Cement Test Methods High Alumina

Global Product Data
Calcium Aluminate Cements

Cement Test Methods
Chemical
Analysis PSD
%
µm
Vicat
Setting
Time
Strength p
Vibration Flow
time
EXOthermic
T Reaction
good flowing set mortar

time mortar
Think alumina, think Almatis.

GP-006/R07/0516
Cement Test Methods
Chemical Analysis by X-Ray Fluorescence (XRF)
Vicatronic -- Measurement for Setting Time
Cilas -- Measurement for Particle Size Distribution
page 02 of 22 GP-006/R07/0516
Almatis Global Product Data

Cement Test Methods
Introduction
This brochure explains the Almatis cement test methods for Calcium Aluminate Cements which are used to provide
the data on the product data sheet. Test descriptions for analyzing chemical composition and fineness of pure cement
as well as determining setting, exothermic reaction, flow and strength properties in a cement test mortar are also
given.
The principle for our testing is the European Norm EN-196 “Methods of Testing Cement”, designed for testing
Portland cements. The EN-196 Normsand test grog was replaced by a Tabular Alumina grog (NORTAB).
This was done because Silica, the raw material for Normsand, is not a major component in refractory concretes.
Also cement setting in sand-based concretes is generally faster than with Tabular, thus covering up differences in
cement hydration behavior.
NORTAB test grog has a similar Particle Size Distribution (PSD) as Normsand. Using NORTAB brings our Calcium
Aluminate Cement testing, refering to EN-196, closer to the field requirements. NORTAB mortar is composed of 80 % test
grog and 20 % cement plus individual water additions for each cement type as required for good working
consistency: 10 % water for CA-14 cements, CA-670, CA-25 R and CA-25 M and 9 % water for CA-270 and CA-25 C.
For CA-470 TI a Tabular based self flow castable with 5% cement is used for testing (NORCAST). A water addition
of 4.9% is required for the NORCAST mix to achieve good self flow consistency.
Contents List
Page
• Chemical Analysis 4
• Fineness by Laserdiffractometer 5
• Vicat Setting Time 6-7
• Exothermic Reaction Time 8 - 9 and 14 – 15
• Vibration Flow 10 - 11
• Self Flow 16 – 17
• Strength 12 – 13 and 18 – 19
• Page for personal notes 20
page 03 of 22 GP-006/R07/0516
Cement Test Methods for all cement grades
Chemical Analysis
1. Objective
This procedure describes the Almatis method for the chemical analysis of Calcium Aluminate Cement.
2. Principal features of the method
This method determines the chemical analysis of Calcium Aluminate Cement for CaO, Al2O3, Fe2O3, Na2O, SiO2
and MgO. The chemical composition is measured with Wavelength Dispersive X-Ray Fluorescence spectrometry
(WD-XRF). This method utilizes the element specific X-Ray wavelength, which is created by an electron beam direc-
ted on the sample. The intensity of the X-Ray radiation of the specific element provides the concentration of that ele-
ment in the sample.
3. Laboratory and equipment
A Wavelength Dispersive XRF Spectrometer, Sequential-Simultaneous configuration is used.

The instrument is fitted with a SmartGonio™ for the elements Al (Z=13) to U (Z=92) and fixed channels for the
elements Na (Z=11) and Mg (Z=12).
4. Procedure
10.000 g Calcium Aluminate Cement and 0.6 gram wax binder is ground in a laboratory disk mill to less than 50
microns to reduce particle size effects. The obtained homogeneous mixture is pressed into a 30 mm steel ring with
a hydraulic press at approx. 15 MPa. The binder is used to obtain better pressed pellets.
This pressed pellet is placed into the Wavelength Dispersive - XRF for the determination of the concentration of
Ca, Al, Fe, Na, Si, and Mg. The results are provided as CaO, Al2O3, Fe2O3, Na2O, SiO2 and MgO.
Reference curves are made from guaranteed reference sample Reference curve
concentrations, which are obtained from an external certified Oxide Crystal/ Line concentration
laboratory and cover the full reference concentration range Detector [wt%]
shown in the table. A reference curve is made for each element CaO Lif200 / FPC CaKa1,2 0 – 33.0
oxide using Multi-Variable-Regression. Al2O3 PET / FPC AlKa1,2 0 – 99.0

