Compare the properties of the entire ITW Densit® product line. The categories are: Density, Compressive Strength, Fluxural Strength, Dynamic E-Modul, Cast Shrinkage, Thermal Conductivity, Coefficiant of Thermal Expansion, Heat capacity, Maximum Service Temperature, Shrinkage after firing, Abrasion Resistance, Erosion Resistance, Chemical Composition, Bag Size and Pallet Size.
Wear-Con Densit® WearFlex™ 2000 Chemically Bonded Corundum-Ceramic wear resistant lining is a trowellable, one-component ready-mix wear compound combined with wear-resistant aggregates to provide a tough and long-lasting wear solution. WearFlex™ 2000 is applied directly to an anchoring mesh in thicknesses from 3/4” to 2”, providing seamless graduation in lining thicknesses on almost any shape without vulnerable joints. Fast and easy to install, even overhead, WearFlex™ 2000 can be used after just 24 hours.
Wear-Con Densit® WearFlex™ 2000 can be installed in five simple steps:
Wear-Con Densit® WearFlex™ 2000 is a high-strength wear compound combined with corundum aggregates to provide excellent protection against severe erosive wear at temperatures up to 750°F (see reverse for more technical data).
Wear-Con Densit® WearFlex™ 2000 is delivered in 55 lb bags.
Wear-Con Densit® WearFlex™ 2000HT High-Temp Chemically Bonded Corundum-Ceramic wear resistant lining is a trowellable, one-component ready-mix wear compound combined with wear-resistant aggregates to provide a tough and long-lasting wear solution in extreme heat situations. WearFlex™ 2000HT is applied directly to an anchoring mesh in thicknesses from 3/4” to 2”, providing seamless graduation in lining thicknesses on almost any shape without vulnerable joints. Fast and easy to install, even overhead, WearFlex™ 2000HT can be used after just 24 hours.
Wear-Con Densit® WearFlex™ 2000HT can be installed in five simple steps:
Wear-Con Densit® WearFlex™ 2000HT is a high-strength wear compound combined with corundum aggregates to provide excellent protection against severe erosive wear in extreme temperatures up to 2190°F.
Wear-Con Densit® WearFlex™ 2000HT is delivered in 55 lb bags.
Wear-Con Densit® WearFlex™ 1000 Chemically Bonded Bauxite-Ceramic wear resistant lining is a trowellable, one-component ready-mix wear compound combined with wear resistant aggregates to provide a tough and long-lasting wear solution. WearFlex™ 1000 is applied directly to an anchoring mesh in thicknesses from 3/4” to 2”, providing seamless graduation in lining thicknesses on almost any shape without vulnerable joints. Fast and easy to install, even overhead, WearFlex™ 1000 can be used after just 24 hours.
Wear-Con Densit® WearFlex™ 1000 can be installed in five simple steps:
Wear-Con Densit® WearFlex™ 1000 is a high-strength wear compound combined with bauxite aggregates to provide excellent protection against severe erosive wear at temperatures up to 750°F.
Wear-Con Densit® WearFlex™ 1000 is delivered in 55 lb bags.
Wear-Con Densit® WearFlex™ 1000HT High-Temp Chemically Bonded Bauxite- Ceramic wear resistant lining is a trowellable, one-component ready-mix wear compound combined with wear-resistant aggregates to provide a tough and long-lasting wear solution in extreme heat situations. WearFlex™ 1000HT is applied directly to an anchoring mesh in thicknesses from 3/4” to 2”, providing seamless graduation in lining thicknesses on almost any shape without vulnerable joints. Fast and easy to install, even overhead, WearFlex™ 1000HT can be used after just 24 hours.
Wear-Con Densit® WearFlex™ 1000HT can be installed in five simple steps:
Wear-Con Densit® WearFlex™ 1000HT is a high-strength wear compound combined with bauxite aggregates to provide excellent protection against severe erosive wear in extreme temperatures up to 2190°F.
Wear-Con Densit® WearFlex™ 1000HT is delivered in 55 lb bags.
Wear-Con Densit® WearFlex™ 3000 Chemically Bonded Silicium-Carbide-Ceramic wear resistant lining is a trowellable, one-component ready-mix wear compound combined with wear-resistant aggregates to provide a tough and long-lasting wear solution. WearFlex™ 3000 is applied directly to an anchoring mesh in thicknesses from 3/4” to 2”, providing seamless graduation in lining thicknesses on almost any shape without vulnerable joints. Fast and easy to install, even overhead, WearFlex™ 3000 can be used after just 24 hours.
