KCCCerak Wool

INDEX
. INTRODUCTION
1. INTRODUCTION OF CERAKWOOL
2. FEATURES OF CERAKWOOL
. PRODUCT INFORMATION
1. MATERIAL
1) CERAKWOOL BULK FIBERS
2) CERAKWOOL 1300 BLANKET
3) CERAKWOOL 1100 FELT
10
4) CERAKWOOL HTZ-BLANKET
13
5) CERAKWOOL HARD BOARD
16
6) CERAKWOOL WET FELT
19
7) CERAKWOOL 1300 PAPER
21
8) CERAKWOOL MODULE SYSTEM
23
9) CERAKWOOL VACUUM FORMED PRODUCTS
25
10) CERAKWOOL TEXTILE
26
11) CERAKWOOL 1300 ROPE
28
12) CERAKWOOL MOLDABLE
29
2. SUPPLEMENTARY MATERIAL
1) CERAKWOOL RIGIDIZER
31
2) CERAKWOOL BOND
32
3) CERAKWOOL COATING CEMENT
33
3. BIO-SOLUBLE CERAKWOOL 11001300
34
4. MARINE INSULATION MATERIAL (H - Class specification)
38
. CONSTRUCTION
1. MATERIAL USE
40
2. INSTALLATION OF CERAKWOOL LININGS

1) CERAKWOOL PAPER LINING
44
2) CERAKWOOL KH-MODULE LINING
54
3) CERAKWOOL K-MODULE LINING
57
4) CERAKWOOL STACK LINING
63
5) CERAKWOOL VENNER LINING
65
3. APPLICATION EXAMPLE
67
. INTRODUCTION
. INTRODUCTION
1. INTRODUCTION OF CERAKWOOL
CERAKWOOL the brand name of ceramic fiber manufactured by KCC Corporation is a high temperature, fireresistant material produced by Spinning Process, the most advanced technology for ceramic fiber of the best quality.
KCC Corporation a global leading manufacturer and supplier of building & industrial materials, provides CERAKWOOL
with confidence in excellent quality. CERAKWOOL by Spinning Process has superior tensile strength and other
properties.
2. FEATURES
1. High heat-resistance : The maximum service temperature of CERAKWOOL is
(1) CERAKWOOL 1300 BLANKET : 1,260 (2) CERAKWOOL HTZ BLANKET : 1,430
2. Low thermal conductivity : Excellent heat-insulating property due to low thermal conductivity at high temperature.
3.Low heat storage : L
ow heat storage due to its lower density than that of refractory bricks reduces heat loss due to heat
storage of furnace components.
4. Light weight : Its light weight and flexibility provide easy installation at any jobsite.
5.Chemical stability : CERAKWOOL made from highly pure silicate and alumina has superior resistance to chemical attack such
as acids and alkalis.
6. Cost efficiency : Its excellent insulating property saves fuel costs and its reduction in installation time due to easy handling
and application minimizes construction costs. Its easy maintenance offers cost efficiency.
1. MATERIAL
1) CERAKWOOL BULK FIBERS
CERAKWOOL BULK FIBER is a high temperature light weight ceramic bulk fiber ideal for use as a fill or packing
material in a number of industrial applications it is made from alumina-silica fibers and can be used at temperatures
ranging to 1,260-1,430 CERAKWOOL BULK FIBERS has excellent high temperature resistance thermal stability and
resistance to vibration as well as outstanding low thermal conductivity and heat storage.
CERAKWOOL BULK FIBER has the following outstanding properties which carry through the entire CERAKWOOL
products line.
OUTSTANDING CHARACTERISTICS
* Low thermal conductivity
* Low heat storage
* High temperature stability
* Light weight
* Excellent corrosive resistance
CHEMICAL PROPERTIES
BULK FIBER exhibits excellent chemical stability resisting attack from most corrosive agents exceptions are hydrofluoric
areas.
* Roofs of furnaces and kilns
* Expansion joints
* Vacuum formed shapes
* Kiln car tops
* Packing and fast repairs in kilns and furnaces
USE AS ASBESTOS REPLACEMENT.
FIRE STOP IN BUILDINGS.
LIGHT WEIGHT REFRACTORY FILL.
CERAKWOOL BULK FIBER insulation is used as a resilient fill or as packing material in numerous high temperature
TYPICAL APPLICATIONS
Technical Book 2013
and phosphoric acids and concentrated alkalies. CERAKWOOL BULK FIBER also resists oxidation and reduction.
PHYSICAL PROPERTIES
1300 BULK
HTZ-BULK
Maximum service temperature
1,260
1,430
Color
White
White
Fiber diameter
Ave 3 microns
Ave 3 microns
Fiber length
Ave 200 mm
Ave 200 mm
Specific heat (at 1,000 )
0.255
0.255
Specific gravity
2.55
2.72
CERAKWOOL BULK FIBER has a density of about 100 kg/ as it comes from the carton. The packed density when
installed will range between 130-160 kg/. It is difficult to achieve a density more 160 kg/ by hand packing thus
the installed density will vary depending upon the force used.
STANDARD PACKAGE
1300, HTZ Bulk ..................... 15 kg/bag
THERMAL CONDUCTIVITY
Thermal conductivity vs. mean temperature
kcal
mh
Mean temperature ()
CHEMICAL ANALYSIS
1300 BULK
HTZ-BULK
Alumina
Al2O3
47-49 %
34 %
Silica
SiO2
50-52 %
48 %
ZrO2
16-20 %
Trace inorganics
0.5 %
0.5 %
Leachable chloride
10 ppm
10 ppm
2) CERAKWOOL 1300 BLANKET
CERAKWOOL 1300 BLANKET is a low iron, high purity ceramic fiber blanket developed especially for use in highly
reducing atmospheres. It is light weight, flexible and suitable for operating temperatures up to 1,260 . CERAKWOOL
1300 BLANKET is a highly efficient insulator having low heatstorage capacity and complete resistance to damage from
thermal shock. CERAKWOOL 1300 BLANKET has excellent resistance to oxidation and reduction and can withstand
most corrosive agents. Hydrofluoric and phosphoric acids are exceptions. It has excellent strength, both hot and cold.
If wet, steam or oil, thermal and physical properties remain unaffected after drying.
Its sound absorption ability is greater than dense or insulating refractories and it stores some 95 % less heat than
dense fire brick and about 75 % less than insulating brick.
*R
emoval insulating blankets for field stress relieving
* Glass furnace crown insulation
welds
* Reusable insulation for steam and gas turbines
*H
eat treating furance with high percentages of
hydrogen
* High temperature pipe insulation
* Soaking pit seals
* Annealing cover seals
* Thermal reactor insulation.
* Investment casting mold wrappings
* Expansion joint seals
* Pressure and cryogenic vessel fire protection
* Primary reformer header insulation
* High temperature filtration
* High temperature gasketing
* Nuclear insulation application
* Incineration equipment and stack lining
* Furance door linings and seals
* Furance, kiln and boiler linings
Technical Book 2013
*L
ow thermal conductivity
* Resiliency
*L
ow heat storage.
*L
ight weight
*T
hermal shock registance.
*G
ood sound absorption
* Excellent corrosion resistance
* Easy to cut, wrap, or form
*E
xcellent tensile strength.
* Excellent hot strength
PHYSICAL PROPERTIES
Color
White
1,260
Melting point
Above 1,760
Fiber diameter
Ave. 3 microns
Fiber length
Ave 200 mm
Specific heat at 1,000
0.255
Specific gravity
2.25
Tensile strength #130
80-100 kpa
kcal
mh
Mean temperature ()
PERMANENT LINEAR CHANGE(% Shrinkage)

24 Hours at 1,000
1.6-1.8 %
1,100
1.8-2.1 %
1,260
2.4-3.0 %
The permanent linear change in a 24 hour test is representative of the shrinkage that will be experienced in actual
service.
Four hour test data is not representative.
CHEMICAL ANALYSIS
Alumina Al2O3
47-49 %
Silica SiO2
50-52 %
Trace inorganics
0.5 %
Leachable chloride
< 10 ppm
STANDARD SIZES

