From Damage to Daily Output: Furnace Repaired and Back in Production in Just 17 Days – Beating the 6-Week Estimate by Over a Month
- Immediate Onsite Damage Assessment
Damage was assessed within hours of the incident, allowing planning efforts to begin quickly and ensuring repair activities could be prioritized without delay. - Coordinated, Multi-Team Response
A full team was assembled quickly, including demolition specialists, materials manufacturing, installation crews, and dry-out experts to keep work moving without delay. - Accelerated Manufacturing of Refractories
Materials were produced and delivered just-in-time from Plibrico’s own facility, allowing work to proceed without delays tied to long lead-time supply chains. - Installation Executed in Freezing Conditions
Despite extreme winter temperatures, 87,000 lbs of castables and shotcretes were installed successfully by preheating materials and maintaining application readiness. - Controlled, Phased Reheat Process
The furnace was reheated using a closely monitored dry-out schedule, reducing the risk of thermal shock and ensuring the new lining set properly. - Repair Timeline Cut in Half
What was originally expected to take 6 weeks was completed in just 17 days—restoring production far sooner than the customer estimated. - Full Return to Production Output
The aluminum melter resumed daily billet output of 250,000 lbs, demonstrating successful repair execution and process continuity.