Wear-Con Densit® WearFlex™ 3000 can be installed in five simple steps:
Wear-Con Densit® WearFlex™ 3000 is a high-strength wear compound combined with silicium-carbide aggregates to provide superior protection against severe erosive wear at temperatures up to 750°F.
Wear-Con Densit® WearFlex™ 3000 is delivered in 55 lb bags.
Wear-Con Densit® WearFlex™ 500 Chemically Bonded Quartz-Ceramic wear resistant lining is a trowellable, one-component ready-mix wear compound combined with wear resistant aggregates to provide a tough and long-lasting wear solution. WearFlex™ 500 is applied directly to an anchoring mesh in thicknesses from 3/4” to 2”, providing seamless graduation in lining thicknesses on almost any shape without vulnerable joints. Fast and easy to install, even overhead, WearFlex™ 500 can be used after just 24 hours.
Wear-Con Densit® WearFlex™ 500 can be installed in five simple steps:
Wear-Con Densit® WearFlex™ 500 is a high-strength wear compound combined with quartz aggregates to provide excellent protection against moderate wear at temperatures up to 750°F.
Wear-Con Densit® WearFlex™ 500 is delivered in 55 lb bags.
Wear-Con Densit® WearSpray™ 2000 Chemically Bonded Corundum-Ceramic wear resistant lining is a sprayable, trowellable one-component ready-mix wear compound, allowing for fast monolithic coverage over large surface areas and system components with complex geometric shapes. Along with the flexibility of multi-dimensional coverage with seamless thickness graduation, WearSpray™ 2000 is fast and easy to install and can be used after just 24 hours.
Wear-Con Densit® WearSpray™ 2000 can be installed in five simple steps:
Wear-Con Densit® WearSpray™ 2000 is a high-strength wear compound combined with corundum aggregates to provide excellent protection against moderate wear at temperatures up to 750°F
Wear-Con Densit® WearSpray™ 2000 is delivered in 55 lb bags.
Wear-Con Densit® WearSpray™ 500 Chemically Bonded Quartz-Ceramic wear resistant lining is a sprayable, trowellable one-component ready-mix wear compound, allowing for fast monolithic coverage over large surface areas and system components with complex geometric shapes. Along with the flexibility of multi-dimensional coverage with seamless thickness graduation, WearSpray™ 500 is fast and easy to install and can be used after just 24 hours.
Wear-Con Densit® WearSpray™ 500 can be installed in five simple steps:
Wear-Con Densit® WearSpray™ 500 is a high-strength wear compound combined with quartz aggregates to provide excellent protection against moderate wear at temperatures up to 750°F.
Wear-Con Densit® WearSpray™ 500 is delivered in 55 lb bags.
Wear-Con Densit® WearCast™ 2000 Chemically Bonded Corundum-Ceramic wear resistant lining is a castable, trowellable one-component ready-mix wear compound, able to conform to almost any shape and size specification. Frequently used to line pipes, bends, and other system components, WearCast™ 2000 is fast and easy to install and can be used after just 24 hours.
Wear-Con Densit® WearCast™ 2000 can be installed in five simple steps:
Wear-Con Densit® WearCast™ 2000 is a high-strength wear compound combined with corundum aggregates to provide excellent protection against severe wear at temperatures up to 750°F.
Wear-Con Densit® WearCast™ 2000 is delivered in 55 lb bags.
Wear-Con Densit® WearCast™ 2000HT Chemically Bonded Corundum-Ceramic wear resistant lining is a castable, trowellable one-component ready-mix wear compound, able to conform to almost any shape and size specification, even in extreme temperatures. Frequently used to line pipes, bends, and other system components, WearCast™ 2000HT is fast and easy to install and can be used after just 24 hours.
Wear-Con Densit® WearCast™ 2000HT can be installed in five simple steps:
Wear-Con Densit® WearCast™ 2000HT is a high-strength wear compound combined with corundum aggregates to provide excellent protection against severe wear in extreme temperatures up to 2190°F.
Wear-Con Densit® WearCast™ 2000HT is delivered in 55 lb bags.
