Refractory Materials, Precast Shapes, and Custom Solutions

Plibrico Company Acquires TFL

Wed, 04 Feb 2026 14:53:13 GMT

Expanding Precast Manufacturing and Refractory Solutions Across Texas and Southern U.S.

Plibrico Company, a leading manufacturer of monolithic refractories, precast shapes, and engineered refractory solutions, has acquired TFL, a long-standing refractory distributor, service provider, and precast shape manufacturer based in Houston, Texas.

As a well-established PliPartner of Plibrico, TFL joins Plibrico in a combination that brings together two organizations with deep industry experience and a shared commitment to refractory quality, service, and trusted partnerships. The acquisition strengthens Plibrico’s presence in Texas and the Southern U.S. while expanding precast manufacturing capabilities, technical resources, and operational capacity.

Operating as TFL, A Plibrico Company, customers gain access to broader capabilities, deeper technical resources, and enhanced engineering expertise. At the same time, the dependable, responsive support customers rely on continues uninterrupted, helping keep operations running efficiently.

“This combination enhances the technical and operational strengths that matter most in the field,” said John Paul Surdo, President and CEO of The Plibrico Company. “TFL has earned customer trust through proven expertise, responsive support, and strong partnerships. With Plibrico’s engineering depth, technical resources, and precast shape capabilities reinforcing that foundation, customers gain broader solution options, stronger technical collaboration, and dependable support that helps improve performance in demanding heat-processing environments.”

These combined strengths extend those benefits across a wide range of industries and critical heat applications, reinforcing responsive service and reliable support at every stage of the customer experience.

Plibrico extends a Big Welcome to all of the TFL employees, customers, and suppliers to the Plibrico Team.

Get to know the Plibrico Company

For more information contact the Plibrico Company at contact@plibrico.com , or 312-337-9000.

Customization of Precast Shapes

pgaul@plibrico.com (Pamela Gaul) — Thu, 25 May 2023 18:14:11 GMT

Details in Precast Refractory Shapes

Clients request a variety of precast refractory shapes , being able to manufacture customized shapes is what we pride ourselves on. The manufacturing of precast shapes is very much a science, but can resemble art as well.

Our specially designed shapes, such as burner blocks and pier blocks , can be used for almost any application. When it comes to precast shapes every small seemingly meaningless detail matters. A half-inch too thin and the product may not be sturdy enough, too thick and it may be too heavy to function properly. Our team has mastered the ins and outs of the manufacturing process to provide the best shapes and solutions you’ll need.

It’s not enough for a project to have a detailed design and precise measurements, they must all be anchored properly. A beautiful building without a foundation or support beams won’t stand for very long. We have a full inventory of anchors here to help with even the most detailed and complex designs.

Give TFL a call to discuss your next precast project!

Avoid These Common Refractory Installation Mistakes

pgaul@plibrico.com (Pamela Gaul) — Tue, 16 May 2023 00:40:33 GMT

Using the wrong refractory materials can lead to failure

When it comes to refractory installation , there are many things that can go wrong. Refractories are a crucial part of many industrial processes, and even small installation mistakes can lead to significant problems down the line. That’s why it’s essential to get it right the first time. Here is a look at some of the most common refractory installation mistakes and how to avoid them.

1. Failure to Properly Prepare the Surface Area

Before installing refractory materials , it's essential to ensure that the surface area is adequately prepared. Surface preparation is one of the most crucial aspects of proper refractory installation. Any dirt, oil, or other contaminants must be removed from the surface before installation. Otherwise, the contaminants can mix with the refractory and create weak spots that will eventually lead to failure.

2. Ignoring Recommended Curing Times

Curing is a vital aspect of refractory installation. It is the process of letting the refractory dry and harden after installation. Ignoring the recommended curing time can lead to early failure of the refractory. It's essential to adhere to the recommended curing time and temperature, as these factors can greatly affect the refractory performance.

3. Poor Mixing Techniques

Mixing refractory materials can be a bit tricky, but it’s an essential part of the installation process. Poor mixing techniques can create voids or air pockets in the refractory, which can weaken it and cause it to fail. Proper mixing ensures adequate bonding and maximum performance of the refractory.

4. Not Using Appropriate Refractory Materials

Using the wrong refractory materials can lead to failure and, in the worst cases, catastrophic accidents. Each refractory material has its own unique properties and intended use. Failing to use the appropriate refractory material can lead to early failure or create a safety hazard. It's essential to consult with a refractory expert or engineer to determine the best materials for the application.

5. Poor Application Techniques

The application of refractory materials requires precision and attention to detail. Poor application techniques, such as leaving voids, not tamping properly, or using too much or too little material, can lead to refractory failure. It's essential to follow proper application techniques to ensure a quality installation.

Proper refractory installation is essential for ensuring the safe and efficient operation of many industrial processes. By avoiding these common mistakes, you can improve the lifespan and performance of your refractory materials. Remember to properly prepare the surface area, adhere to recommended curing times, use proper mixing techniques and appropriate materials, and follow proper application techniques. Our team of experts at TFL can help you avoid these mistakes and ensure a successful installation. Contact us today.

Safer Dry-Outs Using Plibrico Kwik Kure Fibers

pgaul@plibrico.com (Pamela Gaul) — Tue, 21 Mar 2023 14:36:47 GMT

We Are a Major Distributor for Plibrico Company LLC.

Plibrico’s anti-spalling additive ensures a safe dry-out resulting in maximum refractory strengths. One critical part of the refractory installation process is the initial dry-out, where moisture is removed from refractory castables, plastics, and precast shapes in a controlled and safe way. When this is not done right, it can cause thermal damage to refractory linings, and in some instances can even lead to injuries.

One way to minimize the susceptibility of refractory castables to explosive spalling and structural damage during dry-out is to use anti-spalling additives, such as organic fibers. At TFL, we are a major distributor for Plibrico Company LLC. Plibrico’s Kwik Kure Fibers (“KK”) are organic fibers that burn out during the initial dry-out, ensuring proper dry-out and maximum refractory strengths. The channels formed as the fibers are burned away increase permeability, providing faster and shorter paths for steam to escape.

To learn more about how Plibrico’s Kwik Kure Fiber additive can help your refractory installations, contact our TFL experts to discuss your next project.

Choosing the Correct Refractory Vendor

pgaul@plibrico.com (Pamela Gaul) — Wed, 01 Mar 2023 17:35:23 GMT

When looking at multiple precast refractory vendors do your research

Not all refractory vendors are created equal. Cheapest isn’t always best when considering the

implications of an abrupt breakdown. You can avoid the agony of unexpected failures that can stop your

production line cold by knowing how to cut through the vendor rhetoric and stay focused on your end

goals.

Single source vs. components

Buying piecemeal components from multiple vendors may appear to save time and money:

● you must work with multiple vendors on everything from billing to delivery

● your components may not all be compatible with one another

● you lose system accountability

● you don’t have a single source when something goes wrong

Category and Industry knowledge

When looking at multiple vendors, do your research and find out how much they know about their industry and yours. Remember, your vendor should be an expert in their field first; the ideal ones are also well-versed in working in your field. Since every application is unique, expertise in direct or adjacent fields helps ensure you get advice you can trust.

Satisfied Customers

Although everyone can pull out a decent customer reference or two, ask your vendor for permission to speak to a couple of clients. A potential vendor with satisfied clients who will rave about the vendor’s services and are willing to talk to you about it is likely to be a vendor you can rely on to help you through any unexpected issues. Also, check out how the vendor addresses emergencies. Are they available 24/7? What can you expect from them when you face an unexpected challenge?

Quality of Materials Produced

If you’re looking at a few vendor options, browse their product spec sheets to look for any differences that may make them stand out. Higher-quality materials typically have higher ratings and tolerance levels. Look at the product lines they represent. Are they well-known and trusted?

How TFL supports industrial refractory needs

For over 40 years, TFL has offered its industrial customers a broad range of high-quality refractory products. TFL specializes in the manufacture of precast refractory shapes systems. We supply high-quality refractory materials and anchoring systems produced by leading U. S. manufacturers. We can also provide customized steel fabrication and shop linings, and our Convey-It system is a very useful tool for the efficient handling of refractory materials. Contact TFL today to learn more.

TFL Completes Unique Precast Refractory Shape Application For Oakland Area Municipal Utility District

pgaul@plibrico.com (Pamela Gaul) — Tue, 19 Apr 2022 20:40:46 GMT

The East Bay Municipal Utility District (EBMUD) Wastewater Treatment Plant, located on the eastern shore of San Francisco Bay, provides service for an estimated 740,000 people in the greater Oakland, California area. In addition to traditional wastewater treatment, the plant also collects and treats solid waste from Bay Area food and animal processing facilities, restaurants, and wineries, diverting this waste stream away from landfills. The methane gas that is generated from the decomposition of this solid waste is then used internally as a renewable source of energy to help supply the treatment plant’s energy needs.

When EBMUD began looking for a way to upgrade the failing brick refractory lining in their emergency digester gas flare structure, they turned to TFL, Incorporated. TFL developed an innovative precast refractory shape system that would offer dependable performance, structural integrity, and ease of installation. The unique system of floating wall panels is held in place using tongue-and-groove tieback shapes, bolted to the existing concrete structure. The individual panels in the system can absorb thermal and mechanical stresses independently. Given the location, potential seismic loading was also considered in the development of the system.

The existing flare containment building is an oval-shaped concrete structure, with inside dimensions of 17’ wide by 47’ long. The refractory lined upper section of the structure is just over 21’ tall. The refractory wall thickness is 4-1/2”. A 2” air gap between the refractory wall and the concrete wall allows for airflow and ventilation.

The refractory wall system consists of 514 precast shapes of four basic types, all manufactured in TFL’s Houston, Texas facility. The shapes were cast using Plicast HyMOR 3000 KK, a low-cement castable refractory manufactured by Plibrico Company. Stainless steel needle fibers were used for added reinforcement and to improve resistance to thermal shock and cracking. The shapes were fired to 1250o F prior to shipment, optimizing strengths and allowing the flare structure to be immediately operational, without the need for a field dry out of the refractory.

NTK Construction, Inc. of San Francisco, California, was the installation contractor for EBMUD.

4 Mistakes to Avoid in Refractory Repairs | Precast Refractory Shapes

pgaul@plibrico.com (Pamela Gaul) — Tue, 12 Oct 2021 16:00:03 GMT

Common Refractory Mistakes

Selecting and installing a proper refractory lining for your application can be complicated. Picking the wrong refractory material or installing it incorrectly can lead to premature failure, making you less productive and costing you more money than you planned to spend. Here are four common mistakes that must be avoided when making refractory repairs:

1. Thinking that all refractory materials are the same and can be used for any application: Refractory materials have a wide range of physical properties, and are designed for specific purposes. Materials should be carefully selected for each application . There are often trade-offs in physical properties (insulating capability vs strength, for instance), which must be considered.

2. Improper anchoring: Providing the correct anchoring system is just as important as material selection in the design of a durable refractory lining. Improper anchor spacing, selecting the wrong anchor type, or having the wrong anchor metallurgy can all lead to the premature failure of a refractory lining.

3. Thinking that “anyone can put this stuff in”: Refractory installation requires special know-how, experience, and expertise. Your installer s should be skilled in multiple methods of refractory installation to prevent any issues.

4. Implementing the wrong mixing process: The proper placement of refractory castables requires close attention to details. Common mistakes include using too much water, using the wrong type of mixer, not allowing the cast material to set properly, and not following initial dry out.

Don’t let these common and avoidable mistakes happen to you. To speak to the refractory experts, give TFL a call today!

Benefits of Material Property Enhancement For Precast Shapes

pgaul@plibrico.com (Pamela Gaul) — Tue, 15 Jun 2021 19:23:24 GMT

Produce the Perfect Refractory Linings for Your Next Project

Over the years, the refractory industry has faced many challenges. Precast-shape technology has helped us overcome some of them. The technology is used across different industries to produce better results and save money.

If you choose to work with refractory castables, the process needs to be perfect. The physical properties of the material are sometimes weakened during the manufacturing stages by several factors. It’s even more crucial to get it right when the complexity increases to secure the performance of the lining. You can take full advantage of a castable’s physical properties by casting precast shapes in a controlled environment with experts overseeing the whole process.

When it comes to drying and firing a refractory castable, you want the best lining production. Precast shapes allow you to ensure that the bake-out schedule recommended by manufacturers is followed to the tee since they can be fired in a digitally-controlled furnace. The shapes can also be fired from all sides, reducing moisture and giving off a uniform look that diminishes cracks. Additionally, the lining is less susceptible to stress, and its performance is more predictable.

Precast-shape technology has many benefits, and you should take advantage of it. If you’re ready to use precast shapes to optimize your next project, contact us today to learn more about how we can help you.

Long Lead Times Are Common for Many Refractory Manufacturers These Days…Get Your Schedule Back on Track with Plibrico Products From TFL!

pgaul@plibrico.com (Pamela Gaul) — Tue, 15 Jun 2021 19:22:55 GMT

Don’t Settle for Extended Deliveries – Plibrico is Keeping Our Customers Happy in Today’s Unusual Market. Here’s How:

As industries continue to recover from COVID-19 impacts, supply chain delays have become more prevalent in our industry, making it harder for many refractory companies to meet the urgent demands of their customers. Fortunately, Plibrico prepared and stayed ahead of the curve. While other companies minimized their inventories in 2020 in response to reduced demand, Plibrico did not. Instead, Plibrico strategically invested in raw material inventory to meet anticipated growth in demand. Plus, Plibrico has committed orders with suppliers for additional raw materials to support further near-term increases in production demands.

Since the beginning of our partnership with Plibrico, in 1982, TFL has consistently ranked among Plibrico’s largest distributors in the organization, and we are proud to offer Plibrico refractories to our valued customers. Let us help you overcome supply chain inefficiencies prevalent in our industry today and meet your scheduling needs with Plibrico refractories available at TFL!

Click here to view our Plibrico product listings and contact us today to discuss your next project

Durable Precast Refractory Shapes Manufactured To Your Exact Specifications.

Thu, 13 May 2021 17:46:00 GMT

Minimize Downtime And Increase Performance With Precast Refractory Solutions from TFL!

Precast Refractory Shapes can be used for a wide range of applications and industries ranging from foundry and boiler applications to petrochemical and refinery industries. Regardless of your industry or application, we have the expertise necessary to custom-manufacture durable precast shapes to meet your exact project requirements. Since 1977 , we’ve made it our mission to support petrochemical refineries along the Texas Gulf Coast , offering innovative solutions to streamline your projects .

Today, we recognize the growing demand for precast refractory shapes in the Petrochemical Industry and have adapted our services to accommodate your most demanding refractory projects. Another advantage we offer to our clients is our location. Our 12,000 sq. ft. manufacturing facility is located near Houston’s George Bush Intercontinental Airport, the Port of Houston, and is convenient to major freeways.

Some of the applications we provide precast shapes for include but are not limited to the following :

Applications For Petrochemical Industry:

Contact us today to discuss your next precast project and click here for more information about our precast refractory shape solutions!

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TFL Uses Custom Molding Techniques to Make Precast Refractory Shapes With Extremely Tight Tolerances

Fri, 30 Apr 2021 13:51:00 GMT

With Proper Attention to Dimensional Tolerances, Field Fit-up Problems With Precast Shapes Go Away

The manufacture of precast refractory shapes inherently requires the use of some type of mold or pattern to form the castable into the desired shape. Some precast applications, like burner blocks , may require extremely tight dimensional tolerances, while others require less. The level of dimensional tolerance required for a shape (“tight” or “loose”) is an important consideration when designing the mold and determining the type of mold materials to be used.

For simplistic shapes with relatively loose dimensional tolerances, plywood or metal fabricated forms are commonly used. Styrofoam is also commonly used when dimensional tolerances are not so strict. On the other hand, shape applications with extremely tight dimensional tolerances may require the use of more sophisticated molds and materials.

Precast Shape Applications Requiring Tight Dimensional Tolerances:

Precast Shape Applications Requiring Less Stringent Dimensional Tolerances:

Depending on the requirements of a particular application , molds may also incorporate precisely machined, milled or sanded surfaces, similar to a metal-casting foundry pattern. No matter the application, TFL offers engineering services and field support to help you with the design of a successful precast shape system.

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Refractories Play a Pivotal Role in Virtually Every Industrial Process

Wed, 07 Apr 2021 16:26:00 GMT

The Rewards of Being a Part of “The Hidden Industry”

Despite their historical significance, refractories are seen and understood by few, and their role is difficult to explain to the average person. Whenever most people hear the word “ refractories ” for the first time, confused expressions are a common response.

Refractories have played an integral part in the development of almost every industrial process – from the forging of primitive hand tools to the lining of launch pads sending spaceships to Mars. In the production of plastics, steel , aluminum , rubber, glass, textiles, and papers, the common denominator is the use of heat-intensive processes that all depend on refractories to be successful.

At TFL, we are proud to build on the foundations of our predecessors and solve refractory problems through creativity and ingenuity. We embrace the responsibility of continuing the illustrious history of our industry, finding solutions where others haven’t looked.

