Keramicalia

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

Miscellaneous

Some of these products are imported, others sourced locally, and stocked at Keramicalia.

Papers;
Ceramic fibre paper is stocked in 1mm and 3mm thick.
Graphite paper is stocked in 1mm and 2mm thick.
Mica paper is sometimes stocked.
Ceramic pipes/ tubes;
We keep a lot of ceramic tubes, thermocouple sleeves, beads etc. mostly 5mm to 25mm O.D. and 100mm to 800mm long.

Porcelain;
We do some porcelain and cordierite specialties

Loose fibres;
We stock coarse polypropylene fibres, fine cellulose fibres, “Granulated ceramic fibres,” water soluble glass fibres and RFT fibres( (rapid fire technology)

Markers;
We manufacture cobalt oxalate crayons which make an almost unreadable pink marking, which turns black at 300°C and then bright blue at 1000°C. The marking therefore tells you whether the sample is air dry, cured or fired. We also manufacture wax crayons with iron oxide or manganese oxide pigments. A few temperature indicating crayons are normally available. These are brilliant for measuring surface temperatures.
We supply stamping inks in chrome oxide green and cobalt black.

Metals;

We normally have small stocks of expanded metal and hexmetal, and some stainless steel melt extract fibres. We supply some custom made chills and ingot moulds.
Keracomp is a steel fibre- ceramic composite which works in those extremely arduous applications where both refractory and metals fail.

We are offering Ferrosilicon balls in various sizes, but have not yet found a market.

We manufacture Orton pyrometric cone sets.
High temperature grease is another obscure product which we make.

Electrical;
In line with our “one stop furnace shop” policy we now stock programmable controllers, set point controllers, thermocouples, elements and line taps.
We manufacture most of the components for kilns, and can supply off the shelf all you need except the steelwork for your furnace.
We manufacture electric incinerators for hospital wastes.
Sometimes we have safety equipment.
We have 23 years worth of contacts from America to Zimbabwe where we source specialities.

 

keracomp

Description:   The name is a contraction of "Keramicalia composite material of ceramic and stainless steel fibres." Ceramics are all brittle but many have high melting points, whereas metals are non-brittle but oxidise or melt at high temperatures. Some difficult metallurgical applications are not satisfied by either ceramic or metals, but require properties of both. Keracomp is designed to meet this need.

The fibres are compacted into a mould in the highest concentration possible, and a thin ceramic slurry is infiltrated into the matrix between the fibres. On heating, the structure develops millions of micro-cracks due to the differential expansion of steel and ceramic, but the microstructure is interlocking, making it extremely difficult to break mechanically.

Think of it as a three dimensional jigsaw puzzle: It is not a solid material but millions of tiny interlocking pieces. It can be stretched or deformed without breaking and no stress points can be formed for tearing of cracking because the structure is already in millions of tiny pieces.

Maximum service temperature:  Keracomp can be used at high temperatures as long as there is a thermal gradient. The whole structure should not be surrounded by heat without any source of cooling.

The chemical analysis may be varied to suit the application, but is typically about 85% alumina ceramic and high nickel content stainless steel.

Physical properties cannot be tested by conventional ceramic and refractory procedures, nor by normal metallurgical tests. The reason for this is that the material is not a solid, but is already broken into tiny pieces. In the cold crushing strength test the cube does not break. Densities are around 3 tons per cubic metre.

Applications:  Nearly all applications in which refractories and steels are both known to give poor performance. Keracomp can be attached to steel.

 Installation: Pack fibres as densely as easily practical into the mould.   Add +22% water to the Keracomp Slurry powder and mix well until it becomes a smooth creamy pourable fluid.   Pour it over the fibres and allow it to penetrate completely.

Pilot Plant code;  

Dev. no. 206 and 1011

Miscellaneous

Some of these products are imported, others sourced locally, and stocked at Keramicalia.

Papers;
Ceramic fibre paper is stocked in 1mm and 3mm thick.
Graphite paper is stocked in 1mm and 2mm thick.
Mica paper is sometimes stocked.
Ceramic pipes/ tubes;
We keep a lot of ceramic tubes, thermocouple sleeves, beads etc. mostly 5mm to 25mm O.D. and 100mm to 800mm long.

