The abrasion has caused substantial damages and losses in many fields of the industry. Usually, such damages are reduced by the application of wear resistant materials of metallic or non-metallic origin. We supply several industries with fused cast refractories. We have recognized the importance of the prevention against abrasion and developed a family of wear resistant products named ZIRKOSIT-K. ZIRKOSIT-K is a hard, corundum-baddeleyite based wear resistant material of dense structure and high compression strength. According to grinding abrasion tests the abrasion resistance of the ZIRKOSIT-K products is 3 to 10 times higher than that of fused cast basalt shapes and 10 to 15 times higher than that of alloyed steel shapes. Due to their chemical composition and physical structure, heat resistance and warm abrasion resistance of ZIRKOSIT-K shapes are excellent. By its application, maintenance costs can be considerably reduced in areas where big volumes of abrasive materials slide, flow or collide.

Standardized wear resistant tiles

A great number of shapes and blocks were standardized by us. These shapes may offer economic advantages in case of most surfaces to be protected by lining against abrasion.
Another advantage derived from standardization is the reduction of stocks in the warehouse of both the producer and the user, furthermore, shorter delivery times can be achieved.
However, depending on the equipment to be lined, it may be necessary to install shapes, the dimensions of which differ from standard ones. Within the limits of productibility, we undertake to produce - relying on the drawings submitted by the buyer - flat and arched shapes, as well as cutting to size of the same with the use of diamond-based tools. Resulting from the properties of fused cast blocks, the thickness of ZIRKOSIT-K products can not be less than 20 mm.

ZIRKOSIT-K tiles - as any other fused cast products - are rigid, consequently, their installation requires great attention. The operating temperature is a decisive factor when the appropriate embedding material is to be selected. It has been found that the different types of resins and adhesives as well as the usual cement mortar can be applied up to temperatures between 100 to 150 °C The bond between cement mortar and the shapes can be improved if resin is previously applied and sand is blasted to the side of the wear resistant tiles which will face the wall covered by cement mortar. In case of higher temperatures heat-resistant mortars should be applied. In steep-walled steel bunkers it is expedient to attach a layer of undulated wire-texture by welding in order to assure better adhesion of the mortar.
In case of even higher working temperatures, it is necessary to allow for dilatation spaces in every direction between the ZIRKOSIT-K tiles. The width of these spaces shall be determined using the heat-dilatation diagram. In equipment, operating at high temperatures, the change of temperature on the ZIRKOSIT-K tiles may be max. 60 °C/hour.
For the lining of surfaces steeper than 75°, bored wear resistant tiles are used. The bored ZIRKOSIT-K blocks are mounted by screws, using previously inserted washers. In the course of installation, some resilient material of min. 4 mm thickness has to be laid between the steel plate and the wear resistant tiles.
This resilient material may be of rubber or - if the working temperature exceeds 100 °C - of some sort of elastic, inorganic fibrous texture. When the fused cast wear resistant tiles are actually fixed, their rigid cracking can be avoided if the screw nuts are tightened by a torque wrench at a max. of 40 Nm.
Following the attachment the remaining hole above the nut shall be filled up with wear resistant or - at high working temperatures - refractory mortar.

The bored ZIRKOSIT-K tiles can be attached also to concrete walls if nails (threaded at their end that remains outside) are shot into the concrete wall, and afterwards, the wear resistant tiles are fixed to them using screws with shoulder. This method can be applied if the wall is flat and smooth.
If so required, we are ready to supply the ZIRKOSIT-K tiles with pre-set screws instead of bores or with a steel setting insert if the tiles should be installed by welding.

Wear resistant tube linings

When abrasive materials are transported in pipelines by pneumatic or hydraulic method, mainly the bended sections and their adjoining straight sections are exposed to abrasion. The lifetime of the entire pipeline can be substantially elongated if these sections are lined with ZIRKOSIT-K pipe shapes.
For safety reasons, however, the ZIRKOSIT-K tiles must not be installed and used by themselves but only mantled with steel pipes. When installed, the gap between the steel pipe and the ZIRKOSIT-K lining should be filled with cement mortar made of fine-grain sand. During the curing time, the pipes should be kept in vertical position and special care should be taken to assure concentricity of the ZIRKOSIT-K pipe-shapes. The pipes must not be tilted or moved before total binding of the mortar. The denotation "NA" in the table indicates the internal diameter of the steel pipe.

Other wear resistant product

In addition to the standardized blocks and pipes, we produce also other types of ZIRKOSIT-K shapes of different form, e.g. shapes of bigger size, pipes with brim or of Y-shapes, cyclon-cones, grinding balls, pump inserts, etc.
These types of blocks are suitable for the protection of bunkers, chutes and hoppers used for transport of coal and coke, furthermore of troughs, silos, mixing equipment, dust precipitators, power plant flue-gas channels, grinding mill's lining, flotation equipment, etc.
If so required, we are ready to pre-assemble - according to technical drwings - the appropriate surface from ZIRKOSIT-K shapes and provide the adjacent parts with special marking. Thus, no dimensional problems may occur during the on-site installation and the construction works can be expedited. In case of placing an order for a full-range protection against abrasion of a complete equipment, then we undertake to arrange for the adequate design, production and pre-assembly of the abrasion resistant shapes.

Our experts provide consultation concerning the installation of our ZIRKOSIT-K shapes.