Maximizing Refractory Service Life
Thermal cycling, thermal shock, mechanical impact or vibration can all cause cracking, which in turn can lead to premature failure and substantial cost penalties. Achieving maximum refractory service life at a minimum cost is therefore a key element in the efficient operation of these processes, and in enabling companies to maximize their competitive edge.
Zhuzhou Sunshine New Material Technology Co.,Ltd is the refractory industry's No. 1 supplier of stainless steel fiber and is dedicated to product development and customer service.The Best Choice for Casting and GunningMelt Extract stainless fibers are fully annealed and therefore are more pliable and ductile. This is of particular benefit during the mixing cycle and when the refractory composite is installed.These pliable fibers are not only more user friendly than the stiff "needle-like" cut fibers, but also have better flow characteristics. Dispersion is further aided by the optimum Aspect Ratio design guaranteeing rapid fiber separation during the mixing phase.
The ability to install fiber reinforced refractory mixes by gunning is an important consideration in today's modern refractory industry. Melt extracted fibers are specified as a mandatory requirement by most international petrochemical companies where fiber containing mixes are routinely gunned inside large processing vessels and ductwork. During gunning, annealed RS fibers readily pass through the equipment with minimal additional wear.Cold drawn wire fibers can cause real problems. The "stiff, inflexible" fibers often bridge the ports and orifices in the gunning machine, with resulting blockages leading to expensive delays and wasted materials.50% Less Rebound Melt Extract steel fiber fiber also has a major influence on the cost of the sprayed linings. On impact with a sprayed surface, the majority of ductile fibers contained within a mix stay in place, whereas a high proportion of the stiff drawn wire fibers rebound, resulting in a very expensive waste material. Rebound loss of RS fibers is typically 50% less than that of drawn wire fibers.
Stainless steel fibers is a needle-shaped segments of measured length, obtained by a unique technology of extraction from the molten metal (method of rapid crystallization from liquid to solid), designed for dispersion reinforcement of heat-resistant and building concrete, refractories for lining of various types of heating and melting furnaces.
The fiber is made of carbon ordinary quality, carbon quality, alloyed and high - alloy heat-resistant and corrosion-resistant steels and alloys and has a high-tech geometric shape-the shape of the "boat", thereby providing increased anchor properties of the side surfaces of the fiber, as well as its resistance to rupture and fracture. The versatility of the fiber is in its length.
Currently, the production is based on three sizes: 25±2 mm, 30±3 mm, 35±3 mm, which fully meet the requirements of modern technologies and equipment for the use of heat-resistant fiber concrete and steel-fiber concrete in the construction industry and in the metallurgical complex of the country.
The unique shape of the fiber and a small diameter (0.5-0.8 mm) allow to achieve a uniform distribution of fiber throughout the volume of the prepared mixture after 2 (two) minutes of mixing, completely eliminating the problem of clumping and settling when it is introduced into concrete mixers of various types.
The finished commercial fiber is delivered Packed in corrugated cardboard boxes with a volume of 10 kg and 20 kg, installed on European pallets and fixed by shrink film. At the request of the customer packaging can be changed to any volume.
Due to the constant expansion of the field of application of concrete and reinforced concrete structures in construction and other industries, every year increases the regulatory requirements for such indicators as strength, durability and the most relevant - reliability. Therefore, the use of metal fibers, especially fibers made of heat-resistant and corrosion-resistant steels and alloys turns fragile concrete into a more plastic and wear-resistant material. It shows a sharp increase in fracture strength, tensile strength, increased protection against mechanical stress and thermal overload, provides excellent resistance to shock and dynamic effects, cracking, increase the density, frost resistance, water resistance. Fiber allows for repair work in the most inaccessible places of damaged surfaces and structures, which are currently reinforced with metal products, or their partial replacement with new ones is not possible.
The most technical and economic efficiency and expediency of application of metal and heat-resistant corrosion-resistant fiber are marked by such spheres of activity as:
construction of bridges; runways of airfields; hydraulic structures - coastal dams and dams, locks and river channels; various types of road surfaces-prefabricated and monolithic slabs, curbs, dividing strips, paving slabs;
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construction of civil engineering facilities in areas with high seismic activity, foundations for TV towers, for volumetric industrial equipment of mechanical and dynamic action-rolling mills, hammers, hydraulic presses;
laying of railway tracks and protection of slopes of railway roads from erosion by water of thawed and overflowing rivers, strengthening and repair of vaults of mines and subway tunnels;
the reconstruction of the vault and the safe Deposit boxes, providing the armor - and fire-resistant properties of thin-walled panels and partitions in banks;
oil and gas industry - preparation of monolithic Foundation for drilling rig, lining of walls of heating and cracking furnaces with fiber concrete at oil refineries;
at the enterprises of non-ferrous and ferrous metallurgy-the arch of electric steel furnaces; headers, gas cleaners, supplying air ducts and gutters for draining liquid iron blast furnaces; steel casting hearth and covers of intermediate buckets, prefabricated panels to protect the floor from molten metal;
in designs of engineering constructions for water supply and water disposal-rings of round wells, culverts of various diameter and a configuration;
construction of objects of defence and strategic purposes.
Especially popular in a number of developed countries (Germany, Japan, USA) when carrying out concrete works is the method of shotcrete - spraying of fiber concrete on the repair surface under a certain pressure. This technology allows you to minimize manual labor, eliminate additional costs for the installation of formwork, as well as to combine the two processes together - reinforcement and concreting directly. Shotcrete greatly simplifies the repair and restoration work of thin-walled reinforced concrete structures of large area-vaults of subways and berths of seaports. Due to the high quality of adhesion of the shotcrete to the surface of the application, its strength increases much faster than the strength of conventional concrete, which accordingly extends the service life of these structures and reduces the economic costs of construction and repair work in General.
Bychkov E., Eng., MBA, eduardbychkov@yandex.ru
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