Heat-setting mortars develop a ceramic set with a strong bond only at furnace tem-peratures. These mortars provide flexibility in expansion and contraction as furnace temperature rises and falls. Heat-setting mortars may also compensate for the high thermal expansion of certain brick, and for differences in thermal expansion between brick of different types used in the same furnace. Available in various compositions, heat-setting mortars are supplied for laying refractory brick in applications where full or solid joints with minimum shrinkage are especially desirable; or where a very strong bond through the entire wall thickness is not an essential requirement.
Air-setting mortars take a rigid set when dried. Prepared from suitable refractory materials by proper selection and combination, chemical binders impart air-setting properties, and maintain the strength of the bond up to the temperature at which the ceramic bond takes effect. Air-setting mortars form mechanically strong joints with high resistance to abrasion and erosion. The wall is bonded throughout, from the hot to the cold surface.
The following product descriptions of Harbison-Walaker’s mortar materials
refracto-ries are categorized by their classification. This listing represents the major brands
supplied for a wide variety of furnaces and applications.
Click here for Technical Data Sheets or go to www.hwr.com
BASIC MORTARS THERMOLITH®
An air-setting, high temperature bonding material with a chrome ore base, THERMOLITH® possesses excellent resistance to corrosive slags and fumes through a wide range of temperatures. It is used to lay basic brick of all types or as a neutral layer between brick of any type.
FIRECLAY MORTARS HARWACO BOND®
Shipped wet or dry, HARWACO BOND® refractory mortar consists of high fired, high-alumina calcines and smooth working plastic clays. It combines high refractoriness, volume stability, and smooth trowelling qualities.
’SAIRSET®
A wet, high strength, air-setting, high temperature mortar. This mortar is formulated for trowelled joint, but can be thinned for dipping by adding water.
’SAIRBOND®
A dry, air-setting version of ’SAIRSET®, for use at temperatures up to 3000°F.
’SAIRBOND® has excellent trowelling characteristics.
PHOSPHATE-BONDED HIGH-ALUMINA MORTARS
PHOXBOND®
This phosphate-bonded, wet mortar provides high bonding strength and excellent resistance to corrosion and erosion. PHOXBOND® refractory mortar can be sprayed or brush coated over refractory walls to reduce perme-ability without peeling. PHOXBOND® mortar should not be thinned unless absolutely necessary, and then very cautiously. Rolling the drums prior to opening will help bring the mortar to working consistency. Heating to a minimum of 500°F (260°C) is necessary to develop full strength.
GREENSET® -85-P
A wet, phosphate bonded, high alumina mortar, with smooth working characteristics, and good resistance to slag attack.
GREENSET®-94-P
A wet, 94% alumina, phosphate-bonded mortar with excellent refractori-ness. GREENSET®-94-P has excellent resistance to aluminum reaction, smooth working characteristics, and resistance to slag attack. It is especially effective in laying extra high-alumina brick and as a coating in a variety of applications.
HIGH-ALUMINA MORTARS CORALITE® BOND
A dry high-alumina based air-setting mortar. Develops high strength and has excellent working properties.
CORALITE® BOND his high refractori-ness and excellent resistance to attack by corrosive slags
No. 36 REFRACTORY CEMENT® No. 36 REFRACTORY CEMENT® is a wet, air-setting, high temperature cement with good bonding strength and refractoriness. It can be used for all types of high-alumina brick where extra bond strength is needed in the joints for structural stability.
HIGH-ALUMINA MORTARS Con’t KORUNDAL® BOND
High-Alumina air-setting mortar based on high purity alumina aggregate. It is suitable for use at temperatures up to 3200°F (1760°C).
KORUNDAL® MORTAR
A heat-setting mortar with extremely high refractoriness, KORUNDAL® MORTAR provides excellent service at temperatures up to 3400°F (1873°C). It also has exceptional stability and load-bearing ability at high temperatures and is very resistant to corrosion by volatile alkalies and slags in all types of furnaces.
TUFLINE® MORTAR
A dry, high purity 95% alumina mortar.
TUFLINE® MORTAR has very good trowelling characteristics. It is intended for use with TUFLINE® 95 DM and TUFLINE® 98 DM in applications requiring materials with very low silica contents.
GREENPATCH 421
An air setting high-alumina patching plaster. It is used primarily for repairing fiber lined furnaces.
GREFPATCH® 85 & WET A phosphate-bonded, 84% alumina patching plaster. GREFPATCH® 85 can be applied by trowelling or hand packing of areas that have spalled or eroded. Formulated to minimize shrinkage. A WET version, tempered to a higher workability is also available.
Click here for Technical Data Sheets or go to www.hwr.com
ALUMINA-CHROME MORTARS AUREX® BOND
A 75% chromic oxide containing, phosphated bonded mortar . AUREX® BOND is used in highly corrosive applications such as slagging gasifiers.
RUBY® MORTAR
Phosphate-bonded mortar with 10%
chromic oxide. High bond strength;
excellent resistance to corrosion by non-ferrous and ferrous metals.
RUBY® BOND
A unique air set alumina-chrome mortar with excellent corrosion resistance and high temperature strength
SILICA MORTARS FUSIL® MORTAR
A high purity, air-setting fused silica mortar. Available dry with a separate liquid component. For varying consis-tency, a special liquid thinner is available.