Densit® WearFlex

®
Densit® WearCast
Wear protection Densit® WearSpray
- for a range of processing industries

In processing industries, unexpected or unscheduled plant

shutdowns, caused by wear in processing machinery, are costly
and thus reduce competitiveness. Wear is especially familiar in
those industries that process or use large quantities of abrasive
material in their production plant.
The processing industries’ demands for efficiency and economy,
by reducing main­tenance costs and shutdown time, are an
important source of inspiration.

”
Within the framework of the Densit® With its unique techno­logy, ITW Engineered Polymers has
technology, we fulfil the needs of specific
market segments for materials and developed products especially designed for the wear protection
systems to reinforce areas which are both of processing parts in industrial plants. Over the years ITW
exposed to severe demands and are critical to

”
the end users’ activities. Engineered Polymers has accumulated detailed knowledge and
experience of solving such problems.

®
Product overview Technical Guidelines WEAR PROTECTION
APPLICATIONS
- MATERIALS - wear protection The lifetime of Densit wear
protection increases with
® • Impacting particle velocity is up
to 25 m/s
systems re­duction in particle size, slower • Impact angle is smaller than 45°
•W  hen alkalis are present in the
ITW Engineered
particle velocity, and a smaller Polymers provides
DENSIT® WEARFLEX environment by more than 2 %
Densit® WearFlex is a range of extremely high-strength
angle of particle impact.
(by weight) it will in some cases
wear protection
compounds combined with hard-wearing aggregates. Densit® The Densit® range of attack Densit® products solutions which are
WEARFLEX

Densit® products are safely

WearFlex is available as both low- and high-temperature wear protection systems recommended for wear protection • Densit® products willl show especially suited to
products, catering for process temperatures up to 400°C optimal performance when the
comprises: in environment where: extreme industrial
(750°F) and 1200°C (2190°F) respectively. All low • Impacting particle size is up to 4 environ­ment pH-value is in the
temperature WearFlex products have now been improved t o mm in diameter range 6-11 situations where
a degree making fibres superfluous when trowel on standard ü Densit® wear protection low maintenance
expanded meetal mesh. Densit® WearFlex products can products. Acid pH-Value Base costs and minimum
be troweled directly onto an anchoring mesh in typically a 1 2 3 4 5 6 7 8 9 10 11 12 13 14 shutdown time are
WEARCAST 

thickness of 20-50 mm (3/4“-2“). ü Densit components.

®
critical to the
Strong Attack Weak attack No attack
DENSIT® WEARCAST attack operation.
Densit® WearCast is a range of extremely high-strength ü Densit® insulated wear
compounds combined with hard-wearing aggregates. Densit® protection. Based upon the physics of wear mechanisms the general thumb rule is that the wear rate can be ITW Engineered
WearCast is available as both low- and high-temperature assumed to increase with maximum particle size raised to the third power and with maximum
Polymers delivers
particle elocity raised to the third power (i.e. a 25 % increase in particle size or velocity will
products, catering for process temperatures up to 400°C
ü Auxiliary products. double the wear rate). Also, the wear rate increase with hardness and angularity of the particles, wear-resistant
(750°F) and 1200°C (2190°F) respectively. Densit® determined by media mineralogy and physical form.
WearCast products can be cast in a wide range of shapes. linings for process
WEARSPRAY 

machinery exposed to
DENSIT® WEARSPRAY PRODUCT SELECTION erosive wear such as:
Densit® WearSpray consists of an extremely high-strength Densit wear ®
compound com­bined with hard-wearing aggregates. The
maximum permissible process temperature is 400°C
proctection IF THE PROCESS REQUIRES: ... THE OPTIMAL PRODUCT CHOICE IS: ü Cyclones.
(750°F). Densit® WearSpray is installed by spraying onto an products For serial needs. 500 series
ü Ducts.
Superior wear resistance. 2000 series
anchoring mesh, giving flexibility and speed in installation.
All Densit® solutions offer unique
Temperature resistance
Densit® WearFlex ü Pipes and bends.
properties in wear protection: Densit® WearCast
up to 400°C (750°F ). Densit® WearSpray
ü Venturis.
- CONCEPTS ü High wear resistance.
Densit® WearFlex HT
Temperature resistance
up to 1200°C (2190°F ).
Densit® WearCast HT ü Chutes.
ü No vulnerable joints.
DENSIT® COMPONENTS Wear protection for UNIQUE SOLUTIONS ü Separators.
COMPONENTS

