O ig F LSMIDTH INSTRUKTIONER INSTRUCTIONS ~—INSTRUCTIONS. ANWEISUNGEN — INSTRUCCIONES —_INSTRUCOES 33981-01_ | 1/13 WEAR LINING. DENSIT Installation = Contents: Page GENERAL DESCRIPTION 2. MATERIALS SPECIFICATION +1 Storage +2 Field of application +3. General information |. ___ EQUIPMENT AND TOOLS 1 Mixer 2. Vibrating £1oat 3 Vibrating beam 4 Scales 5 Water, power and compressed air 6 Curing and curing sprayer 7 Various equipment and tools AaeRAWO YW WON BN .__ INSTALLATION 2 Demand on environmental temperatures 2 Preparation of surface 3 Mounting of reinforcement netting 4 Welding of reinforvement netting 5 Mixing of Densit wearCompound 6 Application of WearCompound weaxaue o 5. __WEAR LINING READY FOR USE i 6. __ WORK HYGIENIC DIRECTIONS FOR USE “"—OF DENSIT CASTABLES = 12 SAFETY PRECAUTIONS FOR ADDITIVES ETC. 13 MGHvemark! Nerverende instruktion ombandler de sstuationer, son vi har erfaring for, ef de oftest forekonmende. En udtennende opregning Bf semtlige cancelage Sisuscioner, som mdece kunne opsts under Grite ef aniegget/ neskinen/ose Seyret laser sig tkke gore. Wikis Uerior Cuittoe er sigrent cer mtte torekonse en situation, son As" ex onhendiet 1 instruktionen, og som kunden ikke ar/elier voréeree Sig selv fortrolig med héndteringen af, et FLS uden ugrundet ophald kontaktes med henbitk pé indhentelee ef harmere veiecning. Notet ‘The present instruction manual te concerned with the situations Which, according to our experience, are the most Likely to occur. An exhaustive ehueration of ell conceivable situations which may occur during the ‘Qperation of the plent/nachine/equipsent cannot be provides. Gensequentiy, 1f o eivuation should arise, the occurrence Of which is nat foreseen in ‘the instruction manuel, and which the client ie/or feels unable to handle, we would reconmend that FLS i contacted without undue @eley for advice on appropriate action. Important! Le présent manuel 4* instructions traite des eituations qui, & 18 lustére Ge hos expériences en la natiére, sont celles que 1'on sencontre le plus ‘souvent. Une énunération exhaustive de toutes lee situations susseptibies Ge, se présenter au cours de l'exploieetion de l'usine/ie machine! aequipenent n'est Cout simplenent pas feieaple, Nous vous invitons per conséquent A contecter FLS sans délei efin de Fecourir rapidenent eux prescriptions plus détaiilées dens le ces oo {1 Antervient une situation qui n'est pax traitée dans le manuel et que le client nest pas en mesure d'affronter, ou ne ee sent pas en mesure de Ye faire. Achtung! Die vorliegende Anweisung behandelt die Situationen, die unserer Erfah- Fung nach om haufigeten entstehen. Eine erechaptande Autrahiong eller Genkbaren Situationan, die beim Betried der Aniage/Maschine/Ausrustung euftreten Konneen, iet nicht moplich. Deshalb empfehlen vir, dad falls eine Situation entetehen solite, die ich in der Anweisung'behandelt ict, und ait deren Dewsltigung der kun nicht vertreut oder in der Lage ist’ zu bewiltigen, da FLS onne schuld- haftes Zogern hingichtiicn Ger Einholung nuherer Richtlinien henaenricn~ Rige wirer Atencién! Les presentes inetcucciones versen acerca de situsciones que, segin experience obtenida, son las que se originan més contnnenve. No ee foc tile Lister una eniuneracion exhaustive de todas les condiciones, inepi- pables que pudieren surgir durante el wervicio de 1s inatelacion/mégei~ e/equipo. Por Geneiguente, en,ei gupuesto de que ae originers une eitusctén que us he sige tracode en les instrucciones y sur i cual el crasnee no esaee ester fanilierizedo, © no verse en condiciones de solucionerle, por of Misno, ‘se recomiende tomar contacto sin demora inundede con FLS con Mirae a goliciter inctrucciones de cardcter orientatori observar! Ae prosentes snstrugtes traten de situestes que, segundo a experitncia Obelan, “sho es que parecer con nats fruquencis, NSo € eidvel uma one Reregeo exaustive de coder as condigiea “inaginévets que possan avrgiz Gurente 9 service de inatolagto/maquins equipement. Por cateopeinea’ no cess Ge sucpie bas setlogas que ala teaba sido aboc~ Gedo nas inatrucdes © com a quel o cliente estins nao estar feailierizo do, ou ndo eater en condigies de a solucionsr, reconende-ce contacter sem Senore @ Fis © fin de eoliciter instrupbes Ge caracter oriencetive.33981-01 2) 1, GENERAL DESCRIPTION These instructions describe the procedure for ca- sting a wear lining of Densit WearCompound. Densit WearCompound is produced by mixing Densit WearCast, water, steel fibres and Densit Compound Additive. The consistency of the compound may be changed from that of a free-flowing material into that of a stiff mortar material, simply by adding Denoit com- pound Additive. MATERIAL SPECIFICATION Storage Densit WearCast is available in bags