The post Refractories Play a Pivotal Role in Virtually Every Industrial Process appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Remove and Replace Refractory Linings Fast with TFL’s Convey-It System

Mon, 22 Mar 2021 19:58:00 GMT

TFL’s Convey-It System Is The Ideal Solution To Safely Transport Refractory Materials and Tear-out Debris To and From the Kiln

TFL’s innovative Convey-It System enables your team to perform refractory repairs safely and efficiently. We understand the complexity of refractory repairs and how important it is to have materials transported safely in and out of tight spaces. Instead of overworking your team with heavy hauls to and from the kiln, the Convey-It System uses a continuous conveyor belt system with forward and reverse controls. Also, the Convey-It System comes in 10-foot modular sections so you have the perfect length to meet your exact project requirements. Another benefit of the Convey-It System are standard variable speed controls and remote emergency shut-off buttons.

Convey-It System Advantages Include:

Contact TFL today to see how the Convey-It system can improve your next refractory project.

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The Advantages of ROTALOCK Refractory Anchors, The Most Versatile Anchor System From TFL

Mon, 01 Mar 2021 15:36:00 GMT

Rotalock Anchors Can Reduce Stress On Refractory Linings And Improve Worksite Safety

TFL offers a wide variety of custom refractory anchors professionally engineered in a variety of alloys and sizes. One of our more versatile anchors is the Rotalock anchor system, which features an innovative “break-away” design. This break-away feature reduces stress on refractory linings by allowing for slight movement to occur, while still holding the lining tight to the wall. Unlike other break-away anchors, the impressive friction lock feature of the Rotalock anchor means no tack-welding is required. Read more about the advantages of the Rotalock Anchor System below:

Major Benefits of The Rotalock Anchor System:

Rotalock anchors can be configured for single component linings or multi-component linings depending on your application. Our team of refractory experts are available to answer questions and will make sure your anchors are manufactured to your specifications, in the right quantities, and delivered on time.

Access our full inventory of refractory anchors here to see detailed drawings of the anchors we offer. For more information about Rotalock and TFL’s refractory anchor solutions, contact us today!

The post The Advantages of ROTALOCK Refractory Anchors, The Most Versatile Anchor System From TFL appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Easily Restore Worn Ceramic Fiber Linings with the CERABOLT™ System From TFL

Thu, 11 Feb 2021 17:00:00 GMT

An Economical “Quick Fix” Solution to Extend the Life of Ceramic Fiber Module Linings, When Total Replacement is Not Yet an Option

The post Easily Restore Worn Ceramic Fiber Linings with the CERABOLT™ System From TFL appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Plicast KL 3000 is a Proven “Workhorse” Castable from TFL and Plibrico

Mon, 25 Jan 2021 18:14:00 GMT

A Cost-effective Solution For Many Challenging Refractory Applications

Plicast KL 3000 castable is a super-duty, “workhorse” castable commonly used in the steel , power generation, boiler, incineration, thermal oxidizer, and mineral processing industries. It is one of Plibrico’s oldest products, but one that has been continually updated over the years to meet the demands of some of the harshest applications, in a cost-effective way.

Plicast KL 3000 Features & Benefits

Some advantages of the Plicast KL 3000 include a shelf life of 12 months, a temperature limit of 3000 °F, and good cold and hot strength. Another benefit of this castable is that it is economical and ideal for less demanding applications. The Plicast KL 3000 is made of super duty aggregate and high purity calcium aluminate cement, offering reliable thermal conductivity and strength. Learn more about the technical benefits of Plicast KL 3000 below.

Technical Benefits of Plicast KL 3000:

TFL offers high-quality castable materials manufactured by Plibrico Company, a world leader in monolithic refractory development. Let us help you improve refractory performance and extend the life of your furnace with superior refractory solutions from TFL. Contact us today!

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We Are Pleased To Welcome Heather Smith To The TFL Family

Fri, 08 Jan 2021 14:05:00 GMT

Heather Is The Perfect Fit for TFL, And We’re Excited to Have Her On Board

Heather has over 25 years in customer service, with 12 years working in the industrial sector. Heather’s approach to work instantly stood out to us; her philosophy is, “Do it right the first time every time,” and we share those same values. She’s also passionate about “old things” and eager to learn more about the refractory industry’s ancient origins. Heather will be working directly with our customers with sales support, and will also handle office administration functions. Heather’s enthusiasm is contagious; here’s what she had to say about working with us…” I’m looking forward to building relationships with our customers and clients as we start the new year. I’m excited to be part of a team that loves their jobs, works together seamlessly and strives for perfection every day!

Some Fun Facts About Heather

Heather is an avid fan of music with an extensive collection of digital music and vinyl records; more than anything, she’s a fan of Americana, classic country, punk, soul, blues, and funk. Before COVID-19, she made sure to support her favorite musicians whenever she could by attending live shows and considers the music festival South by Southwest (SXSW) an annual holiday. Heather also enjoys dancing, which is her favorite way to exercise. Her favorite dances are the classic two-step, swing dancing, and doing The Stroll with her girlfriends. Some of her other favorite things include spending time with her granddaughter, wearing vintage western wear, traveling, and art in any form.

We’re excited to have Heather join our team! Contact us today to learn more about TFL and how we can improve your next refractory project!

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Here’s Why You Should Have Plicast Super HyMOR 95V KK On Your Next Refractory Project

Mon, 21 Dec 2020 15:21:00 GMT

A Great Castable Selection For Precast Refractory Shapes

When it comes to meeting your refractory performance goals, Plicast Super HyMOR 95V KK from Plibrico is the ideal material selection for applications such as precast burner tiles , pier blocks , incinerators, reheat and forge furnace hearths, and heat recovery units. Plicast Super HyMOR 95V KK also offers superior resistance to slag and chemical attack to ensure improved refractory performance in the toughest environments.

Two of the main advantages of this product are its modified matrix and low lime content, which help to promote mullite formation at elevated temperatures, greatly enhancing volume stability. Enhanced physical properties make this product well-suited for a wide-range of applications.

Technical Benefits of HyMOR 95V KK:

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Get Refractory Anchors Professionally Engineered By TFL For Your Next Project

Mon, 07 Dec 2020 17:46:00 GMT

Refractory Anchors Designed To Meet Your Specific Project Requirements

Here at TFL, we offer custom refractory anchors professionally engineered for superior durability and designed to withstand the demands of your application. As your premier refractory anchor provider, we’ll ensure your refractory anchor orders are manufactured to your specification, in the right quantities, and delivered on time. Whether you are looking for steer-horn V-anchors, threaded studs, wall support plates, or custom-designed anchors, you can count on our anchors to meet or exceed the highest performance standards. You can access our full inventory of refractory anchors here and see detailed drawings of the anchors we offer. Read more below to see how we can help with your next project.

We’ll Help You Find The Best Anchor Solution.

When choosing the correct refractory anchor for your next project, our team of refractory experts will be available to answer any questions you may have to ensure your anchors meet your exact project requirements. One of the more versatile anchors we offer is our Rotalock anchor; our “break away” anchor design also provides numerous advantages, including reducing stress in the lining while allowing slight movement to occur. Whatever your refractory needs are, we have a comprehensive inventory of anchors available in various alloys and sizes custom manufactured to fit your needs.

To learn more about TFL’s refractory anchor solutions, contact us today!

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Happy Thanksgiving From TFL

Tue, 24 Nov 2020 14:31:00 GMT

Thank You For Choosing Us For Your Refractory Needs

Even though 2020 has presented its fair share of challenges, we recognize that there are many reasons to be thankful. In light of the COVID-19 pandemic, we’ve had to adjust to meet our customers’ demands, but we are pleased that you’ve decided to go with TFL for your refractory needs and precast refractory shapes. We know that this time of year is when families typically come together to give thanks and celebrate. Right now, with social distancing in effect for the foreseeable future, things may be a little different. However, you can still enjoy the same thanksgiving food, rejoice with loved ones via video conference, or watch some good old fashioned football! The challenges of 2020 are not forever, and we hope that you find time to give thanks enjoy one another.

From our family to yours, Happy Thanksgiving!

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Meet Refractory Project Deadlines Easier With The Convey-It System

Mon, 16 Nov 2020 15:18:00 GMT

Reasons Why You Should Have TFL’s Convey-It System For Your Next Refractory Project

The Convey-It system is compact, powerful, and the ideal solution for quickly transporting materials out of or into a furnace or kiln. Refractory projects are not the same as your standard construction projects and come with unique requirements and challenges. Fortunately, we understand these challenges, and TFL’s Convey-It system is designed by refractory experts who know first hand how difficult it is to remove and replace refractory linings. If you’re a refractory installation contractor , the Convey-It system is the premier solution to access kilns and furnaces that are typically small and compact or have restricted accessibility.

Convey-It System Advantages Include:

In addition to these advantages, you can expect a safer and cleaner working environment that ensures better results for your team.

Meet your deadlines easier and Contact TFL today to see how the Convey-It system can improve your next refractory project.

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What You Need To Know About COVID-19 And The Refractory Industry

Mon, 19 Oct 2020 16:45:00 GMT

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Ceramic Fiber Module Lining Repair with CERABOLT™ Overlays

Fri, 17 Jul 2020 15:26:00 GMT

The post Ceramic Fiber Module Lining Repair with CERABOLT™ Overlays appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

9 Common Misconceptions About Precast Refractory Shapes

Tue, 07 Jul 2020 09:00:00 GMT

Precast refractory shapes are a practical solution for a variety of furnace repairs and designs. TFL looks forward to partnering with you to create durable, cost-effective precast shapes for your unique application .

Precast refractory shapes are an efficient, cost-effective solution for repairs and improvements. #TFLHouston
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What are some common misconceptions about precast refractory shapes?

Common misconceptions about precast refractory shapes come in the form of:

1) “Precast shapes are more expensive to install!”

In reality, field installation of a precast shape system is typically much simpler than forming and casting, requiring less equipment on-site and fewer craftsmen. With precast shapes, the job becomes more of a routine mechanical job rather than a specialized job requiring skilled refractory craftsmen. Also, curing time and dry out can be eliminated, resulting in significant savings in time and money.

2) “We’ve always cast the lining…changing over to shapes would be too complicated to figure out!”

It can be surprisingly easy to switch over from the “old way” of forming and casting to the use of precast refractory shapes . TFL can work with you to evaluate the existing furnace structure, develop anchoring options, and access and lifting requirements.

3) “Molds for precast shapes would cost too much!”

Over the years, TFL has perfected the art of making our molds as economically as possible, while still maintaining extremely tight tolerances, durability, and repeatability. Our molding techniques are tailored to the demands of the shape system design. We use a variety of materials and molding processes to efficiently produce quality shape.

4)“I’d have to bring a crew in from the field to the shop to make these shapes!”

Not if you let TFL produce them for you ! Bringing in a project superintendent, craftsmen, and labor support into your shop to cast precast shapes is not the most efficient use of your crew time. At TFL, we are casting refractory shapes every day, all day long, with resources dedicated to the task.

5) “Lead times for precast shapes would be way too long!”

We have both in-house mold making capabilities as well as talented partners that understand the business of making precast refractory shapes. That enables us to have extremely rapid turnarounds in the mold making process. Our shop crews are flexible and scalable. Most importantly, our experienced production staff understands that responsiveness is one of our four foundational elements that has made TFL successful over the years. We meet critical schedules!

6) “It’s just as easy to set forms and cast the job in the field!”

Sometimes our tendencies to “just do what we’ve always done” can cause us to overlook the tremendous benefits of a new way of doing things. The logistical and performance advantages of using precast refractory shapes vs. a field-cast lining have been proven time and again. Typically, setting forms and casting in the field is NOT the easiest way.

7) “There’s no way to anchor a precast shape system in my existing furnace”

It is true that converting from a field-cast lining to a precast shape system for the first time may require a new look at the existing structure of a furnace to accommodate the anchoring of the shapes . However, this can normally be done with minor modifications.

8) “I have to use the shape manufacturer’s desired castable if I buy his precast shapes”

TFL makes precast shapes from a wide variety of materials, from many manufacturers. While we are happy to make product recommendations, we also understand that sometimes there’s a comfort level that exists around a particular castable material. We know that simply changing from a field-cast lining to precast and pre-fired shapes made in our shop, will automatically enhance the physical properties and performance of any castable.

9) “Lifting and handling precast shapes in the field would be a problem!”

Lifting, handling, and manipulating precast refractory shapes in the field is one of our basic considerations when we start the design of a precast system. We have to have a full understanding of on-site lifting capabilities, equipment availability, and crew limitation. We utilize a variety of unique and innovative lifting and handling methods in our designs.

Conclusion

TFL specializes in the design and manufacture of precast refractory shape systems for every application. Precast shapes can help ensure success! Let us work with you to design a precast solution for your toughest application.

Contact TFL today!

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TFL Precast Refractory Shapes – Burner Tiles, Blocks, and Rings

Fri, 19 Jun 2020 09:00:00 GMT

While TFL manufactures a wide variety of precast refractory shapes , one area of special expertise for us is in the production of precast burner tile , blocks, and ring segments.

TFL is a leading provider of precast refractory shapes, including burner tile, blocks, and rings. Learn more about our range of products.
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Burner refractory shapes can range in complexity from simple cylindrical cans with a single hole through the middle, to elaborate rings with complex internal tapers, multiple inlet ports, and close-tolerance anchoring requirements.

Innovative Molding Techniques

TFL has developed innovative molding techniques that enable us to manufacture burner shapes to very tight tolerances. This ensures that installation on the job will go as planned, with no need for “field corrective measures”. Our molding processes also minimizes stresses on the green part when it’s being removed from the mold and handled prior to firing. This avoids the development of micro-cracking that can impact the long-term performance of the shape.

Professional Casting

We cast burner shapes out of a variety of refractory materials, including low-cement castables, high-alumina castables, self-flowing, and rapid-heat up castables. Our customers often specify the specific material to be used, but TFL can also offer our own technical recommendation on product selection.

Quality You Can Trust

TFL routinely produces burner tiles for original equipment burner manufacturers and furnace OEMs, as well as after-market replacement shapes. Major refractory installation contractors, furnace suppliers, refineries, and petrochemical plants have come to depend on TFL for high-quality burner shapes and reliable delivery performance.

Contact TFL today for pricing and availability information regarding our refractory products.

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Plastic Refractories: Highlighting Phosphate Bonds

Fri, 03 Apr 2020 10:00:00 GMT

TFL is a distributor of Plibrico refractory products and carries a wide selection of Plibrico phosphate-bonded refractories. Compared to other monolithic materials, chemically-setting phosphate-bonded refractories offer good refractoriness under load (RUL), volume stability, abrasion resistance, slag resistance, high hot strength, and most are non-wetting to aluminum. These products utilize a high mullite content aggregate in an alumina-fortified phosphate-bonding matrix that incorporates Plibrico Company’s proprietary monoaluminium phosphate.

Check out Plibrico phosphate-bonded refractories for their unique and versatile properties.
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Plibrico Phosphate-Bonded Refractories

Within the plastic refractory category, we offer a number of different phosphate-bonded products. This week, we’ll be highlighting a few popular materials from our Plibrico phosphate-bonded refractory selection. These chemically setting plastics offer long term performance for refractory linings in many industries.

Plibrico 68 S

Plibrico 68 S is mullite-based, phosphate-bonded plastic refractory. Its service temperature limit of 3100°F and high hot strength make this material an effective selection for burner cones, boilers, and incinerator slagging areas. In addition, as Plibrico 68 S is non-wetting to aluminum, it works well in aluminum lower sidewalls, hearths, upper walls and roofs, troughs and lauders.

See the Plibrico 68 S technical data sheet for product details.

Plibrico 68 SA

Plibrico 68 SA is similar to Plibrico 68 S in chemical composition, but different in its improved aggregate sizing distribution. This improvement gives Plibrico 68 SA a smoother texture, improves ramming characteristics, and reduces slumping.

See the Plibrico 68 SA technical data sheet for product details.

Plibrico 85 S Special

Plibrico 85 S Special is a versatile, high-purity plastic refractory. It is non-wetting to aluminum alloys and has been designed to be chemical and abrasion-resistant. Plibrico 85-S Special is an excellent product for boilers, incinerators, wood-fired burners, and many other applications.

See the Plibrico 85 S Special technical data sheet for product details.

Plibrico 90-S

Plibrico 90 S is a 90% alumina, phosphate-bonded plastic refractory. This product is tailored to applications which require a high service temperature (3400°F service limit) and high material strengths, including burner cones, furnace hearths, slag areas, and sulfur recovery units.

See the Plibrico 90 S technical data sheet for product details.

Plibrico SR-90

Also, a 90% alumina, phosphate-bonded refractories, Plibrico SR-90 is manufactured with a soft plastic consistency and is designed for thin applications. Its fine grain size and high workability make Plibrico SR-90 ideal for patching and repairing existing linings.

See the Plibrico SR-90 technical data sheet for product details.

Plastic Refractory Solutions for Your Business

TFL is your source for innovative refractory solutions. We offer superior plastic refractory materials to support your thermal processing equipment for long term performance. With a wide range of products, it is our goal to provide the right material for all of your refractory needs.

