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Introduction ceramic foam ZIRCOFOAM

The ZIRCOFOAM Ceramic Foam replaces many applications of mineral wool but with the “easy to use” and speeds typical of polyurethane foams in an employ range from -20°C to 1100°C. Zircofoam have an instantaneous hardening makes it suitable for injection directly on site or used in injection molding process. With a special pneumatic nebulizer can be used for spray application.

Zircofoam is designed to be used repeatedly operating with small waiting times, together layers for injection spray you get a consistent manufacture.

The release of the product can be done manually with coaxial cartridges and special ma- nual or pneumatic dispensing guns. Mixing is obtained through the use of disposable static mixer. Attention : during the preparation phase by shaking the product for at least 30 rounds to allow suspended particles to a perfect distribution in the solvent.

The minimum thickness recommended by injection into a cavity is 10 mm, with thickness less than you would have difficulties to penetrate the product to the bottom without being hindered by the walls; for the spray application is recommended to operate from a minimum thickness of 1 mm to a maximum of 10 mm, thicker than is advisable for injection.

The volumetric yield of the product is approximately 3:1 from a cartridge of 380 ml and then you get 1.15 liters of ceramic foam, approximately 1 square meter of sprayed surface.

The curing time it's few seconds, then, there is a partial cure in which the material expels moisture free and strengthens the molecular bonds in a time ranging from 24 to 72 hours. The complete polymerization of the material is obtained in 3 days per cm of thickness whe- re the material reaches the full of its own characteristics. is possible and advisable to shor- ten these times, however, subjecting the material to heat treatment by performing the first heating ramp following a gradual increase in temperature, are sufficient for 50 ° C for 30- min for the first inch of thickness and other curing at 180 ° C for 30min cm thick for com- plete polymerization. After that, the material can be subjected to intense heating.

Zircofoam during the first heat will dry completely free from moisture (104 ° C) and water- related at the molecular level (175°C) releasing water vapor. At the temperature of 313°C we have a release of carbon dioxide due to pyrolysis of the organic binder contained in the ceramic matrix (about 2% by weight) at this temperature, the ceramic foam take a gray co- lor due to the presence of carbon particles in the ceramic body; at temperatures above 50- 0°C is the complete combustion of carbon particles by returning to a cream color pottery to become yellow at temperatures above 900°C (sintering).

Warning: Zircofoam items may incur in deformations and cracks in the ceramic body if was subjected to intense heat without having waited for the complete drying.

General information

Methods of application:

Equipments available:

Future equipment available:

Solvent component A (white):

Solvent component B (black):

Method of cleaning equipment:

injection or spray manual coaxial gun, pneumatic coaxial gun, nozzle for spray applications. reactor for industrial application water ethyl acetate wiht water; more resistant dirt to soak in hot water

 

Specifications

 

Cartridge Size

380 ml

Storage position

vertical

Colour

white

Term storage from 10°C 35°C

8 months*

Expansion

3:1

Drying time at 20°C

3 days per cm of thickness

Time hardening

60

sec

Density reached 1,2 x specific weight due to loss of

   

Cutable

60

sec

water vapor from free water.

 

Loadable

1 h

Manageable

5 min

Drying time at 250°C

60

Full curing time

16-24 h

Density reached equal to specific weight due to loss of water vapor from molecular water zeolite.

minutes per cm of thickness

Application temperature

-5°C to 150°C

Storage temperature

0°C to 30°C

   

The chemical-physical and mechanical properties of this ceramic foam were confirmed by testing done in our laboratories and at major laboratories including the Politecnico of Milan and the Italian Naval Register.

We have performed the following tests at the Polytechnic of Milan and integrated into sheets, which you will find the following pages.

Thermogravimetric analysis coupled with infrared spectrometric analysis, as ASTM E 21-

05/00;

Analysis capable of identifying the toxicity index of gases at high temperature, as CEI 20-

37/4-0:2006;

Dimensional stability tests at various temperatures;

Test compression properties in accordance with ISO 604:2002;

Thermal conductivity at 10 ° C according to EN 12667:2002;

Analysis to scanning electron microscope (SEM) by semiquantitative microprobe,

Thermal conductivity in the medium / high temperatures according to ASTM E 2584: 20-

10;

Reaction to fire according to EN ISO 11925-2:2002.

