Calcium Silicate Board, Blocks, Pipe Section | Wedge India
Calcium silicate boards are widely used in industrial insulation due to their excellent thermal insulation properties, fire resistance, and durability. Fire-resistant calcium silicate boards are highly valued in various construction and industrial applications for their superior fire resistance, durability, and insulation properties. Calcium silicate boards are highly effective for thermal insulation due to their excellent thermal properties, durability, and resistance to high temperatures.
Features & Benefits Calcium Silicate Boards
-
High Thermal Insulation: Excellent at reducing heat transfer, making them ideal for high-temperature environments.
-
Fire Resistance: Non-combustible, providing a high degree of safety in industrial settings.
-
Durability: Resistant to physical wear and tear, moisture, and chemical attack.
-
Low Thermal Conductivity: Maintains consistent insulating properties across a wide range of temperatures.
-
Dimensional Stability: Maintains shape and effectiveness even under high temperatures and varying conditions.
-
Lightweight: Easier to handle and install compared to other high-density insulation materials.
Benefits in Industrial Applications
-
Energy Efficiency: Helps in maintaining consistent temperatures and reducing energy consumption in industrial processes.
-
Safety: Enhances fire protection, reducing the risk of fire hazards in industrial plants.
-
Cost-Effective: Long lifespan and low maintenance requirements lead to cost savings over time.
-
Environmental Resistance: Effective in harsh environments where moisture, chemicals, and high temperatures are prevalent.
-
Ease of Installation: Can be cut and shaped on-site to fit various industrial equipment and structures.
Types of Calcium Silicate Boards
Calcium silicate boards come in various types, each designed to meet specific needs in construction, industrial applications, and thermal insulation. Here are the primary types of calcium silicate boards, along with their characteristics and typical uses:
1. Standard Calcium Silicate Boards
Characteristics:
-
Moderate density
-
Good thermal insulation
-
Fire resistance
-
Moisture and weather resistance
-
Easy to cut and shape
Typical Uses:
-
Wall and ceiling linings in residential and commercial buildings
-
Partition walls
-
Cladding for internal and external walls
-
Substrate for tiles in wet areas like bathrooms and kitchens
2. High-Density Calcium Silicate Boards
Characteristics:
-
High mechanical strength and durability
-
Excellent thermal insulation
-
High-temperature resistance (up to 1100°C or more)
-
Good chemical resistance
-
Non-combustible
Typical Uses:
-
Industrial high-temperature insulation, such as in furnaces, kilns, and boilers
-
Insulation for high-temperature ducts and pipes
-
Backup insulation in refractory linings
-
Fireproofing structural steel in industrial facilities
3. Low-Density Calcium Silicate Boards
Characteristics:
-
Lightweight and easy to handle
-
Good thermal insulation properties
-
Suitable for applications where load-bearing is not critical
-
High fire resistance
-
Resistant to moisture and pests
Typical Uses:
-
Thermal and acoustic insulation in walls and ceilings
-
Fire-rated partitions and cladding
-
Industrial thermal insulation where weight is a concern
-
Insulating pipes and ducts carrying hot fluids or gases
4. Fire-Resistant Calcium Silicate Boards
Characteristics:
-
Specifically designed for fire resistance
-
Can withstand high temperatures without degrading
-
Low thermal conductivity
-
Minimal smoke and toxic gas emission in case of fire
-
Durable and moisture-resistant
Typical Uses:
-
Fire-rated walls and partitions
-
Fireproof doors and ceilings
-
Structural steel fireproofing
-
Fire barriers in commercial and residential buildings
5. Acoustic Calcium Silicate Boards
Characteristics:
-
Enhanced acoustic properties for sound absorption and noise reduction
-
Can also offer good thermal insulation
-
Fire resistance
-
Typically used in combination with other soundproofing materials
Typical Uses:
-
Acoustic insulation in theaters, auditoriums, and recording studios
-
Soundproofing in commercial buildings and offices
-
Residential applications for reducing noise transfer between rooms
6. Structural Calcium Silicate Boards
Characteristics:
-
High strength and durability
-
Can bear loads and provide structural support
-
Good thermal and fire resistance
-
Resistant to moisture, chemicals, and pests
Typical Uses:
-
Structural panels in walls and floors
-
Supportive cladding for external walls
-
Underlayments for roofs and floors in high-stress environments
-
Backer boards for heavy tile installations
7. Moisture-Resistant Calcium Silicate Boards
Characteristics:
-
Specifically formulated to resist moisture absorption
-
Maintain integrity and strength in damp environments
-
Good thermal insulation and fire resistance
Typical Uses:
-
Bathrooms, kitchens, and other wet areas
-
Exterior cladding in humid climates
-
Substrate for tiles and other finishes in moist conditions
-
Basements and underground constructions
Calcium silicate boards come in various types tailored to meet specific requirements in construction and industrial applications. Whether you need fire resistance, high strength, lightweight insulation, or acoustic properties, there's a type of calcium silicate board designed to fit the bill. Understanding the specific characteristics and applications of each type ensures that you select the most suitable material for your project needs.
Low Density Calcium Silicate Board
Low-density calcium silicate boards are specialized insulation materials known for their lightweight properties, excellent thermal insulation capabilities, and fire resistance. Here’s an in-depth look at their characteristics, benefits, and applications:
Composition and Manufacturing
Low-density calcium silicate boards are made from a mixture of:
-
Calcium oxide (lime)
-
Silica (sand)
-
Reinforcing fibers (such as cellulose)
-
Additives to enhance performance
These materials are combined with water to form a slurry, molded into boards, and then autoclaved (cured under high-pressure steam). The low-density version is achieved by controlling the formulation and manufacturing process to reduce the board’s overall weight and density.
