SBS Refractory Service

References

Over 500 successfully completed projects across the entire industrial furnace sector. Here we present a selection of project examples.

500+
Projects completed
9
Industrial sectors
40+
Furnace types serviced
35+
Years of experience

Selected projects

Zone-Correct Relining of a Biomass Combustion Chamber
Energy & CombustionRelining

Zone-Correct Relining of a Biomass Combustion Chamber

Relining of the combustion chamber of a biomass CHP plant with a moving grate: brickwork above the grate, monolithic lining above it, a stepped interlocking transition and secondary-air nozzles restored to the millimetre.

Scope of services:

  • Survey of findings and measurement of the nozzle positions
  • Demolition of the worn lining
  • Brickwork above the grate, monolithic lining above it
  • Stepped interlocking transition, expansion joints packed with ceramic fibre
  • +1 more
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Charging chute lined monolithically – second assignment for a long-standing customer
AluminiumRepair

Charging chute lined monolithically – second assignment for a long-standing customer

Follow-up assignment for a long-standing customer: the charging chute was completely relined monolithically – joint-free right into the arch zone.

Scope of services:

  • Strip-out of the knocked-out old lining
  • Formwork construction for chute and arch zone
  • Monolithic lining in a single operation
  • Controlled curing and stripping
  • +1 more
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Precision work on a divider wall
Energy & incinerationComplete relining

Precision work on a divider wall

Monolithic lining of a divider wall in the combustion chamber – a narrow, elongated component where every dimensional deviation changes the flow pattern.

Scope of services:

  • Measurement and formwork construction matched to the component geometry
  • Monolithic lining of both faces
  • Controlled compaction over the entire length
  • Stripping and checking of dimensional accuracy
  • +1 more
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Insulation optimisation on a chamber furnace
AluminiumInsulation

Insulation optimisation on a chamber furnace

Retrofitted external insulation on a chamber furnace – less heat loss through the furnace wall, more stable temperature control inside.

Scope of services:

  • Survey of the existing insulation situation and surface temperatures
  • Removal of the settled old insulation
  • Multi-layer rebuild with staggered joints
  • Separate enclosure of edges, connections and door guides
  • +1 more
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Complete relining at an energy provider's waste-to-energy plant
Energy & incinerationComplete relining

Complete relining at an energy provider's waste-to-energy plant

Refractory relining in the waste-to-energy plant of a major energy provider near Nuremberg – brickwork of the combustion chamber within the scheduled overhaul window.

Scope of services:

  • Assignment and sequence planning before the shutdown began
  • Demolition of the worn existing lining
  • Scaffolding and section-by-section brickwork of the combustion chamber
  • Removal and proper disposal of the demolition material
  • +1 more
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One year without maintenance – and what it cost
FoundriesMaintenance

One year without maintenance – and what it cost

An aluminium furnace went a year without maintenance. The result: heavy slag build-up, reduced charge capacity and a repair bill of over 100,000 euros.

Scope of services:

  • Cold cleaning and complete removal of the slag build-up
  • Condition survey of the exposed lining
  • Repair of the areas no longer load-bearing
  • Care spraying as a protective layer against renewed build-up
  • +1 more
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Hood lining on an aluminium melting furnace
AluminiumRepair

Hood lining on an aluminium melting furnace

Complete refractory lining of the furnace hood on an aluminium melting furnace – executed monolithically for dense, dimensionally stable surfaces.

Scope of services:

  • Demolition of the old hood lining
  • Monolithic relining
  • Integration of the burner and extraction openings
  • Controlled dry-out
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Complete relining of an aluminium melting furnace with a monolithic door frame
AluminiumRepair

Complete relining of an aluminium melting furnace with a monolithic door frame

Complete refractory relining of an aluminium melting furnace – from the extensively broken-out lining through to the seamlessly cast door frame in the most heavily loaded zone.