each contai- ning 40 kilos. The bags are made up of several layers of paper, one of which is coated with po- iyethylene. Each bag is marked with the name of the product and a direction for use. the material is available on pallets each carrying 1200 kilos covered with shrink foil. The material must be stored in a dry and ventilated room. The attention is drawn to the fact that the material has a limited storage time. Bags containing herd lumps must be discarded, since the material is likely to have taken up moisture and thereby set. Steel fibres of a suitable quality and size are a- vailable in paper bags each containing 25 kilos. Densit Compound Additive is available in plastic packings in the quantity required. Densit Binder is available in bags each containing 25 kilos. This material is used where Densit wearCompouna is applied to concrete or Densit surface areas.33981-01 3 2.2 Field of application Densit WearCompound is used for wear protection and has been developed for applying to machines and Plant components. The material is applied to the component in question in a thickness of 30-60 mm. Please see special product sheets. Maximum working temperature for the material is 300°C, 2.3 General information Densit WearCompound contains a cementious matrix and hard wear-resisting particles up to 4 mm. The material consumption is approx. 100 kilos/m?. 3. EQUIPMENT AND TOOLS 1 el Mixer In order to ensure an effective mixing it is abso- lutelly necessary to use either a heavy paddie pan or a similar piece of equipment. Mixing time before adding the fibres is approx. 10 minutes, and after the adding of steel fibres app- xox. 5 minutes. Densit Compound Additive may now be added to the mixture, till the desired consistency has been reached. ie eal Vibrating float A vibration float is recommended for use when app- lying Densit WearCompound. The vibrator fitted on the float may be powered by either air or electri- city.33981-01 4 3.3 Vibrating beam A vibrating beam may be made of a sectional steel beam fitted with vibrators. The vibrators may be Powered by either air or electricity. 3.4 Scales For weighing water and steel fibres scales with a range of 0-10 kilos may be used. Water, power and compressed air Water, power and compressed air must be available at the place of work or near by. Water used for mi- xing must be clean water. water used for cleaning tools may not be used. 6 Curing and curing sprayer Curing (membrane hardener) should be of paraffin wax disperged in water. Curing is sprayed on right after the Wear Compound has been applied. It forms a relatively tight diffusion membrane, which pre- vents water evaporation, and thereby reduces the xisk of cracks deriving from material contraction, and gives the Densit surface an increased strength. Ordinary garden sprayers may be used, and the sprayers may be cleaned with water after use. Note! Certain curing products must be stored and u- sed at temperatures above 5°C. The amount of curing needed for an effective sealing is approx. 0.3 liters per m? Denoit surface. Various equipment and tools When applying a Densit wear lining traditional bricklayer's tools should be used, such as trowels,33981-01 5 steel float, heavy plastic buckets etc. When installing the reinforcement net, welding e- quipment and smith's tools are used. For working in Densit materials an angle grinder is recommended, with discs suitable for cutting and grinding stone and concrete. 4. INSTALLATION 4.t Demands on environmental temperatures Mixing and application should take place in tempe- ratures between 5 and 30°C. If mixing and applica- tion must take place at lower temperatures, it is important that the WearCompound and the area where it is applied are heated to above 5°c until the ma- terial has set - approx. 48 hours at 5°c. NOTE! Application in direct sunshine or strong wind should be avoided because of the dehydration risk. 4.2 Preparation of surface To ensure a proper adhesion between Densit wearCom- Pound and the existing surface the below instruc- tions must be followed when applying Densit on either 1, Metallic surfaces or 2. Concrete surfaces or 3. Densit surfaces. Re point 1: Metallic surfaces of steel or cast iron must be free from of1, grease and any loose partic les. When applying Densit to galvanized surfaces or Vight metal alloys such a6 aluminium, the surfaces must be covered and sealed by means of a diffusion tight paint. The paint prevents any chemical reac-33981-01 6 tion between the light metal alloy and the Densit material. In order to make the application easier and to im- prove adhesion between the Densit WearCompound and the metal surfaces, these must be provided with an expanded metal net. The distance from the net to the surface must large enough to let the material penetrate behind the net and enclose it. Re points 2 and 3: Existing concrete or Densit con- structions are suitable for application of nansit WearCompound. The surface requirements for the two types of surfaces are the sam 1. The surface must be broken or sand blasted to uncover its underlying stone structure. 