Density
kg/
100, 130, 160
Thickness
mm
12.5, 25, 50
Width
mm
610
Length
mm
3,600, 7,200, 14,400
The different widths and lengths can be supplied subject to quantity and delivery requirement.
ACOUSTIC INSULATION
1,300 BLANKET acts as an efficient acoustic barrier
at all temperatures up to its maximum use limit.
The absence of chemical binding agents enables
1300 BLANKET to function as acoustic insulation in
high temperature applications.
Its commonly used as a low temperature acoustic
barrier in situations where it can perform a secondary
Technical Book 2013
function as a fire barrier.
FREQUENCY CYCLES PER SECOND
3) CERAKWOOL 1100 FELT
CERAKWOOL 1100 FELT is a more economical, less refractory, lightweight, flexible ceramic fiber blanket manufactured
from thermally stable alumina-silica ceramic fibers. It is recommended for service to 1,100 in normal oxidizing
conditions, making it an ideal material for lower temperature applications. Even the most extreme temperature changes
will not affect the ability of CERAKWOOL 1100 FELT to insulate and stay in place. CERAKWOOL 1100 FELT stores
some 95 % less heat than dense fire brick and approximately 75 % less than insulating brick.
* Fuel savings
* Faster turn arounds
* Lower construction costs
* Easy to repair
* Permits lighter furnace fabrication
CERAKWOOL 1100 FELT demonstrates excellent strength, both hot and cold. Even after prolonged exposure to high
temperatures it remains in place on the furnace lining anchors. It has good strength before heating, enabling it to
resists damage when subjected to normal mistreatment in shipment and handling.
RESISTANCE OF CORROSIVE AGENTS

Hydrofluoric and phosphoric acids and concentrated alkalies are exceptions.
It also is resistant to oxidation and reduction.
It CERAKWOOL 1100 FELT becomes wet from water, steam, or oil. Its thermal and physical properties are restored
upon drying.
Its sound absorption ability is greater than other dense or insulating refractories.
PHYSICAL PROPERTIES
Color
White
1,100
Melting point
Above 1,700
Fiber diameter
Ave. 3 microns
Fiber length
Ave 200 mm
Specific gravity
2.5
60-80 kpa
kcal
mh
Mean temperature ()
900
1.0-2.1 %
1,000
2.4-3.0 %
service.
11
0.5-0.8 %
10
24 Hours at 800
Technical Book 2013
CHEMICAL ANALYSIS
Alumina Al2O3
46-49 %
Silica SiO2
50-52 %
Trace inorganics
0.5 %
Leachable chloride
< 10 ppm
STANDARD SIZES

Density
kg/
100, 130, 160
Thickness
mm
12.5, 25, 50
Width
mm
610
Length
mm
3,600, 7,200, 14,400
ACOUSTIC INSULATION
1100 FELT acts as an efficient acoustic barrier at all
temperatures up to its maximum use limit.
The absence of chemical binding agents enables
1100 FELT to function as acoustic insulation in high
temperature applications.
Its commonly used as a low temperature acoustic
barrier in situations where it can perform a
secondary function as a fire barrier.
FREQUENCY CYCLES PER SECOND
4) CERAKWOOL HTZ BLANKET
CERAKWOOL HTZ BLANKET is a high temperature, lightweight, flexible ceramic fiber blanket suitable for temperatures
up to 1,430 in nominal oxidizing conditions. It is manufactured from highest quality thermally stable alumina-silica
fibers that remain a soft fibrous structure right up to its maximum recommended usage point.
CERAKWOOL HTZ BLANKET was developed to meet the demand for a high temperature, yet lightweight, insulation for
use in modern industrial applications. It has high temperature resistance, thermal stability, and resistance to vibration
and physical abuse. It has excellent strength, both hot and cold. Even after prolonged exposure to high temperatures it
remains in place on the furnace anchors. Its sound absorption ability is greater than other dense or insulating
refractories, and it stores some 95 % less heat than dense fire brick and about 75 % less than insulating brick.
CHEMICAL PROPERTIES
CERAKWOOL HTZ BLANKET exhibits excellent resistance to most corrosive agents. Hydrofluoric and phosphoric acids
and concentrated alkalies are exceptions. It is resistant to oxidation and reduction. If HTZ BKANKET becomes wet from
* Thermal shock resistance
* Good sound absorption
* Low heat storage
* Good strength
* Light weight
* Extremely low shrinkage
* Resiliency
13
* 1,430 Temperature limit
12
Technical Book 2013
water, steam, or oil, its thermal and physical properties are restored upon drying.
PHYSICAL PROPERTIES
Color
White
1,430
Melting point
Above 1,950
Fiber diameter
Ave. 3 microns
Fiber length
Ave 200 mm
Specific gravity
2.72
Specific heat at 1,000
0.26
70-100 kpa
kcal
mh
Mean temperature ()

24 Hours at 1,200
2.0-2.5 %
1,300
2.5-3.2 %
1,430
3.5-4.0 %
service.
CHEMICAL ANALYSIS
Alumina Al2O3
34 %
Silica SiO2
48 %
ZrO2
16-20 %
Trace inorganics
Less than 0.5 %
Leachable chloride
< 10 ppm
STANDARD SIZES

Density
kg/
100, 130, 160
Thickness
mm
12.5, 25, 50
Width
mm
610
Length
mm
3,600, 7,200, 14,400
* High temperature kilns and furnaces
* Refractory kilns
* Billet and slab reheat furnaces
* Boiler linings
* Forge furnaces
* Furnace door linings and seals
* Soaking pit seals
* Incineration equipment
15
14
Technical Book 2013
* Glass furnace crown insulation
5) CERAKWOOL HARD BOARD
CERAKWOOL HARD BOARD is a light-weight, refractory material processed form alumina-silica ceramic fibers formed
into a predetermined size and thickness. It is especially noted for having low thermal conductivity and exceptionally
good handling strength. Its highly uniform structure assures equal thermal conductivity throughtout HARD BOARD is
easily machined, drilled, sawed and fabricated.
CHEMICAL PROPERTIES
CERAKWOOL HARD BOARD in inert to most chemicals with the exception of hydrofluoric acid, phosphoric acids and
concentrated alkalies.
If it becomes wet due to water, oil, or steam, its thermal and physical properties will return as soon as the material is
throughly dried.
* Low heat storage
* Stability at high temperature
* Light weight
* High heat reflectance
* Good dielectric strength
* Easily cut, trimmed, and fitted
* Combustion chamber linears
* Backup insulation for brick and castables
* High temperature gaskets an seals
* Non ferrous molten metal throughs and pan linings
* High gas velocity furnaces and kiln linings
* Incineration equipment, boiler, and stack linings
* Carbon bake and reverberatory furnace expansion joints
PHYSICAL PROPERTIES
1300 HARD BOARD
HTZ-HARD BOARD
White
White
1,260
1,430
Melting point
Above 1,760
Above 1,790
Nominal density
250, 300 kg/
250, 300 kg/
5.9 kg/
5.9 kg/
@10 % deformation
4 kg/
4 kg/
@25 % deformation
6 kg/
6 kg/
5-6 %
4-5 %
Color
Modulus of rupture
Compressive strenght (#300)
Ignition loss
.30
.25
.10
.05
0
400
600
800
Mean temperature ()
1,000
1,200
17
.15
16
kcal
mh
Technical Book 2013
.20

1300 H/B
HTZ-HARD BOARD
24 Hours at 1,000
1.6-2.0 %
1,100
2.0-2.4 %
1,260
4.0-4.5 %
1,300
2.0-2.5 %
1,430
2.8-3.6 %
service.
CHEMICAL ANALYSIS
1300 H/B
HTZ-HARD BOARD
Alumina Al2O3
44-46 %
34 %
Silica SiO2
54-56 %
48 %
14-16 %
ZrO2
Iron oxide Fe2O3
Less than 0.2 %
Less than 0.2 %
Trace inorganics
Less than 1.0 %
Less than 1.0 %
STANDARD SIZES

