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HARDCAST Hardcast is a range of silicate bonded materials. See separate data sheets on acid resistance(1), mortar, hot floors(2) and shallow repairs(3) Hardcast is a range of silicate bonded materials. Acid resistance. HARDCAST For Acid Resistance(1) Hardcast is a product range based on a complex silicate bonding system. It is totally inorganic, quick setting, strong, acid resistant and refractory. Hardcast sets within 2 hours, and is fully serviceable within 24 hours. It can be applied to any structurally sound surfaces. Damp floors or dirty floors should first be painted with Hardcast binder. This treatment will also neutralise acids on the surface. Hardcast is fully resistant to Sulphuric acid, Hydrochloric acid, Nitric acid, Phosphoric acid and organic acids. It is not resistant to Hydrofluoric acid. Hardcast has a compressive strength of around 60MPa. i.e. twice the strength of a good structural concrete. Hardcast can be made to suit any requirements: Particle size; Coarse castable, mortar or coating. Surface texture; Smooth, sandy or rough. Colour; Light beige, concrete colour, red, blue, white, green, black and most other colours at a slightly increased cost. Hardcast typically costs around R4 000/tonne. Installed cost is typically R12 per mm thick per square metre. Therefore R320 per square metre at 1 inch thick. Hardcast is also available as a lightweight insulation material. The lightest is the injectable insulation, with a density of 0,3g/cm³. Normally the density is around 2,2 to 2,4g/cm³. Hardcast has a thick viscous consistency, and requires experience with installation. The first installation should be done by an experienced operator. Hardcast is supplied in two parts; 25Kg bags of powder and 33.3Kg drums of the liquid Hardcast binder. Add +14% binder to the powder. Hardcast is also made in plaster and fine grades. Shelf life is virtually indefinite in unpunctured bags. HARDCAST FINE Acid Resistant Mortar Hardcast is a product range based on a complex silicate bonding system. It is totally inorganic, quick setting, strong, acid resistant and refractory. Hardcast is also made in plaster and casting grades. Hardcast is also available as a lightweight insulation material. The lightest is the injectable insulation, with a density of 0,3g/cm³. Normally the density is around 2,2 to 2,4g/cm³. Hardcast sets within 2 hours, and is fully serviceable within 24 hours. It can be applied to any structurally sound surfaces. Damp floors or dirty floors should first be painted with Hardcast binder. Hardcast is fully resistant to Sulphuric acid, Hydrochloric acid, Nitric acid, Phosphoric acid and organic acids. It is not resistant to Hydrofluoric acid or alkalis. Hardcast fine is supplied in two parts; 20Kg bags of bright white powder and 33.3Kg drums of the liquid Hardcast Binder. Add +50% binder to the powder. (Two parts powder to one part binder by weight) Shelf life is virtually indefinite in unpunctured bags. Hardcast fine has a thick viscous consistency, and is very easy to work with. It should preferably be placed within 20 minutes of mixing, and should not be left exposed for more than 10 minutes, as it forms a thin air-set skin which will not bond. The surface texture is very smooth. It is not suitable as a traffic surface. It can be made non-slip by sprinkling clean sand onto the fresh surface immediately after trowelling. Hardcast fine can easily be coloured. The natural colour is light beige. Other colours which have been made are; concrete colour, red, blue, white, green, black. Most other colours can be made at a slightly increased cost. Grindings from cutting of acid brick may be added to Hardcast fine and smeared over the joints to make the joints less visible when used with red acid brick. Hardcast fine costs R4 000/tonne. Installed cost is therefore around R50 per square metre at a thickness of 5mm. Ordering; If one tonne is ordered, you will receive 10 x 33,3Kg drums of liquid binder and 33 x 20Kg bags of powder. Powder and binder are both charged at R4 000/ton. Applications; Mostly used as a mortar for acid resistant brick and tiles. It has very good adhesion, and less chance of failing at the contact surface. However, a continuous backing layer must always be trowelled on first as a backup seal. Moulding; Hardcast fine takes up very fine detail. After about an hour, it can be stripped from a mould, at which point it has formed a thin liquid layer which acts as a mould release against impervious surfaces. Hardcast will not bond to plastic at all. It bonds well to glass. When used as a surface finish, The airset skin may shrink and tear, especially in dry weather. To prevent this, cover with plastic immediately after the skin has formed. Otherwise paint the skin with oil. This skin is not chemically