Factory:  Corner Steyr & Alfa Sts 
Aureus Industrial sites 
Email: info@keramicalia.co.za
Website: www.keramicalia.co.za
Cell: Dave  082  808 4757
Email: keraccounts@iafrica.co.za
Accounts: Myrtle Wakeford
Tel: (011) 764 2139
Tel: (011) 412 3261
P O  Box 2288
Wilro Park,1731

Hardcast is a product range based on a complex silicate bonding system. It is totally inorganic, quick setting, strong, acid resistant and refractory. The chemical composition is typically more than 95% silica. Hardcast sets in about one hour at ambient temperature and very rapidly at high temperature. Hardcast dehydrates completely, and will therefore not explode if molten metal or slag is poured over it. Hardcast is ideal for repair of casting floors and ferrochrome furnace charging floors. A patch on a charging floor at around 60 to 100ºC is fully serviceable for charging car traffic in 15 minutes. Repairs can therefore be effected without disrupting production. Hardcast has a compressive strength of around 60 MPa.: twice the strength of good structural concrete. For light service floor repairs 15mm has proved adequate, but for most purposes 50mm is recommended. On new installations, a 50mm capping of Hardcast on ordinary concrete is recommended. Hardcast is supplied in 25Kg thick, clear polyethylene bags, with 33.3Kg drums of liquid Hardcast Binder. Plus 14% binder is mixed into the powder and vibrated into place. The standard casting grade is very coarse. Plaster and fine grades are also available. The density is around 2,3g/cm³. Surfaces to be repaired are usually dirty, dusty and sometimes friable. A coat of Hardcast Binder painted on is often recommended. The casting grade costs R20 338 + VAT /ton. Installed cost would be around R42/m² + VAT per mm thick, i.e. R515/m² + VAT at 1 inch thick. Hardcast for repair of pavements and factory floors(3) Hardcast is a product range based on a complex silicate bonding system. It is totally inorganic, quick setting, strong, acid resistant and refractory. Hardcast is available in several grades for differenr applications. Hardcast sets within 2 hours, and is fully serviceable within 24 hours. It can be applied to any structurally sound surfaces. Damp floors or dirty floors should first be painted with Hardcast binder. Hardcast is fully resistant to Sulphuric acid, Hydrochloric acid, Nitric acid, Phosphoric acid and organic acids. It is not resistant to Hydrofluoric acid or alkalis. The biggest advantage of Hardcast over concrete and cementitious materials is that it can be successfully placed in thin sections. There is no need to dig a vertical hole before repair. The repair can be tapered to 2mm thick. Hardcast is not porous, and will not absorb liquids. The density is around 2,2g/cm³ The maximum particle size is about 4mm. The standard colour is a light grey similar to concrete. The colour is easily modified by addition of oxides. Hardcast is supplied in two parts; 25Kg bags of powder and 33,5Kg drums of the liquid Hardcast Binder. Add about +16% binder to the powder. Shelf life is virtually indefinite in unpunctured bags.

Strength: For hand placed material about 30MPa, for drier, mechanically compacted material, about 60MPa.

Mixing: Hardcast can be mixed by hand or in a concrete mixer or pan mixer. Hardcast has a viscous semi-fluid consistency, and is very easy to work with. It should preferably be placed within 20 minutes of             mixing, and mixing equipment should not be left with material in for more than half an hour.

Surface preparation: Brush the surface clean and remove oil, grease, paint etc. Do not use water. Paint the surface with Hardcast Binder, until all dust is absorbed in the liquid and the whole surface is                                       wetted.

Curing: Cover with plastic for the first hour. (In dry weather it will develop surface cracks if exposed.) Keep water off it for the first two hours. Keep traffic off it for the first four hours. All Hardcast products               set very rapidly on a hot surface. Around a furnace, for example, in fifteen minutes, sufficient strength was achieved to drive a forklift over a 40mm repair.

Applications: Factory floors where rapid repair is needed. Factory floors where the damage tapers to a shallow depth. Roads which cannot be closed for long. Kerbs etc. where the volume of repair is                                too small for concrete to set properly.

Price: Hardcast costs R20 338/ton.

Ordering: Powder and binder are both charged at R16 078/ton on combined weight. If one ton is ordered, one ton of combined net weight of powder and binder will be supplied, rounded off to the nearest                  packaging unit.