Fe2O3 Lif200 / FPC FeKa1,2 0 – 7.70
All samples and reference curves are measured with X-Ray Na2O Fixed NaKa_m 0 – 0.90
Fluorescence spectrometry (WD-XRF). The concentration in the SiO2 PET / FPC SiKa1,2 0 – 1.30
cement sample is determined with the reference curves. MgO Fixed MgKa_M 0 – 0.65
5. Calculation
The sum of the oxides CaO, Al2O3, Fe2O3, Na2O, SiO2 and MgO will be reported as a fixed total of 100% based
on moisture and loss on ignition free material.
page 04 of 22 GP-006/R07/0516

Cement Test Methods for all cement grades
Fineness by Laserdiffractometer
1. Objective
This procedure describes the Almatis method of determining the Particle Size Distribution of Calcium Aluminate Cement.
This method involves the determination of the Particle Size Distribution (PSD) of Calcium Aluminate Cement, measu-
red by Cilas Laserdiffractometer 1090. The PSD is analyzed by ultrasonic dispersion of the Calcium Aluminate
Cement in Isopropyl alcohol. The liquid is passed through the measuring cell of the laserdiffractometer. Two laser
beams are sent through the measuring cell to a detector. The dispersed powder causes scattering of the laser beams.
The scattering pattern is a function of the size of the particles as well as the quantity of a given particle size. The
scattering pattern is measured by the detector and translated into a PSD reported as a sum curve and as a cumula-
tive curve.
Laserdiffractometer (Quantachrome, Cilas Laserdiffractometer 1090).

Isopropyl alcohol.
4. Procedure
The laserdiffractometer is calibrated by using a standardized sample with a defined PSD. As all cement grades have
their typical PSD characteristics, standard samples with a defined PSD are used for calibration before each testing.
Cilas PSD sum curve with D50 and -45µm points (Example CA-270) The sample of 0.3 – 0.5 g Calcium Aluminate Cement is filled.
The material is dispersed for 180 sec in an ultrasonic bath of Isopropyl
-45µm=96%
100
alcohol, followed by the actual PSD measurement.
90
80
70
The PSD is expressed in D90, D50, D10,
PSD
60 reflecting the particle diameter of the mate-
50 rial where 90 %, 50 %, or 10 % of the [%]
40 powder is smaller than the listed diameter
% passing
30 in µm. Recorded is the D50.

20
1 10 100
The weight percentage of material being
D50=7,0µm [µm] [µm]
smaller -45 µm (-325 mesh) is also
calculated by the device, recorded and
corrected to match sieve analysis.
page 05 of 22 GP-006/R07/0516
Cement Test Methods for CA-25, CA-14, CA-270 and CA-670
Vicat Setting Time
1. Objective
This procedure describes the Almatis method of determining the setting properties of Calcium Aluminate Cement mor-
tar. Conditions are as nearly as possible based on the European Standard EN 196-3+A1.
This method involves the determination of the setting properties of cement mortar filled in Vicat moulds. The Vicat
moulds are of truncated conical form, 40 mm high, internal diameter at top of 80 mm and bottom of 90 mm.
The mortar contains 20 wt % of Calcium Aluminate Cement and 80 wt % of a standard Tabular Alumina T60/T64
grog (NORTAB). It has a water/cement ratio of 0.5 for CA-14 cements, CA-670, CA-25 R and CA-25 M, 0.45 for
CA-270 and CA-25 C (see table below).
The mortar is prepared by mechanical mixing and cast in the Vicat moulds without compacting by vibration. The fil-
led moulds are kept in a moist atmosphere. The setting behavior is determined by observing the decrease of pene-
tration depth of a Vicat needle into the mortar. Initial and final setting times are taken when the Vicat needle is sup-
ported 10 or 30 mm above the base plate.
Laboratory conditions complying with 4.1 of EN 196-3+A1. Particle Size Distribution (PSD) of NORTAB grog
and Composition of mortar
Test sieves complying with 4.3 of EN 196-1.
Hobart Mixer (~5 litre bowl volume) complying with 4.4 NORTAB PSD
of EN 196-1.
Square
Vicat moulds complying with 5.1 of EN 196-3+A1. mesh size Sieve Residue
Automatic Vicat apparatus. [mm] [%]
Demineralized water. + 2.0 3±2
+ 1.4 13 ± 3
+ 1.0 14 ± 50
4. Mortar + 0.5 35 ± 50
+ 0.125 29 ± 50
NORTAB grog (made of pure Tabular Alumina T60/T64) is used + 0.063 4 ± 30
– 0.063 2 ± 20
to determine Vicat setting time of Calcium Aluminate Cement
Raw Material: Tabular Alumina T60/T64
according to this procedure. For NORTAB grog sieve analysis and
NORTAB Mortar Composition:
mortar composition see table. NORTAB grog is applied as a premix
80 % NORTAB and 20 % cement plus
of 2800 ± 2 g.
– 10 % H 2O for CA-14 cements
– 10 % H 2O for CA-670
– 10 % H 2O for CA-25 R and CA-25 M
– 9 % H 2O for CA-270
– 9 % H 2O for CA-25 C
page 06 of 22 GP-006/R07/0516

