ISOLOYD NILFLAME
Rigid Polyisocynurate foam insulation, a specialist low temperature and cryogenic insulation which has low thermal conductivity, closed cell, moisture resistance and enhanced compressive strength at low temperature, whilst not comprising its elasticity so as to avoid cracking.

CFC FREE
Isoloyd Nilflame is the only CFC FREE polyisocynurate Insulation product, designed within the guidelines of the Montreal protocol, 1987 for the protection of the Ozone layer.

BETTER EXTREME- TEMPERATURE PERFORMANCE
Unlike most thermoplastics, Isoloyd Nilflame has low smoke & Toxic gas emission, and will not melt or drip in fire. It has low flame spread and and is not easily is not easily ignitable.

It also has a higher hot surface performance Temperature of 150°C. This makes it ideal for use directly over steam or electrical tracing. Its fire classification meets even the stringent requirements of the British Board of Trade for shipboard insulation as per BS 5608, the Indian Navy, and those of the US Bureau of Mines.

INSULATION PERFORMANCE
ISOLOYD Nilflame is amongst the most thermally efficient insulation materials available and retains its thermal insulation materials available and retains its thermal efficiency under the moat sever operating condition due to its closed cell structure resistance to moisture absorption. With ISOLOYD Nilflame insulations thickness can be reduced as compared to other materials like polystyrene foam cellular glass. Lower thickness exposes lower surface area for expensive vapour barrier and outer cladding.

EASE OF APPLICATION
Resistant to almost all solvents, Isoloyd Nilflame is compatible with cold applied adhesives, sealants and vapor -barrier mastics.Isoloyd Nilflame is available in boards, pipe sections, radiused and bevelled lags, with or without factory laminated facings.

buildings. It is provided with a precisely engineered “Rib and Flute” design to ensure wide spanning and quick recovery after being subjected to excessive load.

Lloydtile, in addition to Superdeck, offers new dimensions to architectural aesthetics and frees the designer of monotonous standard Trapezoidal design.

Lloyd Kliplock and Lloyd Standing Seam are laterally trapezoid profile with wide spanning and excellent water shedding capacities. The bold and broad flat outline makes a strong and striking appearance.

Lloyd Superdeck is a high depth roofing metaldeck profile.

Lloyd light groove is a lightly grooved sheet that can be used for plain facings.

Availability

Lloyddeck, Superdeck, Lloydtile, Lloyd Light Groove, Lloydkliplock & Standing Seam profiles are available in following standard finishes:-

• Pre-painted zincalume / galvalume steel with super Polyester, Silicon Polyester or Fluropolymer (PVF₂) coating.
• Pre-painted galvanized steel with polyester coating (SMP / RMP).
• Bare zincalume / galvanized finishes.

Profile

Lloydeck and Lloydtile sheets are available in a profile depth of 28-30mm at 195-200mm pitch and for Superdeck profile depth of 44mm and 130mm pitch. Lloydtile has steps of 200-300mm with height of 12-15mm . Lloyd Kliplock has a profile depth of 41-47mm at 218-250mm pitch. Lloyd Standing Seam has a profile depth of 62mm at 350-550mm pitch. In between 2 profiles, there are two small ribs in all the above profiles.

Base Zincalume / Galvalume Steel

Zincalume / galvalume steel us a zinc aluminium alloy coated steel offering high corrosion resistance.

This alloy coating comprises of 55% aluminium, 43% zinc and silicon. This coating offers a superior barrier protection against coastal atmosphere conditions. The coating class is AZ:1397, which means 150gms/m² minimum coating mass total of both sides. Zincalume / galvalume steel are available in tensile strength of 300, 345 & 550 Mpa.

Galvanized Steel.

Galvanized steel comprises of galvanized zinc coating over mild steel of minimum coating mass 175 gms/m² IS: 277 and tensile strength of min. 240Mpa.

Standard Conformance

As: 2728, AS: 1397
IS: 14246, IS: 513, IS: 277

ISO THANE EMA elastomeric membrane is a liquid applied coating based on urethane perpolymers which cure by reaction with atmospheric moisture to give a continuous film which is elastic. It contains leafing aluminium which gives execellent U.V. resistance.

ISOTHANE EMA is a very high solids coating designed to give a high build film. It can be brush or spray applied (with airless spray equipment) but it has a higher viscosity than a conventional paint and should not be diluted.

