dense concrete.

Insulating casting concrete

Isocast

See technical specifications

Insulating concretes in the ISOCAST line are available in versions with densities ranging from 0.6 to 1.4 g/cm³ and are designed to operate in temperature ranges from 600 °C to 1450 °C. They are produced based on lightweight clays and shales. Although not as durable as dense concretes, they still provide sufficient mechanical strength for many applications in insulating layers of refractory linings.

Insulating gunning mixes

Insulating gunning mixes

Insulating gunning mix is a product used in the spray method. In this method, the refractory mix is pneumatically transported through a hose, and a liquefier, usually water, is added. The mix is then applied to the application surface at high velocity.

Gunning mixes

Isogun

See technical specifications

Similar to the casting versions, ISOGUN insulating spray masses are available in densities ranging from 0.6 to 1.4 g/cm³ and are designed to operate in temperatures from 600 °C to 1450 °C. The masses are easy to apply and contain additives that minimize material loss during spraying (reduced rebound).

Refractory ramming mass

Refractory ramming mass

Refractory ramming masses are unique blends of materials with plastic properties. They are supplied in moist form, either loose in bags or as blocks.

After application to the appropriate surface and drying, the mass hardens. After undergoing proper thermal treatment, it becomes resistant to high temperatures and mechanical factors.

Wet refractory masses

Pcopatch
Żaroplast

See technical specifications

Moist refractory masses based on chamotte raw materials are intended for minor current repairs of chamotte masonry. They are supplied loose in bags or as lumps for ramming with a hammer.

High-alumina wet masses

Alplast
Alkoplast

See technical specifications

Moist refractory masses based on high-alumina raw materials are intended for minor current repairs of high-alumina masonry. They are supplied loose in bags or as lumps for ramming with a hammer.

Refractory mortar

Refractory mortar

Refractory mortars are high-quality aggregate and refractory clay mixtures designed for joining refractory bricks in linings. Their application is essential for the durability and safety of ceramic linings. It is crucial to use the appropriate refractory mortar compatible with the refractory materials used, as it ensures the masonry exhibits minimal binding expansion.

Like traditional masonry mortars, refractory mortars are applied in a wet state and, after use and drying, create durable and tight joints. Various types are available, including mortars with a ceramic bond, e.g., requiring heat treatment at a minimum temperature of 600 °C, known as heat setting, and those with a chemical bond, which hardens upon contact with air, known as air setting.

Dry ceramic bonding mortars

Mortalex

See technical specifications

The dry refractory mortar line MORTALEX is designed to supply an appropriate mortar for every type of brick produced by PCO. Such a combination ensures uniform properties in every layer of the lining. Ceramic bond (headset) mortars require mixing with water, and the bond gains strength only after the lining is heated to a specified temperature.

Dry chemical bonding mortars

Mortalex D

See technical specifications

PCO offers air-setting mortars for every working temperature range. These mortars are supplied in dry form and applied by adding water and application. Unlike ceramic bond mortars, to achieve a durable joint, it is not necessary to heat the lining, as bonding occurs at room temperature.

Wet mastics

Mortalex
(refractory kit)

See technical specifications

MORTALEX refractory wet mastics are ready-to-use adhesives for joining fire bricks and lightweight insulation products (calcium silicate and semi-dense boards). Their advantage is that the joint gains strength immediately after application without the need to perform heating-up.

Dry insulating mortars

Mortisol

See technical specifications

Dry insulating mortars MORTISOL are the right choice for joining fire bricks. Using a dedicated mortar ensures uniform properties throughout the insulating layer – the temperature flow profile between the brick and the mortar is similar.

Why choose our refractories

PCO is more than just a manufacturer of refractory bricks. We strive to provide customers with complete refractory solutions for their equipment. That's why we offer over 180 proven brands - products designed to meet every challenge during the operation of the equipment.

Stable product quality

We ensure the stable quality of our products through a multi-point quality control plan that guarantees each batch complies with established tolerance limits, regardless of the product shape and series size.

Dryout curve recommendation

Recommendations for the heating curve are crucial for achieving optimal properties of monolithic products after thermal processing. Our experts can adjust the temperature increase curve to the specific type of monolithic lining, ensuring ideal startup conditions.

Expert supervision during concrete installation

We provide instructions for preparing and applying each of our refractory concretes along with delivery. Proper preparation of the mix, application, and drying of the monolithic lining is crucial for the device's correct operation. A PCO specialist can be present on-site during the refurbishment and advise on adequately preparing and installing the refractory mass lining.

Own R&D department and laboratory

Our R&D department and specialized laboratory allow us to offer dedicated technical support and advice. This is particularly important in solving challenging technical problems. Our team of technologists and engineers enables the customization and adaptation of products and services to meet clients' unique needs.

Wide range of products and application methods

We have a wide range of products and applications, producing concretes based on various binding systems, such as cementitious, gel, silica, or hybrid. We supply products adapted to the conditions of a given refurbishment, enabling multiple application methods, such as casting, shotcreting, or ramming. Our products are easy to install and start, ensuring efficiency in every refurbishment project.

