|
Ultra-Coat
(The Abrasion and
Chemical Resistant Protective
Coating.)
(Converts soft surfaces to sapphire
hard)
Ultra-Coat is a
matrix specially formulated mixture of Sapphire-hard
spherical High Alumina Micro Beads doped in epoxy resin.
Ultra-Coat is protective coating, providing a surface
resistant to sliding abrasion and chemical attack
(except Hydroflouric Acid).
Ultra-Coat's thixotropic
formulation permits both vertical and horizontal
application. In addition, Ultra-coat can be cast or
moulded into a variety of shapes and
patterns.
Physical
Data
| Composition |
Ultra-Coat
consists 85% concentration of Aluminium Oxide
sapphire hard spherical micro beads suspended in
specially formulated epoxy
resin. |
| Bead
size |
Average Bead
size 1.2 / 1.7mm. |
| Hardness |
Micro Spherical
Beads are the major part of the system of
Ultra-Coat matrix. Hardness of Beads is 9 on mhos
Scale. |
| Vertical Resistance @ 21°C
(70°F) 6mm thick application
coating |
No Sag. Special
blending results in a stiff mix for over head or
vertical with good
spreadibility. |
| Compressive strength(ASTM
695) |
12,000 lb/in².
(840 Kg/cm²) |
| Flexural Strength (ASTM
790) |
10,000 lb/in².
(700 Kg/cm²) |
| Tensile Strength (ASTM
307) |
3,000 lb/in².
(210 Kg/cm²) |
Composite shore D.
Durometer Hardness
(ASTM
D-2240) |
85 |
| Impact strength for
minimum of 5 mm thickness layer (As per Din
standard 53453) |
15
kg/m².
However the coating can
withstand movement load of 5-6 tons/sq.mtr if
applied on floor. |
Ultra-Coat Pot
life
@21°C
(70°F) |
30 to 45
minutes from the time of mix
preparation. |
| Setting
Time |
Approximately 6
Hours at @21°C (70°F) |
| Curing
Time |
Approximately
24 Hours at @21°C (70°F) |
| Max. use
temperature |
85°C / 182°F (
Continuous) |
| Approximate
surface |
1 Kg Ultra-Coat
covers Approximately (¼") 6mm thick layer of
Coverage ( 1 sq. ft.) 0.1 square mtr surface area.
However it depends on surface
condition. |
| Shelf life of Ultra
matrix |
1
Year |
| Shelf life for
Hardener |
8
Months. |
| Colour |
Off
White |
| Packaging |
Ultra-Coat
matrix and hardener are packed separately in
strong air tight plastic containers size 10 Kgs
& 25
Kgs. |
Salient
features
Ultra-Coat is most ideal
coating wherever high wear retards Production and Boosts
Costs, such as Launder and Feed Chutes, Chute linings,
Rod and Ball mills, Feed Plates, Pan Feeders, Conveyor
Skirts and Buckets, Dust Collectors and Cyclones, Soil
and Rock Box outlets, Hoppers, Classifiers, Pipe and
Slurry line Elbows, Coal Exhausters, Chip Cyclones, ID
fan housings in the Coal Power, Sand and Gravel, Grain,
Mineral processing Chemical and Paper Industries
etc.
Advantages
--> Increases Equipment
life
--> Saves down time
--> Reduces
Operating Cost
--> Can be cast - molded
-->
Out-performs other wear Coatings
-->
Cost-Effective
--> Excellent to Convert soft
surfaces in to corrosion, abrasive and Chemical
resistant.
Processs of
Application
ULTRA-COAT can be applied on any
Ferrous-Non ferrous metals, ceramics, stone, concrete,
plastics, wood etc. surfaces to convert them to sapphire
hard, chemical and corrosion
resistant.
SURFACE TREATMENT : Before applying
Ultra-Coat on any surface, clean the surface area
thoroughly make it free from rust, grease, oil, paint
etc. Roughen the surface with coarse-sand paper or sand
blast with S.A. 2 1/2 grade sand blasting to ensure the
surface is clean and rough enough for better
adhesion.