2. The surface must be cleaned carefully and moi- stened with water. 3. Densit Binder is washed unto the moist surface by means of a broom. (See mixing instructions for Densit Binder). + Densit WearCompound is applied right after in the “wet" Densit Binder. 4.3 Mounting of reinforcement net To ensure adhesion to metallic surfaces, these must be provided with a welded-on reinforcement net. In addition the reinforcement net serves to keep the Densit material in place during application, particularly on vertical or up-turned surfaces. An expanded metal with the following mesh is recom- mended for use as reinforcement net33981-01 7 The reinforcement net must be of an steel quality. ungalvanized ‘The reinforcement net may be cut by steel plate shears or by an angle grinder and must be adapted to fit the surfaces to be covered. NOTE! USE GLOWES WHEN HANDLING EXPANDED METAL! 4.4 Welding of reinforcement net The reinforcement net is to he welded to the curfa- ce in a way that allows the densit material to flow underneath the net and enclose it. The clearance between net and surface should be 8-15 mm, depen- ding on the thickness of the wear lining. A recom- mendable clearance between net and surface would be approx. 30% of the lining thickness. The clearance between net and surface may be secured by: 1. Round iron placed between net and surface. As ROUNG 4rOn paateu veumec sce cee eee 2. Dents in the expanded metal, made in the cross points, and corresponding in depth to the clea- rance between surface and net. Re point 1 Round iron rods of a given dimension are spot-wel- ded to the surface using a suitable electrode . and33981-01 8 with a distance of 150-200 mm between the rods. The net is placed on top of the rods and welded to the rods at the cross points Re points 2 and 3: The net is welded directly to the surface, using a suitable electrode. The welds are distributed in a pattern that keeps the net se- curely in place. A pattern, with welds forming squares of 150 mm, is recommended. oe of Densit eons b. Mixing: Use paddle pan mixer only. Add wator to the Gry ponder when mixing. bdasing tt- me must be at least 10 minutes, counted from the moment the water is added. It is important to use the correct amount of water and correct mixing time as stated on the bag. Note that the mix during the first 7-8 minutes mixing time still has the charac- ter of loose gravel. A change in consistency does not occur till after 8-9 minutes mixing time, when the material suddenly takes on a liquid consistency before it is fully prepared as a free-flowing cast- able. c. Adding fibres: After 10 minutes mixing time, as Prescribed in sub-section b, a recommended @USIE® (GEER (0.4x12.5 nm) ore GHRSGTRSETMONRGIEESD of Densit, and the mixing continues far 5 minutes. a. Dosing of Densit Compound Additive: Before use, the "flow" must be removed from the material. While the material is being mixed correctiy, oma11 amounts of The consistency of the mix will change after a few minutes mixing time. It is possible, by adding the correct amount of Densit Compound Additive, to adjust the consistency33981-01 9 of the material to suit the job in question. To judge if the consistency of the material is sui- table, for instance to be applied to a 45° sioping wall, the following procedure may be used: Stop the mixer and observe the movements of the ma- terial. If the movements cease after approx. 5 se- conds, the amount of Densit Compound Additive added is reasonably correct. If on the contrary the mate- rial still moves, flows, it is necessary to add a little more of the Densit Compound additive. The above test procedure in then repeated until the concistency is correct. Pot-life at approx. 15°C: The material stays work- kable for about half an hour aflex the addition of Densit Compound Additive. Larger doses of additives reduce the time in which the material is workable. 