RCF porous rigid boards are manufactured through a vacuum casting process using a slurry made of RCF fibers with inorganic and organic binders, formed to near thickness, dried in an oven, and sanded to final thickness. Standard casting thickness can be up to six inches, but thicker than four inches is often made by stacking board assemblies. Boards are fabricated in low and higher densities to standard sizes, but also available up to 60 inches diameter. Low density boards are slightly better insulators, but they are not as durable and strong as high density.
Customized shapes can be fabricated with made-to-order vacuum molds or by assemblies of smaller parts and layers bonded with RCF cement. The rigid RCF molding mix is machinable and can be manufactured in a wide range of shapes and sizes to meet customer needs, including bolt-together pipes, manifolds, elbows, transitions, and custom fittings, as well as burner blocks, peep-sight windows, and sleeves for any unique furnace system design. It also is possible to embed heating elements in the hot face of the insulation and attachment mechanisms into the body and back of the boards.
