Relining an ingot casting furnace
Rebuilt instead of patched: from the insulation and anchors to the finished opening
Initial situation
The inspection of the ingot casting furnace made it clear that another repair would not hold. The old lining was cracked and displaced in several places, right down to the steel shell. When the load-bearing structure of a lining is affected and not just its surface, every patch only lasts until the next weak spot next to it gives way. SBS Refractory Service therefore relined the furnace completely.
Scope of services
- Break-out of the old lining
- Insulation
- Anchoring
- Monolithic lining
- Arches over formwork
- Dry-out
Project data
The task
The old lining had to be broken out completely without damaging the steel shell
Insulation and anchors form the load-bearing structure of the new lining, so both had to be rebuilt in the correct pattern
Arches, passages and openings had to fit the existing furnace mechanics precisely
The SBS approach
The old lining was broken out down to the steel shell, the substrate cleaned and jointly inspected before the rebuild.
The anchors were set in a grid on the new layer of insulating boards, with protective caps on their heads. They later hold the monolithic lining and end well below the hot face.
Walls and arches were cast monolithically, the arches over timber formwork. This produces seamless surfaces with no joints in the arch.
Finally, passages and openings were formed to size and checked against the drawing before the furnace went into controlled dry-out.
Relining an ingot casting furnace in pictures
Before: the lining is cracked right down to the steel shell
New insulation layer with the anchors set in a grid
Arch cast monolithically over timber formwork
Arch over the passage: seamless instead of bricked
Finished chamber with openings formed to size
Finished opening before controlled dry-out
Measurable results
The key figures of the “Relining an ingot casting furnace” project
Similar references
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