Have you used any of our Plibrico Phosphate-Bonded Refractories? Share with us on social media!

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CERABOLT Overlay vs. Traditional Module Replacement

Fri, 14 Feb 2020 09:00:00 GMT

There’s never a good time for your refractory furnace linings to fail. When your furnace’s ceramic fiber module lining is in trouble, you might ask yourself:

Are your refractory linings beginning to fail? Find out why our CERABOLT System is the solution you need to minimize your furnace downtime.
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The CERABOLT System from TFL is a proven money saver! With Cerabolts to overlay an existing lining, you can save both time and money in your repair process.

On a recent lining restoration, we compared the costs of a Cerabolt overlay and the complete replacement of modules. Here are the details of the furnace we used in our comparison:

As seen in the table below, the Cerabolt overlay option used for the same repair area offered multiple cost advantages. Compared to a complete module replacement, the Cerabolt overlay cost 21% less and the furnace downtime was decreased considerably.

Choose Quality Cerabolt Overlays

Contact TFL today for more information about Cerabolt overlays. Our team is happy to help you find the right refractory solution for you.

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TFL’s Ceramic Fiber Modules Set a New Standard for Quality

Fri, 24 Jan 2020 09:00:00 GMT

We know you have a choice for ceramic fiber modules. TFL is your supplier for the highest-quality modules available, not to mention they’re made right here in the USA!

For high-quality ceramic fiber modules, #TFL sets the standard for high quality and innovative refractory solutions.
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TFL’s modules are manufactured from the finest quality ceramic fiber blanket and come in three styles:

CM-Pleat Style

The CM-Pleat style of modules are folded or stacked modules. They are made for use with “stab-on” hardware such as H-Hangers, L-Hangers, T-Hangers, or Split Hangers.

CM-Weld Style

The CM-Weld style of modules are folded modules with internal anchors. They are designed for quick installation using an automatic stud welding machine.

CM-Channel Style

The CM-Channel style of modules are folded modules with internal anchors. They are designed to be attached using a variety of welded studs, slide channels, or bolts through the furnace shell.

Customizable Modules for Your Furnace Linings

Ordering ceramic fiber modules from TFL is simple. Just let us know the temperature rating required (usually 2300℉ or 2600℉), and the style of anchoring you’re needing. We can supply modules in virtually any size required (up to 24” x 24”) to minimize joints, maximize stability, and accommodate for high-temperature shrinkage.

Our modules come compressed and banded to the required density for ease of handling during installation. In addition, we also have custom module sizes and expedited manufacturing upon request.

Contact TFL for Refractory Solutions

We understand the urgency of most refractory module jobs, and will quickly respond to supply your needs with standard or custom-sized modules. Contact TFL today for pricing and delivery regarding ceramic fiber modules.

For more refractory industry news, connect with us on Facebook.

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3 Refractory Solutions for Your Business in 2020

Fri, 03 Jan 2020 09:00:00 GMT

The promise of a new year is always inspiring, but entering into this new decade seems to carry an even stronger energy.

A New Year and a New Decade! Here are 3 Inspired Refractory Solutions for 2020 and beyond!
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Refractory Solutions for Your Business

TFL is your refractory source for innovative solutions. We are starting this year off discussing three inspired refractory solutions to consider in 2020. We pride ourselves on being able to offer a product line of refractory solutions that will bring continued success to your business.

1. Precast Refractory Shapes

2. New and Improved Materials

3. Refractory Anchors

The quality of refractory installation can mean a difference in years of the lifetime of a furnace, boiler, or other lining. One of the most important aspects of refractory installation to consider are refractory anchors. From common steer-horn V-anchor, threaded studs, wall support plates, or a ceramic anchor assembly, we provide a range of refractory anchors for your use. If you’re unable to find the correct product, we also provide custom-designed anchors to fit the specifications of your project.

High-Quality Year-Round

No matter what may have transpired in 2019, the start of a new year welcomes a fresh start and room to achieve your goals. With TFL’s top-rated products and refractory solutions, your business will be equipped to complete your projects with unmatched quality .

Which refractory solutions does your business need? Share with us on social media!

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Happy Holidays from TFL Incorporated!

Fri, 20 Dec 2019 09:00:00 GMT

2019 has zipped along to the end in the blink of an eye and the holidays are upon us. Amidst the hustle and bustle of celebration, this is the season to pause and reflect on this past year. We consider what went well and look for opportunities for growth. With that in mind, here’s a look at 2019 with TFL Incorporated!

As the holidays draw near, we’re reminiscing over the highlights of 2019 and are looking forward to creating more memories in the new year. Take a look at our annual summary here! #TFL
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Advantages of HyFIBER Technology

TFL is your provider for Plibrico refractory products. We’re proud of the innovations being made with the introduction of HyFIBER technology in our precast refractory shapes. Between toughness and impact resistance, this technology is a benefit to a number of refractory applications.

3 Advantages of Precast Refractory Shapes made with HyFIBER Technology

Completion of Massive Construction Project

This past summer, we successfully completed a construction project with Mitsubishi Heavy Industries. Our manufacture of over 900 unique factory tunnel covers met all of the project’s requirements and deadlines.

TFL Completes Significant Manufacturing Order for Major Construction Firm

Fundamentals of TFL

Our company prides itself on four fundamentals: Innovation, Experience, Responsiveness, and Quality. With these fundamentals as our motivation, we aim to give every client the highest standard of refractory solutions.

The Four Fundamentals of TFL

Ring in the New Year

The holiday season and the end of another year are always busy. As you gather with your family and friends, we wish you all the love and thank you for connecting with us this year. TFL Incorporated is dedicated to improving ourselves in 2020, and we hope to pass that hope for improvement to each of our clients!

What are your holiday plans? Let us know on Facebook and enjoy your time off!

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Plastic Refractories: Highlighting Air Bond

Fri, 06 Dec 2019 09:00:00 GMT

As a distributor of Plibrico refractory products, TFL stocks a selection of Plibrico Air Bond refractories. These air-bonded materials offer a number of benefits for improving your thermal processing equipment.

Check out our wide selection of Plibrico air-bonded refractories for thermal shock resistance and fast start up!
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Plibrico Air Bond Refractories

With a wide range of uses and applications, this week we are highlighting our family of Plibrico Air Bond plastic refractories, which have been designed to be thermal shock resistant and to minimize shrinkage. Another major benefit of air-bonded plastic refractories is the uncomplicated bake out. These materials need no cure time, and go straight from rammed to bake out. This makes these products quicker to install than castable refractories. Within the air bond category, our selection of plastic refractories includes the following.

Plibrico Super F AB

Pioneered in the early 20th century, Plibrico Super F AB is the original rammed plastic refractory material. It is a 43% alumina Super Duty plastic characterized by an air-bonded granular aggregate that gives this product better low-temperature strength and shrinkage control. These features make Plibrico Super F AB an economical material for boiler and furnace walls.

See the Plibrico Super F AB technical data sheet for product details.

Plibrico 60 AB

Plibrico® 60 AB is a versatile air-bonded plastic refractory with 60% alumina designed to withstand temperatures up to 3100°F. With relatively low thermal expansion and spall resistance this material serves well in many applications including steel reheat furnaces, boilers, incinerators, and burner cones.

See the Plibrico 60 AB technical data sheet for product details.

Plibrico 80 AB

Plibrico 80 AB is an 80% alumina air-bonded plastic refractory, and is rated to 3200°F. This product retains good volume stability at high temperatures, as well as good thermal shock and crack resistance. These qualities make Plibrico 80 AB an outstanding material for waste incinerators and thermal oxidizers.

See the Plibrico 80 AB technical data sheet for product details.

Plibrico 90 AB

With 90% alumina content, Plibrico 90 AB is an air-bonded plastic refractory designed to withstand temperatures up to 3400°F. Its high temperature rating, excellent slag resistance and strength under load at high temperature makes Plibrico 90 AB highly effective in severe service applications.

See the Plibrico 90 AB technical data sheet for product details.

Your Source for Plastic Refractory Solutions

TFL is your source for plastic refractory solutions, including air-bonded materials. It is our goal to provide you with quality materials and individualized application consultation for your refractory needs.

Have you used one of the top Plibrico Air bond refractories? Share with us on social media!

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Happy Thanksgiving from TFL, Inc!

Fri, 22 Nov 2019 09:00:00 GMT

Whether you’re new to TFL or you’ve been with us for a while, we want to wish you a happy Thanksgiving! It’s time to take time off work, enjoy a great meal, and spend time with your family. What are you thankful for this year? Here’s what the team at TFL is celebrating this Thanksgiving!

TFL wants to wish you a happy Thanksgiving! Here’s what we’re thankful for this fall. #TFL
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American Innovation

If it’s wasn’t for new technology and innovation in the refractory industry, we wouldn’t be able to offer the services that we do. We are blessed to be able to be a company founded on American roots to inspire change and provide solutions that count.

Impactful Solutions

With their universal design and application, our refractory solutions have the ability to span across continents. We are so thankful to be able to serve a variety of businesses and take pride in being able to provide top-notch engineering solutions.

Plibrico Refractory Materials

Our success is built on the materials from Plibrico , one of the oldest monolithic refractory manufacturers in the United States. We’re proud to offer their quality products and lifetime value as one of their top distributors. Without Plibrico’s turnkey services , we wouldn’t be able to serve as many customers as we do.

Conclusion

As the holiday season begins, we hope you can take the time to be with your loved ones and enjoy Thanksgiving. Those of us at TFL look forward to helping you make this busy season an enjoyable one!

What are your Thanksgiving plans? Share them with us on social media!

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5 Reasons Why Responsiveness Matters in the Refractory Industry

Fri, 13 Sep 2019 14:00:00 GMT

It’s getting late on a Friday afternoon. The furnace has to be back on line by Monday. You’re running low on refractory materials. Who can you call?

Can you rely on your current refractory supplier in a pinch? Why not try #TFL? #TFLHouston
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Responsiveness to Clients

At TFL , we understand the critical nature of refractory installation work. We know that our responsiveness and service is crucial to your success. Here are 5 reasons why responsiveness matters in the refractory industry:

1) Timing is Everything!

We understand the implications of lost production, schedule delays, wasted manhours, and cost overruns. TFL realizes that delays on our end can’t be tolerated, and we help our customers be successful by collaborating on required schedules and meeting our promised deliveries.

2) Refractories are Critical to Industry!

At TFL, we know that our refractory materials are being used in critical furnaces and process units that are vital to our American industrial competitiveness. Furnace operators and refractory contractors that we serve depend on us to provide refractory materials, precast shapes, and anchors on time and within specification.

3) Refractories Often Drive the Schedule!

On most furnace installation or repair projects, refractory installation is the last item on the schedule. When your work is on the critical path, all eyes are on you! The last thing you need in that situation is to be waiting on a material supplier. A responsive supplier can keep you on track.

4) Customer Service Matters

Responsiveness in the refractory industry must be a constant priority for your material suppliers. A truly responsive supplier puts his customer’s needs over all else. Whether it’s one bag or a truckload of refractory, service and response should be the same.

5) What Can We Do for You?

Responsiveness means being proactive and positive. A truly responsive supplier will offer to stretch their own typical services to make life easier for you, the customer. Can we source other items for you in a pinch? Can we help you combine shipments? At TFL, we always ask, “What else can we do for you?”

Choose a Reliable Supplier

TFL’s first priority is always our clients. You can rely on us for fast response times, customer service that goes above and beyond, and delivery on our promises.

Connect with us to start your next project today!

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The Four Fundamentals of TFL

Fri, 30 Aug 2019 14:00:00 GMT

At TFL, we pride ourselves on these 4 pillars of excellence. Find out what they are here!
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When you’ve been in the refractory industry for as long as we have, you simply know what is most important to your customer base. At TFL, our business is built around these four fundamentals:

1) Innovation

We solve refractory problems through creativity and ingenuity, finding solutions where others haven’t looked.

2) Experience

Our decades of hands-on experience guide us as we apply technical reasoning and sound engineering practice to everything we do.

3) Responsiveness

We know that timing is everything in the refractory industry. We meet critical schedules.

4) Quality

We know that our products are crucial to American industrial competitiveness. There is no room in our marketplace for anything but the highest quality products.

Want to know more about us? Connect with us to learn more about how TFL applies the four fundamentals in everything we do!

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Thermal Expansion in Refractories: The Complete Picture

Fri, 16 Aug 2019 14:00:00 GMT

What effect does thermal expansion have on a precast #refractory? As it turns out, quite a bit! Learn everything about the effects of thermal expansion here. #TFL #TFLHouston
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Like all materials, refractories expand and contract when heated and cooled. However, given the fact that refractories are almost always placed into extremely hot environments (that’s their job!), thermal expansion can be a significant factor in the overall performance of a lining and must be carefully considered.

But “thermal expansion” is only one of two quantitative measurements that must be considered when designing a monolithic refractory lining. The other, often overlooked, measurement is the Permanent Linear Change (PLC). A material’s thermal expansion is calculated as a rate of growth per inch, per deg of temperature increase. A material’s PLC is expressed in a percentage and is usually negative.

The reversible thermal expansion of a product is a characteristic of that material’s components. It will be virtually the same on all ensuing heat-ups unless the material is changed somehow due to service conditions.

Permanent linear change in a monolithic refractory is defined as a percentage change in length that happens during the initial heat-up. It only happens once as a refractory is heated up to its operating temperature, and is a result of moisture being released from the material and mineralogical changes that may occur within the material’s ingredients. PLC is typically negative, meaning there is shrinkage happening during the first heat-up.

So for the complete picture in thermal expansion and lining design, one must consider both the true reversible thermal expansion as well as the permanent linear change. The chart below shows how they work together:

The experts at TFL would be happy to help you with your lining design! Contact us today or connect with us on Facebook to get started.

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Your Source for Ceramic Fiber Modules

Fri, 26 Jul 2019 14:00:00 GMT

In addition to our complete line of Plibrico monolithic refractories , custom-designed precast shapes , and refractory anchors , TFL also offers high-quality ceramic fiber modules . We understand the urgency of most refractory module jobs, and can quickly respond to supply your needs with standard or custom-sized modules. Our modules are all made domestically, from superior ceramic fiber blanket with minimal shrinkage.

TFL is your best source for excellent ceramic fiber modules! Here’s an overview of the different types we offer.
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CM-Pleat Style – no internal hardware, designed for use with stab-on hardware such as H-Hangers, T-Hangers, Split Hangers or L-Hangers

CM-Weld Style – Designed for quick installation using automatic stud-welding machine

CM-Channel Style – Designed to be used with individual studs, weld-stud assemblies, slide channels, or thru-bolts.

Modules are formed from a continuous length of top-quality ceramic fiber blanket (2300 or 2600 deg), accordion folded, compressed and banded to the required density and for ease of handling during installation. TFL is able to supply all available module formats, temperature rating, module densities, module sizes, and attachment hardware. Some modules are available in large format (up to 24” x 24”) to minimize joints, maximize stability, accommodate for high-temperature shrinkage and lower installed cost. Custom modules and expedited manufacturing are available upon request.

Contact TFL today for pricing and delivery, and connect with us on Facebook to keep up with the latest news in the refractory industry.

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TFL Completes Significant Manufacturing Order for Major Construction Firm

Mon, 08 Jul 2019 14:00:00 GMT

With the demands of an extremely short delivery schedule, the risk of performance penalties, and extremely tight production demands, TFL Incorporated has successfully completed a significant order for precast refractory “tunnel tiles”. The shapes were exported to the Caribbean nation of Trinidad, to be used in a new methanol plant being constructed there by a consortium which includes Mitsubishi Corp, Mitsubishi Gas Chemical, Mitsubishi Heavy Industries, Trinidad’s state-run utility and Trinidad-based Massy Holdings.

TFL is proud to announce the successful completion of a massive production project! Get all the details here. #TFL #TFLHouston
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TFL was contacted by Mitsubishi Heavy Industries (MHI), lead construction partner in the US $1 billion project, to manufacture over 900 specially designed refractory tunnel covers. Using innovative molding techniques never before used for this type of shape, TFL was able to hold to the extremely tight dimensional tolerances required by the customer, with repeatability. Plicast HyMOR 3000 KK, a low-cement castable manufactured by Plibrico Company (USA), was selected for use on the project based on its high hot strengths and refractoriness under load. The average weight of the shapes was approximately 225 lbs. All shapes were fired to 1250 deg. F prior to shipment.

Performance incentives and penalties were included in the contract. TFL successfully met or beat all delivery deadlines for the 5 different releases.

The plant is expected to start production in the next few months, and will have a capacity of 1 million tonnes/year of methanol, and another 20,000 tonnes/year for dimethyl ether (DME).

“The TMD project with Mitsubishi Heavy Industries enabled us to really show off our core competencies as a company. It required innovative manufacturing techniques, tight quality control, and responsiveness to both our direct customer and the larger project. It also required that we draw on our years of experience as a precast shape manufacturer to make it all come together”, said Emory Laningham, President of TFL. “We were thankful for the opportunity, and look forward to more projects like this one.”

