Complete relining of an aluminium melting furnace with a monolithic door frame
From a broken-out lining to an operational furnace – complete relining including a monolithic door frame.
Initial situation
The aluminium melting furnace reached us with extensive damage to its lining: the refractory material around the charging opening and the frame broken out, the brickwork slagged, the lintel destroyed to the point where it would not have survived another furnace campaign. Instead of a partial repair, a complete relining was required. The door frame is the most demanding zone here: every charge brings a sudden drop in temperature, charging causes mechanical impacts, and molten aluminium finds its way through every joint.
Scope of services
- Demolition of the damaged frame area
- Clean cut line to the existing brickwork
- Monolithic relining by casting
- Controlled dry-out
- Heat-up and handover
Project data
The task
Highest number of load cycles in the entire furnace – every change of charge means a temperature drop
Mechanical impacts from charging hit precisely this zone
Molten aluminium infiltrates every joint and every crack
Corundum growth: if the melt reacts with silicate-bearing material, the growing corundum bursts the structure apart
The new casting has to connect crack-free to the remaining existing brickwork
The SBS approach
Monolithic casting instead of shaped bricks at the frame – no joints form in the hottest zone where molten aluminium could infiltrate
Non-wetting, infiltration-resistant castable: additives such as barium sulphate and fluorides (including AlF₃/CaF₂) prevent the melt from entering the pores
Low-silicate to silicate-free materials – free SiO₂ would react with aluminium to form corundum and burst the lining from within
High-alumina quality (around 80–85 % Al₂O₃) for the mechanically and chemically most heavily loaded frame zone
Defined cut line to the existing lining and thermal shock resistant material selection to withstand the load cycles of every charging operation
Controlled dry-out and heat-up – everything from a single source, with no interface between several trades
Complete relining of an aluminium melting furnace with a monolithic door frame in pictures
Before: lining broken out over a large area around the charging opening and frame
After: monolithically relined frame – seamless, with dimensionally accurate openings
Before: material broken out around the charging opening, slagged brickwork
After: monolithic relining – one pour, clean edges, no joints
Measurable results
The key figures of the “Complete relining of an aluminium melting furnace with a monolithic door frame” project
Similar references
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