Ceramic Protective Coating and Abrasion Resistant Coating
Corrosion, Abrasion & Chemical Attack destroys million of dollars worth of equipments each year .Worldwide research shows that nearly 70% to 80% equipment failures are purely on account of their surface errosion, hence it has become imperative to have a effective preventive maintenance solutions at hand. Protection is the best insurance against corrosion and abrrasion
The time has arrived for Ceramic to finally take centre stage and we at Jyoti Ceramic take great pride in spearheading its ascent. We leave no stone unturned to guarantee optimum quality.
Our legacy of redefining quality standards in the industry has inspired us to manufacture high quality industrial ceramics for a wide variety of applications. Our range of products include Ceramic wear resistant lining tiles and Ceramic Protective Coating compounds, High temperature heat resistant ceramic refractory coating compounds, Adhesive cements, Ceramic ballistic armor tiles, High purity alumina ceramic pyrometry tubes and custom ceramic parts etc.
Bolstering Jyoti's umbrella further is its Aluma-Coat Coating Compound. Introduced in 1998, this polymer based ceramic coating has proved to be an excellent corrosion and abrasion resistant coating. The credit for it goes to our team of R & D scientists, who have developed these coating products.
We hereby stand fully committed and assured you of path-breaking ingenuity, through the consistent delivery of world-class quality ceramic corrosion and abrasion resistant Ceramic Protective Coating compounds
Total customer satisfaction is our avowed goal.
Looking into this scenario Jyoti Ceramic has specially developed a ceramic rich polymer based coating compound called Aluma coat.
Aluma coat coating compound are available in two categories.
(Trowelable)
USP : Converts soft surfaces to abrasion and corrosion resistant.
Aluma-coat TW : A 2 part epoxy resin based coating compound. It comprises of sintered sapphire hard aluminium oxide ceramic micro beads doped in resin, designed to resist chemical attack, cavitations, abrasion, moderate impact and also withstand maximum temperature upto 1500C / 3200F.
Aluma-coat TW can be applied on any surface such as ferrous, non-ferrous metals, stone, concrete, wood, plastics etc
Use in major industries : Mining and mineral processing, Cement, Power, Petrochemical, Paper and paper pulp, Fertilizers, Dredging and a host of surface treatments requiring corrosion and abrasion resistance.
Areas of applications : Chutes, Rod and ball mill feed plates, Pan feeders, Conveyors, Bucket elevators, Dust collectors, Cyclones, Soil and rock box outlets, Hoppers, Classifiers, Pipe elbows, Slurry lines, Coat exhausters, Chip cyclones, Tanks, Dredging equipments etc.
(Brushable / Sprayable)
USP : A corrosion, abrasion and chemical resistant coating.
Aluma-coat BR : A specially formulated 2 part epoxy based coating consisting of 80% micro fine sintered ceramic powders. It is a satin smooth, high gloss, low friction coating designed to protect surface against turbulence, corrosion, erosion, chemical attack and withstand maximum temperature up to 1500C (302 0F). It can also be applied on steel & concrete structures prone to corrosion due to chemicals, saline atmosphere and contact with liquids.
Use in major industries : Shipping, Cement, Fertilizer, Paper pulp, Sugar and a host of other industries which require surface treatments for corrosion and erosion resistance.
Areas of applications : Fan propellers, Pump shafts, Pump housings, Flanges, Machine ways, Anti-friction bearing housings, Sleeve pots, Castings of submersible water pumps, Potable water tanks, Chemical handling pumps, Butterfly valves, Repairs of pin hole leakages due to sludge line erosions and for many other applications where abrasion, cavitation, corrosion and chemical corrosion are chronic problems.
Aluma coat is a protective coating providing surface resistant to sliding abrasion, corrosion and chemical attack except hydrofluoric acid and temperature resistant upto 150ºC (302ºF)
Aluma coat thixotropic , brushable/sprayable formulations permits both vertical and horizontal applications with simple hand tools.
ALUMA COAT IS AN EXCELLENT TO ANY PLANT'S PREVENTIVE MAINTENANCE PROGRAM WHERE ABRASION & CORROSION ARE CHRONICAL PROBLEM
Industries that we serve our Aluma Coat Corrosion & Wear Resistant Coating
Cement Industry
Aluma Coat is widely used in cement industry to protect metal surface of Cement Hoppers and Storage Silos .