MIXING
HARDENER TO FORM ULTRA-COAT : Take 96 % by wt. of
Ultra matrix and add 4 % by wt. of hardener, gradually
mix them with spatula, when Ultra-Coat forms thick paste
of tooth paste consistency start applying on surface and
finish the Ultra-Coat stock in 30 minutes, do not add
any liquid or water for thinning. If thinning is
required, we recommend to add in the matrix 0.5 to 1 0%
xylene or acetone solvent.
CURING
TIME : After coating the surface with Ultra-Coat
leave it for setting for minimum 6 hrs at ambient temp.
Lower the ambient temp., longer the curing time, thick
coating cures faster than thin coating due to build up
of internal heat. If desired speedy setting, heat up the
coated surface area gently at 50 to 60°C for 3-4 hours,
after 24 hours of drying in room temperature
Alumna-Coated surface will be
serviceable.
TO
ENSURE SERVICEABLE SURFACE : To ensure, whether
coating is properly cured or not, pierce your finger
nail into the Ultra-Coat, if nail fails to pierce in, it
indicates coating is cured and surface is serviceable,
otherwise leave it for further period to cure
up.
CLEANING OF TOOLS : We recommend to
clean tools mixing vessels etc. used in mixing Ultra
matrix with Acetone or Xylene.
Chemical/Temperature resistant Chart
for Ultra Coat
| Temperature |
150
°C |
| Acetic
Acid |
R 50
% |
| Glacial Acetic
Acid |
NR |
| Acetone |
NR |
| Aqueous
Ammonia |
R 20
% |
| Benzyl
Alcohol |
NR |
| Calcium
Chloride |
R 20
% |
| Calcium
Hydroxide |
R 30
% |
| Chlorine
Gas |
NR |
| Chromic
Acid |
R 10
% |
| Ethyl
Acetate |
NR |
| Formaldehyde |
R
25% |
| Hydrochloric
Acid |
R 5
% |
| Hydrochloric
Acid |
NR 36
% |
| Lactic
Acid |
R 5
% |
| Magnesium
Chloride |
R
25% |
| Magnesium
Sulphate |
R
25% |
| Maleic
Acid |
R
30% |
| Methyl Ethyl
Ketone |
NR |
| Nitric
Acid |
R
25% |
| Oils &
Minerals |
R |
| Oleic
Acid |
R
30% |
| Oxalic
Acid |
R
50% |
| Phosphoric
Acid |
R
30% |
| Pthalic
Acid |
R 25
% |
| Salicylic
Acid |
R 30
% |
| Sulphuric
Acid |
R 25
% |
| Toulene |
NR |
| Urea |
R
50% |
| Urine |
R
50% |
| Uric
Acid |
R
50% |
| Water |
R |
| Xylene |
NR |
| Zinc
Salts |
R
50% |
*R -
Indicates Recommended
*NR -Indicates Not
Recommended
Food
Products
| Baby
Food |
R |
| Beer |
R |
| Chocolate
Syrup |
R |
| Coffee,
Tea |
R |
| Gluten
Flour |
R |
| Lard |
R |
| Orange
Juice |
R |
| Milk & Milk
Products |
R |
| Sugar &
Sugar Solutions |
R |
| Spices |
R |
| Wine-Red |
R |
| Wine -
White |
R |
*R -
Indicates Recommended
*NR -Indicates Not
Recommended
Typical Properties of
Ultra-Coat
| Properties |
Units |
Ultra-Coat |
| Physical
Properties |
| Nominal
Composition |
- |
90%
Al2O3 |
| Colour |
- |
Off
white |
| Average Grain
Size |
Micron |
10 |
| Specific
Weight |
- |
3.5 -
3.55 |
| Water
absorbtion |
% |
0 |
| Flexural
Strength |
Kg/Cm² |
700 |
| Compressive
Strength |
Kg/Cm² |
840 |
| Young's
Modulus |
Kg/Cm² x
106 |
2.5 |
| Hardness |
Moh's |
9 |
| Thermal
Properties |
| Co-efficient of thermal
expansion |
(20-1000°C)x10-6
/°C |
7.4 |
Thermal Shock
resistance
(Down Shock
DT) |
°C |
170 |
| Thermal
Conductivity(20°C) |
W/M°K |
22 |
| Safe Operating
temperature |
°C |
150°C |
| Electrical
Properties |
| Dielectric strength (20°C)
5mm thick |
KV/mm |
25 |
| Dielectric strength (20°C:
1 MHz) |
- |
8.5 |
| Dissipation Factor (20°C:
1 MHz) |
- |
0.0006 |
| Volume Resistivity
(20°C) |
Ohm-cm |
>1013 |
| Te-Value |
°C |
840 |
|
Frequently Asked
Questions
What is
Ultra-Coat?