We have performed the following tests in RINA tests laboratory :

Fire reaction test classification for civilian use in accordance with EN 13501-1: 2002 in accordance with test methods EN ISO 1182:1990, EN ISO 1716:2002;

Fire reaction test classification for naval applications second Directive 96/98 / EC test methods in accordance with EN 13501-1, EN-ISO 1716:2002, IMO FTPC Part.1, ISO 1182:1990;

test for determining the calorific value according to EN ISO 1716:2002.

the calorific value according to EN ISO 1716:2002. This product has been tested and verified by

This product has been tested and verified by the Politecnico di Milano as Report No. 132/10 classification according to the following regulations and test standards:

EN 13501-1:2007, EN-ISO 11925-2:2002; The product in relation to Fire Resistence is rated:

E
E

This product has been tested and verified as per Report No. 2007CS015485 classification according to the following regulations and testing standards:

EN13501-1: 2002, EN-ISO 1716:2002, EN-ISO 1182:1990; the product in relation to Reaction to Fire is rated:

A1
A1

ZIRCOFOAM DATA SHEET Applied by injection

 

Description

Method

Value

Maximum temp (continuos)

 

1000°C

Maximum temperature for short time

 

1100°C

Melting point

 

>1200°C

Wet nominal density

 

0,46 g/cm 3

Nominal density after thermal cycle 250 ° - 700 °

   

C

(average)

0,28 g/cm 3

Nominal density after thermal cycle 750 ° - 1100 °

   

C

(average)

0,34 g/cm 3

Open porosity

 

25%

Compression resistance

ISO 604:2002

0,14 MPa

Thermal conductivity W / mK at mean

   

temperature:

 

10°C (partially wet, density 0.43 g/cm³)

UNI EN 12667:2002

0,16

 

150°C

 

0,071

 

250°C

0,083

 

400°C

ASTM E2584

0,102

 

600°C

0,144

 

800°C

0,209

 

950°C

0,249

Permanent linear change (%)

   

20°C - 250°C

 

-2,52%

250°C - 700°C

 

-3,30%

750°C - 1000°C

 

-11,05%

Chemical Analysis (average)

   

Si

 

13,4%

Al

 

6,5%

Zr

 

8,2%

Ti

 

4,2%

Na

 

4,2%

Ca

 

3,2%

O

 

53,0%

C

 

6,9%

Index toxicity of gases

CEI20-37/4-0:2006

1,6

ZIRCOFOAM 200 DATA SHEET Applied by injection

 

Description

Method

Value

Maximum temp (continuos)

 

1100°C

Maximum temperature for short time

 

1200°C

Melting point

 

>1250°C

Wet nominal density

 

0,42 g/cm 3

Nominal density after thermal cycle 250 ° - 700 °

   

C

(average)

0,24 g/cm 3

Nominal density after thermal cycle 750 ° - 1100 °

   

C

(average)

0,20 g/cm 3

Open porosity

   

Compression resistance

ISO 604:2002

0,20 MPa

Thermal conductivity W / mK at mean

   

temperature:

 

10°C (partially wet, density 0.38 g/cm³)

UNI EN 12667:2002

0,12

 

150°C

 

0,062

 

250°C

0,074

 

400°C

ASTM E2584

0,097

 

600°C

0,124

 

800°C

0,189

 

950°C

0,209

Permanent linear change (%)

   

20°C - 250°C

 

-2,52%

250°C - 700°C

 

-3,00%

750°C - 1000°C

 

-3,30%

Chemical Analysis (average)

   
 

SiO2

 

34,5%

 

Al2O3

 

46,2%

 

ZrO2

 

1,0%

TiO2

 

0,1%

 

Na2O

 

7,0%

CaO

 

11,2%

Organic

 

<1%

ZIRCOFOAM 250 DATA SHEET Applied by injection

 

Description

Method

Value

Maximum temp (continuos)

 

1100°C

Maximum temperature for short time

 

1200°C

Melting point

 

>1250°C

Wet nominal density

 

0,46 g/cm 3

Nominal density after thermal cycle 250 ° - 700 °

   

C

(average)

0,30 g/cm 3

Nominal density after thermal cycle 750 ° - 1100 °

   

C

(average)

0,25 g/cm 3

Open porosity

   

Compression resistance

ISO 604:2002

0,30 MPa

Thermal conductivity W / mK at mean

   

temperature:

 

10°C (partially wet, density 0.40 g/cm³)

UNI EN 12667:2002

0,11

 

