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Monolithic Spray-Applied Insulation System

Temperature Grade

1200°C (2192°F), 1400°C (2550°F), 1600°C (2912°F)

Chemistry

Alumina, Silica

CCEWOOL® Fabrication-Grade Monolithic Spray-Applied Insulation System is a high-performance wet spray-applied insulation material developed for high-temperature furnace lining protection, surface reinforcement, and localized repair applications.

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CCEWOOL® Monolithic Spray-Applied Insulation System

CCEWOOL® Fabrication-Grade Monolithic Spray-Applied Insulation System is a high-performance wet spray-applied insulation material developed for high-temperature furnace lining protection, surface reinforcement, and localized repair applications. The product is mainly composed of in-house produced high-purity high-temperature insulation fibers and selected refractory fillers, combined with an inorganic bonding system. It can be applied by mechanical spraying or manual troweling onto the surfaces of brick linings, castable linings, fiber module linings, and other refractory insulation linings.

In industries such as petrochemical, metallurgy, ceramics, and non-ferrous metals, some furnaces operate for long periods under combined conditions of high temperature, high gas velocity, frequent thermal shock, and localized chemical attack. Conventional hot-face materials such as refractory bricks, ceramic fiber boards, and fiber modules may develop cracking, spalling, erosion damage, or localized flame penetration after long-term service. These issues can shorten lining service life, increase shutdown frequency, and raise maintenance costs.

CCEWOOL® Fabrication-Grade Monolithic Spray-Applied Insulation System is developed specifically for these demanding service conditions. After application, the material forms a continuous and dense protective layer on the hot-face surface of the lining. After drying, it forms a hard and tough surface layer. When the service temperature reaches above 1100°C (2012°F), a stronger bond forms between the fibers and fillers, further improving the surface strength, integrity, and high-temperature stability of the lining, while providing effective protection for the backup materials underneath.

This system is suitable for both large-area spray application and localized repair work, including crack filling, local damage repair, hot-face protection enhancement, and energy-saving retrofit projects. It provides an integrated high-temperature insulation solution combining protection, repair, and hot-face reinforcement.

Application and Storage Instructions

  • Application Methods

    Mechanical spraying
    Manual troweling
    Localized spray repair
    Crack filling and surface repair
    The typical coating thickness can be determined based on the application area and system requirements. It is suitable for both large-area installation and localized reinforcement.

  • Storage Conditions

    Recommended storage temperature: above 4°C
    Store in a cool and dry environment
    Avoid freezing and exposure to high temperatures or direct sunlight

  • Shelf Life and Packaging

    Shelf life: 90 days
    Packaging: 25 kg per pail

  • Handling Precautions

    During application and handling, operators are advised to wear:
    Filtering face mask
    Safety goggles
    Protective work clothing
    Rubber gloves

Features of Monolithic Spray-Applied Insulation System

  • Excellent Resistance to High-Velocity Gas Erosion

    After curing, the material forms a dense and tough surface layer that can withstand hot gas flow erosion up to 80 m/s. It is especially suitable for hot-face protection in areas exposed to high gas velocity and intense flame impingement.

  • Good High-Temperature Stability

    The product is available in different temperature grades for various high-temperature service conditions. It provides good structural stability and low linear shrinkage at elevated temperatures, making it suitable for long-term continuous operation.

  • Outstanding Crack Resistance and Thermal Shock Resistance

    Under frequent heating, cooling, and thermal cycling conditions, the coating is less prone to cracking or delamination, helping improve the integrity and durability of the lining surface.

  • Good Resistance to Erosion and Chemical Attack

    The product provides good resistance to common flux attack, surface burn-off, and certain alkaline chemical attacks found in industrial furnaces and kilns, helping extend lining service life.

  • High Surface Hardness and Wear Resistance

    After drying and firing, the material forms a hard surface layer that improves hot-face wear resistance and reduces lining degradation caused by erosion, friction, and localized damage.

  • Strong Application Flexibility

    The product can be applied by spraying, spray repair, troweling, and localized patching. It is suitable for surface reinforcement of new linings as well as repair and upgrade of existing linings.

  • Hot Repair Capability

    Under certain application conditions, hot-face repair can be carried out without cooling down the entire furnace, helping shorten maintenance time and improve equipment operating efficiency.

