Comprehensive partial repair in combustion plant construction
Melting furnace systematically overhauled in several areas
Initial situation
A long-standing customer required a targeted partial repair of the refractory lining. Several structural and thermally highly stressed areas of the aluminium melting furnace showed advanced wear that called for a comprehensive refurbishment. Slag deposits, dross residues and residual aluminium had accumulated over the operating period and were impairing both furnace performance and the service life of the lining.
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
- Levelling of the floor area and complete rebuilding of the burner wall
- Full-surface maintenance gunning with high-quality gunning mix
Project data
The task
Several damaged areas in different furnace zones required systematic prioritisation and processing
In the charging shaft, the insulation and the anchoring system were damaged over a large area and had to be completely renewed
The door frame of the melting chamber including the door beam and load-bearing pillars was structurally weakened
The burner wall required complete dismantling and rebuilding
The SBS approach
The work began with thorough preparation: slag, dross and residual aluminium were carefully removed in order to create optimum conditions for the repair and to assess the actual extent of the damage.
At the charging shaft, the damaged wall zones were partially dismantled and then professionally restored with complete renewal of the insulation and the anchoring system. In the melting chamber, the door frame with door beam and load-bearing pillars was dismantled and rebuilt. The right-hand side wall was given a load-bearing concrete shell for structural reinforcement, and the floor area was provided with a levelling concrete layer.
The burner wall was completely dismantled and professionally rebuilt. Finally, the entire furnace received full-surface maintenance gunning with high-quality gunning mix, ensuring additional durability and an extended service life.
Comprehensive partial repair in combustion plant construction in pictures
Systematic overhaul of the melting chamber – focus on the door frame and side walls
Restored side wall after the targeted overhaul
A clean base: the furnace after thorough preparation for the repair
Measurable results
The key figures of the “Comprehensive partial repair in combustion plant construction” project
Similar references
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