REFRACTORY ANCHOR SYSTEMS



Dickinson Group of Companies' Anchor Division has been designing, manufacturing and installing standard, custom-made high-quality refractory anchors and a wide range of anchor supporting systems for more than 30 years. The division manufactures and distributes an extensive range of refractory anchors, steel fibres, hex mesh, stud-welding equipment, shear connectors, arc and wear studs for standard industrial use, through to specialty applications in the Mining, Metals Smelting, Mineral Processing, Petrochemical Industries.



The Anchor division strategically stocks a substantial amount of inventory of various high temperature alloys including 304, 310, 316 and 253MA in shapes such as round bars, flat bars, plates and round wire so as to confidently offer clients short delivery times. Should the client have a preference on self-designed anchoring systems, our company will offer these according to specific drawings, samples or sketches.



Dickinson has business operations throughout Africa in South Africa, Zambia and Egypt the company is able to respond to all your refractory anchor needs. The company has concluded a manufacturing know-how and technology agreement with Borg El Arab for Steel Fabrication, located in Alexandria Egypt, to supply our complete range of refractory anchor products to the North Africa and Middle East region.

The extensive range of Refractory Anchor Systems includes the following categories:

  • Refractory Anchors
  • Ceramic Fibre Anchors
  • Refractory Armour Systems
  • Reinforcing Fibres
  • Stud-welding Equipment
  • CD Pins and Clips
  • Wear Studs and Spike Studs
  • Shear Connectors





REFRACTORY ANCHORS

Since the development of monolithic refractory products, metal anchoring systems have been utilized in supporting monolithic materials. The Anchor Division designs, manufactures and supplies an extensive range of high quality custom made refractory anchor systems suitable for any refractory lining; including bricks, castable, mouldable or ceramic fibre for temperatures up to 1600°C.

With state-of-the-art manufacturing facilities, in-house design capabilities and rapid response services; the resulting unique range of anchor systems increase performance, speeds up installations and saves money for the clients.

The Anchor Division uses wire coils that adhere to strict internal material specifications and has undergone the annealing process. Anchors are produced by means of free bending on the CNC-3D bending machine; that ensures that the anchors meet the required high quality standards.





Refractory Anchor Benefits

Benefits of Dickinson Group of Companies’ range of refractory anchors includes:

  • Comprehensive range of common anchor shapes and sizes
  • Full in-house design and manufacturing for fast turnarounds on custom anchor designs
  • Range of stainless steel and nickel alloys including alloy 304, 310, 316 and 253MA
  • Specialty high-temperature heat-resistant alloys available on request





Refractory Anchor Applications

Dickinson offers an extensive range of hand and stud welded refractory anchors for all applications:

CERAMIC FIBRE ANCHORS

One of the fastest growing materials for heat conservation is high temperature insulation in the form of ceramic fibre blankets, modules, and boards. These high temperature insulation materials provide energy savings, operational flexibilities, and thermal shock resistance when utilised in tunnel kilns, heating, annealing and petrochemical process furnaces.


Dickinson’s Anchor Division offers several systems suitable for anchoring ceramic fibre linings over a range of operating temperatures:

  • Press On Clip Systems - the threaded studs allow for combinations with anchors from various series. With the possibility of a hand weld, Rapid Arc Weld and threaded version; these anchors suit any refractory fibre lining.
  • Threaded Studs - the division provides a variety of threaded refractory anchors and studs.
  • Washers - provision of a variety of washers, plates and clips for refractory anchors and general applications.
  • Wide range of Ceramic Fibre Fixings including Fibre-lock Pin, Lock Washer and Spring Clip Washer.




HEX MESH & REINFORCING FIBRES

Hex mesh is a unique honeycombed steel designed to provide excellent retention and reinforcement of thin wall refractories and fully complements dense hydraulic and chemically bonded refractories in resisting erosion.

Applications

Process plants which are subject to the passage of erosive gas streams, particularly at high temperatures significantly benefit from claddings consisting of Hex Mesh and erosion resistant refractories. Typical applications are found in any vessel or section that is subject to erosion or abrasion including Cyclones, Flue Gas Lines, Reactor Vessels, Windboxes, Fan Casings and Burner Quarls.



REINFORCING FIBRES

Dickinson Group’s Anchor Division offers a range of Melt Extract (ME) reinforcing fibres for standard industrial use through to specialty applications such as extreme temperature, high corrosion and niche industry requirements. Reinforcing fibre applications include refractory use, defense, automotive and marine. Dickinson Group is an exclusive distributor of one of the world’s leading manufacturers of reinforcing fibres for Melt Extract Fibre range in Southern Africa.

The alliance partners have strong technical capabilities and production capacities, together with advanced production lines test and measuring equipment. The products are certified by China’s Petrochemical Research Institute in Beijing Analysis and Test Center of Baoshan Steel Co. Ltd, Quality Inspection Center of Lanzhou Petrochemical Project as well as the ISO 9001:2000 Quality System Certification.



