Densit® Wear Protection Products

densit aps

Densit ServicesDensit ApS specializes in the development, productionand delivery of high-performance solutions forindustrial strengthening and repair of equipment basedour unique, high-strength and dense cement-basedDensit® materials.

Densit® high-performance solutions are applied worldwide for:� Wear protection solutions� Foundations for Renewable Energy Solutions� Strengthening of oil and gas platforms and jackets� Industrial flooring and pavements

Global PresenceDensit ApS was founded in 1983 in Denmark. Densit ApS main-tains a project office and component fabrication for all Densit® wear protection solutions in Germany and a branch office in Ma-laysia for its offshore activities. Furthermore, Densit ApS is represented worldwide through a large and growing network of qualified partner companies.

An ITW CompanyDensit is part of the Illinois Tool Works (ITW) Group, with more than 875 companies in 54 countries - www.itw.com

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

densit WeaR pRotection solutions

Consultation and DevelopmentDensit will develop for you an economic wear protection system with recommendations regarding the tribology protection ma-terials that need to be applied as well as their manufacture and assembly.

Our goals for you:� Proper selection of materials� Optimal durability� Time and cost saving assembly� Low periods of inactivity for your facilities

Engineering / Production /Project Management Densit produces ready-to-install system components that are constructed for your specific usage needs. This includes pipeline systems, cyclones, air classifiers, chutes, valves, Venturi nozzles cones and panels, often together with qualified suppliers in Eu-rope, China and other Asian countries.

Densit has at its disposal more than 25 years of worldwide experi-ence in project development.

Our project team is engaged in every aspect of project develop-ment, from construction to production; from quality control to logistics.

InstallationA basic requirement for efficient wear protection is proper instal-lation.The wear protection composite material from Densit can be ap-plied in cast or sharpening procedures or as a trowel plaster. Your personnel can easily install these products. Pressure can be ap-plied to the coating 24 hours after application. Densit or one of our qualified partners can also perform or monitor the installa-tion.

DENSIT® WearFlex

DENSIT® WearCast

DENSIT® WearSpray

DENSIT® Cast Basalt

DENSIT® Aluminium Oxide Ceramic

DENSIT® Wear Plates

DENSIT® Pipe Components

DENSIT® Installation Service

DENSIT® Maintenance Service

DENSIT® Engineering

DENSIT® Training Courses

densit® dsp tecHnoloGy

�

�

�

The DSP technology – Densified Systems with ultrafine Particles – combines cement, microsilica and super plasticizer extremely tight, which leads to extremely low moisture content in the ma-terial. This ultra strong material is known worldwide as Densit® Binder.

The highly thick microstructure of Densit® Binder results in a par-ticularly high impermeability for chloride ions and a high electri-cal resistance. These two traits give the material, in addition to a particularly high corrosion resistance, an extraordinary durability against various stresses, such as abrasion.

Densit® Binder’s special characteristic is made clear in connection with its additives in a pressure test, for which a Densit® test cylin-der is used.

The additives are so tightly incorporated that they break before the Densit® Binder surrounding them.

The DSP technology was developed by Densit® and a patent for it was first applied for in 1978.

It is the basis for the ultra thick structure of Densit® materials and the key to their extraordinary attributes.

Our Goals for You:� Ultra strong materials (470 MPa)� Impermeability� High wear protection� Shock resistance� Chemical consistency� High temperature resistance

Normal cement structure

Cement particle and water

wc = 0.5 – 0.7

Super plasticized cement structure

Cement particle, super plasticizer and water

wc = 0.3 – 0.35

DSP Technology

Cement particle, super plasticizer, microsilica and water

wc = 0.1 – 0.3

Traditional cement-based mortar after pressure resistance test

Densit® Materialafter pressure resistance test

densit® WeaRflex, WeaRcast and WeaRspRay

DEnSIT® WEArFlEx Densit® WearFlex is a material combination of high-strength binder and extremely wear-resistant ceramic additives. Densit® WearFlex is produced as a normal temperature material (Max. 400°C consistent temperature) and as a high temperature mate-rial (max. 1,200°C consistent temperature.