Connect with us to keep up with all the latest updates from TFL!

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Has Your Car-Bottom Furnace Refractory Seen Better Days?

Fri, 21 Jun 2019 14:00:00 GMT

The refractory linings of car-bottom furnace cars present an ideal opport unity for the use of precast refractory shape systems. Many of our heat-treating customers have chosen this new approach over the “old ways” of refractory maintenance. Here’s why:

Find out how precast refractory shape systems can improve car bottom furnaces here! #TFL #TFLHouston
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Other Advantages

Conclusion

Precast shapes for car-bottom furnace refractory linings are easier to install and provide vastly improved performance over cast-in-place refractories. We can also manufacture these shapes with a specially formulated fused-silica castable that is specifically designed to resist damage from thermal cycling- a common source of problems in car bottom furnaces.

Want to learn more about the advantages of precast refractory shapes from TFL? Contact us today!

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Applications: Pligun ® HyREZIST® TS Mix

Fri, 19 Apr 2019 15:00:00 GMT

Applications: Pligun ® HyREZIST ® TS Mix

Pligun® HyREZIST® TS Mix is a thermal shock resistant gunning material based around a fused silica/mullite matrix with a modified high cement bond. This formulation allows for both good gunning characteristics and physical properties, as well as excellent thermal cycling resistance. Maximum service limit for cycling is 2500°F while the optimum cycling performance range is 1500°F to 2300°F.

The product is advantageous in a number of ways:

Have you heard of Pligun HyREZIST TS Mix? Learn the specs, best applications, and industries here! #TFL #TFLHouston
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Specifications

Industries

Applications

Conclusion

TFL is a leading supplier of Plibrico castable and monolithic refractory materials including the Pligun® HyREZIST® TS MIX . Our refractory experts are dedicated to providing innovative solutions with the highest quality precast refractory shapes , refractories , and anchors . We also provide reliable turnkey services .

Would you like to learn more about the advantage of working with TFL? Chat with our refractory experts, today!

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The TFL Advantage

Fri, 15 Mar 2019 13:41:00 GMT

At TFL, we pride ourselves on providing the best refractory services to a variety of industries. We specialize in refractories, refractory shapes , anchors, and refractory installation and design. We’re a recognized leader in the refractory industry, because of our dedication to our clients and our continuous advancements in refractory technology.

We’ve been in business for over forty years- since 1977. The founder of TFL, Teddy Laningham established herself as a leading supplier of Hex Steel. This led to her becoming a distributor for Plibrico . Since then, we’ve become leaders in the refractory industry.

We’ve become industry leaders by working endlessly to develop our company while keeping the following concepts at the core of all that we do. #TFL #TFLHouston #refractories
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Innovation

We use our creativity to solve refractory related problems daily. We think outside of the box to come up with state-of-the-art solutions to improve thermal processing equipment.

Experience

Our experience sets us apart from our competitors and makes us leaders in the industry. With decades of practice, we’ve been able to learn from what’s worked well and what hasn’t in the past. We use technical reasoning and our years of experience to guide us to the best practices in the industry.

Responsiveness

In order to minimize downtime, and improve efficiency, responsiveness is critical in the refractory industry. At TFL we recognize this and act fast to provide necessary solutions for industrial heat processing equipment.

Quality

Lastly, our refractory products are guaranteed to be top-notch quality in high-temperature situations. There is no room in this industry for anything less than the best. From refractory installation services to high-quality Plibrico products , excellence is key for TFL.

TFL: A Company You Can Trust

Our core values have been at the center of our business practices throughout the decades. It’s no wonder we’ve become a leader in the refractory industry.

Would you like to know more about our refractory parts and services? Contact us to speak with our team of refractory experts, today!

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Can Your Refractory Project Benefit from HyFIBER Shape Technology?

Fri, 01 Mar 2019 15:15:00 GMT

HyFIBER precast refractory shapes from TFL utilize a very high quantity of stainless steel reinforcing fibers, infiltrated with a unique low-cement castable slurry in the mold. The resulting refractory shapes exhibit extremely high toughness and impact resistance, as well as excellent resistance to thermal shock during high-temperature applications.

7 Excellent HyFiber Shape Applications

Have you considered HyFIBER Shapes for your refractory project? HyFIBER shape technology offers superior performance where high impact and mechanical loads are prevalent. Stainless steel reinforcing fibers and a unique low-cement castable slurry in the mold makes these precast shapes extremely tough – standing up to extreme impact and thermal shock.

Find 7 reasons why HyFiber shapes provide excellent thermal protection of refractories. #TFL #TFLHouston
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These 7 applications are greatly improved with HyFIBER Shape Technology:

1) Furnace Door Sills, Jambs & Lintels

Door sills, jambs and lintels often take tremendous mechanical abuse from impact. This can result in an improper seal around the door, leading to heat loss and further heat damage.

2) Damper Blades

Often a very high-abrasion area, damper blades are a prime candidate for the additional abrasion resistance that a HyFIBER lining can provide.

3) Curb Shapes

Curb shapes around a car-bottom furnace hearth can take serious abuse when loading and unloading a car. HyFIBER curb shapes are the answer!

4) Impact Pads

Impact pads are some of the toughest refractory applications. HyFIBER shapes can provide durability and toughness to extend the life of pads.

5) Skimming Blades and Stirring Fixtures

A combination of mechanical strength, abrasion resistance, and thermal shock are all required for this application.

6) Rotary Kiln Nose Rings

One of the toughest applications for precast refractory shapes, Rotary Kiln Nose Rings shapes require the ultimate in mechanical strength and abrasion resistance. HyFIBER shapes ensure those needs are met.

7) Replacement for Water-Cooled Doors and Structures

The continual, often expensive maintenance issues that are inherent with the use of water-cooled structures can be eliminated with the use of structurally sound HyFIBER shapes.

Technology that Benefits You

Whether you need to extend the life of your impact pads or improve the abrasion resistance of your damper blades, HyFiber shape technology is the solution.

Would you like to know more about how our precast refractory shapes and refractory materials can improve your refractory operations? Contact us to speak with our refractory experts today.

The post Can Your Refractory Project Benefit from HyFIBER Shape Technology? appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

3 Advantages of Precast Refractory Shapes Made with HyFIBER Technology

Fri, 15 Feb 2019 15:33:00 GMT

Plibrico’s HyFIBER technology utilizes a high concentration of stainless steel reinforcing fibers permeated with a low-cement castable slurry in the mold. The HyFIBER technology is used within our precast refractory shapes because of its distinctive characteristics.

Here are 3 reasons that we utilize HyFiber technology in some of our precast refractory shapes. #TFL #TFLHouston
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The Advantages of HyFIBER Technology

Stainless steel reinforcing fibers are lightweight but incredibly strong. Complementing the high-strength fibers, the specially formulated HyFIBER castable slurry is specifically made to increase density while reducing water demand. HyFIBER products provide the thermal protection of refractory in high-temperature applications, along with the mechanical properties approaching those found in steel or cast iron parts.

Here are three advantages of HyFIBER technology in precast refractory shapes:

1) High Toughness

Toughness is the ability of a refractory shape to absorb high amounts of energy without shattering. HyFIBER shapes are designed for maximum toughness.

2) Impact Resistance

High impact loading on refractory shapes can be caused by dropping or falling furnace loads, or from unintended contact with equipment like forklifts or manipulators. These areas are great candidates for HyFIBER precast shapes .

3) Excellent Resistance to Thermal Shock

With the high amount of stainless steel fiber in HyFIBER shapes, they are able to withstand and resist damage due to extreme thermal cycling.

Unique Precast Refractory Shapes

HyFIBER technology proves to be beneficial in numerous refractory applications. Our unique refractory shapes utilize HyFIBER technology to be incredibly durable and provide excellent resistance to damage.

Would you like to know more about our precast refractory shapes made with HyFIBER technology? Join us on Facebook to speak with our refractory experts today!

The post 3 Advantages of Precast Refractory Shapes Made with HyFIBER Technology appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

TFL Now Offers Plibrico’s FAST TRACK Rapid Heat-Up Refractory Products

Fri, 01 Feb 2019 15:33:00 GMT

As a full-line distributor of Plibrico monolithic refractory products, TFL Incorporated can offer Plibrico’s fast-drying, rapid heat-up castable refractories and gun mixes for time-critical applications . Plibrico’s Fast Trackcastable refractories come in both casting grade and gunning grade. Fast Track refractories significantly reduce down time and get process units back on line faster.

#TFL is now providing FAST TRACK Rapid Heat-Up Refractory products, here’s how they can improve #refractory processes. #TFLHouston
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Less Downtime

Downtime is a refractory consumer’s least favorite word. Fast Track castables and gun mixes require a minimum cure time, and may be dried out/heated at an accelerated rate as compared to most conventional castables, enabling you to get process units back on line quicker. Fast Track refractories are suitable for all refractory applications, generally for linings less than 8″ thick.

FAST TRACK Castable Products

TFL offers four distinctive Plibrico FAST TRACK castable refractory products:

FAST TRACK Gunning Products

We offer three various FAST TRACK products specifically for gunning applications:

Global Refractory Supplies

TFL is a key supplier of Plibrico refractory materials. We carry many refractory products including refractory anchors and precast refractory shapes . We serve many industrial companies globally. Would you like to know more about our refractory products and services? Contact us to speak with our team today!

The post TFL Now Offers Plibrico’s FAST TRACK Rapid Heat-Up Refractory Products appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

The Boiler Refractory Dry Out Process

Fri, 18 Jan 2019 15:11:00 GMT

Moisture will most likely accumulate after the refractory is manufactured during the transit. The boiler refractory dry out process is necessary to remove the moisture from the refractory product after installation but before starting operations.

What is the Process for Boiler Refractory Dry Out?

Boiler refractories may be dried out initially before beginning operations or after refractory repairs. This process is done to avoid any damages to your refractory linings.

When it comes to boiler #refractory dry out, it's critical to work with trained professionals. If you want to learn about the process, here are the 4 important steps involved. #TFL #TFLHouston
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1) Consult with Refractory Manufacturer

Speaking with the refractory manufacturer should be your first step, prior to the lining installation . The refractory manufacturer will know the correct refractory placement and curing temperatures for the dry out process.

2) Comprehend the Thermal Profiles

Various temperatures can have extreme effects on refractory systems . While water boils at 212°F, chemically combined water boils at different temperatures depending on the composition. The chemical water is released deeper within the lining as the lining is heated up. Another consideration is that the refractory bricks used in furnaces often have low permeability. It’s critical to understand the constantly changing thermal profile to ensure temperatures do not rise too fast inside the lining. There needs to be ample time for the steam to travel through and out of the lining without an intense steam pressure that is more than the lining can handle.

3) Understand the Various Linings

Complicated linings have various lining configurations within the same unit. This can mean a change in material quality or thicknesses. Thickness changes include the fluctuation in water volume and the thermal profile through the varying lining thicknesses. The diversity in thickness produces different water release points at the different hot face temperatures. All of this must be considered when creating a dry out schedule that accounts for all essential points in the complete lining system to be fired.

4) Plan Accordingly

The refractory designer, manufacturer, and refractory designer must work together with the dry out subcontractor to create a functioning and accurate dry out schedule. Plenty of time and money needs to be allocated to the dry out process.

A Complex Process

Refractory dry out is a complex process that requires careful planning and consideration. Work with a team of experts before scheduling your dry out.

Do you want to learn more about the boiler refractory dry out process? Join the conversation to speak with our team about refractory processes.

The post The Boiler Refractory Dry Out Process appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Your Guide to Selecting the Best Insulation Bricks

Fri, 11 Jan 2019 15:46:00 GMT

Fire bricks are used in high-temperature settings such as furnaces, kilns, and manufacturing facilities. They are preferred due to their thermal conductivity. Furthermore, they are ideal for reducing the amount of energy used.

Here’s a guide intended to help you select the best insulation firebrick for your specific needs. #TFL #TFLHouston
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How Can You Choose the Best Insulation Bricks?

The type of bricks that will work best for you is entirely dependent on your intended application. Here are three types and what they’re used for:

1) Super-Duty Firebricks

Super-duty firebricks are used for thermal insulation in higher temperatures. Many super-duty firebricks are made from a very durable and heat resistant material such as silica. Various kinds of super-duty are used in industrial settings such as the glass and steel industry.

2) High-Alumina Firebrick

High-alumina firebricks are a great choice due to their resistance to corrosion and their performance in high-temperature furnaces. They’re used in various applications like in and around blast furnaces, cement, lime, ceramic kilns, and glass tanks.

3) Insulating Firebrick

Insulating firebricks are lighter weight and used in lower temperatures. They don’t absorb the heat like other refractory bricks. However, they can be used around furnaces to trap the heat in.

Selecting the Right Firebrick

No matter the application, it’s critical to select the best insulation brick for your project. While this guide may help you in selecting the ideal brick, you should always speak with a professional to ensure you’re using the appropriate firebrick.

Are you looking for insulation bricks? Join the conversation to speak with an expert about which one will work best for your application.

The post Your Guide to Selecting the Best Insulation Bricks appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

What are the Characteristics of Refractory Castables?

Fri, 04 Jan 2019 15:06:00 GMT

Refractory Castables are typically used within kilns and furnaces to create the monolithic linings. Refractory castables are made from fine – course refractory grains that are combined together with a cement binder.

Refractory castables are combined with water and then poured, pumped, or pneumatically shot into position to form refractory shapes. There are different types of refractory castables that have their own unique characteristics based on the composition.

Are you interested in learning about the various types of castables? Here are three types of castables and their traits. #TFL #TFLHouston
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Conventional High Alumina Cement

High alumina cement castables are most commonly used in boilers and furnaces. They are resistant to abrasion. Gunning and casting are the methods used to install these castables. Gunning is the preferred installation method when working with bulk materials.

Low Density

Low-density materials are used for insulating in high-temperature facework. A characteristic of these insulating castables is that they are not good thermal conductors. They’re typically used as backup linings in refractories because they are not resistant to abrasion.

Free Flowing

Free flowing castables are easier to shape. They are abrasion resistant and have low porosity. It takes minimal effort to pump these castables into the correct position because they use less cement.

Understanding Refractory Castables

It’s important to understand the various types of castables and their characteristics when working with refractories.

Do you have any questions about the specifications of each refractory castable type? Join the conversation to speak with one of our experts about castables for refractory shapes.

The post What are the Characteristics of Refractory Castables? appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

3 Industrial Safety Goals to Set for 2019

Fri, 28 Dec 2018 15:31:00 GMT

Workplace safety should always be a priority for every industry. It’s essential for management and staff to work together to ensure safety guidelines are in place and understood. While following the rules is important, it’s critical to recognize unsafe activities and have policies in place to properly handle them.

Your Safety Goals

The refractory and installation industry is unique because employees are consistently in close contact with intense, high-temperature heat. People working in the steam and power generating industries must be aware of the boilers and their components.

In order to stay accident-free in the refractory industry, education and understanding of health and safety requirements are mandatory. #TFL #TFLHouston
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Be Aware

Always pay close attention to what’s happening around you. This is imperative when working with extreme heat. Understanding dangers in the workplace and having a policy in place to report them can protect employees.

Dress Appropriately

It’s absolutely mandatory to wear the correct, protective clothing. When removing or installing refractory material containing any chromium base product, wear protective suits to protect skin from refractory dust, and masks to prevent inhalation of dust. When removing or installing ceramic refractory materials , wear gloves and long sleeves. Additionally, safety goggles and a respiratory mask must be worn.

Keep the Workplace Clean

Clean work areas frequently to prevent dust from collecting. Use HEPA filters, or wet sweep and use dust-suppressing compounds when cleaning. Keeping a tidy work area can prevent accidents from happening in the steam and power generating industries.

2019- An Accident-Free Year

Staying safe should always be of utmost importance in the refractory and installation industries. Practicing accurate safety standards should be a regular part of your work routine.

How will you stay safe in the in the industrial, manufacturing and construction industries? Join the conversation and let us know how you’ll stay accident-free in 2019.

The post 3 Industrial Safety Goals to Set for 2019 appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Happy New Year from TFL!

Fri, 21 Dec 2018 15:48:00 GMT

2018 has zipped along to the end in the blink of an eye. This is the time of the year we take a moment to slow down and reflect, remember the year behind us and look ahead with great anticipation for the year to come. We consider what went well and look for opportunities for personal growth.

Now that 2018 has come to an end, here's a look at the year with TFL. #TFL #TFLHouston
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What are the Most Common Refractory Installation Mistakes?

Refractories are an admittedly complicated product and a fundamental part of many industrial processes, but despite their importance, they are frequently seen almost as an afterthought by many plant managers. This presents a unique problem, as they will likely be in charge of selecting a refractory contractor to complete the critical job of refractory installation.

Common Refractory Installation Mistakes

Furnace Refractories and Kiln Insulation: How to Get the Best Results

The configuration of your furnace or kiln is obviously of utmost importance to successful operations, but the correct selection and installation of refractory products used are just as important. All refractories insulate to some extent, but when it is required to minimize the loss of heat without enlarging the structure, an exact selection from a small group of specific materials is necessary.