Density
kg/
250, 300
Thickness
mm
12.5, 25, 50
Width
mm
600
Length
mm
900
6) CERAKWOOL WET FELT
CERAKWOOL WET FELT is made from alumina-silica fiber blanket and inorganic bonding agent. flexibility makes it
highly moldable. Upon air-drying the inorganic binder is activated and the fiber becomes rigid.
CERAKWOOL WET FELT is ideal for insulation of complex shapes and for service under conditions of high hot gas
velocities.
CHEMICAL PROPERTIES
CERAKWOOL WET FELT resists oxidation, reduction, and attack from most corrosives except hydrofluoric acids,
phosphoric acids and heavy alkali concentration.
It permits rapid heat-ups and cool-downs never before possible, because it will not spall or crack from thermal shock.
* Flexibility to fit most configurations
* Fire protection for ships and railroad tankers
* Light weight for easy handling
* Pipe wrapping for both insulation and noise
* Easily cut or trimmed
reduction
* Easily impaled over studs
* Hot gas duct, flue and stack lining
* Contains no asbestos
* Combustion chamber linings
* Reformer header insulations
* Low heat storage
* Process furnace tube weld protection
* Excellent noise reduction properties
White
1,260
Melting point
Above 1,760
Nominal density (after dried)
450 /
Specific heat (At 1,000 )
2.7 kcal/
Tensile strength 6 mm thk.(dry)
410 kpa
PACKAGED in a clear polyethylene bag to retain the wet binder during shipment at storage.
Curing of product can be accomplished by air drying for one or two days or by immediate temperature exposure in
the application. Curing is merely a function of removal of the water in the inorganic binder.
19
Color
18
PHYSICAL PROPERTIES
Technical Book 2013
* Excellent thermal shock resistance
kcal
mh
Mean temperature ()

24 Hours at 1,000
1.6-2.0 %
1,100
2.0-2.5 %
1,260
3.5-4.5 %
service.
CHEMICAL ANALYSIS
Alumina Al2O3
40-45 %
Silica SiO2
60-55 %
Iron oxide Fe2O3
Less than 0.3 %
Trace inorganics
Less than 0.4 %
STANDARD SIZES

Density
kg/
450
Thickness
mm
6, 12.5, 25
Width
mm
600
Length
mm
900
7) CERAKWOOL 1300 PAPER
CERAKWOOL 1300 PAPER is a lightweight refractory material processed from alumina-silica ceramic fibers formed
into a flexible sheet.
It is recommended for continuous use at temperatures up to 1,260 . It is clean and efficient, contains no unfiberized
shot. It is especially noted for having exceptional conductivity and good handling strength. Its highly uniform structure
assures equal thermal conductivity throughout and its clean, smooth surface makes it ideal as a gasket, seal, and
spacer material.
CERAKWOOL 1300 PAPER contains an organic binder to provide increased handling strength. It possesses excellent
chemical stability resists attack from most corrosive agents.
Hydrofluoric and phosphoric acids and concentrated alkalis are exceptions. It also resists oxidation and reduction.
* Combustion chamber linears
* Temperature stability
* Back-up lining for metal through
* High temperature gaskets
* Low heat storage
* Parting agent in brazing, heat treating, and metal
* Light weight
forming process
* Resiliency
* Thermal and electrical insulation
* Blast furnace blow pipe insulation
* High heat reflectance
* Coke oven door shock absorption medium
* Hot top linings
21
Technical Book 2013
20
PHYSICAL PROPERTIES
Color
White
1,260
Melting point
Above 1,700
Nominal density
180 /
Nominal thickness, mm
1, 2, 3, 5
Tensile strength
400 kpa
Ignition loss
7-8 %
kcal
mh
Mean temperature ()
CHEMICAL ANALYSIS OF FIBERS(% by weight, binder free)

Alumina Al2O3
50-52 %
Silica SiO2
47-49 %
STANDARD SIZES

Density
kg/
Thickness
mm
Width
mm
Length
mm
180
1
20,000
40,000
600
8,000
12,000
If CERAKWOOL 1300 PAPER becomes wet due to water, steam, or oil, its thermal and physical properties will return
as soon as the material is thoroughly dried.
No water of combination is present.
8) CERAKWOOL MODULE SYSTEM
CERAKWOOL MODULE SYSTEM is a block-type product which is compressed over 30 % after folding CERAKWOOL
BLANKET with automatic folding machine and inserting anchoring system in it.
* Iron and steel : Heating furnace, Heat treatment furnace
* Nonferrous metal : Aluminum heat treatment furnace
* Ceramic : Baking furnace, Annealing furnace
* Petrochemical : Naphta analyzing furnace, Reformer
FEATURE OF MODULE SYSTEM
K-Module
(A.I.U TYPE)
Veneer Module
(I TYPE)
It has two kinds of type, Direct Welding Type that Module containing anchor system saves the installing time without
marking process and individual module type that stud bolts are prewelded for back-up use.
The separation between Module and Anchor provides easy application to the corners and complicated parts.
CERAKWOOL VENEERING MODULE provides a fast and simple technique for insulating many types of heat
processing equipment.
It can be used as the total lining or as a veneer in units already having a refractory lining in satisfactory condition
with Cerakwool Bond.
Technical Book 2013
(A TYPE)
23
KH-Module
Feature
22
Item
kcal
mh
Mean temperature ()
PHYSICAL PROPERTIES
KH/K MODULE
VENEER MODULE
1300 Module
HTZ Module
1300 V-Module
HTZ V-Module
Color
White
White
White
White
1,260
1,430
1,260
1,430
Nominal density
170 /
170 /
170 /
170 /
1,100
0.5 %
0.2 %
1,260
2.5 %
1.2 %
Linear shrinkage
1,430
2.5 %
STANDARD SIZES
KH/K MODULE
VENEER MODULE
1300 Module
HTZ Module
V-Module
Thickness
mm
50-300
50-300
50, 75, 100
Width
mm
300
300
300
Length
mm
300
300
300
The different width and lengths can be supplied subject to quantity and delivery requirement.
9) CERAKWOOL VACUUM FORMED PRODUCTS
CERAKWOOL VACUUM-FORMED PRODUCTS are formulated from a blend of high purity alumina-silica ceramic fibers
with an appropriate combination of organic and inorganic binders. Handling strength is provided by the organic binder,
while product integrity at high working temperature is maintained by the inorganic binder. Maximum use temperature for
the standard formulation is 1,260 .
CHEMICAL PROPERTIES
CERAKWOOL VACUUM FORMED SHAPES is inert to most chemicals with the exception of hydrofluoric acids,
phosphoric acids and concentrated alkalies. If it becomes wet due to water, oil, or steam, its thermal and physical
properties will return as soon as the material is throughly dried.
* Combustion chambers for oil and gas fired heating boilers
* Low heat storage
* Gaskets
* Flue linears
* Stability at high temperature
* Tap-out cones for aluminum furnaces
* Light weight for easy handling
* Tundish linear boards and hot tops for nonferrous metals
* Non wetting by nonferrous molten metals
* Riser sleeves
* Electric range burner insulation
* Asbestos free
* Giant rings to line aluminum crucible furnaces
White
1,260
Melting point
Above 1,760
Nominal density /
150-600
Typical chemical analysis of fibers (% by Weight, binder free)

Alumina, Al2O3
50-52 %
Silica, SiO2
47-49 %
25
Color
24
PHYSICAL PROPERTIES
Technical Book 2013
* Easily cut, trimmed, and fitted
10) CERAKWOOL TEXTILE
CERAKWOOL TEXTILES are noted for superior insulating ability to 1,260 . These products have excellent resistance
to thermal shock, corrosive attack and breakdown due to mechanical vibration and stress.
CERAKWOOL TEXTILE product forms are unique high temperature fabrics useable in a wide variety of industrial
applications. These are made from long staple CERAKWOOL BULK FIBER and 15-20 % organic fiber as a carrier
fiber. A blend of long staple fibers and organic carrier fibers, CERAKWOOL TEXTILES are an excellent choice where a
flexible, strong temperature resistant product is required. All TEXTILES contain 15-20 % organic fiber added during the
carding process to produce roving. The roving is further processed into two-ply yarn for weaving into CERAKWOOL
TAPE, CLOTH and SLEEVING.
Insert material are incorporated into the CERAKWOOL YARN to increase fabric tensile strength. Alloy wire inserts are
available for obtaining maximum strength at elevated temperatures. Glass filament inserts are used in applications
where metal is undesirable as in the case when using CERAKWOOL TEXTILES as a dielectric. These may be used to
1,260 in applications where tensile strength is not important.
* Fuel line insulation
* Furnace heat zone separators
* Cable and wire insulation
* Infrared radiating diffusers
* Gasket and wrapping material
* Induction heating furnace coil insulation
* High pressure steam portable flange covers
CHARACTERISTICS OF WOVEN TEXTILES

Type
Temperature
(Limit of insert)
Insert material
Weave
GF
650
Glass filament
Twill or Plain
SS
800
Stainless steel wire
FC
1,100
Fe-Cr wire
IN
1,200
Inconel wire
PHYSICAL PROPERTIES
Thickness (mm)
Tensile strength (kgf/25 mm)
20
Loss on ignition (WT %)
20 (1,000 )
CONSTITUTION OF CERAKWOOL TEXTILES

