Kay-Dee Engineering Plastics Ltd.

Engineered Polyurethane Solutions.

Kaylan® is a unique range of formulatedplastics whose outstanding physical propertiesprovide the ideal solution to a wide range ofengineering problems in a variety of industries.High performance polyurethane elastomers don’t come any tougherthan Kaylan. Proven in some of the harshest, most demanding conditionsthroughout the world, it consistently outperforms more traditionalmaterials such as rubber, metal, plastic and ceramic.

A wealth of experience in precision manufacturing

The secret of Kaylan’s success as an effective alternative in a wide range ofmanufacturing applications lies in the extensive knowledge and expertiseof its creators, Kay-Dee Engineering Plastics Ltd. Our wealth of experienceallows us to select the optimum grade of polyurethane and combine it withthe most appropriate additives. This results in durable components that canbe offered in a variety of different hardnesses and varying levels of resilience.At the same time Kaylan is incredibly lightweight and abrasion resistant,demonstrating high strength and an impressive load bearing capacity.

Enhancing your brand identity

We recognise the importance of a strong corporate image which is whywe offer the facility to incorporate your name and logo into the design.

Combined with our ability to supply parts in almost any colour and anyshape or form, Kaylan parts will complement existing designs and suitalmost any new requirement.

In addition to coming in all shapes and colours, Kaylan mouldings areavailable in sizes up to 10 metres in length, up to 2 metres diameter andfrom just a couple of grams in weight to in excess of 1000kg. Our flexibleproduction techniques also enable us to alter our production runs, thusaccommodating requirements from just a single one-off part to over onemillion pieces per annum.

Bespoke mouldings

Whilst Kaylan is often manufactured as standard sheeting, rod and blockit is primarily supplied as bespoke mouldings. Customers can be assuredthat the fitting and replacement of spare parts can be achieved withminimal disruption. For instance, there’s no need for on-site drilling ofholes or alteration of size since all necessary slots and fittings are alreadymoulded into the finished part.

The following pages detail some of the more popular applications of Kaylanin industries as diverse as mining to motorsport. However, the one thingthey all have in common is the desire to use a material that not only outperforms traditional ones, but also offers long-term cost saving benefits.

In short, Kaylan is lighter than metal, stronger than ceramic and moredurable than rubber. And whatever type of component you need, thechances are that we can make it for you.

Whatever the problem, we can engineer a solution.

Kaylan® performance characteristics:

• Excellent hydrolytic stability

• Excellent resistance to oil, grease and chemicals

• Excellent machining capabilities (the harder grades)

• Very good insulating properties

• Very good resistance to degradation by oxygenand ozone

• Very good resistance to fungus and bacterial growth

• Good range of different hardnesses

• Good ability to bond to other materials such as metals and plastics

Kaylan. The secret behind its success.

Most people encountering Kaylan® for thefirst time are amazed at its incredible rangeof properties, which make it ideal for such awide range of engineering applications.Although it possesses all the benefits of many traditional ‘tough’ materials,Kaylan can also feature the kind of elasticity and extensibility normallyonly associated with rubber. The result is a material that can be both toughand flexible at the same time.

Hardness tailored to your needs

Kaylan is available in a wide range of hardnesses, from 10° Shore A to over80° Shore D. In other words, it can be softer than a car tyre or harder thana golf ball.

What’s more, in applications where severe wear and tear is a problem,Kaylan offers outstanding durability compared to conventional plastics oreven hardened metals; and, of course, it doesn’t corrode either.

Greater load bearing

Kaylan’s compression properties also exceed conventional elastomers of equalhardness. In addition to tension and compression, it has a greater load-bearing capacity as well as extremely high load-bearing properties in shear.

Superior impact resistanceUnlike many conventional elastomers, Kaylan loses none of its elasticityand won’t crack under impact at higher hardnesses. Not only does it possesssignificantly better impact resistance than most other plastics, it also resistscracking under repeated flexing.

It’s extremely resilient too. Formulations are available offering reboundvalues of 10-30%, ideal for use as shock absorbers; and 50-75% for high-frequency vibrations or where fast recovery is needed.

Outstanding thermal properties

Kaylan retains its properties at very low temperatures, down to -30°C, andthanks to its outstanding resilience to thermal shock, will continue toperform well in arctic conditions. Likewise, it will also sustain continuoususe at +80°C.