Wear-Con Densit® WearCast™ 1000 Chemically Bonded Bauxite-Ceramic wear resistant lining is a castable, trowellable one-component ready-mix wear compound, able to conform to almost any shape and size specification. Frequently used to line pipes, bends, and other system components, WearCast™ 1000 is fast and easy to install and can be used after just 24 hours.
Wear-Con Densit® WearCast™ 1000 can be installed in five simple steps:
Wear-Con Densit® WearCast™ 1000 is a high-strength wear compound combined with bauxite aggregates to provide excellent protection against severe wear at temperatures up to 750°F.
Wear-Con Densit® WearCast™ 1000 is delivered in 55 lb bags.
Wear-Con Densit® WearCast™ 3000 Chemically Bonded Silicum-Carbide-Ceramic wear resistant lining is a castable, trowellable one-component ready-mix wear compound, able to conform to almost any shape and size specification. Frequently used to line pipes, bends, and other system components, WearCast™ 3000 is fast and easy to install and can be used after just 24 hours.
Wear-Con Densit® WearCast™ 3000 can be installed in five simple steps:
Wear-Con Densit® WearCast™ 3000 is a high-strength wear compound combined with silicum-carbide aggregates to provide ultimate protection against severe wear at temperatures up to 750°F.
Wear-Con Densit® WearCast™ 3000 is delivered in 55 lb bags.
Wear-Con Densit® WearCast™ 500 Chemically Bonded Quartz-Ceramic wear resistant lining is a castable, trowellable one-component ready-mix wear compound, able to conform to almost any shape and size specification. Frequently used to line pipes, bends, and other system components, WearCast™ 500 is fast and easy to install and can be used after just 24 hours.
Wear-Con Densit® WearCast™ 500 can be installed in five simple steps:
Wear-Con Densit® WearCast™ 500 is a high-strength wear compound combined with quartz aggregates to provide excellent protection against moderate wear at temperatures up to 750°F
Wear-Con Densit® WearCast™ 500 is delivered in 55 lb bags.
Densit® Coat Q25 is a shrinkage compensated high performance concrete with extreme capability to bind to old as well as new concrete surfaces. Densit® Coat Q25 provides an impermeable barrier that effectively prevents penetration of chlorides. Densit® Coat Q25 is especially suitable for patching of spalled concrete and resurfacing of damaged concrete. Densit® Coat Q25 is applied in 5-40 mm thickness by use of wet spraying equipment on vertical as well as horizontal surfaces, - even over-head on horizontal surfaces. (For lining thicker than 40mm anchoring and mesh must be used.) Densit® Coat Q25 can be glazed or covered with Densit® Coat Q5.
Wear-Con Densit® Coat Q25™ can be installed in five steps:
Densit® Coat Q5 is a thin topcoat to be used for concrete repair jobs. The primary types of applications are as spraying mortar for top coat repair of big continuous areas. Densit® Coat Q5 is shrinkage compensated high performance concrete with extreme capability to bind to old as well as new concrete surfaces. Densit® Coat Q5 provides an absolute barrier that effectively prevents penetration of chlorides. Densit® Coat Q5 is applied in 3-8 mm thickness by use of wet spraying equipment on vertical as well as horizontal surfaces, - even over-head on horizontal surfaces. Without any post treatment the surface will appear rustic concrete-grey with an orange skin texture.
Wear-Con Densit® Coat Q5™ can be installed in five steps:
Concrete silos spalling due to age and weather has become a huge problem. Conventional patching has only proven to be temporary at best. There has been no solution...until now. Wear-Con & Densit® have the solution. Q25™ is a shrinkage compensated high performance concrete with an extreme capability to bind to old, as well as new, concrete surfaces. Q25™ provides an impermeable barrier that effectively prevents penetration of chlorides and moisture. (For lining thicker than 40mm anchoring and mesh must be used.)
First the surface to be repaired is thourghly cleaned and the old rebar is primed. Extra vertical rebar is welded into place if the spalding is deep. Heavy expanded metal reinforcement mesh is welded on the new vertical rebar. This mesh is what gives Q25™ its support while being sprayed and while curing for lining thicker than 40mm. Thickness of Q25™ is critical in the application. The the mesh has to be positioned properly. Measurements are taken to ensure the final product will be correct.
