Keramicalia

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

Precast

Keramicalia makes fine pourable ceramics called refracramics, which are used to make a wide range of products that could only be made previously by pressing. We have over 600 moulds along with Gee Kay Industrials and Scottley Ceramics, which also precast with refractoramics.

Crucibles

We make a range of crucibles from tiny to around 50kg at present, however few are stocked. Chemical qualities are Zircon for flux resistance, silicon carbide for good heat transfer and alumina for high temperature.

MOULD VOLUME CAPACITY I.D. O.D. H T MASS SHAPE PRICE
no. litres kg brass mm mm mm mm kg   incl VAT
313 0.006 0.042 32 39 11 3 15 solid R 67
418 0.014 0.1 40 58 13 4 64 flat R 67
285 0.028 0.2 34 45 60 4 83 straight R 93
326 0.036 0.25 40 51 50 7 130 straight R 50
285 0.04 0.3 38 45 60 3.5 0.05 C L R 67
333 0.062 0.4 71 77 27 5 80   R 67
181 0.042 0.3 63 76 40 -7 290   R 67
284 0,028 0,2 40 48 58 4 80 conical R 67
372 0.074 0.5 57 75 35 2.5 102 round R 87
254 0.082 0.6 52 57 48 205 54 typical R 85
379 0.082 0.6 60 80 43 7 435 solid R 152
371 0.09 0.6 75 85 40 7 350 solid R 103
675 0.1 0.7 62 67 47 3 350 round R 83
373 0.102 0.7 53 78 40 5 175 round R 103
541 012 0.8 52 72 78 10 310 spout R 125
203 0.125 0.8 54 71 80 7 400 straight R 146
283 0,16 1 55 70 90 7 320 round R 126
478 0.2 1.4 70 92 98 12 510 conical R 170
479 0.255 1.8 68 88 116 10 600 conical R 187
520 0.3 2 62 73 127 6 320 dr.glass R 139
646 0.325 2 64 185 130 4 370 spout R 166
645 0.34 2.3 63 72 135 4 290 dr.glass R 166
481 0.345 2.4 72 82 122 5 370 straight R 140
176 0.4 2.8 80 166 150 13 1060 C R 279
175 0,42 3 92 110 110 9   C R 216
477 0.56 4 87 100 145 15 1500 conical R 373
480 0.69 4.8 91 107 133 7 680   R 209
566 0.5 3.5 77 118 150 20 2300 straight R 277
540 0.5 3.5 116 150 80 16 1340 flat R 319
31 0,5 3,5 98 116 140 9 1,15 R R 300
286 0,7 5 93 117 155 12 1300 Conical R 416
496 0.8 6 94 122 155 15 1800 round hole R 443
495 0.9 6 95 123 157 13 1770 round R 420
482 1.05 7 90 125 155 12 1915 typical R 448
432 1.1 7.5 95 112 200 8 930   R 253
494 1.62 10 95 123 157 13 2770 round R 618
229 1.7 12 128 164 180 18 3000 R S R 681
436 0.09 0.6 75 85 40 -7 350 solid R 624
426 2.3 16 114 142 192 10 2435 straight R 552
500 4.5 32 170 190 260 10 3000 R S R 947
539 1.47 10.2 120 150 105 14 2530 typical R527
923                 R166
926                 R55
988                 R83
999                 R635
958                 R111

image071

Sintering trays

Can be made to your size quite easily.

 

MOULD

VOLUME

EXTERNAL

INTERNAL

MASS

PRICE

NOTES

No.

Litres

Length

Width

Height

Length

Width

Height

Kg

exVAT

 

443

10

340

290

125

320

275

115

5.6

R 998

square

899 4,87 300 300 73 285 285 60 3,8 R 569 rounded

935

6,3

405

325

88

370

328

71

6,3

R1082

rounded

768 3,3 210 210 100 195 195 87 2,7 R 404 rounded

303

3,26

323

323

53

297

297

377

5,0

R 499

castellated

223

2,0

298

200

65

270

175

50

2,3

R 508

rounded

198

2,0

298

200

65

270

175

50

2,5

R 573

with feet

224

2.0

298

200

65

270

175

50

4,8

R 640

solid

769 2,0 235 175 70 220 162 58 1,6 R 239 rounded

226

1,8

210

160

77

194

140

70

2,1

R 399

straight

770 0,87 275 135 41 260 120 28 1,5 R 225 rounded

225

0,55

234

135

40

207

108

30

1,2

R 275

tapered

514 0,33 170 130 40 145 105 28 0,9 R 134 tapered

180

0,14

306

158

26

290

144

7

2,0

R 300

flat

 

