THE REAL COST OF REWORK - AND HOW TO AVOID IT
- DGC AFRICA
- 8 hours ago
- 3 min read
Refractory rework during shutdowns isn’t just frustrating - it’s expensive and places additional strain on the people responsible for delivering a safe, on-time installation.
In theory, shutdowns should run like clockwork. Materials arrive on time, installation is smooth, and the lining is complete ahead of schedule. But in reality, delays, missing shapes, and on-site rework remain common — and the costs can be significant, both financially and operationally.
At DGC Refractories, we’ve seen how proactive planning, verified supply, and site-ready packaging can dramatically reduce shutdown risk. Because once rework begins, the pressure, cost, and risk increase rapidly.
WHAT REWORK REALLY COSTS
The visible cost is labour and lost time. But the true cost of rework includes:
Extended downtime — every extra hour offline affects production targets
Unplanned labour mobilisation — overtime, fatigue, and compressed schedules
Increased installation risk — rushed work leads to long-term performance issues
Logistical disruption — needing to cut bricks on site or source last-minute replacements
Management stress — cascading delays that affect other maintenance tasks
For large-scale kilns, furnaces, and smelters, even a one-day delay can lead to millions in lost output and significant pressure on operational teams to recover lost time.
WHY REWORK HAPPENS
In most cases, on-site rework stems from issues that could have been prevented upstream:
1. Incomplete lining drawings or unclear shape codes
2. Materials not matched correctly to profile zones
3. Dimensional inconsistencies not detected pre-shipment
4. Missing special shapes or packing errors
5. Last-minute scope changes without alignment
While some variability is unavoidable, rework is rarely just bad luck — it’s often the result of overlooked detail in the planning and supply phases.
HOW DGC HELPS MINIMISE REWORK RISK
Our approach is grounded in one principle: build it right the first time. We support our clients with:
Detailed pre-shutdown planning, including shape lists, CAD support, and scope walkthroughs
Dimensional QA and third-party verification before materials are shipped
Labelled and logically packed materials, grouped per installation zone
Technical standby or on-site support, where required
Full documentation packs to ensure installers have what they need
The result? Faster installs, fewer surprises, and shutdowns that run to plan, giving teams the clarity and confidence they need to deliver safely and efficiently.
LESSONS FROM THE FURNACE FLOOR
In a recent cement kiln project, a client previously faced significant delays due to unmarked brick layers and incorrect shapes mixed during packing. When DGC took over the supply, we implemented clear labelling, zone-based packaging, and issued a brick map aligned to the drawing. Installation time improved noticeably — with zero rework required during the subsequent campaign.
"Having the right materials, in the right order, with clear labelling — it’s one of the most underrated shutdown success factors."
— Refractory Supervisor, South African Cement Plant
DON’T LET REWORK DERAIL YOUR SHUTDOWN
In complex maintenance environments, every detail matters. Rework not only wastes time — it reduces confidence in the whole process and increases pressure on the people delivering it.
Let’s eliminate the risk before it reaches your furnace floor.
Over a Century of Trusted Service — Committed to Safety, Quality, and On-Time Delivery.
📩 Contact DGC Refractories to schedule a pre-shutdown lining review or learn more about our supply and packaging methodology. 👉 Visit www.dgc-africa.com to speak with our technical support team.
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Dickinson Group of Companies (DGC) was founded in 1910. Please visit our website for comprehensive information about Our Company – History, Vision & Values, Strategy, Global Alliances, Africa Footprint, Commitment to Safety, Anti-Corruption Policy, References, and Industrial Solutions.
