| REFRACTORY BOARD TYPES ZIRCAL-18, ZIRCAL-45
AND ZIRCAL-95 |
(PDF
VERSION) |
GENERAL INFORMATION
ZIRCAL-95 is ideal for machining to
tight tolerances.
-
Thermal shock resistance and stability - will
withstand continuous heat up to its full temperature limit.
-
A consistently low thermal conductivity means high
energy savings.
-
High structural strength at elevated temperatures
- retains full integrity across a broad range of temperatures.
-
Incombustible - ideal for personnel protection,
cable trays, fire doors, and marine applications.
-
Easily machined to tight tolerances with
conventional tooling.
ZIRCAL-18 is the ideal choice
for efficient back up insulation of kilns, furnaces, ovens, stoves,
boilers, soaking pits, regenerators, mains and other combustion
equipment.
ZIRCAL-18
Type ZIRCAL-18
Refractory Board is a high temperature calcium silicate block
insulation with excellent mechanical properties and stability up to 1100°C(2000°F).
Its high thermal insulating value makes it ideal for many
fireproofing and heat processing equipment applications. ZIRCAL-18
is designed to serve as a backup insulation for any refractory
construction, such as insulating fire brick, dense refractory brick,
castable, gunning mix, plastic refractory or ceramic fiber.
ZIRCAL-18's high refractoriness and strength help
prevent catastrophic failure of the refractory system. Often the hot
face refractory can crack in service allowing the backup insulation
to be exposed to elevated temperatures. ZIRCAL-18 makes continued
use of the operation possible, allowing for orderly shutdown and
maintenance.
In the aluminum industry, ZIRCAL-18 is ideally
suited as an electrolytic cell insulation. Its combination of
strength, thermal conductivity, stability and handleability makes it
ideal for reduction cell applications.
In the petrochemical industry, ZIRCAL-18 is ideally suited as a
backup insulation in heaters and furnaces, and in applications
requiring high strength such as insulated pipe supports.
ZIRCAL-45
Type ZIRCAL-45
Refractory Board is a self supporting, high strength, rigid
refractory product fabricated from calcium silicate, inert fillers
and reinforcing agents. Its high structural strength combined with
high thermal insulating value make it ideal for many fireproofing
and heat processing equipment applications up to 650°C(1202oF).
ZIRCAL-45 is highly damage resistant, non-corroding, and extremely
water-resistant.
ZIRCAL-45 in full size 4’ x 8’ panels offers
major economic advantages in the construction of ovens, dryers, and
other insulated housings for the retention and control of heat.
ZIRCAL-45 can be readily fabricated into various sizes and shapes
for heat baffles and all types of insulating parts.
It is used in fire safety applications such as
fire stops, fire walls, cable trays and fire doors, and provides an
ideal, incombustible base for melamine veneers. ZIRCAL-45 panels
have flame spread and smoke developed ratings of 0 & 0, and are
not damaged by inflammable charges that are subject to occasional
flaming.
ZIRCAL-45 is not affected by moisture or high
humidity, and will not rust or corrode. The panels will not
disintegrate even after prolonged immersion in water. While panels
can be painted if desired, preservative treatments are not required
for interior applications. ZIRCAL-45 is hygroscopic and electrical
resistance is reduced when it absorbs moisture. For electrical
applications, ZIRCAL-45 components should be thoroughly dried or
moisture proofed before use.
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ZIRCAR
Refractory Composites, Inc. provides
a variety of non-asbestos calcium silicate structural insulations that
combine high strength and excellent thermal insulating characteristics
for use in a variety of heat processing, fire protection and
electrical resistance applications. The unique calcium silicate
structure provides excellent thermal shock resistance as evidenced in
its typical use as a direct contact board for non-ferrous metals and
in fire training burn rooms. They are fire resistant to temperatures
approaching 1100°C(2012°F). They also exhibit low thermal conductivities that
remain relatively constant over a broad range of operating
temperatures.
ZIRCAL-45 boards are used in a
variety of heat insulating process, fire protection and as machined
parts.
Uses include insulation for Annealing furnaces,
Blast furnace stoves, Bustle pipes, Car tops, Forge furnaces, Glass
lehrs, Heat treating, Hi-temp mains and flues, Industrial boilers,
Kiln cars, Kilns, Laboratory furnaces, Marine boilers, Ovens, Pot
furnaces, Petrochem heaters, Pipe supports, Regenerators, Reheat
furnaces, Reverberatory furnaces, Roasters, Soaking pits, and Utility
boilers.
ZIRCAL-95
Type ZIRCAL-95
Refractory Board is produced from a combination of natural organic
fibers and inert reinforcing fillers in a high density calcium
silicate hydrate matrix. Designed as a substitute for asbestos cement
boards, ZIRCAL-95 is useful as structural and electrical insulation in
applications with temperatures to
1100°C(2000°F).
