Refractory linings are constantly exposed to the most extreme conditions that are characterised by heat, physical stress and chemical attack.

Consequently, in order to maintain optimal levels of plant performance; repairs of different magnitudes will be necessitated at various intervals throughout the lifespan of a facility. Given the high costs refractory materials and unplanned stoppages; high quality refractory materials have to be properly installed during refractory relining campaigns. This article briefly discusses some critical refractory installation issues that need to always be carefully addressed:

  • Refractory relining campaigns should be sufficiently resourced with skilled refractory technicians and well experienced supervisors to ensure the highest quality outcomes

  • Comprehensive pre-shutdown inspections and scope identification have to be carried out with the involvement of all relevant personnel prior to the commencement of the works.

  • Advanced project and construction management techniques should be employed to ensure timeous completion of the works within budgets

  • Effective refractory material management procedures have to be applied throughout the process; right from material selection, procurement, transportation, quality analysis through to stock management

  • The correct refractory material installation techniques have to be used at all times, some of installation techniques are listed at the end of the article

  • An appropriate commissioning criteria has to be developed to ensure that the life of the refractory lining is maximised; this involves correctly scheduling heat-up phases and dry-out periods

  • Once in operation, various condition monitoring techniques can be continuously used to establish a holistic overview of the state of the refractories production facilities as well as the respective efficiencies


Refractory masonry products

  • Specialized refractory bricklaying

  • Rigging of refractory blocks

Monolithic refractories

  • Vibrocasting

  • Shotcreting

  • High density and pneumatic gunning

  • Ramming installations

  • Grouting installations

  • Dense pneumatically applied castable

Ceramic fibre

  • Installation of various types of ceramic fibre