Monolithics

IMS supply a wide range of monolithics, including refractory castables, gunmixes, mortars, and plastics & rammings.

Insulating Castables and Gunmixes

IMS supply a comprehensive range of insulating Castables and Gunmixes which are generally used as back-up insulation behind a hot face material such as a Dense or Low Cement Castable. Temperature gradients, thermal efficiency, atmospheric conditions and strength generally determine the choice of material along with the maximum service temperature requirement. Certain applications where temperature and abrasion resistance are not an issue allow the use of insulation castable as a one shot hot face lining therefore exhibiting excellent thermal characteristics. Materials can be installed by casting or gunning techniques – the method chosen is generally dependant upon application, access and cost.

Further Information

Key Attributes:

  • Thermally Insulating
  • Flexible Installation Characteristics
  • Densities Ranging from 0.5 to 1.5 T/M3
  • Low Iron Compositions

 Typical Applications:

  • Flues
  • Stacks
  • Controlled Atmosphere Furnaces
  • Petro Chem Transfers
  • After Burners
  • Waste Heat Boilers
  • General Insulating Backup

Key Brands:

Products | Alumina Content % | Temperature Rated ° C

  • Superlite | 8.0 | 870
  • Coolcast | 22.7 | 1100
  • Kastolite 23 LI | 33.4 | 1260
  • Kastolite 26 LI | 44.6 | 1427
  • Kastolite 25 | 37.0 | 1370
  • Kastolite 30LI | 57.0 | 1650
  • Insulite | 37.1 | 1370
  • Insulcast | 31.3 | 1200
  • IC12 | 35.0 | 1300 

Dense Castables and Gunmixes

IMS supply a comprehensive range of Dense Castables and Gunmixes which exhibit excellent strength and abrasion resistance. These materials can be used as a one shot lining or more commonly as a hot face material with an insulation grade as a back up lining. Again application conditions form a major part in the correct choice of material, whatever the application IMS can supply a suitable material. The hot face lining is the working lining of the vessel therefore it is essential that the chosen material exhibits the required characteristics to obtain optimum life. Resistances to thermal shock, abrasion, chemical attack, reducing atmospheres are a few of the key factors determining choice of material along with the maximum service temperature requirement. Materials can be installed by casting and gunning techniques. The method chosen is generally dependant upon access and cost.

Further Information

Key Attibutes:

  • User Friendly Products
  • High Temperature Resistant
  • 45 to 85% Alumina – ‘Fit for Purpose’

Typical Applications:

  • Aluminium Furnaces
  • Tundishes
  • Heat Treatment Cars
  • Kiln Cars
  • Incinerators
  • Arc Roofs
  • Non Ferrous Ladles

Key Brands:

Products | Alumina Content % | Temperature Rated °C

Mizzou | 60.0 | 1650

Greenspray 16 | 47.0 | 1600

Arelcrete 1400 | 45.0 | 1400

Arelcrete 1600 | 48.7 | 1600

Midcast | 76.0 | 1550

Guncrete 160 | 50.3 | 1600

KS4 | 45.0 | 1400

Ex HS Castable | 39.9 | 1250

Plastics & Ramming Mixes

Our range of Plastics and Ramming Mixes are both clay and chemically bonded materials installed by ramming techniques. Clay bonded materials exhibit a good green strength when allowed to air dry. Chemically bonded materials form their strength during the curing or heat treatment process.

The choice of material is dependent upon temperature, atmospheric conditions, chemical attack and application; phosphate or chemically bonded materials show excellent resistance to chemical or slag attack.

The course grained nature of both these generic materials allows for good abrasion and thermal shock resistance. They are ideally suited for use in restricted areas such as boilers, ladle linings and burner quarls.

Further Information

Key Attributes:

  • Excellent Thermal Cycling Properties
  • Good Resistance to Chemicals and Slags
  • Versatile / Ready to Use

Typical Applications:

  • Burner Blocks
  • Boiler Linings
  • Furnace Walls
  • Combustion Chambers
  • Molten Steel / Iron
  • Thermal Shock Applications
  • General Maintenance
  • All Reverberatory Furnaces

Key Brands:

Product | Alumina Content % | Temperature Rated °C

Super G | 60.0 | 1650

Greenpak 45 | 45.8| 1600

Greenpak 85P | 85.0 | 1700

Greenpak 90P | 92.0 | 1800

BluRam HS | 72.0 | 1650

Jadepak 88P | 87.0 | 1700

Greengun | 85.0 | 170

Low Cement Monolithics

IMS supply a comprehensive range of Low Cement Monolithics which exhibit extremely high hot strength and abrasion resistance characteristics.

These materials are more technically advanced than the family of dense castables and show low porosity and good resistance to slags where molten metals attack the refractory.

In addition to their excellent performance characteristics we have materials available for every conceivable application; these materials are termed ‘free flow’ materials which can be installed by pumping or casting. The term Free Flow means they do not need vibrating into position therefore aiding installation.

We also offer a range of multi-purpose Low Cement Castables which can be pumped, vibrocast or cast as a free flow material. The strict water addition determines the mode of installation.

