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Practice sheets

Expertise as PDF — free to download

Each sheet deepens an article or field of application: the checklist for the acceptance walk-through, the table of empirical values, the damage pattern for comparison. All sheets are open, without sign-up.

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Repair or reline? The three findings
PDFAll furnace types

Repair or reline? The three findings

When a targeted repair is enough, and the three findings where only a relining will hold.

Only in the PDFDecision table with 6 findings, the 3 typical wrong decisions, 2 photos from a relining
To the article
Refractory on the tube wall: The inspection points
PDFEnergy & Combustion

Refractory on the tube wall: The inspection points

Protecting without blocking the heat: what matters when lining a boiler tube wall.

Only in the PDF7-point checklist for tube walls, the 3 typical mistakes, 2 photos from the boiler
To the article
Working in confined spaces: Before we go in
PDFAll plants

Working in confined spaces: Before we go in

Access, supervision, light and air: what is settled before anyone enters a furnace or boiler.

Only in the PDF7-point pre-entry checklist, the 3 typical omissions, 2 photos
Ducts and passages: The three inspection points
PDFMulti-chamber furnaces

Ducts and passages: The three inspection points

Thermal cycling, false air, cross-section: why ducts between furnace chambers need a lining of their own.

Only in the PDF6-point checklist for ducts and passages, the 3 typical mistakes, 2 photos
To the article
Sign-off before the first heat-up: The inspection points
PDFAll furnace types

Sign-off before the first heat-up: The inspection points

What gets checked before the first firing — afterwards nothing can be reworked.

Only in the PDF7-point sign-off checklist, the 3 typical omissions, 2 photos from the job
To the article
Mechanical wear: The three points of attack
PDFAluminium & non-ferrous metals

Mechanical wear: The three points of attack

Angular spalling instead of even wear: where the lining wears mechanically.

Only in the PDFTable of location – finding – response, the 3 most common material mistakes, 2 photos
To the article
Flame pattern and burner control: Where the flame impinges
PDFBurner-fired furnaces

Flame pattern and burner control: Where the flame impinges

One-sided wear, glazed surfaces, wear pockets: what the flame pattern reveals.

Only in the PDFFindings table with possible causes, the 3 most common wrong conclusions, 2 photos
To the article
Prefabricating furnace lids: Workshop instead of downtime
PDFFurnaces with lids

Prefabricating furnace lids: Workshop instead of downtime

Why lid lining belongs in the workshop — and why the anchor system decides the service life.

Only in the PDF6-point checklist, the 3 causes of early detachment, 2 photos from the workshop
To the article
Refractory work during ongoing operation: The preparation
PDFAll plants

Refractory work during ongoing operation: The preparation

Dust, removal, noise, cleanliness: what has to be settled before the first blow is struck.

Only in the PDF6-point checklist before work starts, the 3 typical disruptions, 2 photos
Combustion chamber acceptance: The 10 inspection points
PDFEnergy & Combustion

Combustion chamber acceptance: The 10 inspection points

The complete acceptance walkthrough as a printable checklist.

Only in the PDF10-point checklist, joint and interlocking rules, 2 photos from actual execution
To the article
Substrate preparation: The hour before lining installation
PDFAll furnace types

Substrate preparation: The hour before lining installation

The work step nobody sees decides whether the lining bonds.

Only in the PDF6-point checklist before every relining, the 3 most expensive mistakes
Thermography: From measured value to maintenance calendar
PDFAll furnace types

Thermography: From measured value to maintenance calendar

Around 80% of refractory failures announce themselves — on the furnace shell, weeks in advance.

Only in the PDFMeasuring-point system, trend thresholds (+60–80 °C), documentation scheme
The bath line: The most critical zone in the aluminium furnace
PDFAluminium & Non-Ferrous Metals

The bath line: The most critical zone in the aluminium furnace

Where metal, oxygen and refractory meet.