The entire prepped area is soaked down with water to ensure a proper bond. Densit® Q25™ dry mortar is mixed with water in a batch mixer. When ready, the mortar is pumped to the spraying nozzle. Even and consistent spray application is used ensuring that no voids exist behind the mesh. Densit® Q25™ is applied in 5-40 mm thickness by use of wet spraying equipment on vertical as well as horizontal and even over-head surfaces. (For lining thicker than 40mm anchoring and mesh must be used.) Spraying continues until all mesh is covered completely. Densit® Q5™ is a thin topcoat applied over Q25™. Q5™ provides an absolute barrier that effectively prevents penetration of chlorides and moisture. Densit® Q5™ is applied in 3-8 mm thickness and is oversprayed past the Q25™ layer.
Wear-Con Densit® Curing Compound is a surface sealer that is applied to all Densit® wear protection products after installation to retain water in the lining throughout the curing period. It reduces shrinkage and thus also the risk of poor bonding and minimize crack formation. The Densit® Curing Compound must be applied as a uniform coating after surface preparation has been achieved. It will dry in approximately 4 hours depending on the temperature and moisture of the atmosphere.
The Wear-Con Densit® Mixer is specifically designed to mix Densit® WearFlex to the perfect consistency in the least amount of time. This makes the Wear-Con Densit® Mixer the most cost effective method of preparing WearFlex for application.
The Wear-Con Densit® Mixer is easy to operate. We will thoroughly instruct you how to use it.
Wear-Con Densit® Curing Compound is a surface sealer that is applied to all Densit® wear protection products after installation to retain water in the wear-resistant lining throughout the curing period. It reduces plastic shrinkage and thus also the risk of poor bonding and minimize crack formation.
Wear-Con Densit® Curing Compound is a “ready to use” water-based white liquid and is applied using a sprayer with an atomizing spray nozzle. The Densit® Curing Compound must be applied as a uniform coating after surface preparation has been achieved. It will dry in approximately 4 hours dependent on temperature and moisture of the atmosphere.
Wear-Con Densit® Curing Compound’s active component is paraffin wax, appearing as a white liquid and it has no odor. Density g/m3 (lb/in3) 0.97 (0.035). Storage temperature °C (°F) 5-25 (41-77). Maximum storage time is 12 months. Efficiency (ASTM c 156) % Approximately 90.
Wear-Con Densit® Curing Compound is delivered in 30, 190 and 900 kg.
Densit® WearCast 2000™ is the same as WearFlex 2000™ and WearSpray 2000™ in every way except that it is castable and is able to conform to almost any shape and size specification such as pipes, bends, and other system components.
Densit® WearFlex™, WearSpray™, and WearCast™ are also available in three other formulas: 500 Quartz Ceramic, 1000 Bauxite Ceramic, and 3000 Silicium Carbide Ceramic. The 2000 Corundum Ceramic has traditionally been the most effective Densit® Wear solution for the North American continent. Densit® is also available in a high temp formula. Wear-Con Densit® WearFlex 2000™, WearSpray 2000™, and WearCast 2000™ are all come packaged in 55 lb bags.
Cyclones are used in so many industries—from grain processing, to cement to coal burning power plants to everything in between. Cyclones come in a lot of different sizes and shapes and can be found performing a variety of tasks. Regardless of the industry, they all have one thing in common...wear.
Cyclones are used in so many industries—from grain processing to cement to coal burning power plants to everything in between. Cyclones come in a lot of different sizes and shapes and can be found performing a variety of tasks. Regardless of the industry, they all have one thing in common...wear.
In 2008 Wear-Concepts took on a riddle that presented itself at a Midwest coal burning power plant. The conundrum was found in the labyrinth of the upper and lower Riffle Housings. The purpose of the Riffles is to equalize the pressure drop of the Pulverized Coal headed for the boiler. The Riffle Housing is in constant contact with pulverized coal, which causes wear. A large amount of wear at the exit and near the edges of the Riffle Elements was costing the plant a bundle in repairs. The power plant’s maintenance team was rebuilding the housings once every year with hardsurface welding rod. It took one man working ten-hour days for one full week to build up the housings and get them back into service.
Hi, I’m Dean Green, Wear-Concepts Project Maintenance Manager and Field Crew Supervisor. I’ve been inside of hundreds of plants and repaired thousands of wear problems in facilities just like yours. Along the way I have developed some great methods for installing a variety of different wear solutions. I’d like to share some of my tips & tricks with you.
Click on the link to the left to view the Densit® WearSpray™ Pictorial
Click on the link to the left to view the Densit® WearCast™ Pictorial.