ZIRCAL-95's surface is sanded smooth. It has a
uniform consistency making it a useful source for custom machined
insulating parts.
ZIRCAL-95
combines low thermal conductivity and good dielectric properties with
high mechanical strength. It is hygroscopic and contains a small
amount of moisture. For certain high temperature electrical insulation
applications, ZIRCAL-95 should be thoroughly dried for 24 hours at 100°C-150°C.
It is ideal for use as press platen insulation, foundry core and blow
plates, induction furnace casing, electrical resistance insulation,
hot glass handling, as well as many others.
FABRICATION INFORMATION
Zircal-95 has unique machining characteristics. It is
easily cut with hand held woodworking tools using slow
cutting action. Operator will notice the rate of material removal
decreases as increased force and tool speed is applied. When sawing by
hand, a slow steady motion works best. Zircal-95 has been successfully
machined using power equipment with the following parameters:
- Sawing: Diamond wheel, approximately 250 mm diameter with 12 mm
long teeth spaced 25 mm apart, 1800 RPM.
- Milling: Double edge carbide end mill, speed approximately 4000
RPM , feed rate - 4 m/min.
- Turning: Carbide tipped tools used on 50 mm diameter part at
1200 RPM, feed rate - 4 m/min.
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CHARACTERISTICS & PROPERTIES
|
TYPE |
ZIRCAL-18 |
ZIRCAL-45 |
ZIRCAL-95 |
|
Nominal composition, wt% |
|
|
|
|
CaSiO3
|
93 |
95 |
96 |
|
Other oxides
|
1.5 |
<5 |
<4 |
|
Moisture
|
- |
3 |
1 |
|
Loss on ignition
|
5.5 |
- |
- |
|
Density, g/cc
(pcf) |
0.28(17.5) |
0.76(46) |
1.4(85) |
|
Maximum use temp.*, °C(°F) |
1100(2012) |
650(1202) |
1000(1832) |
|
MOR**,
MPa(psi) |
|
|
|
|
MOR @ room temp.
|
1.1(160) |
5.6(800) |
18(2600) |
|
Compressive strength**,
MPa(psi) |
|
|
|
|
5% deformation
|
1.4(203) |
70(1000) |
450(6400) |
|
Linear reheat shrinkage, %‡ |
|
|
|
|
12 hrs. at 650°C(1202°F)
|
0.0 |
0.4 |
0.13 |
|
12
hrs. at 1050°C(1922°F)
|
1.0 |
- |
0.5 |
|
Thermal Conductivity**, |
|
|
|
|
W/mK(BTU/hr ft2
oF/in.)
|
|
|
|
|
200°C(392°F)
|
0.07(0.49) |
0.12(0.81) |
0.31(2.13 |
|
400°C(752°F)
|
0.09(0.62) |
0.12(0.81) |
0.27(1.80) |
|
600°C(1112°F)
|
0.10(0.69) |
0.12(0.81) |
0.29(2.01) |
|
Coefficient of thermal |
|
|
|
|
expansion, K-1(°F-1) |
5.5 x 10-6 |
5.5 x 10-6 |
5.5 x 10-6 |
|
20°C - 700°C(68°F - 1292°F) |
(3.1 x 10-6) |
(3.1 x 10-6) |
(3.1 x 10-6) |
|
Volume
Resistivity, ohm-cm |
|
|
|
|
ASTM D-257
|
- |
9.8 x 107 |
4.52 x 1012 |
|
Arc Resistance, sec. |
|
|
|
|
ASTM D-495
|
- |
- |
314 |
|
Dielectric Strength, volts/mil |
|
|
|
|
ASTM D-495
|
- |
45 |
61 |
|
Screw holding strength |
|
|
|
|
@ 7/8" penetration,
kg(lbs)
|
- |
91(200) |
397(875) |
* Maximum use temperature is dependent
on variables such as stresses, both thermal and mechanical, and the chemical
environment that the material experiences.
** Properties expressed parallel to
thickness.
‡ Properties expressed perpendicular
to thickness.