Scope of services:

  • Demolition of the damaged frame area
  • Clean cut line to the existing brickwork
  • Monolithic relining by casting
  • Controlled dry-out
  • +1 more
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Maintenance gunning and shotcrete on a melting furnace
AluminiumWear protection

Maintenance gunning and shotcrete on a melting furnace

Professional maintenance gunning with a 5–7 cm protective layer to extend service life – prevents slag build-up and sustainably increases aluminium yield.

Scope of services:

  • Inspection and preparation of the existing lining
  • Professional maintenance gunning using the dry gunning process
  • Even application of a 5–7 cm protective layer
  • Quality control of the applied layer
  • +1 more
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Demolition work on a cupola furnace near Tuttlingen
FoundriesComplete relining

Demolition work on a cupola furnace near Tuttlingen

Professional demolition of the old lining of a cupola furnace near Tuttlingen – safe, on schedule and with the right equipment for confined conditions.

Scope of services:

  • Deployment planning and safety preparation
  • Complete demolition of the old lining
  • Removal and proper disposal of the demolition material
  • Inspection and cleaning of the furnace structure
  • +1 more
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Complete relining of an aluminium melting furnace
AluminiumComplete relining

Complete relining of an aluminium melting furnace

From the bare steel shell to an operational plant: floor, walls, ramp, formwork construction and casting in four documented construction phases.

Scope of services:

  • Demolition of the old lining and cleaning of the steel shell
  • Inspection and supplementation of the anchoring system
  • Floor build-up: insulating layer and brick-laid wear lining
  • Wall lining with insulating boards and insulating firebricks
  • +4 more
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Repair of a chip melting furnace in Hallenberg
AluminiumRepair

Repair of a chip melting furnace in Hallenberg

Comprehensive overhaul of a chip melting furnace – from cleaning and optimisation of the stirring mechanism through to professional maintenance gunning for an extended service life.

Scope of services:

  • Thorough furnace cleaning and removal of deposits
  • Survey and damage assessment of the lining
  • Targeted repair of worn lining areas
  • Inspection and optimisation of the stirring mechanism
  • +2 more
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Complete overhaul of an aluminium furnace
AluminiumRepair

Complete overhaul of an aluminium furnace

Comprehensive modernisation of an aluminium furnace following a leak at the door frame – with a 30 % increase in capacity and 23 % lower energy consumption per tonne.

Scope of services:

  • Systematic damage analysis extending beyond the local defect
  • Overhaul of the door frame with new seals
  • Renewal of the refractory lining in critical areas
  • Revision of the thermal insulation and control systems
  • +1 more
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Combustion chamber refurbishment in a biomass power plant
Energy & incinerationRepair

Combustion chamber refurbishment in a biomass power plant

Fundamental overhaul of the combustion chamber of a biomass power plant – including renewal of the side brickwork, new expansion joints and thorough cleaning for optimised efficiency.

Scope of services:

  • Damage analysis and refurbishment planning
  • Complete renewal of the side brickwork
  • Professional re-execution of the expansion joints with fibre blankets
  • Thorough cleaning of the combustion chamber
  • +1 more
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Aluminium melting furnace back in operation after relining
AluminiumComplete relining

Aluminium melting furnace back in operation after relining

Refractory lining of a converter melting furnace in secondary aluminium by our own installation teams – the even glow pattern in operation proves the quality of the workmanship.

Scope of services:

  • Refractory lining of the melting chamber
  • Zone-specific material selection for hearth, walls, arch and burner area
  • Non-wetting mixes in the bath line
  • Controlled first heat-up with holding stages
  • +1 more
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Charging chamber of an aluminium melting furnace renewed
AluminiumMaintenance

Charging chamber of an aluminium melting furnace renewed

Complete renewal of the charging chamber with measurable results: 30 % lower energy costs and up to 2 tonnes of additional melting capacity per day.