Only in the PDFDesign of the bath-line band (±20–30 cm), material selection, corundum control
Casting instead of bricklaying: The decision zone by zone
PDFAluminium & Non-Ferrous Metals

Casting instead of bricklaying: The decision zone by zone

20–30 joints per metre of brickwork — or none at all. But at what price?

Only in the PDFDecision guide for each zone, drying rules, transition detailing
The combustion chamber from the inside: Zones and their lining
PDFEnergy & Combustion

The combustion chamber from the inside: Zones and their lining

The hottest zone of the plant forgives no one-size-fits-all solution.

Only in the PDFZone map of the critical spots, from burner vicinity to boiler inlet
Anchoring: The invisible part of the lining
PDFAll furnace types

Anchoring: The invisible part of the lining

The castable does not support itself — it hangs on the anchor.

Only in the PDFMaterial selection by peak temperature, grid rules, inspection points
The arch above the furnace door: Why it fails first
PDFHeat Treatment

The arch above the furnace door: Why it fails first

Thermal cycling, charging impacts and a geometry with no reserve.

Only in the PDFInspection points on the arch, reading the joint pattern, regular 5-minute visual check
Refractory damage emergency: The first 24 hours
PDFAll furnace types

Refractory damage emergency: The first 24 hours

Whether damage costs 3 days or 3 weeks is decided by the first phone call.

Only in the PDFChecklist for the first call, parallel workflow instead of sequential steps
Dosing furnace: Different rules from the melting furnace
PDFAluminium & Non-Ferrous Metals

Dosing furnace: Different rules from the melting furnace

It does not melt — it doses. And must not alter the metal.

Only in the PDFThe 6 dosing-furnace particularities, dosing weight as an early indicator
Slagging: The surface determines the interval
PDFEnergy & Combustion

Slagging: The surface determines the interval

Clean every four weeks — or twice per season?

Only in the PDFLevers against build-up, fuel alkalis, cleaning rules
To the article
Relining under time pressure: The sequence that holds
PDFAluminium & Non-Ferrous Metals

Relining under time pressure: The sequence that holds

The difference between 10 days and 3 weeks is decided before day one.

Only in the PDFOn-schedule workflow plan, interlocking of trades, drying in the schedule
Expansion joints: The most inconspicuous cause of damage
PDFAll furnace types

Expansion joints: The most inconspicuous cause of damage

Ten metres of wall grow by centimetres — that has to go somewhere.

Only in the PDFThe 5 rules of the expansion joint, placement, upkeep in the inspection log
Component repair: Repairing instead of remanufacturing
PDFAluminium & Non-Ferrous Metals

Component repair: Repairing instead of remanufacturing

Hoods, lids and launders: Often only the lining is at the end of its life.

Only in the PDFDecision path repair vs. new, exchange-component strategy
The 50 per cent requirement: The furnace in reinvestment planning
PDFEnergy & Cross-Sector

The 50 per cent requirement: The furnace in reinvestment planning

Half of the relief must be reinvested — the furnace belongs on the list.

Only in the PDFElectric vs. gas-fired, orders of magnitude, documentation of evidence
To the article
Running heat-up curves correctly
PDFAll furnace types

Running heat-up curves correctly

Why the first days decide over years of service life.

Only in the PDFExample curves for ramming mix, castable and brick lining with hold points and ramp rates
To the article
Reading crack patterns: The comparison chart
PDFAll furnace types

Reading crack patterns: The comparison chart

Symptom, cause and required action side by side.

Only in the PDFSix damage patterns from real furnace inspections with classification: observe, plan or act immediately
To the article
Application area Aluminium & Non-Ferrous Metals
PDFAluminium & Non-Ferrous Metals

Application area Aluminium & Non-Ferrous Metals

Melting, holding and dosing furnaces: zones, material selection, typical damage.

Only in the PDFChecklist with 10 points, typical mistakes, practical guidance, 2 photos
Application area Steel & Foundry
PDFSteel & Foundry

Application area Steel & Foundry

Ladles, EAF, cupola furnace: what the lining has to deliver there.

