Method Statement Repair of Cracked Kiln Tyre

Method Statement
of
Repair of Fractured Kiln Tyre

Compiled by:
Atef Badr
Originated by
MESSER Eutectic Castolin Egypt LLC
As carried out at
Heidelberg Cement
Helwan white cement Plant
El-Minya - Egypt
Dec. 2018
Statement of Liability
Due to variations inherent in specific applications, the technical

information contained herein, including any information as to
suggested product applications or results, is presented without
representation or warranty, express or implied. Without limitation,
there are no warranties of merchantability or of fitness for a
particular purpose. Each process and application must be fully
evaluated by the user in all respects including suitability,
compliance with applicable law and non-infringement of the rights
of others and, Eutectic Castolin Corporation and its affiliates shall
have no liability in respect thereof.
Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

Repair of Fractured Kiln Tyre P a ge |2 Atef Badr Tel:+2 0100 66-83-908
Table of Contents
1 Introduction. .................................................................................................................4
2 Causes and Modes of Failures.........................................................................................4
3 Technical data of the Kiln Tyre metal: .............................................................................5
4 Repair Decision Constraints............................................................................................6
4.1 Replacement Option:.............................................................................................6
4.2 Repair Option:.......................................................................................................6
5 Process Considerations. .................................................................................................8
5.1 Welding alloys considerations. ...............................................................................8
5.2 Electrode selection. ...............................................................................................9
5.2.1 Linear coefficient of thermal expansion...............................................................9
5.2.2 Tolerance to the effects of dilution ...................................................................11
5.2.3 Microstructural stability. ..................................................................................12
5.2.4 Resistance to hydrogen-induced cracking. ........................................................14
5.3 Recommendation ................................................................................................15
6 Execution plan.............................................................................................................16
6.1 Tools Required ....................................................................................................16
6.2 Welder’s Qualifications. .......................................................................................16
6.3 NDT & Quality control..........................................................................................16
6.4 Preheating & PWHT. ............................................................................................17
6.5 Acceptance criteria..............................................................................................19
6.5.1 Acceptance criteria for visual controls ...............................................................19
6.5.2 Acceptance criteria for ultrasonic controls.........................................................19
6.5.3 Acceptance criteria for Magnetic particle and/or Dye penetrant controls............19
7 Summary of successful Welding procedure ...................................................................20
8 Appendix 1: Chemical analysis of Kiln metal sample............................................... 34
9 Appendix 2: Certificate of the recently calibration of Heating equipments . .................36
10 Appendix 3 Health And Safety With Welding Fumes Follow ........................................ 52

1 Introduction.
There has always been a difference of opinion as to whether or not fractured or
spalled kiln tyres can be welded with any reliability. With the great number which have
been repaired around the world in recent years, however, and which are still operating
without subsequent breakage or problems, it seems worthwhile to examine and
elaborate on a procedure which has proven to be eminently successful.
We will discuss the procedures, welding materials and methods that have proven
successful at many plants around the world. Specific examples illustrated here is
Helwan Cement company at south of Helwan city ; Tourah Cement at south of Cairo
and Helwan whit cement at east of Samalout city in Minia - Egypt.
2 Causes and Modes of Failures.

Cement and lime kilns are vulnerable to thermal shock and cycling, torsion stress,
"compressive loading and even fatigue. This is due to their size and length as well as
the operating conditions and extreme loading they must endure.
The kiln tyres carry all the weight of the kiln, sup- ported between two relatively small-
diameter trunnions, creating rather high ratios of line loading on the surface of the
cast steel tyres.
Due to the high fatigue accumulation rate these stresses can eventually result in
cracks, which form initially under the surface. The fracture mechanism is one of fatigue
and will typically propagate from weaknesses in the original material such as casting
inclusions adjacent to the original riser positions.
Because of the ongoing work hardening and associated strengthening of the tyre
surface, defects or cracks initially form almost invariably below the surface. The
defects or cracks propagate unseen until the cross-sectional area is large enough to
weaken the tyre sufficiently that they cause a sudden and unforeseen break through
the entire section of the tyre.
Overall, The main causes of tyre cracks is:

1. Excessive Hertz pressure between tyre and roller, or excessive tyre ovality
1.1. Kiln not aligned.
1.2. Kiln crankshaft.
1.3. Shape deformation of roller or tyre, excessive skewing, wobbling.
1.4. Temperature gradient
2. Fatigue
3. Material defects
3.1 Surface micro-cracks.
3.2 Casting defects.
3.3 Surface pitting, holes, foreign bodies trapped

At last, repairing a crack is an emergency plan only. It will not solve the problem by
itself. Root cause should be identified and best solution has to be implemented.
3 Technical data of the Kiln Tyre metal:

The base metal most generally used in kiln tires is a low alloy cast steel containing
approximately 0.4 percent Carbon. While each manufacturer seems to prefer and use
their own specific composition, they will generally fall into the classification of ASTM
A356.
Although this is not considered an exceptionally difficult grade of steel to weld, it must
be remembered that the part has been subjected to severe mechanical stresses and
some degree of work hardening.
The mass and configuration of the tire must also be taken into consideration as well as
the conditions under which the welding is to be done, and, last but not least, what the
effects of post welding cooling and stresses will be on the base metal, weld metal and
the heat affected zone.
In light of these multiple and varied factors it becomes apparent that any attempt at
repairing a cracked or broken kiln tire successfully will depend on proper preparation
and welding procedure as well as the selection of an absolutely reliable filler metal or
welding alloy with superior characteristics. And the success of the repair operation
relies ultimately on strict adherence to the proper time and temperature parameters
for both preheating and post heating, as well as maintaining proper interpass
temperatures during the continuous welding procedure.
According to the composition analyses that was done for the sample taken from the
kiln tire material is following table: (appendix 1)
Ferrous Carbon chrome Manganese Molybdenum Vanadium Nickel Copper

97.0 0.394 0.401 0.41 0.095 0.003 0.237 0.172
Table 1 : the chemical composition of kiln metal sample
Steel casting ASTM A356 Mechanical properties:
Steel casting ASTM A356

Mechanical Properties
Tensile Strength N/mm2 695 (70,000 psi)
Yield Strength N/mm2 370 (36,000 psi)
Elongation % 13%
Hardness (HB) 179-229
Impact Value (J) 25 @ 20°C
Reduction in Area 35%
Table 2 : Mechanical properties of ASTM A356

4 Repair Decision Constraints
According to reliability basic concepts, before doing any repair, replacement option
has to be considered. In case of old components where fatigue failure is envisaged,
repair option is a temporary measure. It can be selected when there is no availability
of spare.
Otherwise, in today’s highly competitive market, the profitable manufacture of