5. Procedure
NOTE Set up of Vicat apparatus: Use of an automatic Vicat tester device with
- cylindrical Vicat needle, effective length = 50 ± 1 mm, diameter = 1.13 ± 0.05 mm;
- total mass of the moving parts is 1000 ± 1 g.
Composition of the mortar for CA -14 cements, CA-670, for CA -270, CA -25 C
CA -25 R and CA-25 M
2800 ± 2 g NORTAB 2800 ± 2 g NORTAB

2700 ± 1 g cement 2700 ± 1 g cement
2350 ± 1 g water 2315 ± 1 g water
Fill the NORTAB grog in the mixing bowl and add the cement. Start the mixer at low speed, note the starting timer
as zero. After 1 min. add the demineralized water. Stop mixer after total mixing time of 5 min.
Fill the mortar immediately into a Vicat mould without compacting by vibration, large end facing up, cover and invert.
Place the mould in upright position in a holder (pan). Cover the mould in the holder with a thin layer of deminerali-
zed water (~1-2 mm) to prevent drying out of mortar surface during testing. Transfer the holder to the calibrated
automatic Vicat apparatus and position under the Vicat needle. All needle penetrations should be at 10 mm from
the rim of the mould and 10 mm from each other.
Start the automatic Vicat apparatus 10 min after start of mixing. Record the depths of penetration against time. Time intervals are
every 10 min for CA-14, CA-670 and CA-270 cements, every 2 min for CA-25 R and every 5 min for CA-25 C and CA-25 M.
The time measured from the start of mixing to the time at which the distance between the needle and the base plate
is 10 ± 1 mm, followed by successive measurements at which this distance is equal or exceeded, is recorded as the
Initial Setting time (IS).
The time measured from the start of mixing to the time at which the distance between the needle and the base plate
is 30 ± 1 mm, followed by successive measurements at which this distance is equal or exceeded, is recorded as the
Final Setting time (FS).
Vicat Setting Time: Measuring curve with Initial and Final Setting points (Example CA-14 M)
Vicat
Setting

40 Time
depth in NORTAB mortar [mm]
30
Vicat needle penetration
Final Setting (>30 mm): 260 min

20
10
Initial Setting (>10 mm): 240 min
0
10 100 200 300 time [min]
page 07 of 22 GP-006/R07/0516
Exothermic Reaction (EXO)
1. Objective
This procedure describes the Almatis method of determining the exothermic properties of Calcium Aluminate Cement
mortar. Conditions are as nearly as possible based on the European Standard EN 196-1.
This method describes the determination of the exothermic heat development during cement hydration of a cast mor-
tar test specimen. The cast sample has a weight of 1.5 kg.
grog (NORTAB). It has a water/cement ratio of 0.5 for CA-14 cements and CA-670, for CA-25 R and CA-25 M,
0.45 for CA-270 and CA-25 C (see table below).
The mortar is prepared by mechanical mixing and cast in the moulds under light vibration. A thermocouple (type J)
is put into the mortar and connected to a measurement device. The mortar in the moulds is covered. The temperature
development of the mortar until completion of the main hydration is measured as function of the time after mixing.
Laboratory conditions complying with 4.1 of EN 196-1. Particle Size Distribution (PSD) of NORTAB grog
Hobart-Mixer (~5 litre bowl volume) complying with 4.4 NORTAB PSD
of EN 196-1.
Vibration table complying with EN 196-1. Square
mesh size Sieve Residue
Test apparatus for recording exothermic temperature increase. [mm] [%]
Demineralized Water.
+ 2.0 3±2
+ 1.4 13 ± 3
4. Mortar + 1.0 14 ± 50
+ 0.5 35 ± 50
+ 0.125 29 ± 50
NORTAB grog (made of pure Tabular Alumina T60/T64) is used + 0.063 4 ± 30
to determine the exothermic reaction of Calcium Aluminate – 0.063 2 ± 20
Cement according to this procedure. For NORTAB grog sieve ana- Raw Material: Tabular Alumina T60/T64
lysis and mortar composition see table. NORTAB grog is applied NORTAB Mortar Composition:
as a premix of 2800 ± 2 g. 80 % NORTAB and 20 % cement plus

