📍 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.
