In this Issue:
- Stellar Materials Makes Significant Improvements to Phoscrete 601 P
- Thermbond Tips: How to Mix Partial Units of Thermbond
- Happy Thanksgiving from Stellar!
- Application Report: Premier UAE Primary Smelter, Casting
Plant Manager of Aluminum Foundry in Texas
"Have used Thermbond for 2 years now to patch our 2 aluminum remelt furnaces. We have found that using Thermbond 4-P for patching below the metal line and Thermbond 5-P above the metal line bonds and holds up longer than any other materials used in the past for patching"
Stellar Materials Makes Significant Improvements to Phoscrete 601-P
Stellar Materials Incorporated, manufacturers of Thermbond Refractories and Phoscrete Concretes made significant improvements to one of their Phoscrete products, for applications in concrete renewal. See pictures below for examples of applications.
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After Repair |
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After Repair |
Phoscrete 601-P is a patch product developed to handle the difficult vertical and overhead applications that are normally found on surface transportation bridge columns and beams. This product was developed for use in ambient condition applications only. The industry considers it a major material breakthrough in its daily struggles to restore deteriorating concrete surfaces. It has undergone significant changes which have tremendously improved the characteristics and performance of this formula. The strength has almost doubled and the working time is longer, both great advantages for a patching material. Phoscrete 601-P has a wet to dry ratio of 15 percent and a working time of up to 25 minutes.
Standard lab testing has been done as with all Thermbond and Phoscrete Products.
Account Representative, Dennis Buckshaw talks about the initial testing, “Several weeks ago Jens Decker, Stellar’s Vice President of Engineering, called me to our material test room with a smile on his face and a trowel filled with what turned out to be a major improvement to our Phoscrete 601-P. I watched as Jens easily took the trowel and applied the new mix to existing test material over head. Within less than a minute Jens removed the trowel and the improved Phoscrete 601-P defied gravity and remained in place. With our old formula it was a bit of a struggle to keep the material in place on over head applications. This mix is much more user-friendly.
“The new formula has superior adhesive and early bond strengths which greatly enhance the 'grip/cling' power of Phoscrete 601-P. Simply put, it stays in place.
“In addition, the new formula allows Phoscrete 601-P to be used in all seasons and in all climates. It is now classified as a non-seasonal material."
The updated Technical Data Sheet has been posted on our website.
Mechanical Engineer of Petrochemical Facility in the Gulf Coast
"Thermbrake 403G and Formula 18G was installed in a boiler that had to be back in service in two days. The call went out to Stellar on the weekend and the material was delivered on time. Because of eliminating dry out we finished the job on time. We will look for other areas to use Thermbond."
Thermbond Tips: How to Mix Partial Units of Thermbond
Mixing partial units of Thermbond products requires some special procedures to make sure that any settling of ingredients that may have occurred in the bags does not affect the results. Following these instructions will insure an homogenous mix and a quality product.
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When mixing partial units, dry mix the bag prior to weighing out the required amount of dry material.
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When mixing partial units, agitate the entire jug prior to weighing out the liquid. Use the wet-to-dry ratios specified on the individual product data sheets. These percentages should be calculated as a percentage of the dry material. For instance, if the wet-to-dry ratio is 19%, then for every 10 lbs of dry mix, use 1.90 lbs of Formula Series Activator.
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Always mix the dry material into the Liquid Activator, never the reverse.
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The material should be completely wetted-out within one minute after you begin mixing. If your mixer is not mixing the material at least this quickly, then use a Hobart- type mixer set on slow speed, or a heavy duty drill motor (at least 7 amps) with a Jiffler-type paddle blade.
The above information can be found in our Thermbond Installation Guide.
Testimonial from a Customer in the Petrochemical Industry, in the Gulf Coast:
"Thermbond has really helped when we want to start up quickly. It typically takes about an entire day out of the dry-out procedure. Depending on the unit, an extra day of downtime could be very costly."
Happy Thanksgiving from Stellar Materials
Can you believe it? It is that time of year once again! With the Holidays fast approaching we want to take this time and say Thank You! It is with great joy that we extend our sincere gratitude to you wonderful people that make our business possible. We have so much to be thankful for; we are especially grateful for our good friends and customers that help our business grow and succeed. It is truly a pleasure working with you. As we celebrate the Thanksgiving holiday here in the US, we offer our warmest wishes to all our friends and business partners worldwide. Enjoy this beautiful season!
Thank you and Happy Thanksgiving!
Stellar Materials Incorporated
Testimonial from a Customer in the Power Generation Industry, in Southern California:
"We like the fact that Thermbond does not need any outside heat source to attain good strengths. We would normally have to completely replace the top 2 to 3 feet of the ash hopper in each unit every other year. When we switched to Thermbond in most cases we only needed to flash over the top 2 to 3 feet. This has saved us a lot of time and money by not having to tear out and replace the refractory over and over again."
Application Report
Industry: Aluminum Industry in the Middle East
Description of Equipment: 70 MT Melting Furnace
Problem: Heavy erosion on lintels, side jambs, sills, side walls, roof and burner throat
Solution: Cast and gun a variety of Thermbond products over existing conventional refractory
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Damaged burner throat before being repaired with
Thermbond. |
Lintel and roof cleaned and ready to be repaired with
Thermbond formula 5L and Thermbond formula 6AG. |
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Repaired burner throat and upper side wall. |
Thermbond Installation in Premier Aluminum smelter. |
Product Being Replaced: Conventional low cement castables
Savings Using Thermbond: Because Thermbond bonds to existing fired refractories and can be fired in very rapidly, the customer reduced downtime in a number of ways. The majority of the existing lining remained in place and only needed to be cleaned and chipped back to good refractory. Many hours were saved by not having to tear out the lining. In addition Thermbond could be fired in much faster than conventional refractories allowing the furnace to be brought back online sooner.
Products Applied: Formula 5 L to repair the lintels, jambs and burner throat. Formula 2104 L cast on the sill, Formula 6 L for the door, gunned Formula 6 AG on the roof and side walls above the melt line.
Method of Installation: Casting and Gunning
Scope of Work: Cast 100 mm of Thermbond on the burner throat, 200 mm on the jambs, 220 mm on the sill and 120 mm on the lintel. Gunned 60 mm of Thermbond on the roof and 25 mm on the upper side walls. Cast 175 mm on the door.
Installation Date: October 2008
Follow Up: Inspection planned for February 2009
If you would like additional information regarding this application report, please contact Stellar's Middle East Sales Manager, PM Sundaram @: Mobile: +971506891327 , Email: pm.sundaram@thermbond.com
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Stellar Materials Incorporated is a privately-held corporation headquartered in Boca Raton, FL with manufacturing facilities in Whitmore Lake, MI, stocking warehouses worldwide, and wholly-owned subsidiaries in Rotterdam, NL and Abu Dhabi, UAE. |
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Stellar Materials Incorporated
7777 Glades Road, Suite 200
Boca Raton, Florida 33434
USA
(561) 330-9300 |
Stellar Materials International, LLC
Nieuw Mathenesserstraat 39 - 41 Unit 1 B
3029 AV Rotterdam
The Netherlands
+31 (10) 2460264 |
Stellar Materials M.E. FZE
P.O.Box No 10559
Ras Al Khaimah
United Arab Emirates
+971506891327 |
Thermbond and Phoscrete are registered trademarks of Stellar Materials Incorporated.
Copyright 2008 Stellar Materials Incorporated. All Rights Reserved.
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