Insulation against heat loss by

The linings are completely jointless and can be formed ü Seamless graduation in lining adiation and replacement of Densit® wear protection provides
into any geometry. thick­nesses, including refractories.
Densulate
many industries unique solutions to wear problems ü Mills.
eccentric lining in pipes. in many industries by:
The flexibility and smoothness means that the lining can
Densit® wear-resistant linings are ü Fan casings.
 lexibility in installation for
üF especially suitable for protecting ü Increasing lifetime of new and
be formed into the ideal shape, graduating seamlessly IF THE COMPONENT REQUIRES: ... THE OPTIMAL PRODUCT CHOICE IS:
in thickness to meet the need for greater or less wear complex geometries. processing parts in pneumatic existing components. ü Valves.
transport and the transport of ü Increasing safety margins
protection in different areas within a component. Overhead wear lining. Densit® WearSpray
 ast and easy installation
üF slurries, and also against wear by against unscheduled shutdowns. ü Sluices.
including overhead applications. bulk solids. ü Minimising maintenance costs.
DENSIT® INSULATED WEAR PROTECTION Complex geometry.
Densit® WearFlex
ü Optimising pollution control ü Bunkers.
DENSULATE 

Densit® WearSpray
Densulate insulated wear-resistant linings are designed ü Mechanical reinforcement Densit® wear solutions are mainly of plants by reducing particle
to protect components against erosive wear, while at the ensuring that linings do not Densit® WearFlex installed in these industries: emissions through exposed wear ü Pits.
In-situ lining.
same time reducing heat loss by radiation. They consist of become dislodged. Densit® WearSpray areas.
Densit® wear protection lining installed over an underlying
ü Cement and lime. ü Outlet/cyclones.
Lining before installation. All products and Densit® components ü Coal-fired power generation.
insulation layer.  igh thermal resistance and
üH ü Steel. ü Hoppers.
absorption. Very fast installation. Densit® WearSpray ü Paper.
ü Mineral sands. ü Back house filters.
Technical specifications Densit® Standard Wear Protection Products
Densit® Densit® Densit® Densit®
WEAR 500 WEAR 1000 WEAR 2000 WEAR 3000
Low temperature Low temperature Low temperature High temperature Low temperature
Comments Flex Spray Flex Cast Flex Spray Cast HT Flex HT Flex

Description Trowel product. Sprayable product. Trowel product. Castable product. Trowel product. Sprayable product. Castable product for high Trowel product for high Trowel product.
To use in almost all kind of Suited for the protection To use in almost all kind of To use in pipings/­elbows To use in almost all kind of Suited for the protection tempera­ture applications. temperature applications. To use in almost all kind of
application. Very good for of larger surface, complex application. Very good for and pre­cast shapes, where application. Very good for of larger surface, complex Excellent for wear/­heat Excellent for use as wear/ application. Very good for
complex geometry. geometry. complex geometry. in-sito lining is geome­ complex geometry. geometry. protec­tion of piping/­ heat protection in almost complex geometry.
Fast and easy installation. Very fast installation there Fast and easy installation. trically impractical or would Fast and easy installation. Very fast installation there elbows and precast all kind of application. Very Fast and easy installation.
reduce the outage time. involve extended outage reduce the outage time. shapes, where in-sito lining good for complex geometry.
time. is geometrically im­­prac­tical Fast and easy installation.
or would involve extended
outage time.

Density of material Kg/m3 2400 2270 2650 2950 2900 2625 3050 2900 2575
(lb/ft3) (150) (140) (165) (184) (181) (164) (190) (181) (161)

Hardness Mohs scale 7.0 7.0 8.0 9.0 9.0 9.0 9.0 9.0 9.0

Compressive Strength MPa 100 100 200 170 160 110 170 133 130
(Kpsi) (14.5) (14.5) (29.0) (24.7) (23.2) (16.0) (24.7) (19.3) (18.9)

Flexural strength MPa 16 15 25 23 20 12 16 15 20
(Kpsi) (2.3) (2.2) (3.6) (3.3) (2.9) (1.7) (2.3) (2.2) (2.9)

