Calcium Aluminate Cements (CAC): Chemistry, Properties, Applications, Global Suppliers & Market Outlook: Applied Intelligence
Calcium Aluminate Cements (CAC): a field guide for engineers & buyers
CAC / HAC Refractory Rapid set Sulfate & acid resistance
1) What are calcium aluminate cements?
Calcium aluminate cements (CAC, also called high-alumina cements) are specialty hydraulic binders made primarily from limestone (CaO) and bauxite/alumina (Al₂O₃). They differ from Portland cement: their main clinker phases are aluminates (not silicates), which gives CAC very fast strength gain, high temperature performance and strong chemical resistance.[S1]
Chemistry & key phases (cement chemist notation)
| Phase | Formula | Notes |
|---|---|---|
| CA | CaO·Al₂O₃ | Dominant phase in many CAC grades |
| CA₂ | CaO·2Al₂O₃ | Higher alumina, slower hydrate kinetics |
| C12A7 (Mayenite) | 12CaO·7Al₂O₃ | Reactive, contributes to very early set |
Hydration and “conversion” (why mix design matters)
Early hydrates include CAH₁₀ and C₂AH₈; over time (and with temperature) they convert to denser C₃AH₆ + AH₃, which can reduce porosity but also nominal strength if water/cement and curing are not controlled. Proper mix design (low w/c, adequate curing, correct grading) mitigates this.[S2][S3][S4]
2) Properties, applications & “why CAC?”
- Very fast set & early strength (hours, not days)
- Excellent sulfate & acid resistance (no free Ca(OH)₂)
- High temperature service (refractories)
- Low efflorescence; dimensional stability in drymix systems
- Refractory castables, kiln/furnace repairs
- Sewer & wastewater, marine, chemical exposure
- Rapid pavement/airfield repairs; fast screeds
- Drymix mortars (accelerated, self-drying systems)
Why it works: aluminates hydrate without portlandite release, improving resistance to sulfates/biogenic corrosion; rapid hydrate formation enables early opening to traffic or demolding in prefabrication.[S1][S5][S6]
3) How CAC is produced (quarry → customer)
- Raw materials: crushed limestone and bauxite/refined alumina.
- Clinker making: fusion/sintering at ~1,600 °C in electric/oxy-fuel/reverberatory or rotary systems (energy-intensive vs. OPC). Clinker is rapidly cooled.[S7]
- Grinding & classification to target fineness and phase balance.
- QA/QC & certification: EN 14647 composition/mechanical criteria in Europe; EPD/DoP for specific products.[S8]
- Logistics & formats:
- 25 kg bags (palletized), ~1,000 kg big bags, and bulk (pneumatic tanker) for silos.[S9][S10][S11]
- Shipping as bulk/break-bulk or containerized pallets depending on route.
4) Leading suppliers, brands & production locations
| Company | Brands / Grades (examples) | Main CAC sites serving EMEA / Americas |
|---|---|---|
| Imerys Aluminates (ex-Kerneos) | Ciment Fondu®, Secar®, Ternal® | France (Fos/La Rochelle, others); UK (historic Purfleet); USA (Chesapeake, VA); India (Atchutapuram, 30–50 kt/yr binder plant).[S12][S13][S14] |
| Calucem (Molins Group) | Istra®, Refcon® | Pula (Croatia ~100 kt/yr); Barcelona (ES, QA/tech); New Orleans (USA, new CAC plant investment).[S15][S16][S17] |
| Górka Cement (PL) | GÓRKAL® 40/50/70 | Trzebinia, Poland (100+ years of HAC/CAC production).[S18][S19] |
| Çimsa (TR) | ISIDAÇ® 40 / 52 | Mersin/Eskisehir/Afyon (TR) + Buñol (ES for white cement; CAC produced in TR).[S20][S21] |
| Almatis | CA-50/60/70/80 series (high-purity CAC) | Global network (EU, US, CN) supplying high-purity CAC for refractories/ceramics.[S22][S23] |
5) Trade flows & common Incoterms
- Origins (EMEA): France (Imerys), Croatia/Spain (Calucem), Turkey (Çimsa), Poland (Górka), plus China for price-sensitive flows.
- Americas: USA imports from Turkey/EU/China pending new US capacity; Latin America sources EU/TR/CN.[S24][S25]
Incoterms commonly used for CAC in bulk/break-bulk: FOB (seller loads, buyer arranges freight/insurance), CFR/CIF (seller pays freight; CIF includes minimum insurance), and FCA/DAP for palletized/container moves and intra-EU road.[S26][S27][S28][S29]
6) Market size & directional import estimates
Method: combine recent global CAC market values (≈US$1.3–1.7 bn, 2024) with volume estimates (~3.96 Mt, 2025) to derive regional ranges. Prices vary widely by grade (CA50 vs CA70/80), packaging and terms; Western branded CAC often transacts higher than Chinese supply. Ranges below are directional for planning and should be validated with RFQs.