Portland cement hinges on the ability of the individual plant to keep equipment
running and producing at the highest possible level, while still keeping operating costs
at the lowest possible level.
Since a broken kiln tire effectively removes a kiln from operation until the tire is either
repaired or replaced, it is readily apparent that time is absolutely of the essence in any
situation where a kiln tire has broken.
4.1 Replacement Option:
Replacing the tire will generally require removal of a section of kiln in order to remove
the broken tire and install the new one, and then the kiln section must be repositioned
and welded back into place.
Also, Large castings are not only expensive, they are tailor made and are never readily
available on site. A large broken part cannot be used anymore and the equipment
becomes idle, there are many different factors for the economical calculation. These
factors include redundant production capability, capital tied up in intermediate stock
during the delivery time of the spare part.
Even if a new tire is on hand or readily available, removal and replacement of the kiln
section can still be time consuming. If no replacement tire is available, repair of the
broken tire may be the only chance of getting the kiln back in operation reasonably
quick, especially since delivery of a new tire may be in the range of four to seven
months.
Therefore, a reliable repair is mandatory, at least to be used during the lead-time for
the spare parts delivery and a time extension to allow the exchange during a scheduled
production stoppage
4.2 Repair Option:
If the repair route is selected, a number of decisions must be made very quickly, those
include whether to do the repair in-house with existing staff and/or contract welders,
or whether to contract the job out to a company with experience and equipment to do
the entire job. In recent years the latter has increasingly been the most prevalent
choice, especially in light of the reduced welding staff available in most plants today.

Consider also, that once the repair has begun it is most efficient and almost imperative
to weld around the clock until it is finished.
This is much more cost effective than ongoing stopping and starting, and minimizes the
difficulties involved in maintaining correct base metal temperatures throughout the
entire repair cycle.
To improve the reliability of this difficult to check application, we in Castolin insist on

the supervision of the work and the control of the procedure. We provide assistance
and operator training as well as perform or license the application itself. In a more and
more competitive environment, where production losses may cost a company its
reputation, its market and its profits, researchers, maintenance and design engineers
should be made aware of this reliable solution.

5 Process Considerations.
5.1 Welding alloys considerations.
There are generally two alternate routes for selecting the welding alloys and
procedures to be used:
• OPTION 1: The use of an autogenous AWS specification ferritic electrode, such

as a 7018-type low- hydrogen electrode that meets the general specification for
welding this type of steel.
• OPTION 2: The use of a dissimilar, non-ferrous nickel-based alloy electrode with
a basic coating specially formulated by "MESSER Eutectic Castolin" for repairing
hardenable steels.
While the Ferritic alloy (OPTION 1) closely matches the chemistry and alloy content of
the base metal, the air harden-ability of the large volumes of weld metal to be
deposited would require rather high preheat requirements, creating both practical and
procedural problems. In addition, post weld heat treatment (PWHT) would be
mandatory. The difficulties associated with these levels of heating, considering the
mass involved and the amount of lost heat through radiation and conduction can be
almost insurmountable.
Another factor that must be considered also is the softening of the work hardened
surface in the welded area, and a severe hardness gradient at the each end of the heat
affected zone.
These effects, themselves, can give rise to increased susceptibility to subsequent

cracking and a repeat failure at those points after the tire has been put back in service.
With respect to the use of non-Ferritic alloys (OPTION 2), one alloy has been widely
accepted as the single most reliable alloy of its type by the major OEMs. Castolin
electrode NucleoTec® 2222 is a high alloy nickel alloy with tensile strengths slightly
higher than that of the cast steel tire, but it has exceptional ductility and impact values,
along with 40–45 percent elongation and exceptional resistance to cracking, even
under continuous thermal cycling.
By using NucleoTec 2222, pre-heat is more easily attainable, and there is no need for
PWHT providing that certain techniques are rigidly adhered to during the welding
operation. The performance of these products in relation to tensile strength and
particularly ductility, even without PWHT, is far in excess of the parent material. When
coupled with good metallurgical integrity at the weld and parent metal interface and
skilled execution, NucleoTec 2222 gives the highest reliability of repair possible. The
concern of surface hardness degradation is also avoided. Naturally, due the high nickel
content there is an economic disadvantage, but bearing in mind the reliability of the
repair and the downtime cost savings involved, the consideration is of no practical
importance.

Mechanical Steel casting ASTM A 356 Xuper NucleoTec 2222
Properties
Tensile Strength 695 650-690
(N/mm2)
Yield Strength 370 390
(N/mm2)
Elongation (%) 13 40-45
Hardness (HB) 179-229 170-220
Impact Value (J) 25 @ 20 °C 120 @ 20 °C
Table3 : Difference between mechanical properties of the Tyre metal and Xuper
NucleoTec 2222.
5.2 Electrode selection.
When making the final selection of the electrode to be used on a kiln tyre repair, it is
important to remember the severe penalties associated with having the repair fail
again. The cost of the right electrode, then becomes much less important than
knowing it will not only do the job, but will continue to hold up for many years to
come.
Primary factors that affect an electrode's suitability include:

• Linear coefficient of thermal expansion,
• Tolerance to the effects of dilution,
• Microstructural stability
• Resistance to hydrogen induced cracking
Unless the electrode is designed to accommodate the above factors, welding residual
stresses and the presence of hydrogen in hardenable zones will increase the risk of
provoking unexpected “cold cracking” phenomena.
5.2.1 Linear coefficient of thermal expansion.
Various materials expand and contract at different rates during the welding process.
Stainless steel alloys, for example, expand and contract much more than the carbon
steel tyre, thereby increasing residual stresses and distorting the joint.
Xuper NucleoTec 2222 has a coefficient of expansion very similar to that of the mild
steel tyre over a very wide temperature range. Only minimal residual stresses can
occur in the joint, either during welding or during subsequent thermal cycling, which
promotes maximum safety margin repairs.

Figure 1: The difference between thermal expansion coefficient between Xuper
NucleoTec 2222 and others alloys.