ISOTHANE EMA curves to a permanently flexible seamless membrane which, by virtue of its chemical reactivity in the wet state has good adhesion to a wide ranges of substrates (given proper preparation) such as roofing asphalt, slates, tiles, asbestos, concrete, brick, wood, glass and metals. Unlike more traditional bitumen based product ISOTHANE EMA does not readily embrittle with age, exposure to ultra violet radiation or weathering and hence it does not crack or craze.

Since it is elastomeric ISOTHANE EMA is not adversely affected by extremes of temperature, consequently it does not crack at low temperatures or suffer thermal flow at elevated temperatures.

ISOTHANE EMA can be applied by brush, airless spray or roller without the need to mix, stir or heat before application.

APPLICATION
ISOTHANE Elastomeric Membranes are designed to bond to many types of substrate particularly those commonly used as roofing, such as felt, asphalt, slate, tiles, asbestos, concrete, brick, wood, glass and metals. They can also be applied to sprayed polyurethane (p.u) foam insulation. However, it is essential that substrate and structures are properly prepared, and stable.

Surface previously treated with silicon based materials will inevitably be difficult to overcoat and this should not be attempted with IOSTHANE products.

Substrates with poor adhesion to the underlying structure (e.g. blistered roofing felt) may also cause problems in providing sound over-coating.

Preferential vapour drive in building must also be borne in mind when over coating the roof and it may be judged expedient to employ ventilation to cope with transmission of high levels of moisture vapour.

METHOD OF APPLICATION
The dry film thickness(DFT) of ISOTHANE EMA, should not be less than 0.5mm or more than 1.0mm for each coat. Rough or textured surfaces will reduce the coverage rate and consequently more material must be allowed to achieve the minimum D.F.T. IOSTHANE EMA is a membrane coating, not a paint and as such protection is only achieved with a high film build, i.e. 1mm minimum. It is therefore essential that this is achieved. The membrane can be applied in one 1mm or two 0.5mm coats. Two coats are recommended on uneven and jointed surfaces to minimise the possibility of thin patches, missed areas and pinholing. In case of two coat application, it is important to recoat within 24 hours of the coat becoming sufficiently curved to allow operator access.

DO not dilute ISOTHANE EMA

Method

1. Remove all loose material by vigorous brushing. Wire brush if necessary.
2. Treat any remaining fungal growth with proprietary fungicide as recommended.
3. Allow surface to dry thoroughly and any moisture contained in the structure to evaporate. Isothane special primer and EMA should not be applied to damp substrates.
4. Fill cracks and voids with a mastic sealant.
5. Prime with Isothane special primer (6-10 m2/lt) depending on substrate texture and porosity) when cures to a slightly tacky film in 2-4 hours. Overcoat with Isothane EMA as sson as possible after this time and certainly within 48 hours. If delay exceeds this, re-priming is advised.
6. Apply Isothane EMA at a maximum film thickness of 0.5mm for two coat applications and 1mm for one coat.
7. In the case of two coat application, the first coat should be touch dry in 12-48 hours (in some conditions this might be delayed) and the second coat should be applied within 24 hours of this stage to ensure good adhesion.
8. Second coat delay:- if more than 24 hour elapse after the touch dry stage of the first coat, prime the entire surface with special with special primer and allow to dry before recoating within 4-8hours.
9. Day-work joints- where application extends over more than a working day, an overlap of 15mm should be used.
10. Aromatic hydrocarbon solvent should be used to clean equipment etc.

     

    Spray application
    Only airless spray should be used
    Graco king 60 to 1 ratio or similar
    Compressor: 100psi, 60cft min.
    Tip Siz: 28/30 thou. 60° Angle.

    APPLICATION RATE
    ISOTHANE EMA is easily and quickly applied manually at a rate of 40m2 per man hour or up to 600 m2 per day by spray application.

    REPAIRS
    Minor damage to ISOTHANE EMA, can be repaired by removing loose membrane, cleaning the surrounding area with aromatic hydrocarbon solvent overlapping by 150mm, priming the area with special primer and finishing with two coats of IOSTHANE EMA.

    COVERAGE
    Coverage rate may vary with surface texture and porosity. The information given is based on average usage. A site trial is recommended.
    
    ISOTHANE special primer 6-10m2/lt
    
    ISOTHANE EMA 1kg (0.8lt)/ m2 on a smooth surface will provide and adequate film thickness of approx 1mm. Any surface texture will increase the surface area which must be allowed for when calculation usage- e.g. on a chipping embedded surface the actual area will be approximately doubled.

    STORAGE
    Store in a cool place and avoid unnecessary opening of cans. In very cold conditions inside before using - do not attempt to thin.
    
