Densit Wear Protection Products

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Barnard Underwood
5 years ago
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1 Densit Wear Protection Products

densit aps densit WEAR protection solutions Densit Services Densit ApS specializes in the development, production and delivery of high-performance solutions for industrial strengthening and repair of

Densit high-performance solutions are applied worldwide for: Wear protection solutions Foundations for Renewable Energy Solutions Strengthening of oil and gas platforms and jackets Industrial

Densit ApS maintains a project office and component fabrication for all Densit wear protection solutions in Germany and a branch office in Malaysia for its offshore activities.

An ITW Company Densit is part of the Illinois Tool Works (ITW) Group, with more than 875 companies in 54 countries - www.itw.

2 densit aps densit WEAR protection solutions Densit Services Densit ApS specializes in the development, production and delivery of high-performance solutions for industrial strengthening and repair of equipment based our unique, high-strength and dense cement-based Densit materials. Densit high-performance solutions are applied worldwide for: Wear protection solutions Foundations for Renewable Energy Solutions Strengthening of oil and gas platforms and jackets Industrial flooring and pavements Global Presence Densit ApS was founded in 1983 in Denmark. Densit ApS maintains a project office and component fabrication for all Densit wear protection solutions in Germany and a branch office in Malaysia for its offshore activities. Furthermore, Densit ApS is represented worldwide through a large and growing network of qualified partner companies. An ITW Company Densit is part of the Illinois Tool Works (ITW) Group, with more than 875 companies in 54 countries - Quality Assurance Densit provides high performance wear protection solutions to customers in accordance with its ISO 9001, ISO and OHSAS quality system, certified by Lloyd s Register Quality Assurance. Consultation and Development Densit will develop for you an economic wear protection system with recommendations regarding the tribology protection materials that need to be applied as well as their manufacture and assembly. Our goals for you: Proper selection of materials Optimal durability Time and cost saving assembly Low periods of inactivity for your facilities Engineering / Production / Project Management Densit produces ready-to-install system components that are constructed for your specific usage needs. This includes pipeline systems, cyclones, air classifiers, chutes, valves, Venturi nozzles cones and panels, often together with qualified suppliers in Europe, China and other Asian countries. Densit has at its disposal more than 25 years of worldwide experience in project development. Our project team is engaged in every aspect of project development, from construction to production; from quality control to logistics. Installation A basic requirement for efficient wear protection is proper installation. The wear protection composite material from Densit can be applied in cast or sharpening procedures or as a trowel plaster. Your personnel can easily install these products. Pressure can be applied to the coating 24 hours after application. Densit or one of our qualified partners can also perform or monitor the installation. DENSIT Installation Service DENSIT Maintenance Service DENSIT Engineering DENSIT Training Courses DENSIT WearFlex DENSIT WearCast DENSIT WearSpray DENSIT Cast Basalt DENSIT Aluminium Oxide Ceramic DENSIT Wear Plates DENSIT Pipe Components

DENSIT DSP TECHNOLOGy DENSIT wearflex, wearcast and wearspray The DSP technology Densified Systems with ultrafine Particles combines cement, microsilica and super

The highly thick microstructure of Densit Binder results in a particularly high impermeability for chloride ions and a high electrical resistance.

Normal cement structure Cement particle and water wc = 0.5 0.

Densit WearFlex is produced as a normal temperature material (Max. 400 C consistent temperature) and as a high temperature material (max. 1,200 C consistent temperature.

Densit Binder s special characteristic is made clear in connection with its additives in a pressure test, for which a Densit test cylinder is used.

The DSP technology was developed by Densit and a patent for it was first applied for in 1978.

35 DSP Technology Cement particle, super plasticizer, microsilica and water densit WearCast Densit WearCast is a material combination of high-strength binder and extremely

1,200 C consistent temperature. Densit WearCast is produced as a casting compound for all types of cast mountings.

3 densit WearSpray Densit WearSpray is a material combination of high-strength binder and extremely wear-resistance additives.

With Densit WearSpray, large area capacities, extreme mounting locations, short mounting times and overhead mountings are all possible.