Repair of Fractured Kiln Tyre P a g e | 10 Atef Badr Tel:+2 0100 66-83-908
5.2.2 Tolerance to the effects of dilution
Dilution refers to the percentage of base metal found in the weld deposit. When
conventional stainless steel alloys are used to join or repair carbon steels, the weld
deposit will invariably contain at least 20-30 percent base metal, which creates a weld
deposit prone to embrittlement due to the formation of hard martensite structure.
Xuper NucleoTec 2222 on the other hand will tolerate up to 50 percent dilution with
carbon steels and still retain its tough austenitic structure again promoting maximum
safety margin welds.
Figure 2: Xuper NucleoTec 2222 on Schaeffler diagram

5.2.3 Microstructural stability.
Since it has been reject to use of a mild steel electrode because of its lack of
elongation. The next choice is to use an AWS A 5.4 309 electrode as this type of
product is traditionally used for joining wrought or cast steel to ferritic or austenitic
steels.
But it is reported on the Schaeffler diagram it is situated in an area where there is a

danger of formation of an iron-chromium phase called Sigma Phase . Another factor is
the formation of an hard zone on the interface between carbon steel and the welded
deposit.
Although the sigma phase is developed during a heat treatment between 500oC and
900oC, we know that during multi-pass welding, the weld creates, in the preceding
layer, a zone which is subjected to this temperature. This phenomenon will appear in
the bulk of the depost, especially if the weld is overheated during the welding
operation. We are, therefore, confronted with a problem of brittleness, in the
interface and in the deposit.
A special nickel base electrode "Xuper NucleoTec 2222" was developed to eliminate
both problems, the low chromium content does not allow the formation of a sigma
phase, the high nickel content allows a perfect match with most of the iron base
material. The risk of hot cracking associated with high nickel content electrodes, was
first reduced by the addition of molybdenum, which increases, in nickel alloy, the
elevated temperature resistance and secondly by a controlled procedure.
As seen from the Ternary Phase Diagram Xuper NucleoTec 2222 is situated far away
from the critical Sigma Phase zones. Even with dilution, Xuper NucleoTec 2222 remains
immune to the formation of harmful, embrittling Sigma Phases provoked by thermal
cycles either during welding or service conditions.

Figure 3: Ternary Phase Diagram for Ni-Fe-Cr System at 1200°F (650° C)

5.2.4 Resistance to hydrogen-induced cracking.
The risk of “cold-cracking” in steels is multiplied whenever a hardened welding zone

accumulates tensile stresses and excessive residual hydrogen which is unable to
escape by diffusion phenomena (Hydrogen Induced Cracking-HIC).
Xuper NucleoTec 2222 minimizes HIC risks in two complementary ways:
1. The basic extruded flux coating ensures tough, ductile welds with lowest
diffusible hydrogen contents.
2. The austenitic weld deposit structure is characterised by both a higher
solubility and lower diffusibility for hydrogen than for traditional ferritic
deposits.
This simply means that any errant hydrogen entering the molten weld pool will be
safely dissolved and retained after solidification, allowing very little to diffuse towards
the hardened HAZ steel interface, thus countering the HIC risks.
Relative Diffusion Rate Hydrogen
7
Relative Diffusion rate
6
Ferrite
5
4
Aus te nite
3
1
100 200 300 400 500 600 700 800 900
Temperature °C
Hydrogen Diffusion Rate VS Temperature and Phase

Hydrogen Solubility
H concentration ppm
6
5
4
Aus te nite
3
2
Fe rrite
1
0
100 200 300 400 500 600 700 800 900
Temperature °C
Hydrogen Solubility VS temperature and Phase.

5.3 Recommendation
The comparison of the physical properties of typical cast steel kiln tyre material with
the Xuper NucleoTec 2222 electrode explains the exceptional success and reliability of
this product when repairing kiln tyres and rollers.
Their tensile strength, yield strength and hardness values are almost identical. Both the
impact strength and elongation of the Xuper NucleoTec 2222 electrode, however, are
more than triple those of the base metal. This unique combination of properties
provides tough, ductile welds that are virtually resistant to crack formation when
proper welding techniques and procedures are employed. While initial surface
hardness of the weld metal is lower, it increases rapidly in service by work hardening
effects until it is almost the same as that of the surrounding base metal.
This also helps explain the fact that after more than 12 years, many of the repairs
made with this product worldwide are still operating, with no documented cases of
cracking in the weld deposit or the heat affected zone of the base metal.
While the cost of this specifically developed, high-nickel alloy is considerably higher
than that of standard 7018 low hydrogen electrodes, the reliability of Xuper NucleoTec
2222 in this type repair makes the initial investment negligible when compared to the
cost of potential failure if traditional repair electrodes are used.
In addition, the savings generated by carrying out an in-situ repair, without

necessitating the removal and replacement of kiln sections, makes the selection and
use of Xuper NucleoTec 2222 almost imperative, hence its OEM recommendations.

6 Execution plan.
6.1 Tools Required
The following are the tools and tackles required, has to be arranged before starting the
welding operation.
1. Welding machines Generators or rectifiers with a capacity of at least up to 400

Amps. DC is preferred.
2. Tarpaulin to cover the weld area
3. Arc-air, compressors for gouging, flame cutter oxygen-acetylene.
4. Pneumatic air hammers with needles for peening
5. Steel wire brushes
6. Grinding machines
7. Electric preheating equipment.
8. RTD/ pyrometer/ temperature sensors
9. Power/cables for the tools
10. White, quick-drying paint for marking
11. Ultrasonic testing equipment
12. Dye penetrant, magnetic particle testing
13. Template of the component’s curvature/profile
14. Welding electrodes, dia. 3.2 mm for first layer, dia.4 and 5 mm for filling-up
15. Welders and helpers for continuous work 24 hr/day
16. Safety tools and equipment required for the weld operation (Particular
attention to contact with burning material)
17. Furnace (portable oven) for drying/preheating the electrodes
18. Ceramic wool mats
19. Fixture to hold the crack portions together
20. Electrical Hand grinder/cutter machine
6.2 Welder’s Qualifications.
It is recommended that welding operators be certified in accordance with the

requirements of Section IX of the ASME Code or ASTM A-488. Under this section
performance qualification of welders is that, testing the ability of the welder to
produce a “sound” weld in small carbon steel test plate.
Soundness of the weld means weld should be free from any form of surface/sub
surface defects. DPT, MPT and UST can be used to ensure this.
6.3 NDT & Quality control.
After the weld repairs are completed, quality control has to be done using dye
penetrate testing,
• Magnetic particle examination as per ASTM E-709.
• Ultrasonic contact examination as per ASTM E-164.