Get the Best Results in Furnace Refractory and Kiln Insulation

Why Refractories Fail and How to Prevent it From Happening to You

Refractory materials and lining are essential factors for optimizing production and minimizing energy costs. Refractory failure can cause expensive setbacks, higher energy expenses, or in some instances, complete factory closure while repairs are made.

Prevent Refractory Failure

A Safe New Year

2018 has been a wonderful year for TFL Houston. We want to thank our loyal customers and employees for their support. We hope that you have a safe and happy New Year’s Eve, surrounded with loved ones. Here’s to an even better 2019! From our family to yours, Happy New Years!

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How Cerabolt™ Makes Refractory Repair Easier

Fri, 14 Dec 2018 15:04:00 GMT

Refractory repairs are critical but can be tedious and time-consuming. When the lining of your refractory becomes worn and cracked, the complex process of removing the old lining, disposing of it properly and replacing it can seem daunting.

Save Time

Save Money

Save Resources

Refractory Lining Restoration

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10 Characteristics of Refractories Every Plant Manager Should Know

Fri, 07 Dec 2018 15:18:00 GMT

Refractory materials play an integral role in many industrial heat processes, from glass manufacturing to steel and aluminum production. As a plant manager, you’re not expected to understand the nuances of this complex material, but it’s helpful to know some basic principles and characteristics.

As a plant manager, you should be familiar with some common refractory material traits. Brush up on your knowledge to ensure when the time comes for a repair, you are well equipped to make a decision. #TFL #TFLHouston
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Characteristics of Refractories

Refractories face an enormous amount of stress in operation. High temperatures are just one of many factors they must weather. Here are 10 common traits of refractory materials:

1) Abrasion resistance

Refractory bricks and precast shapes face a number of stressors and must be resistant to more than just pressure. The attacks by gases and fine dust particles result in wear, and the rate of wear is the material’s abrasion resistance, contributing to the life of the refractory.

2) Bulk density

The bulk density (BD) is a measure of the weight of a given volume including the pore space of the refractory. It is one of the most important characteristics and provides a good general indication of product quality.

3) Cold compressive strength

In furnaces, cold compressive strength (CCS) is a measure of the mechanical strength of the refractory shapes. Refractories with high compressive strength are more resistant to impact from rods or slag penetration than shapes with a low CCS.

4) Creep

Refractory material must maintain dimensional stability under extreme temperatures and constant corrosion from hot liquid and gases. Creep (thermal expansion under load) is a property which determines the physical change over time and at a given temperature by a refractory in service.

5) Melting point

Melting point gauges the ability of refractory materials to withstand high temperatures without chemical change or physical destruction.

6) Porosity

Porosity measures the open pore space in the refractory and is expressed as the average percentage of open pore space in the volume of the refractory. With respect to porosity, an important factor is its behavior during an extreme chemical attack by molten metal, slag, fluxes and vapors that can penetrate and contribute to refractory degradation.

7) Pyrometric cone equivalent

PCE is a quality control method that detects variations in batch chemistry. Pyrometric cone equivalent is the ability to withstand exposure to elevated temperature without undergoing notable deformation. Due to their chemical complexity, refractories melt over a range of temperatures. In this test, ceramic specimens of known softening behavior (Seger or Orton cones) are compared with the cone of the refractory after firing. This ensures consistency and measures refractoriness.

8) Refractoriness under load

Refractoriness under load (RUL) evaluates the softening behavior of fired refractory bricks at rising temperature and constant load conditions. It gives a forecast of the temperature at which the brick will collapse in service condition with a similar load.

9) Stability, Expansion, and Shrinkage at High Temperature

This is the permanent change in the dimension of the refractory due to contraction and expansion in service. Applying extremely high temperatures followed by cooling often creates a permanent change in dimensions. This may cause loosening or destruction of bricks during service.

10) Thermal conductivity

Thermal conductivity is defined as the quantity of heat that will flow through a unit area in a direction normal to the surface area in a defined time with a known temperature gradient under steady state conditions. It indicates general heat flow characteristics of the refractory and depends upon the chemical and mineralogical composition as well as the application temperature. High thermal conductivity refractories are needed for some applications such as coke ovens, regenerators etc, while refractories with lower thermal conductivity are preferred in most applications since they help conserve heat.

Extending the Life of Your Refractory

The refractory material used in your industrial plant play a critical yet often overlooked role in your daily operations. Familiarizing yourself with the general concepts and properties of refractories will only benefit your decision making when the time comes for repairs.

Contact Us to learn more about selecting the right kind of refractory material for your application.

The post 10 Characteristics of Refractories Every Plant Manager Should Know appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

A Plant Manager’s Guide to Boiler Refractory and Repair

Fri, 30 Nov 2018 15:07:00 GMT

Refractories are one of the most crucial components of a boiler system, creating a heat resistant liner that’s integral to its functioning. Unfortunately, the boiler refractory lining is often the most common reasons for outages and energy loss.

The importance of the refractory lining to a boiler’s overall efficiency cannot be overstated. Review our Boiler #Refractory and Repair Guide. #TFL #TFLHouston
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Boiler Refractory and Repair

Boiler refractory lining repair is an inevitable part of operating an industrial boiler. Problems with your boiler refractory may include cracking, refractory door issues, pressure leaks, or damage to seals and joints. Once you’ve noticed signs of damage or dips in boiler performance, a refractory repair might be in order.

Common Materials

In order to hold in the heat contained in boilers and furnaces, specific refractory materials are used. The materials used in boilers must be able to withstand extreme heat, pressure, and sometimes intense chemical processes. Common materials used are monolithic refractories or firebrick.

Problems

There can be a number of reasons why a refractory lining needs to be replaced in a boiler, including:

Considerations

Repairing Refractory Linings

Boilers are critical process components that can completely shut-down a plant’s production when they fail. Partner with a refractory expert to better understand refractory linings and their proper maintenance.

Contact Us to learn more about the refractory materials that will work best for you.

The post A Plant Manager’s Guide to Boiler Refractory and Repair appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Key Considerations for Refractory Dry Out

Fri, 23 Nov 2018 15:18:00 GMT

With the pressure to perform comes the desire to push production levels and postpone necessary refractory repairs and maintenance, with very little consideration given to furnace heat up rates that could prevent damage to refractory linings. As a result, significant fluctuations in temperature have devastating effects on your refractory systems.

There are several key factors in refractory dry out that could affect your project. Learn how to address these challenges.
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Curing & Dry Out

The curing process of a refractory cement takes place within the castable material after the dry material is mixed with water and either poured or guided into place. The water and refractory material then react to form a strong bond with the aggregate at ambient temperatures. This normally occurs in the first 24-48 hours after placement. Dryout is the initial application of heat under controlled rates to safely remove free and chemically combined water from the refractory lining after the curing process is complete. This may be the initial dry out after installation, or a subsequent dry out following repairs.

Budget

Budget constraints and economic restrictions are often the driving force behind inadequate or improper dry out. While your refractory might benefit from a slow, continuous ramp-rate dry out schedule if you did not plan for enough downtime the temptation to speed up the timeline might seem like a gamble worth taking.

Experience

For a new unit commissioning or a complete refractory system replacement, advanced planning for time and budgetary allowances is essential. Unfortunately, due to inexperienced engineers or contractors, these critical items may be missed in the project planning phase until very close to the intended startup date. This can lead to damage to the refractory before it is even able to perform.

Environment

Unit configuration and environmental considerations play an important part in planning for a proper dry out. This process entails more than just following a heating schedule. Issues such as burner sizing and location, exhaust location, air volume, and velocity, etc need to be addressed. The best dry out plan and schedule will fail if the unit environment isn’t factored in. For example, if you plan to use the main burner for dry out with no backup plan to use a third party burner/contractor to aide in the work, your process will grind to a halt if it’s discovered that the main burner is unable to do the dry out.

No Universal Dry Out Method

All dry out schedules should be developed with the specific unit to be dried out kept in mind. For castable linings, the refractory industry has typically utilized a ramp and hold regimen. Temperatures are ramped up at not to exceed rates (say 25°F – 75°F/hour) and then held at various hold points for specific periods of time. Even with this method, timelines and temperatures will vary, so it’s critical that you have an expert on your side.

Considerations for Refractory Dry Out

The combined efforts of an experienced refractory manufacturer, installer and dry out contractor result in optimal refractory performance . Do you have the best team for your refractory installation and dry out?
Contact Us to learn more about proper refractory dry out, startup and shutdown.

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What are the Most Common Refractory Installation Mistakes?

Fri, 16 Nov 2018 15:13:00 GMT

Refractories are an admittedly complex product and an integral part of many industrial processes, but despite their importance, they are often seen almost as an afterthought by plant managers who don’t understand them. This presents a unique dilemma, as they will likely be tasked with selecting a refractory contractor to complete the crucial job of refractory installation.

If you’re planning a refractory installation job, watch for these common mistakes.
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Common Refractory Installation Mistakes

Selecting and installing refractory lining materials is a process best suited for someone with accurate knowledge of the chemical and physical properties of the refractories and refractory materials, and the stresses these materials encounter during service. If the decision-maker lacks this kind of expertise, you may run into trouble. Here are some common installation mistakes made by inexperienced contractors:

Selecting the Wrong Materials

Choosing the best refractory materials is critical to protecting and maintaining the efficiency of your heat processing equipment, but it’s not always a priority for many industrial plant managers. However, modern refractory materials are engineered for specific applications that require specific placement techniques. Choosing the wrong material can sabotage your entire project.

Mixing Errors

When installing castable refractory, paying attention to the mixing process and keeping the consistency of each batch the same will help ensure that a proper refractory installation is off to a good start. Here are some common mixing errors encountered:

Neglecting Dry Out

Dry out is the slow application of heat under controlled conditions to safely remove water from the refractory lining after the curing process is complete. Improper dry out can have devastating consequences for your refractory. If the time is cut too short in order to speed the commissioning of the unit, the refractory could experience damage before it’s even in use.

Choosing the Wrong Installation Company

There is nothing simple or easy about a material that is expected to work under extreme conditions. While keeping costs down is an undeniable consideration, picking a well-trained and experienced installation company will ultimately ensure the success of your refractory lining installation.

An Often Overlooked But Critical Component

Though refractory linings are often an overlooked component on an industrial furnace or kiln, they are one of the most important for heat containment, energy efficiency, and proper operation of the industrial process. Consult with a competent refractory installer to achieve a better refractory installation, review the best practices, and avoid refractory failures.

Contact Us to learn more about refractory installation or to speak with a member of our team to find out how we can assist you with your refractory related needs.

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TFL: Bringing You the Plibrico Advantage

Fri, 26 Oct 2018 13:29:00 GMT

In addition to their large variety of ceramic fiber and firebrick refractory materials and accessories, TFL is a major distributor for Plibrico Company LLC, a leading manufacturer of monolithic refractory materials.

TFL only delivers the best in refractories, which is why we supply Plibrico materials. Learn what sets us apart from other manufacturers.
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The Plibrico Advantage

For more than a century, Plibrico has pioneered the research and development of monolithic refractory technology. Used in a variety of demanding thermal applications, these materials stand the test of time. Plibrico provides the industry expertise needed for the most demanding operations.

Plibrico in The News: Industrial Heating Today Magazine

Plibrico was featured on the cover of Industrial Heating Today , The Industrial Journal of Thermal Processing in their October 2018 issue. The magazine provides timely technical information and news on a variety of topics, including heat treatment, metallurgy, brazing and much more. The article, written by Plibrico’s Director of Marketing Pamela Gaul, is titled “Maintain Your Refractories – Avoid Costly Refractory Repairs with Proper Maintenance.” It provides a basic overview of refractory maintenance and explains how readers can help extend the life of their refractories.

Furnaces North America 2018

Furnaces North America is the heat-treating industry’s main event of the year, attracting attendees from all over the world to learn more about emerging technologies, trends and equipment updates. FNA 2018 showcases equipment enhancements, business opportunities, new innovations in technology and the opportunity for technical training. Plibrico was showcased at Industrial Heating Today’s booth, where the October issue was once again front and center.

TFL & Plibrico

As a long time distributor for Plibrico Company, LLC, TFL has seen first hand the quality and consistency of these refractory materials. We’re proud to provide the technical expertise and practical knowledge to ensure our customers get the material, value, and installation they deserve.

Contact Us to learn more about Plibrico, or any of our other top quality refractories .

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Choosing a Monolithic Refractory Installation Method

Fri, 19 Oct 2018 14:41:00 GMT

Choosing the best refractory material can be overwhelming by itself, but that’s only half the battle. You also need to select the right installation method and get a team with the experience and skill to get the job done right.

How should you choose the right refractory installation method? Use this guide to help you along the way.
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Monolithic Refractory Installation

Technology has advanced to make the installation of refractories more cost-effective. Consider the refractory lining, which is a protective layer inside the kiln or furnace. The lining acts as a form of insulation to withstand high temperatures, and also helps protects the structure from thermal shock and abrasion. Here’s a summary of the best ways to install monolithic refractory linings:

1) Shotcrete

Shotcrete is typically a low-cement, low-moisture refractory that is fully tempered and mixed with water and special binding additives, and then projected at high velocity onto a surface.

2) Gunite

Gunite is a dry monolithic refractory designed for use with dry gunning equipment. It uses compressed air to send the dry material to the nozzle, where it mixes with water. Then it sprays out at super high velocity, which compacts the material on placement.

3) Ramming

Ramming plastics or castables are versions modified such that they can be hand-rammed into place. Lining-support fittings are attached to the shell (metal anchors or ceramics tile anchors for the wall). The material is quite literally rammed into place using a pneumatic hand hammer. Forms may or may not be used, depending on the situation.

4) Casting

Casting refers to pouring wet castables into forms. Castables can be molded by hand or poured into forms to achieve whatever shape is desired. Once hydration of the cement in the mix is complete, the forms are removed.

Choosing an Installation Method

Proper refractory installation is vital to achieving a quality refractory lining. Choosing the right installation method comes down to several factors, including:

Partner With an Expert

There’s no universal method for installing monolithic refractory linings, but if you do your research and partner with a refractory expert, you’ll be more likely to choose the best method for your specific requirements. Remember that using top quality refractory materials, like Plibrico , will further set you up for success.

Contact Us to learn more about refractory installation methods.

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3 Lessons Learned From Industrial Plant Fires

Fri, 05 Oct 2018 13:12:00 GMT

In March 2015, a fire broke out in SCHOTT North America’s Duryea glass plant causing more than $50 million in damage. Unfortunately for industrial plants that involve extremely high temperatures and flammable liquids or chemicals, such incidents are very real. The most common reasons for plant fires are electrical hazards, flammable materials, combustible dust, and heat-related work.

Plant fires can cause millions of dollars of damage and millions more in lost revenue. Here are 3 lessons learned from industrial disasters.
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Preventing Industrial Plant Fires

About 37,000 fires occur at industrial and manufacturing properties each year, leaving billions of dollars in damage, causing injuries and in some cases, loss of life. Here are 3 lessons to take away from such devastating accidents:

1) Inspections

Many industrial processes that use furnaces or other insulated vessels are lined with refractory insulation to protect the exterior metal from the high temperatures and caustic properties of the product. Over time, the lining deteriorates and must be replaced. An inspection of the structure should be undertaken when damage or wear is suspected. Additionally, routine inspections of the entire plant and all machinery and flammable or combustible substances used within it should be commonplace.

2) Maintenance

Heating and related equipment are a common source of industrial fire, in particular, furnaces that weren’t properly installed , operated, or maintained. Always follow the recommended maintenance procedures for all of the equipment and machinery in your plant. Not only does routine maintenance reduce your fire risk by preventing overheating, regular maintenance will also keep your equipment working.

3) Prioritize Safety

The importance of workplace safety in industrial plants cannot be overstated. Not only must the physical environment be kept clean and free of flammable debris, but employees must be aware of their surroundings and each other. They should be encouraged to report potential violations for immediate rectification.

A Safe Workplace

Even with all the precautions of inspections and routine maintenance, accidents will still happen in plants that deal in dangerous temperatures or substances. With vigilance and a proactive safety strategy, many similar situations will be avoided or lessened in severity.

Contact Us to learn more about refractory inspection, maintenance and repair.

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A Brief History of Refractories

Fri, 28 Sep 2018 14:36:00 GMT

Refractories are used in countless industries, from iron and steel to energy and glass. Manufacturing in its current form could not exist if not for the technological advancements in refractory materials since the Industrial Revolution.

A Simple Start

Because of their chemical composition and reactions, refractories are fairly complex. However, the basic principles behind them are remarkably simple. In fact, those principles were present as early as 3000 BC, when people began to dig primitive pit kilns in the ground to fire their earthenware (bowls, plates, etc.)

Iron Age

Refractory technology began in earnest during the Iron Age (2000 BC). Using charcoal in a furnace, iron was produced by reducing the iron ore with extreme heat. Furnaces used in iron production featured very elementary refractory lining, usually consisting of unshaped fireclay, carbon-added composite materials, and silica rock, although blocks cut from natural stones or fireclay brick were also used.

