Refractory Mastics & Coatings
Refractory mastics, cements and coatings by Morgan Thermal Ceramics and Alkegen® (formerly Unifrax®) for repair, protection and insulation at temperatures up to 1650 °C. SENN supplies the full range — from brushable coatings to hand-formable moldables.
- Product Forms
- Mastic | Coating | Moldable | Cement | Rigidizer
- Application Method
- Trowel / Spatula | Spray | Brush / Roll | Pour / Gun
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Multiple Brands
Morgan Thermal Ceramics (Kaowool®, Superwool®, Unikote™, Cera-Kote™) and Alkegen® (Fiberfrax® QF Cements, Coatings, Moldables) — all from a single source at SENN.
Up to 1650 °C
Depending on the product and composition, these mastics and coatings cover classification temperatures from 1260 °C to above 1650 °C — from standard coatings to high-duty specialty systems.
Versatile Application
Brushable, sprayable, trowelable or hand-formable — mastics and coatings adapt to any geometry and repair task. Suitable for both hot and cold repairs.
Product Types & Applications
Refractory mastics and coatings serve the repair, protection and insulation of furnaces, boilers, ladles and process equipment. They are applied to existing linings or pumped into voids.
Mastics: Thick, trowelable compounds for grouting, sealing and crack repair in refractory linings
Coatings: Thin protective layers for fibre modules, refractory materials and metal contact surfaces — brushable or sprayable
Moldables: Plastic, putty-like compounds for shaping, plugging and patching launders, ladles and contoured surfaces
Cements: Air-setting binders for bonding fibre blankets, boards, bricks and as surface coatings
Material Overview
The composition determines temperature resistance and chemical stability:
Alumino-silicate (RCF): Classic ceramic fibre base, up to 1260 °C. Used in Fiberfrax® QF Cements and Kaowool® Mastic
AES / Alkaline Earth Silicate (Q): Bio-soluble alternative to RCF, up to 1300 °C. Superwool® HT Mastic — lower biopersistence, preferred from an occupational health perspective
High-Alumina / Mullite: Al₂O₃-rich systems (>65 %), up to 1425–1538 °C. Unikote™ M and S for aggressive environments
Specialty Ceramic / Silica: Fiberfrax® Coating 125 with melting point >1650 °C for extreme duty
Morgan Thermal Ceramics
Morgan Advanced Materials offers a broad portfolio of mastics, coatings and specialty products:
Superwool® HT Mastic: AES-based (Q), classification 1300 °C, density 1420 kg/m³ (wet) / 730 kg/m³ (dry), linear drying shrinkage <1 %, MOR 1.5 MPa. Trowelable and formable.
Kaowool® Mastic: RCF-based, classification 1260 °C, alumino-silicate fibre base. For grouting and sealing fibre blankets and modules.
Unikote™ M: High-alumina coating (Al₂O₃ >65 %), classification 1425 °C, density 1105 kg/m³, shrinkage ≤0.75 % (24 h @ 1315 °C). Protects fibre modules against metal oxide, chemical attack and erosion.
Unikote™ S: High-temperature variant, classification 1538 °C (2800 °F), for aggressive environments with iron oxide and slag attack. Must be fired at >1260 °C during service.
Cera-Preg™: Inorganic rigidizer for preformed and vacuum-formed shapes. Acts as a binder and stiffening agent for ceramic fibre products.
JM 2600™: Air-setting refractory mortar, service up to 1430 °C (2600 °F). For laying firebricks and insulating bricks.
Cera-Kote™: Non-fibre based specialty coating for protecting and sealing refractory linings.
Alkegen® (formerly Unifrax®)
Alkegen® supplies a proven range of cements, coatings and moldables under the Fiberfrax® brand:
Fiberfrax® QF-180 Cement: Brush/spray/trowel cement, classification 1260 °C (2300 °F), density 1.74 g/cm³, Al₂O₃ 37.2 % / SiO₂ 59.1 %, shrinkage 3.2 % (24 h @ 1260 °C). Coverage 50–100 SF/Gal (1 coat).
Fiberfrax® QF-150 Cement: Thicker consistency than QF-180, classification 1260 °C, density 1.80 g/cm³, Al₂O₃ 38.6 % / SiO₂ 57.5 %. Coverage approx. 20 SF/Gal. For heavier coats and bonding.
Fiberfrax® Coating 125: High-temperature coating with melting point >1650 °C. As a protective topcoat for high-temperature insulation wool and ceramic surfaces.
Fiberfrax® LDS Moldable: Formable compound (putty-like), classification 1260 °C (2300 °F), dry density 721 kg/m³, wet density 1280 kg/m³, shrinkage 4.0 % (24 h @ 1090 °C). Applied by trowel, spatula or hand.