3 DENSIT DSP TECHNOLOGy DENSIT wearflex, wearcast and wearspray The DSP technology Densified Systems with ultrafine Particles combines cement, microsilica and super plasticizer extremely tight, which leads to extremely low moisture content in the material. This ultra strong material is known worldwide as Densit Binder. The highly thick microstructure of Densit Binder results in a particularly high impermeability for chloride ions and a high electrical resistance. These two traits give the material, in addition to a particularly high corrosion resistance, an extraordinary durability against various stresses, such as abrasion. Normal cement structure Cement particle and water wc = Super plasticized cement structure densit WearFlex Densit WearFlex is a material combination of high-strength binder and extremely wear-resistant ceramic additives. Densit WearFlex is produced as a normal temperature material (Max. 400 C consistent temperature) and as a high temperature material (max. 1,200 C consistent temperature. Densit WearFlex is used as mortar on an expanded metal substructure. Overhead mounts are also possible. Densit Binder s special characteristic is made clear in connection with its additives in a pressure test, for which a Densit test cylinder is used. The additives are so tightly incorporated that they break before the Densit Binder surrounding them. The DSP technology was developed by Densit and a patent for it was first applied for in It is the basis for the ultra thick structure of Densit materials and the key to their extraordinary attributes. Cement particle, super plasticizer and water wc = DSP Technology Cement particle, super plasticizer, microsilica and water densit WearCast Densit WearCast is a material combination of high-strength binder and extremely wear-resistance additives. Densit WearCast is produced as a normal temperature material (Max. 400 C consistent temperature) and as a high temperature material (max. 1,200 C consistent temperature. Densit WearCast is produced as a casting compound for all types of cast mountings. Our Goals for You: Ultra strong materials (470 MPa) Impermeability High wear protection Shock resistance Chemical consistency High temperature resistance wc = densit WearSpray Densit WearSpray is a material combination of high-strength binder and extremely wear-resistance additives. Densit WearCast is produced as a normal temperature material (Max. 400 C consistent temperature). With Densit WearSpray, large area capacities, extreme mounting locations, short mounting times and overhead mountings are all possible. Traditional cement-based mortar after pressure resistance test Densit Material after pressure resistance test Densit Wear 500 Densit Wear 1000 Densit Wear 2000 Densit Wear 3000 Flex Spray Flex Cast Flex Spray Cast HT Flex HT Spray HT Flex Cast HT Thickness Kg/m Durability Mohs Pressure resistance MPa Bend tensile strength MPa Max. constant temperature C Wear test cm 3 /50 m CaO Chemical composition in % Sio Al 2 O 3 +TiO SIC

DENSIT Cast BASALT densit ALUMINIUM OXIDe ceramic Cast Basalt is made from special quality

The basalt is melted in shaft furnaces at 1,300 C and then poured into the desired forms.

One of the most important processes in the production of Cast Basalt is the subsequent tempering

A myriad of geometric forms are produced through compression or casting.

The raw ceramic parts are baked at about 1,500 C.

Physical attributes: Raw thickness g/cm 3 3,4-3,65 Porosity % 0 Cast Basalt: Technical data Raw

Bending strength N/mm 2 40 Temperature change resistance C 0-110 Constant temperature resistance

expansion coefficient 1/K 6-8 x 10-6 Heat conductivity W/mK 20-22 Temperature application limit C

Standard Aluminium Oxide square plates Mosaic plates vulcanized in rubber Plate thickness in mm

X X X 75 x 150 X X X Square tiles (Paper base) 75 x 100 X X X 100 x 100 X X X 150 x 100 X X X 200

