Keeping aluminum melting furnaces at peak operating efficiency is vital. It extends the life of the furnace and minimizes any downtime that comes with minor or major repairs. Moreover, it lets you catch small problems before they become major (expensive) disasters. No matter the type of metal processing, unplanned downtime can be devastating to a…
In September 2019, Schad completed a project for a Great Lakes Region steel producer. The project called for the complete reline of a combustion chamber for an electric arc furnace (EAF). Schad had previously completed some “hot-gun” repairs on the combustion chamber, but it was great to have an opportunity to perform a complete relining….
In October, Schad took on a challenging project at an Eastern Ohio steel mill. The project involved working on four different furnaces during a two-week period. The furnaces included austenitizing, rotary, shell, and tempering furnaces. Schad was involved in every aspect of the project including inspection/scope development, material procurement, installation, and safety coordination. The various…
Every so often, we get introduced to a project where we have to rethink our approach. Schad recently just finished one of those projects for a mineral processor in the Great Lakes region. Schad was tasked with the installation of refractory materials in a “feed-end assembly” for a 10’6” rotary kiln. Due to the specs…
Erin is January’s employee of the month because he leads in the fabrication shop by example. During the past several months he has exhibited great commitment to project needs and deadlines. He takes ownership of getting each project out on time and correctly. Erin is always eager to learn new skills. Not just trade skills…
In November, Schad performed maintenance work on a round-top melting furnace at a Western Kentucky aluminum plant. The scope included removal and replacement of the ramp, sill, jambs, and arch as well as cold cleaning the furnace and repairing the bellyband. As always, there was an ambitious schedule and high customer expectations. “We have worked to build…
Schad completed a large project on a pusher style reheat furnace at a Great Lakes Region steel mill. The project included a full hearth replacement, a leading edge replacement, work on the extractor piers, and sidewall replacement. It also included casting materials, shooting materials, and placing brick and insulation products, which required a crew with…
Metal covers are often used atop bottle cars that carry molten metal from one side of a steel mill to another. The covers are designed to keep heat in the bottle car during transit. When the ceramic refractory inside these covers failed, one Schad client called us in to investigate. The customer was an integrated…
When Kenny first came to work for Schad, he came in for a one-day job on a down day and because of his ambitious ready to work attitude, he has been with Schad ever since. Kenny has taken on the role of foreman and has led many successful projects. He constantly sets goals for himself…
In January 2019, Schad completed two large aluminum reverb furnace relines for a single customer at two facilities, one in the Northern Great Lakes and one in Kentucky. While the scopes of work were similar, the way they were performed, as well as their geographies, were quite different. One of the furnaces was planned well…