Coefficient of thermal exp.1/°C 10x10-6 10x10-6 10x10-6 10x10-6 10x10-6 10x10-6 10x10-6 10x10-6 10x10-6
1/°F) (5.6x10 ) (5.6x10 ) (5.6x10 ) (5.6x10 ) (5.6x10 ) (5.6x10 ) (5.6x10 ) (5.6x10 ) (5.6x10-6)
-6 -6 -6 -6 -6 -6 -6 -6

Thermal conductivity W/m °C 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 5.0

Maximum service temper. °C 400 400 400 400 400 400 1200 1200 400
(°F) (750) (750) (750) (750) (750) (750) (2190) (2190) (750)

Abrasion resist. cm3/50 m2

2.5-3.5 2.5-3.5 1.5-2.0 1.5-2.0 2.0-3.0 0.5-1.0 1.5-2.0 0.5-1.0 0.5-1.0

Erosion resistance min./cm3 55 55 85 140 130 100 170 140 280

Casting Shrinking vol. % 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2

% CaO 18 15 20 18 18 13 6 6 17
% Sio2 80 82 30 25 25 35 6 6 14
Chemical % Al2O3+TiO2 1 1 48 55 55 50 87 86 7
composition % SiC 62
% Fe2O3 < 0.2 < 0.2 < 0.7 < 0.2 < 0.2 < 0.2 < 0.3 < 0.3 <0.6
% Cr6+ < 0.0002 < 0.0002 < 0.0002 < 0.0002 < 0.0002 < 0.0002 < 0.0002 < 0.0002 < 0.0002
Densit® anchoring/reinforcement WEAR PROTECTION Technical Guidelines
- auxiliary products for use in Densit® wear protection APPLICATIONS
- wear protection The lifetime of Densit® wear
protection increases with
• Impacting particle velocity is up
to 25 m/s
Steel mesh is used for anchor­ing of Densit® wear-resistant linings for a range of process ITW Engineered systems re­duction in particle size, slower • Impact angle is smaller than 45°
• When alkalis are present in the
temperatures. Polymers provides particle velocity, and a smaller
environment by more than 2 %
wear protection angle of particle impact.
(by weight) it will in some cases
solutions which are The Densit® range of attack Densit® products
Densit® products are safely
The Densit Anchoring mesh
®
Further details for choosing the right thickness are outlined in the Densit ® especially suited to wear protection systems recommended for wear protection • Densit® products willl show
optimal performance when the
400°C is mainly used when method of installation at given lining WearFlex Installation Manual. extreme industrial comprises: in environment where:
• Impacting particle size is up to 4 environ­ment pH-value is in the
installing a Densit® WearFlex or
situations where mm in diameter range 6-11
Densit® WearSpray lining, but is
low maintenance ü Densit® wear protection
also suitable for installing Densit®
WearFlex HT in cases where max. costs and minimum products. Acid pH-Value Base
ope­­rating temperature is limited to shutdown time are 1 2 3 4 5 6 7 8 9 10 11 12 13 14
500°C. critical to the ü Densit components.
®

Strong Attack Weak attack No attack

At higher operating temperature
operation. attack
ü Densit® insulated wear
Densit® Anchoring mesh 800°C
ITW Engineered protection. Based upon the physics of wear mechanisms the general thumb rule is that the wear rate can be
must be used. Depending on PROPERTY
Anchoring mesh Anchoring mesh
assumed to increase with maximum particle size raised to the third power and with maximum
installation situation the mesh must 400°C 800°C Polymers delivers particle elocity raised to the third power (i.e. a 25 % increase in particle size or velocity will
be placed in an appropriate distance Material type
Mild steel
AISI 304 L wear-resistant ü Auxiliary products. double the wear rate). Also, the wear rate increase with hardness and angularity of the particles,
stainless steel determined by media mineralogy and physical form.
from the steel casing. linings for process
Weight kg/m2 (lb/ft2) 4.4 (0.9) 2.0 (0.4)
E-modulus GPa (Mpsi) 205 (30) 205 (30) machinery exposed to
Maximum erosive wear such as: PRODUCT SELECTION
°C (°F)
service temp. 500 (930) 800 (1470)
Densit wear ®

ü Cyclones. proctection IF THE PROCESS REQUIRES: ... THE OPTIMAL PRODUCT CHOICE IS:

