use of PRE-CAST SHAPES has dramatically increased. If properly manufactured,
they have a distinct advantage over conventionally installed refractories.
Increased service life, while decreasing installation time and cost
are optimum features. At our facilities, strict quality control
procedures and controlled manufacturing techniques, assures that
the highest quality product is produced. Manufacturing variables
such as amount of mixing water, mixing time, optimum vibration (
compaction ), and proper bake-out are rigorously adhered to. Thus
the risk of human error, when installing refractories in place,
is eliminated. The following pictures illustrate some of the shapes
we manufacture for various industries.
You Should Consider Precast/Prefired Cooler Blocks
of Start Up Time - Without doubt, one of the greatest advantages
of utilizing pre-cast Cooler Blocks is that complex and time consuming
initial firing schedules can be avoided. Because it is often difficult
to control Cooler temperatures over the first few hundred degrees
of start up, refractory linings' are likely to crack and spall,
brining about premature failure. Because pre-cast Cooler Blocks
are already dried out, start up time can be reduced, resulting in
more production time.
Cost Savings - All pre-cast, pre-fired blocks are delivered free
of unnecessary cracking. Any costs associated with cracking or spalling
during dry out, is absorbed by the manufacturer and not the end
Maximization - Pre-cast Cooler Blocks are fired isothermally, meaning
the Cooler Block absorbs the heat evenly on all sides. Linings cast
on site, are often fired from only one direction, therefore, maximum
strength is not always obtained due to the thermal gradients that
exists between the hot and cold faces of the lining. On site casting
can greatly compromise the strength and durability of the refractory.
Work Elimination - The need for complex and often expensive forming
required for on site casting is eliminated, resulting in savings
of form material, installation and transportation costs.
Time Savings - By employing pre-cast Cooler Blocks, installation
time can be drastically cut, as there is no need to allow time for
stripping the forms or drying out the castable.
Minimization - Castable refractory exhibits lower strength when
dried then when fired and when installed under load, it can lead
to premature failure during the initial firing process.
Dimensional Stability - All castable refractory is subject to permanent
linear change during firing. The use of pre-cast, Cooler Blocks
allows the placement of components and expansion joints to produce
the best possible lining, reducing your exposure to expensive rework.
Maintenance Cost - Should a pre-cast, pre-fired Cooler Block ever
need replaced, simply remove the nut on the outside of the cooler
shell and use the All Thread to tap out. A new Block can then be
inserted in it's place. No need for messy, time consuming tear out
or time consuming set up, for casting or gunite installation.
you think about it, it just makes sense!
[ Click here for sample pictures!