4 DENSIT Cast BASALT densit ALUMINIUM OXIDe ceramic Cast Basalt is made from special quality natural basalt. The basalt is melted in shaft furnaces at 1,300 C and then poured into the desired forms. Cast Basalt is produced in form components. Essentially, this means sheets and pipe components. One of the most important processes in the production of Cast Basalt is the subsequent tempering during which the Cast Basalt forms a uniform crystalline structure that guarantees its high hardness and wear resistance. Due to its bargain price/performance ratio, Cast Basalt is a material often used in tribology protection. In addition to its wear resistance, Cast Basalt is characterized by its singular resilience with regards to almost all acids and bases. Cast Basalt surfaces remain permanently smooth and even while in use and thus offer the advantage of little caking. PRODUCTION The base product for the production of Aluminium Oxide Ceramic ist highly pure, synthetic (Alpha) Aluminum Oxide. Nowadays, due to weartechnical and economic reasons Aluminium Oxide is predominantly produced with a purity level of 85 92%. The standard quality of 90 92% has been established in the industry. A myriad of geometric forms are produced through compression or casting. Slip casting is used for extreme geometric shapes. The raw ceramic parts are baked at about 1,500 C. The ceramic parts are subsequently thick and without porosity. Physical attributes: Raw thickness g/cm 3 3,4-3,65 Porosity % 0 Cast Basalt: Technical data Raw thickness g/cm 2 2,8-2,9 Porosity % 0-3 Durability Mohs ~ 8 Pressure resistance N/mm Bending strength N/mm 2 40 Temperature change resistance C Constant temperature resistance C 350 Durability in Mohs ~ 9 Pressure resistance MPa > 3000 Bending strength MPa Length expansion coefficient 1/K 6-8 x 10-6 Heat conductivity W/mK Temperature application limit C 1500 Pipe cylinders can be delievered with an inner diamter of mm. Standard Aluminium Oxide square plates Mosaic plates vulcanized in rubber Plate thickness in mm 1, x x 20 Rubber thickness (4 mm) Square plates (20 x 20 mm) 50 x 150 X X X 75 x 150 X X X Square tiles (Paper base) 75 x 100 X X X 100 x 100 X X X 150 x 100 X X X 200 x 150 X = deliverable with hole Papier base Square tile (20 x 20 mm) Densit Cast Basalt sheets are produced in the standard size 200 x 200mm, or as a hexagon with width across flats SW 200. Lining thickness is available from 30mm. Radial sheets, special forms or custom linings can be delivered at any time Densit Cast Basalt pipe components are delivered in nominal diameters from 40mm to 600mm. As a rule, the lining thickness is 20 or 25mm. Advantages: High hardness and wear resistance Even abrasion High temperature resistance High corrosion resistance Low specific weight Custom-made lining upon request Variable lamination thicknesses from 1-50mm Plate mounting with glue, welding or bolting Cap glued Hexagon plates glued to paper Hexagon plates (Ø 20 Width across flats) Glue Base plate Glue Base plate Spot weldings Welding shell Bolt connection

DENSIT WEARPLATES densit wearplates The universally installable wear protection for extreme needs Densit WearPlates are economically produced connecting sheets made using special welding procedures

Using modern cutting techniques such as plasma, laser, or water jet cutting, Densit WearPlates can be cut into parts that are in accordance with drawings and that are malleable either warm or cold.

Standard plate thickness conbinations for all systems Base sheet in mm Buildup Welding in mm Total thickness in mm 5 3 8 6 4 10 8 4 12 10 4 14 15 4 18 8 4+4 16 10 5+5 20 15 5+5 25 Mounting systems:

Shaped sheets 4. Installable constructions Buildup construction II DSP 55 HRC Fe Si Mn Cr Durability aprox. 50 60 HRC* Temperature resistance up to 500 C DSP 60 HRC Fe C Si Mn Cr Nb Durability aprox.

5 DENSIT WEARPLATES densit wearplates The universally installable wear protection for extreme needs Densit WearPlates are economically produced connecting sheets made using special welding procedures out of a weldable base materials and a buildup welding material that has been adjusted to its intended uses. Using modern cutting techniques such as plasma, laser, or water jet cutting, Densit WearPlates can be cut into parts that are in accordance with drawings and that are malleable either warm or cold. Mounting is always possible, just like with traditional welding construction. The most popular methods are welding or bolting. Standard plate thickness conbinations for all systems Base sheet in mm Buildup Welding in mm Total thickness in mm Mounting systems: Buildup construction I Densit WearPlates are available for delivery in four forms: 1. As a standard sheet in accordance with measure ments, basic body and lining qualities 2. In custom-cut sheets 3. Shaped sheets 4. Installable constructions Buildup construction II DSP 55 HRC Fe Si Mn Cr Durability aprox HRC* Temperature resistance up to 500 C DSP 60 HRC Fe C Si Mn Cr Nb Durability aprox. 60 HRC* Temperatue resistance up to 650 C Carbide caulk of buildup welding Buildup construction III DSP 65 HRC Fe C Si Mn Cr B Durability aprox. 65 HRC* Temperature resistance up to 750 C * Durability of the pure welding material The following steels are used as basic material for our Hard Wearplates: S 235 (St 37) S 355 (St 52) Or use-specific steel qualities such as boiler plate or corrosion-resistant steels Material advantages: High shock resistance High wear resistance High thermal stability Special production application ranges: Screening sheets Coke sliders Impact tables Chutes Pneumatic conveyor systems Coal dust distributors Screw flights Fan flights Cyclones Deliveries Throat armor sheets etc. Bolt mounting with mother with internal thread Sizes of our standard sheets 2900x1800 mm 2900x1350 mm Bolt mounting using vertical boring 2400x1100 mm 1900x850 mm 900x 850 mm Service Advantages: Comprehensive experience in welding techniques Comprehensive portfolio of engineering solutions with welding techniques Bolt mounting with threaded stud

