FAQs

Yes, GAC backs its turnkey supply-and-installation projects with a formal technical and performance warranty. We provide a 12-month warranty for high-impact and heavy mechanical applications (such as sinter-crusher chutes, coke screens, and skip cars) and a 24-to-36-month warranty for monolithic, erosion-resistant systems (such as Kalcret-lined slag pipes and weld-on Kalocer ceramic chutes).

The steel backing plate must be grit-blasted or mechanically ground to achieve a white-metal finish conforming to the SA 2.5 standard. Following blasting, the surface must be thoroughly degreased using professional-grade solvents (such as Acetone or Lacquer thinner) to remove all traces of grease and dust. Ceramics must be bonded within a few hours of cleaning to prevent surface oxidation.

Dynamic fan impellers rotating at high speeds are highly sensitive to weight distribution. Conventional hardfacing overlays leave a rough, uneven surface that increases aerodynamic drag and causes dynamic imbalance. GAC shields impeller blades with ultra-thin (10mm), lightweight Kalocer high-alumina ceramic tiles bonded with heat-resistant Kalfix epoxy, extending blade service life by 3 to 4 times while keeping the fan perfectly balanced.

Sintered coke is highly abrasive and sharp. Falling from a height of 5m onto vibrating screens, it exerts severe combined sliding wear and dynamic impact, quickly deforming mild steel decks. GAC solves this with a combined lining layout: the sliding screen deck is lined with Kalmetall W100 clad plates (10+10mm, HV 700) to resist abrasive wear, while the fastening bolts are protected with heavy-duty caps fabricated from tough Hardox 500 TUF (15-20mm) to absorb dynamic impacts.

Immediately after troweling, GAC technicians apply Kalcure specialized spray-on curing compound to seal surface moisture and prevent rapid evaporation. Thanks to its fast-curing polymer-silica formulation, Kalcret achieves over 70% of its full compressive strength within 24 to 48 hours, allowing the plant to resume operations quickly.

Per Kalenborn engineering standards, the expanded steel mesh must be welded with a precise 5mm clearance from the steel backing plate. This creates a robust mechanical anchor within the mortar layer to absorb shrinkage stresses. The mesh-anchoring pins must be plug-welded at intervals of 250mm to 300mm to distribute mechanical shear stresses evenly across the 25-30mm lining thickness.

Kalmetall bimetallic cladding contains a high concentration of carbon (5%) and chromium (30%), forming a dense network of chromium carbides that are highly resistant to thermal oxidation. Standard oxy-fuel cutting cannot reach the temperature required to melt these carbides. Cutting must be executed using high-capacity Plasma Arc systems (minimum 150A) or Ultra-High-Pressure Water-Jet systems.

No, GAC utilizes a recessed stud-welding fastening system. Threaded studs are welded to the silo’s steel wall. The Tivar sheets are pre-bored with countersunk holes, secured with recessed locknuts, and sealed with matching Tivar plugs flush with the lining surface. This creates a completely flat, seamless sliding surface with no exposed bolt heads to obstruct material flow or wear out.

GAC lines the silo hopper cones with Tivar 88-2 UHMW-PE sheets (12.7mm thickness). Thanks to its low dynamic friction coefficient (0.08) and near-zero water absorption (<0.1%), Tivar 88-2 prevents wet cohesive materials from bonding to the silo walls, shifting the discharge profile from core flow/funnel flow to smooth, continuous Mass Flow.

Abresist Fused Cast Basalt is a mineral-based material with high compressive strength but relatively low tensile strength and high brittleness. Under direct, heavy dynamic impact from large falling ore lumps, fused basalt will fracture and shatter. It is best suited for sliding wear applications or pipeline systems carrying fine slurries or ash.

GAC utilizes a specialized dual-fixation weld-on ceramic system (weld-on Kalocer). Each Kalocer tile (13 – 25mm thick) features a pre-formed countersunk hole. A metal socket is inserted through the tile and plug-welded directly to the skip car’s steel floor. The socket is then filled with Kalfix adhesive and capped with a matched ceramic plug. This mechanical weld lock, combined with epoxy bonding, prevents the tiles from dislodging under heavy vibrational shocks.