THE CHALLENGE
We were tasked with coming up with a design to enable our customer to easily replace the floors outside their furnaces.
We needed to design a precast block flooring system for a melt shop where they repeatedly suffered damage from molten metal spillages, impact and general wear and tear to the areas around the furnaces.
Our customer was experiencing significant unplanned downtime to be able to effect the repairs required and this had a negative impact on their through processing capability.
Having worked with us for more than 30 years our customer could trust that our materials would withstand the test of time and that as a team we would come up with the right solution to suit their needs.
THE SOLUTION
To address our customer's issues with molten metal spillages, impact, and wear in the melt shop, we designed a custom precast block flooring system around the furnaces.
The system utilised abrasion resistant, high-strength precast refractory slabs that were manufactured off-site in controlled conditions, allowing us to optimise the material's quality and properties.
By removing moisture during the curing process, we minimised the risk of steam spalling, which could compromise the refractory's performance. Additionally, to make allowances for irregularly shaped areas material can be cast to the periphery in situ.
The slabs were designed for easy handling with embedded provisions for lifting, and we supplied appropriate lifting tools to ensure a smooth installation process.
This innovative approach not only reduced the need for onsite adjustments but also helped our customer streamline future maintenance efforts. The faster installation time and reduced risk of material degradation ensured that repairs could be completed efficiently, reducing overall downtime.
THE RESULT
Our customer has not had a single failure, they are so delighted with the results they are installing the same system across their melt shop
The installation of the precast block flooring system had an immediate positive impact on the customer's operations.
By significantly reducing the installation time, they were able to quickly resume normal operations with minimal disruption to their production schedule.
The precast slabs, dried under controlled conditions, eliminated the risk of steam spalling, which had previously led to failures due to permeability and porosity issues in the flooring.
Additionally, by casting any irregular shapes in situ, this achieved a seamless integration with the existing furnace areas, ensuring a durable and reliable solution.
Quality control during the precasting phase meant that all slabs met stringent specifications, ensuring optimal performance under extreme conditions.
With a focus on in-process control, we were able to guarantee consistent product quality, reducing the likelihood of premature failure.
The customer also benefited from the ease of future maintenance, as the system allowed for individual slabs to be replaced without significant downtime.
This solution reduced the need for emergency repairs, allowing the customer to plan maintenance schedules more effectively.
VALUE DELIVERED
A safer, easy and quick to repair solution which is long lasting and suited to the needs of the customers application
Our precast block flooring system delivered substantial value to the customer by addressing their critical operational challenges.
The shorter installation time directly translated into reduced downtime, which in turn improved their through-processing capability. This allowed them to avoid costly interruptions and maintain productivity, even in the face of unexpected events like molten metal spills.
Additionally, the ease of future maintenance meant that the customer could schedule planned outages for repairs, further minimising operational disruptions.
The superior quality of the precast slabs, dried to remove moisture and prevent steam spalling, ensured long-term durability.
The controlled manufacturing conditions provided consistent product quality and eliminated the risks associated with onsite material aging or delays in the construction schedule. By reducing the complexity of the installation and ensuring a seamless fit through both precast slabs and in situ casting, we delivered a robust, reliable solution that met the customer's needs.
WHAT OUR CLIENT SAID
Trent’s ability to offer up solutions to complex problems and deliver to promise is second to none. I have worked with many companies over the years and can honestly say that Trent has never failed to deliver and never let me or my associated companies down on delivery, service, or application.
George Dyer | Site Manager