Understanding the Refractory Installation Process

Industries that operate at high temperatures require a refractory setup. Industrial equipment like kilns, boilers, and furnaces use heat to process metal, glass, petro-chem, grains, cement, and more. In many ways, refractory is the backbone of industry.

Supporting the critical refractory process are the best, most reliable refractory components. If equipment needs to work at high temperatures, it requires a durable, heat-resistant environment. Refractory installation is crucial to your operations as it safeguards the longevity and efficiency of your equipment.

What is Refractory Installation?

At RSI, we’re a leader in refractory industry solutions. We have years of experience assisting our clients with everything from planning to installation to continued maintenance. In this exacting industry, it’s crucial to work with a team of experts who understand the intricacies and safety needs of refractory installations. When you work with RSI, you can rest assured that we have the experience, knowledge, and equipment necessary for the job.

What is a refractory installation, and what does it entail? Installing refractory involves constructing heat-resistant surfaces and components within industrial processing equipment such as furnaces, reactors, boilers, kilns, dryers, and heat-treat equipment.

The process begins with an assessment of your operational requirements and the needs of your business. From there, we can help your team select the ideal refractory materials and components to optimize your business’s performance.

Industries Relying on Refractory Installation

What industries need refractory installation services? We service customers across many different sectors, companies large and small. Here are some of the operations and industrial applications that require refractory services:

• Aluminum and Secondary Metals: High-temperature processes are needed for metal melting, treatment, and holding.
• Forging and Heat-Treat Facilities: Thermal treatments require equipment with precise temperature control.
• Ethanol Production: Refractory lines boilers that generate the steam needed for the distillation process in the ethanol industry. They are also in the grain dryers, and pollution control equipment.
• Steel Manufacturing: Refractory is essential for maintaining the integrity of furnaces and other processing equipment.

Of course, those aren’t the only businesses that depend on reliable refractory applications. Many manufacturing operations, like cement, lime, petro-chem processors, and die casting facilities need durable refractory lining to keep up efficient operations and uphold safety standards.

Materials Used in Refractory Installation

At RSI, we’re well known for offering the top refractory components and materials. For industries like foundries, glass manufacturing, and cement production, refractory installation requires the ideal materials and components.

We’ll help you explore what you need for your refractory project or application. We’ll look at factors like temperature, physical wear, and the chemical environment that your refractory will need to withstand. Some of those crucial materials and components used in refractory installation include:

Bricks and Tiles

Fire bricks are made with clay and minerals that can withstand temperatures up to 3,000 degrees. These are mainly used in general industrial furnace construction and are often considered the gold standard. We also offer refractory bricks in specialty materials for different applications.

Cement Castables:

We carry refractory cement castables that can be mixed on-site and poured into forms. As a monolithic material, it can be used to form complex shapes and sizes.

Refractory Plastics:

Refractory plastics come ready to use. These workable components can be rammed into place to create a monolithic structure. Ideal for patching and refractory repair services, refractory plastics may also be used as a lining as well.

Ceramic Fiber:

Insulation materials are available in board, blanket, paper, rope, and module forms. Ceramic fibers reflect heat rather than absorb it, making them the best material for the linings of furnaces, kilns, and thermal oxidizers needing low thermal mass.

We also carry specialty sands, anchors, and other types of refractory materials you may require. Each component helps tailor the refractory installation to your application’s demands.

The Refractory Installation Process

What does the refractory installation process look like and entail? Well, typically, it all begins with a conversation. From there, we can help you with the planning and material selection. If you need site prep or the removal of old materials, we can help with that too.

While each refractory installation looks a little different, depending on the applications, equipment, and process, here are the basic steps to the process:

1. Initial Consultation and Assessment: You’ll contact RSI’s experts to walk you through our refractory construction services and the installation process. During the conversation, we’ll ask questions to help us thoroughly understand your operational parameters and needs. 
2. Material Selection: Every furnace is unique due to environmental and performance needs. We’ll explore the optimal refractory materials based on their thermal conductivity and mechanical strength, along with environmental factors that might impact your operation. This crucial step determines longevity and reduces downtime.
3. Site Preparation and Removal: Whether you’re installing in a new facility or relining and existing unit, we will help you prepare. Often you may need the removal of older materials and debris before a new installation.
4. Refractory Installation: Once the site is ready, we start setting up formwork or molds, installing anchoring systems, and placing the refractory materials. This installation process helps ensure that you have a durable, reliable refractory.
5. Curing and Heat-Treating: Many refractory materials require curing and heat-treatment. These crucial steps help to stabilize the material—setting your refractory up for optimal performance.
6. Quality Control and Documentation: Once your refractory is in place, a thorough inspection of the installation is conducted. This ensures that you get detailed documentation for the upkeep, maintenance, and safety compliance of your refractory.

Frequency and Timing of Refractory Installation

How long does a refractory installation take? How soon can RSI help?

Many factors go into the timeline of refractory installations. It often depends on the planned intensity of usage, operational conditions, maintenance abilities and practices, and more.

Major refractory installations are typically required every few years if regular maintenance and minor refractory repairs are performed in between.

In most cases, the RSI team will mobilize quickly, often beginning the process within hours of your initial contact. Most installations are complete within a few weeks. Repairs and components are available fast.

We know that when your refractory is down, operations drastically slow. We’ll help you avoid the cost and stress of unplanned downtime. The safety and output of your operation rely on refractory installations that last.

How RSI Can Assist with New Refractory Installations

We’re well known for our rapid response to customers and our comprehensive capabilities. We carry well-made, quality refractory products and can assist you with any refractory needs.

From our first consultation to the final quality control checks on your refractory installation, RSI provides:

• Turnkey Solutions: Full-service offerings, including installation and maintenance.
• Expert Team: Professional guidance from refractory engineers, contractors, and safety experts.
• Quality Materials: Access to top-tier, reliable refractory products and components.

When you’re working with high-temperature industrial operations, there’s no margin for error. It’s critical that you select the right partner for your refractory installation and components.

RSI has a long-standing commitment to excellence and customer support in our industry. Every refractory installation meets the highest performance and quality standards, whether we’re updating an existing installation or assisting with a new project.

To start your refractory installation or learn more about how RSI can help your industrial operations, reach out to our dedicated professional team. Ensure your refractory operations are built on a foundation that values quality, efficiency, and above all, safety.