02 Aug Aluminum Furnace Door Repair
APPLICATION REPORT
Industry: Aluminum
Description of Equipment: Aluminum furnace door
Problem: Severe damage to door during operation. The customer needed a material to withstand mechanical abuse and thermal shock. The door also needed to be repaired and back in operation quickly.
Solution: Cast Thermbond in the door and on a small door jamb cavity.
Before Repair
Thermbond Formula 3-L cast repair complete
Product Being Replaced: Conventional low cement castable refractory.
Savings Using Thermbond: End-user required furnace to be up and running in less than two days. Thermbond was chosen for its fast heat-up and no dry out features and its ability to withstand thermal shock and mechanical abuse.
Products Applied: Thermbond Formula 3-L and Thermbond Formula 2104-L
Method of Installation: Casting
Equipment Used: 220V Delport mixer, 50mm diameter electric pencil vibrator, and hand tools
Scope of Work: The old damaged refractory was inspected for integrity. Any loose material was removed, damaged steel repaired, new anchors installed, and back-up insulation placed. Mixing 3 units at time the crew quickly cast 59 units of Thermbond Formula 3-L into the damaged area of the door. An additional 8 units of Thermbond Formula 2104-L were cast on the top right side corner of the furnace door jamb. The entire installation took one shift and the door was put back on the furnace in less than 24 hours. The furnace was put into operation shortly after the door was reinstalled.
Installation Date: August 2010
Follow Up: Customer was impressed enough that they are considering Thermbond products for their next furnace belly band repair.
For additional information regarding this application report, please contact Stellar’s Aluminum Industry Specialist, Jeff Pchola at [email protected]