Properties of Low-Density Calcium Silicate Boards
-
Low Thermal Conductivity: Provides excellent thermal insulation by minimizing heat transfer.
-
Lightweight: Easier to handle and install compared to higher density boards, reducing labor and structural load.
-
High Temperature Resistance: Can withstand high temperatures (typically up to 1000°C or more) without significant degradation.
-
Fire Resistance: Non-combustible, providing effective fire protection.
-
Dimensional Stability: Maintains shape and structural integrity under varying temperatures and conditions.
-
Moisture Resistance: Resistant to moisture, which prevents degradation in humid environments.
-
Durability: Resistant to physical wear, rot, fungi, and pests, ensuring long-term performance.
Benefits Low-Density Calcium Silicate Boards
-
Energy Efficiency: Reduces energy consumption for heating and cooling by providing effective thermal insulation.
-
Ease of Installation: Lightweight nature makes them easier to cut, handle, and install, saving time and labor costs.
-
Safety: Enhances fire protection in buildings and industrial facilities.
-
Cost-Effective: Long-lasting with minimal maintenance, leading to lower lifecycle costs.
-
Versatility: Suitable for a variety of applications, both in construction and industrial settings.
Applications Low-Density Calcium Silicate Boards
-
High-Temperature Insulation: Insulates industrial furnaces, kilns, and other high-temperature equipment to maintain operational efficiency and protect surrounding structures.
-
Boilers and Pressure Vessels: Used to insulate boilers, pressure vessels, and heat exchangers, improving energy efficiency and preventing heat loss.
-
Pipe and Duct Insulation: Insulates pipes and ducts carrying hot gases or fluids, maintaining temperature and improving system efficiency.
-
Refractory Backup Insulation: Acts as a backup insulation layer in refractory linings, enhancing overall thermal performance and durability.
Low-density calcium silicate boards offer an effective and versatile solution for thermal insulation in both construction and industrial applications. Their lightweight nature, combined with excellent thermal and fire-resistant properties, makes them ideal for improving energy efficiency, safety, and overall performance in various settings. Whether used for insulating walls, ceilings, high-temperature industrial equipment, or as refractory backup insulation, these boards provide reliable and durable insulation solutions.
High Density Calcium Silicate Board
High-density calcium silicate boards are highly suitable for applications requiring excellent thermal insulation and durability under extreme conditions, such as in aluminium melting furnaces.
High-density calcium silicate boards are ideal for insulating aluminium melting furnaces due to their excellent thermal insulation, high temperature resistance, mechanical strength, and durability. These boards help improve energy efficiency, safety, and operational efficiency in high-temperature industrial applications. By using high-density calcium silicate boards, industries can ensure long-lasting and reliable performance in their thermal insulation systems, especially in demanding environments like aluminium melting furnaces..
Wedge high density Boards are manufactured with Filter Press Technology to achieve very high strength, high temperature insulation, high machinability, and non-wettability to molten metals. These boards and machined ready to use designs are most suitable as thermal insulation for processes in direct contact with molten aluminium such as transfer ladle, casting, holding, metal bath furnace in launders, spouts, floats, hot top ring headers, and holding furnaces for die-casting.
Advantages
-
Low thermal conductivity, Low heat capacity Molten aluminium can be transferred with minimal reduction in temperature.
-
Used for the lining of the holding furnace, energy savings can be achieved by raising temperature in a shorter time than conventional castable.
-
Excellent machinability for variety of shapes such as floats, spouts, hot top ring headers, etc.
-
It is non-wettable with molten aluminium, so it is easy to remove solidified metal.
Applications
-
Molten aluminium launders.
-
Molten aluminium baths for holding furnaces
-
Floats, spouts, stopper pins.
-
Hot top ring headers, Floats, Spouts, etc.
-
Distribution boxes, dams, baffles, filter boxes,
-
Troughs, head boxes,
-
Working lining in low energy aluminium die cast holding
Calcium silicate Pipe Section
Calcium silicate pipe sections are widely used in industrial applications for their excellent thermal insulation properties, fire resistance, and durability. These pipe sections are designed to insulate pipes carrying hot fluids or gases, maintaining the temperature within the pipes and protecting the surrounding environment.
Composition and Manufacturing
Calcium silicate pipe sections are made from a mixture of:
-
Calcium oxide (lime)
-
Silica (sand)
-
Reinforcing fibers (typically cellulose)
-
Additives to enhance performance
This mixture is shaped into the form of pipe sections and then autoclaved (cured under high-pressure steam), resulting in a rigid, durable, and thermally efficient insulation material.
Environmental Impact
Calcium silicate pipe sections are environmentally friendly as they are made from natural and recyclable materials. They do not emit harmful substances during use or in the event of a fire, contributing to a safer and healthier environment.
Summary
Calcium silicate pipe sections are an effective and reliable solution for insulating high-temperature pipes in industrial applications. Their excellent thermal insulation properties, high temperature resistance, fire resistance, and durability make them ideal for maintaining energy efficiency and safety in various industrial processes. By choosing calcium silicate pipe sections, industries can ensure long-term performance and protection in demanding environments.