Only in the PDFChecklist with 10 points, typical mistakes, practical guidance, 2 photos
Application area Heat Treatment & Forging
PDFHeat Treatment

Application area Heat Treatment & Forging

Chamber, bell and pusher furnaces: all-fibre linings and seals.

Only in the PDFChecklist with 10 points, typical mistakes, practical guidance, 2 photos
Application area Glass
PDFGlass

Application area Glass

Feeders, lehrs, regenerator chambers.

Only in the PDFChecklist with 9 points, typical mistakes, practical guidance, 2 photos
Application area Ceramics & Bricks
PDFCeramics & Bricks

Application area Ceramics & Bricks

Tunnel kilns, kiln cars, dryer zones.

Only in the PDFChecklist with 9 points, typical mistakes, practical guidance, 2 photos
Application area Petrochemicals & Reformers
PDFPetrochemicals

Application area Petrochemicals & Reformers

Steam reformers, cracking furnaces, hot-gas ducts.

Only in the PDFChecklist with 10 points, typical mistakes, practical guidance, 2 photos
Application area Energy & Combustion
PDFEnergy & Combustion

Application area Energy & Combustion

Biomass, waste incineration, boiler plants.

Only in the PDFChecklist with 10 points, typical mistakes, practical guidance, 2 photos
Application area Battery Storage
PDFBattery Storage

Application area Battery Storage

BESS containers: compartmentalisation and fibre-free parts lists.

Only in the PDFChecklist with 10 points, typical mistakes, practical guidance, 2 photos
Turnaround in summer: plan it in good time
PDFEnergy & Combustion

Turnaround in summer: plan it in good time

Why the summer half of the year is the most economical turnaround window.

Only in the PDFNine points that have to be settled before the turnaround date — from thermography to sign-off
Guides

Demolition & defence guides — complete as PDF

The detailed guides from our industrial demolition and defence industry areas — print-ready with all tables, checklists and FAQ.

Thermal compartmentalisation in battery storage systems: Refractory materials against thermal runaway
PDFBattery Storage

Thermal compartmentalisation in battery storage systems: Refractory materials against thermal runaway

How planners and operators of battery energy storage systems limit thermal propagation between cell, module, rack and container — regulations, materials, installation and testing.

Only in the PDFThe complete guide (18 min.) as a print-ready PDF with standards table and FAQ
Read online
Planning a plant closure properly — The complete guide
PDFDismantling

Planning a plant closure properly — The complete guide

Planning a plant closure: legal foundations, scheduling, dismantling phases and documentation. Practical guide for operators and project managers.

Only in the PDFThe complete guide (15 min.) as a print-ready PDF with all tables and FAQ
Read online
Permits and regulations for industrial dismantling
PDFDismantling

Permits and regulations for industrial dismantling

All permits and regulations for industrial dismantling: BImSchG (German Federal Immission Control Act), GefStoffV (Hazardous Substances Ordinance), KrWG (Circular Economy Act), building code and occupational safety at a glance.

Only in the PDFThe complete guide (12 min.) as a print-ready PDF with all tables and FAQ
Read online
What does industrial dismantling cost?
PDFDismantling

What does industrial dismantling cost?

Cost factors in industrial dismantling: hazardous-material remediation, disposal, demolition and savings potential. Realistic cost ranges for planning.

Only in the PDFThe complete guide (10 min.) as a print-ready PDF with all tables and FAQ
Read online
Structural change in German industry — Market analysis
PDFDismantling

Structural change in German industry — Market analysis

Analysis of structural change in German industry: affected sectors, causes, effects and opportunities for brownfield development.

Only in the PDFThe complete guide (8 min.) as a print-ready PDF with all tables and FAQ
Read online
Industrial dismantling checklist — Step by step
PDFDismantling

Industrial dismantling checklist — Step by step

Industrial dismantling checklist: 12 steps from the decision to the handover of the construction-ready site. Available for download as a PDF.

Only in the PDFThe complete guide (5 min.) as a print-ready PDF with all tables and FAQ
Read online
Circular economy in industrial dismantling
PDFDismantling

Circular economy in industrial dismantling

Circular economy in dismantling: 10 steps to maximum recovery rates. AVV classification (German Waste Catalogue Ordinance), waste hierarchy and documentation.

