Purpose and uses

• Patching
• Repairs
• Fill small voids in brick lining
• Line geometry that is difficult to
brick or cast
• The original no-cement
monolithic
• Fast dryout
Main liner is brick but dished head
geometry does not allow for brick or
casting

SUPER HYBOND 60 PLUS

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Major Applications

» Cement/Lime
» Steel Ladles
» Foundries
» Copper
» Incinerators
» Petrochem & Refinery
» Boilers
» Secondary Aluminum
Ramming a plastic bullnose

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Bond Technology

AIR-SET
• Forms an air-setting bond
• Gains additional strength at high
temperature from secondary clay bond

PHOSPHATE
• Will develop a strong chemical bond
above 650°F
• Bond is typically stronger than airset ECLIPSE-80 P (phosphate bonded) submerged in
plastics water for 3 days. 230°F prefired sample has
• Water soluble until 650°F degraded while the 650°F prefired sample
• Susceptible to volatilization in reducing remains unaltered. Note: the 650°F sample slab
atmospheres was broken in MOR test before this hydration test.

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 HWI Plastic Shelf Life

Shelf
Product Life
(days)

PLASTECH® 180-270

FOUNDRYPAK 120

ECLIPSE 90-120

SUPER HYBOND® 120

5
 Manufacturing, Packing, and Storage

1 Wet mixture is 2 The sliced

simultaneously
slab moves
extruded,
down a
vertically sliced
conveyor and
into smaller
is wrapped in
slabs, then cut
plastic.
off to length.

3 4

The plastic-wrapped block Finally, the boxes are palletized and the
is then boxed. whole pallet is plastic-wrapped. The pallet
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is still not intended for outdoor storage.
Consistency options

How to pick?
» General: standard
» Overhead: firm
» Handpack: soft

Thickness
Options mainly offered for:
» PLASTECH®
» FOUNDRYPAK
Firm Standard Soft

Liquid Content

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Anchoring
Plastics require high holding strength from anchors
due to low ‘green strength’

Ceramic ‘bottle’ anchors are standard and preferred

• Best holding power
• Hold lining all the way to hotface
• Used even if temperature is <2000°F
• Minimum lining thickness without cutting: 6”
• Minimum lining thickness with cutting: 4.5”

Metallic type when needed

• Used for small geometries or thin linings where
large ceramic anchor won’t fit
• ~2000°F limitation for 310SS
• Hexmesh is used for thin, low temp wear linings
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 Installation - during

• Product is ready to use out of the box

• Break into pieces to ensure there are
no cracks or laminations while
installing
• If patching lining, make sure existing
lining is clear of loose material.
GREENSET®-85-P can be used to
wet down lining and promote
adhesion.
• Prevent lining from drying out prior to
completing installation
• Refer to HWI’s official plastic
installation guidelines
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Installation - after
CONTRACTION CUTS & VENT HOLES OVERHEAD STABILITY

=5.75 ft

Make contraction cuts on 6-8’ centers between anchors at

a depth of 1/3rd the thickness of lining All-thread rods are welded to the roof structural
steel that extend through the refractory roof to
Make vent holes at depth of 2/3rd the thickness of secure wire mesh in place AFTER a plastic
installation on 12” centers between contraction cuts refractory roof is installed.

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Curing, setting, and heatup

No cure or set time Avoid prolonged air

needed drying

Phosphates can be Ensure cold face

soluble until dryout exceeds 650°F by
is complete end of dryout

Not all are PLUS

rated

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 Total installation time
forms install set time dryout
castable
gunite or
shotcrete

install dryout
ram plastic

gun plastic

install
brick
Major HWI plastic brand families

Brand Meaning Example

PLASTECH® Extended shelf life (12 months) plastic PLASTECH® 85P

Low cost plastic compositions -- reduced

FOUNDRYPAK FOUNDRYPAK 75P
shelf life vs PLASTECH compositions
Phosphate bonded, quick set, short cure
EXCELERATE time, and can handle heat-up of EXCELERATE ABR PLUS
150°F/hr. Can also be cast and gunned.
ECLIPSE Silicon carbide containing composition ECLIPSE-60P ADTECH®

SUPER HYBOND® Air set plastic SUPER HYBOND® PLUS

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 HWI plastics by chemistry type

