Features & Benefits

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.

Installation

Wear-Con Densit® WearFlex™ 2000 can be installed in five simple steps:

1. Install mesh. WearFlex™ 2000 should be installed on a standard expanded metal mesh welded on the steel casing.
2. Mix dry WearFlex™ 2000 compound for 1 minute with a paddle mixer. Product must be kept completely dry until used.
3. Add water and mix for 8 minutes with a paddle mixer. A significant change in consistency of the material (from a dry powder to wet mortar) must be observed within 3 minutes from addition of water.
4. Trowel WearFlex™ 2000 onto mesh. Avoid making contact with aluminum or galvanized steel when using WearFlex 2000™.
5. Apply Densit® Curing Compound. For more details refer to the “Densit® WearFlex™ Manual”.

Technical Specifications

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).

Sizes

Wear-Con Densit® WearFlex™ 2000 is delivered in 55 lb bags.

Features & Benefits

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.

Installation

Wear-Con Densit® WearFlex™ 2000HT can be installed in five simple steps:

1. Install mesh. WearFlex™ 2000HT should be installed on a standard expanded metal mesh welded on the steel casing.
2. Mix dry WearFlex™ 2000HT compound for 1 minute with a paddle mixer. Product must be kept completely dry until used.
3. Add water and mix for 8 minutes with a paddle mixer. A significant change in consistency of the material (from a dry powder to wet mortar) must be observed within 3 minutes from addition of water.
4. Trowel WearFlex™ 2000HT onto mesh. Avoid making contact with aluminum or galvanized steel when using WearFlex™ 2000HT.
5. Apply Densit® Curing Compound. For more details refer to the “Densit® WearFlex™ Manual”.

Technical Specifications

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.

Sizes

Wear-Con Densit® WearFlex™ 2000HT is delivered in 55 lb bags.

Features & Benefits

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.

Installation

Wear-Con Densit® WearFlex™ 1000 can be installed in five simple steps:

1. Install mesh. WearFlex™ 1000 should be installed on a standard expanded metal mesh welded on the steel casing.
2. Mix dry WearFlex™ 1000 compound for 1 minute with a paddle mixer. Product must be kept completely dry until used.
3. Add water and mix for 8 minutes with a paddle mixer. A significant change in consistency of the material (from a dry powder to wet mortar) must be observed within 3 minutes from addition of water.
4. Trowel WearFlex™ 1000 onto mesh. Avoid making contact with aluminum or galvanized steel when using WearFlex™ 1000.
5. Apply Densit® Curing Compound. For more details refer to the “Densit® WearFlex™ Manual”.

Technical Specifications

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.

Sizes

Wear-Con Densit® WearFlex™ 1000 is delivered in 55 lb bags.

Features & Benefits

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.

Installation

Wear-Con Densit® WearFlex™ 3000 can be installed in five simple steps:

1. Install mesh. WearFlex™ 3000 should be installed on a standard expanded metal mesh welded on the steel casing.
2. Mix dry WearFlex™ 3000 compound for 1 minute with a paddle mixer. Product must be kept completely dry until used.
3. Add water and mix for 8 minutes with a paddle mixer. A significant change in consistency of the material (from a dry powder to wet mortar) must be observed within 3 minutes from addition of water.
4. Trowel WearFlex™ 3000 onto mesh. Avoid making contact with aluminum or galvanized steel when using WearFlex™ 3000.
5. Apply Densit® Curing Compound. For more details refer to the “Densit® WearFlex™ Manual”.

Technical Specifications

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.

Sizes

Wear-Con Densit® WearFlex™ 3000 is delivered in 55 lb bags.

Features & Benefits

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.

Installation

Wear-Con Densit® WearFlex™ 500 can be installed in five simple steps:

1. Install mesh. WearFlex™ 500 should be installed on a standard expanded metal mesh welded on the steel casing.
2. Mix dry WearFlex™ 500 compound for 1 minute with a paddle mixer. Product must be kept completely dry until used.
3. Add water and mix for 8 minutes with a paddle mixer. A significant change in consistency of the material (from a dry powder to wet mortar) must be observed within 3 minutes from addition of water.
4. Trowel WearFlex™ 500 onto mesh. Avoid making contact with aluminum or galvanized steel when using WearFlex™ 500.
5. Apply Densit® Curing Compound. For more details refer to the “Densit® WearFlex™ Manual”.

Technical Specifications

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.

Sizes

Wear-Con Densit® WearFlex™ 500 is delivered in 55 lb bags.

Features & Benefits

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.

Installation

Wear-Con Densit® WearSpray™ 2000 can be installed in five simple steps:

1. Install mesh. WearSpray™ 2000 should be installed on a standard expanded metal mesh welded on the steel casing.
2. Mix dry WearSpray™ 2000 compound for 1 minute with a paddle mixer. Product must be kept completely dry until used.
3. Add water and fibers, then mix for 8 minutes with a paddle mixer. A significant change in consistency of the material (from a dry powder to wet mortar) must be observed within 3 minutes from addition of water.
4. Convey mixed WearSpray™ 2000 through recommended pump, then spray onto mesh. Smooth surface if needed. Avoid making contact with aluminum or galvanized steel when using WearSpray™ 2000.
5. Apply Densit® Curing Compound. For more details refer to the “Densit® WearSpray™ Video”.

Technical Specifications

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

Sizes

Wear-Con Densit® WearSpray™ 2000 is delivered in 55 lb bags.

Features & Benefits

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.