Densit® WearFlex is used as mortar on an expanded metal sub-structure. Overhead mounts are also possible.

DEnSIT® WEArCASTDensit® WearCast is a material combination of high-strength binder and extremely wear-resistance additives. Densit® WearCast is produced as a normal temperature material (Max. 400°C con-sistent temperature) and as a high temperature material (max. 1,200°C consistent temperature.

Densit® WearCast is produced as a casting compound for all types of cast mountings.

DEnSIT® WEArSPrAYDensit® WearSpray is a material combination of high-strength binder and extremely wear-resistance additives. Densit® WearCast is produced as a normal temperature material (Max. 400°C con-sistent temperature).

With Densit® WearSpray, large area capacities, extreme mounting locations, short mounting times and overhead mountings are all possible.

Densit® Wear 500Densit®

Wear 1000

Densit® Wear 2000 Densit®Wear 3000

Flex Spray Flex Cast Flex Spray Cast HT Flex HT Spray HT Flex Cast HT

Thickness Kg/m3 2400 2270 2650 2950 2900 2625 3050 2900 2700 2575 2800

Durability Mohs 7.0 7.0 8.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0

Pressure resistance MPa 100 100 200 170 160 110 170 133 120 130 120

Bend tensile strength MPa 16 15 25 23 20 12 16 15 13 20 20

Max. constant temperature °C 400 400 400 400 400 400 1200 1200 1200 400 1200

Wear test cm3/50 m2 2.5-3.5 2.5-3.5 1.5-2.0 0.5-1.0 1.5-2.0 1.5-2.0 0.5-1.0 0.5-1.0 1.0-1.5 0.5-1.0 0.5-1.0

Chemical composition in %

CaO 18 15 20 18 18 13 6 6 6 17 6.0

Sio2 80 82 30 25 25 35 6 6 6 14 4.5

Al2O3+TiO2 1 1 48 55 55 50 87 86 86 7 11.0

SIC 62 63.2

densit® cast Basalt

Cast Basalt is made from special quality natural basalt. The basalt is melted in shaft furnaces at 1,300°C and then poured into the desired forms. Cast Basalt is produced in form components. Essentially, this means sheets and pipe components.

One of the most important processes in the production of Cast Basalt is the subsequent tempering during which the Cast Basalt forms a uniform crystalline structure that guarantees its high hard-ness and wear resistance.

Due to its bargain price/performance ratio, Cast Basalt is a material often used in tribology protection. In addition to its wear resis-tance, Cast Basalt is characterized by its singular resilience with regards to almost all acids and bases.

Cast Basalt surfaces remain permanently smooth and even while in use and thus offer the advantage of little caking.

Cast Basalt: Technical data

raw thickness g/cm2 2,8-2,9

Porosity % 0-3

Durability Mohs ~ 8

Pressure resistance n/mm2 400-450

Bending strength n/mm2 40

Temperature change resistance °C 0-110

Constant temperature resistance °C 350

Densit® Cast Basalt sheets are produced in the standard size 200 x 200mm, or as a hexagon with width across flats SW 200. lining thickness is available from 30mm.

Densit® Cast Basalt pipe components are delivered in nominal diameters from 40mm to 600mm. As a rule, the lining thick-ness is 20 or 25mm.

radial sheets, special forms or custom linings can be delivered at any time

Standard Aluminium Oxide square plates

Plate thickness in mm

1,5 2 4 6 10 13 25 50

10 x 10

20 x 20

50 x 150 X X X

75 x 150 X X X

75 x 100 X X X

100 x 100 X X X

150 x 100 X X X

200 x 150

densit® aluMiniuM oxide ceRaMic

PrODUCTIOnThe base product for the production of Aluminium Oxide Ceramic ist highly pure, synthetic (Alpha) Aluminum Oxide.

Nowadays, due to weartechnical and economic reasons Aluminium Oxide is predominantly produced with a purity level of 85 – 92%. The standard quality of 90 – 92% has been established in the industry.

A myriad of geometric forms are produced through compres-sion or casting. Slip casting is used for extreme geometric shapes.

