Infrared specialist and manufacturer Ceramicx has been working with German heating expert Friedr Freek in providing leading manufacturer, BM Anlagenbau, with some leading edge production processes in order to make its innovative range of coated concrete and stone products.

Infrared heat treatment binds the polymer to the concrete

Hameln-based BM Anlagenbau has for many years been supplying merchants in the building and construction sectors with film and paint-protected building products. These specially treated concrete and stone products resist wear and tear; hold their aesthetic through the product lifetime, as well as being graffiti and vandal proof.

The technology is increasing in popularity since it can resist weathering and other aspects of ageing and thus extend product life and service life; reducing efflorescence and guarding against tyre abrasions, food, oil and chemical contaminations.

In production, most of the BM Anlagenbau product range is typically treated with polymer paints and then needs to dry before being packaged and shipped. Infrared heating has a key role to play; firstly in preparing the concrete and stone surfaces before the polymer paints are applied. As with plastics thermoforming, infrared preheating improves the surface readiness and also the penetration of the coating material into the concrete. This makes for better adhesion and for better long-term protection of the concrete product. Pre and post-spray infrared heating also eliminates the tendency for a developing film surface to ‘bubble’ and crack the surface of the coating. With two heat applications the material firstly evaporates from the substrate and then from the top.

The overall effect of the plastic film on concrete is a silk-like finish to the concrete and stone. This is often referred to as the ‘wet-effect’ and increases the depth of colour in the case of concrete – making the product much more visually appealing.

Water and chemical resistance are a key part of the finished product

Ceramicx Founder and Managing Director Frank Wilson says that ‘Infrared technology has an amazing potential for all industries that is still largely untapped. Thanks to the innovation of BM Anlagenbau this part of the construction industry is feeling the benefit – consumers and our environment also. Ceramicx learned a great deal from being part of this project – in designing the right array of elements and infrared emissions to suit – as well as engineering the infrared reflectors to provide exactly the right kind of heating for the concrete and give the whole system the right price/performance ratio. In this case,’ Wilson adds, ‘the high speed infrared heating also allows the client to adjust the overall heating systems in a modular manner –minimising space; helping changeovers, reducing production costs and improving competitiveness.’

Stephan Dullmann for Freek says that ‘we were delighted to be able to help BM Anlagenbau engineer the heating system; producing a fault-free job at an optimum price. Heat systems service and know-how have become synonymous with the Freek company reputation and this project, we are please to say has been no exception.’

BM Anlagenbau director Dirk Matyschiok says that ‘the quick response and the precise control of infrared heat work have been the keys in perfecting our system. Furthermore, the heat applications can be fully implemented into a comprehensive control system, which reduces overall costs significantly. This – combined with the modular system – allows for easy up and down-grading. In addition, the “oversized” integral fans allow for compact ovens without extra blowers .The project has clearly shown the benefit of trusting in the expertise of development partners playing a leading role in their sectors. No need to say who the partners will be for further heat work projects to come.

Ceramicx and Freek are both exhibiting their plastics and polymer know-how together at the prestigious triennial plastics industry exhibition in Dusseldorf this Autumn. Both companies will share an exhibition space at the K show 2010, which runs at the Dusseldorf Messe, Germany, from Wednesday October 27th to Wednesday November 3rd.

Ceramicx Founder and Managing Director Frank Wilson says ‘that we are delighted to be teaming up at K 2010 with a company of such quality as Freek. Last Autumn, Freek already wowed the plastics sector at the Fakuma show with its innovative all-in solutions for nozzle heating and SMA clamping systems “ThermoLock” and “ThermoDrive. The Freek developments in miniaturisation of  manifold heaters were also extremely impressive and many more heating innovations are set to be unveiled by them and by ourselves at the Dusseldorf show this October this year.’

Freek manager Stefan Düllmann says that ‘Ceramicx is the only company on the market which manufactures the complete range of infrared heaters – long, medium and short wave. The elements are perfectly developed for each application, reasonably priced and available on short notice. Furthermore,’ adds Düllmann, ‘Ceramicx has gained a huge knowledge on all details of infrared heating. Superb technical support is always guaranteed.

All further details from Ceramicx, Frank Wilson, Managing Director.
www.ceramicx.com ,
Tel. +353 28 37510,
Fax + 353 28 37509,
frank@ceramicx.com

All further details from Freek, Stefan Düllmann, Marketing & Development.
www.freek.de
Tel +49 2373 9590-16,
Fax +49 2373 959030,
s.duellmann@freek.de

For further information on Ceramicx and Freek at the K Show please see www.kshow2010.com