AVAILABILITY
| Item # |
Description |
| SS01 |
ZIRCAL-95, 48" X 96" X
1/4" |
| SS02 |
ZIRCAL-95, 48" X 96" X
1/2" |
| SS03 |
ZIRCAL-95, 48" X 96" X
3/4" |
| SS04 |
ZIRCAL-95, 48" X 96" X
1" |
| SS05 |
ZIRCAL-95, 48" X 96" X 1
1/4" |
| SS06 |
ZIRCAL-95, 48" X 96" X 1
1/2" |
| SS07 |
ZIRCAL-95, 48" X 96" X
2" |
| SS08 |
ZIRCAL-95, 48" x 96" x
3" |
| SS10 |
ZIRCAL-95, 48" X 48" X
1/4" |
| SS11 |
ZIRCAL-95, 48" X 48" X
1/2" |
| SS12 |
ZIRCAL-95, 48" X 48" X
3/4" |
| SS13 |
ZIRCAL-95, 48" X 48" X 1" |
| SS14 |
ZIRCAL-95, 48" X 48" X 1
1/4" |
| SS15 |
ZIRCAL-95, 48" X 48" X 1
1/2" |
| SS16 |
ZIRCAL-95, 48" X 48" X 2" |
| SS20 |
ZIRCAL-95, 24" X 48" X
1/4" |
| SS21 |
ZIRCAL-95, 24" X 48" X
1/2" |
| SS22 |
ZIRCAL-95, 24" X 48" X
3/4" |
| SS23 |
ZIRCAL-95, 24" X 48" X 1" |
| SS24 |
ZIRCAL-95, 24" X 48" X 1
1/4" |
| SS25 |
ZIRCAL-95, 24" X 48" X 1
1/2" |
| SS26 |
ZIRCAL-95, 24" X 48" X 2" |
| SS30 |
ZIRCAL-45, 48" X 96" X
1/2" |
| SS31 |
ZIRCAL-45, 48" X 96" X
3/4" |
| SS32 |
ZIRCAL-45, 48" X 96" X
1" |
| SS33 |
ZIRCAL-45, 48" X 96" X 1
1/4" |
| SS34 |
ZIRCAL-45, 48" X 96" X 1
1/2" |
| SS35 |
ZIRCAL-45, 48" X 96" X
2" |
| SS36 |
ZIRCAR-45, 48" x 96" x
3" |
| SS40 |
ZIRCAL-45, 48" X 48" X
1/2" |
| SS41 |
ZIRCAL-45, 48" X 48" X
3/4" |
| SS42 |
ZIRCAL-45, 48" X 48" X 1" |
| SS43 |
ZIRCAL-45, 48" X 48" X 1
1/4" |
| SS44 |
ZIRCAL-45, 48" X 48" X 1
1/2" |
| SS45 |
ZIRCAL-45, 48" X 48" X 2" |
| SS46 |
ZIRCAL-45, 48" x 48" x 3" |
| SS50 |
ZIRCAL-45, 24" X 48" X
1/2" |
| SS51 |
ZIRCAL-45, 24" X 48" X
3/4" |
| SS52 |
ZIRCAL-45, 24" X 48" X 1" |
| SS53 |
ZIRCAL-45, 24" X 48" X 1
1/4" |
| SS54 |
ZIRCAL-45, 24" X 48" X 1
1/2" |
| SS55 |
ZIRCAL-45, 24" X 48" X 2" |
| SS56 |
ZIRCAL-45, 24" x 48" x 3" |
| SS60 |
ZIRCAL-18, 24" X 36" X 1" |
| SS61 |
ZIRCAL-18, 24" X 36" X
1.5" |
| SS62 |
ZIRCAL-18, 24" X 36" X 2" |
| SS63 |
ZIRCAL-18, 24" X 36" X
2.5" |
| SS64 |
ZIRCAL-18, 24" X 36" X 3" |
| SS65 |
ZIRCAL-18, 24" X 36" X
3.5" |
| SS66 |
ZIRCAL-18, 24" X 36" X 4" |
| SS70 |
ZIRCAL-18, 48" X 36" X 1" |
| SS71 |
ZIRCAL-18, 48" X 36" X
1.5" |
| SS72 |
ZIRCAL-18, 48" X 36" X 2" |
| SS73 |
ZIRCAL-18, 48" X 36" X
2.5" |
| SS74 |
ZIRCAL-18, 48" X 36" X 3" |
| SS75 |
ZIRCAL-18, 48" X 36" X
3.5" |
| SS76 |
ZIRCAL-18, 48" X 36" X 4" |
PRICES ARE SUBJECT TO CHANGE
WITHOUT NOTIFICATION AND ARE SUBJECT TO ZIRCAR REFRACTORY COMPOSITES, INC. TERMS
AND CONDITIONS. ALL PRICES ARE F.O.B. FLORIDA, NY AND ARE IN U.S. DOLLARS.
BOLD ITEMS ADD $100 CRATING
CHARGE PER ORDER.
HOME
ZIRCAR REFRACTORY COMPOSITES, INC.
P.O. BOX 489
FLORIDA, NEW YORK 10921
TEL: 845-651-2200, FAX: 845-651-1515
email: sales@zircarchina.com
This information, which is subject to change, is offered
solely for your consideration and should not be taken as a warranty or
representation for which we assume legal responsibility. It is not to be
understood as permission or recommendation to practice a patented invention
without a license and the user should determine whether relevant patents exist.
Copyrights and trademarks are the property of ZIRCAR
Refractory Composites, Inc.
{ for technical problems viewing these pages, please contact sales@zrci.com}
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