150°C

 

0,06

 

250°C

0,071

 

400°C

ASTM E2584

0,088

 

600°C

0,113

 

800°C

0,179

 

950°C

0,199

Permanent linear change (%)

   

20°C - 250°C

 

-2,20%

250°C - 700°C

 

-3,00%

750°C - 1000°C

 

-3,30%

Chemical Analysis (average)

   
 

SiO2

 

32,3%

 

Al2O3

 

51,0%

 

ZrO2

 

0,6%

TiO2

 

0,1%

 

Na2O

 

6,0%

CaO

 

10,0%

Organic

 

<1%

ZIRCOFOAM 300 DATA SHEET Applied by injection

 

Description

Method

Value

Maximum temp (continuos)

 

1300°C

Maximum temperature for short time

 

1350°C

Melting point

 

>1450°C

Wet nominal density

 

0,80 g/cm 3

Nominal density after thermal cycle 250 ° - 700 °

   

C

(average)

0,46 g/cm 3

Nominal density after thermal cycle 750 ° - 1100 °

   

C

(average)

0,30 g/cm 3

Open porosity

   

Compression resistance

ISO 604:2002

1,20 MPa

Thermal conductivity W / mK at mean

   

temperature:

 

10°C (partially wet, density 0.56 g/cm³)

UNI EN 12667:2002

0,21

 

150°C

 

0,123

 

250°C

0,134

 

400°C

ASTM E2584

0,151

 

600°C

0,184

 

800°C

0,221

 

950°C

0,263

Permanent linear change (%)

   

20°C - 250°C

 

-2,30%

250°C - 700°C

 

-3,20%

750°C - 1000°C

 

-4,00%

Chemical Analysis (average)

   
 

SiO2

 

24,1%

 

Al2O3

 

44,8%

 

ZrO2

 

15,5%

TiO2

 

6,0%

 

Na2O

 

5,0%

CaO

 

4,6%

Organic

 

<1%

ZIRCOFOAMZIRCOFOAMZIRCOFOAMZIRCOFOAM DATADATADATADATA SHEETSHEETSHEETSHEET SprayedSprayedSprayedSprayed

Description

Method

Value

Maximum temp (continuos)

 

1000°C

Maximum temperature for short period

 

1100°C

Melting point

 

>1200°C

Wet nominal density

 

0,88 g/cm 3

Nominal density after thermal cycle 250 ° - 700 ° C (average)

 

0,56 g/cm 3

Nominal density after thermal cycle 750 ° - 1100 ° C (average)

 

0,62 g/cm 3

Open porosity

 

13%

Compression resistance

 

0,25 MPa

Thermal conductivity W/mK at mean temperature:

   

50°C

 

0,087

150°C

0,099

250°C

0,113

400°C

ASTM E2584

0,126

600°C

0,152

800°C

0,209

950°C

0,242

Permanent linear change (%)

   

20°C - 250°C

 

-2,2%

250°C - 700°C

 

-6,3%

750°C - 1000°C

 

-8,1%

Chemical Analysis (average)

   

Si

 

13,4%

Al

 

6,5%

Zr

 

8,2%

Ti

 

4,2%

Na

 

4,2%

Ca

 

3,2%

O

 

53,0%

C

 

6,9%

Index toxicity of gases

CEI20-37/4-0:2006

1,6

Recommendations for use

Metallic materials

It’s important to remove any grease from the surfaces to be treated either by injection if you want to spray to ensure good adhesion of Zircofoam. Dust, rust and moisture in principle no problem, and the adhesiveness of the foam ceramic is also good on these surfaces.

Zircofoam has an excellent adhesion on steel, stainless steel, galvanized steel, titanium. Good adhesion on copper, bronze and brass. Low adhesion to aluminum and aluminate steel, which in this case can be increased after surface grinding with abrasive paper.

For painted surfaces it is recommended that a preliminary test to assess the degree of adhesion because the paint on most of the ceramic foam has little power to member- ship, in this case we will require the complete removal of paint until you get to bare me- tal.

The temperature of the surface that must be applied Zircofoam must be between -5 ° C and 150 ° C, at higher temperatures is not recommended for use in the early stages of polymerization occurs a release of highly flammable gases and vapors (ethyl acetate, acetylene) from the danger of self-injection and subsequent ignition of gas.