– 10 % H 2O for CA-670
– 9 % H 2O for CA-270
– 9 % H 2O for CA-25 C
page 08 of 22 GP-006/R07/0516

5. Procedure
Composition of the mortar for CA -14 cements, CA-670, for CA - 270, CA - 25 C

CA - 25 R and CA-25 M

2350 ± 1 g water 2315 ± 1 g water
Transfer the mortar immediately to a box, using 1500 g mortar. Compact the mortar by vibrating for 10 sec. Put a
thermocouple (type J) into the mortar and connect to a data recorder (PC logger). Cover the mortar in the mould.
Measure the temperature of the mortar as function of time after start of mixing (zero) until the completion of the
main hydration.
• The time measured from the start of mixing until the exothermic reaction shows a temperature increase of +5 °C
is recorded as EXO+5.
• The time measured from the start of mixing until maximum temperature of the exothermic reaction is reached is
recorded as EXO max. It corresponds to the time when there is sufficient green strength for demoulding.
46
44
42
40
5°C Temp.
38
Increase
36
temperature [°C]
[EXO +5]
34 Max. Heat
=> FS Vicat
Development
32
[EXO max]
30 => green
28 strength EXOthermic
26 Reaction
24 T
22
20
18
time
0 60 120 180 240 300 360 420
time [min]
page 09 of 22 GP-006/R07/0516
Vibration Flow
1. Objective
This procedure describes the Almatis method of determining the flow properties of Calcium Aluminate Cement mor-
tar. Conditions are as nearly as possible based on the European Standard EN 196-1.
This method involves the determination of the flow properties of cement mortar filled in Vicat moulds. The Vicat
moulds are of truncated conical form, 40 mm high, internal diameter at top of 70 mm and bottom of 80 mm.
Sufficient mortar to fill three Vicat moulds is prepared by mechanical mixing. The three Vicat moulds are casted
without vibration. The filled moulds are covered. After defined time intervals, a filled Vicat mould is placed on a
vibration table, the mould is lifted off, and the mortar sample is vibrated. The diameter after vibration indicates the
flow property as a function of time.
Laborator y conditions complying with 4.1 of EN 196-1. Particle Size Distribution (PSD) of NORTAB grog
Hobart Mixer (~ 5 litre bowl volume) complying with 4.4 of NORTAB PSD
EN 196-1. Vibration table complying with EN 196-1. Vicat moulds
Square
complying with 5.1 of EN 196-3+A1 *. mesh size Sieve Residue
Demineralized water. [mm] [%]
Plexi-glass plates. + 2.0 3±2
+ 1.4 13 ± 3
+ 1.0 14 ± 50
*Dimensions of Vicat mould for determination of flow properties
+ 0.5 35 ± 50
in use is: 40 mm hight, 70 mm upper diameter, 80 mm lower + 0.125 29 ± 50
diameter. + 0.063 4 ± 30
– 0.063 2 ± 20
4. Mortar
NORTAB grog (made of pure Tabular Alumina T60/T64) is used
to determine the flow properties of Calcium Aluminate Cement – 10 % H 2O for CA-14 cements
– 10 % H 2O for CA-670
according to this procedure. For NORTAB grog sieve analysis and – 10 % H 2O for CA-25 R and CA-25 M
mortar composition see table. NORTAB grog is applied as a premix – 9 % H 2O for CA-270
of 2800 ± 2 g. – 9 % H 2O for CA-25 C
page 10 of 22 GP-006/R07/0516