Wear-resistant pipe components densit Pipe components Densit pipe components for pneumatic and hydraulic conveying systems Pipe bends, pipes,

Densit disposes of more than 25 years of experience creating the optimal tribology protection system for you.

Pipeline components with the following linings are available: Densit materials Cast Basalt Aluminium Oxide Ceramic Buildup welding Special

Construction of wear protected pipe components Worn out pipe bend repaired out of necessity Construction also occurs beginning with the desire

Depending on the choice of wear protection lining, this results in an altered outer diameter for the pipes and the flange connections, which are

Example of system construction Normal flange connection Connection with counter flange Connection with adapter flange Material selection: Before

6 Wear-resistant pipe components densit Pipe components Densit pipe components for pneumatic and hydraulic conveying systems Pipe bends, pipes, branch pipes or similar pipeline components often number amongst the most capable wear protection systems in industrial facilities. Densit disposes of more than 25 years of experience creating the optimal tribology protection system for you. Densit offers solutions for all wear protection media. Pipeline components with the following linings are available: Densit materials Cast Basalt Aluminium Oxide Ceramic Buildup welding Special materials Densit delivers pipeline components worldwide in all industrial fields. Construction of wear protected pipe components Worn out pipe bend repaired out of necessity Construction also occurs beginning with the desire nominal diameter of the pipeline system. Depending on the choice of wear protection lining, this results in an altered outer diameter for the pipes and the flange connections, which are adjusted to fit the system. Example of system construction Normal flange connection Connection with counter flange Connection with adapter flange Material selection: Before determining the appropriate wear protection material, Densit conducts a system analysis, the goal of which is to be able to offer the customer an optimal material selection. The material selection and the design of the individual pipe components always occur based on the project and thus are always compatible with the existing pipeline system. Sheet jackets: As standard material, the pipe components are made out of steel S235JR. Straight pipes, longitudinal weld or spiral weld. Surface preparation: Manual removal of rust or blasted SA2.5 Primer coat, primer 40 µ. connections: Straight pipe, standardized based on DIN 2576, PN 10, bilateral compact flange. Pipe bend, standardized based on DIN 2642, PN 10, bilateral coil and loose flange. In addition to construction, Densit also offers all internationally used flange connections such as ASME, BS, Victaulic or Viking-Johnson connections.

Pipes with DENSIT Lining PIPES WITH CAST BASALT LINING In contrast to other wear protection materials such as cast basalt or aluminum oxide ceramic, Densit materials are not installed in the pipework

This produces advantages such as a caulk-free lining, the ability to have eccentric linings and inclusion of the tribology protection over the entire wall thickness.

Cast Basalt is poured as a semi-finished product in the form of cylinders in the desired nominal diameter, with 20mm wall thickness and 500mm component length.

Due to its high wear-resistance, Cast Basalt is used everywhere where abrasive media are transported pneumatically or hydraulically.

7 Pipes with DENSIT Lining PIPES WITH CAST BASALT LINING In contrast to other wear protection materials such as cast basalt or aluminum oxide ceramic, Densit materials are not installed in the pipework components as semi-finished products in the form of pre-assembled cylinders or sheet goods. Using a special core technology, Densit is poured cold directly into the pipe components. This produces advantages such as a caulk-free lining, the ability to have eccentric linings and inclusion of the tribology protection over the entire wall thickness. A high temperature resistance of 400 C completes the extraordinary attributes of pipework components lined with Densit. Cast Basalt is poured as a semi-finished product in the form of cylinders in the desired nominal diameter, with 20mm wall thickness and 500mm component length. Worldwide, cast basalt is the most often used wear protection material in piping systems. Due to its high wear-resistance, Cast Basalt is used everywhere where abrasive media are transported pneumatically or hydraulically. Standard measurements of Cast Basalt pipe components with flange connection PN 10 (other measurements or pressure level are always available) Ø Ø Ø Thickness Ø Amount Ø Ø Thickness Nominal diameter pipe Pipe bend NW Bolt circle Bores Bores Coil Coil Advantages of Densit Pipe Components: High wear resistance Caulk-free lining Eccentric linings Tribology protection over the entire wall thickness Temperature resistance 400 C Bargain price/performance ratio Standard measurements for Densit pipe componenets with flange connection PN 10 (other measurements or pressure levels available at any time) Ø Ø Ø Thickness Ø Amount Ø Ø Thickness Nominal diameter Pipe Pipe bend NW Bolt circle Bores Bores Coil Coil ,3 114, ,7 139, ,3 168, ,7 193, ,1 219, ,5 244, ,5 298, ,9 323, ,6 355, , ,7 152, , , , , , , Custom-fit radial mould lining is delivered for larger pipe diameters. Application for the pneumatic or hydraulic transport of: Coal dust Flue ash Cement Sand Calcium Coke Ore Plaster Splints Pneumatic stowing Other abrasive media