Only in the PDFThe complete guide (6 min.) as a print-ready PDF with all tables and FAQ
Read online
Industrial dismantling in insolvency proceedings
PDFDismantling

Industrial dismantling in insolvency proceedings

Industrial dismantling in insolvency: liability, time pressure and realisation of the estate. Practical guide for insolvency administrators and trustees.

Only in the PDFThe complete guide (7 min.) as a print-ready PDF with all tables and FAQ
Read online
Site clearance for brownfield investors
PDFDismantling

Site clearance for brownfield investors

Site clearance for investors: due diligence, contamination risk, dismantling planning and construction-ready handover. Guide for brownfield projects.

Only in the PDFThe complete guide (7 min.) as a print-ready PDF with all tables and FAQ
Read online
High-temperature processes in the defence industry
PDFDefence

High-temperature processes in the defence industry

Why refractory technology is indispensable in the defence industry: metallurgy, thermal protection and energy systems in the defence context.

Only in the PDFThe complete guide (12 min.) as a print-ready PDF with all tables and FAQ
Read online
Certifications for defence suppliers
PDFDefence

Certifications for defence suppliers

ISO 9001, AQAP, security clearance and export control: which certifications and approvals suppliers to the defence industry require.

Only in the PDFThe complete guide (10 min.) as a print-ready PDF with all tables and FAQ
Read online
Becoming a supplier to the defence industry
PDFDefence

Becoming a supplier to the defence industry

Market entry as a tier-2/tier-3 supplier to the defence industry: requirements, qualification routes, timeframes and practical recommendations.

Only in the PDFThe complete guide (14 min.) as a print-ready PDF with all tables and FAQ
Read online
Dual use: When civilian technology becomes security-critical
PDFDefence

Dual use: When civilian technology becomes security-critical

Dual-use regulation for industrial companies: classification, licensing requirements, examples from the high-temperature sector and compliance requirements.

Only in the PDFThe complete guide (8 min.) as a print-ready PDF with all tables and FAQ
Read online
Strengthening the industrial base: Opportunities for German SMEs
PDFDefence

Strengthening the industrial base: Opportunities for German SMEs

Analysis of the German defence industry landscape: how small and medium-sized enterprises can benefit from the strengthening of the industrial base.

Only in the PDFThe complete guide (10 min.) as a print-ready PDF with all tables and FAQ
Read online
Resilient supply chains in the defence industry
PDFDefence

Resilient supply chains in the defence industry

Forward manufacturing, decentralisation and supply chain resilience: why the defence industry is rethinking its supplier structures.

Only in the PDFThe complete guide (9 min.) as a print-ready PDF with all tables and FAQ
Read online
For defence contractors: Refractory expertise as a supplier
PDFDefence

For defence contractors: Refractory expertise as a supplier

Why defence contractors should rely on specialised refractory suppliers: technical expertise, certifications and added value for the value chain.

Only in the PDFThe complete guide (7 min.) as a print-ready PDF with all tables and FAQ
Read online
For research institutes: Joint development of high-temperature solutions
PDFDefence

For research institutes: Joint development of high-temperature solutions

Cooperation models for research institutes: joint development of high-temperature solutions for defence applications with industrial implementation expertise.

Only in the PDFThe complete guide (7 min.) as a print-ready PDF with all tables and FAQ
Read online
Reading a UL 9540A Report Properly: Which Values Matter for Thermal Barrier Design
PDFBattery Storage

Reading a UL 9540A Report Properly: Which Values Matter for Thermal Barrier Design

UL 9540A reports provide the data basis for compartmentation design in battery energy storage systems. This guide shows which parameters from cell, module and unit level testing belong in the design process.

Only in the PDFThe complete guide (8 min.) as a print-ready PDF with FAQ
Read online
NFPA 855 and Separation Distances: What Siting Design Means for Fire Compartments
PDFBattery Storage

NFPA 855 and Separation Distances: What Siting Design Means for Fire Compartments

Separation distances, energy limits per fire compartment, fire resistance: what NFPA 855 specifies for siting — and how its logic can be transferred to German fire protection concepts.