    Once opened ISOTHANE EMA will start to cure and a skin will form, even on re-sealed cans. This can be removed if material is used within approximately a month.

    HEALTH & SAFETY
    The recommendations in our material safety data sheet (MSDS) ref. 05 should be followed at all times.

    1. • Paints products UN 1263.
       • Keep out of reach of children.
       • Keep away from sources of ignition.
       • No smoking.
       • Do not breathe vapour / spray.
       • Ensure good ventilation during application and drying.
       • In case of eye contact- wash with plenty of clean water and seek medical advice.
       • Avoid prolonged skin contact; wear suitable protective clothing and gloves.
       • Remove from skin with mild solvent / hand cleanser and wash with warm soapy water.
       • Contains isocyante, specific information available on request.
    2. Note: More details on the above are available in lidquid polymers publication "A Guide to the safe Handling of polyurethane Resins." This document should be consulted before use of any ISOCYANATE based materials.

Boards & Blocks
Supercera Boards and Blocks are made from superspun Supercera fibres by multi component organic / inorganic bonding process.

Supercera Blocks and shapes are obtained by vacuum suction of a mixture of Supercera ceramic fibres with organic and mineral binders. These vacuum formed products can be moulded and cured into a wide variety of shapes to have a smooth inside surface and a rougher outside, as demanded by the application.

Supercera Fibre Boards, Blocks and shapes can be rendered machinable- to be sawed, drilled or machined, when required.

Application (Vacuum Formed Shapes)

• Combustion Chambers
• Domestic boiler doors
• Peep holes, Pipe Seals
• Special furnace lining parts
• Radiant element supports in vitroceramic hotplates (Either electric resistance or halogen)

 

Application (Boards and Blocks)

• Lining of : Furnaces including electric Furances; Flue and chimney of furnace and kilns; Hot gas ducts; combustion chamber in central heating boiler;
• Glass tank side, ends walls, and port neck, low and high temperature driers.
• Trough and distribution lining for conveying molten metal
• Refractory backup for bricks and castables.
• Pouring forms for non ferrous castings
• High temperature baffles and muffles
• Heat shield for personnel protection
• Rigid high temperature gaskets and seals
• Expansion joints.

 

Availability (Boards)

Grade	Size (mm)	Available Thickness (mm)
HTZ, RTZ	1000 x 500 and 915 x 610	10-50 (in increments of 5)

 

Availability (Boards)

Density *	260 - 320 kg/m3
Dimensions (mm)	915 x 610 and 1000 x 500

* Higher Density products offered on request.

 

Physical Properties

Melting temperature (°c)		1700-1760
Specific Heat (KJ / Kgk)		1.07
Fibre Diameter (Mean)		2.8µ
Linear shrinkage (%) after 24 hrs Firing / Soaking	1000°c	1.5
	1100°c	2.2
	1200°c	3.0
Bulk Density (per m3) 260 - 320
Max Service Temp. (°c) 1260

 

Supercera Anchored Modules and Veneereing Modules

Anchored Modules are made from folds of Supercera Ceramic fibre - the only superspun double-needled fibre in the country. The module is held in compression by removable strapping. Each module has an integral anchoring system- the result of continuous R & D and advanced design.

Fixing of the module to metal shell is achieved by welding specially designed studs, supplied integral with the module, resulting in efficient, fast and error free installation,

Advantages

• Fast and efficient installation
• Lesser down time
• No gap between the casing plate and the module
• Faster cycling with increased plant utilization
• Higher fuel economy
• Lower installed cost
• Lower maintenance cost

 

Application

• Reheating furnaces
• Bell Annealing Furnaces
• Soaking pit seals and covers
• Laddle Preheaters
• Chemical precoess Heaters
• Kilns
• Incinertors
• Reformers, etc.

 

Typical Physical and chemical properties*

Grade	Classification temp (°c)	Chemical Analysis (%)
		Al2 O3	SiO2	ZrO2	Fe2O3
HT	1425	32-36	44-48	16-18	Trace
RT	1260	46-48	52-54	-	Trace
RTZ	1300	40-44	50-54	4-6	Trace

Fibre diameter (micron): 2-3
Fibre Length (mm): 150-200
These are indicative only.