• Inspection for weld defects is as per CSA Standard W59 or AWS D1.1 Code.
• Inspectors should be ASNT certified in Nondestructive testing recommended
practice No. SNT-TC-1A, personnel qualification and certification.
6.4 Preheating & PWHT.
PWHT may be used for Xuper NucleoTec 2222 repairs but when heavy steel sections
are involved, PWHT is not always a economic in-situ solution. Many E+C case histories
have proven that Xuper NucleoTec 2222 weld repairs without subsequent PWHT have
given totally safe and satisfactory service performance. but to more successfully/safety
job, PWHT is recommended if it's easier possibility.
A preheating temperature Tp measured only once immediately before any welding

operation according to EN ISO 13916. If required a maintenance temperature Tm shall
be maintained on a minimum temperature in the weld zone when welding is
interrupted
So, Before gouging/cutting the base metal should be preheated to 200 C°. then cut the
sample to send it to analysis to know the exactly the chemical composition of the base
metal. Then continue the gouging with this condition until decided the preheating
parameters.
once the material composition of the base metal is known, preheat temperature can
be calculated based on the thickness of the work piece and its carbon equivalent%
according to the following equation.
Mn% Cr % + Mo% + V % Ni % + Cu %
Ceq = C % + + +
6 5 15
Formulae Equivalent Carbon
TP = 350 Ceq − 0.25

Seferian Formulae

350
CE=0,80%
CE=0,70%
300
CE=0,60%
Preheating temperature 0C
250 CE=0,50%
200
CE=0,40%
150 CE=0,30%
CE=0,25%
100
CE=0,20%
50
0
۰ ۲۰ ٤۰ ٦۰ ۸۰ ۱۰۰
Thickness mm
Figure 5: Pre-Heating temperature for Ceq. % and thickness
Preheating should be done using electrical preheater with the following precautions:
1. Either side of repair location must be preheated, at least 600mm from

the crack. In case of castings of more than 150mm thick, this should be
at least 900mm.
2. Heating must be done slowly and evenly. Temperature gradients of
more than 40° C per hour should be avoided.
3. Through PWHT process, the temperature must be uniform throughout
the section preheated. Holding times of 25 min/cm of metal section
should be observed, but not ever exceed more than 6 hours.
4. “K” type thermocouples of 0.5o C accuracy can be used for checking
temperature, and its mA current signals as an input to the electrical pre
heater ON/OFF switch control. This is to avoid any misalignment due to
uneven temperature difference, which may cause considerable shear
stress on the weld as it cools following repair.
5. All of heating equipments (machine, thermocouples and heat recorder)
should be have a certificate of the recently calibration. see appendix 2
to find a copy of last job certificate.

6.5 Acceptance criteria.
6.5.1 Acceptance criteria for visual controls
Undercuts are not allowed and, a wash not exceeding 1 mm depth is allowed, in place
welding near flange location.
Structural discontinuities, including incomplete fusion and penetration, will be

evaluated case by case.
Laminations and other discontinuities in the weld area should not exceed 3 mm in any
direction. Laminations and other discontinuities greater than 3 mm size shall be
repaired.
100% close visual inspection of the plate after welding is required with special
emphasis on plate edges because of possible appearance of laminations and/or
lamellar tearing. Any visual lamination of lamellar tearing is reject-able. Any of these
defects must be removed and repaired.
6.5.2 Acceptance criteria for ultrasonic controls
Table 4: Acceptance criteria for ultrasonic controls
6.5.3 Acceptance criteria for Magnetic particle and/or Dye penetrant controls
• Component should be free of any crack after repairing. This will be checked
during the visual inspection, either by magnetic particle or by dye penetrant test.
Both inspections are important to cover the part in its entirety for 100%
inspection. In case of MPT, it will be with a tangential field of 2000 to 3000 A/m.
• Any indications showing the existence of cracks are to be rectified.
• Magnetization should be obtained by passing a current or, with a horseshoe
magnet.
Wet process MPT (fluorescent or black and white) is recommended for better visibility.

Summary of successful
Welding procedure

1. Prior to commencing work on the kiln,
safety locks must be attached to the power
source by every workman. If the repair is to a
spare tyre, ensure that the working area is free
from any obstructions and fully accessible.
2. The kiln was stopped and allowed to

cool down, then scaffolding was erected on the
middle station of the kiln, to allow an access on
the full circumference of the kiln tire, further
cleaning of the kiln tire surface from grease and
dirt was performed to allow an access on the
full circumference of the kiln tire, further
cleaning of the kiln tire surface from grease and
dirt was performed. In case of equipment at
open place, make necessary temporary cover
over the working area, to carry out the repair
job day and night and protect against rain.
3. Rotate the kiln until the area of the

fracture is at top at the position of 2 o'clock
or 10 o'clock, which are be the best
positions for crack repair, were almost
minimal stresses will act on the kiln tire
during the repair.

4. Release partly the load of the shell on the tyre by using:
• Spider inside the kiln (compulsory) to reinforce for the kiln shell from the inside.
• Two Saddle on both sides of tyre, directly under tyre-shell (not under tyre) for
lifting the kiln. It will need for Hydraulic Jacks with a capacity of 100 Tons each were
used to lift the kiln, and secure it by means of safety locks.
5. Remove stop blocks from the tyre pads in crack area and slide tyre pads from under
tyre crack area.

6. The area around the fracture is then degreased and thoroughly cleaned of any
contaminants, rust and surface debris and imperfections. Dye penetrant or preferably
ultrasonic testing is used to establish the full extent of the fracture and any associated cracks
or fissures. It is prudent to perform this on the whole tyre. A visual inspection of the spalled
area will determine the areas for further investigation, these must be clearly identified with a
paint marker pen.
Note: Kiln tyre’s are manufactured using low alloy cast steel containing approximately 0.3%
Carbon, which contains by its nature numerous inclusions and laminates, making the material
prone to ultrasonic misreadings. Because of this symptom, a visual inspection at this stage is
considered more prudent.

7. Restraining bars and brackets should be installed to ensure that the two halves of the
tyre do not move relatively during cutting and welding. If the tyre has sprung apart, it will have
to be dogged back into alignment and wedged to maintain alignment during the actual repair.
The tyre can then be accurately realigned using, for example, “screw blocks”.

8. Heating blankets should be
anchored around the repair area and the
tire temperature raised to 200-300 C . Use a
heat treatment machines resistance heaters
to provide a preheating temperature
degrees around the hour, preheating is
monitoring using 'K' type thermocouples
and documented for further reference.
Then cover it by using Mineral wool with
ASTM E84 Characteristics.
The maximum theoretical pre-heat required

may be determined by the Carbon
Equivalence but can be safely reduced by 50
°C when Xuper NucleoTec 2222 is used. It is
important that this minimum calculated
pre-heat is maintained throughout the
entire buttering and root weld operations
that follow.
If a complete through crack has occurred,

the two sides of the preparation (being completely separated from each other) can be
preheated and controlled independently using type "K" thermocouples. These give a nominal
accuracy of ± 5 °C at the temperatures required. This is of major importance in such cracked
tyres, since any misalignment due to uneven preheat at the time of joining will apply
considerable shear stress on the weld as the tyre cools following repair. Failures can and have
occurred by not following this procedure. The sequence of welding must be established before
any welding is started.
9. Cut the sample to send it to metallurgical lab for chemical analysis.