Ultra-Coat
consists 85% concentration of Aluminium Oxide sapphire hard
spherical micro beads suspended in specially formulated epoxy
resin.
What are the
advantages of Ultra-Coat?
Ultra-Coat
provides a protective coating, providing a surface resistant
to sliding Abrasion and Chemical attack
(except Hydroflouric
Acid).
Where all can
Ultra-Coat be applied?
Ultra-Coat can be
applied on any ferrous/ non-ferrous metals, ceramics, stones,
concrete, wood, etc. It is the most ideal coating wherever
high wear retards Production and Boosts Costs, such as Launder
and Feed Chutes, Chute linings, Rod and Ball mills, Feed
Plates, Pan Feeders, Conveyor Skirts and Buckets, Dust
Collectors and Cyclones, Soil and Rock Box outlets, Impellers,
Hoppers, Classifiers, Pipe and Slurry line Elbows, Coal
Exhausters, Chip Cyclones, ID fan housings in the Coal Power,
Sand and Gravel, Grain, Mineral processing Chemical and Paper
Industries etc.
Where all can
Ultra-Coat be used?
Ultra-Coat
thixotropic formulation permits both vertical and horizontal
application and hence can be cast or moulded into a wide
variety of shapes, patterns etc. and can be used at
practically all places.
What is the
Hardness of Ultra-Coat?
Ultra-Coat has a very high
hardness 9 on mohs scale.
What is the curing
time of Ultra-Coat Coating?
The setting time
for Ultra-Coat is 6 hrs at ambient temperature. Lower the
temperature, longer the curing time, thick coating cures
faster than thin coating due to build up of internal heat. If
desired speedy setting, heat up the coated surface area gently
at 50° to 60° C for 3-4 hours, after 24 hrs of drying in room
temperature Ultra-Coated surface will be
serviceable.
Ensuring the
surface serviceability?
To ensure, whether
the coating is properly cured or not, pierce your finger nail
into the Ultra-Coat, if nail fails to pierce in, it indicates
coating is cured and surface is serviceable, otherwise leave
it for further period for cure.
Can Ultra-Coat be
used for patchwork?
Yes, Ultra-Coat
can be used for patchwork also.
In what form is
Ultra-Coat available?
It is available in
the form of matrix and hardener, packed in easy to use
containers.
How to mix matrix
and hardener?
Mix 96% by Wt. of
Ultra-Coat matrix with 4% by Wt. of hardener and gradually mix
with spatula, when Ultra-Coat forms a thick paste of
toothpaste consistency, it is ready for
applying.
How can Ultra-Coat
be applied?
Clean the surface
thoroughly and make it free from rust, grease, oil, paint,
etc. Roughen the surface with coarse-sand paper or sandblast.
After ensuring that the surface is clean apply with a
trowel.
At what
temperatures can Ultra-Coat be used?
The safe operating
temperature is 85°C but it can withstand temperatures as high
as 150°C for short duration.
What is the
coverage of Ultra-Coat?
The specific
gravity of Ultra-Coat is 3.50 to 3.55. A layer of One Sq. ft.
with 6mm thickness of Ultra-Coat weighs
@1Kg.
What is the
economics of usage of Ultra-Coat?
Although the
initial cost may seem high, the basic economics of usage of
Ultra-Coat is the fact that there is practically zero
downtime, thus leading to enhanced production. The economical
bonus is the fact that costly equipment does not corrode or
errode. Thus replacement of parts are greatly reduced. Hence
Ultra-Coat is highly economical, over a period of time.
|