6.1 EMEA & the Americas — directional split
| Region | Indicative share of CAC value | € value (range) | Tonnage (range) | Typical origins |
|---|---|---|---|---|
| Europe | ~25–30% | €350–€500 m | 0.8–1.1 Mt | FR, HR/ES, PL, TR |
| Middle East & North Africa | ~8–12% | €110–€200 m | 0.2–0.35 Mt | FR, TR, HR, CN |
| Sub-Saharan Africa | ~5–7% | €70–€110 m | 0.1–0.2 Mt | EU, TR, CN |
| North America | ~15–20% | €210–€330 m | 0.35–0.6 Mt | TR, EU, CN (and new US supply) |
| Latin America | ~5–8% | €70–€130 m | 0.1–0.25 Mt | EU, TR, CN |
Derived by reconciling value-based reports and a 3.96 Mt global tonnage baseline with mid-range EU landed prices.[S30][S31][S32]
6.2 Country clusters (Europe)
| Cluster | Annual potential (tons) | € potential (assume avg €700–900/t) | Notes |
|---|---|---|---|
| DACH (DE/AT/CH) | 120–180k | €84–€162 m | Large refractory, steel, waste-to-energy base |
| France | 90–140k | €63–€126 m | Local supply (Imerys), strong building chemistry |
| Italy | 80–120k | €56–€108 m | Ceramics, foundry, WtE |
| Spain | 50–80k | €35–€72 m | Drymix & wastewater; Calucem tech hub in Barcelona |
| Benelux | 25–40k | €18–€36 m | Ports, chemicals, distribution |
| Portugal | 10–20k | €7–€18 m | Marine & wastewater |
6.3 Middle East, Libya/Egypt & Maghreb; West Africa
| Region | Annual potential (tons) | € potential (avg €650–850/t) | Buyer profile |
|---|---|---|---|
| GCC + Levant | 80–120k | €52–€102 m | Refinery/petrochem, desalination, WtE, airports |
| Egypt | 20–30k | €13–€26 m | Steel, fertilizers, cement kilns, wastewater |
| Maghreb (MA/DZ/TN) | 30–50k | €20–€43 m | Industrial contractors, sewer rehab, ports |
| Libya | 5–10k | €3–€9 m | Oil & gas maintenance, ports |
| West Africa (NG, GH, SN, CI…) | 20–40k | €13–€34 m | Gold/alumina, ports, industrial estates |
All ranges are indicative imports; Maghreb/Egypt lack local CAC plants and import from EU/TR/CN.
7) Buyer personas & channels (by region)
Europe
- Refractory castable producers & precast shops
- Drymix mortar blenders (fast screeds/repairs)
- Municipal & EPC contractors (sewer/marine)
- Steel/cement/glass kilns maintenance firms
- Distributors with hazardous-goods logistics
Middle East & North/West Africa
- Oil & gas / petrochem maintenance contractors
- Ports & desalination EPCs
- Sewer rehab & industrial flooring applicators
- Mining/metallurgy refractories (NG, GH)
- State utilities & municipalities (tenders)
8) Practical purchasing tips
- Specify to EN 14647 grade and target early strengths; fix water demand & set control in the spec.
- For hot climates: manage conversion risk (low w/c, correct curing, optimized aggregates).
- Choose Incoterms to match mode: bulk/break-bulk often CFR/CIF/FOB; palletized intra-EU tends to FCA/DAP.
Disclaimer: Market/tonnage figures are directional estimates derived from public sources and trade intelligence; validate with supplier RFQs for your lanes, grades and terms.#OSINT business case
| Stakeholder | Country (HQ) | Website |
|---|---|---|
| Imerys Aluminates (SECAR®, TERNAL®, Ciment Fondu®) | France | imerys.com/product-ranges/secar |
| Calucem (Molins Group) | Spain (HQ); plants HR/US | calucem.com |
| Górka Cement (GÓRKAL®) | Poland | gorkal.com |
| Çimsa (ISIDAÇ® / REFRO series) | Türkiye | cimsa.com.tr |
| Almatis (High-purity CAC) | Netherlands | almatis.com |
| Denka (Denka Alumina Cement) | Japan | denka.co.jp |
| Elfusa (Curimbaba Group) | Brazil | elfusa.com.br |
| Royal White Cement (CAC 40/50/70/80) | United States | royalwhitecement.com |
| Caltra Nederland B.V. (ACA / CAC / CSA) | Netherlands | caltra.com |
| Rongsheng Refractory (CAC for refractories) | China | rongshengrefractory.com |
| U.S. Electrofused Minerals (industrial minerals incl. CAC) | United States | usminerals.com |
| GCCA – Global Cement & Concrete Association | United Kingdom | gccassociation.org |
| CEN – European Committee for Standardization (EN 14647) | Belgium | cencenelec.eu |
| ASTM International (cements & materials standards) | United States | astm.org |
| RILEM – Intl. Union of Laboratories & Experts in Construction Materials | France | rilem.net |
Calcium Aluminate Cements (CAC) in Ports, Harbors, Shipyards & Energy Platforms
Why CAC matters not only in docks and artillery platforms, but also in shipyards, offshore terminals and cross-border pipeline infrastructures.
