Shotcrete is a technique for applying shotcrete by wet spraying, at high speed, without dust and with minimum rejection. In the area of Refractory, this method involves the projection of refractory concrete by means of a special nozzle where compressed air is added, having been previously pumped with high performance equipment, and at the beginning of the process prepared in a mixer with the totality of its liquid.
The versatility and efficiency of Shotcrete Technology have made it the preferred option for dense refractory concrete applications in industrial equipment that require, on the one hand, refractory linings resistant to high temperatures and in extreme conditions of abrasion, erosion, corrosion and thermal shock, and on the other hand, to reduce the downtime of such equipment with a fast application of the refractory. Our experience of more than 30 years allows us to optimize the use of this Shotcrete technology to offer safe, durable, efficient and environmentally sustainable solutions. Throughout these years, we have developed and improved a proprietary system that we have patented as “Alfranjet®, to guarantee maximum efficiency, which translates into a longer service life of the installations and less downtime for our customers’ industrial equipment.
The use of shotcrete not only improves the efficiency of industrial facilities, but also contributes to process safety and sustainability. Thanks to its ability to form dense and uniform refractory coatings, it is possible to protect structures against wear and corrosion, critical factors in aggressive industrial environments. In this article, we will explore in detail what Shotcrete technology is, how we use it at Alfran and its various industrial applications.
What is shotcrete
Shotcrete is particularly valued for the ability of the refractory castables it projects to adhere to irregular and vertical surfaces, making it ideal for repairs and coatings in hard-to-reach places. In addition, precise control over the amount of mixing liquid and admixtures allows the properties of the sprayed refractory concrete to be adjusted, optimizing its strength and durability. This flexibility is crucial in applications requiring high performance, in industries such as cement, steel, non-ferrous metals, energy, oil & gas, among others.
Industrial applications of shotcrete
The applications of shotcrete in the industrial sector are wide and varied. In the cement industry, shotcrete is used to coat and/or re-lining with refractory concrete practically all the equipment involved in the manufacture of clinker, protecting these structures from wear caused by high temperatures and chemical processes.
In the steel industry, shotcrete is essential for the maintenance and repair of refractory linings in blast furnaces, reheating furnaces and converters, as well as steel maintenance and transfer equipment, where a material that can withstand extreme heat and abrasion is required.
In the aluminum industry, this technique uses refractory castables with anti-wetting properties, which minimize the formation of corundum, as well as the effects of erosion and corrosion.
In the energy industry, shotcrete applies refractory castables in boilers and combustion systems, where it provides a protective barrier against corrosion and oxidation. In addition, in the petrochemical sector, shotcrete is used to line refractory in reactors and processing units, ensuring safe and efficient operation in highly corrosive and high temperature environments.
Why and what we use shotcrete for at Alfran
With our patented alfranjet® system, nº1 in Shotcrete technology, with more than 30 years of experience and worldwide references in Cement, Iron and Steel, Energy and other industries, we offer the best solution for the installation of dense refractory concretes by wet spraying. At Alfran, we use shotcrete as a safe, efficient and effective solution for the installation and repair of refractory linings. This technique allows us to offer fast and high quality services, minimizing downtime.
The application of refractory castables by shotcrete minimizes the risk of accidents due to the reduction of the number of people involved in the installation process, with no need to lift material, as well as high performance due to its high installation speed, and minimal material losses in the process.
Our experience has taught us that each project has specific needs, so we adapt our technology to the particular conditions of each client. We use advanced equipment and refractory concretes that do not expire, guaranteeing optimal stock control. In addition, we have a highly trained staff with the objective of ensuring a safe, precise and efficient execution.
Thanks to our experience and dedication, we continue to lead the way in the application of wet sprayed refractory castables, ensuring maximum durability and efficiency of industrial facilities.