Reinforcing Fibre Properties

The company supplies the finest steel fiber products and technology with excellent properties including:

  • Custom fiber designs.
  • Excellent crack control.
  • Superior installation performance.
  • Unequaled cost-effectiveness.
  • Ideal for all modern installation techniques.
  • Lightweight.
  • High Stiffness.
  • High energy absorption.
  • High noise and vibration damping properties.

Reinforcing Fibre Quality Assurance

To meet the demands of the customers in high-temperature processing industries, we continually strive to improve product performance, purity and consistency, as well as customer service and price. The products conform to the ISO 9001 quality standards. Our stainless steel reinforcing fibers consistently meet and exceed ASTM standards, the company also demands that all facilities adhere to its corporate-wide quality assurance procedures. These efforts include upgrading facilities as needed and contracting independent researchers to assess product quality.


STEEL FIBRES FOR REFRACTORY APPLICATIONS

The following features make the use of stainless steel alloy fibres ideal for high temperature applications; resistance to spalling, enhanced flexural strength, excellent impact resistance and lower permeability, all these substantially benefit refractory applications.

Our fibre technology extends refractory life and offers added benefits such as outstanding spalling resistance, superb fracture toughness, better abrasion resistance, superior thermal and mechanical shock resistance and uniform alloying characteristics.



The Company’s fibres are of extremely high quality both in terms of metallurgy and dimensional tolerance.

To meet the demands of its customers in high temperature processing industries, Dickinson Group of Companies exacts strict quality control and quality assurance measures to ensure alloy purity and consistency while enforcing the dimensional and physical requirements.

Raw material is verified for chemical and physical composition prior to use and final fibre shapes are continuously sample inspected for size and aspect ratio.

The use of our stainless steel alloy fibres substantially improves refractory durability and performance, and reduces refractory installation, maintenance and material.





Refractory Armour Systems

The products include Hex Metal (Hex Mesh), as well as Flex Metal (Flex Mesh), as a method of retaining and armouring the thin wall dense castable refractories used to combat erosion by particulate in high velocity gas streams within process plants.

The range of anchors and armours is fully integrated and includes the Sheet Armour, Hex Metal and Flex Metal, the Independent Armour Systems of 'S' Anchors, Curl Anchors and Hex cells. A full range of lining ancillaries (Adjustable Corner Tabs, Edge Tabs etc.) for the easy connection of armour systems and protection of the mother steel work when plant geometry dictates directional changes in gas flow and refractory termination devices.

STUD WELDING SYSTEMS

Dickinson Group’s Anchor Division supplies a full range of equipment from hand held, lightweight units to fully automated CNC and Robotic Studwelding Systems. Dickinson Group is the exclusive distributor of Taylor Stud Welding Systems (United Kingdom) and Soyer (Germany), two world leading manufacturers of stud welding equipment. With over 30 years in the industry, the company has vast professional experience together with extensive resources to build up an enviable reputation exporting products throughout Africa and beyond. The state-of-the-art, purpose built, computerized office and manufacturing facilities allows for fast, efficient and friendly services. While the company’s strategic warehousing system allows for sufficiently large stocks to fulfil even the most complex orders. The division also offers full turnkey solutions to any stud welding requirements.



What is Stud Welding?

A method of applying a single side fastening to a metal component.

Stud Welding Applications

Stud Welding Systems
offer a lot of flexibility and reliability accessories and consumables with versatility to simply and effectively meet different application needs.



Studwelding Product Range



Advantages of Stud Welding

Stud Welding provides 3 primary advantages:
  • Tremendous time and cost savings through elimination of drilling, punching, threading, gluing, riveting, screwing or finishing.
  • Greater flexibility in design and usage through the studs high strength and ability to be applied on very thin plates and platforms with limited or only one sided access.
  • Unsurpassed economy through high levels of automation, fast weld rates and low price for standard studs.




CD PINS & CLIPS

Fastening systems that are ideal for stud-welding fasteners for heating, ventilation and air-conditioning, signage and construction industries. The stud welding insulation pin is a capacitor discharge weld insulation fastener. Insulation welding pins work with a stud welding machine, weld the pins on the sheet metal, then put the insulation through the welding pins, press a self-locking washer onto the pin, bend over or clip off the pin to finish fastening insulation installation.
SHEAR CONNECTOR STUDS

Shear Connectors are used as an essential component in steel-concrete composite structures, beam design and construction. Composite construction combines the positive features of steel construction and structural concrete. This means that a steel skeleton structure is combined with concrete parts so that a joint bearing effect is created. The steel beams bear the tensile forces, while the concrete bears the compressive forces and provides fire protection. Dickinson Group of Companies Anchor Division produces a large range of Shear Connectors for the construction industry.



Advantages of using Shear Connector Studs

Below are some important advantages of Shear Connectors in construction:
  • Cost savings in reduction of building materials in the design of composite structures.
  • Reduces building height and saves on materials as lighter beams result in shallower floor sections.
  • Secures concrete to steel structural components.
  • Increases shear loading capacity in steel buildings.
  • Provides larger rooms with fewer obstructions because longer beams can be used.
  • Reliable and safe under static and dynamic stress.
  • Mechanical interlock of steel and concrete.