YARN
Insert material
Diameter
Packing unit
Glass filament
2, 3 mm
1 kg/m (1 g/m)
Inconel wire
2, 3 mm
1 kg/m (1 g/m)
CLOTH
Thickness (mm)
2, 3
Width (mm)
1,000
Length (mm)
30,000
Thickness (mm)
2, 3
Width (mm)
25, 50, 75, 100
Length (mm)
30,000
27
26
Technical Book 2013
TAPE
11) CERAKWOOL 1300 ROPE
TWIST ROPE
CERAKWOOL TWIST ROPE is a twisted three-ply rope manufactured from CERAKWOOL long staple fibers.
It contains 15 to 20 % organic carrier fiber to facilitate the carding process and impact mechanical strength. The
carrier fiber burns out at a low temperature, but this has no affect on the properties of the CERAKWOOL itself.
CERAKWOOL TWIST ROPE is a dense, resilient, high temperature refractory processing the thermal properties and
chemical stability common to all CERAKWOOL product forms.
BRAID ROPE
CERAKWOOL BRAID ROPE is comprised of high strength CERAKWOOL BLANKET STRIP, twisted and wound with
a cordage to achieve a round, compacted rope product.
The inherent strength of the base constituent, CERAKWOOL BLANKET STRIP, is sufficient to eliminate the need for
textile process, woven ropes in most application.
*
*
*
*
*
*
*
*
STANDARD PACKAGE
Glass furnace tuckstone seal

Skid rail insulation
Expansion joint packing in boilers & furnaces
Furnace door seal
Hot top seal
Car deck seal
Gasket, flange packing
Seal for pressurized atmosphere furnaces
Diameter (mm)
Length/Roll
90 m
12
60 m
25
30 m
40
12 m
50
10 m
PHYSICAL PROPERTIES
Twist rope
Braid rope-G
Braid rope-A
1,260
1,260
1,260
Braided material
Glass yarn
SUS 304 wire
Density (kg/)
130-160
130-160
130-160
Diameter (mm)
6-50
6-50
6-50
12) CERAKWOOL MOLDABLE
CERAKWOOL MOLDABLE is easy to install. Directly from the pail it can be installed in thicknesses from 3 mm up to
100 mm thickness over existing refractory or directly applied to metal surfaces. It is applied by hand using rubber
gloves-kneaded, patted, or smeared into place and then smoothed and shaped with a trowel or putty knife.
* Non-wetting to molten aluminum and other non ferrous metals
* Will stick to most any surface
* Lightweight, good insulator
* High strength
* Excellent workability
* Excellent compressibility
Small ladle lining, ladle maintenance

Die cast dipping wells
Tap holes, pot line ladle seals
Carbon bake furnace fuel caps
Void fills of all kinds
29
Throughs, runners, distribution pans
28
* ALUMINUM and NON-FERROUS
Technical Book 2013
* HYDROCARBON PROCESSING
Reformer and heater tube seals
Filling cuplocks on CERAKWOOL LINING
Flue and ductwork linings or expansion joint
Filling voids around burnerblocks and access doors
* HEAT TREATING, KILNS, BOILERS
Flue stack linings and repairs
Void fills-cracks and patching
Door and burner seals
* IRON AND STEEL
Coke oven standpipe and door seals
Expansion joints for reheat and other furnaces
Crack and void fill throughout the plant
PHYSICAL PROPERTIES
Color
Off-White
Recommended temperature
For maximum service temperature
1,260
For cuplocks and void fills
1,340
Nominal density(after drying)
450, 700
Permanent linear shrinkage

Heated at 1,100 and then cooled
Quantity required for installation
2.7-3.2 %
1,400-1,600 kg/
NOTE : Store in 5-25 room.
STANDARD PACKAGE
25kg/can
2. SUPPLEMENTARY MATERIAL
1) CERAKWOOL RIGIDIZER
CERAKWOOL RIGIDIZER is a colloidal silica compound dispersed in water, which is used as a surface treating agent
to increase hardness, erosion-resistance, flame-resistance and gas permeability of CERAKWOOL materials. It is easily
applied by employing standard brushing, spraying, dipping, techniques. It contains a wetting agent for better saturation
of the substrate.
CERAKWOOL RIGIDIZER shall be diluted with water to a suitable viscosity for each application technique as applied.
*E
rosion resistant surface for CERAKWOOL BLANKET, FELT, BOARD and MODULE furnace linings exposed to high
-velocity gases.
* Bonding agent in the manufacture of CERAKWOOL composites and laminated.
* Structural hardening agent for CERAKWOOL PAPER, BLANKET, and BOARD.
PHYSICAL PROPERTIES
Specific gravity
Solid content
Viscosity, CPS (25 )
PH
1,500
1.2
30 ~ 40 %
6
9
Composition
Colloidal silica
0.5-1.0 kg/
30
Repeated freezing may damage it.
Technical Book 2013
Transparent liquid
31
Appearance
STANDARD PACKAGE
20kg/can
2) CERAKWOOL BOND
CERAKWOOL BOND has been expecially developed for CERAKWOOL MODULE applications to walls of furnaces in
use and as an undercoat for MOLDABLE lining. It is a pre-mixed refractory bonding mortar, with high strength and
excellent erosion and abrasion resistance. CERAKWOOL BOND attains high strength upon air setting at room
temperature and expands and contracts with temperature change.
Other features include, slag resistant, spall resistant, virtually no shrinkage.
When MODULES are to be used as a complete lining, they can be mortared with CERAKWOOL BOND to expanded
metal which has been tack welded to the steel shell. This prevents any metal hardware from being exposed to the
furnace environment.
* Adhering MODULE to refractory
* Adhering BLANKET to refractory
* Adhering BLANKET to BLANKET
PHYSICAL PROPERTIES
Color
Brown
1,500
Bonding strength, /, fired and cooled

125
91.4
540
77.3
1,000
77.3
Al2O3
52 %
SiO2
44 %
Fe2O3
0.2 %
Others
3.6 %
Chemical analysis
Quantity required for installation (3 mm thk.)
STANDARD PACKAGE
25kg/can
6-8 kg/
3) CERAKWOOL COATING CEMENT
CERAKWOOL COATING CEMENT is especially formulated for coating or bonding CERAKWOOL products. The
inorganic binder provides an irreversible bond which will not soften in the presence of moisture. It dry to a hard
surface which is resistant to erosion and flame abrasion. It help prevent substrate material from spalling because of its
insulating efficiency and inherent resistance thermal shock. Its excellent chemical resistance to wetting by many nonferrous molten metals, enables the cement to be used as a protective coating for a wide variety of porous and nonporous materials.
* Module lining adhesive for CERAKWOOL paper used with high purity metals and glass.
* Flame resistant coating for CERAKWOOL linings of domestic oil-fired combustion chambers.
* Electronics potting compound.
* Oxidation resistant coating for chlorine injection tubes and graphite crucibles.
* Corrosion barrier for aluminum dip tubes, cast iron thermocouple tube and galvanizing tanks.
* Electrical insulation for counter-top stove heating elements
* Infrared radiating surface for heating elements.
1,260
Specific gravity
1.5
Nominal shelf life
3 months
3-4 kg/

Repeated freezing may damage it.
STANDARD PACKAGE
20kg/can
33
White paint
32
Appearance
Technical Book 2013
PHYSICAL PROPERTIES
3. BIO-SOLUBLE CERAKWOOL 11001300
KCC CERAKWOOL New-Bio is high temperature, fire-resistant insulation material manufactured by Spinning Process with high
purity of Calcium, Magnesium, Silicate. It can be applicable to ship building industry, various marine structure and other general
industry.
KCC CERAKWOOL New-Bio is safe insulation material to human body and it successfully passed Europe Animal Test. (EU
directive 67/548 EWG & German TRGS 905)
Its fiber can be quickly soluble and exhausted from human body even after inhalation.
* Exonerated from carcinogenic classification under EC and restriction under German regulation
* Low heat storage
KCC CERAKWOOL New-Bio