Only in the PDFThe complete guide (7 min.) as a print-ready PDF with FAQ
Read online
LFP, NMC and Sodium-Ion from a Fire Protection Perspective: What Cell Chemistry Means for the Barrier
PDFBattery Storage

LFP, NMC and Sodium-Ion from a Fire Protection Perspective: What Cell Chemistry Means for the Barrier

Onset temperature, gas quantity, heat release: cell chemistry determines whether the compartmentation of a battery energy storage system must be designed primarily against heat or against gas.

Only in the PDFThe complete guide (7 min.) as a print-ready PDF with FAQ
Read online
Gas Venting and Deflagration Protection: NFPA 68/69 and the Consequences for the Lining
PDFBattery Storage

Gas Venting and Deflagration Protection: NFPA 68/69 and the Consequences for the Lining

With battery energy storage systems, the explosion is often more dangerous than the fire. What NFPA 68 and 69 require for explosion venting and ventilation — and what that means for the lining.

Only in the PDFThe complete guide (8 min.) as a print-ready PDF with FAQ
Read online
Barriers at Cell and Module Level: Fibre Paper, Microporous Laminates and Aerogel Compared
PDFBattery Storage

Barriers at Cell and Module Level: Fibre Paper, Microporous Laminates and Aerogel Compared

Which barrier material prevents propagation between cells and modules most reliably? Fibre paper, microporous laminates and aerogel composites compared.

Only in the PDFThe complete guide (8 min.) as a print-ready PDF with FAQ
Read online
Container Lining in Execution: Fixings, Joints, Penetrations
PDFBattery Storage

Container Lining in Execution: Fixings, Joints, Penetrations

A container lining is only as good as its workmanship. What matters with fixings, joint detailing and cable penetrations in battery storage containers.

Only in the PDFThe complete guide (8 min.) as a print-ready PDF with FAQ
Read online
Retrofitting Existing Assets: Thermal Compartmentation of In-Service Storage Containers
PDFBattery Storage

Retrofitting Existing Assets: Thermal Compartmentation of In-Service Storage Containers

Many first-generation battery energy storage systems no longer meet today's safety expectations. How existing containers can be upgraded with compartmentation and explosion venting.

Only in the PDFThe complete guide (8 min.) as a print-ready PDF with FAQ
Read online
VdS 3103 and Property Insurers' Expectations: The Evidence That Secures Insurance Cover
PDFBattery Storage

VdS 3103 and Property Insurers' Expectations: The Evidence That Secures Insurance Cover

What the VdS 3103 guidance sheet means for battery energy storage systems and which evidence designers and operators should provide so that insurance cover holds in the event of a loss.

Only in the PDFThe complete guide (8 min.) as a print-ready PDF with FAQ
Read online
Maintaining and Inspecting Thermal Barriers in Operation: Intervals, Checkpoints, Documentation
PDFBattery Storage

Maintaining and Inspecting Thermal Barriers in Operation: Intervals, Checkpoints, Documentation

Thermal barriers only protect as long as they remain intact. This guide shows proven inspection intervals, inspection points and robust documentation for authorities and insurers.

Only in the PDFThe complete guide (7 min.) as a print-ready PDF with FAQ
Read online
Permitting and Building Law for Battery Storage in Germany: Where Fire Protection Enters the Procedure
PDFBattery Storage

Permitting and Building Law for Battery Storage in Germany: Where Fire Protection Enters the Procedure

Battery energy storage systems are mostly approved as unregulated special structures. This article puts planning law and building regulations into context and shows where the fire protection verification is decisive in the procedure.

Only in the PDFThe complete guide (8 min.) as a print-ready PDF with FAQ
Read online
Acceptance of the thermal barrier in a battery energy storage system — 12 inspection points
PDFBattery Storage

Acceptance of the thermal barrier in a battery energy storage system — 12 inspection points

Twelve inspection points for the acceptance walkdown after installation of the thermal barrier: barrier layers, joints, penetrations, fixings and documentation.