 

Availability Densities and Thickness

Types of Modules	Grade	Densities** (kg/m3)	Available Thickness (mm)
Anchored	HT, RT	128, 160	100-300
Veneering	HT, RT	128, 160	5075

**Higher Densities are available on request.

 

Speciality Products

A. Supercera Cermic Fibre Cloth/ Tape

Supercera cloth/ tape is a high temp. specially fabric used for variety of industrial applications. It contains 15-20% organic carrier fiber to facilitate the carding process, which may burn off at a lower temperature. This however does not change the mechanical features including strength. It exhibits excellent chemical stability, resistance attack from most corrosive agents. Available in standard thickness of 3mm. Other thicknesses available on request.

Technical Details
Size / Packing
Cloth: 3mm x 300mm x 10RMT
Tape: 3mm x 50mm x 25 RMT

B. Supercera Twisted Rope/ Braids

Supercera Twisted Rope is a three-ply rope manufactured from supercera long fibres. It contains 15-20% organic carrier fibre to facilities the carding process which may burn off at a lower temperature.

Supercera Twisted Rope is a dense, resilient high temperature refractory possessing excellent thermal properties, chemical stability and high mechanical strength.

Supercera Braids: Supercera Braided Rope is available with SS 304/ SS 310 Braiding.

Technical Details

Size	6mm Dia. to 40mm Dia.
Density	300 kg/m3 (Min.)
Diameter Tolerance	-15% to + 30%
Length Tolerance	-0, Excess Permitted.
Tensile Strength	1kg/cm2
Packing	10/25 RMT- Coils

C. Supercera paper

 

Supercera Ceramic paper is manufactured from high temperature Supercera ceramic fibre product containing 20-25% organic material to give it an extra ordinary pliability. If wet by water, steam or oil, its thermal and physical properties are restored up on dying.

Technical Data

Size	1000mm x 500mm (other sizes on request)
Standard Thickness	1mm to 6mm
Dimension Tolerance	-0, Excess Permitted
Density	240 kg/m3 (-155 to 30%)
Tensile Strength	0.4 kg/cm2
Linear shrinkage	3.5% maximum at 1260°c for 24 hours

Rockloyd is a precisely engineered Resin Bonded Fibrous Insulation to offer maximum resistance to heat passage. Rockloyd fibres are spun from selected rocks, melted at 1600°c and blended to a carefully adjustment chemical composition. Its centrifugally spun fibres have a diameter 1/20^th that of human hair which are felted using State of the Art Technology into bonded and cured mattress to optimum density and resilience. Over 25million sq.mts. of Rockloyd Insulation are in services in prestigious projects within the country saving millions of tones of fuel year after year.

Rockloyd, like all scientifically processed fibrous insulants is composed of fibres which are laid in the optimum configuration to offer maximum resistance to heat flow. To retain these exceptional properties up to the point of end-use, fibres are interlocked by lightly bonding them together using a thermosetting binder. Subsequently, matts are factory stitched to specified wire mesh using a continuous stitching machine to permit a ready-to-use configuration.

Salient Feature

• Higher Thermal Performance, as it is made out of Rockwool and not slagwool.
• Eliminated setting and sagging.
• Longer Life, permitting reuse after removal during maintenance.
• Environment Friendly, as there is no chicken feathering (Which normally pollutes the environment). It is ECO friendly to personnel due to the chemistry of fibres.
• Uncontaminated, as manufacturing is totally a DRY Process.
• Application Friendly, as it permits very fast installation.
• Can feature Resistance to capillary if needed

 

Specification conformance
Rockloyd mattress manufactured from select rocks to state of Art Specification fully conform to local & International Standards such as.

IS	8183-1993
BS	3958 Part-3
ASTM	C 592

Approved for A-60 Class insulation*
* The only product in India.

 

Technical Specifications

Standard Densities	100, 120 & 150 Kg/m3
Application Temperatures	-100°c to +800°c
Standard Thickness*	25, 40, 50, 60, 65, 75mm
Standard Size	1520 x 1220 mm

* Other thickness from 20 to 100 mm in steps of 5mm can also be made available.

 

Corrosion Protection
Rockloyd fibres, in the first place, are devoid of impurities like Halides (Chlorides & fluorides) and Sulphides which are commonly found in other materials such as Calcium Silicate. This is due to the fact that Rockloyd fibres are manufactured by a dry manufacturing process and its faint alkalinity actually fight against corrosive reactions. It meets various critical specifications including ASTM C 795 requirements where specified.

This feature is responsible for its exclusive selection for critical applications such as Nuclear Power plants, ship building and Railways coaches where corrosion resistance is of vital significance.

Fire Resistance
Incombustible when tested as per IS:3144 Melting point of fibres is above 1000°c (1825°F)

Compression Resistance & Sound Absorption
Excellent compression resistance & sound absorption by virtue of its scientific fiber lay pattern which ensures controlled dispersion of air pockets.