set, and is water soluble. It is however only a fraction of a millimetre thick. All Hardcast products set very rapidly on a hot surface. Hardcast is not porous, and will not absorb liquids. HARDCAST Floors around Furnaces(2) Hardcast is a product range based on a complex silicate bonding system. It is totally inorganic, quick setting, strong, acid resistant and refractory. The chemical composition is typically more than 95% silica. Hardcast sets in about one hour at ambient temperature and very rapidly at high temperature. Hardcast dehydrates completely, and will therefore not explode if molten metal or slag is poured over it. Hardcast is ideal for repair of casting floors and ferrochrome furnace charging floors. A patch on a charging floor at around 60 to 100ºC is fully serviceable for charging car traffic in 15 minutes. Repairs can therefore be effected without disrupting production. Hardcast has a compressive strength of around 60 MPa.: twice the strength of good structural concrete. For light service floor repairs 15mm has proved adequate, but for most purposes 50mm is recommended. On new installations, a 50mm capping of Hardcast on ordinary concrete is recommended. Hardcast is supplied in 25Kg thick, clear polyethylene bags, with 33.3Kg drums of liquid Hardcast Binder. Plus 14% binder is mixed into the powder and vibrated into place. The standard casting grade is very coarse. Plaster and fine grades are also available. The density is around 2,3g/cm³. Surfaces to be repaired are usually dirty, dusty and sometimes friable. A coat of Hardcast Binder painted on is often recommended. The casting grade costs R4 000/ton. Installed cost would be around R12/m per mm thick, i.e. R150/m² at 1 inch thick. Hardcast for repair of pavements and factory floors(3) Hardcast is a product range based on a complex silicate bonding system. It is totally inorganic, quick setting, strong, acid resistant and refractory. Hardcast is available in several grades for differenr applications. Hardcast sets within 2 hours, and is fully serviceable within 24 hours. It can be applied to any structurally sound surfaces. Damp floors or dirty floors should first be painted with Hardcast binder. Hardcast is fully resistant to Sulphuric acid, Hydrochloric acid, Nitric acid, Phosphoric acid and organic acids. It is not resistant to Hydrofluoric acid or alkalis. The biggest advantage of Hardcast over concrete and cementitious materials is that it can be successfully placed in thin sections. There is no need to dig a vertical hole before repair. The repair can be tapered to 2mm thick. Hardcast is not porous, and will not absorb liquids. The density is around 2,2g/cm³ The maximum particle size is about 4mm. The standard colour is a light grey similar to concrete. The colour is easily modified by addition of oxides. Hardcast is supplied in two parts; 25Kg bags of powder and 33,5Kg drums of the liquid Hardcast Binder. Add about +16% binder to the powder. Shelf life is virtually indefinite in unpunctured bags. Strength: For hand placed material about 30 MPa, for drier, mechanically compacted material, about 60 MPa. Mixing: Hardcast can be mixed by hand or in a concrete mixer or pan mixer. Hardcast has a viscous semi-fluid consistency, and is very easy to work with. It should preferably be placed within 20 minutes of mixing, and mixing equipment should not be left with material in for more than half an hour. Surface preparation: Brush the surface clean and remove oil, grease, paint etc. Do not use water. Paint the surface with Hardcast Binder, until all dust is absorbed in the liquid and the whole surface is wetted. Curing: Cover with plastic for the first hour. (In dry weather it will develop surface cracks if exposed.) Keep water off it for the first two hours. Keep traffic off it for the first four hours. All Hardcast products set very rapidly on a hot surface. Around a furnace, for example, in fifteen minutes, sufficient strength was achieved to drive a forklift over a 40mm repair. Applications: Factory floors where rapid repair is needed. Factory floors where the damage tapers to a shallow depth. Roads which cannot be closed for long. Kerbs etc. where the volume of repair is too small for concrete to set properly. Price: Hardcast costs R4 000/tonne. Ordering: Powder and binder are both charged at R4 000/ton on combined weight. If one ton is ordered, one ton of combined net weight of powder and binder will be supplied, rounded off to the nearest packaging unit. Description;
A refractory material for resistance to chlorides. Applications; Incinerators burning PVC. Vessels in which metal chlorides are reacted. Protection from chlorine or HCl vapours. Installation; Density; Packaging; 22kg polythene bags of powder plus 6,5kg polythene bottles of Hardcast binder.
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