CALDERYS Expertise in Foundry
Enjoying more than 100 years of success in the industry, Calderys is a world leader in refractory solutions for both ferrous and non-ferrous market. The many years of maturity of Calderys as a leader of product and concept development has resulted in hundreds of long term customers who have forged a working partnership based on service and trust resulting in a proven long lasting mutual benefit. Calderys offers full value in use to the customer. By combining all products, concepts, knowledge and experiences, Calderys is able to offer a comprehensive set of refractory solutions for all segments of the Foundry industry, from the initial design including thermal calculations, lining profiles, drawings for the installation and refractory commissioning services. The worldwide presence of Calderys and local experience allows the company to propose the most suitable cost effective and technical solutions that will contribute to our customer's productivity and efficiency.
Calderys creates working partnerships to evaluate and give optimized refractory concepts through:
- Reliability and predictability
- Long life
- Low waste
- Reduced repair
- Energy and Time savings
- Ease of Installation
Calderys offers a full range of solutions for all the cupola zones such as the siphon box, well area, melting zone, stack, and gas offtakes. Concepts include precast wear parts, special coated and protected raw materials, special bonded rammings, as well as more traditional concepts. We have developed specific products for cupola siphon box, such as the new CALDE™ CAST G UC 76S14. Also, our CALDE™ GUN G C 65S25 product is dedicated to the lining and repair of the cupola hearth or melting zone by gunning. Customers working in close partnership with Calderys, and using the company's latest advanced products, have often seen their specific refractory consumption reduce to below 0.5kg/ton of metal processed.
Calderys most used products:
- CALDE™ CAST G 7 P
- CALDE™ RAM G C 65S20
Coreless Induction Furnace:
The Coreless Induction Furnace is considered by many to be the most versatile melting unit available for the foundry industry. The demands placed on the refractory lining vary and are often very complex, bringing very different sets of circumstances that can affect the performance of the refractory lining, including:
- High Thermal Shock
- Lining Wear (corrosion and erosion)
- Metal Static Pressures
- Mechanical Stress
- Gas Penetration
- Slag Build Up
In the CIF segment, Calderys has had more then 50 years of successful partnerships in the foundry industry worldwide. We offer a full set of monolithic linings covering all refractories for the complete furnace (hot face lining, cast blocks, coil grouts, covers, spouts, mica slip planes, etc). Calderys offers a unique naturally formed micro-crystalline silica-based Dry Vibratable Mix from our own 100% controlled Swedish quarry in Åmål. This raw material uniquely gives slow in line crystal transformation, in turn giving excellent thermal stability, uniform hardness and high refractoriness and has long been considered to be the benchmark lining for CIF. All products manufactured with the Åmål material are sold under the name the SILICA MIX brand name.
Calderys most used products for Coreless Induction Furnaces – Iron:
- SILICA MIX 7
- SILICA MIX Q
Calderys most used products for Coreless Induction Furnaces – Steel:
- CALDE™ MIX SC 84 M16
- CALDE™ MIX SC 85 M17
Calderys most used products for Coreless Induction Furnaces – Copper:
- SILICA MIX B CU 7
- SILICA MIX I/CU
Channel Holding and Pouring:
Calderys has extensive experience in this field for both iron and copper based applications. The need for higher productivity and lower costs whilst seeing conditions harden due to available scrap qualities has placed increasing demands on the refractory lining. Due to the various elements causing different forms of stress (erosion, corrosion, slag buildup and overheating) on the refractory lining, we have created new materials and designs to offer optimized solutions to our customers. The varying chemistry of alloys and the increased demands in production volumes have influenced the development of our products and concepts. Our advanced knowledge also allows us to give the best practical advice based not only on refractories. We provide solutions for all furnaces with a global product range composed of acid, neutral and basic products and from castables (all cement and no cement variants, self-flowing, rodding and vibration), gunning, ramming to dry vibratable mixes. To maximize the furnace performance we also focus on the installation, commissioning, and maintenance of the lining.
Calderys most used products:
- CALDE™ CAST UB
- CALDE™ CAST UT 94
Casthouse (Transfer and Treatment ladles, Convertors, launders):
The importance of the correct refractory solution is often overlooked in these applications. By optimizing refractory life, unit availability, energy consumptio and labor, a foundry can make great savings in their plant from areas such as down time, casting quality, and temperature controls. Depending on what is the most costly area for a given site, Calderys is able to offer a solution from plastic, ramming, castables, dry vibratables, precast monoform parts, and coatings.
Calderys most used products:
- CALDE™ CAST UB
- CALDE™ CAST LX 58
These areas will greatly influence the performance of a refractory. Calderys can offer these services if required to ensure that the refractory has the best chance of maximum performance for the end user.
Calderys employs dedicated skilled staff and the latest advances in refractory installation equipment. This can be applied to large, small, and turnkey projects alike depending on the requirement. Alternatively, Calderys can support the customer's own staff by supervision, job management, equipment, and also direct training. Our aim is to ensure the best installation and dryout of the refractory so that the customer gets maximum performance.
Once in service, the refractory may require specific maintenance which again can be supplied depending on the customer requirements. Services are available 24 hours per day, 7 days per week, ensuring minimum downtime for the customer—especially in times of unplanned emergencies.
Calderys is often invited to take part in the development of a technical solution to cover specific needs. Familiar with the specific processes of each customer, Calderys is able to engineer a refractory solution, provide project management services, and advise on the proper installation techniques for new projects. Calderys has an excellent reputation for providing reliable solutions and thus has created many long-lasting relationships with its customers. Our strategic partnership with the customer ensures that we develop market-oriented solutions. Due to experience in the steel, iron, and non-ferrous foundries, Calderys has the capability to become your integrated refractory partner and meet all your needs from solution design to implementation.
Calderys owns a quarry in Sweden containing rare crushed quartzite that is world renown for its unique qualities. This high grade raw material is used in the SILICA MIX range for the Foundry industry.Read more
The Calderys innovative Quick Drying No Cement Castables provide excellent mechanical strength, quick drying and fast heating capabilities, with no curing time, leading to savings in time and energy.Read more