10. Using 8mm dia. carbon
electrodes and the air arc gouging
process, commence the removal of
the defected area in shallow
sections, keeping a careful eye on
the boundary paint marker.
Laminations, inclusions and spalled
areas can often be chased’ with the
air arc to their conclusion.
There are key factors that must be

taken in to consideration when
repairing spalled tyres that have
been in service for many years.
When arc air gouging the spalled
area back to clean sound material, there is likely to be some stress cracking & oil induced
porosity left in what is otherwise a sound surface. At this stage of the repair a decision should
be made whether to gouge further into the tyre, as experience has shown that that even by
further gouging, the laminations may still be prevalent, i.e. there could still be further stress
cracks & porosity showing to the new surface. The key is to remove the major fault areas,
remembering that tyre castings usually have inherent laminations, which are not always
detrimental to the strength of the casting.
This in turn could significantly increase the amount of welding consumables used and time
scales involved for little benefit.

Maintain visual inspections between arc
gouging operations. Remove any slag
inclusions and traces of carbon left from
the gouging process by grinding. The
area should be ground to a smooth
surface to avoid unnecessary stress
raisers.
The edges of the spalled area are
usually laminated under the surface of
the tyre and should be removed with
other flaked areas. When the gouging
process is completed the defected area
can sometimes be significantly larger in
size and depth to the initial marked
area.
11. Cracks completely through the

tyre will require (a) preparation from
one side; (b) welding from that side;
(c) dye pen inspection to ensure crack
is completely removed. Profiles for
cracks deeper than 40 mm should
ideally have the profile illustrated
where α 20-30 °, r= 6-7 mm and
g= 2- 3mm.
12. Dress weld preparation by full grinding to

obtain a relatively uniform weld preparation and
to remove any possible damaging effects of
carbon picked up from the gouged surface. Dye-
penetrant test to be carried out to the ground
area, if any major cracks are still evident then
these should be removed.

13. The recommended Eutectic electrodes must be pre heated for 2 hours at 200oC in a
suitable baking oven. Remove approx. 10 electrodes at a time and transport to the work place
in portable heated holding quivers.
14. The installation of a copper backing

bar under the tyre together with run-on
and run-off plates at each end will ensure
that all weld starts and stops are outside of
the finished body of the repair. Run-out
tabs should be used on both sides of the
repair to insure 100 percent dense welds
and no undercut at the interface with the
base metal.
15. Apply 3.2mm dia Nucleotec 2222 at

approx. 90 amps and ‘butter’ (surface coat) the
complete surface of the prepared area. To
obtain optimum mechanical soundness
weaving must be avoided, therefore, use
stringer beads up to a deposit width of twice
the electrode diameter.
The temperature must be checked periodically,
applying further heat when necessary. Inspect
for inclusions and if present, grind out and re
weld.

16. A root weld is deposited using 3.2 mm electrodes. Once the entire weld prepared
surface has been buttered and the root welded, the Xuper NucleoTec 2222 allows the pre-heat
requirements to be relaxed for economic and practical purposes. The area is then filled to
about 25 mm using 4.0 mm electrodes to accelerate deposition rate (3,4,5).
The entire repair area is then filled, using 4.0 mm and 5.0 mm electrodes (6-11). Stringer bead
welds are used for all passes, with no weaving at the lowest practical welding current.
17. A rounded-tip needle gun is used constantly to

stress relieve deposits by peening, as well as to ensure
there are no slag inclusions from previous weld passes.
Peening time is for approximately the same time as it
takes to produce the weld.

18. Combined magnetic forces can cause momentary arc interruptions or deflections (Arc
Blow) leading to defects like slag inclusions, lack of fusion and porosity. Residual magnetism
can be due to the use of magnetic hoists, magnetic welding cable clamps, magnetic particle
inspection, manufacture or storage near DC power sources or north–south orientation in the
earth's magnetic field. Arc blow problems may be minimised by using AC power sources,
angling the electrode away from the vertical, following a back step technique, increasing the
current to stiffen the arc or repositioning the workpiece cable.
19. Finish welds and dress if necessary to leave smooth contours, a minimum of inter-bead
craters and undercut or overlap. When all welding and grinding have been completed, allow
the weld to cool slowly. If the welding operation was a major one and added security is
required, a PWHT soaking temperature of 620 °C can used and held for one hour per 3 cm of
thickness. The temperature should then be lowered 20-40°C per hour until ambient
temperature has been reached.

20. The finished surface should be ground flush at the ends of the crack and the top
surface profiled using grinders and a profile gauge. Best results are produced with a tyre
grinder. This can be adapted to mount in a frame which moves across the weld area. This
grinding of the weld cap to the exact profile of the tyre is much easier and quicker. Advantages
are a more accurate grinding operation, time saving and less impact load produced when the
tyre passes over the rollers. In some cases 0.5 mm excess height has been left after grinding to
allow for compression of the weld overlay during operation.

21. Recommendations.
We would strongly recommend that a contractor with experience in welding with 2222 on this
type of application be used. We would also recommend some form of Eutectic supervision be
employed on this type of repair, whether it be full time on site or periodic visits to ensure the
stated methods of repair are adhered to. The most important aspect of this supervision would
be to make the decision whether the surface is ready to be welded and the cut-off point for
excavation, as there are often some small cracks and porosity evident to the surface and edges
of cut out as already explained. A repair following this method should prove successful and a
long lasting repair can be achieved.
For any advising

kindly, contact our application specialist
Atef Badr
Atef.Badr@castolin.com
+2 0100 66-83-908

Appendix 1
Chemical analysis of
Kiln metal sample

Appendix 2
Certificate of the recently calibration

of
Heating equipments

Repair of Fractured Kiln Tyre P a g e |36 35 Atef Badr Tel:+2 0100 66-83-908
Appendix 3
Health And Safety With Welding Fumes Follow

Health and safety with welding fumes follow
Introduction
More than a supplier of consistently high quality products, Eutectic Castolin is a stable
and reliable partner on whom our customers can always rely for the resolution of
technical issues and for ongoing support.
The use of modern welding and surface coatings has been established for many years
as a means of combating wear, breakage and corrosion of components within industry.
The correct choice of process and material is critical to the success of any repair.
Substantial cost savings can, and are being achieved by such reclamation and this can
also impact on inventory, production downtime and can lead to increased service life.
This document concentrates on the Health and Safety considerations of welding

fumes. We have endeavoured to give the most detail in the briefest format to make
this document an easy to use tool for your engineering department.
Welding Fumes
• Sources of Fumes
It is often a requirement to remove dirt, grease, paint, rust and scale from the metal’s
surface before welding and brazing can be carried out to produce a defect free weld. It
is also advisable to grind after welding and cutting operations.
With regard to grinding or any other mechanical methods of removing surface

coverings prior to welding, the following safety aspects must be addressed:
1. Eye protection
2. Dust released by the removal method
3. Chemical involving the use of solvents
• Precautions when Welding etc on Coated Materials
Unless the welding process, which can only be established by carrying out tests similar
to those that apply in practice, produces any fumes, it will be necessary to take
precautions by way of fume extraction with adequate ventilation and/or personal
protection. Alternatively, by the removal of the coating by means other than burning.
• Eye Protection
Eyes must be protected at all times by the correct type of goggles. This is a goggle of
impact resistance with complete impregnable side protection to BS 2092 1987, eye
protection for industrial and non-industrial uses. See grade 1 and 2 impact.