Specialist grades

Kaylan is also available in several specialist grades such as high temperatureand FDA approved. High temperature formulas can run up to 150°C in awide range of demanding applications, particularly in the mining, and oiland gas industries. Here they are used for high load and speed situationssince they they exhibit exceptional properties even at such elevatedtemperatures. FDA compatible grades of Kaylan, suitable for use in contactwith foodstuffs and medical applications, can also be manufactured in awide range of different hardnesses.

High performance plastics. Tough in the extreme.

Few industries put vehicles and machinerythrough a tougher test than mining andconstruction. Not only does equipment haveto stand up to the rigours of the job, it alsoneeds to stand the test of time. This is whereKaylan® and its unique hard-wearing propertiesset it apart from other traditional materials.In some of the most demanding conditions imaginable, Kaylan excels dayin and day out. Highly resistant to wear and tear, unbreakable and virtuallyindestructible, Kaylan can be specified with confidence – safe in theknowledge that it will continue to provide maximum performance evenin the most arduous of applications.

It’s worth remembering that whilst being incredibly strong, Kaylan is alsoextremely lightweight and offers impressive load-bearing properties inboth tension and compression. Add to this its resistance to corrosion, aswell as many oils, greases and other potentially harmful chemicals, and itisn’t difficult to see why more and more companies insist that Kaylanelastomers are specified for their critical parts.

Kay-Dee can manufacture precisely what you need to provide bothperformance and long-term economy. Shown below are some of the manyareas where Kaylan is already used in the mining and construction industries.However, the list is by no means exhaustive, so if you have a potentialapplication that you don’t see listed here, ask us anyway.

• Hydraulic-Hose Reels • Drill Guides • Buffers

• Wear Strips • Cable Clamps • Wire Cable Pulleys

• Track Pads • Mudflaps • Impact Bars

• Conveyor Scrapers • Protection Sheets • Flexible Ladder Supports

• Wheels • Tyres • Suspension Buffers

Rocket Boomer case study with kindpermission from Atlas Copco, Sweden.

The hostile and demanding world of marineexploration offers yet another opportunityto showcase the benefits of Kaylan. The cold,dark seabed is the last place you need apolyurethane product to fail. So it’s the perfectreason to trust a range of materials with animpeccable pedigree in harsh conditions.The protection of underwater pipes, flexible flowlines and cables againstthe damage from abrasion, impact and flex fatigue is the number onepriority of both contractors and operators alike. What’s required is a highlydurable yet low cost protective system that can be used wherever standardprotection or maintenance is unable to function.

We can manufacture a variety of durable, high performance products foruse in the offshore oil and gas industries. State-of-the-art, computercontrolled processing equipment ensures that each moulding is manufacturedto the same consistently high standard, whether it’s 100g or 2000kgs.

Designed for a wide range of underwater applications either sub-sea oron the seabed, Kaylan products can be used as protection when layingpipelines or cables, for protection near to platforms, rocky outcrops andriver crossings, as well as seals and spacers in pipeline pigging.

Offshore wind farms also benefit from specialist Kaylan anti-vibrationdampers, which neutralise damaging resonating frequencies that build upduring constant or dangerously high wind speeds.

And in common with all Kaylan products, the exact grade of material canbe specially manufactured to ensure that it meets the specific load bearingand temperature requirements that the environment demands.

Shown here are just some of the Kaylan parts that are manufactured forthe offshore and marine industries.

• Bend restrictors • Bend stiffeners• Riser clamps • Cable and pipe protection• Spacers • Pigs• Piggy Back Blocks and Clamps • Fenders• Seals • Anti-vibration pads

Underwater solutions for offshore and marine.

The outstanding physical properties offeredby Kaylan® elastomers make it the idealmaterial for use in the rugged world ofmunicipal and highway.Incredibly tough and resilient throughout its hardness range, more and

more vehicle and equipment manufacturers are coming to realise that

Kaylan adds quality to their products as well as years to the life of their

equipment.

Thanks to its outstanding resistance to high impact and abrasion, Kaylan

is increasingly used in the manufacture of tyres, wear strips, scrapers and

bearing covers to name just a few examples. Also, because Kaylan mouldings

can be produced in just about any colour, and incorporate individual logos,

large OEMs and municipal fleet organisations are finding that their corporate

image is not only being maintained but can even be enhanced.

