Keramicalia

Tel: +27 (0)11 412 3261 or +27 074 587 2728 Fax: +27 (0)11 692 1232
We manufacture specialised refractories and ceramics.

Fire Protection

We have many materials for fire prevention and containment. Many are based on Cellular Insulation technology, and many include almost impervious microstructures to exclude oxygen.

Fire proof paintis a very hard paint, not flexible. It is thermally insulating and very impervious, to keep oxygen from the combustible substrate.

Intumescent Paint looks like a normal high quality white paint but when suddenly heated it expands to become thermally insulating.

Electric Blue is a sticky insulation supplied wet, for application onto plastic coated cables.

Oxycoat is a refractory paint to retard oxidation of steel at high temperatures. Oxidation eventually starts behind it, and has to be sand blasted off and replaced. It can extend the life of a hot steel shell by years if used as a maintenance measure, but is not very effective as fire protection.

Kerafire is a pourable insulation which sets quickly, takes days to dry and gives excellent insulation.

Insulag 2 is a plaster with excellent insulation and it absorbs heat during a fire, retarding the heat transmission still further. Not for use outdoors, useKeratuff 2 outdoors. Fibre Plaster is a high temperature insulation plaster supplied wet, ready to use.

Reforce is a ceramic coating applied by dipping non-woven textile into it and then wrapping around pipes or “wallpapering” sensitive surfaces. It has high rigidity.

Fireproof ceiling boards were developed for sugar mills, and can replace conventional ceiling boards if the anchoring system is also fire resistant.

Insulgun is a high quality insulation which can be gunited and sticks well, even onto raw coal.

Electric Blue

Description;

An extremely sticky insulating ceramic for fire protection of cable trays.

 Colour; Blue

 Composition;

Quartz free and asbestos free. Contains mostly closed cell ceramic bubbles, spun ceramic fibre, zirconia- ceramic drawn fibres, organic binders, plasticisers and moisture retainers, inorganic binders, plasticisers and ablative materials. Contains no toxic or hazardous materials and has no restrictions on disposal.

 Density; 1,14g/m³

Thermal conductivity; After initial flames, drops to O,3W/mK.

 Melting point; 1250°C

 Application;

Clean cables and trays from dust and oil. Rub material onto surface to make it stick. Build up to 20mm thick, 30mm if ambient temperature is high, 50mm where fire hazard is particularly high, eg. solvent store, gas bottles, Oxygen lines. Paint with roof paint if exposed to rain.

 Packaging;

6kg in 10 litre buckets, 12kg in 20 litre buckets.

Fibre Plaster

Description:

Aluminosilicate ceramic fibre in plaster form, supplied wet ready to use. Very easily applied to any surface

Applications:

High temperature insulation

Heat shields

Burner cores

Chimneys

Thermal shock protection

Furnace hoods

Preheater lids

Ladle lids

High gas flow areas of fibre lined furnaces

Repair of cracks and joints

Protection of equipment

Protection of electrical cables

Upgrading of linings for thermal efficiency or faster cycle times.

Repair of broken element holding lips.

Sealing of kiln and furnace doors

Lightweight doors.

 

Properties:

Very low thermal conductivity; 0,2W/mK.

Electrically insulating,

Very low density; 1,3g/cm³ wet, O,7g/cm³fired.

Low shrinkage; normally 12% but all taken up in the thickness of the layer, therefore no cracks.

Extreme thermal shock resistance.

Very low thermal mass.

High reflectivity.

Low permeability compared to fibre blanket or modules.

High reflectivity.

Rapid comissioning.

Excellent adhesion to all surfaces.

Minimal anchoring required.

 

Chemical composition:

aluminosilicate 55%

Fe203 < 0,1%                                     

Alkalis O,27%

Volatiles 45%

Installation:    

Fibre Plaster is supplied wet in well sealed plastic 10kg buckets. The wet density isnormally 1,1g/cm³.

It can easily be thinned down with water or it ordered stiffer for tamping applications

Onto brick; Blow dust off and trowel on.

Insulating firebrick or very porous surfaces; Rub a thin layer on very firmly before builing up the profile.

Cables;                 No preparation required.

Ceramic fibre; Over fresh fibre, softening by water dilution usually helps.

