SBS Refractory Service
AluminiumRepair

Emergency repair of an aluminium furnace

Reported on Thursday – repaired on Friday

Furnace type:Aluminium furnace, melting area
Damage pattern:Collapse of the rear wall lining
Response time:Under 12 hours
Repair duration:1 day
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Project overview

Initial situation

A customer got in touch on a Thursday evening with an urgent problem: the rear wall in the melting area of his aluminium furnace was overheating severely. The readings pointed to a collapse of the refractory lining inside – a condition that, had operation continued, would have led to considerable damage to the steel shell and a complete production stoppage. Fast action was called for.

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
  • Return to service and function test

Project data

Furnace typeAluminium furnace, melting area
Damage patternCollapse of the rear wall lining
Response timeUnder 12 hours
Repair duration1 day
Challenges

The task

The damage was reported late on Thursday evening – the response team had to be mobilised immediately

The overheating of the rear wall pointed to a partial collapse of the lining, the exact extent of which could only be assessed on site

Every hour of shutdown meant a direct loss of production for the customer

The repair had to be carried out under heightened safety requirements while the furnace was still warm

Our solution

The SBS approach

Our emergency team was mobilised that same evening and was already on site on Friday morning with the necessary equipment and material. A rapid damage assessment showed that a section of the rear wall lining in the melting area had collapsed and that the steel shell was directly exposed to the heat.

The damaged areas were specifically dismantled and professionally restored with suitable refractory material. Our team worked with focus and efficiency in order to complete the repair the same day.

Thanks to the fast response time and the well-practised working methods, the furnace was able to be started up again on Friday evening. Downtime was reduced to an absolute minimum.

Project impressions

Emergency repair of an aluminium furnace in pictures

Damaged rear wall of an aluminium furnace before the emergency repair by SBS Refractory Service
01

Initial situation: collapsed lining in the melting area with exposed brickwork

Professionally repaired furnace wall after the emergency overhaul
02

After the repair: rear wall restored and the furnace ready for service

Results

Measurable results

The key figures of the “Emergency repair of an aluminium furnace” project

<24 hrs
From the damage report to the return to service
Minimised
Production stoppage thanks to immediate mobilisation
Protected
Steel shell saved from further damage
Reliable
Durable repair with no rework
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