 

 

 

 

 

 

 

 

 

 

 

 

Automatic ladles

Most of these are cloned from steel ones and are therefore poorly designed

image064 image065

Pipes

We stock various thermocouple tubes etc. in fully dense mullite and alumina in small diameters, up to 30mm, and can supply larger diameters in refractoramics, up to 1 metre diameter. The refractoramics are somewhat porous and permeable, but have good thermal shock resistance. Dense sintered ceramic has very poor thermal shock resistance.

image076

image069

funnels

Most of our funnels are for feeding high-pressure die casting machines. The foot is custom made to fit your shot hole.

Launders

Launders are most commonly made of keratuff, fibre reinforced materials.

image066

Thermal Cups

Protect flexible cables, hydraulic hoses and water cooling pipes around furnaces. They withstand intense radiant heat and molten metal splashing. The ceramic sleeves are threaded over the pipes or cables, and allow them to bend while still covering them. Steel springs cast into the ceramic thermal cups give them good resistance to abrasion and impact.

image001

I.D. 22 40
O.D. 60 83
Length 48 60
Cups/ metre 21 17
Mass/ cup 185g 315g
Mass/ metre 3.9kg 5.4kg
Rad. of bend 350mm 600mm
Price/ cup R 15 R 23
Price/ metre R 1007 R 1612


Moulds can be made for any I.D.
For I.D. 20 to 35mm, O.D. = 60mm
For I.D. 35 to 50mm, O.D. = 83mm

Curtain Bricks

This is a suspended wall design which needs lateral support, but can save a great deal of space in boilers and rotary hearth furnaces.

image080 image081

Permeable Parts

We have a range of different permeabilities in course or fine pore sizes, which can be used for; Fluidised beds, Porous plugs, Fluxing tubes, Liquid filtration, possibly hot gas filtration

image085

Element Supports Ribbon Elements Roof Hangers & Sidewall

We have made various specials, such as high purity alumina and ultra lightweight…

We encourage furnace builders to make their own designs, which we can manufacture exclusively for them, competitively priced.

image086

image012

Comb Tiles

These are floor tiles for keeping ribbon elements raises off the floor, so that scale and rubbish can fall past them and accumulate harmlessly below the elements.

image013

Wound Elements

We can supply tubes and large and small support blocks

image091

Stove Type Elements

These are normally supported by metal parts, but we have some fancy roof bricks and some candle discs.

image093

Globars

Globars are silicon carbide heating elements. We can supply various lead outs, sleeves and silicon carbide sheaths to protect them from furnace and fluxes

Muffles

We make two standards with element grooves. Special sizes without grooves can be made to order, with one end closed if desired.

image110

Elements Cages

These are Jay Lloyd’s invention. Best thind scince sliced mouldable. Mostly custom made to fit some crucible of machine. Silicon carbide, with hugely efficient line of sight radiant transfer

image120 image033 image122

Radiators

Favored by powder coaters and ostrich breeders!

image124

Furnace Shells

Those arose from cage technology. They crack quite appreciably in the vertical plane. Don’t patch these cracks, they are healthy.

Flat Bricks and Tiles Open Groove

These bricks are individually anchored through the shell. They can move sideways, upp and down, even twist, without exerting undue pressure on their neighbours. Consequently, they almost never break. When chemically attacked or contaminated or otherwise melted down, single bricks can be replaced without damaging the wall structure. We make 3 groove 230 x 230 x 100mm, 4 groove 230 x 230 x 76mm and 3 groove 450 x 300 x 100mm bricks. Quality usually keramite 4, with low thermal mass.

image130

Embedded

These originated in Europe, but we believe our quality embedding is better, and our backing more insulating. The “boards” are popular in crucible furnaces, because an element can be replaced almost “on the run” without cooling down the furnace.

image131

Semi Enclosed

We supply cones of the unaffordable Wild Barfield spares, and a huge size range of Arthur Kuhler’s technology from dental kilns to metre scale.

Pizza Ovens

Keramicalia Pizza Ovens (available in kit format) Commercial and Home Versions

Contents: Principles of Keramicalia pizza ovens, Pricing details, Construction Instructions, Cross section of oven, Material specifications, Contact Details

Principles
Home use

22092011621We supply kits to make you own pizza oven, these are completely portable and water resistant. Our pizza and/or chicken ovens are wood burning ensuring the genuine flavor we have come to know and love. A home oven takes twenty minutes to heat up after which it should take two to four minutes to cook up to three pizzas at a time!