Only in the PDFThe complete checklist (6 min.) as a print-ready PDF
Read online
Fire protection in a new-build BESS: planning checklist from concept design to tender
PDFBattery Storage

Fire protection in a new-build BESS: planning checklist from concept design to tender

The fire protection decisions for a new BESS in twelve steps — from site selection and cell chemistry through to a tender-ready performance specification.

Only in the PDFThe complete checklist (6 min.) as a print-ready PDF
Read online
Annual fire protection inspection in a battery energy storage system — 10 inspection points for existing plant
PDFBattery Storage

Annual fire protection inspection in a battery energy storage system — 10 inspection points for existing plant

The annual inspection of passive fire protection in an existing storage system: ten inspection points on barriers, penetration seals and documentation — and how to record findings.

Only in the PDFThe complete checklist (6 min.) as a print-ready PDF
Read online
Battery storage for project developers and EPC contractors: anchor fire protection early instead of retrofitting at a premium
PDFBattery Storage

Battery storage for project developers and EPC contractors: anchor fire protection early instead of retrofitting at a premium

How project developers and EPC companies define the passive fire protection of a large-scale storage system as early as the preliminary design stage — from the UL 9540A report to a thermal barrier that will pass permitting.

Only in the PDFThe complete article (7 min.) as a print-ready PDF
Read online
Battery storage for operators and asset managers: fire protection in ongoing operation
PDFBattery Storage

Battery storage for operators and asset managers: fire protection in ongoing operation

Passive fire protection does not end at acceptance. How operators and asset managers keep the condition of the barrier demonstrable over the service life and control third-party interventions.

Only in the PDFThe complete article (7 min.) as a print-ready PDF
Read online
Battery storage for insurers and expert assessors: what makes a storage system insurable
PDFBattery Storage

Battery storage for insurers and expert assessors: what makes a storage system insurable

What property insurers and expert assessors look for in large-scale storage systems, and the part the structural thermal barrier plays in the maximum loss — with reference to VdS 3103 and UL 9540A.

Only in the PDFThe complete article (7 min.) as a print-ready PDF
Read online
Battery storage in industrial plants: self-consumption, peak shaving and the fire protection consequences in an existing building
PDFBattery Storage

Battery storage in industrial plants: self-consumption, peak shaving and the fire protection consequences in an existing building

A commercial storage system pays for itself through self-consumption and peak shaving, but in an existing building it changes the fire protection situation. What has to be settled for siting and permitting.

Only in the PDFThe complete article (7 min.) as a print-ready PDF
Read online
The battery storage market in the DACH region: new-build capacity, drivers and bottlenecks
PDFBattery Storage

The battery storage market in the DACH region: new-build capacity, drivers and bottlenecks

New-build capacity is shifting from home storage to utility-scale storage. This analysis places installation figures, the grid connection pipeline and permitting practice in the DACH region in context — with consequences for thermal barriers.

Only in the PDFThe complete market analysis (8 min.) as a print-ready PDF
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Regulation in flux: what NFPA 855, UL 9540A and the EU Battery Regulation mean for storage projects
PDFBattery Storage

Regulation in flux: what NFPA 855, UL 9540A and the EU Battery Regulation mean for storage projects

NFPA 855 (2026 edition), the sixth edition of UL 9540A and the EU Battery Regulation are shifting the burden of proof from the cell to the installation. This analysis places the deadlines in context.

Only in the PDFThe complete regulatory outlook (8 min.) as a print-ready PDF with sources
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Fire incidents in battery storage: what the loss record shows
PDFBattery Storage

Fire incidents in battery storage: what the loss record shows

The failure rate of utility-scale storage has fallen sharply since 2018, but the causes often do not lie in the cell. This analysis evaluates documented incidents — with consequences for thermal barriers.

Only in the PDFThe complete incident review (8 min.) as a print-ready PDF with sources
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