The raw ceramic parts are baked at about 1,500°C. The ceramic parts are subsequently thick and without porosity.

PHYSICAl ATTrIBUTES:

raw thickness g/cm3

3,4-3,65

Porosity % 0

Durability in Mohs ~ 9

Pressure resistance MPa > 3000

Bending strength MPa 240 - 300

length expansion coefficient 1/K 6 - 8 x 10-6

Heat conductivity W/mK 20 - 22

Temperature application limit °C 1500

Pipe cylinders can be delievered with an inner diamter of 40 -400mm.

X = deliverable with hole

Advantages:� High hardness and wear resistance� Even abrasion� High temperature resistance � High corrosion resistance � Low specific weight � Custom-made lining upon request� Variable lamination thicknesses from 1-50mm

Plate mounting with glue, welding or bolting

Glue

Base plate

Glue

Base plate

Cap glued

Welding shellSpot weldingsBolt connection

Mosaic plates vulcanized in rubber

Square tiles (Paper base)

Hexagon plates glued to paper

Rubber thickness (4 mm) Square plates (20 x 20 mm)

Papier base Square tile (20 x 20 mm)

Hexagon plates(Ø 20 Width across flats)

The universally installable wear protection for extreme needs

Densit® WearPlates are economically produced connecting sheets made using special welding procedures out of a weld-able base materials and a buildup welding material that has been adjusted to its intended uses.

Using modern cutting techniques such as plasma, laser, or wa-ter jet cutting, Densit® WearPlates can be cut into parts that are in accordance with drawings and that are malleable either warm or cold.

Mounting is always possible, just like with traditional welding construction.

The most popular methods are welding or bolting.

Densit® WearPlates are available for delivery in four forms:1. As a standard sheet in accordance with measure ments, basic body and lining qualities2. In custom-cut sheets3. Shaped sheets4. Installable constructions

DSP 55 HrC

Fe Si Mn Cr Durability aprox. 50 – 60 HRC* Temperature resistance up to 500°C

DSP 60 HrC

Fe C Si Mn Cr NbDurability aprox. 60 HRC* Temperatue resistance up to 650°C

DSP 65 HrC Fe C Si Mn Cr BDurability aprox. 65 HRC* Temperature resistance up to 750°C

* Durability of the pure welding material

The following steels are used as basic material for our Hard Wearplates:

S 235 (St 37)

S 355 (St 52)

Or use-specific steel qualities such as boiler plate or corrosion-resistant

steels

Sizes of our standard sheets

2900x1800 mm

2900x1350 mm

2400x1100 mm

1900x850 mm

900x 850 mm

SErvICE ADvAnTAGES:� Comprehensive experience in welding techniques� Comprehensive portfolio of engineering solutions with welding techniques

densit® WeaRplates

MATErIAl ADvAnTAGES:� High shock resistance� High wear resistance� High thermal stability� Special production

Carbide caulk of buildup welding

Standard plate thickness conbinations for all systems

Base sheet in mm

Buildup Welding in mm

Total thicknessin mm

5 3 8

6 4 10

8 4 12

10 4 14

15 4 18

8 4+4 16

10 5+5 20

15 5+5 25

MOUnTInG SYSTEMS:

densit® WeaRplates

Buildup construction I

Buildup construction II

Buildup construction III

Bolt mounting with mother with internal thread

Bolt mounting using vertical boring

Bolt mounting with threaded stud

APPlICATIOn rAnGES:� Screening sheets� Coke sliders� Impact tables� Chutes� Pneumatic conveyor systems� Coal dust distributors� Screw flights� Fan flights� Cyclones� Deliveries� Throat armor sheets� etc.

Densit® pipe componentsfor pneumatic and hydraulic conveying systems

WeaR-Resistant pipe coMponents densit® pipe coMponents

Pipe bends, pipes, branch pipes or similar pipeline components often number amongst the most capable wear protection systems in industrial facilities.Densit disposes of more than 25 years of experience creating the optimal tribology protection system for you.

Densit offers solutions for all wear protection media.

Pipeline components with the following linings are available:

� Densit® materials� Cast Basalt� Aluminium Oxide Ceramic� Buildup welding� Special materials

Densit delivers pipeline components worldwide in all industrial fields.