Applications in Shipyards & Dry Docks
Shipyard facilities require concretes that can endure continuous immersion, hydrocarbon spills, and abrasion from vessel docking. CAC-based concretes are applied in:
- Dry dock basins and retaining walls, exposed to seawater pressure and rapid empty/fill cycles.
- Slipways and ramps, where abrasion resistance and saltwater durability are critical.
- Repair mortars for quay edges and dock floors that must return to service quickly between ship overhauls.
Energy Platforms & Pipelines
CAC is also valuable in energy logistics, especially where marine exposure and chemical attack coincide:
- Offshore artillery or defense platforms: vibration resistance plus saltwater durability.
- Subsea pipeline anchor blocks and coastal terminals: CAC concrete resists sulfate-rich sediments and seawater infiltration.
- Nigeria–Morocco Gas Pipeline (example): A transcontinental project with long stretches of subsea pipeline and shore approaches. CAC concretes can be used for:
- Anchoring systems and protective mattresses along seabed pipeline segments.
- Coastal compressor station foundations exposed to salt spray and sulfates.
- Emergency fast-setting repairs of underwater supports or landfall structures.
Summary Table
| Scenario | Why CAC is Needed |
|---|---|
| Shipyards & dry docks | High abrasion, immersion cycles, hydrocarbon exposure; fast repairs between vessel dockings. |
| Harbors & artillery platforms | Resistance to chlorides, sulfates and rapid return-to-service after impact or damage. |
| Offshore terminals | Durability in splash/tidal zones; impermeability against aggressive seawater. |
| Nigeria–Morocco Gas Pipeline | Pipeline anchoring blocks, compressor stations, subsea protective mattresses; sulfate and chloride resistance plus rapid-setting repair options. |
Calcium Aluminate Cement (CAC) Suppliers – Spain, France and Italy
🇪🇸 Spain
-
Molins – ELECTROLAND (CAC)
Address: Crta. N-340 km 1242.3, 08620 Sant Vicenç dels Horts (Barcelona), Spain
Tel.: +34 936 806 030 | Email: sat.cmt@molins.es
Product: ELECTROLAND (high strength CAC); corporate sales & technical support.
Source: molins.es / Electroland, Molins Contact. -
Molins – ALUMINITE (Refractory Cement)
Distributed via Molins industrial network.
Source: Molins Industrial – Aluminite. -
Calucem (Molins Group) – European Office
Address: CN-340, km 1242.3, 08620 Sant Vicenç dels Horts (Barcelona), Spain
Tel.: +34 93 680 60 00 | Email: info@calucem.com
Products: ISTRA 40/50 and CAC product line.
Source: Calucem Contact, Calucem Products. -
Imerys (Imerys Aluminates) – CAC Division
Global contact channel for CAC (Fondu Technology).
Source: Imerys – Contact us, Imerys – Calcium Aluminate.
🇫🇷 France
-
Imerys Aluminates (ex-Kerneos) – Ciment Fondu® / Fondu Technology
Headquarters: 8 rue des Graviers, 92521 Neuilly-sur-Seine, France
Tel.: +33 1 46 37 90 00
Products: Ciment Fondu®, SECAR®, TERNAL® ranges.
Source: Imerys – Fondu Technology, Imerys – Contact, Ciment Fondu® Datasheet. -
Saint-Gobain Weber (Distributor of Ciment Fondu)
Technical service (France): Tel. +33 (0)1 45 13 45 20
Source: Weber – Ciment Fondu. -
National Distributors (e.g. Calcia network, retail)
Example: Union-Matériaux (retail distributor of “ciment fondu”).
Source: Union-Matériaux.
🇮🇹 Italy
-
Imerys Aluminates Italia S.r.l.
Address: Viale Milanofiori – Strada 6 – SNC, 20089 Rozzano (MI), Italy
Contact via Imerys “Contact us” form.
Source: Imerys – Contact. -
Harpo S.p.A. (Distributor – ISTRA / CAC)
Address: Via Torino 34, 34123 Trieste, Italy
Tel.: +39 040 3186611 | Email: info@harpogroup.it
Products: ISTRA 40 / ISTRA 50 (Calucem aluminous cements).