Low Cement Monolithics

Key Attributes:

  • Excellent Abrasion Resistance
  • Non Wetted / Close Porosity
  • High Strength

Typical Applications:

  • Aluminium Furnaces
  • Tundishes
  • Heat Treatment Cars
  • Kiln Cars
  • Incinerators
  • Arc Roofs
  • Non Ferrous Ladles
  • Precast Shapes
  • Rotary Kiln Linings

Key Brands:

Products | Alumina Content % | Temp Rated °C

  • Ultragreen 45 | 47.0 | 1650
  • Versaflow 55ARC | 56.0 | 1650
  • Versaflow 65ALC | 66.5 | 1430
  • Greentec170LG | 72.7 | 1700
  • Arelcrete 1600LC | 57.5 | 1600
  • Albond | 81.0 | 1400
  • Hicast Extra | 82.2 | 1700

Silicon Carbide Mixes

IMS supply Silicon Carbide materials which by their nature possess excellent volume stability right through their temperature range along with high abrasion resistance and thermal shock characteristics. These materials are designed as free flow materials to eliminate the need for vibrating the product into place, thus eliminating grain segregation and maintaining a high strength profile. These materials are designed for specialist applications and can be installed by casting or pumping into place.

Mortars

IMS supply a range of exclusive mortars exhibiting both high refractoriness and bond strength. We supply both dry and ready mixed materials depending upon preference.

The materials produced cater for a wide temperature range and for more arduous applications where the materials are prone to attack and reducing atmospheres, we have a hybrid range of products which show excellent resistance to attack therefore retaining their original integrity for extended periods.

IMS mortars are renowned for their use in the most exacting of environments.

Further Information

Key Attributes:

  • Supplied Dry and Ready Mixed
  • Air & Heat Setting
  • Range of Purities and Temperatures

Key Brands:

Product | Alumina Content % | Temp Rated °C | Setting

Sairset | 43.0 | 1700 | Air

KD2 | 53.0 | 1650 | Heat

No 36 | 70.0 | 1760 | Air

Wrightset Super | 37.5 | 1600 | Air  

Greenset 94p | 98.0 | 1870 | Air

Jadeset Super | 87.0 | 1870 | Air/Heat

Pre-Casting

IMS Provide Extensive Pre-Casting Facilities.

Material Selection – It is important to ensure the correct selection of raw material prior to casting. When selecting raw material consideration should be given to the demands of the application. The choice of material can ultimately depend upopn cost and relative performance, however the complexity and required surface finish together with the physical volume of the cast shape can also be a determining factor. Our technical staff are on hand to offer advice should this be required.

Mould Manufacturing – The mould type used in the casting process often determines the finished quality of the fired shape. IMS provide an in-house mould making service, where moulds can be manufactured from polystyrene, wood, plastic, plaster and steel substrates. Customers can supply their own pre-manufactured moulds into which IMS cast the refractory.

Drying / Firing – Drying / Firing of the cast shape is carried out in our state of the art kilning department. Following firing the cast shape undergoes final inspection. Rigorous testing methods following stringent internal controls ensure that the finished shape meets the customers requirements.

Casting – Once material selection has been completed and the moulds have been produced casting of the shape is undertaken. IMS cast shapes using several casting techniques including vibration, vibroflow, free-flow and slip. Consideration is given to the material shrinkage during the firing/drying process and the mould is manufactured ”oversize” to accommodate this effect. The firing/drying process removes any excess water from the shape before despatch.

Inspection and Despatch – As soon as the shape has been passed by our inspection department it is shrink wrapped to reduce moisture ingress during transit and then made ready for customer collection or delivery.

Zircon Patches

Zircon patch is a specially blended product consisting mainly of zircon grades with plasticizers and a chemical bond. It is supplied ready-for-use, in a putty consistency for direct application by hand or suitable implement. Zircon patch can also be supplied in powder form which can be mixed with Zircon Bonding Solution to give consistencies suitable for tamping, trowelling or pouring. Zircon Patch will give good strength on drying at ambient temperature but is best heated to 200/300°C, for optimum strength and service performance. It is a high strength patching material for hot and cold repairs in glass tank furnaces. It is suitable for repairs to Zircon, Silica, Mullite, Alumina and in fact, any non-basic refractories.

Further Information
Typical Applications:

  • Repairs to crowns and superstructures in glass furnaces
  • Filling at expansion joint gaps where the material must be forced into the void to obtain a complete seal
  • Repairs to metal melting surfaces and ladles
  • Zircon Patch is best used in conjunction with a coating of Zircon Paint, applied after drying, in all applications where this is possible. Zircon Paint can be applied by brush or spray gun.

Zircon Patch Z/S Super 150 (wet)

Zircon Patch Z/S – Super 150 is a high purity chemically bonded zircon supplied in a plastic putty consistency ideal for direct application.It can be applied by hand or trowel and if required a small amount of water can be added to ‘wet down’ the putty to give a softer consistency. It will develop limited strength at ambient temperature but is best heated to 200/300°C, after a cold repair, for optimum strength and service performance. This is a high strength material for hot and cold repairs to Ziron, Silica, Mullite, Alumina and Fusion Cast Refractories.

Typical Applications:

  • Repairs to crowns and superstructures in glass furnaces
  • Filling at expansion joint gaps to give maximum sealing
  • Patching and filling regenerate crowns, breast front and back walls and port areas

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