Refractory Guidance – Informational Links

F.S. Sperry is a refractory contractor. Back in , we began sharing our thoughts and experiences via our blog and newsletter. We decided that it was time to catch up with many other industries who share information digitally.

Please visit our website for more information on this topic.

We also found that it was helpful to create articles that answer many of the questions we heard on a regular basis regarding materials, installation methods, equipment, cost, etc. This article is a summary of key links to refractory guidance that you might find useful (so you don’t have to sift through the individual blog posts). We’ve grouped these by category.

Feel free to bookmark this page for easy future access. We’ll continue adding links to new articles as we create them. Since many of our jobs are confidential, we can’t provide photos or descriptions, but we are able to talk about our capabilities one-on-one, so reach out to us if you have questions that you don’t see answered here.

Discussions About Refractory Materials

Here we talk about differences in materials and how the equipment and each situation affect the material selection.

• How To Choose the Best Refractory Material
• A High Tech Application of a Low Tech Refractory
• Mud is Mud …
• A Special Veneer Coating to Preserve Ladle Preheaters
• Top 5 Refractory Mistakes to Avoid
• Case Study: Foamfrax Veneer vs. Coating
• Case Study: Using No-Cement Castable Instead of Firebrick to Prevent Rapid Expansion in Rotary Kiln
• Case Study: Foamfrax RG Instead of a Low-Temperature Board System

Refractory Cost – Lowering and Comparing

Using inexpensive materials doesn’t always provide the lowest total job cost. Here we provide tips on how to keep your costs under control.

• 5 Tips to Reduce the Total Cost of Your Refractory Installation
• An Unusual Way to Get the Lowest Cost for Your Refractory Project
• Buying Refractories the Smart Way

Equipment – Boilers, Furnaces, RTOs and Kilns

Here are checklists for your equipment and case studies of work on specific types of heat processing equipment.

• An Alternative Refractory Hot-face Lining Reduces Electricity Consumption by 10%
• Choosing the Best Refractory Material for an Aluminum Furnace
• The Hidden Cost of Corundum Growth in Aluminum Furnaces
• Considerations for Keeping Your Wood-Fired Boiler Running Efficiently
• Case Study: A Quick Response for Our Customer’s Heat Recovery Regenerative Thermal Oxidizer (RTO)
• Preventative Maintenance Checklist for Your Refractory Linings
• Low and Slow – How to Get the Perfect Bakeout
• Repair or Replace? Our Recommendations for a 12-Year-Old Cyclone
• Rebuilding a Kiln for a Major Refractory Manufacturer

Refractory Installation Methods

Installation methods need to be properly matched to the materials, equipment, downtime and equipment access. Here’s a discussion of each.

• Proper Anchor Selection
• Expansion Joints for Installation of a Castable
• The Refractory Failed … Or Did It?
• If the Instructions Are Right on the Bag, Can Anyone Install Refractory?
• Situational Analysis: When Traditional Vibe-casting with Large Mixers Beats Pump Casting

General Refractory Guidance and Education

Here are articles about refractories in general and discussions about common misconceptions about refractories.

• Refractories are NOT a Commodity
• 5 Common Misconceptions About Refractories
• Interpreting a Refractory Technical Datasheet
• Refractory Technical Datasheets Don’t Tell the Whole Story
• Refractories Primer: 3 Things Every Plant Manager Should Know
• A Primer on the Basic Physical Properties of a Refractory Product
• There’s a Crack in My Refractory

Evaluating Refractory Contractors

Here are articles about evaluating refractory contractors and their bids for a project.

With competitive price and timely delivery, Mingte sincerely hope to be your supplier and partner.

• How to Avoid Getting Fooled When Evaluating Refractory Contractor Bids
• When Refractory Contractors Fail to Bid on Complete Project Requirements
• How to Choose a Refractory Contractor
• Double the Refractory Cost, Triple the Savings
• The “Taillight Guarantee”
• Deciding Between a Sole Proprietor or Full-Service Refractory Contractor

Examples of F.S. Sperry’s Work

Here are some case studies about our work.

Things to Remember When Using Castables and Advantages of Castable Refractories

Castable refractory products are non-metallic materials with physical and chemical properties that allow them to withstand high temperatures and retain their composition. Some of their common application is in furnaces, kilns and boilers.

In a high-temperature environment, specific products must withstand such a heavy temperature. That is precisely what castable refractory does.

There is no doubt about the vital role that refractory castable plays. But there are a couple of things one needs to remember while using this refractory material.

Things To Remember When Using Castable

• Castables must always be stored in a cool and dry area.
• One must ensure that the mixers and tools are free from old castable or any other material that can contaminate the product. Such contamination could affect the strength of the castable mix.
• Only drinking suitable water should be used to mix castable. The temperature of the mix should be optimal as well.
• Be careful while mixing castable, like castable refractory cement. Too much mixing generates heat and speeds up the setting time.
• The forms should be covered with oil or grease to prevent moisture loss.
• After placing the mix, the castable needs to be cured for 18 to 24 hours straight. Cover it with polyethylene sheets and spray it with cold water periodically. It will maintain the moisture of the mix and promote uniform curing at the applied area.

Advantages Of Castable Refractories

Castable refractories are an essential part of the manufacturing process. One can easily find a castable supplier online suited to their requirement. But what are the advantages of castable refractories that make them so popular? Let’s have a look at that.

Saves Time

The biggest industrial advantage that castable refractories offer is the time they save. Take the case of a furnace, for example. The castable refractory is made before its usage. Therefore, it significantly reduces the construction time of the furnace. Additionally, the castable refractory does not require extra baking time. That allows one to use their time efficiently. Castable refractories do a marvelous job in industries where timely production and delivery can be crucial.

Ease in usage

Castable refractories are pretty easy to use. But what is even better is how easily they can be cast in different shapes. Moreover, when treated and prepared, Castable refractories can meet harsh conditions without noticeable changes.

Significantly Better Structure Performance

Castables refractories are monolithic refractories, which is one of its biggest selling points. Once applied, the castable refractory can handle the harsh condition of the working environment for an extended period. Additionally, it also requires little to no maintenance throughout its life. That allows for overall sound structure performance and durability.

Choosing castable refractories for the insulation process is one of the most thoughtful decisions. Their advantages and wide application seal the deal.  But what is even more important is finding a reliable refractory material supplier. And for that, one could not find a better companion than Refmon Industries.

The company is the world’s best refractory boards(fr,ko,pt) supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.