5. Procedure
Composition of the mortar for CA -14 cements, CA-670, for CA -270, CA -25 C

2350 ± 1 g water 2315 ± 1 g water
After mixing, immediately fill the Vicat moulds with mortar. Use 450 g castable per mould to fill them.
Cover the moulds with a plexi-glass plate.
9 min after the mixing started, place the first mould on the vibration table with the large end facing down. Remove
the plates and the mould.
10 min after the mixing started, vibrate the mortar sample for 30 sec at amplitude 0.5 mm, frequency 50 Hz, mea-
sure the diameter in four directions, average the value and record it as Vibration Flow F10 (i.e.: F10=16 cm stands
for a vibration diameter of 16 cm tested 10 min after begin of mixing).
Repeat the above procedure for the other two mortar samples at defined intervals, see table below.
The sample is set when the flow diameter equals the large inner diameter of the mould.
Flow measurement intervals Vibration Flow
Test Recorded
Interval Value time
10 min F10
30 min F30
60 min F60
mortar
page 11 of 22 GP-006/R07/0516
Strength
1. Objective
This procedure describes the Almatis method of determining the cold modulus of rupture (CMOR) and cold crushing
strength (CCS) of Calcium Aluminate Cement mortar. Conditions are as nearly as possible based on the European
Standard EN 196-1.
This method involves the determination of the cold crushing strength, and optional the flexural strength of test bars
of 40 x 40 x 160 mm size.
The mortar is prepared by mechanical mixing and is compacted in a mould using a vibration table. The bars are
cured for 24 hours in the mould covered with a plexi-glass plate and demoulded afterwards. The bars will either (1)
be directly used for strength testing, (2) be dried for 24 hours at 105°C, or will (3) be fired for 5 hours at 1000°C
before strength testing. The bars will be broken under bending conditions into 2 halves, indicating the cold modu-
lus of rupture. Each half will be tested for cold crushing strength.
Laboratory, test sieves, mixer, moulds for three bars, flexural and Particle Size Distribution (PSD) of NORTAB grog
cold crushing strength testing machines are according to the
EN 196-1. NORTAB PSD
Vibration table according to the EN 196-1.
Square
Metal spatula (strong material). mesh size Sieve Residue
[mm] [%]
4. Mortar + 2.0 3±2
+ 1.4 13 ± 3
+ 1.0 14 ± 50
NORTAB grog (made of pure Tabular Alumina T60/T64) is used
+ 0.5 35 ± 50
to determine the strength properties of Calcium Aluminate Cement + 0.125 29 ± 50
according to this procedure. For NORTAB grog sieve analysis and + 0.063 4 ± 30
– 0.063 2 ± 20
mortar composition see table. NORTAB grog is applied as a premix
of 2800 ± 2 g.

– 10 % H 2O for CA-670
– 9 % H 2O for CA-270
– 9 % H 2O for CA-25 C
page 12 of 22 GP-006/R07/0516

