What are Granulated Coatings?

Granulated coatings are a “wet powder” form of refractory coating that can be prepared ahead of use so the coating is always fresh. On-site, the product can be turned into a premix coating by adding water and mixing it under high shear, which eliminates the need to ship water and helps reduce freight costs. Because it has a potting-soil-like consistency, cleanup is as simple as sweeping it up. A special mixer is required to process the granulated coating into a slurry product. ​
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Slurry vs Granular Powder Coatings

Compared with conventional slurry refractory coatings, granulated coatings significantly reduce logistics cost because they avoid transporting large volumes of carrier liquid. In serial production, slurries typically contain only ~40–50% solids, with the balance being liquid, whereas granulated products can reach ~75–90% solids, improving shipped payload efficiency and lowering transport-related emissions, supporting a better overall CO₂ balance. Granulated coatings also simplify packaging and waste handling: reusable IBCs used for slurries require cleaning, and any residual material remaining in containers must be disposed of or recycled, while granulated products generally avoid these cleaning requirements and minimize container residue losses.

Relative to powder systems, granulated coatings provide a more controlled, production-ready formulation. The granulate contains the complete raw material package, typically requiring no additional additives—effectively functioning as a two-component system (granulate + water). This enables faster make-up and improved stability during preparation and application. In addition, the granulated form improves dispersion behavior, reducing lump formation and producing a more homogeneous coating compared with conventional powders. Handling is also safer and cleaner, as the material generates minimal dust and is easier to meter and manage on the shop floor.