Reliable raw material sources

We utilize primary and secondary sources in our raw material sourcing strategy. Primary raw materials are always obtained from certified, vetted suppliers and manufacturers worldwide. Secondary raw materials are generated through the recycling of products and semi-finished products. Each raw material undergoes rigorous quality control upon delivery, both on the supplier's side and with us.

Production process and quality control steps

Click the step to show more details
1. Preparation of the dry mix
2. Packing the mix into bags
3. Palletizing and wrapping
What we do at this stage?

We mix refractory aggregate of carefully selected fractions with cement or another binding agent, adhering to the proportions prescribed for the specific concrete formula. An industrial mixer ensures the proper combination of the mass.

What we control at this stage?

We check the correctness of the chemical and granular composition, setting time, fluidity of the mix, refractoriness, bulk density, open porosity, and compressive strength.

What we do at this stage?

On an automated weighing line, we load our mixture into bags up to 25 kg or into big bags. Then, the bags are automatically labeled with the product name and production date.

Skrupulatnie sprawdzamy wagę worków oraz poprawność oznaczeń.

What we control at this stage?

We verify the bags' weight and the labels' accuracy.

What we do at this stage?

After a successful production cycle, we load our products onto 1100 x 800 mm wooden pallets according to IPPC standards or 1200 x 800 mm according to EUR standards.

An automated packaging line equipped with a robot precisely stacks the bags on the pallet according to the program. Then, a film sheet is applied to the pallet, and the whole is secured with stretch film. At this stage, each pallet receives a product label containing specified information and the barcode of the production batch.

What we control at this stage?

We monitor the durability of the packaging, the stability of the load on the pallet, and the effectiveness of protection against moisture.

  • 1. Preparation of the dry mix
    What we do at this stage?

    We mix refractory aggregate of carefully selected fractions with cement or another binding agent, adhering to the proportions prescribed for the specific concrete formula. An industrial mixer ensures the proper combination of the mass.

    What we control at this stage?

    We check the correctness of the chemical and granular composition, setting time, fluidity of the mix, refractoriness, bulk density, open porosity, and compressive strength.

  • 2. Packing the mix into bags
    What we do at this stage?

    On an automated weighing line, we load our mixture into bags up to 25 kg or into big bags. Then, the bags are automatically labeled with the product name and production date.

    Skrupulatnie sprawdzamy wagę worków oraz poprawność oznaczeń.

    What we control at this stage?

    We verify the bags' weight and the labels' accuracy.

  • 3. Palletizing and wrapping
    What we do at this stage?

    After a successful production cycle, we load our products onto 1100 x 800 mm wooden pallets according to IPPC standards or 1200 x 800 mm according to EUR standards.

    An automated packaging line equipped with a robot precisely stacks the bags on the pallet according to the program. Then, a film sheet is applied to the pallet, and the whole is secured with stretch film. At this stage, each pallet receives a product label containing specified information and the barcode of the production batch.

    What we control at this stage?

    We monitor the durability of the packaging, the stability of the load on the pallet, and the effectiveness of protection against moisture.

We control the quality of every delivered batch

Quality tests of each production batch are conducted in our fully equipped laboratory. These include checks of chemical composition, density, porosity, temperature resistance, expansibility, and thermal conductivity, which ensures the consistently high quality of our products.

Transparent technical specification of products

Our Technical Data Sheets include a column with the product’s guaranteed properties. A dedicated Standard Tolerances document applies for each family of formed refractory products, clearly defining the quality framework without surprises.

We issue international inspection certificates

We test and report product values according to commonly used industry standards, such as ISO and ASTM. Each order is documented with a type 3.1 certificate by the EN 10204 standard, available in selected languages.

Insight into the production history of each product

All processes in our factory comply with the ISO 9001 management standard. An integrated ERP and workflow management system records every stage of production. Using barcodes, we have complete insight into each product’s history, enabling precise tracking of when and from which batch of raw material was produced.

Supplementary products

In addition to refractory ceramics for the working layer of linings, we also provide a range of additional products.

Do you need help deciding which material to choose or how to arrange the brick layers? Our engineers will perform a temperature flow calculation for you and suggest a layout from the working layer to the insulation layer.

Refractory mortars heatseting and airsetting, ready to use

Ceramic papers, thicknesses 1 to 5 mm

Bulk ceramic fiber, ropes and sealing joints

Semi dense insulating boards, thicknesses 10 to 100 mm

Calcium-Silicate boards

Ceramic fiber blankets, thicknesses 13 to 100 mm

Our offer

Designing

Creating designs for the linings of industrial furnaces.

Advising

Offering specialized consultations, opinions, and analyses.

Producing

Manufacturing and assembling the necessary lining components.

Delivering

Organizing product deliveries to every corner of the world.

Installing

Dismantling old linings and executing new installations.

Supporting

We provide supervision during cooling down, heating, installation, or repair.
  • Designing

    Creating designs for the linings of industrial furnaces.

    Delivering

    Organizing product deliveries to every corner of the world.
  • Advising

    Offering specialized consultations, opinions, and analyses.

    Installing

    Dismantling old linings and executing new installations.
  • Producing

    Manufacturing and assembling the necessary lining components.

    Supporting

    We provide supervision during cooling down, heating, installation, or repair.

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