This may seem like a small benefit, yet it is just one more element in the

‘Kaylan mix’ that can help your company stand out from the crowd – often

making the difference between success and failure in today’s marketplace.

The same is true for the municipal spares market, where parts for cleansing,refuse, sweeping and snow clearance vehicles are supplied in a variety oftough Kaylan grades.

Detailed below are just a few of the product areas where Kaylan is currently

enhancing the performance of equipment in both the municipal and

highway industries. As always, if you have an application in mind that isn’t

listed below, it doesn’t mean we can’t help you. We’re always looking to

break new ground with innovative products, even if they’re just one-offs.

• Road Roller Scraper Blades • Brush Holders

• Wear Guides • Suspension Buffers

• Wheels and Tyres • Mudflaps

• Snow Plough Blades • Nozzle Rubbers

• Suction slides • Flexible Couplings

• Shock Absorbers • Protective Skirts

Driving the municipal and highway industry.

The underside of a World Rally Car sustainsincredible punishment on just a single forestor gravel rally stage, so it’s obvious why ahard wearing, durable material like Kaylan®is proving so popular in the motorsport world.With up to 450bhp going to the wheels, you can imagine the damage thatstones, mud, grit and sand can do to the exposed suspension and othermechanicals as they bombard these precision, and extremely expensive,items at high velocity. Accordingly, manufacturers who have spent millionsof pounds designing such thoroughbreds, insist that only the very bestmaterials are used to protect the vehicle properly.

Fortunately, Kaylan special elastomers are purpose-built to overcome therigours of such harsh environments. Capable of withstanding repeated flexing,excellent in extremes of temperature (-30°C to +80°C), and resistant to bothhigh impact and abrasion, Kaylan is the ideal material to protect suchexpensive machinery.

Add to this Kaylan’s excellent resistance to oils, greases and other potentiallyharmful chemicals and it’s clear to see why the world’s top works rallyteams trust their cars to the lightweight material that beats all othertraditional ones hands down.

Both works teams and privateers alike are saving thousands of pounds,week in week out, by not having to replace damaged parts; and bothgroups know the value in the saying “To finish first, first you have to finish”.

Shown below are some of the areas where Kaylan can be successfully usedto enhance performance and protect against race wear and tear:

• Mudflaps (both moulded and punched)

• Protection for; Trailing Arms, Gearbox, Rose Joints, Toe Links,• Differential and General Underbody Protection

• Wheel Arch Lining

• Engine and Gearbox Mounts

• Bushes and Bumpstops

• Sump and Tank Guards

• Aerodynamic Splitters

The winning formula in high performance plastic.

WRC case study.(Left) Kaylan mud flaps, sills and splitters – working hard to protectthe 2008 World Rally Subaru; courtesy of McKlein Photography.

An integral part of modern engineering solutions.

In today’s modern aerospace industry thereis no margin for error. Only the finest, mostreliable products are used in the productionof parts assembled into the latest aircraft.Naturally Kaylan®, with its impressive list ofqualities, makes for an obvious choice forsheet metal forming and many otherapplications within the industry.Kaylan is used to protect aerospace components from accidental damageduring the assembly of the wings and other structures, particularly in thenew carbon fibre construction of many modern aircraft. These items includespar and manhole protection, anti-fatigue/memory foam mats, rib and stringerprotection, and ribbay mats. All are produced not only to protect the assembliesbut also to enable fitters to work in a more comfortable environment.

Sheet metal forming is a highly technical and demanding process. Thoseorganisations using specially-formulated Kaylan within their manufacturingfacility achieve superior tolerance control during the production of vitalaircraft components. However, by not just getting it right, but getting itright first time, Kaylan has been able to eliminate 90% of the manualre-work that has historically been required, thus demonstrating substantialtime and cost benefits.

A specially-developed range of Kaylan materials is being used to enhanceperformance across a wide range of metal pressing techniques fromtraditional press braking, rubber pad pressing and stretch forming rightthrough to the latest fluid forming processes. What’s more, Kaylan notonly withstands repeated flexing under enormous pressure, it also intensifiesthe pressing action to ensure a superior finished product.

Resistant to cuts, abrasion and punctures, Kaylan slave sheets also improvethe life of the presses by protecting the rubber pad or polyurethanediaphragm from damage by debris and sharp edges. Additionally, byoffering improved forming characteristics at lower pressing forces, Kaylanreduces both stress and wear on the machine allowing for longer serviceintervals and improved productivity.