CERAKWOOL New- Bio 1100
Chemical
Analysis
CERAKWOOL New- Bio 1300
SiO
58-67 %
75-80 %
10-14 %
CaO
26-34 %
MgO
2-8 %
4-9 %
Etc.
0-4 %
1.5 %
AlO
1%
1,100
1,260
Tensile strength (128K, ASTM C 209)
50 kPa
50 kPa
at 1,100,24h
2%
1%
at 1,260,24h
3%
Typical linear
shrinkage
STANDARD SIZES
Density (kg/)

12.5
25
38
50
Width (mm)
610
610
610
610
Length (mm)
14,640
7,320
4,880
3,660
Technical Book 2013
15 kg/Bag
35
Bulk fiber
Thickness (mm)
34
Blanket
64, 96, 100, 128, 130, 160
THERMAL CONDUCTIVITY (ASTM C 201)

Biosoluble
CerakWool
1100 96K
mean Temp
mean Temp
Thermal
Conductivity,W/mK
200
93.3
0.038
400
204.4
0.058
800
426.7
0.110
1200
648.9
0.183
1600
871.1
0.284
mean Temp
mean Temp
Thermal
Conductivity,W/mK
200
93.3
0.039
400
204.4
0.056
800
426.7
0.102
1200
648.9
0.164
1600
871.1
0.243
[Biosoluble Cerakwool 1100 96K]
Biosoluble
CerakWool
1100 128K
Biosoluble
CerakWool
1300 128K
mean Temp
Thermal
Conductivity,W/mK
200
0.058
400
0.097
600
0.154
800
0.231
1,000
0.338
BIO-PERSISTENCE TEST
Certificate authority : Fraunhofer ITEM(German)
Target : Lower durability in-vivo condition / Higher durability in use condition
Technology : Glass composition research / Production process development
Sucess : Successful animal test result / Getting the EU certificate of safety
* Fiber dissolution
* Animal test of fibers
CERTIFICATES OF BIO-PERSISTENCE TEST
37
Technical Book 2013
BIO-CERAKWOOL 1300
36
BIO-CERAKWOOL 1100
MARINE INSULATION MATERIAL(H-CLASS SPECIFICATION)
Bulkhead
H-60
Deck
H-120
Insulating Thickness
Product
Item
Bulkhead
Deck
Palte/Stiffener, mm
50+50/50+50
CERAKWOOL Bio_ Marine 1100 96K
38+38/38+38
50+38+38/50+38+38
CERAKWOOL Bio_ Marine 1100 96K ,128K
50+38/50+38
H-60 Bulkhead
Cerakwool Bio-Marine packed into stiffner
Fire Either side
Anchor 50mm
From blanket
edge
50mm x 96kg/ KCC Cerakwool

blanket
Second
Layer
First
Layer
H-60 Deck
Cerakwool Bio-Marine packed into stiffner
Fire Insulation
side
Anchor 50mm
From blanket
edge
38mm x 96kg/ KCC Cerakwool

blanket
Second
Layer
First
Layer
H-120 Bulkhead
25mm x 128kg/ KCC Cerakwool Blanket
Fire Either side
Anchor 50mm
From blanket edge
38mm x 96kg/ KCC Cerakwool Bio- marine Blanket

H-120 Deck
Fire Insulation
side
Anchor 50mm
From blanket
edge

H-120 Bulkhead (DNV)
Technical Book 2013
H-120 Deck (DNV)
39
H-60 Bulkhead (DNV)
38
H-60 Deck (DNV)
. CONSTRUCTION
. CONSTRUCTION
1. MATERIAL USE
A typical furnace lining of the commonly used layer construction is made up of CERAKWOOL BLANKET and less
expensive back-up insulation. The lining selection is generally dependent on four factors :
1. The maximum furnace temperature to which the lining will be subjected.
2. The desired temperature of the shell or cold face.
3. The velocity of the gas inside the furnace.
4. The furnace atmosphere and the fuel which will be used.
After the above four factors are known, these further decisions can then be made :
1. T
he first thing to the decide is the hot face material to be used. Generally 130 / density is recommended for all
hot face layers. Depending on what the temperature will be, a selection of CERAKWOOL BLANKET or CERAKWOOL
HTZ BLANKET will be used. CERAKWOOL BLANKET should be selected for temperatures up to 1,260 , If
temperatuers exceed 1,260 -up to 1,430 -CERAKWOOL HTZ BLANKET should be used. To be considered in
this selection is the tendency of all ceramic fiber to shrink at temperatures above 985 . This shrinkage is taken into
account by design.
2. T
he decision can now be made as to what material is to be used behind the hot face. This question is dependent
upon the desired temperature of the shell or cold face. Normally, an economic balance of lining thickness can be
achieved by using a rule of thumb that the cold face be designed for 10 % of the hot face. If this does not meet the
criteria selected, additional layers can be added or subtracted or a change in the density of each layer can be made.
This is to say that if a typical lining of does not meet the customers needs, consider the following change.
The addition of 25 mm of #130. reduces the cold face to 76 . or, changing the density of the layers as shown
below reduces the cold face to 79 .
Technical Book 2013
76 Cold Face
Heat Loss of 559 kcal/h
41
985
Hot face
84 Cold Face
Heat Loss of 673 kcal/.h
40
985
Hot Face
. CONSTRUCTION
79 Cold Face
Heat Loss of 605 kcal/h
985
Hot face
3. T
he next factor to be considered-the velocity of the gas inside the furnace-is one of importance. CERAKWOOL
FELT, CERAKWOOL 1300 BLANKET, or CERAKWOOL HTZ-BLANKET in the 130 / range will perform quite
satisfactorily on the hot face layer at velocities created under normal combusion conditions. If the velocity should
exceed 10 m/second, an application of RIGIDIZER can be sprayed or brushed on. A pressure atomizing gun is ideal
for applying RIGIDIZER and should be applied to get a penetration of approximately 3-4 mm. In addition, care should
be taken to run the blankets aprallel to these velocities. The surface is much more resistant to velocities than an
exposed edge. See Figure D-1.
VELOCITY DIRECTION GAS FLOW
FIGURE D-1
With the rigidizer applied, the blanket will withstand velocities up to approximately 25 m/second
* AT 900
Product
CERAKWOOL BLANKET #130
Velocity (m/sec)
0-10
CERAKWOOL BLANKET #130 with RIGIDIZER
10-25
CERAKWOOL HARD BOARD
25-33
NOTE : O
ver 1,000 these numbers will decrease. Please contact CERAKWOOL ENGINEERING DIVISION for velocity
resistance at elevated temperatures. These numbers are for clean air containing no particulate.
The last factor to consider for the lining selection is the furnace atmosphere and the fuel which will be used.
CERAKWOOL FELT, CERAKWOOL BLANKET, and CERAKWOOL HTZ-BLANKET are suitable for all furnaces burning
in normal atmospheres(i.e.light oil or natural gas). When heavier fuels are burned(i.e.low grade crude), caution must be
taken to protect the anchoring system. The use of CERAKWOOL BLANKET, and CERAKWOOL HTZ-BLANKET in
reducing atmospheres is acceptable in many cases, provided the temperature limitations of the material are observed.
Endothermic atmospheres, which are common in the heat treating industry, can reduce metal or metal oxide at about
650 therefore, the use of CERAKWOOL 1300 BLANKET, a high purity ceramic fiber, should be recommended for
the hot face layer. CERAKWOOL HTZ-BLANKET, a high purity blanket by nature, may also be used in this application.
The use of Inconel 601 studs and ceramic cuplocks should be incorporated to prevent carbon absorption and
43
42
Technical Book 2013
embrittlement.
. CONSTRUCTION
2. INSTALLATION OF CERAKWOOL LININGS

