Zircon Based Coatings (Water Based Refractory Wash)
A premium, water-dilutable zirconium silicate refractory coating engineered with high solid content and an advanced suspension system — delivering extreme refractoriness up to 1800°C, zero metal penetration, and impeccable surface finish for heavy steel, grey iron, and ductile iron castings.
High Refractoriness Barrier for Critical Casting Demands
BR Chemicals Water-Based Zircon Coating is a high-performance refractory slurry formulated from ultra-pure, finely milled Zircon Flour ($\text{ZrSiO}_4$). Utilizing water as an eco-friendly, non-flammable carrier, this coating incorporates advanced inorganic and organic binders coupled with superior thixotropic suspension agents. It guarantees zero settling, exceptional brushability, smooth flow in dipping and flow coating, and uniform dry layer formation.
Designed specifically to withstand intense thermal shocks and molten metal hydrostatic pressures, our water-based zircon wash builds an impermeable thermal barrier between molten metal and the sand mould or core surface. By eliminating sand burn-on, veining, scabbing, and chemical mould-metal reactions, it dramatically slashes post-casting fettling, shot-blasting, and cleaning overheads for foundries across India and global markets.
Proven Advantages on the Foundry Floor
Engineered to deliver defect-free casting skins, enhanced shop safety, and maximum refractory adhesion.
Superior Refractoriness
Milled zircon refractory withstands pouring temperatures beyond 1650°C in heavy steel without blistering, cracking, or vitrifying.
Extreme Penetration Resistance
Forms an impenetrable, dense refractory shield that eliminates molten metal entry into sand interstices, avoiding burn-on.
Anti-Settling Suspension
Specially synthesized chemical suspenders prevent hard cake formation in storage and ensure effortless re-homogenization.
Low Gas & Clean Peel-Off
Minimal volatile binder content eliminates gas defects like blowholes and pinholes, facilitating quick post-cast peel-off.
Foundry Applications & Casting Sectors
- ✓ Heavy plain carbon steel, alloy steel, and stainless steel casting moulds and cores
- ✓ Ductile Iron (SGI / SG Iron) and heavy Grey Iron (CI) casting applications
- ✓ High-pressure valve bodies, steam turbine housings, and mining crusher wear parts
- ✓ Critical cores made from Furan No-Bake, Phenolic Acid Cured, and Cold Box systems
- ✓ Application via Brushing, Dipping, Spraying, or automated Flow Coating stations
- ✓ Mould areas exposed to prolonged thermal radiation and high ferrostatic ferro-pressure
System Formulation & Performance Highlights
Pure Zirconium Silicate
Formulated using high-grade, low-impurity Zircon flour ($\text{ZrSiO}_4$) boasting minimal thermal expansion and neutral chemical reaction.
Aqueous Eco-Carrier
Non-hazardous, non-flammable water carrier eliminating fire risks, VOC penalties, and odor complaints on shop floors.
Dual Binder Architecture
High-temperature ceramic bonding agent combined with ambient binders to guarantee crack-free drying and abrasion-resistant handling.
Technical Specifications & Grades
| Property / Parameter | Standard Specification (BR-1419W / High Solid) | Ready-to-Use / Dipping Grade |
|---|---|---|
| Refractory Filler | Pure Zircon Flour ($\text{ZrSiO}_4$) | Pure Zircon Flour ($\text{ZrSiO}_4$) |
| Carrier Base | Water (Aqueous System) | Water (Aqueous System) |
| Color & Physical State | Off-White / Creamish Viscous Thixotropic Paste | Smooth Off-White Liquid Slurry |
| Specific Gravity / Density (g/cc) | 2.0 to 2.5 g/cc | 1.7 to 1.9 g/cc |
| Solid Content (%) | 72% – 76% | 55% – 62% |
| pH Value | 7.0 – 8.5 | 7.0 – 8.5 |
| Application Methods | Brushing, Swabbing (dilute as needed) | Dipping, Spraying, Flow Coating |
| Dilution Ratio (if required) | 300 g Coating + 80-100 g Water (per requirement) | Ready for use or minimal water trim (5-10%) |
| Drying Mode | Forced hot air, Oven baking, or Gas burner torching | Oven drying / Forced dry air |
| Standard Packaging | 40 Kg / 50 Kg Poly Carboys & 300 Kg Drums | 40 Kg / 50 Kg Poly Carboys |
| Shelf Life & Storage | 6 months from manufacturing date in tightly sealed containers. Store in cool, dry areas away from frost. | |
*Values mentioned are representative and can be custom-tailored to suit specific foundry core shop dipping tanks, viscosity flow cups, and drying ovens.
Upgrade Your Casting Surface Quality Today
Contact our technical coating specialists for product TDS, Material Safety Data Sheets (MSDS), sample trial buckets, or customized dilution recommendations for your core line.