Industrial Revolution

During the 18th and 19th century, refractory technology took great strides. Many industries began using the new technology, prompting a label of the “smokestack industries” for the looming smokestack billowing smoke into the air. The driving force behind the growth was the steel industry. Furnaces used for iron and steel manufacturing during this time had the following characteristics:

New Refractory Technology

While steelmaking was transforming the firing process, refractories were making great advancements, including:

The 20th Century

In 1901 US Steel was founded as the world’s largest steel manufacturer, and in 1902 Harbison Walker Refractories opened as the largest refractory manufacturer. Thus, the USA was the center of steel manufacturing in the world. Even interrupted by several wars, advancements in refractory technology in this time included:

Post-WWII

Following the second world war, refractory technology continued to be refined and improved upon. The high-pressure, high-temperature blast furnace became widely used, and the performance of various types of refractories became more clear, and material designs were altered to facilitate greater efficiency. Other innovations included:

Limitless Growth

While refractory technology saw the biggest growth in the Industrial Revolution and in the years since WWII, there continue to be advancements and exciting innovations in the field.

Contact Us to learn more about the most cutting-edge refractories available.

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Top Benefits of Precast Refractory Shapes

Fri, 14 Sep 2018 13:37:00 GMT

Refractory repair can be a daunting, expensive process when you consider the downtime, demo, installation, and bake-out. With precast refractory shapes, much of that headache is eliminated.

Precast refractory shapes are consistent in composition, reliable in service and facilitate speedy repairs.
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The Advantages of Precast Refractory Shapes

Refractory materials are generally divided into two kinds: precast (shaped refractories) and monolithic (unshaped refractories). Using precast refractory shapes has many advantages, including predictability, simplicity, and durability.

More Predictable

Physical properties of the material can be optimized if fired slowly, from all sides, through the entire thickness of the shape, not just the surface. The result is a truly homogeneous lining, uniform in nature and incredibly reliable. Since the intial firing is more controlled, there is also a reduction in m icro-cracking within the shape. In service, precast shape refractory linings see less stress and cracking, thanks to their independent nature.

Simplified Installation

Refractory installation contractors have come to consider precast refractory shapes much like any other pre-manufactured item, including insulation, ceramic fiber blanket and anchors. Precast shapes allow a bulk of refractory repair work to be completed prior to crews being on site, which can significantly reduce costs. This can give installation contractors a substantial advantage in competitive bid situations. In other installation methods such as guniting, as 45% more material is required to compensate for rebound and other loss. Using precast shapes requires significantly less material, translating to more savings.

Fast Bake-Out

An expensive and time-consuming aspect of refractory repair is the initial bake-out. The use of precast refractory shapes can reduce or even eliminate the need for an extensive bake-out. If all repairs are made with a prefired system, then normal furnace functioning can resume, without the fear of steam spalls or damage during initial heating. Bake-out of multi-component linings, which may include precast shapes and other materials,, can often be reduced by the pre-firing of the castable shapes.

Choosing the Right Material

The applications for precast shapes are virtually endless, with uses in a variety of different industries. Their use results in better performance, decreased downtime and significant cost savings. The successful design and manufacturing of high-performance refractories requires a thorough understanding of refractory materials, and no one knows them better than TFL.

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How To Evaluate Your Refractory Technical Datasheet

Fri, 07 Sep 2018 14:30:00 GMT

Refractory datasheets are a valuable resource when selecting the right refractory material for a specific application. They provide good general information about the physical and chemical characteristics of a refractory, including density, thermal expansion, and porosity.

The refractory datasheet can only provide general information, not specific to your application.
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Understanding the Technical Datasheet

Refractory datasheets list the physical properties, chemical makeup and testing results of the material. They usually include:

Performance on Paper

Datasheets are great for getting general information, but because they can’t take into account the variables unique to your application, they can only tell you how they’ll perform on paper. Real service is a very different beast! A refractory datasheet that shows an in-service temperature of 3,000 degrees Fahrenheit may not actually function under real use at those temperatures.

Performance in Use

A datasheet contains very useful information, but it’s important to keep in mind that mineralogy and physical properties vary due to refractory thickness. Linings between layers will affect the performance of the refractory when in use.

The Right Choice

The technical datasheet is just one tool to help you choose the right refractory material. It should be taken into account along with all other relevant factors. Ultimately, your refractory material supplier or contractor should evaluate all the options before making an informed, expert decision.

Contact Us to learn more about refractory data sheets, or to get help deciphering one.

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Refractory Bids: 5 Tips to Help You Choose the Best Contractor

Fri, 31 Aug 2018 14:25:00 GMT

So you’re ready to start your refractory project, but you need to choose the best contractor for the job. What’s your first step? The bidding process can give you insight into the cost and process of various contractors, but going with the cheapest option may come back to haunt you. Choosing a refractory contractor should be based on much more than price.

Refractory Bids

As US manufacturing faces mounting pressure to cut costs and turn a profit, it’s crucial that construction and maintenance expenses be kept as low as possible. However, with something as crucial as refractories , you can’t afford to be cheap. Here are 5 tips to help guide you in the bid process:

1) Think Long-Term

It may be tempting to opt for the lowest priced bid but keep in mind long-term costs. What’s initially the cheapest bid could lead to additional expenses if it’s not done well. This means that the lowest price might actually be the highest total cost.

2) Be Specific

Your bidders should have all the facts and background in order to make an educated quote. This includes the scope of the work, all relevant factors and the type of refractory you desire.

3) Ask Questions

What criteria are your bidders using? There are so many factors to consider and each of those factors affects price, so make sure you ask a lot of questions to ensure that you understand the quote.

4) Disclose Everything

Don’t try to hide anything or sugarcoat your situation to a refractory installation contractor. It will not save you money and could actually cost you more in the end.

5) Include Stakeholders

People who don’t have the best interests of the business in mind will often choose the cheapest bid. They’re not invested in the long-term success of the refractory. Someone with a stake in the business should play a big part in choosing the refractory contractor.

A Successful Refractory Process

While the temptation to save money can be overwhelming, the success of your entire operation hinges on a long-functioning refractory. Making the right choice the first time around will benefit your profitability in the end.

Contact Us to learn more about expert refractory contractors.

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Why Refractories Fail & How to Prevent It From Happening To You

Fri, 24 Aug 2018 14:27:00 GMT

Refractory materials and lining reliability are critical factors for optimizing production yield and minimizing energy costs. Refractory failure can cause costly delays, increased energy expenses, or in some cases, complete shutdown while repairs are made.

The more you know about common refractory failures, the better you can avoid them.
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Why Refractories Fail

Refractory failure is a major cause of production delays as well as a major contributor to plant outages. Understanding why a refractory material fails requires a thorough analysis of many related factors.

Castable Cracks

Much like cement mix, castable linings are not in a finished state when they leave a manufacturing facility. This means that the final product is dependent upon proper installation.
Materials must be mixed with clean water within the right temperature range and installed and cured before water is removed during the dry-out. If dry-out is not done in a slow and controlled manner, shrinkage may occur. Some shrinkage and cracking is normal, but if it becomes excessive, it could be a consequence of poor installation using too much water.

Roof Collapse

Leaning Walls

It’s not all that uncommon to see inner walls lean slightly. However, dramatic leaning could signal that the floor isn’t level, which can cause failure. A lot of wall issues are also due to inadequate expansion provisions, such as increasing operating temperatures to higher than expected. The key to making the best selection is investigating both the ambient and hot strength properties.

Mixing Materials

While it’s not uncommon to mix refractory materials , particularly around openings such as doors (fiber and brick), peep sights (IFB, castable, fiber modules) and burner blocks. Because dissimilar materials often have different chemical properties at elevated temperatures, this can result in vulnerabilities around those areas, which can lead to refractory failure. Avoid these issues by using similar refractory materials to those surrounding openings to create the best possible seal.

Focus on Reliability

Finding the root cause of a refractory failure must take into account factors such as material type, manufacture date, plant operations, material storage, mixing, installation, curing, and drying. By better understanding refractory materials and installation processes, you can help eliminate future failures. When it comes to refractories, don’t focus too much on cost, but on reliability. Remember that the best products and professionals for the job are typically not the cheapest.

Contact Us to discuss your refractory project and find out how we can help.

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Selecting the Right Anchor For Your Refractory Project

Fri, 17 Aug 2018 14:00:00 GMT

An often overlooked component of refractory installation is the anchoring system. Refractory materials require anchors to provide stability to keep them in place throughout the life of the refractory lining.

Proper anchor selection is a crucial part of the foundation necessary to ensure your refractory project is a success.
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Selecting The Proper Anchors

Why do refractories fail? Most often the failure is due to a problem that occurred during installation, which can include a lack of understanding regarding anchors. When choosing an anchor design system, it’s important to take into account:

Types of Anchors

Anchors are typically alloy (metallic) or ceramic. Alloy anchors are traditionally used in low to moderate temperature applications, while ceramic anchors like Plibrico , are usually used for monolithic refractories and can withstand extremely high temperatures.

Why It Matters

In fairly recent years, refractory materials have faced new challenges, including the need for resistance to very specific chemical environments, particularly in the cement industry. At high temperatures and during prolonged exposure, the presence of harsh chemicals in different states wreak havoc on the ceramic of the lining. As a result, there have been many advances in the chemical composition of refractories to better protect them from degradation.

However, the same care has not been shown to the refractory anchors that will retain the lining, often resulting in refractory failure. What was once considered a simple accessory to the refractory, anchors have become valued for their importance. To reduce the risk of anchor failure, certain basic requirements have to be met. The anchor should be chosen with care in terms of shape, composition and the way it’s produced.

A Firm Foundation For Refractory Project Success

Your anchors serve as the foundation for your refractory lining. Selecting the appropriate anchors is crucial to the success of your project, and will ensure the longevity of your refractory.

Contact Us to learn more about refractory anchors, including Plibrico, Rotalock and more.

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Top Tips For Choosing a Refractory Contractor

Fri, 10 Aug 2018 14:00:00 GMT

Wondering how to choose a refractory contractor for your upcoming project? Choosing the right person for the job can be a challenge, especially because refractories are more complex than many people realize.

With a variety of refractories to choose from, it's vital you choose a contractor capable of selecting the right one for your project.
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Selecting a Refractory Contractor

Refractories are often the lowest priority for plant managers and engineers, not because they aren’t important but because they’re not well understood. In addition, even the best-laid plans can meet complications during installation. An experienced contractor will know how to handle them, while an inexperienced contractor may make costly mistakes. Here are the best ways to vet your contractor:

Plant engineers and maintenance staff shouldn’t be expected to keep up with changing refractory technology, but that’s your contractor’s job. They should be aware of all types of refractory materials, installation methods and the latest products.

Contractors can expose you to liabilities, so it’s crucial that you review their safety program. Use of subpar materials or turning a blind eye to hazards for the sake of profits can create significant safety risks. Ensure that there is clear and comprehensive training for all employees, safety equipment provided and a strict adherence to safety regulations.

A reputable contractor should always stand behind his or her work and materials. While some may try to skimp or save on materials, refractories should be carefully selected to fit each application. A guarantee provides peace of mind that your contractor is putting the success of the project ahead of their bottom line.

Does your contractor have a good reputation? While the industry has many skilled and experienced players, there are also inexperienced newcomers that lack the proper resources. Make sure you read all reviews and consider reaching out to people that have worked with your prospective contractor before to get their feedback.

Get The Job Done Right

Can you afford downtime if your refractory installation isn’t done right? If not, then you need to do a lot of research and go with a reputable contracting company with many years of experience.

Contact Us to get more information about choosing the right contractor.

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How to Choose the Best Refractory Material

Fri, 03 Aug 2018 14:30:00 GMT

While refractories are crucial to many industrial operations, the person charged with selecting the appropriate materials may not be a refractory expert. That can open the door for new or inexperienced refractory dealers to provide a product that may not be the best choice.

Only an experienced refractory professional should be trusted to make the final decision regarding the best material for the job.
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The Best Refractory Material

While certain refractory materials work better than others for specific applications, there is no perfect refractory material. There is only the best material for the job. What works well in an aluminum furnace may not work in a rotary kiln.

Consider the Application

The refractory material you choose depends entirely on the application. Since these materials have a range of chemical compositions, installation methods and specific temperature thresholds, choose based on the application, not the refractory.

Watch For Red Flags

One thing to watch out for when choosing a refractory material is a contractor that is overzealous about one type of refractory material. If they push the same material for every different application, they may have their own motives. The sign of a good contractor is a wealth of knowledge about various refractory materials and a sound opinion of what will work best and why.

Don’t Sugarcoat

There may be things that the customer doesn’t divulge, or sugarcoats either in an attempt to save money or avoid additional time on installation or repairs. This is not beneficial for anyone and is usually caught by an experienced contractor anyway. In the end, a few more days or dollars will be worth it, especially when the alternative is a refractory that may have vulnerabilities.

Trust a Professional

There’s always buzz when a new refractory option is introduced, but it’s important not to be swayed by trends. Trust a professional with enough experience to know what will work best for your needs.

Contact Us to learn more about choosing refractory materials for your industrial operations.

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Refractory Misconceptions That Could Cost You

Fri, 27 Jul 2018 14:30:00 GMT

Not every plant manager or industrial engineer is a refractory expert, nor do they need to be. However, without an expert on your team, it’s easy for mistakes to be made. If your industrial facility uses or needs to install refractories, there are certain misconceptions you’ll need to be aware of to avoid disaster.

There is no one-size-fits-all solution when it comes to refractories.
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Refractory Misconceptions

Refractory installation , repair, and maintenance require special considerations and customized strategies for every unique situation. Here are some common refractory misconceptions that could cost you:

Manufacturing is Identical

Refractory products aren’t universal. One manufacturer’s precast refractory might have a slightly different chemical makeup than another’s. This means that it’s crucial to have a refractory engineer with plenty of experience to help you select the correct refractory materials for the job.

Any Water Will Work

In many construction applications, the quality of the water you use to mix materials doesn’t matter much. However, when mixing castable refractories, dirty water can adversely affect your outcome. Water that might contain bits of debris should not be used in refractory installation.

The Inside is the Only Concern

The heat and chemical reactions that occur inside industrial furnaces, boilers, kilns, gasifiers, and incinerators certainly affects refractory materials, but so does the weather outside. Mixing, installing and storing castables in cold temperatures requires additional precautions.

Risks Associated With Refractory Failure

Refractories protect industrial workers from serious heat-related injuries. A refractory failure can make your facility vulnerable to rising temperatures, which could spell big trouble for your workers. In addition, mistakes made during the installation of your refractory can lead to incredibly expensive periods of downtime for repairs.

Get an Expert on Your Team

Given their importance to industrial processes, you might think that everyone knows about refractories. However, their complexity means that only an experienced refractory team will be able to help you select and install the right materials for your specific application.

Contact Us to learn more about refractory options to suit your needs.

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3 Reasons Industrial Furnace Cleaning is a Must

Fri, 20 Jul 2018 16:00:00 GMT

Industrial furnaces do a lot of work every day, and even one working properly will develop normal wear and tear. With regular maintenance and preventative care, your industrial furnace can be kept functioning efficiently, which minimizes downtime for major repairs and improves productivity.

Furnace Cleaning

Scrape the walls of your furnace with specialized rakes every shift will decrease the risk of furnace downtime and costly repairs. Buildup occurs from lack of cleaning, or not cleaning on a regular basis.

It’s critical to hot clean the furnace after every shift, and schedule cold cleanings biannually.
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1) Maintain Capacity

The buildup in your furnace does more than wear on it. It takes up room. With months or years of buildup taking up so much interior space, there is less capacity for metal. Less product in the furnace equals less available metal for production, which results in decreased efficiency and profitability. Imagine your freezer. When thick ice begins to build up on the sides of your freezer, you can’t fit as much food inside.

2) Increase Production

Furnaces that need emergency repairs usually require about two days to tear out, three days to make repairs, and two days for the furnace to cure and heat up. If the issues are significant or the materials aren’t available, this process can take even longer. Occasionally residual damage to the electric elements or burners can cause additional downtime. With less unscheduled downtime you can maximize production and ensure fewer costly delays.

3) Save Money

Emergency repairs and downtime take away from production potential, and repair costs can be very expensive. Depending on the size of your facility, costs can reach into the tens or hundreds of thousands, not including lost sales potential. For facilities that have multiple furnaces, this number can be even higher. Save money with preventative maintenance and regular cleaning to ensure that downtime is minimized and repairs are few and far between.

Prevent Future Problems

Prevent small problems from becoming huge with routine inspections of the furnace, refractory , and linings. Small cracks can be easily repaired, but left unchecked they can devastate your furnace and hurt your operations.

Contact Us to learn more about preventative cleaning and maintenance for your industrial furnace.

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A Brief History of TFL

Fri, 13 Jul 2018 15:00:00 GMT

TFL was built around the concept of improved customer service, responsiveness, and care. Founded by Teddy Faun Laningham in 1977, TFL has always maintained a stellar reputation, and in today’s refractory marketplace, we’re able to dive deep into each customer’s business, learn their problems, and help them improve their situations through refractory maintenance and performance.

