Polybond Limited specialist coatings, custom made colour powder coatings and wet paints
General 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.   Polybond   Fibrecoat    will   enhance the   performance   of   Refractory   Ceramic   Fibre   (RCF)   in   all   applications,   whilst   at   the   same   time   solving   many   of   the problems associated with the reclassification of RCF as a Class 2 Carcinogen. 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. In   binding   the   surface   fibres   and   forming   a   thin   skin   over   the   ceramic   fibre   linings,   Polybond   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   Polybond   Fibrecoat    stops   the   passage   of   hot gases into the fibre lining reducing heat loss from energy conducted through the fibre. Polybond   Fibrecoat    is   supplied   as   a   dry   powder   which   is   mixed   with   cold   water   to   form   a   slurry.   A   typical application will form a 1 to 3mm spray applied coating to encapsulate and seal the ceramic fibre.
Polybond Ltd, Unit 6, William Street, Northam, Southamton, Hampshire, SO14 5QH, United Kingdom Tel: 02380 988350    Fax: 02380 988355    sales@polybond.co.uk
A   typical   application   will   use   a   1   to   3   mm   spray   applied   coating   to   encapsulate   and   seal   the   ceramic   fibre   with   the following resulting benefits: • Increased erosion resistance to flames and high velocity gases from approximately 12m/s up to 70m/s. • Reduced surface dusting and fibre breakdown. • Fibre is protected against chemical attack from combustion gases and harsh process environments. • Enables the fibre to work closer to its specified maximum working temperature. • Reduced penetration of hot gases into the fibre. • Reduced heat loss from energy radiated into the fibre. • Improved insulating quality of the fibre. • Increased lifespan of ceramic fibre linings. Polybond Fibrecoat  is suitable for use on both new and old fibre linings. Application Notes Polybond   Fibrecoat    should   only   be   applied   to   clean,   sound   surfaces.   Any   very   loose   material,   powders   or contamination   should   be   removed   before   application.   Polybond   Fibrecoat    should   not   be   applied   to   RCF   which have   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. Polybond   Fibrecoat    is   designed   for   spray   application   using   textured   paint   or   cement   spraying   equipment.   Use   a gravity   fed   hopper   gun.   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). Polybond   Fibrecoat    may   also   be   brushed   onto   hard   surfaces.   A   coating   of   approximately   1.5   mm   will   provide economical   protection   to   most   ceramic   fibre   linings. A   gas   tight   coating   is   attained   at   3.0   mm.   Several   thin   coatings each allowed to dry out are the best way or achieving coatings >3 mm eg. for use on kiln car decking. Mixing Mix   25   kg   of   Polybond   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. Pre-Wetting To   reduce   mixing   time   on   site,   Polybond   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. For   the   strongest   coating   on   uncompressed   blanket,   spray   the   fibre   surface   with   cold   water   to   a   depth   of   5   to   10mm and then compact the wetted surface before applying Polybond Fibrecoat. Drying & Firing For   best   results,   the   coating   should   be   air-dried   thoroughly   then   heated   for   2   to   3   hours   at   a   temperature   of   400   to 600°C before taking up to operating temperature. Coverage 1.5mm of dried Polybond Fibrecoat over 1m² weighs 4.5kg. Properties
TM
Appearance Storage Life Density Thermal Expansion Bulk Factor K Value Resistance to powdering Odourless, Tasteless and Non Toxic powder. Indefinite. in original 25kg plastic tubs. 12 months after mixing with water. 3.30 g/cm³ Approx. 1% from 0°C to 1,500°C. Shrinkage < 0.3%. 2.10 3.05 at 500°C. Excellent. Chemical Analysis (Mainly as Oxides) - % Zirconium Silicon Sodium Aluminium Calcium Health & Safety 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. 62.50 28.48 4.03 1.65 1.40 Boron Magnesium Titanium Flourine (as flouride) 1.10 0.34 0.25 0.25
The claims in this leaflet were believed to be correct at the time of going to press and made in good faith based on exhaustive tests carried out over a long period. Polybond Ltd and their agents cannot, however, accept responsibility for the behaviour of the material(s) in any individual case, and potential users are advised to check this information is still applicable and that the product(s) are suitable for their intended use.