Building materials

It’s important to remove any grease and paint from surfaces to be treated either by injection spray if you want to ensure good adhesion of the ceramic foam. Dust, mold and moisture in principle no problem, and the adhesion of the ceramic foam is also good on these surfaces.

Zircofoam has an excellent adhesion to concrete, mortar, bricks, refractory materials, stone materials and all materials of mineral origin in general. Good adhesion to wood and wood products.

For painted surfaces require the complete removal of any paint and substrates of low consistency through the use of metal spatulas or brushes.

Zircofoam have a very low water vapor barrier and thanks to the large exchange surface increases the ventilation of the building by implementing the dispersion of moisture to the environment. The high resistance at moisture and mold makes Zircofoam suitable for use on surfaces subject to deterioration.

The temperature of the surface that must be applied to the ceramic foam must be between 0 ° C and 150 ° C. It is not recommended for use higher temperatures because in the early stages of polymerization occurs a release of gases and vapors of solvents highly flammable (ethyl acetate, acetylene) and danger of self-injection and ensuing fire gas.

Fibrous materials

Excellent adhesion to mineral wool, glass fibers, mineral fibers, plant fibers in general. Good adhesion to plastics, non-compact fibers.

Plastic materials

Adhesion grade almost absent. It was found a certain stickiness than plastics that have a certain affinity with water (nylon), obtained by following a particular process of preparation.

Examples of use of Zircofoam

Spray applications:

small parts for industrial use. (1) Welding head for sealing plastic with complex geometry;

pipes, valves and fittings of industrial and domestic use

(2);

heat insulation of metal surfaces in general (3);

fibrous materials: containment effect; to eliminate the effect dusting under air flowing effect or to make easier maintenance operation (4);

Just one layer of 1 mm to lower the surface temperature of 30% (depending on environmental conditions), for example, on piping hot water at 60°C with ambient temperature of 25°C in still air, after applying a layer of 1 mm ceramic foam produces a surface temperature of 38°C, for example, or on a metal surface with a temperature of 240°C, ambient temperature of 18°C in still air after application a layer of 1 mm ceramic foam produces a surface temperature of 165°C.

3

3

4
4

4

1

1

2

2

3

3
3

Applications on-site by injection :

Thermal insulation for filling cavities (1)

Quick repair masonry refractory furnaces or fireplaces (2)

Pipe insulation (3)

Injection moulding various items (4)

There are some examples of reduction of temperature with the use of ceramic foam in filling a gap.

Ceramic foam thickness = 2 cm, hot face temperature 100°C to 36°C cold face; hot 200°C to 53°C cold face; hot 350°C to 83°C cold face; hot face 400°C to 95°C cold face; hot face 500°C to 124°C cold face.

Ceramic foam thickness = 3 cm, hot face temperature 100°C to 30°C cold face; hot face 200°C to 47°C cold face; hot face 350°C to 62°C cold face; hot face 400°C to 73°C cold face ; hot face 500°C to 87°C cold face.

Ceramic foam thickness = 8 cm, hot face temperature 850 ° C to 88 ° C cold face.

Example : we have an oven built with a multilayer wall where 3 cm thick refractory bricks + 100 mm ceramic foam injected + 2 mm galvanized steel + 1mm ceramic foam sprayed on the outer surface will have a temperature difference of more than 1000 ° C. We have a temperature inside the furnace chamber to 1100 °C and the outer wall surface of 60 °C.

2 before

2 before

3

3

2 after

2 after

4

4

1 before

1 before

1 after

1 after

1

1

4

4

Alternative applications:

Have been identified alternative uses than the ceramic foam for high temperatures insulation ,between these :

Plastering with high moisture-resistant breathable. (1)

Sealing water leaks in cement filming (2)

Sound insulation

Absorbing the impact force. (filling deformable elements)

1 before

1 before

1 after

1 after

2 before

2 before

2 after

2 after

deformable elements) 1 before 1 after 2 before 2 after Safety advice : Always use Zircofoam

Safety advice :

Always use Zircofoam in ventilated ambient : danger of forming an explosive mi- xture due to evaporation of solvents and gases blowing (present only during the early stages of expansion and hardening). The ceramic foam it's not toxic, but it is essential to use protective devices to prevent irritation to eyes, skin and respi- ratory tract. The smell is due to small emissions of solvents such as ethyl acetate and acetic acid (about 15 g per liter) and expanding gas (acetylene). This odor will decrease and disappear in a few hours to totally dry.