4.6 Application of WearCompound The Densit WearCompound must be used right after mixing. The material may for instance be carried from the mixer to the working area in plastic buc- kets. a. Preparation uf surfaces to be lined: The surface must be cleaned and the reinforce- ment net fitted. Before applying the material,33981-01 10 it is recommended to install the levelling or demarcation irons. the purpose of these irons is partly to ensure a correct thickness of the 11- ning, and partly to demarcate the lining areas. When the setting time is over (24h at 20°C) the levelling irons may be removed. It is an advantage, if components to be lined a- re designed in such a way that their frames and flanges may be used as demarcation irons, as permanent parts of the wear lining. Examples of the fitting of flat irons at demarcations and edges. When working on components, where the abrasive material is tranported at right angles to the wear lining, it is necessary to protect the ex- posed surface with for inetance a permanent flat iron. b. Application on horizontal surfaces. On horizontel surfaces the material is applied in layers of approx. 15-20 mm. The layer is to be vibrated underneath the reinforcement net, and the application is then continued until the lining has the desired thickness. It is impor- tant tehat the applied layers are vibrated to- gether right after application, before the set- ting of the material takes place. The finished surface is glazed manually by the xotary movements of a steel board.33981-01 a ©. Application on vertical or up-turned surfaces To vertical and up-turned surfaces the material is applied by means of trowel and float. Vibrator floats may be used for compacting the material on vertical surfaces, but not when api- lying the material to up-turned surfaces. The material is applied in small areas and pres- sed behind the reinforcement net - normally in layers of about 20 mm. This layer forms a foun- dation for the application of more material up to the desired thickness, normally about 30 mm. Some experience, and som experimenting with do- sing Densit Compound additive and finding the right consistency, will required before attemp- ting application on up-turned surfaces. The finished surface is glazed manually by the rotary movements of a steel board. The steel board may be moistened with a little water, if a smooth surface is desired. 4. Curing When the wear lining is finished, the curing is sprayed upon the Densit surface as described in sub-section 3.6. A garden sprayer with nozzles is suitable for this purpose. NOTE! Mixer, tools, etc. should be cleaned care- fully with water after use. 5. WEAR LINING READY FOR USE Generally the developing of strength starts after approx. 10 hours, and at a surrounding temperature of 20°C the material will get its operational strength after hardening for 2-2 days. At surrounding temperatures of 5°C the lining will not be ready till 6-7 daye after application. The reason for this is that the strength of the mate- rial develops more slowly at low temperatures.33981-01 12 6. WORK HYGIENIC DIRECTIONS FOR USE OF DENSIT §: WORK HYGIENIC DIRECTIONS FOR USE OF DENSIT CASTABLES ae Trade name. This set of instructions concerns the use of Densit WearCast and Densit WearCompound. 2. Field of application Wear proof linings and corrosion protective ca- stings. 3. Limitation of application None in particular. Irraspective of storage time cromate is less than 2 mg/kg. 4, Requirements as to cpecial training No particular safety requirements 5. Properties hazardous to health Breathing: Breathing large quantities of Dersit dust should be avoided, as the densit dust may irritate the breathing organs. Skin contact:Densit mixed with water, i.e. fresh unhardened material, is strongly alka- line and has a caustic effect at pro- longed contact. Eyes: Densit may cauterize the eyes. Ingestion: No information available about possib- le health hazards. 6. Precautions for use At large formations of Densit dust, it is recommen- ded to use respiratory protection: When directly in contact with Densit mixed with wa- ter, it is recommended to use glowes and eye pro- tectors. After work and during breaks hands should be was- hed, and a moisture cream used.33981-01 13 oe First aia Breathing: Seek fresh air. Eyes: Rinse immediately with plenty of water for at least 15 minutes. By continued irritation, see your doctor without delay. Skin contact:Wash with soap and water. Ingestion: No information available about possib- le health hazards. 8. Properties concerning heat and fire. The material is non-combuetibic. 9. Fire precautions. The material is non-combustivie. 10. Precautions concerning waste and disposal The axe no specific regulations as to the disposal of Densit. a. Storage safety precautions. Store in a dry place, out of reach of children 12 Labelling CAUSES BURNS Do not breath dust ; | Keep out of reach of children In case of contact with eyes St rinse immediately with plenty cm a of water and seck medical ad- Mixing with water forms cal- i wal cdiumhydroxide. 7. SAFETY PRECAUTIONS FOR ADDITIVES ETC. When handling materials like hardening additives membrane hardener, curing etc. the apertaining sa- fety instructions must be strictly adhered to.