Pumps & Valves
Aluma Coat is the optimum solution in pump & Valve industry to protect pumps & valves surface from Highly corrosive chemicals & salty water .
Heavy Engineering Machinery
Aluma Coat Serves needs of heavy engineering Industry By protecting their costly machineries and equipments from severe Corrosion and Wear
Solar Water Heater Manufacturing
We Provide Aluma Coat to Solar Water Heater Industry which is Fastest Growing Industry and using our Aluma Coat to Protect Solar Water Heater Storage Tanks from Corrosion .
Advantages
- Aluma Coat has the superior abrasion-resistance and impact resistance.
- Aluma Coat has the excellent resistance to water and corrosive atmosphere.
- Aluma Coat has good resistance to a wide range of chemicals including diluted acids, alkalis and solvents.
- Aluma Coat is easy to mix and to use, adheres to almost any cleaned surface.
- Aluma Coat decreases downtime and costs, Aluma coat increases equipment life.
- Aluma Coat has the wide industrial applications .
Typical Properties
| PROPERTY | ALUMA COAT – TW TROWELABLE |
ALUMA COAT – BR BRUSHABLE |
|---|---|---|
Type |
Two component Epoxy Resin based doped with 80-85% spherical Alumina Oxide Beads |
Two component Epoxy Resin based doped with 80% fine sintered ceramic powders. |
Colour |
White |
Terracotta Brown and Grey. |
Appearance at 25°C/77°F |
Granular highly viscous paste. |
Smooth highly viscous paste. |
Average particle size. |
Ø 0.4mm - 0.8mm |
60 - 65 microns. |
Mixing Ratio |
|
|
Pot Life 25°C/77°F for 500 gms Mix. |
30 - 45 minutes |
30 - 45 minutes |
Initial setting time at 25°C/77°F |
4 - 5 hrs. |
4 - 5 hrs. |
Curing time at 25°C/77°F |
24 hrs. for about 5 - 6 mm |
24 hrs. for about 0.8 - 1 mm |
Application method |
By Trowel. |
By Brush / Spray |
Thinning recommended by commercially available Acetone / Xylene. |
Not recommended. |
As per consistency required. |
Over coat time or time interval between two coats. |
Not recommended. |
After approx 6-8 Hrs. or when 1st coat has just become tack free. |
Recommended thickness. |
About 5 - 6 mm. |
About 0.8 - 1 mm . |
Approximate coverage per Kg. mix. |
0.1 m2/Kg. at about 5 mm thick coating. |
0.7 m2/Kg. at about 0.8 - 1 mm Thick coating. |
Maximum service temperature |
150°C / 302°F |
150°C / 302°F |
*Mechanical strengths |
||
Compressive strength as per(ASTM-695 Standards) |
840 Kg./cm2 |
840 Kg./cm2 |
Flexural strength (ASTM-790) |
700 Kg./cm2 |
700 Kg./cm2 |
Adhesive strength. |
90 - 95 mpa. |
90 - 95 mpa. |
Shore 'D' Hardness (ASTM-D-2240) |
85-90 |
85-90 |
Salt / Cyclic corrosion Test. According to ASTM B-117-97 standards after 1000 Hrs. of test at 35°C, PH value 7.2, Humidity 95% RH |
No changes observed. |
No changes observed. |
*Note: Mechanical properties were tested 7 days post curing.
Surface Treatment
- For long term performance of Aluma coat, proper surface preparation is of at most important. The exact requirement of surface preparation depends upon the severity of the application, expected service life and initial surface condition.
- All this should follow up by vacuum cleaning or oil free dry blasting.
- A clean abraded surface will hold the applied coating compound firmly.
| No | Desired result | Method |
|---|---|---|
| 1 | Removal of dust, dirt, grease, oil etc. | Use any industrial grade cleaner |
| 2 | Removal of rust | Roughening the surface with sander or any other suitable tool |
| 3 | Removal of sever surface corrosion | Use SA2.5 grade grit or sand blasting |
Coating Quality
At Jyoti Ceramics, we believe our real work begins at the application stage in our customer’s workshop. Keeping this in mind, our dedicated Q.C team strives relentlessly to ensure optimum quality assurance and customer care.
Technical Tips For Successful Working With Aluma Coat
- Working time and curing of the coatings depends on temperature and mixing mass.
- Higher the ambient temperature faster will be the rate of curing.
- To reduce the curing time for Aluma coat coating compound at lower ambient temperatures
- We recommend
- a) Store Aluma coat at room temperature.