Zircofoam ECO it’s a spray-on ceramic foam was crea- ted as coating of metals and

Zircofoam ECO it’s a spray-on ceramic foam was crea- ted as coating of metals and building materials to offer an insulanting material in combiantion of depolluting property in a temperatures range between - 20 ° C to 700 ° C. The innovative feature of this ceramic foam it's the strong resistance to moisture, weathering and normal mechanical stress , jointly the property offered by a particular cristalline form of titanium dioxide (anatase) as catalyst to split some complex organic molecules in elementary form, or with redox reaction of nitrous oxi- des and water to obtein nitrates. All taht thanks to pho- tocatalysis property of Anatase under UV beams. With Zircofoam Eco we have increased the efficiency of this process thanks to high exchange surface offered by ceramic foam morphology

to high exchange surface offered by ceramic foam morphology ZIRCOFOAMZIRCOFOAMZIRCOFOAMZIRCOFOAM ECOECOECOECO
to high exchange surface offered by ceramic foam morphology ZIRCOFOAMZIRCOFOAMZIRCOFOAMZIRCOFOAM ECOECOECOECO
to high exchange surface offered by ceramic foam morphology ZIRCOFOAMZIRCOFOAMZIRCOFOAMZIRCOFOAM ECOECOECOECO

ZIRCOFOAMZIRCOFOAMZIRCOFOAMZIRCOFOAM ECOECOECOECO DATADATADATADATA SHEETSHEETSHEETSHEET OnlyOnlyOnlyOnly SprayedSprayedSprayedSprayed

Description

Method

Value

Maximum temp (continuos)

 

600°C

Maximum temperature for short period

 

700°C

Melting point

 

>1200°C

Wet nominal density

 

0,76 g/cm 3

Nominal density after thermal cycle 250 ° - 700 ° C (average)

 

0,45 g/cm 3

Open porosity

 

15%

Compression resistance

 

0,25 MPa

Thermal conductivity W/mK at mean temperature:

   

50°C

 

0,102

150°C

0,118

250°C

ASTM E2584

0,147

400°C

0,163

550°C

0,178

700°C

0,212

Permanent linear change (%)

   

20°C - 250°C

 

-2,2%

250°C - 700°C

 

-8,5%

Index toxicity of gases

CEI20-37/4-0:2006

1,6

DepliantDepliantDepliantDepliant :::: Z.G.Z.G.Z.G.Z.G. CAMINICAMINICAMINICAMINI INOXINOXINOXINOX S.r.lS.r.lS.r.lS.r.l Via

DepliantDepliantDepliantDepliant ::::

Z.G.Z.G.Z.G.Z.G. CAMINICAMINICAMINICAMINI INOXINOXINOXINOX S.r.lS.r.lS.r.lS.r.l

Via Dei Peschi, 12 37141 Montorio - Verona - Italy Tel.045 8840041 Fax. 045 8840771 www.zgcamini.it info@zgcamini.it

Price per cartridge 380ml (unitary) Box 12 pieces Pallet of 96 boxes

cartridge 380ml (unitary) Box 12 pieces Pallet of 96 boxes Static Mixer Package 10 pieces Manual
cartridge 380ml (unitary) Box 12 pieces Pallet of 96 boxes Static Mixer Package 10 pieces Manual

Static Mixer

Package 10 pieces

12 pieces Pallet of 96 boxes Static Mixer Package 10 pieces Manual Coaxial Gun . Optional:

Manual Coaxial Gun . Optional: Nozzle and valve for Spray application .

Gun . Optional: Nozzle and valve for Spray application . Pneumatic Coaxial Gun Optional: Nozzle for

Pneumatic Coaxial Gun Optional: Nozzle for Spray application .

Coaxial Gun Optional: Nozzle for Spray application . Optional pneumatic spray nozzle with valve drive. Reactor

Optional pneumatic spray nozzle with valve drive.

. Optional pneumatic spray nozzle with valve drive. Reactor for industrial use available from June 2012

Reactor for industrial use available from June 2012

Z.G. CAMINI INOX SRL

Phone: 0039 045 8840041 - Fax: 0039 045 8840771 Via dei Peschi, 12 - MONTORIO (VR) - ITALY Web site: www.zircofoam.com - e-mail: info@zircofoam.com Web site: www.zgcamini.it - e-mail: info@zgcamini.it