Inhibited Rockwool
Where stress corrosion is there on austenitic stainless steel, inhibited Rockwool Mattressess are used. Inhibition is done by spraying sodium silicate of adequate quantity in order to lower chloride content as low as 2ppm.

Water Repellent Grade
It is special grade Rockwool materials wherein special type of chemical is added during its manufacturing process to make it water repellent grade. For this property it is tested as per BS:2972 with partial immersion in water for 48hrs. which exhibits superior results as compared to normal grade Rockwool.

Thermal Conductivity
Resin Bonded Rockloyd material is the only one to offer the LOW THERMAL CONDUCTIVITY to weight ratio among all industrial insulants thus minimizing the total load on the applied equipment.

Rockloyd Slab - Resin Bonded, Rockwool Slabs
Rockloyd is a precisely engineered Resin Bonded Fibrous Insulation to offer maximum resistance to heat passage. Rockloyd Fibres are spun from selected rocks, melted at 1600°c and blended to a carefully adjusted chemical composition. Its centrifugally spun fibres have a diameter 1/20^th that of human hair which are felted using state of art Technology into bonded and cured slabs to optimum density and resilience.

Over 25 million sq. mts. Of Rockloyd Insulation are in service in prestigeous projects within the country saving millions of tones of fuel year after year.

Specification Conformance
Rockloyd Slabs manufactured from select rocks using state of the art technology conforms to and exceeds requirements specified in local & international standards such as

IS 8183: 1993
BS: 3958 Part-5
ASTM C 612

IMO for A15, A-30& A-60 class fire barrier insulation. **
** The only product to carry this certification in India.*

Physical Data for Standard Products
 

Slab Grade	Slab Density kg/m3	Optimum Temperature Limits °c	Thickness (mm)**	Size (m)
300	48	250	25,40,50,60,65 & 75	1.0x0.50, 1.0x0.60 or 1.2 x 0.75
400	64	300	25,40,50,60,65 &75	1.0x0.50, 1.0x0.60 or 1.2x 0.75
600	96	400	25,40,50,60,65 &75	1.0x0.50, 1.0x0.60 or 1.2x 0.75
900	144	550	25,40,50,60&65	1.0x0.50, 1.0x0.60 or 1.2x 0.75

** Can be made available with increments in thickness of 5mm against special orders.

 

Water & Moisture Repellence
Rockloyd Slabs by virtue of fiber surface treatment and lay pattern has an angle of contact exceeding 90°c which result good resistance to water and moisture ingress and hence does not promote capillary action. When tested as per IS, BS and ASTM standards the material exhibits excellent resistance to moisture absorption and is superior to materials like Calcium Silicate and Glasswool which are inherently hygroscopic in nature.

* All insulation materials degrade in their properties when water or moisture enters their body.

Sound Absorption
Excellent sound Absorption by virtue of its scientific fibre lay pattern ensuring controlled dispersion of air pockets and prices air flow resistance.

Sound absorption co-efficient of Rockloyd Slabs 48 Kg/m³ are furnished below:
 

Thickness in mm		25*	50*	25**	50**
Frequency	125	0.13	0.23	0.16	0.28
	250	0.32	0.58	0.41	0.68
	500	0.82	0.85	0.84	0.98
	1000	0.95	0.96	0.96	0.97
C/S	2000	0.94	0.98	0.96	0.95
	4000	0.76	0.94	0.92	0.94
NRC			0.84	0.79	0.89

* With rigid backing ** with 1" air gap

 

Fire Resistance
Totally Incombustible when tested as per IS: 3144 (Melting point of fibres is above 1000°c [1825°F])

Corrosion Protection
Rockloyd Fibres, in the first place, are devoid of impurities like Halides (Chlorides & Fluorides) and Sulphides which are commonly found in other materials such as Calcium Silicate. This is due to the fact that Rockloyd fibres are manufactured by a dry manufacturing process and its faint alkalinity, actually fights against corrosive reactions. It meets various critical specification including ASTM C795 requirements where specified.

This is feature is responsible for its exclusive selection for critical application such as Nuclear Power Plants. Ship building and Railways coaches where corrosion resistance is of vital significance.

Thermal Conductivity
Resin Bounded Rockloyd material is the only one to offer the LOW THERMAL CONDUCTIVITY to weight ratio when compared t block type insulants like Clacium Silicate. This minimizes the total load on the piping and equipment while maximizing thermal efficiency with a given thickness of usage.