5. Procedure
Composition of the mortar for CA-14 cements, CA-670, for CA-270, CA -25 C

2350 ± 1 g water 2315 ± 1 g water
Run the vibration table at an amplitude of 0.50 mm. Cast the bars immediately after the preparation of the mortar
by filling in two layers:
Introduce the first layer into each mould with the help of a spreader into the three compartments within 20 sec, vibra-
te the first layer for the next 20 sec. Then introduce the second layer of mortar within 20 sec and vibrate the layer
for 60 sec.
Lift the mould from the vibration table and remove any excess with a strong spatula. Do this in each direction. Then
level the surface with the spatula held almost flat.
Cure the bars in the mould covered with a plexi-glass plate for 24 hours at 20 ± 1°C. Remove the mould (if needed
a rubber hammer can be used).
• Bar 1: Determine within 20 minutes after demoulding the cured strength according to EN 196-1.
• Bar 2: Place cured bars directly after demoulding for 24 hours in a preheated drying chamber at 105 °C. Take
the dried bar out and let cool to 20 °C. - Determine the dried strength according to EN 196-1.
• Bar 3: Place dried bars in a cold firing furnace. Heat the furnace during 5 hours up to 1000 °C and hold for
5 hours, then shut down. Take the fired bars out and let cool to 20 °C. - Determine the fired strength according
to EN 196-1.
Remark: Strengths are recorded in MPa. 1 MPa = 145 psi
p
Strength
page 13 of 22 GP-006/R07/0516
Cement Test Methods for CA-470 TI
Exothermic Reaction (EXO)
1. Objective
This procedure describes the Almatis method of determining the exothermic properties of Calcium Aluminate Cement
CA-470 TI test castable. Laboratory conditions are as nearly as possible based on the European Standard EN 196-1.
This method describes the determination of the exothermic heat development during cement hydration of a low
cement castable test specimen. The casted sample has a weight of 1.5 kg.
The test castable based on tabular alumina contains 5 wt % of Calcium Aluminate Cement CA-470 TI. The water
addition for the test castable is 4.9%. Composition of the test castable is given under “4. Castable”.
The castable is prepared by mechanical mixing and casted in a box. A thermocouple (type J) is put into the casta-
ble and connected to a measurement device. The box is closed during the measurement. The temperature develop-
ment of the castable until completion of the main hydration is measured as function of the time after mixing.
Laboratory conditions complying with 4.1 of EN 196-1. Composition of NORCAST test castable
Hobart mixer (~ 10 liter bowl volume) complying with 4.2 of EN 1927-5. NORCAST 5
%
Plastic box with cover. 3 – 6 mm 30
Test apparatus for recording exothermic temperature increase. Coarse 1 – 3 mm 15
Demineralized water. fraction 0.5 – 1 mm 10
T60/T64 0.2 – 0.6 mm 5
0 – 0.3 mm 10
4. Castable Fine fraction - 45 MY Li 8
T60/T64 - 20 MY 7
Reactive
NORCAST 5 is a low cement self-flow castable based on Tabular CL 370 10
Alumina
Alumina T60/T64. It contains 5 wt % of Calcium Aluminate Cement Cement CA-470 TI 5
Dispersing ADS 3 0.8
CA-470 TI. The castable matrix is composed of T60/T64 -45MY Li
Alumina ADW 1 0.2
and -20MY and reactive alumina CL 370. As additives dispersing Water 4.9
aluminas ADS/W are used. For NORCAST formulation see table.
page 14 of 22 GP-006/R07/0516

5. Procedure
Weigh in the single components in the mixing bowl including the cement and the additives. Total batch weight is 5
kg. Start the mixer at low speed, note the starting timer as zero. After 1 minute add demineralized water. Stop mixer
after total mixing time of 5 minutes.
Transfer the castable immediately to a plastic box, using 1500 g of castable. Put a thermocouple (type J) into the
castable and connect to a data logger (PC logger). Cover the castable in the box. Measure the temperature of the
castable as function of time after start of mixing (zero) until the completion of the main hydration.
• The time measured from the start of mixing until the first temperature peak starts to rise is recorded as EXO start1.
It correlates to the end of working time.
• The time measured from the start of mixing until the maximum temperature peak starts to rise is recorded as
EXO start 2.
• The time measured from the start of mixing until maximum temperature of the exothermic reaction is reached is
recorded as EXO Max. It corresponds to the time when there is sufficient green strength for demoulding.
32
1 EXO start 1: end of working time

30
2 EXO start 2: beginning of strength development 3
28 3 EXO Max: sufficient green strenght for demoulding

temperature [oC]
26
24 2
1
22
20
0 200 400 600 800 1000
time [min]
page 15 of 22 GP-006/R07/0516
Self Flow
1. Objective
This procedure describes the Almatis method of determining the flow properties of Calcium Aluminate Cement
CA-470 TI containing test castable. Laboratory conditions are as nearly as possible based on the European Standard
EN 196-1.
This method involves the determination of the flow properties of cement containing castable filled in truncated cones.
The cones are made out of stainless steel, 80 mm high, internal diameter at top of 70 mm and bottom of 100 mm.
The test castable based on Tabular Alumina T60/T64 contains 5 wt % of Calcium Aluminate Cement CA-470 TI. The
water addition for the test castable is 4.9%. Composition of the test castable is given under “4. Castable”.
The castable is prepared by mechanical mixing. The three flow cones are casted without vibration. The filled moulds are
covered. After defined time intervals, a filled flow cone is placed on a metal plate, the cone is lifted off, and the casta-
ble is flowing without being vibrated. The diameter after two minutes indicates the flow property as a function of time.