The dome is made from a lightweight refractory material that radiates heat effectively. While the outside remains cool enough to touch. The floor is made of  a dense , hard smooth refectory with high heat retention.


The basics


Pizza ovens cook by radiant heat from above, and conducted heat from the floor. The air sucked over the pizzas through the mouth towards the fire is cold, dry air. Electric ovens cook in hot, damp air. The flame must be drawn over the roof, so the smoke offtake must be near the door. The fire must be at the back of the oven. The roof must be an insulating material, so that it heats up rapidly and radiates the heat into the floor. The floor must be a dense, heat retaining material, because once the pizza is on it, it receives no additional heat. We supply Keratuff 2 for the roof. It is light, with a density of 0,8kg/litre. A home pizza oven typically uses 45kg. It is fibre reinforced, but will still crack. It has to be coated with roof paint and scrim, an open weave textile, to keep it together.

We supply pizza oven floor mix for the surface of the floor. Use between 15kg and 25kg, just over the area inside the dome and mouth. It is hard, and if you cast it upside down onto "Formica" gives a very smooth surface. Behind it, cast Keralite 2 to keep the heat inside the floor. Turn the floor casting upside down, with the hard face upwards and place it in position at a height of about 1,1 meters. Glue the dome onto it with Kerasil Mortar.

The floor will crack if not supported properly. Leave an air gap under it and support it around the edges. This leaves the hard floor under compression and it will not crack.

To run it in, place a layer of 3mm of sand onto the floor, and then start the fire. Without this protection, the dense layer builds up steam and explodes.

Pricing Details – Commercial Ovens

These are supplied in kit form, with a hemispherical dome 1,2m inside diameter or 1,4m inside diameter. We do not install them, but can refer you to experienced contractors. We sell them for cash in banknotes only.

1,2m is R 26 809.00 -  1,4m is R 36 156.00

The kit is for the working parts only and does not include the exterior,

Finish. The oven is a. fuel efficient, rapid heating, wood fired oven.

The interior surfaces will develop cracks, but will not fall in.

  1,2m Ø 1,4mØ
Dome with preformed mouth R 3 825.00 R 5 156.00
Smoke off take R 1 497.00 R 1 996.00
Floor tiles;   500mm x 500mm x25mm 9 tiles R 3 231.00 R 3 231.00
Firebricks arch; R 4 158.00 R 5 821.00
Fire bricks for skirt; 12 for 1,2m 30 for 1,4m dome R 1 082.00 R 2 703.00
72 litres Blended insulation  =  80kg for 1,2m , 120 for 1,4m R 2 474.00 R 3 659.00
Chimney pipe R 437.00 R 437.00
200 litres Keratuff 2 for outer insulation = 160kg (220) R 7 762.00 R 10 672.00
20kg Kerasil mortar R 666.00 R 666.00
Damper Block R 1 192.00 R 1 330.00
Paddle, tongs, recipe book R 485.00 R 485.00
  R 26 809.00 R 36 156.00
Discounted Price R 24 128.00 R 32 540.00

You must cost into your budget; Bricks, cement, sand, concrete, shuttering or corrugated iron for slabs or lintels, subcontractors price for demolition, building, removing rubble.


Instructions for assembly are issued with the kit. Allow one day to prepare the platform.

Allow an extra day for concrete to harden if lintels are not used. Allow one day for assembling the kit. Allow one day for completing the outside and connections.

The floor tiles are usually prefired, so you can start cooking immediately.

CONSTRUCTION.

Please read all the instructions before starting.

1. ASSEMBLY

Choose location;
You will need an area of 1,5 metres square.
Consider the following points in choosing the position;
It is strongly advisable to display the oven mouth, where it adds to the atmosphere, and where it can attract the attention of passers-by.
Where kitchen space is limited, the body of the oven can be built outside, with only the mouth open to the kitchen.
It helps if the chimney can be simple and straight up.
Remember that the cook will be using a long paddle, and will need free space behind him.

2. Build a platform 1,5 x 1,5 metres wide, at a height of 1,1 to 1,15 metres high. The space below the platform can be used as a wood store. A brick arch over the wood store to match the oven mouth looks attractive.

3. Lay the first course of bricks

4. Mix the Kerapour with water and pour it onto the platform.
It horizontal surface. It must be 50mm thick to bring the floor tiles level with the mouth.

