Calderys Boosts Aluminum Production Efficiency with ALKON® Fast Dry Technology

In the aluminum industry, downtime is costly—and every hour, a furnace is not operational, affects the bottom line. At one of our key aluminum clients in the UAE, we saw an opportunity to challenge the conventional.

Traditionally, relining furnaces at this site involved full in-situ casting with gunning backup, a method that extends the total project timeline to 23 days, including 7 full days for dry-out. This means significant furnace unavailability, lower operational productivity, and increased manpower exposure on-site. To transform this process, Calderys introduced to its customer a hybrid approach using:

  • Precast, Pre-fired (PCPF) blocks

  • Spraycasting

  • ALKON® FD products, a range dedicated to Aluminum contact equipped with the Fast Dry technology

ALKON®FD is the latest cement-bonded monolithics range dedicated to line the furnaces of aluminum producers and any industry using monolithics for their furnaces. Find out more by visiting the ALKON®FD page.

This innovative method enabled the team to deliver faster installation, reduce dry-out time and quickly put the furnaces back into operation. As a result, the customer saved 5 working days with this innovative method and delivered measurable improvements across key areas including safety, sustainability, productivity, and quality. 

This innovation didn’t just deliver technical success, it also provided clear commercial value to the client by minimizing downtime, boosting efficiency, and supporting sustainability goals.

Contact us for more information at: info@calderys.com 

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