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Case Study: Thermbond Formula 28-S
New Product: Thermbond Formula 2104-E
Happy Thanksgiving from Stellar Materials!
Application Report: Crematory Repair
Testimonial from a Secondary Aluminum Maintenance Manager:
"My experiences with Thermbond Formulas 2104-L, 2104-A and 2104-G have all been good. These products saved us time getting a furnace back in production because of the fast dry out time and extending its life."
Case Study: Thermbond Formula 28-S
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Before coating of 28-S |
After coating of 28-S |
This is an application for coating an aluminum melting furnace door. The customer’s large fiber lined furnace door measures 26 feet long by 7 feet high and is susceptible to damage from molten metal splash.
Aluminum splashed on the furnace sill sticks to the insulating fiber on the furnace door. Every time the furnace door is opened a little, fiber is torn off the furnace door. Over time, most of the fiber on the lower 12” of the furnace door is lost.
The solution was to spray Thermbond Formula 28-S coating onto the new fiber insulation on the furnace door. Because Formula 28-S is a heat set product, the coating was applied just prior to dry out of the furnace. Formula 28-S creates a protective non-wetting coating over the fiber insulation.
The customer expects to save approximately $15,000 per year by applying Thermbond Formula 28-S coatings to one furnace door.
Testimonial from a Secondary Aluminum Maintenance Manager:
"I have used Thermbond Formula 2104 to repair walls, floors and ramps with great success. I cast a complete ramp with 2104-L to extend the life until we could schedule an outage to make proper repairs. Because of the condition of the 2104-L ramp upon inspection, we decided not to replace the ramp during the outage. This ramp lasted for over one year."
New Product Thermbond Formula 2104-E
Stellar Materials Incorporated, manufacturers of Thermbond Refractories developed a new product for the Aluminum Industry, Thermbond Formula 2104-E.
A contractor working with Formula 2104-L requested an extended set time because larger pours in hot, ambient conditions can result in insufficient working time. This product was developed to address that issue.
At 75°F/22°C Thermbond Formula 2104-L has 35-45 minutes of working time while Formula 2104-E has approximately 90 minutes of working time. Other than this difference, 2104-E is very similar to 2104-L. The abrasion resistance is excellent, testing at less than 4cc.
This product is recommended for higher wear applications in aluminum furnaces, predominantly below the metal line. It is non wetting and can be used for sills, ramps, lower side walls and floors.
Thermbond Formula 2104-E is currently available for installations requiring extra working time. If you are interested in using Formula 2104-E please contact your local Thermbond sales representative, strategic partner, or email jeff.pchola@thermbond.com.
The technical data sheet is now posted on our website.
Testimonial from a Foundry Manager in an Aluminum Die Casting Plant:
"I have recently been experimenting with a Thermbond 4-P patch material, using it for repairs to my launder system. Our launder system is 121 sections long or a 1/4 of mile long, one of the longest if not the longest in North America. I have been extremely pleased with the results of the 4-P patch material. It has been going on almost a year when I fist used the 4-P and the patch areas are still holding up very well. This material is very easy to mix and apply; I am most impressed with the quick set time."
Happy Thanksgiving!
It's that time of year again! The Holidays are right around the corner, and Stellar Materials extends our warmest wishes to you and yours for a very Happy Holiday Season!
Now is the time when we all take a moment to reflect upon the important things in our lives, and you top our list! To all of our dear friends worldwide who contribute to the growth of our business, Thank You!
We have so much to be thankful for, and we sincerely appreciate our relationship with each and every one of you. Enjoy this magnificent Holiday season and know that we are sending good thoughts your way.
Happy Thanksgiving from all your friends at Stellar Materials!
Testimonial from a Foundry Manger in an Aluminum Die Casting Plant:
"Although this material is a little more expensive than some others, I personally prefer the Thermbond, I do not typically recommend one material over another but the results speak for itself, this is an exceptional product that I would recommend to anyone."
Application Report
Industry: Crematory
Description of Equipment: Human crematory operating between 1,800°F (1000°C) and 2,000°F (1100°C).
Problem: The cremator refractory floor wears in the center from raking the remains out of the furnace after each processed case. When the worn area of the floor gets too deep, the furnace must be to shut down for several days to tear out, reline, and heat the furnace back up. Depending on caseload, minimizing downtime is critical.
Solution: Instead of tearing out all the existing refractory and replacing with conventional refractories which would require a lengthy dry out, use Thermbond to veneer over remaining conventional refractory, and save time.
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1. Cut around worn refractory.
2. Chip out refractory within the cut area.
3. Cast Thermbond Formula 9-L |
Product Replaced: Conventional 60% alumina castable refractory
Product Used: Thermbond Formula 9-L
Method of Installation: Cast
Equipment Used: Circular diamond blade cutting saw, pneumatic chipping hammer, portable electric hand mixer, and compressor.
Scope of Work: A saw cut was made around the perimeter of the worn refractory and a chipping hammer was used to remove worn refractory to a depth of two to three inches. Using buckets, vibrators, and trowels, Thermbond Formula 9-L was cast and vibrated into place. The complete installation took four hours and the furnace was put under heat by afternoon.
Installation Date: May 2009
Follow Up: November 2009 - the crematory floor did not show any wear and the customer is extremely pleased with the results.
To view this application report in a printable format, please click here.
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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., and Mongaguá -SP Brasil. |
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 |
Stellar Materials do Brasil
Avenida São Paulo
1380 sala 07 - Centro
Mongaguá - SP Brasil
11730-000
+55-13-3448-6516 |
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Thermbond and Phoscrete are registered trademarks of Stellar Materials Incorporated.
Copyright 2009 Stellar Materials Incorporated. All Rights Reserved.
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Last modified at 11/25/2009 2:07 PM by Ashley Garcia
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