POLYBOND Polybond Limited, Unit 6 William Street, Northam, Southampton, Hants. S014 5QH Tel: 023 80 223266 Fax: 08700 527587 |
Polybond Fibrecoat is a zircon based refractory composition specially developed for use as a surface coating and binding agent for ceramic fibre and other fibrous refractory insulation materials.
Refractory Ceramic Fibres (RCF) were re-classified as Class 2 Carcinogens in 1997 by the European Commission. Since then, the industry has been desperately seeking safer replacements or ways of reducing the fibre dust generated in existing operations. Polybond has studied this problem in depth and, through its Furnascote Laboratories in Southampton have developed this new product.
By binding the surface fibres and forming a thin skin over the ceramic fibre linings, Fibrecoat strengthens the surface of an otherwise weak material greatly improving its resistance to erosion in areas subject to high gas velocities, flames, splashes from molten metals and many industrial chemical processes. The ceramic fibre is rendered harmless under normal conditions of use and is also able to serve closer to its general classification temperature. Improved insulation is also achieved as the layer of Fibrecoat stops the passage of hot gases into the fibre lining reducing heat loss from energy conducted through the fibre.
A typical application will use a 1 to 3 mm spray applied coating to encapsulate and seal the ceramic fibre with these resulting benefits :
Fibrecoat should only be applied to sound surfaces. Any loose material, powders or contamination should be removed before application. Fibrecoat should not be applied to RCF which has been treated with silica-sol rigidisers, neither will it adhere properly to modules containing processing oils. Any mineral oil should be burnt off prior to application.
The product is designed for spray application using textured paint or cement spraying equipment.
Use a gravity fed hopper gun - available from Polyceramics. Nozzle = 4 to 6 mm, inner air orifice 1 to 2 mm. Air pressure 5.6 to 7.0 kg/cm² (80 to 100 psi).
It may also be brushed onto hard surfaces. A coating of approx. 1.5mm will provide economical protection to most ceramic fibre linings. A gas tight coating is attained at >2.5mm. Several thin coatings each allowed to dry out are the best way or achieving thick coatings (>3mm).
Mix 25kg Fibrecoat powder briskly for two minutes with 4 litres of clean, cold water using a mechanical stirrer. Allow to stand after mixing for about 40 minutes (or longer if schedules allow) then re-mix (mechanically) for a further 3 minutes adding more water at this stage for any final adjustments to viscosity, bearing in mind the final application method.
To reduce mixing time on site, Fibrecoat can be supplied pre wetted with 3 litres of water. Prior to spraying, a further 1 litre of water should be added and stirred mechanically for 2 to 3 minutes, until the mix is smooth and creamy.
Allow the coating to dry out completely before firing.
| Coverage | 1mm of dried Fibrecoat over 1m² weighs 3kg |
| Pack Sizes | Fibrecoat is supplied as a dry powder in 25kg plastic tubs |
| Shelf Life | Indefinite if stored as a powder in airtight containers as supplied. Approx 12 months after mixing with water. Fibrecoat is supplied either as a dry or pre-wetted powder in 25 kg plastic tubs. In the powdered form, it will keep indefinitely, - pre wetted mix should not be allowed to become frozen. However this will not cause permanent harm to the mix. Recovery is achieved by thawing the mix thoroughly to a temperature of at least of 5°C before spraying |
Avoid inhalation of dust. Wear dust mask, gloves and goggles whilst mixing and applying Fibrecoat.
Spray application will generate significant atmospheric dust, sheeting should be used on floors, and to surround the spray area.
For best results, the coating should be air-dried thoroughly then heated for 2 to 3 hours at a temperature of 400°C to 600°C before taking up to operating temperature - see technical information sheet TI 002/03 for further details.
| Product Reference No: FIBR | Amendment Date: August 2003 |
For use on both new and existing fibre linings...
Prolonging the life of Furnaces ...
Polybond LtdUnit 6, William Street, Northam, Southampton, Hampshire, SO14 5QH
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