Basalt is a volcanic rock with a high density and uniform mineral structure. Its hardness makes it the perfect raw material for the mineral wear protection products that are used worldwide under the brand name ABRESIST. ABRESIST cast basalt reliably protects plant components such as scale chutes, marl funnels or coke bunkers in the iron and steel industry or pipelines, e.g. fly ash pipes in thermal power plants, against frictional wear.
Zircon corundum wear protection with high temperature and abrasion resistance
The cast ceramic material KALCOR has proven itself in the lining of plant components in which high temperatures and temperature changes occur in addition to extreme wear stress, e.g. in chutes for hot sinter or clinker, in hot gas pipes or in dust removal cyclones and separators.
Ceramic wear protection for plant components with extreme wear and temperature stresses
The material oxide ceramic KALOCER made of more than 90 % aluminium oxide is produced as plates, fittings and cylinders. KALOCER is ideal for system parts with extreme frictional wear. Linings with material thicknesses from 1.5 mm thus also open up use under confined conditions. KALOCER is particularly suitable for lining separators, bunkers, chutes, belt transfers, concrete mixers or cyclones in all industries. With KALIMPACT as a hard-substance rubber composite, high impact resistance is also provided.
Trowelable, sprayable or castable hard compound for plant components and pipe systems
The hard compound KALCRET combines excellent wear protection properties with easy handling. Mineral hard materials serve as the basis. The special advantage of all compounds is their flexibility in practice. Large areas are coated quickly and safely, so that plant availability is restored in a short time.
KALCRET is suitable for lining plant components and pipe systems, in power plants, in the steel and cement industries and in waste incineration plants. Examples include pipe bends of pulverised coal lines, swirlers for dedusting blast furnace gases in steel plants, wind boxes and classifier linings in cement grinding.
Options for applying KALCRET:
Abrasion-resistant sliding promotion with high friction wear resistance
KALCERAM is an abrasion-resistant hard ceramic with good sliding properties. KALCERAM is the most economical material for lining plant components which, in addition to protection against frictional wear, require good sliding properties at higher temperatures. The material is particularly suitable for lining coal bunkers, chutes and flumes in coking plants, chutes of bag loading plants in cement works, as well as cyclones, separators and classifiers.
Hard overlay welding for high impact and wear resistance
KALMETALL is a metallic material produced by applying a hard overlay weld to sheet steel. As a manufacturer, we can specifically control the properties of the hard overlay welding by changing the filler metals and adjust them precisely to the needs of the application. The sheets produced by Kalenborn are characterised by excellent wear and impact resistance. As a rubber composite KALIMPACT a high reduction of noise and vibration is possible. These properties open up a wide range of applications for KALMETALL in numerous industrial plants.
Typical applications are: Screw conveyors, fan housings, cyclones and separators, mixer linings, piping components, screens, troughs and conveying troughs.
Hard rubber compound for heavy impact and friction wear
KALIMPACT as a hard rubber composite is used in particular when high impact loads occur in combination with strong abrasion. The wear protection is vulcanised in rubber.
KALIMPACT consists of either the fusion base ABRESIST, the oxide ceramic KALOCER or the hardfacing KALMETALL, depending on the requirements for friction wear and impact resistance in the composite system.
Standard sizes or elements adapted to the previous fastening systems, everything is feasible. In this way, the KALIMPACT system is designed to suit the respective application, thus providing the best cost/benefit factor for the user.
Not to be neglected is also the noise-reducing effect, which can demonstrably amount to up to half the perceived noise level. Operators of plant components in the vicinity of such stressed employees or those of opencast mines and quarries in the vicinity of residential areas are likely to be familiar with this problem.
Delivery forms and installation:
The rubber bond with KALOCER is laid in KALFIX laying compounds. In the additional bond with a carrier sheet, mechanical bolts are easily and securely fastened to the substrate. Depending on the version, KALIMPACT can also be fastened with magnets.
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