Precast Shapes

PRECAST REFRACTORY SHAPES

Superior Precast Refractory Shapes For Virtually Any Industry

At TFL, we’ve mastered all phases of the manufacturing process to ensure that we deliver the absolute best precast refractory shapes for your application. The successful design and manufacture of a high-performance refractory shape system requires a unique understanding of refractory materials, manufacturing processes, anchoring systems, and construction practice.

Using innovative molding techniques, we can create custom precast refractory shapes with extremely tight dimensional tolerances for a wide range of applications. Each shape system we produce is made of the highest quality pre-fired refractory materials.

We employ state of the art equipment which includes high-energy, large capacity mixers, variable-speed vibration tables, digitally-controlled water addition, mixing time controllers, digitally controlled furnaces for firing, and adequate lifting capabilities for large shapes.

Our refractory experts know exactly what is required to produce a reliable precast shape design that will improve your refractory lining performance. Take advantage of the benefits of precast solutions on your next project!

$Precast Refractory Shapes$

$Precast Refractory Shapes$

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Typical Precast Shape Applications

Custom Refractory Shapes
Burner Blocks
Pier Blocks
Manway Plugs
Wall Panels
Burner Pipe Covers
Curb Blocks

Hearth Shapes
Jambs, Lintel & Sills
Peep Sites
Flare Tips
Roof Sections
Spouts

Superior Precast Refractory Shapes

No matter the industry or type of furnace, precast shape technology can likely be applied. If you can dream it, we can build it!

Through our decades as a precast refractory shape manufacturer, we've adapted precast solutions to meet the needs of most refractory applications. We routinely produce durable precast refractory shapes for a wide range of industries.

Innovation remains a core focus for us at TFL and we've made it our business to integrate the latest refractory technologies and materials into our arsenal of services. Let us help you design a precast refractory shape system for your toughest project.

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Refractory Products

More About Precast Shape Technology

Precast shape manufacturing inherently requires the use of a mold or pattern to form the shape. There are several methods for mold-making which are routinely employed, and the type of mold construction and materials used depends on the size, complexity, and dimensional tolerances required in the shape, and sometimes the quantity of shapes required. For simplistic shapes with loose dimensional tolerances, plywood forms or metal fabricated forms can be used. Toward the other extreme, some shapes may require extremely tight tolerances, which require the use of a more sophisticated mold made from wood, plastic or metal. These molds may be of the type made by a foundry pattern maker or machine shop.

Another factor in the design of a precast shape has to do with the schedule and sequencing of the actual field installation. The shape design must take into account job accessibility, what other lining components will already be in place when the shapes are to be installed, and how the shape can be handled physically on the job site. Weight and lifting limitations must be considered and planned for, as well as the type of access available into the furnace or vessel. If necessary, lifting lugs or other fixtures can sometimes be incorporated into the shape design.

The design of the anchoring system to be used in the shape is of tremendous importance. In addition to the normal considerations of alloy type and anchor size, the precast shape design must also consider all alternatives for attaching the shape to the structure. Numerous methods can be used, including threaded stud attachments through the wall, welded fixtures, or bolted assemblies. Perhaps most importantly, the proper refractory material must be selected to suit the demands of the application. Factors such as the desired temperature profile through the lining, expected mechanical stresses, potential chemical attack on the lining, erosion mechanisms, and expansion allowance must all be understood prior to selecting a material to be used in the precast shape.

A well-equipped precast manufacturing facility should include high-energy, large capacity mixers, automated mixing stations with conveyors for material delivery, vibration tables, digitally-controlled water addition, mixing time controllers, and adequate lifting capabilities for large shapes. Firing of shapes is accomplished with a digitally-controlled furnace with burners capable of firing to at least 1300 deg. F. In-house mold/pattern fabrication capabilities and CAD-generated drawings for design assistance should also be expected

Benefits from Material Property Enhancement

Regardless of how complex or sophisticated the refractory castable is that is selected for an application, the physical properties of the material can be drastically reduced if care is not taken during the mixing, pouring, and curing processes. Particularly with the use of more complex refractory castables to solve specific wear issues, installation variables become even more critical to the performance of a lining. Unfortunately, lining quality is often compromised by field conditions during material placement. Project schedules, crew skill levels, equipment availability, job cost pressures, or other demands can sometimes have an impact on proper refractory installation. Improper water addition, mix time variations, over- or under-vibration, and improper curing can drastically affect material quality. With precast shapes, cast in a controlled shop environment, the physical properties of a castable will be more fully optimized.