Repair of Fractured Kiln Tyre Atef Badr Tel:+2 0100 66-83-908
• Dust Released by the Removal Method
Where dust is released by any method of material removal in excessive quantities, or is

toxic or of unknown origin, local exhaust ventilation or respiratory protection will be
required.
Where the parent metal has a surface coating such as galvanising, which would
produce an undesirable fume if welded, it may be acceptable to remove this coating by
grinding (taking suitable precautions).
• Chemical Methods involving the use of Solvents
For instance: Trichloroethylene, Carbon tetrachloride, Benzene Toluene, White spirits

and Solvent naphtha.
Solvent cleaning is either carried out using swab or immersion of the work into a tank
or bath. Carbon tetrachloride and benzene are poisonous substances and their use
must be avoided even in small quantities.
Commercial toluene (Totuol), in the past found to contain up to 15% benzene, makes it
a dangerous cleaning agent. Newer distillate with less than 1% benzene is now
standard. The safest degreasing agent to use is the water-based family. Advice must be
sought on the correct type for the application.
Action of the Heat Source on the Parent Metal
As the parent metal is raised to its melting point in welding it is likely to generate
fumes. These fumes contain oxides of the metal. The fumes from carbon steels or
aluminium are not usually troublesome.
Copper and its alloys may produce fume levels exceeding their O.E.L’s unless
ventilation is good. Stainless steel can also release oxides of chrome and nickel,
therefore, a combination of ventilation and fume extraction should be used.
Actions of Heat on Flux
The majority of manual metal arc welding electrodes have a flux coating. These come
in various forms.
Alloying Elements
High levels of chromium and nickel are added to stainless steel electrodes. These
elements may be toxic and be present in the fumes.
MMA (Manual Metal Arc)
MMA electrodes can contain high levels of iron oxide. This can settle in the lungs and
though produces no symptoms of ill health is visible in normal chest radiographs. This
condition is known as Siderosis, or welder lung. This build-up over a period of years, if
exposure is continued, is gradually dispersed if active welding is stopped.

Repair of Fractured Kiln Tyre Atef Badr Tel:+2 0100 66-83-908
MSDS can change and this MSDS is only valid today:
12.08.2018
Revision date: 15.07.2015
Safety Data Sheet according to Regulation (EC) No 1907/2006
MEC Holding GmbH Revision No: 3,0
SDS 00015 EutecTrode X2222
SECTION 1: Identification of the substance/mixture and of the company/undertaking
1.1. Product identifier

EutecTrode X2222
1.2. Relevant identified uses of the substance or mixture and uses advised against
Use of the substance/mixture

Welding rod, welding wire
1.3. Details of the supplier of the safety data sheet
Company name: Castolin Eutectic Ireland Ltd. MEC Holding GmbH
Street: 36 Magna Avenue, Magna Business Park CitywestMesser-Platz 1
Place: IRL-24 Dublin D-65812 Bad Soden

Telephone +353 (0) 145 158 33 +49 (0) 6196 7760-555
Telefax +353 (0) 145 151 97 +49 (0) 6196 7760-561
Verantwortlich für das Sicherheitsdatenblatt: sds@gbk-ingelheim.de
1.4. Emergency telephone number: Emergency telephone :+49 (0) 6132 / 84463 (GBK GmbH, Ingelheim)
SECTION 2: Hazards identification

2.1. Classification of the substance or mixture
Classification according to Regulation (EC) No. 1272/2008 [CLP]
Hazard categories:
Respiratory or skin sensitisation: Skin Sens. 1
Carcinogenicity: Carc. 2
Specific target organ toxicity - repeated exposure: STOT RE 1
Hazardous to the aquatic environment: Aquatic Chronic 3
Hazard Statements:
May cause an allergic skin reaction.
Suspected of causing cancer.
Causes damage to organs through prolonged or repeated exposure.
Harmful to aquatic life with long lasting effects.
2.2. Label elements
Additional advice on labelling
As an article the product does not need to be labelled in accordance with EC-directives or respective national laws.
Signal word: Danger
Pictograms: GHS07-GHS08
Hazardous components which must be listed on the label

nickel
Trisodium hexafluoroaluminate (cryolite)
Hazard statements
H317 May cause an allergic skin reaction.
H351 Suspected of causing cancer.
H372 Causes damage to organs through prolonged or repeated exposure.
H412 Harmful to aquatic life with long lasting effects.
Precautionary statements
P285 In case of inadequate ventilation wear respiratory protection.
P314 Get medical advice/attention if you feel unwell.
P280 Wear protective gloves/protective clothing/eye protection/face protection.
P202 Do not handle until all safety precautions have been read and understood.
P260 Do not breathe dust/fume/gas/mist/vapours/spray.
Print date: 24.08.2015 IRL - EN Page 1 of 8

12.08.2018
P501 Dispose of contents/container to waste treatment facility in accordance with local and national
regulations. .
2.3. Other hazards
Welding and brazing processes can cause spatter , melting metal and UV/IR heat can cause burns or start fires.
During welding- and brazing processes formed metallic fumes are suspected of being cancer causing agents.
Brazing/welding vapours and fumes from brazing/welding may cause metal fumes fever. Symptoms can appear 4 to 12
hours after. (headache, dizziness, dryness, cough, nausea and fever)
May cause irritation by prolonged inhalation of brazing/welding fumes.
Welding fumes (not otherwise specified) are considered to be carcinogenic with no further categorization by NIOSH
(National Institute for Occupational Safety and Health) and IARC ( International Agency for the Research on Cancer).
IARC - International Agency for Research on Cancer
NIOSH - National Institute for Occupational Safety and Health
SECTION 3: Composition/information on ingredients

3.2. Mixtures
Chemical characterization
Base metals and alloys
Hazardous components
EC No Chemical name Quantity
CAS No
Index No Classification according to Regulation (EC) No. 1272/2008 [CLP]
REACH No
231-111-4 nickel >50 %

7440-02-0
028-002-00-7 Carc. 2, STOT RE 1, Skin Sens. 1; H351 H372 ** H317
231-157-5 Chromium 10-50 %

7440-47-3
239-148-8 Trisodium hexafluoroaluminate (cryolite) 0,1 - 5 %

15096-52-3
009-016-00-2 STOT RE 1, Acute Tox. 4, Aquatic Chronic 2; H372 H332 H411
Full text of H and EUH statements: see section 16.
SECTION 4: First aid measures