1) CERAKWOOL PAPER LINING
Once determination of the stud pattern has been made, the first step in the installation is to lay out the pattern on the
furnace shell. Start the stud pattern in a corner, taking the lining thickness of the adjacent wall into consideration.
Starting from the corner, measure 75 mm plus the lining thickness out from the wall and down from the roof. This
properly locates the edge row of anchors and prevents them from being buried. It also provides working areas
between opposing studs located at the corners. The same procedure is followed at each corner location. Since almost
all studs run in vertical and horizontal rows, it is necessary only to measure and mark the perimeter of the area to be
lined. A chalk line is then snapped across the corresponding points vertically and horizontally, resulting in a grid
whose points of intersection are the placement points for the studs. See Figure D-2. Additional studs around burners,
flue openings, and other apertures are desirable.
After the stud pattern has been laid out on the steel shell, the studs are welded to the steel shell either with an
automatic stud gun or by conventional welding methods. While manual welding can be done, it is slow and the
potential for a defective weld is greater than with stud gun welding.
STUD LAYOUT
OVERHEAD
FIGURE D-2
After the studs have been welded in place, the back-up insulation is impaled on the studs.
To facilitate temporary retention of the back-up insulation, especially on a roof, sus 304 speed clips are installed over
the studs. One speed clip for every fourth stud is sufficient on roofs. If cuplocks are used as retainers, speed clips
cannot be used within 75 mm of the hot face since they will prevent proper installation of the cuplocks. In this situation,
twine or rubber bands can be strung across the studs and left in place. This will hold the intermediate layers
temporarily in place. Special consideration should be given to back-up insulation around burner blocks and other
openings in the hot face lining so the hot gases cannot reach lower grade back-up insulations and cause
deterioration. Most installations are more than one layer of back-up insulation. It is important that the joints on
successive layers be staggered a minimum of 100 mm so that hot gases cannot be channeled back to the steel shell.
See Figure D-3.
STAGGERED LAYERS
FIGURE D-3
Anchor patterns are based on the proper positioning of the studs with the exposed hot face layer of insulation without
regard to the intermediate layers. When installing successive layers of material, care must be taken to insure that all
joints are staggered by at least 100 mm and that the exposed hot face layer is properly positioned on the studs.
When using alloy washers as the final retainer, place the washers on the washers on the studs and push in until the
lining is compressed about 20 mm then lock into place. For higher temperature applications where ceramic cuplocks
will be used, different techniques are required when installing hot face insulation. Since the stud will not protrude
through the final layers, these layers cannot be impaled on the studs. Thus the blanket must be temporarily held in
place until the cuplocks are installed. On sidewalls, the easiest method is to place the blanket in position, then stick
small dowels through the entire lining at a 45 to 60 angle. The dowels can be any available material(i.e. welding rods,
gutter nails, etc). Three or four dowels near the top of the vertical strip are normally sufficient to temporarily hold a 600
mm wide piece in place. If an additional layers is required, simply repeat the procedure, being sure to remove any
metallic dowels from the under layer. See Figure D-4. When the final layers are temporarily secured, about 20 % of
the cuplocks should be installed at random and the dowels removed. This same procedure can be used on a roof,
although more dowels will be required over the entire surface of the strip.
ATTACHING ADDITIONAL LAYERS
FIGURE D-4
45
CERAKWOOL
Felt and Blanket
44
CUPLOCK
Technical Book 2013
NAIL OR DOWEL FOR

TEMPORARY ATTACHMENT
BE SURE TO REMOVE
. CONSTRUCTION
After the final layer of insulation is secured by about 20 % of the cuplocks, the remaining studs will not be visible on
the surface. These studs can be located by pressing the lining in the general area of the stud. The point of the stud
can be felt through the CERAKWOOL BLANKET. A knife blade is then inserted through the insulation, making the
cross cut. Then slip the shank of the cuplock on the stud, push it back until the flange of the cuplock has compressed
the lining slightly, and turn it 90 , locking it in place. After the cuplocks are in place, the opening in the cuplock is
then packed with CERAKWOOL BULK dipped in mortar. Pack the entire cuplock in this manner.
In some installations it may not be practical to remove the brick lining from an existing furnace or kiln and replace it
with fiber. An example of this is the classic bee hive kiln that does not have a steel shell. The fuel savings obtainable
by the use of CERAKWOOL BLANKET are available to operators of this type of equipment simply by installing blanket
over the hot face of the existing brick or castable. This approach, called veneering, is now widely accepted.
Installing CERAKWOOL BLANKET over existing refractory linings gives reduced fuel consumption and faster cycles.
Also, the service life of the existing refractory is increased as the brick or castable no longer reaches the full operating
temperature of the kiln. Fuel consumption is reduced because of the reduction in heat loss through the walls and
because the refractory section of the lining is not brought up to the operating temperature of the kiln, thereby requiring
fewer calories. Heat-up time is reduced for the same reasons.
Figures D-5 and D-6 show the method for laying CERAKWOOL BLANKET around an inside corner.
LAP JOINT BLANKET

INTERSECTION AT A CORNER
CERAKWOOL
Felt and Blanket
METAL ANCHOR
FIGURE D-5
BLANKET EXTENDING
AROUND A CORNER
CERAKWOOL
Felt and Blanket
METAL ANCHOR
FIGURE D-6
Figure D-7 shows a method used to protect CERAKWOOL BLANKET joints against directional gas flow.
GAS FLOW
METAL ANCHOR
47
46
FIGURE D-7
Technical Book 2013
CERAKWOOL Felt and Blanket
. CONSTRUCTION
Figure D-8 and D-9 show methods used to lay CERAKWOOL BLANKET around a burner block.
Figure D-8 details design when using all CERAKWOOL BLANKET. Figure D-9 details design when a fire brick support
ledge is used.
BURNER BLOCK SURROUNDED BY CERAMIC FIBER BLANKET
CERKWOOL
Felt and Blanket
FIGURE D-8
BURNER BLOCK w / SUPERDUTY FIRERICK SUPPORT
CERAKWOOL Felt and Blanket
SUPERDUTY FIREBRICK
48
FIGURE D-9
49
Technical Book 2013
CERAKWOOL PAPER
. CONSTRUCTION
Figure D-10 shows the method for repairing an existing ceramic fiber blanket wall.
PEPAIRING A DAMAGED WALL
CERAKWOOL BLANKET
REMOVE DAMAGED MATERIAL
AND CLEAN DAMAGED AREA
REPLACE WITH NEW

MATERIALS AND COVER
WITH AN EXTRA LAYER
OF CERAKWOOL BLANKET
FIGURE D-10
Figure D-11 and D-12 details the construction techniques for typical door seals. Figure D-11 details the use of
CERAKWOOL BLANKET for a guillotine door. Figure D-12 details the use of CERAKWOOL BLANKET for a door face seal.
BOTTOM SEAL FOR A GUILLOTINE DOOR
CERAKWOOL
Blanket
CERAKWOOL
Blanket
METAL ANCHOR
25 mm MIN
FIGURE D-11
TYPICAL DOOR SEAL

CERAKWOOL Blanket
FIGURE D-12
51
METAL ANCHOR
50
DOOR
Technical Book 2013
WALL OR ROOF
. CONSTRUCTION
CERAKWOOL PAPER LINING HEAT FLOW

THK. (mm)
INNER TEMP ()
700
800
900
1000
25
HTZ Blanket (#130)

1,300 Blanket (#130)
25
25
50
50
1,100 Felt (#100)
25
75
75
75
Mineralwool (#100)
50
50
50
50
Lining thk. (mm)
100
150
175
200
Surface temp. ()
68
61
67
72
Heat loss (Q)
490
441
678
544
Heat storage (H)
1,189
2,062
2,893
3,381
30
#1
ET
30
0
#1
NK
10
T
LA
T#
E
B
K
Z
EL
0
N
T
H
10
LA
LF
L
B
O
L#
O
L
OO
OO
OO
KW
KW
W
A
W
L
A
R
K
A
R
CE
RA
ER
CE
CE
MIN
1,000
0
13
0
T#
10
KE
00
T#
AN
#1
L
EL
OL
LB
LF
O
O
O
O
WO
L
W
W
A
K
K
ER
RA
RA
CE
CE
MIN
900
* Condition
Ambient Temp. : 25
Emissivity : 0.9
Wind Velocity : 0 m/sec
* Heat Loss(Q) : kcal/h
Heat Storage(H) : kcal/
0
13
0
T#
10
KE
00
T#
AN
#1
L
EL
OL
LB
LF
O
O
O
O
WO
L
W
W
A
K
K
ER
RA
RA
CE
CE
MIN
800
0
13
T # 100
#
KE
00
AN ELT
#1
L
OL
LB LF
OO WOO
WO
L
W
A
K
K
ER
RA RA
CE CE
MIN
700
ANCHORING SYSTEM FOR PAPER LINING