Construction of wear protected pipe components

Material selection:Before determining the appropriate wear protection material, Densit con-ducts a system analysis, the goal of which is to be able to offer the custom-er an optimal material selection.

The material selection and the design of the individual pipe components al-ways occur based on the project and thus are always compatible with the existing pipeline system.

Sheet jackets:As standard material, the pipe compo-nents are made out of steel S235JR.

Straight pipes, longitudinal weld or spiral weld.

Surface preparation:Manual removal of rust or blasted SA2.5Primer coat, primer 40 µ.

Flange connections:Straight pipe, standardized based on DIN 2576, PN 10, bilateral compact flange.

Pipe bend, standardized based on DIN 2642, PN 10, bilateral coil and loose flange.

In addition to construction, Densit also offers all internationally used flange connections such as ASME, BS, Victau-lic or Viking-Johnson connections.

normal flange connection Connection with counter flange Connection with adapter flange

Example of system construction

Worn out pipe bend – repaired out of necessity

Construction also occurs beginning with the desire nomi-nal diameter of the pipeline system.

Depending on the choice of wear protection lining, this results in an altered outer diameter for the pipes and the flange connections, which are adjusted to fit the system.

pipes WitH densit® lininG

In contrast to other wear protection materials such as cast basalt or aluminum oxide ceramic, Densit® materials are not installed in the pipework components as semi-finished products in the form of pre-assembled cylinders or sheet goods.

Using a special core technology, Densit® is poured cold directly into the pipe components. This produces advantages such as a caulk-free lining, the ability to have eccentric linings and inclu-sion of the tribology protection over the entire wall thickness.

A high temperature resistance of 400°C completes the extraordi-nary attributes of pipework components lined with Densit®.

Ø Ø Ø Thickness Ø Amount Ø Ø Thickness

nominal diameter Pipe Pipe bend Flange

nW Flange Flange Bolt circle Bores Bores Coil Coil

40 108 108 100 220 16 180 8 18 158 15

50 114,3 114,3 110 230 16 190 8 18 168 15

65 127 127 125 250 16 210 8 18 188 15

80 139,7 139,7 150 285 16 240 8 22 212 15

100 168,3 168,3 150 285 18 240 8 22 212 15

125 193,7 193,7 175 315 18 270 8 22 242 17

150 219,1 219,1 200 340 18 295 8 22 268 17

175 244,5 244,5 225 370 19 325 8 22 295 18

200 298,5 298,5 250 395 19 350 12 22 320 18

225 323,9 323,9 275 425 19 375 12 22 345 18

250 355,6 355,6 300 445 24 400 12 22 370 20

275 343 368 325 475 24 430 16 22 400 20

300 368 368 350 505 24 460 16 22 430 20

350 419 419 400 565 28 515 16 25 482 24

400 470 470 450 615 28 565 20 25 532 24

450 520 520 500 670 32 620 20 25 585 24

Standard measurements for Densit® pipe componenets with flange connection Pn 10(other measurements or pressure levels available at any time)

Advantages of Densit® Pipe Components:� High wear resistance� Caulk-free lining� Eccentric linings� Tribology protection over the entire wall thickness� Temperature resistance 400 C� Bargain price/performance ratio

pipes WitH cast Basalt lininG

Ø Ø Ø Thickness Ø Amount Ø Ø Thickness

nominal diameter pipe Pipe bend Flange

nW Flange Flange Bolt circle Bores Bores Coil Coil

40 127 127 100 220 16 180 8 18 158 15

50 127 139,7 110 230 16 190 8 18 168 15

65 139,7 152,4 125 250 16 210 8 18 188 15

80 159 168,3 150 285 16 240 8 22 212 15

100 168,3 184 150 285 18 240 8 22 212 15

125 193,7 210 175 315 18 270 8 22 242 17

150 219,1 238 200 340 18 295 8 22 268 17

175 244,5 258 225 370 19 325 8 22 295 18

200 273 290 250 395 19 350 12 22 320 18

225 290 307 275 425 19 375 12 22 345 18

250 323,9 340 300 445 24 400 12 22 370 20

275 343 368 325 475 24 430 16 22 400 20

300 368 390 350 505 24 460 16 22 430 20

350 422 442 400 565 28 515 16 25 482 24

400 470 492 450 615 28 565 20 25 532 24

450 530 545 500 670 32 620 20 25 585 24

Standard measurements of Cast Basalt pipe components with flange connection Pn 10(other measurements or pressure level are always available)

Cast Basalt is poured as a semi-finished product in the form of cylinders in the desired nominal diameter, with 20mm wall thickness and 500mm component length.