Installation

Wear-Con Densit® WearCast™ 2000 can be installed in five simple steps:

1. Install mesh. Install or build mold. WearCast™ 2000 should be cast in suitable molds with adequate reinforcement such as steel bars and/or expanded metal mesh.
2. Mix dry WearCast™ 2000 compound for 1 minute with a paddle mixer. Product must be kept completely dry until used.
3. Add water and fibers, then mix for 8 minutes with a paddle mixer. A significant change in consistency of the material (from a dry powder to wet mortar) must be observed within 3 minutes from addition of water.
4. Pour mixed WearCast™ 2000 into mold under vibration. Avoid making contact with aluminum or galvanized steel when using WearCast™ 2000.
5. Remove mold from WearCast™ 2000 after adequate curing time.

Technical Specifications

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.

Sizes

Wear-Con Densit® WearCast™ 2000 is delivered in 55 lb bags.

Features & Benefits

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.

Installation

Wear-Con Densit® WearCast™ 2000HT can be installed in five simple steps:

1. Install mesh. Install or build mold. WearCast™ 2000HT should be cast in suitable molds with adequate reinforcement such as steel bars and/or expanded metal mesh.
2. Mix dry WearCast™ 2000HT compound for 1 minute with a paddle mixer. Product must be kept completely dry until used.
3. Add water and fibers, then mix for 8 minutes with a paddle mixer. A significant change in consistency of the material (from a dry powder to wet mortar) must be observed within 3 minutes from addition of water.
4. Pour mixed WearCast™ 2000HT into mold under vibration. Avoid making contact with aluminum or galvanized steel when using WearCast™ 2000HT.
5. Remove mold from WearCast™ 2000HT after adequate curing time.

Technical Specifications

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.

Sizes

Wear-Con Densit® WearCast™ 2000HT is delivered in 55 lb bags.

Features & Benefits

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.

Installation

Wear-Con Densit® WearCast™ 1000 can be installed in five simple steps:

1. Install mesh. Install or build mold. WearCast 1000™ should be cast in suitable molds with adequate reinforcement such as steel bars and/or expanded metal mesh.
2. Mix dry WearCast™ 1000 compound for 1 minute with a paddle mixer. Product must be kept completely dry until used.
3. Add water and fibers, then mix for 8 minutes with a paddle mixer. A significant change in consistency of the material (from a dry powder to wet mortar) must be observed within 3 minutes from addition of water.
4. Pour mixed WearCast™ 1000 into mold under vibration. Avoid making contact with aluminum or galvanized steel when using WearCast™ 1000.
5. Remove mold from WearCast™ 1000 after adequate curing time.

Technical Specifications

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.

Sizes

Wear-Con Densit® WearCast™ 1000 is delivered in 55 lb bags.

Features & Benefits

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.

Installation

Wear-Con Densit® WearCast™ 500 can be installed in five simple steps:

1. Install mesh. Install or build mold. WearCast 500™ should be cast in suitable molds with adequate reinforcement such as steel bars and/or expanded metal mesh.
2. Mix dry WearCast™ 500 compound for 1 minute with a paddle mixer. Product must be kept completely dry until used.
3. Add water and fibers, then mix for 8 minutes with a paddle mixer. A significant change in consistency of the material (from a dry powder to wet mortar) must be observed within 3 minutes from addition of water.
4. Add water and fibers, then mix for 8 minutes with a paddle mixer. A significant change in consistency of the material (from a dry powder to wet mortar) must be observed within 3 minutes from addition of water.
5. Remove mold from WearCast™ 500 after adequate curing time.

Technical Specifications

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

Sizes

Wear-Con Densit® WearCast™ 500 is delivered in 55 lb bags.

Features & Benefits

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.

Specifications

The Wear-Con Densit® Mixer is easy to operate. We will thoroughly instruct you how to use it.

Determination of Rental Period

1. All rental equipment will be shipped via freight carrier unless otherwise requested by the customer. All freight charges will be added to the customer invoice. The rental period and charges are outlined in the Customer Quote as agreed by both the Customer and Wear-Concepts.
2. All return freight charges are the responsibility of the customer. No collect or C.O.D. shipments will be accepted.

Features & Benefits

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.

Installation

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.

Technical Specifications

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.

Sizes

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.

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® WearFlex™ Pictorial.

Click on the link to the left to view the Densit® WearSpray™ Pictorial

Features & Benefits

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!

Installation

Wear-Con Densit® Cast Basalt Tiles can easily be installed by securing with mortar.

Technical Specifications

Sizes

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.

Features & Benefits

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.

Installation

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.

Technical Specifications

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.

Sizes

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.

Features & Benefits

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.

Installation

Wear-Con Densit® Densulate™ can be installed in the following manner:

1. Weld Densulate™ pins to the inner casing of the part or component. For operating temperatures up to 750°F, mild or stainless steel components may be used. For operating temperatures above 750°F, only stainless steel components of type 1.4301 may be used.
2. Install and fix insulation (such as Densit® Super-Isol™/1100™ Densulate™ Insulation Slabs). Place Densulate™ self-fastening clips and spacers at pins.
3. Install mesh and fix by bending excess length of pins neatly into insulation.
4. Apply Densit® Bonding Compound to make a water-repellent surface.
5. Apply a Densit® wear protection lining (such as WearSpray™, WearFlex™, or WearCast™)
6. Apply Densit® Curing Compound.
7. Allow to dry. For drying times, consult the Densit® Drying Curve in the Densit® Installation Manual. For further installation information, see the Densit® Installation Manual.

Technical Specifications

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.

Sizes

Wear-Con Densit® Densulate™ systems vary according to process parameters including temperature, media type, and component size and geometry.