Top Notch Service

TFL takes pride in the quality of the items we make in-house, and we realize the importance of product quality in manufacturing performance and critical operations.
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Emory Laningham, President

TFL is led by Emory Laningham. Emory has over 30 years of experience in the refractory industry. He received his B.S. in Industrial Distribution from Texas A&M University in 1984. He is actively involved in all aspects of the company, including administration, project management, sales, and service

“We feel deeply rewarded when we are able to use our experience and fresh thinking to bring new ideas to the table. For us to be able to earn a customer’s trust such that they want to hear about new designs and try new things, and then to implement them with us, is extremely gratifying. That’s why we do what we do. “ -Emory Laningham

Paul Fisher, VP

Paul Fisher joined TFL in 1985, after earning a B.S. degree in Civil Engineering. He is a Professional Engineer, registered in the State of Texas. Paul has over 32 years of experience in the refractory industry.

Troy Fondon, Warehouse Manager

Precast shape production, shipping/receiving, and warehouse management is handled by Troy Fondon. Troy is a seasoned refractory professional who has over 30 years of experience in the refractory industry and has been with TFL for 21 years.

Pete Molinar, Refractory Technician

Pete Molinar has been with TFL for 7 years. His 35+ years of experience in the refractory industry provides us with invaluable expertise as a refractory technician in our precast shape manufacturing operations.

Julie Laningham, CPA

Julie Laningham manages all accounting functions in the company, including payroll, accounts payable, and accounts receivable. She earned her B.S. degree in accounting from California State University – Bakersfield.

Lindsey Greenwell, Inside Sales

Lindsey handles the office management and inside sales for TFL. She earned her B.S. in Natural Sciences from Colorado State University and a Master of Education from Framingham State University. She’s TFL’s newest employee.

TFL: Professional Service With a Personal Touch

With a solid team backing up a high-quality product, TFL is truly a one of a kind company. For more than 40 years we’ve provided consistent, innovative service with a personal touch.

Contact Us to find out how we can help your refractory project succeed.

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New Employee Spotlight: Lindsey Greenwell

Fri, 06 Jul 2018 14:30:00 GMT

TFL is happy to welcome our newest employee to the team! Lindsey Greenwell will handle Inside Sales and Office Management. We’ve worked hard over many years to build a solid reputation upon a commitment to our customers and unmatched attention to detail. We know that Lindsey will bring that same commitment to her role. Here’s a bit more about our new employee:

What are you most excited about working for TFL?

I am most excited to join such a supportive and welcoming team. The people at TFL are inspiring and friendly, and I am very excited to work with them. It’s clear they’ve intentionally developed a responsive and accessible business culture both inside the office and out.

What have you learned that has surprised you so far?

The most surprising part of the job is how relevant my background in chemistry has been in the refractory industry. This ancient industry is truly high-tech science and engineering!

Where do you see TFL in the future?

I see TFL continuing to lead the industry in innovative refractory solutions. I am surrounded by ambitious and creative people who have been refractory movers and shakers for decades. Without a doubt, our experienced team will continue to pave the way in refractory engineering and application.

Tell us a bit about yourself:

I’m a Chicago native, but got to Texas as soon as I could! I earned my B.S. in Natural Sciences from Colorado State University and my Master of Education from Framingham State University. I spend my free time running marathons, surfing and traveling. With experience teaching high school chemistry, I am excited to bring my love for connecting with people, finding creative solutions, and fostering communication to the dynamic world of refractory at TFL, Inc.

Welcome to the team, Lindsey!

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Refractory Tips: 5 Things Every Plant Manager Should Know

Fri, 29 Jun 2018 18:30:00 GMT

Refractories are a substantial investment, whether you’re managing a new construction or overseeing repair work. While refractory work might only be a small part of your construction project, the materials will protect your equipment, keep production online, and provide safety to your staff.

The cost of your refractory is far less than the value it will bring to your manufacturing plant.
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Refractory Tips for Plant Managers

If refractory work is not the driving force of your plant, you may not have the level of expertise necessary to make decisions without help. Meeting with a reputable refractory expert can provide further insight and valuable advice. Here are 5 basic tips to help you in the meantime:

1) Refractories have different chemical compositions

2) Extreme heat isn’t the only threat to your refractory

Refractories must not only withstand extreme heat but must also be resistant to the chemicals that are released during the manufacturing process. If the wrong refractory is used, the chemical interaction between the refractory and byproducts of the materials being heated can cause catastrophic failure.

3) A small crack can be a big problem

Refractory inspection and repair should be a routine part of your refractory management plan. A very small crack can let enough heat out to disrupt the chemical process of the heated materials or can allow heat to burn the refractory fiber acting as insulation. The results can be devastating.

4) Installation matters

Correct refractory installation is crucial to the productivity of your plant and the safety of employees. Don’t forget that your refractory will need time to cure. Include this in your installation plan, and don’t try to rush it or cut corners!

5) Customization is key

Refractories aren’t one size fits all. Your plant may require custom refractory ingredient combinations explicitly created to provide the right protection for your application. Research and developments in the refractory industry have led to significant improvements and streamlining, but what works for one doesn’t work for all.

The Best Results

Whatever the size of your production facility, we can guide you through the process and show you how to find the best solution for your refractory application. You should never go into the process without an expert on your side.

Contact Us to learn more about choosing the right refractory for the job.

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The Essential Industrial Safety Guide

Fri, 22 Jun 2018 15:35:00 GMT

Workplace safety goes beyond best practice guidelines and policies, requiring both management and staff to adhere to safety standards. The foundation of any successful industrial safety guide is empowered employees that are encouraged to identify unsafe behaviors or environments for the benefit of everyone.

Prioritizing workplace safety can help prevent devastating injuries and penalties for safety infractions.
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Industrial Safety & Refractories

Refractory materials and installation require their own unique safety guidelines, particularly if you’re working around extreme heat. Safety attire and equipment should be mandatory, and procedures should be established prior to the start of work. Here are some other essential safety tips:

Stay Alert

Situational awareness means always being cognizant of your surroundings, including coworkers, machinery, and equipment. Staying alert will not only help protect you from injury but can allow you to spot workplace dangers or risks before they cause injury.

Wear Proper Attire

If you don’t wear proper attire or utilize the correct safety equipment for a task, you’re more likely to be injured. Depending on the job, equipment like eye protection, hard hats, gloves or heat protection gear are absolutely necessary.

Encourage Cooperation

It’s up to facility managers and construction foreman to get their team onboard with workplace safety efforts, encouraging them to prioritize the safety process. Share workplace injury statistics and the inherent risks of an industrial job, particularly where extreme heat is involved.

Use Equipment Appropriately

Shortcuts and inappropriate use of machinery or equipment is a leading cause of workplace injury. Using tools improperly, or forgoing proper procedures to save time can easily lead to injury.

Take Breaks

Many work-related injuries occur because a worker is tired, overworked, and therefore not alert to their surroundings. Taking regular breaks, especially outside if possible, helps you stay fresh on the job.

Keep Exits Clear

While this seems like a no-brainer, exits should never be blocked, even temporarily. In case of an emergency, you’ll need quick access to the exits. It’s also recommended that you keep unfettered access to equipment shutoffs in case you need to quickly stop them.

Report Violations

Your supervisor should be informed about any workplace safety risks or violations. They’re legally obligated to ensure that employees have a safe working environment and will remedy unsafe conditions and make them safe.

A Safe Workplace

Workplace safety is a great concern for the industrial, manufacturing and construction industries. Remember that written safety measures are in place due to real events, where someone, somewhere has paid a price for lax safety standards.

Contact Us to learn more about industrial safety and refractory materials handling systems that can help.

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The Many Uses of Refractory Ceramic Fiber

Fri, 15 Jun 2018 14:45:00 GMT

Refractory ceramic fiber products have become invaluable in businesses that require operations and manufacturing processes that generate extremely high temperatures. They’re used both in direct contact with fire, and as insulation to retain heat in one place.

Ceramic Fiber has a variety of uses and is a favorite in the manufacturing and automotive industries.
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Refractory Ceramic Fiber

Refractory ceramic fibers have heat-resistant properties and are an excellent material for heat-resistant insulation. Ceramic fiber comes in several different forms and can be used for numerous applications. Here are some fast facts about refractory ceramic fiber:

Traits

Types & Uses

A Versatile Product

Because refractory ceramic fiber can take such a variety of forms, it is frequently used in many different ways. From brake pads to furnace insulation, they’ve become an invaluable tool in high heat situations and processes.

Contact Us for more information about refractory ceramic fiber modules or our other refractory materials.

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Your Guide to Full and Partial Refractory Relining

Fri, 08 Jun 2018 19:28:00 GMT

With the reinvigoration of the manufacturing industry around the country comes the need to renovate older industrial furnaces. Whether your facility needs a full or partial relining will depend on several factors, including the extent of damage and the materials used previously.

A thorough inspection will tell you whether or not your #refractory can be salvaged with relining.
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Refractory Relining

Refractory relining describes the replacement of the brickwork or monolithic refractory material from a furnace, oxidizer or boiler. Relining may be done as part of necessary repairs or to update an outdated machine.

Structural Integrity

Structural integrity is a top priority in refractory relining. Older materials were generally heavier, so after years or even decades of neglect, they may not be structurally sound. A thorough inspection should be done before relining, to ensure that the structure itself can withstand renovations.

Update Materials

Many furnaces built from 1960 – 1990 were lined with firebrick on the walls and roof. Often, an original brick roof in an older furnace will partially or totally collapse. If not totally collapsed, they may have cracked due to thermal stress. Instead of hunting for an experienced refractory brick mason, you may opt for an easier to apply material, such as monolithic or fiber refractory.

Easier Installation

If you want to stick with firebrick, make installation easier on yourself with a Convey-It System® , which is a conveyer belt system that streamlines brick refractory installation. It’s compact and durable, making a normally intensive and tedious process easier and faster.

Heat Flow Analysis

An experienced refractory contractor or manufacturer should perform a heat flow analysis or inspection to demonstrate the suitability of the new lining. This takes into account temperature fluctuations, maximum temperature, internal stress, slag and chemical composition. This will help ensure heat containment capabilities.

A Fresh Start

Many old furnaces have excellent bones and will operate for years to come with a partial or full relining. With the right refractory material, relining can give your furnace a new lease on life.

Contact Us to learn more about refractory relining and how to get your furnace back online.

The post Your Guide to Full and Partial Refractory Relining appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Monolithic Refractory Installation: A Break Down

Fri, 01 Jun 2018 13:52:00 GMT

Monolithic refractories are loose materials, often powders, that can be used to form a smooth lining. Various methods are used to install monolithic refractories, such as casting, gunniting, spraying, and slinging.

Monolithic refractories are known for their versatility and usefulness in difficult projects.
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Monolithic Refractory Installation Advantages

Monolithic refractories are preferred because they eliminate joints, a known weakness with brick linings. It’s much easier to transport and handle it, and the normal methods of application are faster and easier than others. They also reduce downtime for repairs. Here are the most popular installation methods:

Methods for Monolithic Refractory Installation

Choosing The Right Method

Monolithic refractories are versatile and enjoy various industrial applications in the steel, cement, metallurgical, waste disposal and petrochemical industries. The best refractory installation method depends entirely on the specifics of the job, so while recommendations will help, your needs will determine the best method.

Contact Us to find out if monolithic refractories are the best option for your project.

The post Monolithic Refractory Installation: A Break Down appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Understanding Refractory Classifications Based on Chemical Properties

Fri, 25 May 2018 19:52:00 GMT

There are many ways to classify refractory materials, including the method of manufacturing, how they’re used, refractoriness, physical form, and thermal conductivity. In this article, you’ll learn more about classification based on the refractory’s chemical properties.

3 Basic Refractory Classifications

There are 3 basic refractory classifications based on chemical properties, which help determine how each one should be used. This is one of the most general classification methods but helps you understand what the material can withstand.

Understanding the chemical makeup of refractory materials is critical to their appropriate use.
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Acid

Acid refractories are attacked by alkalis (caustic and/or corrosive substances). They’re used in areas where both slag and atmosphere are acidic. Examples include silica refractories, zirconia refractories, and alumino-silicate refractories.

Basic

These refractories are attacked by acid slags but stable to alkaline slags, dust, and fumes at high temperatures. Since they don’t react with alkaline slags, these refractories are of considerable importance for furnace linings where the environment is alkaline such as steelmaking operations. The most important basic refractories are magnesite refractories, dolomite refractories, and magnesia-chrome refractories.

Neutral

Neutral refractories are chemically stable to both acids and bases and are used in areas where slag and atmosphere are either acidic or basic. Common examples of these refractories materials are carbon graphite, chromite refractories, and alumina refractories. Graphite is the least reactive and is extensively used in metallurgical furnaces where the process of oxidation can be controlled.

Special Refractories

Special refractories are manufactured using synthetic grains free of impurities, under very stringent parameters. They’re used for special purposes, where cost is not an issue, as they’re extremely expensive.

Understanding Chemical Properties

Vital to refractory installation and use is an extensive knowledge of the chemical properties of the material themselves. This will dictate where they should be used, how they’re used and what factors will negatively affect them.

Contact Us to learn more about refractory classification or to find out more about installation .

The post Understanding Refractory Classifications Based on Chemical Properties appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

How the Convey-It System® Can Help Streamline Your Refractory Project

Fri, 18 May 2018 14:50:00 GMT

Refractory demolition and installation are not your standard construction projects. They pack unique requirements and challenges that those outside the industry often don’t understand. The level of extensive planning, engineering, and design that goes into a refractory project means that it can be a stressful and tedious task. That’s where this innovative system comes in.

The Convey-It System® is compact, powerful, and is changing the way refractory projects are completed.
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Convey-It System®

This innovative system was designed by people in the refractory industry who know firsthand the difficulties often encountered during the removal and replacement of refractory linings. In the past, these kinds of jobs were extremely labor intensive, slow and inefficient. The Convey-It System® provides faster removal and installation, reduces manpower requirements, and a creates a much safer, cleaner work environment.

Easy Transporting

The narrow profile and high power of the Convey-It System® make the best option for transporting refractory brick into rotary kilns. It’s the perfect partner to portable pneumatic brick ring setups. The conveyor does the job of a large team in half the time.

Size & Assembly

The Convey-It System® can fit almost anywhere. The conveyor belts are only 15 inches wide with a belting surface of 12 inches wide. A 100-foot system can be assembled by a 2 person crew inside a rotary kiln in about 30 minutes using just a wrench and pliers. Once you’re finished with the job, simply dismantle it and remove it from the job site.

The Ideal System

The Convey-It System® is hydraulically powered, durable and extremely dependable, even under harsh conditions. This makes it the ideal system for refractory demolition and installation. Because it was designed by a team of refractory experts, it addresses every need and limitation of the installation process. Streamline your project and finish sooner, safer and with a smaller crew!

Contact Us to learn more about how the Convey-It System® can assist your next refractory project.

The post How the Convey-It System® Can Help Streamline Your Refractory Project appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Introduction to the Various Types of Refractory Materials

Fri, 11 May 2018 19:40:00 GMT

There are various forms of refractories available today. They differ in chemical and structural makeup and heat threshold capacities. When correctly applied, your heating facilities reap the rewards of an efficient heat containment machine.

The right refractory material will create a safe, cost-effective, and low maintenance heating system that delivers consistently.
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Types of Refractory Materials

Refractory materials are sorted primarily based on their chemical behavior and strength. Materials that can withstand specific types of slag (toxic waste of metal burn-off) and especially valued for their durability. Here are the main kinds of refractory materials and their uses:

Fireclay

Fireclay brick is durable and inexpensive, making it the most common type of refractory brick used in furnaces, kilns, stoves, and kilns.

Alumina

Alumina refractories are used primarily in and around blast furnaces, lime, cement and ceramic kilns, glass tanks and for melting a variety of metals.

Silica Brick

Silica brick is very strong, even at temperatures that approach their fusion point. Various kinds of silica brick are used extensively in the glass and steel industry

Chromite

Chromite (chrome-magnesite) refractories are used for in high-temperature furnaces. These materials can withstand corrosive matter and gases, making them suitable for use in steel metal and similar functions.

Magnesite

The physical properties of magnesite brick are fairly poor, with their value primarily in their resistance to lime and iron-rich slags. Magnesite refractories are critical to the steelmaking processes.

Zirconia

These refractories have very impressive strength at room temperature, a strength that is maintained up to temperatures reaching 15000C. Zirconia does not react with liquid metals and molten glasses. This makes them particularly useful in glass furnaces.

Monolithic

Monolithic refractory is the umbrella term to describe all unshaped refractory products, installed as a powder mixed with a liquid that that hardens to form a solid mass. (Similar to poured or sprayed concrete.)

Professional Guidance

Without extensive knowledge of the types of refractory materials, you put yourself at risk of choosing the wrong one. Sound, professional guidance is critical to making the right choice for your refractory needs.
Contact Us today to learn more about the best refractory material for your industrial project.

The post Introduction to the Various Types of Refractory Materials appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

What Are Refractories? Learn the Basics.

