Keramicalia

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

Versimould

Versimould is a range of quick-setting mineral materials with a variety of applications. They are inorganic, but unlike other inorganic materials they are not brittle. They have properties somewhere between those of concrete and epoxy resins.

TYPICAL PHYSICAL PROPERTIES

 

  Concrete Versimould Epoxy resin
Compressive strength Good Reasonable Reasonable
Tensile strength Poor Reasonable Good
Resistance to impact Poor Good Good
Resistance to abrasion Good Excellent Poor
Resistance to chemicals Poor Good Good
Resistance to heat Fair Excellent Poor
Resistance to water Good Good Good
Resistance to u-violet Excellent Excellent Poor
Resistance to Shrinkage Negligible None Small
Resistance to Machinability Very poor Reasonable Good
Ease of handling Corrosive Reasonable Messy
Setting time Very slow Very fast Fast
Porosity High Low Negligible
Permeability High Low Negligible
Cost Cheap Medium Expensive

 

 

CHEMISTRY: Versimould bond is based on the reaction of soluble acid Aluminium Orthophosphate and alkaline powders. The reaction is strongly exothermic and self-accelerating.

CONSISTENCY: The consistency can be varied between pourable self-levelling mixes, through vibration castables to a dry tamping consistency. The consistency of any Versimould product can be varied by adjusting the powder to liquid ratio.

STRENGTH: Dry mixes are stronger than fluid mixes.

SETTING TIME: Dry mixes set faster than wet mixes. Accelerator may be bought separately and added to speed up setting. Compressive strengths of 20MPa can be achieved in 20 minutes. The ambient temperature affects setting speed. To slow down the speed to get maximum compaction or flow, the materials can be refrigerated before mixing. Large castings reach higher temperatures as the heat builds up more. Thermal expansion of trapped bubbles may cause castings to expand.

DENSITY: Can be varied between 1 and 5 grams per cm³.

COLOUR: Most colours can be achieved but not clear.

MIXING: Hand mixing is usually prefered as time is limited. Containers must be washed with water as soon as possible after use.

HANDLING: No precautions need be taken. Do not spill the liquid on clothing, as it is acidic.

MOULD RELEASE: Oils, grease, petroleum jelly and waxes all work well.

STRIPPING: Castings can be stripped as soon as the surface can no longer be dented by pressure from your finger nail.

CURING: No temperature or humidity control is required.

PACKAGING: Liquid and powder are packed separately, supplied in the correct quantities with mixing ratios marked, and charged per kilogram of combined materials.

DESIGN: Most Versimould mixes are custom designed for the customer's specific application.

CONFIDENTIALITY: Product designs requested will not be offered to compettitors.

Versimould Panel

Versimould is a range of quick-setting mineral materials with a variety of applications.  The inorganic, but unlike other inorganic materials they are not brittle.   They have properties somewhere between those of concrete and epoxy resins.   See general data sheet on Versimould.

Chemistry

Versimould bond is based on the reaction of soluble acid aluminium Orthophosphate and alkaline powders.   The reaction is strongly exothermic and self-accelerating.

Consistency

The consistency is like putty with 22% Versimould binder.   The consistency of any Versimould product can be varied by adjusting the powder to liquid ration.

Strength

Dry mixes are stronger the fluid mixes.  22% Binder will give 10Mpa.   Fresh samples will deform on the CCS test without fracturing.   When it hit hard with a hammer it will dent and not fracture.

Setting time:

Dry mixes set faster than wet mixes.  Accelerator may be bought separately and added to speed up setting.  Compressive strengths of 20Mpa can be achieved in 20minutes.  The ambient temperature affects setting speed.  To slow down the speed to get maximum compaction or flow, the materials can be refrigerated before mixing.   Large casting reach higher temperatures as the heat builds up more. At 22% Binder it, will set in one hour. Thermal expansion of trapped bubbles may cause castings to expand.

Density

Wet;      1,95g/cm³ = 1,95kg/litre = 1,95tons/m³

Dry;        1,65/cm³ = 1,65kg/litre = 1,65tons/m³

MAXIMUM PARTICLE SIZE: 3mm

PERMANENT LINEAR CHANGE:  Expands 0,2% in a polystyrene mould on setting.

400°C – 0,5% 1200°C -1,3%

COLOUR: light grey when mixed yellow after firing.

MIXING

Hand mixing is usually preferred as time is limited. Containers must be washed with water as soon as possible after use.   If using a mixer, wash it down at least once an hour, otherwise the deposits stick very tightly.

HANDLING

No precautions need be taken.  Do not spill the liquid on clothing as it is acidic. If you are not using gloves, wash your hands at least  every 20 minutes.

 

Mould release:

Oils, grease petroleum jelly and waxes all work well.

STRIPPING:

Castings can be stripped as soon as the surface can no longer be dented by pressure from your finger nail.

CURING:

No temperature or humidity control is required.

PACKAGING

Liquid and powder are packed separately, supplied in the ratio 78% powder (25kg) to 22% Versimould binder (4,5kg). For hand packing installation use one bottle to one bag.

Development no. 6933

Versimould Plug

Description:A quick-setting putty for plugging holes, cracks and apertures in furnaces.

Installation:  mix a very small quantity of the powder and liquid in the ratio 100 weight parts powder to 46 weight parts liquid.  Decide if you want it stiffer or softer and add powder or liquid accordingly.  In most applications less than 1kg is mixed at a time.  If you need more than 2kg at a time, use Versimould Panel.

Maximum particle size: 1mm

Maximum service temperature: 1400°C

Chemical composition:

                                                Al2O3                     45, 6%

SiO2                        42, 4%

MgO                      4, 6%

P2O5                       7, 4%

 

Mineral composition:

Chamotte, Kaolin, Synthetic corundum, periclase, and phosphates.

Versimould Plug expands on setting, making a very tight seal.  In general, it should not be used to plug cracks on the hot face of furnace brickwork.  It is excellent for patching, as it sticks well, even to hot dry surfaces.

A peculiarity of this material is that it will last in a furnace for many years, but will disintegrate if the furnace is cooled to ambient temperature for a few weeks.

Development no: 6921

Claimer: The above information had better be correct, since Dave Onderstall stakes his reputation on it.