ü Ducts.
products For serial needs. 500 series
Superior wear resistance. 2000 series
When installing the new improved WearFlex products (except HT-products) on expanded
All Densit® solutions offer unique
metal mesh fibres are generally NOT required. ü Pipes and bends.
Temperature resistance
Densit® WearFlex
properties in wear protection: Densit® WearCast
up to 400°C (750°F ).
ü Venturis. Densit® WearSpray
ü High wear resistance.
Densit® WearFlex HT
Fibres protect the wear-resistant service temperatures up to 1200°C. material the lining is protected ü Chutes. Temperature resistance
up to 1200°C (2190°F ).
Densit® WearCast HT
lining against settlement cracks and WearSpray fibres are suitable for use against settlement cracks only. ü No vulnerable joints.
random impact of larger particles. with WearSpray product, and due to
Wear protection for UNIQUE SOLUTIONS ü Separators. Insulation against heat loss by
Steel fibres are suitable for use with the properties of the poly­propylene Densit® wear protection provides ü Seamless graduation in lining adiation and replacement of
WearFlex and WearCast products, for many industries unique solutions to wear problems ü Mills. thick­nesses, including refractories.
Densulate

in many industries by: eccentric lining in pipes.

PROPERTY
Steel fibres Steel fibres Steel fibres WearSpray Densit® wear-resistant linings are ü Fan casings.
400°C 800°C 1200°C fibres especially suitable for protecting ü Increasing lifetime of new and  lexibility in installation for
üF IF THE COMPONENT REQUIRES: ... THE OPTIMAL PRODUCT CHOICE IS:
DIN 17140
Hardened 1.4016 1.4841 Poly-
processing parts in pneumatic existing components. ü Valves. complex geometries.
Material Werkstof
mild steel Stainless Stainless propylene transport and the transport of ü Increasing safety margins Overhead wear lining. Densit® WearSpray
ü Sluices.
no. steel steel
slurries, and also against wear by against unscheduled shutdowns.  ast and easy installation
üF
Length mm (in) 12.5 (0.50) 12.5 (0.50) 12.5 (0.50) 6 (0.25)
bulk solids. ü Minimising maintenance costs. including overhead applications.
Diameter mm (in) 0.4 (0.016) 0.4 (0.016) 0.4 (0.016) N/A
ü Optimising pollution control ü Bunkers. Complex geometry.
Densit® WearFlex
Densit® WearSpray
Thickness µm N/A N/A N/A 35-40
Densit® wear solutions are mainly of plants by reducing particle ü Mechanical reinforcement
Width µm N/A N/A N/A 100-250
installed in these industries: emissions through exposed wear ü Pits. ensuring that linings do not Densit® WearFlex
Density g/cm3 (lb/in3) 7.8 (0.28) 7.8 (0.28) 7.8 (0.28) 0.9 (0.033) In-situ lining.
areas. become dislodged. Densit® WearSpray
Tensile strength MPa (kpsi) 1200 (175) 900 (130) 1600 (235) 425 (62) ü Cement and lime. ü Outlet/cyclones.
E-modulus GPa (Mpsi) 205 (30) 205 (30) 205 (30) 13 (1.9) ü Coal-fired power generation. Lining before installation. All products and Densit® components
Ultimate strain % N/A N/A N/A 7 ü Steel. ü Hoppers.  igh thermal resistance and
üH
Maximum ü Paper. absorption. Very fast installation. Densit® WearSpray
°C (°F) 400 (750) 800 (1470) 1200 (2190) 100 (210)
service temp.
ü Mineral sands. ü Back house filters.
 TRACK RECORD

ITW Engineered Polymers has

more than 30 years’ experience
in the development and
installation of reliable wear
protection.
Densit® wear-resistant linings
are already standard solutions
for specific components
within a range of processing
industries.
Major system suppliers world-
wide use specified Densit®
wear-resistant linings in key
parts of their processing
equipment.

ITW Engineered Polymers

provides high performance
solutions to customers in
accordance with its ISO 9001,
ISO 14001 and OHSAS 18001
quality system, certified
by Lloyd’s Register Quality
Assurance.

The appropriate Densit® wear protection is selected

according to the specific requirements for each
process and component.

ITW Engineered Polymers ApS | T: +45 9816 7011 | E: [email protected] | www.itwengineeredpolymers.com

©2015 ITW Engineered Polymers ApS 01.03.2015