  • Anchorage of steel parts in concrete for various load directions, no cracking forces because of mechanical interlock.
  • Firm welds produced by stud welding.
  • Electronically controlled and monitored stud welding equipment ensures repeatability and verifiable quality of the weld.
  • Easy to install, Application can be done by trained operators.

WEAR STUDS AND SPIKE STUDS

The use of cold-forged shear connectors allows for composite construction on a large scale.

The principal benefit of using Wear Studs is the extreme abrasion resistance, which ultimately extends the machinery's wear life. Wear Studs reduce wear on surfaces which are exposed to abrasion by forming a barrier between the machinery and the material being moved. This is achieved by applying high-chromium and high-carbon abrasion resistant studs to machinery in close formation. Wear Studs are ideally suited for use on ground engaging equipment across many applications including the underground mines, open pit mines, quarries, maintenance shops, steelworks and ore preparation plants.

In some areas the applied stud welded Wear Stud pattern retains the mineral debris establishing a dead bed effect, which further improves the wear resistance factor for the equipment.

Wear Studs, in contrast to wear plates also offer permanent protection as the studs will not pop off even when buckets or plates buckle.

Compared to conventional welding, the process for applying Wear Studs is both quicker and more precise. The easy to handle welding gun offers reduced heat thereby reducing the risk of warping. Additionally the ability to apply the wear studs on-site reduces labour costs and machinery down-time.

Wear Studs & Spike Studs Specifications

Wear Studs are available in 3 specifications:
  • Standard Range: M16 & M20 diameters and maintain a core hardness after welding of 58-60HRC.
  • Premium Range: M16 diameters and features a tapered top that fits perfectly into the chuck. Fast loading for efficiency they maintain a core hardness after welding of 58-60HRC.
  • High Performance Range: M16 diameters and features a Tungsten Carbide insert for higher wear resistance. Recommended for use across 10 - 20% of total surface area for additional durability, these studs maintain a core hardness after welding of 1,200HV.

REFRACTORY ANCHOR INSTALLATION SERVICES



Dickinson Group’s Anchor Division offers flexible services ranging from simple supplies of anchors to full turnkey services involving design and planning of anchoring systems, manufacturing of the anchors and installation on site by hand welding or stud welding. The following are some of the important design and installation considerations during for anchor systems:

Anchor Depth

Many specifications call for refractory anchors to be 66% to 75% of the lining depth. In general practice, however, the anchor should extend no closer than 25mm of the lining surface.



Anchor Spacing

To a great extent, anchor spacing depends on the type of material used, the operating conditions and the physical characteristics of the unit to be lined. Spacing from 75mm on centres to 300 or 400mm is quite common. Some specifications call for spacing the anchor on centres three times the lining thickness.

General guidelines for the spacing of anchors are as follows:

  1. The more severe the operating conditions, such as cyclic temperatures, physical abuse, abrasion and vibration, the closer the anchors should be spaced.
  2. The lower the physical stress imposed on the lining by the physical characteristics of the unit to be lined, the wider the anchor spacing.



Anchor Patterns

All three anchor patterns illustrated in the catalogue have been widely and successfully used. The most important fact is that an irregular pattern is achieved by opposing individual anchors.

This increases the overall holding power of the anchor pattern, it also helps prevent cracks from extending dangerously far in any one direction or from linking together in regular networks to cause weakened areas.





Anchor Attachment

The fixing point of a metal anchor is one of the areas of the anchoring system subject to the greatest load. In refractory installation, anchors are attached to the shell in different ways, in addition to welded connections, screw-in, bolt-on, clip-on and plug-in connections are used. The choice of the type of attachment depends on the type of anchor, the alloy, the installation situation and the amount of anchors to be attached. The more common attachment methods are hand welding and stud welding. Hand welding is slower, more costly and requires skilled welders and welding electrodes. Stud welding is much faster, cheaper and only requires semi-skilled welders and no welding electrode is required.

Anchor Alloys

The Anchor Division supplies a wide range of stainless steel grades including 304, 316, 309 and 310. The aforementioned grades are also provided in various diameters such as 5.5mm, 8mm, 10mm and 12mm .Other alloys grades are available but would be on special order.



Stud Welding

During the stud welding process, an arc is ignited between the face of the stud and the surface of the work piece. Once both surfaces melt, the stud is smoothly pressed against the work piece and joined together. Welding elements like threaded studs, pins and tapped pads are welded by an arc without any additional material being required. As the stud is joined with the work piece over the whole surface of the stud, the strength of the joint is even higher than the base material or the stud. The company employs two types of Stud Welding:

  • Capacitator Discharge (CD) Stud Welding
  • Arc Stud Welding


GALLERY



                



CORPORATE HEAD OFFICE
Tel: +27 (0) 16 421-3720
Fax: +27 (0) 16 422-1038
Email: sales@dgrp.co.za



10 Smuts Avenue
P.O. Box 63, Vereeniging
1930. South Africa