Worldwide, cast basalt is the most often used wear protection material in piping systems.

Due to its high wear-resistance, Cast Basalt is used everywhere where abrasive media are transported pneumatically or hy-draulically.

Custom-fit radial mould lining is delivered for larger pipe diameters.

Application for the pneumatic or hydraulic transport of:� Coal dust� Flue ash� Cement� Sand� Calcium� Coke� Ore� Plaster� Splints� Pneumatic stowing� Other abrasive media

pipes WitH aluMiniuM oxide ceRaMic lininG

Aluminium Oxide Ceramic, as the hardest available wear protection material, is often used if the basic conditions in the pipeline systems are extreme.

High delivery rate and speeds, powerful closing pumping media and tight wiring often lead to high wear rates, for which only the application of aluminum oxide ceramic leads anappropriate durability for the pipework.

Even thin lining thicknesses result in increased durability.

Aluminum Oxide Ceramic is mounted as a semi-finished product in the form of pipe cylinders or as sheet goods in various lining strengths in the piping components.

Advantages:� Extremely wear-resistant� Variable lining thicknesses� Low installation weight� High durability

pipes WitH Buildup WeldinG

Buildup welding systems such as Densit® WearPlates are effec-tive in all respects as universally mountable wear protection – even for extreme demands.

In the past, pipework components had to be formed from iron sheets and painstakingly welded together in segments.

Today, thanks to state-of-the-art robot technology Densit is able to directly provide pipes and pipe bends with buildup welding – both inside and outside.

Ø Ø Thick-ness

Thick-ness Ø Thick-

ness Ø Amount Ø Ø Thick-ness

noninal dia-

meterPipe Pipe

bend Sheet Buildup Flange nW Flange Flange Bolt

circle Bores Bores Coil Coil

100 121 121 7,1 3,4 100 220 16 180 8 18 158 15

125 139,7 139,7 4 3,35 125 250 16 210 8 18 188 15

150 168,3 168,3 5,6 3,35 150 285 16 240 8 22 212 17

175 193,7 193,7 5,6 3,75 175 315 18 270 8 22 242 17

200 219,1 219,1 6,3 3,25 200 340 18 295 8 22 268 18

250 273 273 8 3,5 250 395 19 350 12 22 320 18

300 323,9 323,9 6,35 3,6 300 445 24 400 12 22 370 20

350 355,6 355,6 6,35 3,45 350 505 24 460 16 22 430 20

400 406,4 406,4 6,35 3,5 400 565 28 515 16 25 482 24

450 457,2 457,2 6,35 3,25 450 615 28 565 20 25 532 24

500 508 508 6,35 3,65 500 670 32 620 20 25 585 24

Standard measurements for pipes with building up welding

Site Measure Design and drafting Fabrication Lining Protective coatings

S

hipp

ing

Inst

alla

tion

Maintenance and Support

We close the circle of services for our customer!

Project OfficeDensit GermanyFritz-Peters-Str. 40 · D-47447 MoersTel.: +49 2841 88237-0Fax: +49 2841 88237-10E-Mail: ger@densit.comInternet: www.densit.com

Densit ApS Gasværksvej 46 · DK-9000 Aalborg Tel.: +45 9816 7011 Fax: +45 8818 4979 E-Mail: mail@densit.com Internet: www.densit.com

Component FabricationDensit GermanySaalhoffer Str. 17 · D-47495 rheinbergTel.: +49 2841 88237-0Fax: +49 2841 88237-10E-Mail: ger@densit.comInternet: www.densit.com