- b) Pre-heat the surface to be repaired until warm to touch.
To test for serviceable surface
Pierce a finger nail into the Aluma coat coated area, if the nail pierces in the coating, it indicates that the coating is not cured, allow the coating for further period of curing. If the nail fails to pierce in, then it indicates that the coating has completely cured and surface is in serviceable condition.
Shelf Life of Aluma Coat TW/BR Resin part at 25-30 ºC/77-86ºF: around 24 months in original air tight container.
Shelf life of Aluma Coat TW/BR Hardener at 25-30 ºC / 77-86/ºF: around 24 months in original air tight container.
Aluma coat - TW (Trowelable)
USP: Converts soft surfaces to corrosion and abrasion resistant.
Aluma Coat-TW is a 2 part epoxy resin based coating compound. It comprises of sintered sapphire hard aluminium oxide ceramic micro beads doped in resin, designed to resist chemical attack, cavitation, abrasion, moderate impact and also withstand maximum 150° C/302° F temperature.
Aluma Coat TW can be applied on any surface, such as ferrous, non ferrous metals, stone, concrete, wood, plastics etc.
Areas of Application: Chutes, rod and bal mill feed plates, pan feeders, conveyors, bucket elevators, dust collectors, cyclones, soil and rock box outlets, hoppers, classifiers, pipe elbows and slurry lines, coal exhausters, chip cyclones, tanks, dredging equipments etc.
Major Industries: shipping, cement, fertilizer, paper pulp, sugar and most of other industries which require surface treatments for corrosion and erosion resistance.
Aluma coat thixotropic , brushable/sprayable formulations permits both vertical and horizontal applications with simple hand tools.
ALUMA COAT IS AN EXCELLENT TO ANY PLANT'S PREVENTIVE MAINTENANCE PROGRAM WHERE ABRASION & CORROSION ARE CHRONICAL PROBLEM
Versatile Industrial Applications
Specifications of Aluma Coat TW
| Technical Parameters |
Aluma Coat –TW (Trowelable) |
|---|---|
| Mixing Ratio | 100 : 4 By weight |
| Thinning Agent (Acetone / Xylene) |
Not Recommend |
| Dry film thickness(DFT) | 5 mm to 6 mm |
| Coverage Area | 0.1 Sq.mtr/kg at about 5 MM thick Coat |
| Temperature Resist | 150 0C (3020F) |
| Drying /Curing | 24 Hours Air Drying @ Ambient Temperature |
| Note : Surface should be thoroughly cleaned & abraded before application of Aluma Coat TW | |
Aluma coat - BR (Brushable & Sprayable )
USP: Converts soft surfaces to corrosion and abrasion resistant. .
Aluma Coat-BR Specially formulated 2 part epoxy resin based coating compound. Consisting of 80% sintered micro fine ceramic powder.
It is a satin smooth, high gloss, low formulation coating designed to protect surface against turbulence, corrosion, erosion, chemical attack. It can also applied on steel and concrete Structure. Prone and corrosion due to chemicals, saline actrosalice contact with liquid.
Major Industries: Mining and mineral processing,dredging industry, Cement Industry,Power industry,petrochemical industry,pulp and paper,Fertilizer and host of many other surface treatments requiring corrosion and abrasion resistance.
Aluma coat thixotropic , brushable/sprayable formulations permits both vertical and horizontal applications with simple hand tools.
ALUMA COAT IS AN EXCELLENT TO ANY PLANT'S PREVENTIVE MAINTENANCE PROGRAM WHERE ABRASION & CORROSION ARE CHRONICAL PROBLEM
Versatile Industrial Applications
Specifications of Aluma Coat BR
| Technical Parameters |
Aluma Coat –BR (Brushable/Sprayable) |
|---|---|
| Mixing Ratio | 100 : 8 By weight |
| Thinning Agent (Acetone / Xylene) |
5 to 10 % Recommended for Sprayable Appliaction Only |
| Dry film thickness(DFT) | 0.8 mm to 1 mm |
| Coverage Area | 0.7 Sq.mtr/kg at about 0.8 - 1 mm thick Coat |
| Temperature Resist | 150 oC (302 0F) |
| Drying /Curing | 24 Hours Air Drying @ Ambient Temperature |
| Note : Surface should be thoroughly cleaned & abraded before application of Aluma Coat BR | |