Application of Monolithic Spray-Applied Insulation System

Hot-Face Lining Protection and Surface Reinforcement

Suitable for hot-face surface protection of brick linings, castable linings, fiber module linings, and composite lining systems. It helps improve lining surface integrity and enhances resistance to gas erosion, surface burn-off, and cracking.
Typical equipment includes:
· Reheating furnaces
· Heating furnaces
· Cracking furnaces / pyrolysis furnaces
· Reformers
· Hydrogen reformers
· Coke oven doors
· Forging furnaces
· Pelletizing furnaces
· Roller kilns
· Tunnel kilns
· Intermittent kilns

Spray-Applied Insulation for Irregular and Complex Areas

Suitable for monolithic spray application in air ducts, flues, chimneys, vessel linings, reactors, and other irregular spaces. It forms a continuous insulation layer and reduces heat loss through joints. Typical equipment includes: Reaction vessels; Ducts and chimneys; Hot air generators; Process heaters; High-temperature areas related to boilers

Protection for High-Gas-Velocity and Flame-Impingement Areas

Suitable for hot-face areas exposed to long-term high-velocity hot gas flow, flame impingement, or localized surface burn-off. It helps extend lining service life and reduce the risk of localized failure. Typical equipment includes: Regenerative thermal oxidizers; Flare systems; Incinerators; Cremators; High-flow areas in boilers; Aluminum melting furnace doors

Localized Repair and Hot Maintenance

Suitable for rapid repair of lining surface damage, cracks, hot spots, and localized erosion areas. It is also suitable for online hot spray repair and refractory layer restoration, helping reduce furnace shutdown time. Typical applications include: Hot spot repair; Hot spray repair; Furnace lining maintenance and patching; Restoration of cracks and localized spalling areas

Backup and Composite Insulation Systems

Can be used as a backup layer behind high-density sprayed refractories or as a functional layer in composite lining systems. It is also suitable for low-heat-storage and energy-saving lining structures. Typical applications include: Backup insulation behind brick linings, plastic refractories, and castables; Backup layer for high-density sprayed refractories; Low-mass kiln car decks; Heat treatment furnaces and kiln car platforms; Annealing furnace bases; Molten metal transfer ladles and preheating stands; Tundish covers

Ceramic, Glass, and Foundry Thermal Processing Equipment

Suitable for thermal processing equipment requiring temperature uniformity, lining integrity, and surface protection. It can be used for monolithic insulation and protection in high-temperature zones. Typical equipment includes: Technical substrate kilns; Refractory production kilns; Kiln cars; Foundry furnaces

Specifications & Sizes

CCEWOOL® Monolithic Spray-Applied Insulation System
Property Unit / Condition Grade 1200 Grade 1400 Grade 1600
Al2O3 + SiO2 % ≥ 95 ≥ 98 ≥ 99
Permanent Linear Shrinkage After Heating % 1100°C×24 h≤1 1250°C×24 h≤1 1400°C×24 h≤1
Long-Term Service Temperature °C ≤ 1100 ≤ 1250 ≤ 1400
Density (Wet) kg/m³ 1300 1300 1300
Density (Dry) kg/m³ 650 650 650
Color — Green Blue Pink
Maximum Gas Velocity Resistance m/s ≤ 80 ≤ 80 ≤ 80
Thermal Conductivity at Hot Face 600°C W/m·K 0.13 0.13 0.14
Thermal Conductivity at Hot Face 800°C W/m·K 0.15 0.15 0.16
Thermal Conductivity at Hot Face 1000°C W/m·K 0.17 0.17 0.18
3-10 mm Coating Layer Room Temperature No Cracking No Cracking No Cracking
Dried at 110°C No Cracking No Cracking No Cracking
Fired at Service Temperature No Cracking No Cracking No Cracking

Custom size are available.Contact Us

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Adhere to Strict Quality Control System

CCEWOOL® products have won a number of authoritative certifications, including rach certification, Fraunhofer laboratory certification and CE certification, which fully prove the excellent quality of our products. These certificates are not only a strong guarantee of the quality of our products, but also ensure a worry-free process for your order. If you need to know more certification details or request relevant certificates, please feel free to contact us!

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