4.1. Description of first aid measures
After inhalation
Take affected person into fresh air.
Consult a physician if necessary.
After contact with skin
Wash off immediately with plenty of water for at least 15 minutes.
In the event of persistent symptoms receive medical treatment.
After contact with eyes
Rinse thoroughly with plenty of water, also under the eyelids.
In the event of persistent symptoms receive medical treatment.
After ingestion
Rinse the mouth. Give the patient plenty of milk or other calcium source, e.g. calcium gluconate if available. Take the patient to
hospital. Do not induce vomiting
As soon as possible, take phials of calcium chloride and seek hospital.
Hazard statements

12.08.2018
SECTION 5: Firefighting measures

5.1. Extinguishing media
Suitable extinguishing media
Use fire fighting measures that suit the environment and products stored.
5.2. Special hazards arising from the substance or mixture
In case of fire formation of dangerous gases possible. Hydrogen fluoride (HF), Fluorides
5.3. Advice for firefighters
In case of fire, wear suitable respiratory equipment with positive air supply.
SECTION 6: Accidental release measures

6.1. Personal precautions, protective equipment and emergency procedures
Breathing apparatus (particle filter) only if dust is formed.
6.2. Environmental precautions
Do not discharge into the drains or bodies of water.
6.3. Methods and material for containment and cleaning up
Take up mechanically and collect in suitable container for disposal.
6.4. Reference to other sections
Observe protective instructions (see Sections 7 and 8).
Informations for disposal look up chapter 13.
SECTION 7: Handling and storage
7.1. Precautions for safe handling

Advice on safe handling
Keep container tightly closed.
Avoid contact with skin, eyes and clothing.
Use only in well-ventilated areas.
ANSI Z49.1 Safety in Welding, Cutting and allied processes.
7.2. Conditions for safe storage, including any incompatibilities
Requirements for storage rooms and vessels
Keep in a dry place.
Advice on storage compatibility
Incompatible with strong acids and oxidizing agents.
7.3. Specific end use(s)
Welding rod, welding wire
SECTION 8: Exposure controls/personal protection
8.1. Control parameters

12.08.2018
Occupational exposure limits
CAS No Substance ppm mg/m³ fib/cm³ Category Origin
- Chromium (VI) compounds (as Cr) Insoluble - 0.01 TWA (8 h)

- - STEL (15 min)
7440-47-3 Chromium metal - 2 TWA (8 h)
- - STEL (15 min)
7439-96-5 Manganese, fume (as Mn) - 0.2 TWA (8 h)
- 3 STEL (15 min)
- Molybdenum soluble compounds (as Mo, CAS - 10 TWA (8 h)
7439-98-7, EINECS 231-107-2) (Inhalable
Fraction)
- - STEL (15 min)
- Nickel, inorganic compounds (as Ni), insoluble - 0.5 TWA (8 h)
compounds
- - STEL (15 min)
Biological limit values
CAS No Substance Parameter Value Test material Sampling time
7440-47-3 Chromium Total chromium 25 µg/L Urine End of shift at

end of
workweek
7440-02-0 Nickel Ni 3 µg/L Urine After several
consecutive
working shifts
8.2. Exposure controls

Appropriate engineering controls
Provide appropriate exhaust ventilation at machinery and at places where dust or smoke can be generated.
Protective and hygiene measures
At work do not eat, drink and smoke.
Wash hands and skin before breaks and after work .
Eye/face protection
Use approved tinted welding goggles during welding
Safety goggles with side protection (EN 166).
Hand protection
Use protective gloves for welders (DIN 4841-4).
Use inner-gloves to prevent from allergic reactions due to direct skin contact.
Protective gloves resistant to chemicals made off polychloropren , Minimum coat thickness 0.6 mm, Permeation resistance
(wear duration) approx. 480 minutes, i.e. protective glove <Camapren 722> made by www.kcl.de.
Requirements can vary as a function of the use. Therefore it is necessary to adhere additionally to the recommendations
given by the manufacturer of protective gloves.
This recommendation refers exclusively to the chemical compatibility and the lab test conforming to EN 374 carried out under
lab conditions.
Skin protection
Dust resistant protective clothing.
Respiratory protection
Use suitable breathing apparatus if there is inadequate ventilation.
Multi-purpose filter ABEK/P3
SECTION 9: Physical and chemical properties

9.1. Information on basic physical and chemical properties
Physical state: Solid
Colour:

12.08.2018
Odour: Odourless
pH-Value: n.a.
Initial boiling point and boiling range: n.a.
Flash point: n.a.
9.2. Other information
No data available.
SECTION 10: Stability and reactivity

10.1. Reactivity
No data available.
10.2. Chemical stability
Stable under normal conditions.
10.3. Possibility of hazardous reactions
In contact with acids, may give off poisonous gases.
10.4. Conditions to avoid
Hydrogen fluoride is liberated on heating at high temperatures in the presence of water vapor.
10.5. Incompatible materials
Strong acids and oxidizing agents
10.6. Hazardous decomposition products
In contact with acids, may give off poisonous gases.
Metallic oxides
SECTION 11: Toxicological information

11.1. Information on toxicological effects
Acute toxicity
Based on available data, the classification criteria are not met.
Brazing/welding vapours and fumes from brazing/welding may cause metal fumes fever. Symptoms can appear 4 to 12 hours
after. (headache, dizziness, dryness, cough, nausea and fever)
Risk of fluorose
CAS No Chemical name
Exposure routes Method Dose Species Source
7440-02-0 nickel
oral LD50 > 9000 Ratte
mg/kg
15096-52-3 Trisodium hexafluoroaluminate (cryolite)
inhalative vapour ATE 11 mg/l
inhalative aerosol ATE 1,5 mg/l
Irritation and corrosivity

May cause irritation by prolonged inhalation of brazing/welding fumes.
Sensitising effects
May cause an allergic skin reaction. (nickel)
STOT-single exposure
Severe effects after repeated or prolonged exposure
Causes damage to organs through prolonged or repeated exposure. (nickel), ( Trisodium hexafluoroaluminate (cryolite))
Welding fumes (not otherwise specified) are considered to be carcinogenic with no further categorization by NIOSH (National
Institute for Occupational Safety and Health) and IARC (International Agency for the Research on Cancer).
Carcinogenic/mutagenic/toxic effects for reproduction
Suspected of causing cancer. (nickel)

12.08.2018
Aspiration hazard
Further information
The product was classified on the basis of the calculation procedure of the preparation directive (1999/45/EC).
SECTION 12: Ecological information

12.1. Toxicity
No data available.
CAS No Chemical name
Aquatic toxicity Method Dose [h] | [d] Species Source
7440-02-0 nickel
Acute fish toxicity LC50 > 100 mg/l 96 h Danio rerio
Acute algae toxicity ErC50 100 mg/l 72 h Selenastrum capricornutum
Acute crustacea toxicity EC50 > 100 mg/l 48 h Daphnia magna
15096-52-3 Trisodium hexafluoroaluminate (cryolite)
Acute fish toxicity LC50 > 1000 mg/l 96 h Brachydanio rerio IUCLID
12.2. Persistence and degradability