Scope of services:

  • Damage analysis and survey of the charging chamber
  • Complete dismantling of the worn lining
  • Rebuild with matched refractory materials
  • Optimisation of the thermal insulation
  • +1 more
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Overhauling a furnace hood instead of building a new one
AluminiumFurnace components

Overhauling a furnace hood instead of building a new one

Worn hood of an aluminium melting furnace: the steel structure was retained and only the refractory lining selectively renewed – at a fraction of the cost of a new hood.

Scope of services:

  • Survey of cracks, voids and anchoring
  • Selective demolition of the damaged zones
  • Complete renewal of the anchoring
  • New refractory lining
  • +1 more
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Mechanical demolition of an old lining
AluminiumComplete relining

Mechanical demolition of an old lining

Efficient mechanical demolition of an old lining with an excavator – precise, safe and with minimal impact on the surrounding structures.

Scope of services:

  • Deployment planning and safety preparation for the mechanical demolition
  • Controlled, layer-by-layer demolition of the old lining with an excavator
  • Continuous removal and proper disposal of the demolition material
  • Inspection and cleaning of the steel shell after demolition
  • +2 more
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Lid and door repair for a long-standing customer
AluminiumRepair

Lid and door repair for a long-standing customer

Maintenance work on a lid and door in the storage area of a long-standing customer – carried out quickly, professionally and with the utmost care.

Scope of services:

  • On-site survey of both components
  • Repair of the refractory lining on the furnace lid
  • Overhaul of the door lining and sealing faces
  • Checking the correct seating and closure of the door
  • +2 more
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Relining of a chip melting furnace in aluminium recycling
AluminiumComplete relining

Relining of a chip melting furnace in aluminium recycling

Complete relining of a chip melting furnace at an aluminium wheel manufacturer – from dismantling the old lining through to handover.

Scope of services:

  • Dismantling of the old lining
  • Corundum-repellent special mixes in the melting area
  • Zone-specific design of hearth, melting bridge, charging shaft and door
  • Monolithic, low-joint surface
  • +2 more
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Melting chamber overhaul in Austria
AluminiumRepair

Melting chamber overhaul in Austria

Targeted overhaul of a melting chamber in Austria – side walls partially repaired and floor restored using a pour-on process.

Scope of services:

  • On-site condition assessment of the damaged areas
  • Partial repair of the side walls to restore the chamber structure
  • Pour-on process on the floor to restore the target level
  • Quality control and function test
  • +1 more
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Secondary aluminium in Upper Bavaria: linings and overhauls over several years
AluminiumComplete relining

Secondary aluminium in Upper Bavaria: linings and overhauls over several years

At a secondary aluminium site in Upper Bavaria we have been responsible for the refractory linings and overhauls of the melting and crucible furnaces for several years – complemented by cold cleaning of the transport ladles.

Scope of services:

  • Refractory lining of the melting and crucible furnaces
  • Recurring overhauls within the shutdown window
  • Non-wetting mixes in the bath and melting line
  • Controlled heat-up with holding stages
  • +1 more
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Furnace lid repair with fibre modules
AluminiumInsulation

Furnace lid repair with fibre modules

Repair of an industrial furnace lid with ceramic fibre modules – fast installation, excellent insulation values and a significantly extended service life.

Scope of services:

  • Condition assessment of the existing lid lining
  • Complete dismantling of the degraded old lining
  • Inspection and renewal of the anchoring system
  • Installation of the ceramic fibre modules using the plug-in system
  • +2 more
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Furnace maintenance at a light-alloy wheel forging plant
AluminiumMaintenance

Furnace maintenance at a light-alloy wheel forging plant

Partial repair of a chip melting furnace and two ingot furnaces at a renowned light-alloy wheel forging plant in Medebach – downtime minimised, plants optimally prepared.

Scope of services:

  • Thorough cleaning of all three industrial furnaces
  • Detailed inspection and determination of the repair requirements
  • Partial repair of the chip melting furnace (floor, melting bridge, beams)
  • Partial repairs on two ingot furnaces
  • +2 more
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International assignment in the Czech Republic
AluminiumRepair

International assignment in the Czech Republic

Partial repairs to a melting furnace and a dosing furnace at a customer in the Czech Republic – SBS Refractory Service demonstrates its international capability with its usual quality.