Alumina-Silica Alumina-Chrome Zircon & AZS Silicon Carbide

CORAL® AUREX TZ® 951 ECLIPSE

FOUNDRYPAK PLASTECH® RUBY ® ZIRMUL® 960
PLASTECH®
SUPER HYBOND®

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Alumina-silica
• Most commonly used chemistry type
• Range of alumina content from 44% to 90% Al2O3
• Airset and phos-bonded types are available
Al2O3
Product Application
(wt %)
Airset plastic commonly used for patching
SUPER HYBOND PLUS 44
boilers. Available up to 90% alumina.
<5cc abrasion loss makes it ideal for highly
CORAL PLASTIC 28-82 ADTECH 82 abrasive applications such as cyclones and
clinker coolers
Lower cost high alumina option commonly
FOUNDRYPAK 83P 83
used in foundries
Go-to high-alumina phos-bonded plastic for
use with high alumina linings. Naturally
PLASTECH 85P 85
aluminum resistant. Available up to 90%
alumina.
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Alumina-chrome

• Offers enhanced corrosion and slag resistance over traditional

alumina-silica plastics
• High densities and strengths
• Ideal for steel, incineration, chemical, and gasification industries

Cr2O3
Product Application
(wt %)
Steel ladles and patching alumina-chrome linings in
PLASTECH RUBY 10
waste incinerators and other high wear applications.
PLASTECH RUBY 20 20

SHAMROCK 885 PLASTIC 30

HWI’s highest chrome-containing plastic, used in high-
AUREX 65 PLASTIC 65
wear areas in gasifiers where brick is not feasible.

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Silicon Carbide
60 ECLIPSE-80 P
• SiC provides high thermal PLASTECH 85P

Thermal Conductivity
50
conductivity 40
• “Pulling” heat out of hotface will 30
reduce how deep slag will 20
penetrate 10
• SiC provides additional alkali 0
resistance 0 1000 2000 3000
Temperature, °F

SiC
Product
(wt %) • All products used in power generation
applications for coating water wall tubes
ECLIPSE-60 P ADTECH 60
• ECLIPSE-60 commonly used for ramming
ECLIPSE-70 P ADTECH 70 hot zone bullnoses in clinker coolers due to
good alkali and buildup resistance
ECLIPSE-80 P ADTECH 80

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Zircon & AZS

• Zircon and AZS containing plastics are primarily used in glass applications
• Rarely used as a hot face lining except in very small geometries
• Most often used to patch parent brick of similar chemistry

ZrO2 or AZS
Product Application
(wt %)
Neutral chemistry means it can be used
in contact with alumina and silica. Can
TZ 951 PLASTIC 63% ZrO2
be used to patch zircon brick such as
TZB®.
Used for patching AZS brick such as
ZIRMUL® 960 PLASTIC 25% AZS ZIRMUL®. Cannot be used in contact
with silica refractories.

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How to choose a plastic
Atmosphere composition Slag & chemical resistance
» Oxidizing: phosphate or airset » Phosphate bond – aluminum
» Reducing: airset only (SUPER resistant
HYBOND®) » Alumina-chrome
Refractoriness » No-cement  Cl2 resistant
» Generally, higher alumina the better Thermal conductivity
» PLASTECH® 50P = 2900°F rated » ECLIPSE products
» PLASTECH® 90P = 3200°F rated
Abrasion
» Phosphate bond
» Higher alumina

When in doubt, match the chemistry of the other products in the vessel
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Stocked plastics

SUPER HYBOND® PLUS

PLASTECH® 70P STD

PLASTECH® 85P STD

PLASTECH® 85P FIRM

PLASTECH® 90P

PLASTECH® RUBY

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Other patching options

Product Chemistry Application

General patching applications, can be thinned for

GREENPATCH-421 53% Al2O3
brush coating.
GREENPATCH-421 XTP 53% Al2O3 Even thicker than standard GREENPATCH-421
High alumina patching mortar for higher temperature
GREFPATCH® 85 84% Al2O3
applications
SHAMROCK® 192 PATCH 22% Cr2O3 General patching of alumina-chrome furnace linings.
AZS
ZIRMUL® 160 PATCH Go-to patching material in the glass industry
containing
Aluminum reverb furnace belly band patching; glass
TZ® 150 PATCH 62% ZrO2
furnace crown overcoating.

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Takeaways

» The original no-cement option

» Fast dryout
» Consider shelf life, workability, and
consistency options
» Review the installation guidelines
» HWI carries many plastic chemistry and bond
types to suit nearly all applications

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thinkhwi.com