Plasters are normally troweled into place. They need to have a smooth cohesive consistency and good adhesion to surfaces. Some Keramicalia materials are designed as plasters, but most of the others can be modified into plasters. Insulag s a very good boiler plaster, also used on steam pipes etc, especially the tricky parts where rockwool and cladding are difficult. For outdoor applications, use Keratuff 2 in place of Insulag. Keratuff 1 is a really strong plaster, and is used also for thin walled refractory pieces. Fibre Plaster are famous for being totally immune to thermal shock damage. They can also handle severe vibration and abuse. They can be made to a wide range of consistencies, temperature ratings and hardness.

Fibre Plaster

​Description: Aluminosilicate ceramic fibre in plaster form, supplied wet ready to use. Very easily applied to any surface​

Applications:​ High temperature insulation. Heat shields Burner cores, Chimneys, Thermal shock protection, Furnace hoods, Preheater lids, Ladle lids, High gas flow areas of fibre lined furnaces, Repair of cracks and joints, Protection of equipment, Protection of electrical cables, Upgrading of linings for thermal efficiency or faster cycle times. Repair of broken element holding lips. Sealing of kiln and furnace doors. Lightweight doors. 

Properties:​ Very low thermal conductivity; 0,2W/mK. Electrically insulating, Very low density; 1,3g/cm³ wet, O,7g/cm³ fired. Low shrinkage; normally 12% but all taken up in the thickness of the layer, therefore no cracks. Extreme thermal shock resistance. Very low thermal mass. High reflectivity. Low permeability compared to fibre blanket or modules. High reflectivity. Rapid commissioning. Excellent adhesion to all surfaces. Minimal anchoring required. 

Chemical composition: aluminosilicate 55%Fe20³ < 0,1%                 

Alkalis O,27%Volatiles 45%​

Installation: Fibre Plaster is supplied wet in well sealed plastic 10kg buckets. The wet density is normally 1,1g/cm³.It can easily be thinned down with water or it ordered stiffer for tamping applications.

Onto brick; Blow dust off and trowel on. Insulating firebrick or very porous surfaces; Rub a thin layer on very firmly before building up the profile. Cables;   No preparation required. Ceramic fibre; Over fresh fibre, softening by water dilution usually helps. Onto steel;  Expanded metal, Mentex 72 or similar. Cut and bend a few strands backwards and tack them onto the steel so that the expanded metal sheet is about 5mm off the steel surface. Squeeze some Fibre Plaster through the mesh and then plaster over it to the desired thickness. Free standing structures; Use expanded metal as a skeleton. Door seals; Plaster a narrow strip onto one surface, cover with fibre paper and close the door to press the Fibre Plaster into the exact thickness required.

Insulag​

Insulag is a range of very light insulation materials. They are all asbestos free. Insulag 2 is a white powder, which is mixed with water and trowelled or plastered. It can be used up to 600°C continuous temperature, or as fire protection. Its thermal decomposition is highly endothermic, giving it very superior fire resistance. Density is around 0.6g/cm³, depending on water addition. Thermal conductivity is very low, about 0.2W/mK. Setting time is around 20 minutes. Insulag 2 has no shrinkage below 600°CAfter setting the material is easily cut, machined or sanded. It will deteriorate if exposed to rain for long periods. When used as pipe lagging or boiler plaster, no cladding is required. Mix by hand in small quantities to desired consistency. It will stiffen as the plasticizer dissolves.  Add water as you work, but finish working it within 10 minutes of mixing.

Insulag 1 is the pourable version, for precasting.

Insulag 3 is an ultralight material used in composites.

Insulag 4 is a hard wearing insulation for flooring.

Insulag 5 is very easily removed can be re-mixed with water and re-used. Used where insulation has to be regularly removed for inspection.

Insulag 6 is for cold/ cryogenic insulation. It contains expanded polystyrene in a non-flammable composition.

Insulag 7 is rapid setting insulation.

Insulag 8 is injectable insulation.

Insulag 9 is weather resistant insulation

.Insulag 10 is acid resistant insulation.

Insulag 2​

Insulag is a range of very light insulation materials. They are all asbestos free.

Insulag 2 is a white powder, which is mixed with water and trowelled or plastered. It can be used up to 600°C continuous temperature, or a fire protection. Its thermal decomposition is highly endothermic, giving it very superior fire resistance. Density is around 0.6g/cm³, depending on water addition. Thermal conductivity is very low, about 0.2W/mK. Setting time is around 20 minutes. Insulag has no shrinkage below 60.0°CAfter setting the material is easily cut, machined or sanded. It will deteriorate if exposed to rain for long periods. When used as pipe lagging or boiler plaster, no cladding is required. Mix by hand in small quantities to desired consistency. It will stiffen as the plasticizer dissolves. Add water as you work, but finish working it within 10 minutes of mixing.

Keratuff 1​

Description: Keratuff is a structural refractory insulation. Insulation materials are normally only usable as a backing or with some kind of structural support. Keratuff has sufficient strength to be a free standing structure.

Applications: Precast pizza oven roofs, crucible furnace lids, heat shields, splash boards, aluminium launders, burner shields.

Thermal Conductivity:​​​​​​​​ Maximum Service Temperature:   1200°C.          

Keratuff melts between 1200°C and 1300°C.   Shrinkage at 1200°C is 1,7%.

Density: 1,0 dry, 0,85 fired.

Strength: 23MPa at 110°C, 6MPa fired 1200°c.

Composition: Contains Litefill and Hollofill synthetic aggregates, and zirconia containing ceramic fibres. 53/o alumina.

Preparation: Add +40 to +50% water to the powder, mix well and apply it. It can be vibration cast at +40% water, +50% is easier to apply by trowelling.   Water content is not critical and need not be measured. Extensive mixing and trowelling improves the fibre dispersion and improves strength.   All particles are less than 1mm diameter. Setting time is about one hour.

Packaging:  10Kg in thick polythene bags.

Pilot Plant Code: OEV.

Keratuff 2

​Description:  Keratuff 2 is a structural insulating refractory. Insulation materials are normally only usable as a backing or with some kind of structural support. Keratuff 2 has sufficient strength to be a free standing structure. It has low permeability and is easily machined or cut when dried or fired.

Applications:  Electric kiln walls and element holders, crucible furnace lids, heat shields, masonry protection in charcoal ovens, aluminium launders, burner shields, machined components.


Thermal Conductivity: 
 ​​​​
Maximum Service Temperature: 1230°C.  Shrinkage at 1200°C is 1,91.

Density: 0,8 g/cm3 dry.

Strength: 6 MPa at 110°C,  6 MPa fired 1200°c.

Composition: Contains Litefill and Hollofill synthetic aggregates and zirconia containing ceramic fibres.

Preparation: Add +40 - 5O litres of water to the powder, mix well and apply it.

It can be vibration cast at +40% water.   Water content is not critical and need not be measured.

Extensive mixing and trowelling improves the fibre dispersion and improves strength.  All particles are less than 1mm diameter. Setting time is about one hour.

Colour: Grey.   Yellow when fired 1200°C.

Packaging:  10Kg in thick polythene bags.

Pilot Plant Code: PGK.