📍 Project Overview

JIC Refractory was appointed for a major refractory project at a steelworks facility in Sheffield. The project was notable for its size, strict deadlines, and additional client requirements.

Our team provided a full-service solution, including design assistance, material sourcing, installation, and temporary works, ensuring the project was delivered safely, on time, and to the highest quality standards.

🛠 Scope of Works

• Design input to ensure adequate support, insulation, and durability
• Installation of 75mm thick calcium silicate board
• Laying of 23-grade insulation firebrick
• Application of gunned 1600-grade refractory
• Welding and installation of over 2,000 stainless steel anchors
• Casting of doors and lintels separately and assisting installation once lined
• Supply of labour and materials for a temporary roof prior to pre-firing
• Additional works requested by the client during the project

The project required continuous coordination, maintaining high standards while meeting strict steelworks operational schedules.

🧱 Materials & Methods

• Calcium silicate boards for structural insulation
• High-grade insulation firebrick (23-grade) for hot face lining
• Gunned 1600-grade refractory for critical high-temperature areas
• Stainless steel anchors for secure fixing and long-term stability
• Temporary roofing materials for safe pre-firing procedures

We also provided all welding, fabrication, and installation support to ensure the installation was accurate and safe.

⚙ Project Team & Timeline

• Team of 6 experienced refractory installers
• Duration: approximately 6 weeks
• Worked in coordination with client teams to meet strict operational deadlines
• Flexible workforce to accommodate extra works and site-specific requirements

✅ Results

• Project completed on schedule despite tight deadlines
• All additional client requirements incorporated without delay
• Robust, high-quality lining with consistent insulation and airflow
• Temporary roofing provided safe pre-firing conditions, ensuring no damage to newly installed refractory
• Client reported excellent workmanship and professionalism throughout

This project demonstrates JIC Refractory’s ability to manage large-scale, high-pressure industrial projects, combining technical expertise, efficient workforce deployment, and comprehensive material supply.

📍 Project Overview

We were commissioned to manufacture and supply pre-cast fire tiles for a purpose-built Fire Service training facility. The tiles were required to simulate real fire exposure conditions while offering durability, safety and ease of replacement.

The client required a fast turnaround, consistent quality, and a reliable fixing system suitable for repeated live-fire training exercises.

🧱 Design & Manufacture

All tiles were manufactured in-house using precision-made timber moulds fabricated by our team. This ensured consistent sizing, accurate tolerances and repeatable quality across the full batch.

Each unit was produced using:

• Medium weight refractory castable
• Integrated stainless steel mesh reinforcement
• Controlled curing process for strength development

The stainless steel mesh reinforcement provides additional structural integrity, helping the tiles withstand thermal shock and mechanical impact during training exercises.

🛠 Scope of Supply

• Design and fabrication of bespoke timber moulds
• Casting and finishing of all pre-cast tiles
• Quality checks and dimensional verification
• Rapid production and supply within a short lead time

⚙ Key Challenges

• Tight programme requirements
• Consistency across multiple units
• Requirement for thermal durability under repeated heating cycles
• Safe handling weight considerations

Our experience in refractory casting allowed us to optimise the mix design to balance strength, weight and thermal performance.

✅ Results

• Full batch manufactured and supplied within programme
• Excellent dimensional consistency
• Robust tile construction suitable for repeated fire exposure
• Positive client feedback on quality and turnaround time

The project demonstrates our capability to design, manufacture and deliver bespoke refractory pre-cast components efficiently and to a high standard.

📍 Project Overview

We were called to a crematorium in the north of the UK following unscheduled downtime caused by refractory failure. Our inspection revealed:

• Secondary chamber tile failure restricting airflow
• Incorrect support tiles on a major wall of the primary chamber
• Extensive spalling of secondary chamber bricks

These issues were caused by the use of incorrect materials by a third-party installer, leading to hotspots, restricted air/gas flow, and the risk of catastrophic failure.

The client required a rapid, permanent solution to bring the unit back online safely and efficiently.

🛠 Scope of Works

• Full inspection and assessment of primary and secondary chambers
• Removal of all failed and incorrectly installed tiles/bricks
• Supply of correct refractory materials for high-temperature cremation applications
• Rebuild of all secondary and primary chamber walls to the correct widths to ensure proper air and gas flow
• Continuous on-site work over 1 week with two shifts (days & nights) to meet urgent programme requirements

🧱 Materials & Methods

• High-alumina firebrick for primary and secondary chambers
• Heat-resistant castables for critical joints and corners
• Correct support tiles to maintain structural integrity and airflow
• Precision installation to ensure chamber geometry and consistent gas flow

Our team’s experience allowed us to rapidly assemble the right materials and workforce, delivering a safe, high-quality relining under extreme time pressure.

⚙ Challenges

• Significant existing damage to secondary and primary chambers
• Need to restore airflow and prevent hotspots
• Tight one-week schedule requiring 24-hour shifts
• Correcting previous installation errors while maintaining structural integrity

✅ Results

• Full reline completed in 1 week, restoring the cremator to full operation
• Correct chamber widths ensured consistent airflow and gas flow
• Elimination of spalling and hotspots, preventing future failures
• Safe, high-quality work with minimal disruption to crematorium operations

The project demonstrates JIC Refractory’s ability to rapidly respond to critical failures, delivering durable, high-standard solutions in time-sensitive situations.