* ROD TYPE
Material
SUS 304
SUS 310S
INCONEL 601
Max. application temperature
800
1,000
1,200
5.3
5.3
Diameter (mm)
STUD
Length (mm)
50, 75, 100, 125, 150, 175, 200, 225, 250, 300
Washer-nut
Material : SUS 310S, Size : M6 ( 6 mm) 38 mm
Speed-clip
Material : SUS 304, Size : 0.3 mm(T) 38 mm
* TWIST TYPE
Material
SUS 310S
INCONEL 601
Thk.x Width (mm)
3.2 X 7
Length (mm)
75, 100, 125, 150, 175, 200, 225, 250
Speed clip
Material : SUS 304, Size : 0.3 mm X 38 mm
53
Lock Washer (2 mm X 38 mm), Ceramic CUP-LOCK
52
Washer
Technical Book 2013
STUD
. CONSTRUCTION
2) CERAKWOOL KH-MODULE LINING
INSTALLATION PROCEDURE FOR CERAKWOOL KH-MODULE LINING
STEP 1 : ATTACH WELDING-STUD(BOLT) TO STEEL SHELL ON 300

mm CENTERS.
(STUD GUN)
Wall
STEP 2 : PUSH BACK UP BLANKET OVER ANCHOR
M8 ( 8 mm) Nut
BASES THIS ACTS AS A SEAL TO REDUCE

CHANCES OF STRAIGHT THRU JOINTS.
Anchor
Plate
Backup Blanket
Floor
INSTALLATION PROCEDURE FOR CERAKWOOL KH-MODULE LINING
STEP 3 : INSTALL MODULES ONTO BASES IN A
Backup Blanket
PARQUETED DESIGN. EACH MODULE EXPANDS

AGAINST TWO ADJACENT MODULES WHEN
NET RAP or BAND IS CUT.
Module
Strip Blanket
STEP 4 : WHEN MODULES BORDER AN OPENING, TURN

THE EDGE GRANIN TOWARD THE OPENING SO
THAT THE INSERTS CANNOT FALL OUT OF THE
MODULES. A COMPRESSION STRIP MAY BE
DESIRED IN THIS AREA. WHEN A JOB IS
FINISHED, REMOVE TUBES
Tool
M8 ( 8 mm) Nut
54
55
Technical Book 2013
Wrench
. CONSTRUCTION
ANCHORING SYSTEM for KH-MODULE LINING
TP 304 10.5 mm 1.5 mm

(SUPPORT TUBE)
TP304 2 mm
(ANCHOR PLATE)
40
10.5 mm
15
20 20
160
9.5 mm
120(Tube Center To Center)
20 20
160
DETAIL for KH-MODULE Stud Bolt & Nut

TP 304
M8( 8 mm) NUT
TP 304
M8( 8 mm) NUT
TP 304
STUD BOLT
FERRULE
3) CERAKWOOL K-MODULE LINING
CERAKWOOL K-MODULE LINING SYSTEMS

MR BASE w/MK
CERAKWOOL
K-MODULE
CERAKWOOL K NODULE
BLANKET BACK-UP
MR BASE w/MK
FOLDED BLANKET STRIP
PROTECTING ANCHOR
BLANKET BACK-UP
MODULES & FOLDED BLANKET

STRIP OVER ANCHORS w/BLANKET
BLANKET BACK-UP
FOLDED
STRIP
STACKED
BLANKET
STRIP
STACKED
ACCORDION
FOLDED
FOLDED BLANKET
STRIP PROTECTING
ANCHORS
MR BASE w/MK
LOOP FOLD w/
BLANKET BACK-UP
ACCORDION FOLD w/
BLANKET BACK-UP
57
EDGE STACK w/
BLANKET BACK-UP
BLANKET BACK-UP
56
BLANKET BACK-UP
Technical Book 2013
MR BASE w/MK
. CONSTRUCTION
INSTALL ATION PROCEDURE FOR CERAK WOOL

K-MODULE LINING
STEP 1 : WELD ANCHORS TO THE SHELL ON PREDETERMINED

ANCHOR LAYOUT. ADD 25 mm OF LENGTH TO ALL
BASES FOR EVERY 25 mm OF BACKUP BLANKET.
STEP 2 : IMPALE BLANKET LAYER(S) OVER MR-ANCHOR BASES.
INSTALLATION PROCEDURE FOR CERAKWOOL

K-MODULE LINING
STEP 3 : INSTALL FIRST ROW OF MODULES OVER BACK-UP

BLANKET.
STEP 4 : PLACE FOLD OF BLANKET BETWEEN ROWS OF

MODULES FOR NO THROUGH JOINTS TO THE ANCHOR
58
59
Technical Book 2013
BASES.
. CONSTRUCTION
With the new MR-anchor system you have the capability of using safety lining with the CERAKWOOL K-MODULE. If
any joints should open, the steel shell will be protected by layer(s) of blanket.
Vapor Barrier
MR(ADD 1 OF LENGTH FOR
EVERY 1 OF BLANKET)
MODULE W/A BLANKET BACK-UP
REPLACING A MISSING OR DAMAGED MODULE

WITH THE MR ANCHOR
Cut off one of the tines or replace it with a half tine. Weld a new base next to the base with the half tine. Stick another half tine into a new module.
Impale the opposite side of the new module onto the existing tine. Push the module down flush with the other modules. Reach in between the modules
60
61
Technical Book 2013
and slide the new half tine into the new base. Pat the module faces down to close any openings.
. CONSTRUCTION
ANCHORING SYSTEM for K-MODULE(I,U,A Type Module) LINING

* MR & MK SYSTEM
SUS 310S
Max. application temp.
1,250
2.5
30
Material
230
Per
customer specifications
2.5
60
15
CERAKWOOL K and KH MODULE LINING HEAT FLOW

INNER TEMP ()
850
950
1,050
1,200
K/KH Module (#170)
150
175
200
250
Back up Blanket (#130)
25
25
25
25
Lining thk. (mm)
175
200
225
275
Wind velocity : 0 m/sec
Surface temp. ()
50
55
58
61
* Heat loss(Q) : kcal/h
Heat loss (Q)
361.4
429.2
471.2
516.0
Heat storage (H)
3,289
4,356.8
5,486.2
7,760.5
THK. (mm)
CERAKWOOL MODULE
CERAKWOOL BLANKET
Ambient Temp. : 25
Emissivity : 0.9
Heat storage(H) : kcal/
CERAKWOOL MODULE
CERAKWOOL MODULE
CERAKWOOL MODULE
CERAKWOOL BLANKET
CERAKWOOL BLANKET
CERAKWOOL BLANKET
1,200
1,050
61
58
250 mm 25 mm
1,200
* Condition
200 mm 25 mm
1,050
950
850
55
50
175 mm 25 mm
950
150 mm 25 mm
850
4) CERAKWOOL STACK LINING

Figure D-13 shows the stacked method of construction using the MR anchor system. With this system a back-up
safety lining feasible. In the loop fold detail on the bottom of the page, note the anchor is buried in a fold of blanket.
Stack seal linings should be compressed from 25 to 30 %.
STACKED LAYER LINING BURIED ANCHOR SYSTEM
300 mm
600 mm
MR w/MK
63
62
FIGURE D-13
Technical Book 2013
CERAKWOOL
BLANKET
LOOP FODL
. CONSTRUCTION
ADVANTAGE AFTER INSTALLING STACK LINING
INSULATING
FIRE BRICK
CERAKWOOL
FELT
INSULATING
BRICK
1,300
1,300
839
383
156
Stack
installation
180 mm
180 mm
50 mm
87
25 mm
Heat loss (kcal/m2h)
2,353 (100 %)
816 (35 %)
Heat storage (kcal/m2)
112,286 (100 %)
4,901 (4 %)
INSTALLATION EXAMPLE
Installation example 1 (Usage of bond)
Installation example 2 (Usage of stud)
BOLT
NUT
WASHER
CASTING
CASTING
CERAKWOOL FELT
CERAKWOOL BLANKET
175
25
50
CERAKWOOL BOND
25 m/m X 16 pcs
L TYPE PIN
CERAKWOOL BLANKET
300 m/m
ROD
5) CERAKWOOL VENEER LINING

Cerakwool Veneer Lining is an all-round energy saver
Cerakwool Veneer may be applied directly to the ground-work(brick, plastic, refractories, etc) with an inorganic bond.
FEATURES
*N
o Stud is used, so there is no damage or energy lost from stud heat release.
*Q
uick heating for greater productivity.
*F
ast heating and cooling-down.
*E
xcellent spalling resistance protects groundwork refractories.
*E
xcellent sound absorption reduces burner noise.
APPLICATIONS
*B
aking furnace, Ceramic shattle kiln, Tunnel kiln.
*A
nalyzing furnace in petrochemistry
*H
eating furnace.
INSTALLATION EXAMPLE OF VENEER LINING
CERAKWOOL BOND
65
Technical Book 2013
EXISTING
REFRACTORY
BRICK
64
VENEER MODULE
LINING
. CONSTRUCTION
STANDARD INSTALLATION OF CERAKWOOL VENEER LINING BY FURNACE INNER TEMPERATURE