Fiberfrax® LDS AL-Moldable: Variant with excellent resistance to wetting by non-ferrous molten metals (aluminium, magnesium, zinc). For transfer troughs and ladles.
Product Comparison
Product Manufacturer Type Classif. (°C) Density Application Superwool® HT Mastic Morgan Mastic (Q) 1300 730 kg/m³ (dry) Trowel, forming Kaowool® Mastic Morgan Mastic (RCF) 1260 — Trowel, grouting Unikote™ M Morgan Coating 1425 1105 kg/m³ Trowel, application Unikote™ S Morgan Coating 1538 — Trowel, application JM 2600™ Morgan Mortar/Cement 1430 — Trowel, jointing Fiberfrax® QF-180 Alkegen Cement/Coating 1260 1740 kg/m³ Brush, spray, trowel Fiberfrax® QF-150 Alkegen Cement/Coating 1260 1800 kg/m³ Brush, spray, trowel Fiberfrax® Coating 125 Alkegen Coating >1650* — Brush, spray Fiberfrax® LDS Moldable Alkegen Moldable 1260 721 kg/m³ (dry) Trowel, forming, plugging * Melting point >1650 °C per SDS. (Q) = AES/bio-soluble. (RCF) = Alumino-silicate ceramic fibre. All values are typical averages.
TECHNICAL DETAILS
Fiberfrax® QF-180 Cement
Classification 1260 °C (2300 °F) Continuous Use (Air) 1177 °C Density 1.74 g/cm³ Al₂O₃ 37.2 % SiO₂ 59.1 % Shrinkage (24 h @ 1260 °C) 3.2 % Dielectric Strength 1.54 kV/mm Coverage (1 coat) 50–100 SF/Gal Unikote™ M Coating
Classification 1425 °C Density 1105 kg/m³ Al₂O₃ >65.0 % SiO₂ <25.0 % Shrinkage (24 h @ 1315 °C) ≤0.75 % Coverage 3.8 kg/m² Superwool® HT Mastic
Classification 1300 °C Density (wet) 1420 kg/m³ Density (dry) 730 kg/m³ Drying Shrinkage <1 % MOR (dry) 1.5 MPa Material AES / bio-soluble (Q) Fiberfrax® LDS AL-Moldable
Classification 1260 °C (2300 °F) Continuous Use (Air) 1093 °C Density (dry) 721 kg/m³ Density (wet) 1280 kg/m³ Shrinkage (24 h @ 1090 °C) 4.0 % MOR (dry) 0.375 ksi (2.6 MPa) Properties
Low Thermal Conductivity: Reduces heat losses in furnace and boiler systems
Thermal Shock Resistance: Withstands rapid heating and cooling cycles
Chemical Resistance: Resistant to metal oxides, slags and many chemicals (exceptions: hydrofluoric acid, phosphoric acid)
Low Shrinkage: Dimensionally stable even under prolonged high-temperature service
Good Adhesion: Bonds to fibre blankets, modules, bricks, steel and ceramic surfaces
Inorganic: No smoke or toxic fumes when exposed to heat
Occupational Safety (Q): Superwool® HT Mastic is AES-based / bio-soluble — preferred over RCF products from a health perspective
Typical Applications
Furnace Repair: Hot and cold repairs on industrial furnaces, tunnel kilns, bell-type furnaces
Joints and Cracks: Grouting and sealing cracks in refractory linings
Module Protection: Unikote™ coatings protect fibre modules from erosion and chemical attack
Non-Ferrous Melts: Fiberfrax® LDS AL-Moldable for aluminium, magnesium and zinc transfer troughs and ladles
Tube Cavities: Pumping compound behind boiler tubes for thermal insulation
Surface Protection: Erosion and oxidation protection for graphite crucibles, injection tubes, ceramic components
Electrical Insulation: QF Cements as dielectric coatings for high-temperature applications
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Since 2001, KS Kneissl & Senn Technologie GmbH
has been producing insulation materials and seals for a wide range of applications up to a temperature range of 1600 °C. A diverse range of machinery (CNC 5-axis milling, plotting, punching, sewing, water jet cutting, vacuum forming, etc.) enables us to shape a wide variety of materials for you. The main materials include: glass fibers, aramid fibers, mineral fibers, biosoluble fibers, ceramic fibers, silicate fibers, vermiculite, calcium silicate, microporous materials, elastomers (rubber, silicone, silicone foam, etc.), etc.
The company has been ISO9001 certified since 2009, currently in accordance with the 2015 revision of the standard.