Onto steel;Expanded metal, Mentex 72 or similar. Cut and bend a few strands backwards and tack them onto the steel so that the expanded metal sheet is about 5mm off the steel surface. Squeeze some Fibre Plaster through the mesh and then plaster over it to the desired thickness. Free standing structures; Use expanded metal as a skeleton.

Door seals; Plaster a narrow strip onto one surface, cover with fibre paper and close the door to press the Fibre Plaster into the exact thickness required.

 

Fire proof paint

 This is a genuine fire proof paint, not a fire resistant paint nor an intumescent paint.  It is totally inorganic.   The only chemical released in a fire is water.  The paint forms an air tight skin, preventing oxygen from getting to the substrate.

Fire proof paint is much harder than normal paint; it is difficult to scratch with a knife.

Fire proof paint is not as flexible as normal paint.  It can be coloured with oxide pigments.

Fire proof paint is highly alkaline and similar to soap in its corrosive, skin contact and eye contact hazards.

Fire proof paint will stick to most surfaces, including whitewash, but not to oil contaminated surfaces.

Fire proof paint is slightly soluble in water.  Clean paintbrushes with water.

Be careful of dry paint on the bucket; it is hard and razor sharp.

Development no.   94720

Insulag 2

Insulag is a range of very light insulation materials. They are all asbestos free.

Insulag 2 is a white powder, which is mixed with water and trowelled or plastered.

It can be used up to 600°C continuous temperature, or a fire protection. Its thermal decomposition is highly endothermic, giving it very superior fire resistance.

Density is around 0.6g/cm³, depending on water addition.

Thermal conductivity is very low, about 0.2W/mK.

Setting time is around 20minutes.

Insulag has no shrinkage below 60.0°C

After setting the material is easily cut, machined or sanded.

It will deteriorate if exposed to rain for long periods.

When used as pipe lagging or boiler plaster, no cladding is required.

Mix by hand in small quantities to desired consistency. It will stiffen as the plasticizer dissolves. Add water as you work, but finish working it within 10minites of mixing.

Intumescent Paint

Intumescent paints are paints that foam up into a thermal insulation coating as soon as they come into contact with fire.

We make a white one which looks just like highest quality paint until it is heated.   It costs R887/ litre (2017 price).   Uses 3,3kg per m²

Both are based on the exfoliation of raw vermiculite.

Keratuff 2

DESCRIPTION:        Keratuff 2 is a structural insulating refractory. Insulation materials are normally only usable as a backing or with some kind of structural support.Keratuff 2 has sufficient strength to be a free standing structure. It has low permeability and is easily machined or cut when dried or fired.

APPLICATIONS: Electric kiln walls and element holders, crucible furnace lids, heat shields, masonry protection in charcoal ovens, aluminium launders, burner shields, machined components.



THERMAL CONDUCTIVITY:

200°C 0,2W/ mK
4000C 0, 2W/'mK
6000C 0,231W/!mK
800°C 0,28mK


MAXIMUM SERVICE TEMPERATURE:  1230°C.           Shrinkage at 1200°C is 1,91.

DENSITY:      0,8 g/cm3 dry.

STRENGTH:  6 MPa at 110°C,         6 MPa fired 1200°c.

COMPOSITION:       Contains Litefill and Hollofill synthetic aggregates and zirconia containing ceramic fibres.

PREPARATION:       Add +40-5O1 water to the powder, mix well and apply it.

It can be vibration cast at +40% water           Water content is not critical and need not be measured.

Extensive mixing and trowelling improves the fibre dispersion and improves strergth.        All particles are less than 1mm diameter. Setting time is about one hour.

COLOUR:      Grey.   Yellow when fired 1200°C.

PACKAGING:           10Kg in thick polythene bags.

PILOT PLANT CODE          PGK.

Oxycoat

Description; A refractory coating for oxygen lancing tubes. It sis a thermosetting paint based on aluminium oxide.

Chemical analysis after drying to over 450°C;
Al2 O3     83     .3%
P2 O2    16     .7%

pH: 1 (highly acidic)

Density; 2,0 to 2,1 g/cm³

Application; Pipe must be completely clean of everything except rust or scale. Spray or paint on Oxycoat. Dry at 300°C. Application equipment must be completely free of other paints or solvents.

Handling; Although no problems have been encountered with skin contact, treat as strong acid and wear gloves.

Packaging; 20kg in 10litre plastic buckets.

Price 2017; R108/kg