ROCKLOYD PIPE SECTION
Rockloyd is a precisely engineered Resin Bonded Fibrous Insulation to offer maximum resistance to heat passage. Rockloyd Fibres are spun from selected rocks, melted at 1600°c and blended to a carefully adjusted chemical composition. Its centrifugally spun fibres have a diameter 1/20^th that of human hair which are felted using state of art Technology into bonded and cured pipe section to optimum density and resilience.

Over 25 million sq. mts. of Rockloyd Insulation are in service in prestigeous projects within the country saving millions of tones of fuel year after year.

Mandrel wound and concentrically formed form fitting Pipe sections, Precisely made to fit standard pipe diameters offer uniform maximum resistance to passage of heat along and around the entire 360degrees of the pipe axis. Superior density of this product enhances compression resistance in services. These sections are easy to fit and hence afford speedy application to site.

Specification Conformance
Rockloyd Pipe sections manufactured from select rocks using state of the art technology conforms to local & international standards such as

IS: 9842
BS: 3958 Part-5
ASTM C547-95

Thermal Conductivity
 

Standard Densities	144, 150 & 160 Kg/m3
Application Temperatures	-100°c to +8000°c
Standard Thickness*	25, 40, 50, 60, 65, 75mm
Diameter Range**	12.5mm to 350mm Nominal Bore.
Standard length	0.5, 0.75, 1.0 mts.
Facings (if specified)	Kraft {Paper, Scrim cloth, Canvas or Aluminium Foil.

* Other thickness from 20 to 100 mm in steps of 5mm can also be made available.
** Outer Diameter of Pipe to be specified.

 

Water & Moisture Repellency *
Rockloyd Pipe sections, by use of special additives and fibre lay pattern has an angle of contact exceeding 90°c which make it totally resistant to ingress of water wherever called for. When tested as per IS, BS and ASTM standards the material exhibits excellent resistance to moisture as compared to materials like Calcium Silicate and Glasswool which are inherently hygroscopic in nature.

* Insulation materials loose their properties when water or moisture enters their body.

Corrosion Protection
Rockloyd fibres, in the first place, are devoid of impurities like Halides (Chlorides & fluorides) and Sulphides which are commonly found in other materials such as Calcium Silicate. This is due to the fact that Rockloyd fibres are manufactured by a dry manufacturing process and its faint alkalinity actually fight against corrosive reactions. It meets various critical specifications including ASTM C 795 requirements where specified.

This feature is responsible for its exclusive selection for critical applications such as Nuclear Power plants, ship building and Railways coaches where corrosion resistance is of vital significance.

Fire Resistance
Incombustible when tested as per IS: 3144 (Melting point of fibres is above 1000°c (1825°F)).

Sound Absorption
Excellent sound Absorption by virtue of its scientific fibre lay pattern ensuring controlled dispersion of air pockets and prices air flow resistance.

Thermal Conductivity
Resin Bounded Rockloyd material is the only one to offer the LOW THERMAL CONDUCTIVITY to weight ratio thus minimizing the total load on the applied pipelines or equipment.

Inhibited Rockwool
Where the stress corrosion is there on austenitic stainless steel inhibited Pipe sections are used. Inhibition is done b spraying sodium silicate of adequate quantity in order to lower chloride content as low as 2ppm.

SUPERTHERM PIPE SUPPORTS
A heavy duty easy to install prefabricated pipe support system of truly revolutionary proportions Supertherm Pipe Supports are made from specially formulated chemical systems that result in high density rigid polyurethane foam. The very nature of the material immediately yields several advantages.

Property	Advantages
Wide density range possible	Higher densities enable higher loads without increase in surface area.
Pre-engineered at our factory	No sawing and Shaping at site. The support precisely matches pipe's OD. Installation time dramatically reduced.
Material has a closed cell structure	Does not permit water penetration. No wet rot. No dry rot.
Excellent 'K' value	Provides vastly superior insulation as compared to timber and other materials. No condensation at support point. So no drips, puddles or energy wasted.
Good fire resistance	Improved safety at site. Improved durability.
Close dimensional tolerance	Pipe Support thickness precisely matches insulation thickness, resulting in neat finish at support location.
Supplied in assembled condition, complete with all metal attachment	Improved speed of installation. Joint-free in the load bearing area, even for larger diameters of pipe.
Special sizes, shapes and finishes	On request Non-standard sizes and shapes can be manufactured to suit specification. Supports can be supplied with a factory-applied coat of fire-resistive mastic, which also serves as a vapour barrier, on the exposed surface.