Kaylan can also eliminate the secondary polishing often required aftermetal has been marked during the press braking process. By using Kaylanfilm whilst press braking, performance is enhanced and metal parts arerepeatedly produced free of any marking from the press tool.

A summary of the applications for Kaylan forming materials is detailed below:

• Replacement of traditional rubber press pads with superior Kaylan

• Overlay Slave Rubbers • Intensifiers • Press Brake Rubbers

• Non Marking Film • Stretch Forming Pads • Trayfill Pads

Aerospace component used to protectAirbus wing manholes.

Kaylan® high performance materials aremanufactured in a wide variety of shapes,sizes and colours. However, one constantremains present during all phases ofproduction – quality. Whether a simple, one-off prototype is required, or a batch-run ofone thousand pieces, the quality will alwaysbe the same.This is because Kay-Dee only processes its materials via the very latestcomputer controlled casting machines.

Our quality assurance system ensures extensive in-house testing of bothmaterials and procedures at every stage of manufacture. This strict systemgoverns all output, enabling us to obtain the very best results.

Every product fit for purposePrecision moulded products demand exacting manufacturing standards. Inour state of the art testing facility sample parts undergo rigorous examinationto maintain these high standards. Test data confirms that Kaylan productsexcel not only in extremes of heat, cold, wet and dry, but also under extremepressure, stress, flex and compression. This strict approach to standardsensures every Kaylan product is ‘fit for purpose’.

Environmentally friendly

Although our products are designed to work in the harshest of environments,we’re still committed to doing our bit to minimise global warming. Ourpurpose-built factory has been designed with efficiency in mind andfeatures computer-controlled heating and lighting systems that save energyand reduce our carbon footprint. Computers also control our ovens andcasting machines to reduce power consumption, and a solvent recyclingplant dramatically reduces our use of solvents. In fact, everything that canbe recycled, is recycled.

Tried, tested and quality assured.

Whilst specialising in bespoke mouldings,Kay-Dee Engineering also manufacturessheeting, pads, blocks and rods in a widevariety of sizes, hardnesses and colours tosuit most requirements.

Kaylan® Sheeting

Sheeting can be produced in a variety of dimensions and by many different

methods including centrifuged, flat cast, moulded and extruded. Applications

are widespread through a variety of industries and include cutting or

punching gaskets, scrapers and flaps, protecting industrial table tops and

lining wear chutes and blast cabinets.

Kaylan® Blocks

Blocks are produced in an extensive range of sizes and weights. Startingfrom just 10mm square (weighing around 50g) and exceeding 2500mm x1200mm (around 1500kg). They currently find uses in metal forming asmachining blanks, vibration isolation, impact buffers, dry dock supportsand many other applications. If you require a block of any specific size, callus and we will be happy to discuss your requirements in more detail.

Kaylan® RodsRods start at 8mm diameter by 150mm long and can exceed 500mm indiameter by 2000mm long. Some areas in which rods are used are machinebillets, rollers, pressing intensifiers and damping bars. With different formulationsto suit different applications we are sure to meet your exacting needs.

Additional Services

Many existing Kay-Dee customers have benefited from the sourcing of

products and services within other sectors of the rubber and plastics industry.

These include:

• Injection Mouldings • Compression Mouldings • Extrusions

• Machining • Fabrication

• Moulded and Slab Stock Polyurethane Foam

• Materials such as – Nylon, Acrylic, Polycarbonate, Rubber,

• Polyethylene, Polypropylene and many more

• Computer-aided machining and bulk repetition work in all

• the above materials

Meeting all your requirements.

From incredibly small to really quite tall.

Kaylan is a registered trademark of Kay-Dee Engineering Plastics Ltd.

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Kaylan® is manufactured exclusively by Kay-Dee Engineering Plastics Ltd., providingthe ideal solution to a wide range of engineering problems in a variety of industries.

Kaylan is a registered trademark of Kay-Dee Engineering Plastics Ltd.

Unit 2 Jubilee Court Thackley Old Road Shipley West Yorkshire BD18 1QF United KingdomT: +44 (0)1274 590824 F: +44 (0)1274 531409 E: info@kaylan.co.uk W: www.kaylan.co.uk

Kay-Dee Engineering Plastics Limited