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A chemical degradation reaction affecting unfired, lightweight refractory concretes bonded with calcium aluminate cement. The reaction occurs at ambient temperature when carbon dioxide (CO2) from the atmosphere reacts with the cement’s hydration products in the presence of moisture.
This process, also known as carbonation, alters the binder phase, leading to a significant loss of mechanical strength and structural integrity. Alkali hydrolysis is a risk during extended storage periods, even after initial dryout, but is prevented by proper storage, protective coatings, or by completing the final dryout (firing) schedule, which transforms the binder into a stable ceramic bond.
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