Physical Properties for different Densities

Density (kg/m3)	% Closed Cells	Water Vapour Transmission (gms/m2/24hrs)	Compression strength (Kpa)	Tensile Strength (Kpa)
80	93	50	900	1200
120	94	45	1500	1600
180	94	30	2900	2500
250	96	25	4900	3100
320	96	15	8200	5000
This system is 'CFC FREE' and has been designed within the Guide lines of the Montreal Protocol, 1987, for the protection of the Ozone layer.

Comparison with Wood

Wood	Density (kg/m3)	'K' Value at 10°c	Max. Temp °c	Min. Temp °c	Fire Rating
Oak	740	0.159	65	0	Poor
Mahogany	560	0.144	65	0	Poor
Supertherm	80	0.023	110	-185	Class P as per BS: 476 Part-5 for ignitability
	120	0.031	110	-185
	160	0.033	110	-185

Supercera Blankets
Supercera Blanket is a refractory fibre needled mat made without binder from Supercera fibres the only super-spun double needled fibre in the country today. Supercera RTZ and HTZ Blankets are zirconoca stabilized and are suitable or use upto 1260°c and 1425°c respectively.

Both blankets have excellent resistance to most chemicals. If wet by oil or water, thermal and physical properties are fully restored upon drying.

Out Standing Advantage

• Excellent Thermal Stability.
• Low Shrinkage at elevated temperature - due to their excellent Thermal Stability.
• Low Heat Storage Both blanket store approximately 95% less heat than dense firebrick and approximately 75% less heat than insulating firebrick a property of significant importance in the operation of periodic kilns / furnaces.
• Good Cold strength.
• Excellent Hot strength.
• Thermal stock Resistance due to the flexible matrix of Supercera, extreme temperature change do not alter its ability to physically stay in place and perform at higher levels.
• The products are not wetted by molten non-ferrous metals. If wet by oil, water or steam, Thermal and physical properties will be fully resorted after burn out or drying.

 

Applications

• Normalising Annealing furnaces and glass lehrs.
• Reformers & Ducts in petrochemical, fertiliser and Boiler Linings Industry
• Fexible high temperature pipe insulation.
• Low velocity HRSG and stack linings
• Glass Furnace crown insulations
• Trundish cover, Transfer cars in steel plants
• Soaking pit seals and expansion joint
• Kilns, klin cars for ceramic industry
• Annealing cover bottom seals
• Reusable insulation blankets for field stress relieving of welds
• Removable Insulation blankets for steam and gas turbines and fire protection.
• Insulation wrap on investment casting moulds
• Furnace door seals, linings and gaskets
• Temporary repair of refractory furnace linings and roofs
• High temperature filter media / gaskets
• High temperature sound absorption and Nuclear Insulation applications.

 

Availability (for all grades)

Density (kg/m3): 64, 96, 128
Thickness (mm): 6, 12, 20, 25, 50
Roll Dimension: 7620 mm x 610mm
Other sizes available on request.

They conform to IS: 15402-03 & ASTM C 892-00

Supercera Boards & Blocks

Supercera Boards and Blocks are made from superspun Supercera fibres by multi component organic / inorganic bonding process.

Supercera Blocks and shapes are obtained by vacuum suction of a mixture of Supercera Ceramica fibres with organic and mineral binders. These vacuum formed products can be moulded and cured into a wide variety of shape to have a smooth inside surface and a rougher outside, as demanded by the application.

Supercera fibre boards, blocks and shapes are self supporting with excellent stability at high temperatures, having high resistance to thermal shock and chemical attack. Supercera fibre boards, blocks and shapes can be rendered machinable to be sawed, drilled or machined, where required.

Density	260 - 320, 720 kg/m3
Size	915 x 600 mm & 1000 x 500mm
Thickness	10-50 mm

 

Applications (Vacuum formed shapes)

• Combustion chambers
• Domestic boiler doors
• Peep holes, pipe seals
• Special furnace lining parts
• Radiant element supports in vitroceramic hotplates (either electric resistance or halogen)

 

Applications (Boards and Blocks)

• Linning of : Furance including electric furnaces: Flue and chimney of furnaces and Hot gas ducts: combusting chamber in heating boilers: Glass tank side, end walls, and port neck; Low and high temperature driers
• Trough and distribution linings for conveying molten metal
• Refractory backup for bricks and castables.
• Pouring forms for non ferrous castings
• High temperature baffles and muffles
• Heat shield for personnel protection
• Rigid high temperature gasket and seals
• Expansions joints.