No data available.
12.3. Bioaccumulative potential
No data available.
12.4. Mobility in soil
No data available.
12.5. Results of PBT and vPvB assessment
No data available.
12.6. Other adverse effects
No data available.
Further information
Do not flush into surface water or sanitary sewer system.
SECTION 13: Disposal considerations
13.1. Waste treatment methods
Advice on disposal
Where possible recycling is preferred to disposal.
Dust and in exhaust systems separated particles dispose of in compliance with local regulations.
Waste disposal number of waste from residues/unused products
160303 WASTES NOT OTHERWISE SPECIFIED IN THE LIST; off-specification batches and unused products;
inorganic wastes containing hazardous substances
Classified as hazardous waste.
Waste disposal number of used product
150202 WASTE PACKAGING; ABSORBENTS, WIPING CLOTHS, FILTER MATERIALS AND PROTECTIVE
CLOTHING NOT OTHERWISE SPECIFIED; absorbents, filter materials, wiping cloths and protective clothing;
absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing
contaminated by hazardous substances
Classified as hazardous waste.
Waste disposal number of contaminated packaging
150102 WASTE PACKAGING; ABSORBENTS, WIPING CLOTHS, FILTER MATERIALS AND PROTECTIVE
CLOTHING NOT OTHERWISE SPECIFIED; packaging (including separately collected municipal packaging
waste); plastic packaging
SECTION 14: Transport information

Land transport (ADR/RID)

12.08.2018
Other applicable information (land transport)

No hazardous material as defined by the transport regulations.
Inland waterways transport (ADN)
Other applicable information (inland waterways transport)
Marine transport (IMDG)
Other applicable information (marine transport)
Air transport (ICAO)
Other applicable information (air transport)
14.6. Special precautions for user
No specific precautions required.
14.7. Transport in bulk according to Annex II of MARPOL73/78 and the IBC Code
The transport takes place only in approved and appropriate packaging.
Other applicable information
SECTION 15: Regulatory information

15.1. Safety, health and environmental regulations/legislation specific for the substance or mixture
EU regulatory information
1999/13/EC (VOC): 0%
National regulatory information
SECTION 16: Other information

Changes
Section: 2, 3
Abbreviations and acronyms

ADR = Accord européen relatif au transport international des marchandises Dangereuses par Route
RID = Règlement concernant le transport international ferroviaire de marchandises dangereuses
ADN = Accord européen relatif au transport international des marchandises dangereuses par voie de navigation intérieure
IMDG = International Maritime Code for Dangerous Goods
IATA/ICAO = International Air Transport Association / International Civil Aviation Organization
MARPOL = International Convention for the Prevention of Pollution from Ships
IBC-Code = International Code for the Construction and Equipment of Ships Carrying Dangerous Chemicals in Bulk
GHS = Globally Harmonized System of Classification and Labelling of Chemicals
REACH = Registration, Evaluation, Authorization and Restriction of Chemicals
CAS = Chemical Abstract Service
EN = European norm
ISO = International Organization for Standardization
DIN = Deutsche Industrie Norm
PBT = Persistent Bioaccumulative and Toxic
LD = Lethal dose
LC = Lethal concentration
EC = Effect concentration
IC = Median immobilisation concentration or median inhibitory concentration
Relevant H and EUH statements (number and full text)

H332 Harmful if inhaled.
H411 Toxic to aquatic life with long lasting effects.

12.08.2018

Further Information
Data of items 4 to 8, as well as 10 to 12, do partly not refer to the use and the regular employing of the product
(in this sense consult information on use and on product), but to liberation of major amounts in case of accidents
and irregularities.
The information describes exclusively the safety requirements for the product (s) and is based on the present
level of our knowledge.
The delivery specifications are contained in the corresponding product sheet.
This data does not constitute a guarantee for the characteristics of the product(s) as defined by the legal warranty
regulations.
IARC - International Agency for Research on Cancer

NIOSH - National Institute for Occupational Safety and Health
Literature:
(The data for the hazardous ingredients were taken respectively from the last version of the sub-contractor's safety
data sheet.)

Method Statement Repair of Cracked Kiln Tyre

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Method Statement Repair of Cracked Kiln Tyre

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Method Statement

Repair of Fractured Kiln Tyre

Due to variations inherent in specific applications, the technical

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

2 Causes and Modes of Failures.

Overall, The main causes of tyre cracks is:

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

3 Technical data of the Kiln Tyre metal:

Ferrous Carbon chrome Manganese Molybdenum Vanadium Nickel Copper

Steel casting ASTM A356 Mechanical properties:

Steel casting ASTM A356

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

Otherwise, in today’s highly competitive market, the profitable manufacture of

4.1 Replacement Option:

4.2 Repair Option:

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

To improve the reliability of this difficult to check application, we in Castolin insist on

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

• OPTION 1: The use of an autogenous AWS specification ferritic electrode, such

These effects, themselves, can give rise to increased susceptibility to subsequent

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

5.2 Electrode selection.

Primary factors that affect an electrode's suitability include:

5.2.1 Linear coefficient of thermal expansion.

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

Figure 2: Xuper NucleoTec 2222 on Schaeffler diagram

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

But it is reported on the Schaeffler diagram it is situated in an area where there is a

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

The risk of “cold-cracking” in steels is multiplied whenever a hardened welding zone

Xuper NucleoTec 2222 minimizes HIC risks in two complementary ways:

Relative Diffusion Rate Hydrogen

Hydrogen Diffusion Rate VS Temperature and Phase

Hydrogen Solubility VS temperature and Phase.

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

In addition, the savings generated by carrying out an in-situ repair, without

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

1. Welding machines Generators or rectifiers with a capacity of at least up to 400

6.2 Welder’s Qualifications.

It is recommended that welding operators be certified in accordance with the

6.3 NDT & Quality control.

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

6.4 Preheating & PWHT.

A preheating temperature Tp measured only once immediately before any welding

Formulae Equivalent Carbon

TP = 350 Ceq − 0.25

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

Figure 5: Pre-Heating temperature for Ceq. % and thickness

1. Either side of repair location must be preheated, at least 600mm from

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

6.5.1 Acceptance criteria for visual controls

Structural discontinuities, including incomplete fusion and penetration, will be

6.5.2 Acceptance criteria for ultrasonic controls

Table 4: Acceptance criteria for ultrasonic controls

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

2. The kiln was stopped and allowed to

3. Rotate the kiln until the area of the

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC

Method Statement of Copyright MESSER Eutectic Castolin Egypt LLC