Description Kerapatch stainless is a phosphate

bonded chrome-alumina plastic material. Compared to conventional phosphate bonded chrome-aluminas, Kerpatch stainless has appreciably lower shrinkage, which results in superior structural integrity. It is supplied in soft plastic consistency, ready to use, in plastic buckets.


1. Induction furnace repairs.
2. Metal splash shields.
3. Abrasion resistant linings.
4. Sliding gate maintenance.
5. Long-life ladles and teapot ladles.
6. Runners and launders.
7. Water-cooled plate protection.

Composition: The aggregate is fused chrome alumina: a high purity synthetic alpha alumina polycrystalline aggregate with good temperature and chemical stability. The matrix is tabular alumina which has good bonding properties and thermal shock resistance. The phosphate binder develops high strength at 100ºC. A complex series of dehydration reactions follow, culminating in a very strong anhydrous bond at 400ºC. The ceramic bond develops from 1000ºC, and rapidly above 1200ºC. Before the phosphate becomes pyroplastic, the chrome-alumina bond is well developed. Consequently it has very high strength over the whole temperature range from 100ºC to 1800ºC.

Metal Protection: A sheet of expanded metal, heavy duty, such as Mentex 72, is bent and tacked onto the steel substrate such that it is positioned 10 to 15mm above the surface. The material is then pressed into this continuous anchorage and hammered tight. The thickness is typically 25mm. This system is used in the following applications:

1. The outsides of steel shells or structures which sometimes come into contact with pouring steel or ferroalloys. Eg.: Launder casings, especially upper edges. AOD hoods. Ladles with hoods. Bases of steel structures especially where silicon spillage is possible. Spincaster cover ends.
2. Where occasional metal flow is expected yet there is insufficient space to apply conventional refractories: Eg.: Tundish overflows. Continuous caster emergency launders. Teapot ladle spouts. Handheld purging lances.
3. Abrasion resistant linings where geometry is too complex for tiles. eg.: nozzles. 4. Abrasion resistant linings where the temperature fluctuation destroys tiles, Eg.: burner quarls, coke discharge chutes.

Where mechanical stresses are great, another system is used; Hexmetal reinforcing. The sheet of honeycomb metal is welded onto stainless steel plate and the keraplas packed into it. Each cell of the honeycomb is independently anchored, and the structure can withstand severe expansion and contraction and mechanical abuse. This system can be used on water-cooled copper panels etc.

Chemical analysis

Al2O3 82.0%
CrO 7.2%
Fe2O3 1.7%
SiO2 4.0%
TiO2 0.02%
CaO 1.5%
MgO 0.2%
Na2O 0.3%
K2O 1.0%
P2O5 3.4%
Total 101.5%

Packaging; 25kg plastic buckets, ready to intstall.

See also: Keramor chrome alumina mortars Refractory paint, green. Keraplas; Similar material with green chromic oxide. Alumina castables; Keratab and Rubycast. Injectable Rubyject.