Fri, 04 May 2018 20:03:00 GMT

Refractories are materials designed to withstand extremely high temperatures (exceeding 1,000°F) often encountered in modern manufacturing. More heat-resistant than metals, these ceramic materials are used to line the heated surfaces found in many industrial processes.

Refractories can withstand some of the harshest conditions known to man.
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What Are Refractories

In addition to being resistant to extreme thermal stress, refractories can withstand the physical wear and tear caused by chemical agents. This makes them essential in the manufacturing of petrochemical products and gasoline. They’re also crucial in industries that use extreme heat in manufacturing and production, such as steel and iron, just to name a few.

What Are They Made Of?

Refractories are made from natural and synthetic materials, usually nonmetallic. These are usually a combination of compounds and minerals such as fireclays, bauxite, alumina, chromite, dolomite, magnesite, silicon carbide, and zirconia.

What Do They Look Like?

Refractories come in all kinds of shapes and sizes. They can be pressed or molded for use in floors and walls, or made into interlocking shapes and wedges, They can also be curved to fit the insides of boilers. Some small refractory parts possess a complex and delicate appearance, while others are precast into massive blocks that can weigh several tons. The majority of refractory products are either precast shapes or unformed compositions. Then, there are refractory ceramic fibers, which resemble residential insulation but insulate at much higher temperatures. Refractory may also come in the form of powder, similar to cement, then mixed with water and applied as needed.

What Are They Used For?

From fireplace brick linings to re-entry heat shields for the space shuttles, refractories are used to contain heat and protect equipment from intense temperatures. They’re also used to line boilers and furnaces of all types, including nuclear reactors, ladles, stills, kilns, and more. The iron and steel industry uses approximately 70% of all refractories produced today.

Facing Harsh Conditions

Refractories are chosen according to the conditions they’ll face. Some applications require specific refractory materials. Zirconia is used when the material must withstand extremely high temperatures. Silicon carbide and carbon are two other refractory materials used in some very severe temperature conditions, but cannot be used in contact with oxygen, as exposure will cause oxidation and burning. Many modern technological and scientific advances simply would not have been possible without refractories.

Contact Us to learn more about refractories and their installation.

The post What Are Refractories? Learn the Basics. appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Become a Part of the TFL Community!

Thu, 26 Apr 2018 14:00:00 GMT

TFL is excited to invite you to join our extended community. This is your opportunity to connect with us as we offer you our knowledge, experience, and expertise in the form of daily articles, videos, and other helpful information.

TFL values our customers above all else, and we work hard to provide unparalleled quality and care.
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Bringing You Value with Every Post

Most of our time is spent working hard for our customers, so we rarely get the opportunity to engage in proper conversations. Our blog will provide you with that opportunity. You’ll find informative, original content covering a variety of topics. Our goal is to offer thought-provoking articles that fall into one of the following categories:

1) Useful Tips, Strategies, and Information

We strive to provide you with information that’s useful to you about refractories and other related products. Accordingly, the bulk of our content will fall into this category. We’ll cover a broad range of topics, giving you the full benefit of our expertise and years of experience. Learn more about refractory basics, materials, installation and more.

2) Industry updates

Every once in awhile there may be changes, advancements, or other updates specific to the refractory materials industry. Articles that feature industry news will be designed to give you a breakdown of what’s happening and how it may affect you.

3) Company news

Sometimes we may have company changes, growth or improvements that we want to share. These blog posts are intended to make you aware of our growth and progress and how it will benefit you. They’re also intended to give you an inside look at our company values and tell you a bit more about us . TFL prides itself on our unparalleled customer service, and look forward to giving a behind the scenes peek into that culture.

Join the Conversation

In addition to our original articles, we also share a wealth of other information and videos of interest from various sources across our several social media platforms. Connect with us on Facebook , Twitter , and LinkedIn to receive valuable information, updates and tips. We are so grateful to our customers, who have become part of our TFL family. Join us today!

The post Become a Part of the TFL Community! appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

New Website Launch for TFL!

Fri, 20 Apr 2018 17:07:00 GMT

TFL is proud to announce the launch of our newly redesigned website! It’s part of our ongoing effort to improve our products and services for our customers. In today’s marketplace, we find it extremely rewarding to dive into our customer’s business, learn their problems, and help find the right solutions.

About TFL

TFL was established in 1977 when founder Teddy Laningham became one of the leading suppliers of Hex Steel to the petrochemical refineries along the Gulf Coast. TFL was built on a foundation of customer service, responsiveness, and care.

Over the years, TFL has developed and maintained a stellar reputation for service.
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Get to Know Our New Website

The TFL website is easy to navigate and offers solutions for virtually all of your refractory needs. From turnkey packages to anchors and more, you can find everything you need right here. Browse the various services and products we offer, and find out more about how the process works.

Refractories

TFL is a major distributor of Plibrico refractories and also maintains an extensive inventory of other refractory materials. We strive to make your experience seamless while providing efficient delivery. We maintain this level of service by ensuring that we have the materials you need on hand.

Anchors

Whether you need a common steer-horn V-anchor, threaded studs, wall support plates, a ceramic anchor assembly, or a custom-designed anchor, TFL can assist you in choosing the right anchor for your refractory installation. We are the premier supplier of refractory anchors, and we understand that having your supplies delivered on time is of the utmost importance.

Installation

TFL is with you every step of the way, from start to finish. We work in partnership with the best refractory installation contractors and have the flexibility to work within your schedule. We understand that downtime for your equipment is lost revenue for your company. TFL will partner with you to coordinate the project around your needs, with an emphasis on communication and trust.

Ready to Serve You

Whatever your needs are, we make it a priority to find solutions to your refractory maintenance and performance needs. We value our customers above everything, and we work hard to foster trust and respect.

Contact Us for your refractory needs and find out why TFL is the best in the business!

The post New Website Launch for TFL! appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

TFL Meets Critical Overhaul Demands with Emergency Precast Burner Tile Orders

Mon, 26 Mar 2018 18:42:00 GMT

On at least five different occasions in the past eight months, TFL has been given the challenging opportunity of producing high volumes of complex precast burner tiles in emergency situations. On each occasion TFL was able to meet those demands, proving to our customers that we fully understand the importance of responsiveness as a valued supplier of refractories in the industry.

Discovering Damaged Precast Burner Tile

Despite the best efforts of furnace operators and overhaul planners, it is not at all unusual for there to be unexpected “discovered” work added to the original scope of work in refractories. Damaged burner tile can sometimes only be discovered once the furnace has been shut down and inspected. To complicate matters, specialized burner tile is traditionally long lead-time items which are seldom kept in inventory by anyone.

Innovative Solutions

Using innovative mold-making techniques to capture complex geometry, TFL was able to produce high numbers of extremely accurate molds, typically within a week’s time. Then, with our flexible and highly-skilled workforce, we were able to cast and fire these shapes and have them ready for on-time delivery. On these five separate orders, TFL produced over 340 critical burner tiles on an extreme “emergency” basis, typically within a couple of weeks. Delivery quotes from other vendors were typically 8-10 weeks or longer.

The post TFL Meets Critical Overhaul Demands with Emergency Precast Burner Tile Orders appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Introducing Hex Blocks Refractory Pier Blocks From TFL

Wed, 28 Feb 2018 20:18:00 GMT

Refractory pier blocks for heat treating furnaces are often overlooked, but they are an important part of proper furnace operations and the metal treatment process. TFL’s pier blocks have set the standard for many years with their long-lasting performance and durability, routinely out-performing others on the market. Our new HEX BLOCK design builds on that success, extending the life of your pier blocks even further!

View our precast refractory shapes page for more information about applications and technology that can benefit your business operations.

The Advantages of HEX BLOCK from TFL

Unique Hexagonal Shape

The unique hexagonal shape adds to the life of the block, by effectively tripling the number of surfaces where work can rest. Once the top surface is worn, chipped off or becomes uneven, you simply rotate the HEX BLOCK to the next position, and a new unworn surface would be on the top. For heat-treaters who are concerned about maintaining a flat, even surface, this would greatly extend the service life of one block, easily doubling and possibly tripling the life when compared to the traditional rectangular or trapezoidal shapes used today.

Withstands Extreme Thermal Cycling

HEX BLOCKs are cast using our specially formulated, high-strength refractory castable that is designed specifically to withstand extreme thermal cycling. Thermal shock is one of the leading causes of pier block failure, resulting in premature cracking, and eventual destruction of the pier block.

Initial Controlled Firing

All of our pier blocks are fired in our furnaces prior to shipment. This controlled initial firing enables us to ensure that all the water from the refractory mix is released in a controlled manner, minimizing micro-cracking and maximizing the physical properties (and life) of the pier block.

Easy Transition

The HEX BLOCK can be made to match the height of your current pier blocks so that transitioning to a complete HEX BLOCK installation can be easily done.

Working With An Expert

For pricing and more information, contact the professional team at TFL.

The post Introducing Hex Blocks Refractory Pier Blocks From TFL appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

TFL Offers Plibrico’s Rapid Heat-Up Refractory Products

Wed, 28 Feb 2018 19:56:00 GMT

As a full-line distributor of Plibrico monolithic refractory products , TFL Incorporated can offer Plibrico’s rapid heat-up refractory products that are fast-drying, along with gun mixes for time-critical applications. Plibrico’s Fast Track castable refractories come in both casting grade and gunning grade. Both products may be dried out/heated at an accelerated rate and require minimum cure time. Plibrico Fast Track refractory products are ideal for all refractory applications – generally for linings less than 8” thick. Fast Track refractories significantly reduce downtime and get process units back online faster.

Rapid Heat-Up Refractory Products

There are Pilcast Fast Track castable refractory options and Pligun Fast Track gunning refractory options. View the charts below to see the strength and aluminum oxide content for each offering. If you are unsure about which is right for your project, contact the experts at TFL. We can help answer all of your refractory questions.

Plicast Fast Track Castable Refractories

Plibrico offers three unique Plicast Fast Track castable refractory products. All are high-strength, ultra-low cement refractories with unique attributes and varying aluminum oxide content.

Pligun Fast Track Gunning Refractories

Plibrico also offers three high-strength Pligun Fast Track refractory gunning mixes with unique attributes and varying aluminum oxide content:

TFL, Incorporated is a major supplier of Plibrico refractory materials in the Gulf Coast area of the United States. Additionally, TFL is a global supplier of related refractory products , including refractory anchors , and specializes in the design and manufacture of precast refractory shapes . We serve many industries including power generation, steel, aluminum, lumber, pulp and paper, minerals processing and industrial furnaces.

The post TFL Offers Plibrico’s Rapid Heat-Up Refractory Products appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Precast Shape Technology in Refractory Linings

Fri, 26 Jan 2018 22:16:00 GMT

The post Precast Shape Technology in Refractory Linings appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

TFL Approved to Manufacture Plibrico’s HyFIBER REDI-SHAPE™

Fri, 26 Jan 2018 15:19:00 GMT

The HyFIBER manufacturing process utilizes a high quantity of stainless steel reinforcing fibers, infiltrated with a unique low-cement castable slurry in the mold. The resulting shapes exhibit extremely high toughness and impact resistance, as well as excellent resistance to thermal shock.

HyFIBER products provide the thermal protection of refractory in high-temperature applications, along with the mechanical properties approaching those found in steel or cast iron parts. Shapes can be custom-designed for any application. Typical HyFIBER shape applications include areas where high impact and mechanical loads are prevalent, including:

Shapes can be manufactured using a variety of stainless steel fiber alloys. The Plibrico HyFIBER slurry is designed to minimize water demand and increase density. Resulting shape densities can be as much as 18% higher than other similar products on the market. HyFIBER shapes produced with type 304 alloy stainless steel fiber will have a density of between 195 and 210 pounds per cubic foot.

TFL, Incorporated is a supplier of refractory materials, specializing in the design and manufacture of REDI-SHAPE TM precast refractory shapes. TFL serves the refractory needs of many industries including power generation, steel, aluminum, lumber, pulp and paper, minerals processing and industrial furnaces.

For more information on TFL products and HyFIBER precast refractory shapes, please contact:

TFL, Incorporated
www.tflhouston.com
Phone: 281-590-8500
Toll-free: 281-590-8500 (U.S. only)
E-mail: tfl@tflhouston.com

The post TFL Approved to Manufacture Plibrico’s HyFIBER REDI-SHAPE™ appeared first on Refractory Materials, Precast Shapes, and Custom Solutions .

Refractory Materials, Precast Shapes, and Custom Solutions

Plibrico Company Acquires TFL

Expanding Precast Manufacturing and Refractory Solutions Across Texas and Southern U.S. ﻿

Customization of Precast Shapes

Details in Precast Refractory Shapes

Avoid These Common Refractory Installation Mistakes

Using the wrong refractory materials can lead to failure

Safer Dry-Outs Using Plibrico Kwik Kure Fibers

We Are a Major Distributor for Plibrico Company LLC.

Choosing the Correct Refractory Vendor

When looking at multiple precast refractory vendors do your research

TFL Completes Unique Precast Refractory Shape Application For Oakland Area Municipal Utility District

4 Mistakes to Avoid in Refractory Repairs | Precast Refractory Shapes

Common Refractory Mistakes

Benefits of Material Property Enhancement For Precast Shapes

Produce the Perfect Refractory Linings for Your Next Project

Long Lead Times Are Common for Many Refractory Manufacturers These Days…Get Your Schedule Back on Track with Plibrico Products From TFL!

Don’t Settle for Extended Deliveries – Plibrico is Keeping Our Customers Happy in Today’s Unusual Market. Here’s How:

Durable Precast Refractory Shapes Manufactured To Your Exact Specifications.

Minimize Downtime And Increase Performance With Precast Refractory Solutions from TFL!

TFL Uses Custom Molding Techniques to Make Precast Refractory Shapes With Extremely Tight Tolerances

With Proper Attention to Dimensional Tolerances, Field Fit-up Problems With Precast Shapes Go Away

Refractories Play a Pivotal Role in Virtually Every Industrial Process

The Rewards of Being a Part of “The Hidden Industry”

Remove and Replace Refractory Linings Fast with TFL’s Convey-It System

TFL’s Convey-It System Is The Ideal Solution To Safely Transport Refractory Materials and Tear-out Debris To and From the Kiln

The Advantages of ROTALOCK Refractory Anchors, The Most Versatile Anchor System From TFL

Rotalock Anchors Can Reduce Stress On Refractory Linings And Improve Worksite Safety

Easily Restore Worn Ceramic Fiber Linings with the CERABOLT™ System From TFL

An Economical “Quick Fix” Solution to Extend the Life of Ceramic Fiber Module Linings, When Total Replacement is Not Yet an Option

Plicast KL 3000 is a Proven “Workhorse” Castable from TFL and Plibrico

A Cost-effective Solution For Many Challenging Refractory Applications

Plicast KL 3000 Features & Benefits

We Are Pleased To Welcome Heather Smith To The TFL Family

Heather Is The Perfect Fit for TFL, And We’re Excited to Have Her On Board

Some Fun Facts About Heather

Here’s Why You Should Have Plicast Super HyMOR 95V KK On Your Next Refractory Project

A Great Castable Selection For Precast Refractory Shapes

Get Refractory Anchors Professionally Engineered By TFL For Your Next Project

Refractory Anchors Designed To Meet Your Specific Project Requirements

We’ll Help You Find The Best Anchor Solution.

Happy Thanksgiving From TFL

Thank You For Choosing Us For Your Refractory Needs

Meet Refractory Project Deadlines Easier With The Convey-It System

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What You Need To Know About COVID-19 And The Refractory Industry

Ceramic Fiber Module Lining Repair with CERABOLT™ Overlays

9 Common Misconceptions About Precast Refractory Shapes

What are some common misconceptions about precast refractory shapes?

1) “Precast shapes are more expensive to install!”

2) “We’ve always cast the lining…changing over to shapes would be too complicated to figure out!”

3) “Molds for precast shapes would cost too much!”

4)“I’d have to bring a crew in from the field to the shop to make these shapes!”

5) “Lead times for precast shapes would be way too long!”

6) “It’s just as easy to set forms and cast the job in the field!”

7) “There’s no way to anchor a precast shape system in my existing furnace”

8) “I have to use the shape manufacturer’s desired castable if I buy his precast shapes”

9) “Lifting and handling precast shapes in the field would be a problem!”

Conclusion

TFL Precast Refractory Shapes – Burner Tiles, Blocks, and Rings

Innovative Molding Techniques

Professional Casting

Quality You Can Trust

Plastic Refractories: Highlighting Phosphate Bonds

Plibrico Phosphate-Bonded Refractories

Plibrico 68 S

Plibrico 68 SA

Plibrico 85 S Special

Plibrico 90-S

Plibrico SR-90

Plastic Refractory Solutions for Your Business

CERABOLT Overlay vs. Traditional Module Replacement

Choose Quality Cerabolt Overlays

TFL’s Ceramic Fiber Modules Set a New Standard for Quality

CM-Pleat Style

CM-Weld Style

CM-Channel Style

Customizable Modules for Your Furnace Linings

Contact TFL for Refractory Solutions

3 Refractory Solutions for Your Business in 2020

Expanding Precast Manufacturing and Refractory Solutions Across Texas and Southern U.S.