PIPES WITH ALUMINIUM OXIDE CERAMIC LINING Aluminium Oxide Ceramic, as the hardest

pipeline systems are extreme. We close the circle of services for our customer!

often lead to high wear rates, for which only the application of aluminum oxide

Even thin lining thicknesses result in increased durability.

cylinders or as sheet goods in various lining strengths in the piping components.

weight High durability Installation Maintenance and Support Site Measure PIPES

WearPlates are effective in all respects as universally mountable wear protection

In the past, pipework components had to be formed from iron sheets and

Today, thanks to state-of-the-art robot technology Densit is able to directly

Standard measurements for pipes with building up welding Shipping Fabrication Ø Ø

bend Sheet Buildup NW Bolt circle Bores Bores Coil Coil 100 121 121 7,1 3,4 100

16 210 8 18 188 15 150 168,3 168,3 5,6 3,35 150 285 16 240 8 22 212 17 175 193,7

8 22 268 18 250 273 273 8 3,5 250 395 19 350 12 22 320 18 300 323,9 323,9 6,35

8 PIPES WITH ALUMINIUM OXIDE CERAMIC LINING Aluminium Oxide Ceramic, as the hardest available wear protection material, is often used if the basic conditions in the pipeline systems are extreme. We close the circle of services for our customer! High delivery rate and speeds, powerful closing pumping media and tight wiring often lead to high wear rates, for which only the application of aluminum oxide ceramic leads an appropriate durability for the pipework. Even thin lining thicknesses result in increased durability. Aluminum Oxide Ceramic is mounted as a semi-finished product in the form of pipe cylinders or as sheet goods in various lining strengths in the piping components. Advantages: Extremely wear-resistant Variable lining thicknesses Low installation weight High durability Installation Maintenance and Support Site Measure PIPES WITH BUILDUP WELDING Design and drafting Buildup welding systems such as Densit WearPlates are effective in all respects as universally mountable wear protection even for extreme demands. In the past, pipework components had to be formed from iron sheets and painstakingly welded together in segments. Today, thanks to state-of-the-art robot technology Densit is able to directly provide pipes and pipe bends with buildup welding both inside and outside. Standard measurements for pipes with building up welding Shipping Fabrication Ø Ø Ø Ø Amount Ø Ø Thickness Thickness Thickness Thickness Noninal diameter Pipe Pipe bend Sheet Buildup NW Bolt circle Bores Bores Coil Coil ,1 3, Protective coatings Lining ,7 139,7 4 3, ,3 168,3 5,6 3, ,7 193,7 5,6 3, ,1 219,1 6,3 3, , ,9 323,9 6,35 3, ,6 355,6 6,35 3, ,4 406,4 6,35 3, ,2 457,2 6,35 3, ,35 3,

9 Densit ApS Gasværksvej 46 DK-9000 Aalborg Tel.: Fax: Internet: Project Office Densit Germany Fritz-Peters-Str. 40 D Moers Tel.: Fax: Internet: Component Fabrication Densit Germany Saalhoffer Str. 17 D Rheinberg Tel.: Fax: Internet:

For over 30 years, CeraWear Systems has been successfully producing and distributing technical ceramics for the most varied applications.

For over 30 years, CeraWear Systems has been successfully producing and distributing technical ceramics for the most varied applications. CERAWEAR Systems Your competent partner for industrial wear and corrosion protection solutions. Individual and competent development, production and installation of wear protection systems made of high-performance