Initial drying and firing of a refractory castable is a critical installation variable that can influence lining performance. Precast shapes are typically fired in a digitally-controlled furnace prior to shipment, ensuring that the refractory manufacturer’s recommended bake-out schedule is closely followed. Since the shapes are fired slowly from all sides, the moisture is removed through the entire thickness of the shape in a controlled manner. Depending on the temperature to which the shape is fired, this can optimize the physical properties of the material through the entire thickness of the shape, not just the hot face surface. This results in a truly homogeneous lining. Micro-cracking within the shape, which is often introduced during field bake-out but may go unnoticed, may also be reduced since the initial firing is more controlled.

In service, linings comprised of precast shapes often see less stresses and cracking, due to the independent, “floating” nature of the lining. The performance of the lining can also be more predictable, resulting in better opportunities to plan for maintenance and repairs.

Benefits from Installation Logistics

Flare Tips
Roof Sections
Spouts

Other major benefits to be gained from the use of precast refractory shapes are related to simplified installation and repair logistics, which can lead directly to reduced costs and shorter down times. With the use of precast shapes, forming labor, materials, equipment costs, actual placement time and expense, and associated costs during form removal, curing, and cleanup are all eliminated. These costs are shifted back to the manufacturer of the shape, who can absorb them much more efficiently when spread over his overall production capacity.

Refractory installation contractors have begun to consider precast refractory shapes much like they do any other pre-manufactured item such as block insulation, ceramic fiber blanket, anchors, etc. These items can be bought and then re-sold as a component of their installation projects

Whenever any portion of refractory repair work can be completed prior to crews being on site, costs are automatically reduced. Installation contractors have also found that the use of precast shapes can often give them a substantial advantage in competitive bid situations. With the use of precast shapes, crew sizing can be minimized. Speed of installation is another obvious benefit to both the installer and the owner, resulting in reduced costs due to shorter job duration. Material usage is also reduced, when compared to other installation methods such as guniting, where as much as 45% extra material is required to compensate for rebound and other job losses. Environmental hazards such as dusting and tripping hazards associated with equipment and hoses are also reduced substantially, if not eliminated.

Future repairs also become much more economical and quicker to accomplish. Repair areas can often be isolated to just the immediate wear area within the boundaries of a shape. Anchor attachment points can typically be reused. Replacement shapes, purchased early and kept as spare parts on site, can be easily installed in a fraction of the time required for conventional repair methods. Repairs become more of a mechanical maintenance job, rather than a refractory installation job requiring a specialized crew and equipment.

HyFIBER

HyFIBER Precast Refractory Shapes Offer Superior Performance

For the most demanding precast shape applications, TFL offers specialized precast refractory shapes made with Plibrico’s HyFIBER technology. HyFIBER utilizes a high quantity of stainless steel reinforcing fibers, infiltrated with a unique low-cement castable slurry in the mold. The resulting shapes exhibit extremely high toughness and impact resistance, as well as excellent resistance to thermal shock.

Click below to learn more about this unique precast shape technology!

HyFIBER Precast Shapes

Steel Fabrication and Shop Linings

TFL also offers steel fabrication and in-shop refractory installation so we can offer you turn-key responsibility for your fabricated items. We work with highly qualified steel fabrication shops who know what we expect as far as quality, precision and delivery. During all fabrication processes, our qualified refractory technicians will provide the necessary oversight to ensure your fabricated pieces are fabricated and lined properly.

Listed below are some of the fabricated pieces that can be lined at our facility.

Small furnaces
Ducts
Troughs
Expansion joints
Valves

Refractory lining dryout can also be done in our shop, utilizing specialists in the refractory dryout industry. Our attention to detail and quality workmanship means we complete your project on time and on budget.