Furnace inner temp ()
900
1,100
1,300
Existing refractory brick
(S.K34) 230
(B-1) 115
230
115
230
115
Veneer module lining
75
75
75
Lining thickness (mm)
445
445
445
Surface temp ()
72
84
99
Heat loss (kcal/h)
808550
1,054733
1,319985
Heat saving rate (%)
31.9
30.5
25.3
Heat storage (kcal/)
119,24990,439
145,831113,830
172,125142,146
Heat saving rate (%)
24.3
22
22
Material thickness (mm)
(Condition) Ambient Temp : 25
Emissivitc () : 0.85
VENEER LINING ENERGY-SAVING EFFECTIVENESS
RE
FR
AC
TO
RY
BR
ICK
INS
UL
AT
ING
BR
ICK
CE
RA
KV
EN
EE
RM
OD
RE
UL
FR
EL
AC
ININ
TO
RY
G
BR
I
C
INS
K
UL
AT
ING
BR
ICK
Side wall
CE
RA
KV
EN
EE
RM
OD
RE
UL
FR
EL
AC
TO
ININ
RY
G
BR
I
CK
HIG
HT
EM
PE
RA
TU
RE
SIL
ICA
BO
AR
D
INS
UL
AT
ING
FIR
EB
RIC
HIG
K
HT
EM
PE
RA
TU
RE
SIL
ICA
BO
AR
D
Celling
Heat loss (kcal/m2h)
2,101 (100 %)
1,642 (78 %)
98 1(100 %)
767 (78 %)
Heat stoage (kcal/m2)
138,594 (100 %)
115,834 (84 %)
103,223 (100 %)
87,120 (84 %)
3. APPLICATION EXAMPLE
USE FOR EXPANSION ZONE
Pipe
Hot air generator furnace

Castable & Insulating brick
Cerakwool bulk fiber
Refractory
Cerakwool bulk fiber,

blanket
Castable
Fire-proofing of duplicate pipe
Insulating brick
cerakwool
blanket(felt)
Interior pipe
Refractory brick
Castable
Exterior pipe
Vapor-barrier film
USE FOR MAINTENANCE & IMPROVEMENT OF EXISTING REFRACTORY
Reparing damage part
Improvement of existing refractories
Refractory brick or
Castable
Cerakwool bond
(about 3 mm)
Existing refractory
brick
Veneer module
Insulation
67
66
Stick veneer module on existing refractory

brick with Cerakwool bond
Technical Book 2013
Cerakwool moldable
. CONSTRUCTION
USE FOR INSIDE OF FURNACE
Furnace lining(with blanket)

Mineralwool board
To accommodate high velocities, surface defacement
Cerakwool felt
Cerakwool blanket (#100)
Cerakwool blanket (#130)
Mineralwool board
Cerakwool felt or
Cerakwool blanket
Cerakwool wet felt

Stud bolt
Washer net
Hardening the surface
Cerakwool paper lining

or module lining
Rigidizer Spray
Cerakwool wet felt
USE FOR INSULATION OF SKID PIPE
Skid Rail
Cooling
water
Skid pipe
Item
After insulating
Before insulating
Castable
47.5 mm
60 mm
C/F Wet felt
12.5 mm
0 mm
Heat loss
(103 kcal/h)
40.0
52.2
USE IN VARIOUS PROCESS
Uniform heating furnace
Heating retaining cover
Module (Cerakwool
K-module)
Bumer hole
Ingot
Seal material
blanket
Heating retaining cover(Cerakwool blanket)
Veneering
(Cerakwool
V-module)
Slab
Plastic
refractory
Table Roller
Cerakwool heat retaining cover prevents drop in

temperature resulting from insulating hot ingot such
as slab
Insulating brick
Flue gas line
Continuous casting machine
Kiln car
Platform
Insulating surrounding steel support

and frame with Cerakwool
69
Seal material : Blanket

Packing : Module system, paper(insulation : Blanket)
Packing : Vacuum formed products or paper
68
Cerakwool bulk or blanket
Technical Book 2013
Tundish
. CONSTRUCTION
USE IN GLASS INDUSTRY
Furnace
Insulating crown arch
Insulating side wall

Refractory brick
Port neck
Melter and refiner crown
Cerakwool blanket
Regenerator
crown
Metal line
Expanded steel
backup plate
(Insulation thickness : 25 mm ~ 100 mm)

Cerakwool blanket has a great effect on insulating regenerator crown, melter
and refiner crown, port neck.
Preventing burner block thermal shock
Cerakwool hard board

Refractory brick
(Sidewall joint area)
(Thickness : 25 mm-100 mm)
Cerakwool hard board should be installed in the outside refractory brick to
insulate melter side wall and refiner side wall
Insulating feeder channel

Refractory brick
Cerakwool bulk
Cerakwool hard board
(#300, 12.5 mm)
Cerakwool rope 12.5 mm
Cerakwool
bulk
Refractory brick
Cerakwool bond is used to stick cerakwool hard board
Insulating feeder
bowl & orifice ring
and sealing
Casing
Cerakwool bulk should be packde between refractory brick and

casing to insulate feeder channel.
Preventing tuckstone
thermal shock
Feeder bowl
Tuckston
Plunger
Sleeve
Fil ing with
Cerakwool bulk
for insulation
and using
Cerakwool rope
or hard board
and paper along
with Cerakwool
bond for sealing
Cerakwool
bulk
Casing
Cerakwool rope or
hard board paper
Orifice ring
Side wall
Cerakwool paper or
#300 hard board
Cerakwool hard board or paper

is used with Cerakwool bond to
prevent thermal shock

KCCCerak Wool

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INDEX

2) CERAKWOOL 1300 BLANKET

3) CERAKWOOL 1100 FELT

5) CERAKWOOL HARD BOARD

6) CERAKWOOL WET FELT

7) CERAKWOOL 1300 PAPER

8) CERAKWOOL MODULE SYSTEM

9) CERAKWOOL VACUUM FORMED PRODUCTS

10) CERAKWOOL TEXTILE

11) CERAKWOOL 1300 ROPE

12) CERAKWOOL MOLDABLE

3) CERAKWOOL COATING CEMENT

3. BIO-SOLUBLE CERAKWOOL 11001300

4. MARINE INSULATION MATERIAL (H - Class specification)

2. INSTALLATION OF CERAKWOOL LININGS

2) CERAKWOOL KH-MODULE LINING

3) CERAKWOOL K-MODULE LINING

4) CERAKWOOL STACK LINING

5) CERAKWOOL VENNER LINING

1) CERAKWOOL BULK FIBERS

Technical Book 2013

Maximum service temperature

Specific heat (at 1,000 )

2) CERAKWOOL 1300 BLANKET

* Glass furnace crown insulation

* High temperature pipe insulation

* Soaking pit seals

* Annealing cover seals

* Thermal reactor insulation.

* Investment casting mold wrappings

* Expansion joint seals

* Pressure and cryogenic vessel fire protection

* Primary reformer header insulation

* High temperature filtration

* High temperature gasketing

* Nuclear insulation application

* Incineration equipment and stack lining

* Furance door linings and seals

* Furance, kiln and boiler linings

Technical Book 2013

* Excellent corrosion resistance

* Easy to cut, wrap, or form

* Excellent hot strength

Maximum service temperature

Specific heat at 1,000

Tensile strength #130

PERMANENT LINEAR CHANGE(% Shrinkage)

100, 130, 160

3,600, 7,200, 14,400

Technical Book 2013

function as a fire barrier.

FREQUENCY CYCLES PER SECOND

3) CERAKWOOL 1100 FELT

RESISTANCE OF CORROSIVE AGENTS

Maximum service temperature

Tensile strength #130

Technical Book 2013

PERMANENT LINEAR CHANGE(% Shrinkage)

100, 130, 160

3,600, 7,200, 14,400

4) CERAKWOOL HTZ BLANKET

* Thermal shock resistance

* Excellent corrosion resistance

* Easy to cut, wrap, or form

* Excellent hot strength

* Pipe wrapping for both insulation and noise

* Parting agent in brazing, heat treating, and metal