Composition of NORCAST test castable
Laboratory conditions complying with EN 196-1. NORCAST 5

%
Hobart mixer (~ 10 liter bowl volume) complying with 4.2 of EN 1927-5. 3 – 6 mm 30
Metallic flow cones complying with 4.4 of EN 1927-4 *. Coarse 1 – 3 mm 15
Demineralized water fraction 0.5 – 1 mm 10
T60/T64 0.2 – 0.6 mm 5
Plexi-glass plates 0 – 0.3 mm 10
Metal plate Fine fraction - 45 MY Li 8
Metal spatula (strong material) T60/T64 - 20 MY 7
Reactive
Measuring slide CL 370 10
Alumina
Cement CA-470 TI 5
* Dimensions of flow cone for determination of flow properties in use is:
Alumina ADW 1 0.2
80 mm high, 70 mm upper diameter, 100 mm lower diameter. Water 4.9
4. Castable
NORCAST 5 is a low cement self-flow castable based on Tabular Alumina T60/T64. It contains 5 wt % of Calcium
Aluminate Cement CA-470 TI. The castable matrix is composed of T60/T64 -45MY Li and -20MY and reactive alu-
mina CL 370. As additives Dispersing Aluminas ADS/W are used. For NORCAST formulation see table.
page 16 of 22 GP-006/R07/0516

5. Procedure
Weigh in the single components in the mixing bowl including the cement and the additives. Total batch weight is
5 kg. Start the mixer at low speed, note the starting timer as zero. After 1 minute add demineralized water. Stop
mixer after total mixing time of 5 minutes.
After mixing, immediately fill the flow cones with the castable up to the top. Remove excessive material from the top
with a spatula. Cover the flow cones with a plexi-glass plate.
9 minutes after the mixing started; place the first mould on the metal plate with the large end facing down. Remove
the plexi-glass plates.
10 minutes after the mixing started, lift the flow cone up. The castable spreads out evenly on its own without the
means of vibration. Measure the diameter of the flow cake in two directions (vertically to each other) 2 minutes after
lifting the cone, average the value and record it as Self flow F10 (i.e.: F10 = 22,0 cm stands for a self-flow diameter of
22,0 cm tested 10 minutes after begin of mixing).
Repeat the procedure above for the other two castable samples at defined intervals, see table below.
The end of the working time is achieved when the flow diameter equals the large inner diameter of the mould.
Flow measurement intervals Self Flow
Test Recorded
Interval Value time
10 min F10
30 min F30
60 min F60
mortar
page 17 of 22 GP-006/R07/0516
Strength
1. Objective
This procedure describes the Almatis method of determining the cold modulus of rupture (CMoR) and cold crushing
strength (CCS) of Calcium Aluminate Cement CA-470 TI test castable. Laboratory conditions are as nearly as possible
based on the European Standard EN 196-1.
This method includes the determination of the cold crushing strength, and optional the cold modulus of rupture of test
bars of 40 x 40 x 160 mm size.
The test castable based on Tabular Alumina T60/T64 contains 5 wt % of Calcium Aluminate Cement CA-470 TI. The
water addition for the test castable is 4.9%. Composition of the test castable is given under “4. Castable”.
The castable is prepared by mechanical mixing and casted in a mould without the means of vibration. The bars are
cured for 24 hours at 20°C ambient temperature and then demoulded. The bars will either (1) be directly used for
strength testing, (2) be dried for 24 hours at 105°C, or will (3) be fired for 5 hours at 1000°C before strength testing.
The bars will be broken under bending conditions into 2 halves, indicating the cold modulus of rupture. Each half
will be tested for cold crushing strength.
Laboratory conditions complying with EN 196-1. Composition of NORCAST test castable
Hobart mixer (~ 10 liter bowl volume) complying with 4.2 of EN 1927-5. NORCAST 5
%
Moulds for three bars 3 – 6 mm 30
Demineralized water Coarse 1 – 3 mm 15
Strength testing machine according to the EN 196-1. fraction 0.5 – 1 mm 10
T60/T64 0.2 – 0.6 mm 5
Metal spatula (strong material). 0 – 0.3 mm 10
Fine fraction - 45 MY Li 8
4. Castable T60/T64 - 20 MY 7
Reactive
CL 370 10
Alumina
NORCAST 5 is a low cement self flow castable based on Tabular Alumina Cement CA-470 TI 5
T60/T64. It contains 5 wt % of Calcium Aluminate Cement CA-470 TI.
Alumina ADW 1 0.2
The castable matrix is composed of T60/T64 -45MY Li and -20MY and Water 4.9
reactive alumina CL 370. As additives dispersing aluminas ADS/W are
used. For NORCAST formulation see table.
page 18 of 22 GP-006/R07/0516