5. When the Kerapour has stopped flowing, place the floor tiles onto it. The tiles may need to be trimmed on a brick cutter or angle grinder.

6. Place the firebrick arch (mouth) in position. Place the dome behind the arch with the bottom of the opening touching the arch. Mark the outline of the dome on the floor tiles. Remove the dome.

7. Now draw a circle inside the marked outline of the dome, 50mm smaller.  This marks the position of the inside edge of the firebrick skirt.

8. Lay one course of firebrick using Kerasil mortar, along the line marked. (For the 1,4m dome, lay two courses of firebrick.) The  firebrick skirt, is to protect the dome from logs thrown into the oven. If small pieces of wood are placed in the oven with the tongs provided, then a skirt is not required.
Note: When ordering the kit specify whether or not you are going to build a skirt. (The smoke offtake piece differs.)

9. Place the dome on top of the firebrick skirt.We suggest you do not glue it on with Kerasil mortar.

10. Cement the arch into position with Kerasil mortar.

11. Cement the smoke offtake between the arch and the dome with Kerasil mortar.

12. Cement the damper block onto the top of the smoke offtake. 15. Cement the chimney pipe onto the smoke offtake.

13. Mix Keratuff 2 with water, 5 litres per 10kg bag. Plaster over the dome. 20 bags are provided.

14. The pizza oven is now completed. It may be covered with. plaster painted with roof paint, tiled, bricked over, thickened with layers of mineral wool and finishing plaster, left as is, or whatever suits your decor. The easiest finish is simply to build a brick box around it. Make provision to operate the damper if you build a brick box around the, oven.

15. Star- with the damper fully open the plate pushed right in if the draught is too strong and the heat and wood consumption too high, pull the damper forward to choke the flow

LEADING THE CHIMNEY OUTSIDE:

This must be done with careful forethought.It is the commonest source of operating problems. If the chimney can go straight up through the roof, there is no problem, just see that it is not touching or very close to wooden beams, and support the ducting from above, do not place too much weight on the dome. The function of the chimney pipe is  merely to facilitate connection of the oven to the ducting

If the ducting has to travel horizontally try to keep it sloping upwards, otherwise it is difficult to establish draught on light-up. When combining the ducting with other offtakes note that fat/oil and smoke can combine to make tar-like deposits which can choke the ducting. The undiluted heat from the chimney can damage extractor fans. Excessive draught can cause intense heating in the oven and poor fuel economy

If any operating problems arise look first at your extraction system.

Tell the customer that the dome WILL crack, but it is not a problem, as the dome is covered over with Keratuff 2.

Cross section of 1.6m Pizza oven, click on image to see a bigger view

image137

Material Specification

Pizza Oven Floor Mix

This is a high density thermal shock resistant mix designed to store heat
It can withstand repeated heating to 10000C and quenching in water.
The high density results in high thermal mass, and the material has found a number of applications for heat storage and others for heat dissipation.

Density;
Maximum service temperature; 11000 C.
Cold crushing strength;
Maximum particle size;           6mm.
Water addition;           +9%
Packaging; 15kg plastic bags.

Contact Us to place your order or if you need some more info

Enclosed

Enclosed means surrounded by refractory, but loose in a hole. Sort of a compromise between a muffle and an exposed element.

image136

home pizza ovens

You can now buy your own pizza oven which is small enough for home use.

It is portable and weather resistant and, can be placed outside in your braai area. It is a genuine pizza oven, with a wood fire inside, giving genuine pizza flavor.

A pizza bake is much more entertaining than a braai.   Everyone makes their own pizza of their design and no two pizzas are identical!

Don’t worry about the dough, you can buy ordinary bread dough from the bakery or pre-made pizza bases . All the recipes are in the handbook.

The oven takes 20minutes to heat up, and cooks 2 pizzas at a time, faster than you can prepare them. Takes 4 minutes to cook.

The dome is a lightweight refractory material which radiates heat well. The outside remains cool enough to touch. The floor is made of a dense, hard smooth refractory with high heat retention.

Installation: Put it down anywhere outside at a floor height close to 1,1 metres and start cooking .Place spaces (bits of tile will do) under each corner so that the base is raised off the floor. Make a fire in the back of the oven and run it for 20minutes before you start cooking. Keep a flame going all the time you are cooking

Price: R 9 975.00 includes paddle, tongs cutter and recipe book.

Dimensions:     

Base:    820mm wide by 920mm long

Inside area:   840mm deep by 695mm wide

Height:     700mm