WHY REFRACTORY FAILURE HAPPENS - AND HOW TO PREVENT IT

PRACTICAL INSIGHTS FROM SHUTDOWNS, SMELTERS, AND CEMENT KILNS ACROSS AFRICA

In the industrial world, furnace linings aren’t meant to last forever — but when they fail earlier than expected, the impact can be immediate and expensive. From missed production targets and emergency shutdowns to safety hazards and reputational damage, refractory failure often strikes at the worst possible moment.

But here’s the reality: most refractory failures are preventable. At DGC Refractories, our technical teams have supported numerous shutdowns and relines across Africa. The same root causes keep appearing — and the same preventative solutions consistently prove effective.

THE 5 MOST COMMON CAUSES OF PREMATURE REFRACTORY FAILURE

1.     INCORRECT MATERIAL SELECTION

Using the wrong brick type for the thermal, chemical, or mechanical conditions — often due to cost-cutting or outdated specifications.

2.     INCONSISTENT BRICK DIMENSIONS

Minor deviations in tolerance can lead to poor joint alignment, uneven load distribution, and thermal bridging that accelerates wear.

3.     LACK OF INDEPENDENT QA/QC

When refractory materials aren’t independently tested, defects go unnoticed until they fail in service. Many failures begin with something that wasn’t verified in the lab.

4.     IMPROPER INSTALLATION

Even the best brick can fail when laid without proper anchoring, bonding, or expansion allowance. Craftsmanship matters.

5.     POOR SHUTDOWN PLANNING

Last-minute deliveries, missing shapes, and incomplete drawings force on-site improvisation, which often leads to failure later on.

HOW TO PREVENT IT — DGC’S PRACTICAL FIELD GUIDELINES

At DGC Refractories, we help plant managers reduce lining failure risks through:

APPLICATION-SPECIFIC MATERIAL SELECTION

We don’t push product — we match shaped materials to your actual process conditions.

DIMENSIONAL QA WITH EVERY BATCH

All our bricks are manufactured to tight tolerances and independently verified before dispatch.

THIRD-PARTY QA/QC TESTING

Each supply is supported with lab reports covering chemical composition, strength, porosity, and thermal resistance.

SHUTDOWN PREPARATION SUPPORT

We assist clients with supply lists and logistics scheduling to avoid last-minute compromises.

A REAL-WORLD OBSERVATION

In several recent projects, we’ve seen how even modest adjustments in brick specification, dimensional accuracy, or shutdown coordination have led to noticeable improvements in campaign duration and thermal stability. In particular, plants that adopt QA-verified materials and align early with our technical team consistently report reduced need for mid-cycle repairs and smoother shutdown execution.

FAILURE DOESN’T HAVE TO BE A SURPRISE

Refractory failure may seem sudden, but in our experience, it almost always comes with warning signs — or upstream decisions that create the conditions for failure.

At DGC Refractories, our job isn’t just to supply bricks — it’s to help clients build resilience into their linings from day one.

LET’S MAKE YOUR NEXT SHUTDOWN A SUCCESS

If your plant has experienced premature refractory failure — or if you're preparing for a shutdown in the months ahead — we’d welcome the opportunity to share what we've learned and help you improve reliability through smarter supply and planning.

 

Over a Century of Trusted Service — Committed to Safety, Quality and On-Time Delivery.

 

📩 Contact DGC Refractories to schedule a lining audit or discuss QA protocols for your next project.

 👉 Visit www.dgc-africa.com or reach out to our technical team today.

ABOUT OUR COMPANY, HISTORY, AND PARTNERS

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.