5. Procedure
Weigh in the single components in the mixing bowl including the cement and the additives. Start the mixer at low
speed (speed 1) and mix the castable dry for 1 minute. Add the demineralized water and start time measurement.
Stop mixer after wet mixing of 4 minutes.
Cast the bars immediately after the preparation of the castable by filling the moulds at a moderate rate without the
means of vibration. Remove excessive material with a strong spatula. Do this in each direction.
Cure the bars in the mould covered with a plexi-glass plate for 24 hours at 20 ± 1°C. Remove the mould (if needed
a rubber hammer can be used).
• Bar 1: Determine within 20 minutes after demoulding the cured strength according to EN-196-1.
• Bar 2: Place cured bars directly after demoulding for 24 hours in a preheated drying chamber at 105°C.
Take the dried bar out and let cool to 20°C. Determine the dried strength according to EN-196-1.
• Bar 3: Place dried bars directly in a cold firing furnace. Heat the furnace during 5 hours up to 1000°C and
hold for 5 hours, then shut down. Take the fired bars out and let cool to 20°C. Determine the fired strength
according to EN-196-1.
Remark: Strength is recorded in MPa. 1 MPa = 145 psi
p
Strength
page 19 of 22 GP-006/R07/0516
Cement Test Methods
Page for Personal notes
page 20 of 22 GP-006/R07/0516

Cement Test Methods
Exothermic Reaction set-up
NORTAB mortar after vibration table test
Strength Test Self flow test of NORCAST mix
page 21 of 22 GP-006/R07/0516

Cement Test Methods
Contacts for sales, technical information and application assistance
Almatis GmbH Almatis B.V. Almatis, Inc.

Giulinistrasse 2 Theemsweg 30 501 West Park Road
67065 Ludwigshafen 3197KM Botlek RT Leetsdale, PA 15056, USA
Germany The Netherlands
℡ 800 643 8771 General
℡ 49 621 5707 0 ℡ 31 181 2701 00 ℡ 1 412 630 2800
49 621 5707 130 31 181 2178 53 1 412 630 2900
Almatis do Brasil Ltda. Qingdao Almatis Co., Ltd. Almatis Alumina

Avenida Jose de Souza No.1, Songhuanjiang Road Private Limited
Campos, 243 Huangdao District Kankaria Estate
2° Andar – Cambuí Qingdao, 266555 2nd Floor
13025-320 – Campinas, P.R. China 6, Little Russell Street
SP – Brasil Kolkata 700-071, India
℡ 55 19 3515-1400 ℡ 86 21 5879 4987 ℡ 91 33 2289 4694

55 19 3515-1410 86 21 5879 6502 91 33 2289 4693
Almatis Limited
Toranomon Towers Office 13F
1-28, Toranomon 4-chrome,
Minato-ku, Tokyo, 105-8451
Almatis GmbH
Japan
Lyoner Straße 9
60528 Frankfurt/Germany
℡ 81 3 3432 6121
Phone 49 69 957 341 0 81 3 3432 6125
Fax 49 69 957 341 13
info@almatis.com
www.almatis.com
GP-006/R07/0516 Page 22 of 22

Cement Test Methods High Alumina

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Global Product Data

Calcium Aluminate Cements

good flowing set mortar

Think alumina, think Almatis.

Chemical Analysis by X-Ray Fluorescence (XRF)

Vicatronic -- Measurement for Setting Time

Cilas -- Measurement for Particle Size Distribution

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2800 ± 2 g NORTAB 2800 ± 2 g NORTAB

Remark: Strengths are recorded in MPa. 1 MPa = 145 psi

Exothermic Reaction (EXO)

2. Principal features of the method

3. Laboratory and equipment

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1 EXO start 1: end of working time

28 3 EXO Max: sufficient green strenght for demoulding

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Laboratory conditions complying with EN 196-1. NORCAST 5

Calcium Aluminate Cements

Flow measurement intervals Self Flow

2. Principal features of the method

3. Laboratory and equipment

Laboratory conditions complying with EN 196-1. Composition of NORCAST test castable

Calcium Aluminate Cements

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Page for Personal notes

Calcium Aluminate Cements

Exothermic Reaction set-up

NORTAB mortar after vibration table test

Strength Test Self flow test of NORCAST mix

Calcium Aluminate Cements