Porcelain;
We do some porcelain and cordierite specialties

Loose fibres;
We stock coarse polypropylene fibres, fine cellulose fibres, “Granulated ceramic fibres,” water soluble glass fibres and RFT fibres( (rapid fire technology)

Markers;
We manufacture cobalt oxalate crayons which make an almost unreadable pink marking, which turns black at 300°C and then bright blue at 1000°C.   The marking therefore tells you whether the sample is air dry, cured or fired.   We also manufacture wax crayons with iron oxide or manganese oxide pigments.   A few temperature indicating crayons are normally available.   These are brilliant for measuring surface temperatures.
We supply stamping inks in chrome oxide green and cobalt black.

Metals;

We normally have small stocks of expanded metal and hexmetal, and some stainless steel melt extract fibres.     We supply some custom made chills and ingot moulds.
Keracomp is a steel fibre- ceramic composite which works in those extremely arduous applications where both refractory and metals fail.

We are offering Ferrosilicon balls in various sizes, but have not yet found a market.

We manufacture Orton pyrometric cone sets.
High temperature grease is another obscure product which we make.

Electrical;
In line with our “one stop furnace shop” policy we now stock programmable controllers, set point controllers, thermocouples, elements and line taps.
We manufacture most of the components for kilns, and can supply off the shelf all you need except the steelwork for your furnace.
We manufacture electric incinerators for hospital wastes.
Sometimes we have safety equipment.
We have 23 years worth of contacts from America to Zimbabwe where we source specialities.

SAFE REINFORCING

There are ways to combat every type of attack that can be applied to a safe.

  1. Moving it is the most simple mode of attack. To prevent this, the safe must be as heavy as practical, be attached as well as possible to the structure in which is housed, and have no access points for lifting devices.
  2. Blasting: The principles of steel reinforcing are applied, where “re-bar” has good tensile strength and concrete has good compressive strength. There must not be access holes for dynamite, and drilling of holes must be as difficult as possible.
  3. Drilling: The material must be a composite of mineral and steel. The mineral component defeats  a steel drill and the steel defeats a carbide drill. The addition of porcelain balls is highly beneficial to defeat both steel and carbide drill tips.  Balls are seldom contacted head on so the drill is also deflected. Corundum, with a hardness of 9 on the Moh Scale is a popular aggregate. The addition of a bit silicon carbide, 9, 5 on the Moh Scale really messes up drills. Fine zirconia toughened alumina balls are very resistant to drilling and grinding.
  4. Grinding: The same principles apply as for drilling. The addition of sulphur helps. It melts and lubricates the blade.   It also gives off nasty fumes. Aluminium chips clog up a blade.
  5. Thermal lancing: Portland cement is replaced by calcium aluminate cement which has a very high melting point. Use corundum aggregate with a melting point of 2013°c. A high thermal mass aggregate helps a lot, as it absorbs the heat.  Pizza Oven Floor mix is designed for high thermal mass, and is also very heavy. If plastic packets of thermit powder are added to the mix they will endanger the life of the burglar, but also create a serious fire hazard.
  6. Impact: Keracomp is a composite of ceramic and steel fibres which is almost indestructable by impact.

General

Alternating layers of different materials make attack very difficult.

Addition of toxic and noxious substances is advantageous.  This can be considered “counter attack” and some are probably illegal.

Cermets are incredibly tough. I can supply alumina silicon cermets, but I can’t break it into particles.

Tacking expanded metal onto the metal shell keeps it stuck to be concrete, so it cannot be removed as a panel.

Prices: 2017

Porcelain balls;   R42/kg

Corundum;   Various, from R7 to R32/kg

Corundum balls;   R69/kg

Silicon carbide (carborundum);   R83/kg

Zirconia toughened alumina balls;   R166/kg

Pizza Oven Floor Mix.   R14/kg.

Thermit powder;   R74/kg

We make ready to add water powders for specific needs.