Scope of services:

  • Logistics planning and material preparation for the assignment abroad
  • On-site condition assessment of both furnaces
  • Targeted partial repair of the melting furnace with refractory material
  • Partial repair and renewal of the wear zones on the dosing furnace
  • +2 more
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Maintenance of an 18 MW wood combustion plant
Energy & incinerationMaintenance

Maintenance of an 18 MW wood combustion plant

Extensive preventive maintenance of an 18 MW wood combustion plant – furnace cleaning, renewal of arch rings and maintenance gunning for maximum operational reliability.

Scope of services:

  • Thorough cleaning of the entire furnace and gas duct
  • Inspection and condition assessment of all refractory-lined areas
  • Renewal of 6–8 worn sections of the lining
  • Replacement of 12 rings on the intermediate arch
  • +2 more
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Maintenance uncovers a loss of capacity
AluminiumMaintenance

Maintenance uncovers a loss of capacity

Professional maintenance of an aluminium furnace uncovers faulty repairs by a previous contractor – after correction, around 20 tonnes more aluminium per month and noticeably reduced energy consumption.

Scope of services:

  • Comprehensive inspection and damage analysis of the furnace interior
  • Identification of the faulty previous repairs as the cause
  • Proper removal of all deposits and layer build-up
  • Correct repair of the wear areas with a single-layer gunning coat
  • +2 more
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Combustion chamber refurbishment in a biomass power plant
Energy & incinerationComplete relining

Combustion chamber refurbishment in a biomass power plant

Fundamental overhaul of the combustion chamber of a biomass power plant – side brickwork renewed, expansion joints integrated and thermal efficiency sustainably improved.

Scope of services:

  • Complete renewal of the side brickwork
  • Professional integration of new expansion joints
  • Packing and resetting of the fibre blankets
  • Thorough cleaning of the combustion chamber and removal of deposits
  • +2 more
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Comprehensive partial repair in combustion plant construction
AluminiumRepair

Comprehensive partial repair in combustion plant construction

Targeted partial repair on the aluminium melting furnace of a long-standing customer – systematically overhauled from the charging shaft and melting chamber through to the burner wall.

Scope of services:

  • Thorough cleaning and removal of slag, dross and residual aluminium
  • Partial dismantling and restoration of the charging shaft with new insulation
  • Dismantling and rebuilding of the door frame, door beam and load-bearing pillars
  • Structural reinforcement of the side wall with a concrete shell
  • +2 more
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Emergency repair of an aluminium furnace
AluminiumRepair

Emergency repair of an aluminium furnace

Reported on Thursday, repaired on Friday – emergency repair of the overheated rear wall of an aluminium furnace with minimal downtime.

Scope of services:

  • Immediate mobilisation of the emergency team the same evening
  • On-site damage assessment and repair planning
  • Dismantling of the collapsed lining areas
  • Professional restoration with refractory material
  • +1 more
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Complete relining of an aluminium melting furnace
AluminiumComplete relining

Complete relining of an aluminium melting furnace

Complete core refurbishment and relining of an aluminium melting furnace – from careful planning and professional demolition through to brick lining and commissioning.

Scope of services:

  • Detailed survey and lining planning
  • Complete demolition of the old lining with proper disposal
  • Inspection and repair of the steel shell
  • Layer-by-layer build-up of the new refractory lining
  • +2 more
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Cross-industry experience

From the aluminium industry through steelworks to heat treatment – we have gained experience in every sector. This broad expertise benefits each individual project, because solutions from one industry can often be transferred to another.

AluminiumSteelFoundryHeat treatmentIncinerationBoilersSintering plantsForgingEnergy

Planning a project?

Whether complete relining, repair or emergency — free initial consultation and a fast response.

Send enquiry+49 89 541 960 200