In addition to a high level of hardness and abrasion resistance, Wear-Con Densit® Cast Basalt Ceramic Wear Tiles provide excellent resistance to almost all acids and alkalis. Cast Basalt will remain smooth and maintain a low coefficient of friction when used over time, thereby offering the benefit of low caking. Cast Basalt is cost-effecive protection against moderate to severe wear on hoppers, chutes, chain conveyors, separators, pipes, cyclones, and many more!
Wear-Con Densit® Cast Basalt Tiles can easily be installed by securing with mortar.
| Property | Densit® Cast Basalt | |
|---|---|---|
| Density | g/cm² | 2.8 - 2.9 |
| Porosity | % | 0 - 3 |
| Hardness | - | ~8˜ |
| Compressive Strength | N/mm² | 400 - 450 |
| Fluxural Strength | N/mm² | 40 |
| Thermal Conductivity | °F (°C) | 0 - 110 |
| Temperature Resistance | °F (°C) | 350 |
Wear-Con Densit® Cast Basalt is available as square and rectangle tiles in thicknesses from 1 3/16” to 1 15/16”; SW 200 hexagonal tiles in thicknesses from 1 3/16” to 1 15/16”; and pipes with diameters from 1 9/16” to 1’ 11 5/8” and thicknesses from 3/4” to 15/16”. Custom fabrications are also available upon request.
Wear-Con Densit® Super-Isol™/1100™ Densulate™ Insulation Slabs are a range of extremely lightweight instulation with excellent insulating value, high mechanical strength, and exceptional heat resistance. Super-Isol™/1100™ is designed to be used as part of the Densulate™ Insulated Wear Protection System, but can be used as back-up for all refractory equipment. Three Super-Isol™/1100™ surface finishes are available: smooth, rigid, and non-dusting.
Wear-Con Densit® Super-Isol™/1100™ can be installed as a part of the Densulate™ Internally Insulated Wear Protection System (See Densulate™ data sheet). Super-Isol™/1100™ can also be installed independently by welding pins to the surface, pushing Super-Isol™/1100™ onto pins, then fixing by bending excess length of pins neatly into insulation slab.
Due to their exceptional heat resistance and low thermal conductivity properties, Wear-Con Densit® Super-Isol™/1100™ will withstand continuous temperatures up to 1832°F and 2012°F, respectively. Super-Isol™/1100™ is highly resistant to monoxide and hydrocarbons, making them ideal for furnaces with reducing atmospheres, as well as combustion and high-temperature process equipment.
Wear-Con Densit® Super-Isol™/1100™ is available in 1” thick (± 0.06”), 4”x39.4” (± 0.1”) standard slabs. Thicknesses from 1” to 4” available on request.
Wear-Con Densit® Densulate™ Internally Insulated Wear Protection System is designed to protect components from erosive wear, while at the same time reducing heat loss by radiation. Densulate™ combines insulation and wear protection, consisting of an insulation layer followed by a Densit® wear protection lining. Economical and easy to install, Densulate™ eliminates the need for external insulation, lowers construction costs, and reduces component weight and size.
Wear-Con Densit® Densulate™ can be installed in the following manner:
Wear-Con Densit® Densulate™ can be used in operating temperatures up to 2190°F, with thermal conductivity at 1112°F = 0.10 W/m·K. Mortar is used to fill any gaps, and the thickness of the insulation layer depends upon operating temperatures and acceptable heat loss.
Wear-Con Densit® Densulate™ systems vary according to process parameters including temperature, media type, and component size and geometry.
Ammonia. Who would have known that the introduction of ammonia would have such troubling effects on baghouses at cement plants?
Take, as an example, an established cement plant in the southwestern part of the United States. Its baghouses were thirty years old and had experienced very little to no wear, and they had never experienced any rusting at all. However, due to NOx levels in the system, the EPA and the company’s environmental department made them introduce ammonia into the system for the purpose of reducing the levels. That worked. Unfortunately, the side effects were devastating. Because of the ammonia and condensation from varying humidity levels, a very aggressive and corrosive reaction began. The PH levels began to fluctuate between eight and nine. Actual flakes of rust from the corroding baghouses were blown out of the stack and were seen all over the parking lot and on vehicles.
Upon further inspection of the baghouses, it was found that holes had begun to develop and were leaking as well. The cement company’s environmental department saw this as an environmental hazard. The leakage in the baghouse needed to be sealed up and stop the rusting as well.
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