 

Supercera Anchored Modules and Veneering Modules
Supercera anchored modules are made from folds of Supercera ceramic fibre the - only superspun doubled-needed fibre in the country. The module is held in compression by removable strapping. Each module has an integral anchoring system - the result of continuous R & D and advanced designing. Fixing of the module to metals shell is achieved by welding specially designed studs, supplied integral with the module, resulting in efficient, fast, and error-free installation. Supercera Modules are ideal for full thickness lining for new furnaces as well as conversion into fibre lining incase of old furnaces. They enhance the furnace life and performance.

Density: 128, 160kg/m3
Thickness: 100- 300mm for anchored and 50- 75mm for veneering.

Supercera veneering Modules improve the thermal efficiency of old brick linings with minimum downtimes for repairs.

Applications

• Reheating Furnaces
• Bell Anneling Furnaces
• Soaking pit seals and covers
• Ladle preheaters
• Chemical process heaters
• Incinerators
• Reformers, etc.

 

Specially Products
Supercera cloth / tape is a high temp. specially fabric used for a variety of industrial applications. It contains 15 - 20% organics carrier fibre to facilitate the carding process, which may burn off at a lower temperature. This however does not change the mechanical features including strength. It exhibits excellent chemical stability, resisting attack from most corrosive agents. Available in standard thickness of 3mm. Other thickness available on request.

Cloth sizes: 3mm x 300mm / 1000mm x 10m
Tape sizes: 3mm x 50mm x 25mm

Supercera twisted Rope is a three-ply rope manufactured from Supercera long fibres. It contains 15 - 20% organic carrier fibre to facilitate the carding process which burn off at a lower temperature. It is dense, resilient high temperature refractory possessing excellent thermal properties, chemical stability and high mechanical strength . Size 6 to 40mm dia, 10/25m coils & 300 kg.m3 density (min.)

Supercera Braids Supercera braided rope is available with SS304/ss310 braiding Supercera ceramic Paper is manufactured from high temperature. Supercera ceramic fibre product containing 20-25% organic material to give it an extra ordinary pliability. If wet by water, Steam or oil, its thermal and physical properties are resorted up on drying.
 

Size	1000mm x 500mm
Thickness	1 to 6mm
Density	240 kg/m3

Supercera Bulk Fibre
Supercera is a high temperature insulating refractory fibre processed from high purity alumina and silica constituent specially selected for high strength refractoriness and stability even under severe conditions.

Supercera spun texture gives it the added extra of exceptionally long fibres and superior mechanical properties essential to meet service conditions.

Supercera bulk fibres provide superior acoustical benefit in addition to high thermal performance a relevant benefit in process furnaces. Supercera can be handled and worked into expansion joints, wall penetrations and other areas with nominal skills. In specific cases, our application engineers would be happy to assist with heat loss. Surface temperature and heat storage computations.

Salient features

• Low heat storage
• Light weight
• Very low thermal conductivity.
• Resistance to high temperature
• High resilience
• Excellent corrosion resistance
• Resistance to thermal shock
• Excellent resistance to chemical attack (with the exceptions of hydrofluoric and phosphoric acids)

 

Applications
As a resilient fill or packing material in high temperature areas like:

• Burner Openings
• Kiln Insulations
• Furnace patch sealings
• Emergency repairs in refractory
• Glass tanks and glass processing
• Furnace repairs
• Expansion joints
• Fibre boxes.

 

Specifications

Chemical Composition	RT	RTz	HTZ
Al2 O3 (%)	46 - 48	41 - 43	33 - 36
SiO2 (%)	52 - 54	50 - 54	44 - 48
ZrO2 (%)	-	4 - 6	16 - 19
Leachable Chlorides	< 10ppm	<10ppm	<10ppm

Physical Properties		RT	RTz	HTZ
Melting Temperature (°c)		1760	1700	> 1650
Specific Heat (KJ / kgK)		1.07	1.07	1.07
Fibre Diameter (Mean)		2.8µ	2.8µ	2.8µ
Linear Shrinkage (%) After 24 hrs Firing / Soaking	1000°c	1.5	1.5	-
	1100°c	2.2	2.2	-
	1200°c	3.0	3.0	2.7
	1300°c	-	-	3.5
	1400°c	-	-	4.0
Max Service Temp. (°c)		1260	1206	1425

Availability (For all grades)
Supercera Bulk fibre is available in standard packs of 10kg.