Source: Harpo – ISTRA 40/50. -
PREMAR S.r.l. (Distributor of Ciment Fondu®)
Email: info@premarindustrie.it
Product: Ciment Fondu® for special construction uses.
Source: PREMAR – Ciment Fondu. -
Catocci Macchine (Retailer – ELECTROLAND)
Location: Grosseto, Italy
Tel.: +39 0564 451331 | Email: marcocatocci@gmail.com
Product: ELECTROLAND (Molins CAC) in 25 kg bags.
Source: Catocci – Electroland.
This list provides a selection of the main Calcium Aluminate Cement suppliers in Spain, France, and Italy.
Calcium Aluminate Cements (CAC): Producers in Asia, Africa & the Americas
Curated list of notable CAC manufacturers and regional hubs. Always verify grades (CA40/50/60/70/80), whiteness, setting profile, and standards (e.g., EN 14647) directly with each supplier.
Asia
China
-
Zhengzhou Dengfeng Smelting Materials (DFSM) — “Duck” brand
Website | Email: info@dfrlglobal.com | Tel: +86 371 6297 6006
Address: Xuanhua Town, Dengfeng City, Zhengzhou, Henan, China.
Grades: CA50 (multiple variants), CA65/68/70/75/80; CAC for refractories & building chemistry.
Japan
-
Denka Company Limited — DENKA Alumina Cement / ACA (SC-1)
Product page | Special Cement Additives
Notes: Alumina cement line (incl. amorphous calcium aluminate for rapid-hardening mortars).
India
-
CUMI (Carborundum Universal Ltd.) — CUMICEM series
High-purity high alumina cement
Notes: CAC binders for conventional & low-cement castables and gunning/shotcrete.
Pan-Asia (global producer with Asian sites)
-
Almatis GmbH — CA-14 / CA-270 / CA-470 TI (70–80% Al2O3)
CA-14 | Cements & Binders
Notes: High-purity CAC for refractories & building chemistry; manufacturing footprint spans EU/US/Asia.
Türkiye
-
Çimsa — ISIDAÇ 40 / specialty CAC
Product page | About CAC
Notes: CAC production in Mersin; grades for rapid strength, abrasion & sulfate resistance.
Africa
-
Imerys Aluminates (ex-Kerneos) — Regional presence
Calcium aluminate specialty binders | Contact
Notes: Global producer (CIMENT FONDU®, SECAR®, TERNAL®). Supports Africa via labs/distribution (e.g., South Africa). -
South Africa (distribution examples)
ELECTROLAND Aluminate Cement | Aluminate Refractory Cement
Notes: Local availability of CAC products (check origin/producer and grade before specification).
Americas
United States
-
Royal White Cement (RWC) — Calcium Aluminate Cement
Product | Contact (HQ: 14601 Bellaire Blvd, Houston, TX 77083; Tel: +1-866-655-0000; info@royalwhitecement.com)
Notes: CAC for refractories, marine & rapid-repair applications; US terminals/offices in multiple ports. -
Calucem (Cementos Molins) — Global CAC producer expanding in US
Website
Notes: Specialty CAC (e.g., Ternal®); announced US manufacturing investment to expand presence.
Brazil
-
ELFUSA (Curimbaba Group) — EL-60 / EL-61 / EL-70 fused CAC
EL-60/61 | EL-70
Notes: Electrofused CAC for high-purity refractory applications; technical data sheets available.
Also relevant (global brands & references)
- Imerys Aluminates (ex-Kerneos) — CIMENT FONDU®, SECAR®, TERNAL®; global production & regional support. Directory reference.
- Market/industry snapshots — recent summaries naming key CAC players active in Asia/Americas (Almatis, Imerys/Kerneos, Calucem, CUMI, Zhengzhou Dengfeng, Elfusa, RWC). FMI 2025 | Zion 2025.
Notes: This list focuses on manufacturers with verifiable CAC product lines and (where possible) public contacts. Availability varies by grade and region; some African entries reflect regional labs/distribution of global producers rather than in-country CAC kilning. Always request current TDS/SDS and compliance to EN 14647 / ASTM where applicable.
Disclaimer / Aviso legal
Autor: Ryan KHOUJA
Español
El material aquí presentado tiene un carácter educativo e informacional. Cualquier uso distinto al indicado no está permitido.
La reproducción total o parcial sin la autorización previa y expresa del autor está prohibida.
Este trabajo debe entenderse como un ejercicio de catarsis personal más que un texto académico.
English
The material presented here is for educational and informational purposes only. Any use beyond the stated purpose is not permitted.
Full or partial reproduction without the author's prior and explicit authorization is prohibited.
This work should be understood as an exercise in personal catharsis rather than an academic text.
Comments
Post a Comment