Works in Votorantim Rio Branco and Salto de Pirapora. Brazil

We have just finished one of the projects that we were most excited about. A great repair, under our supervision, at the Cemex Balcones cement plant in Texas. Our ALFRANJET ABR CLEAN + was installed using our SHOTCRETING technology. Also, other works were carried out by vibrocasting system with ABR CLEAN SUPER + and high-pressure gunning with HIGH GUN range, in different areas of the plant, in record time, even reducing the deadlines agreed with our client. All the material was supplied directly from our Laredo warehouse.

The outcome of a good job is a satisfied customer

During the past months Alfran-HTR, our subsidiary in the United Arab Emirates, made the main shutdown at Unit 2 of Fujairah Cement Industries. In this project, 65 meters of bricks were installed in the rotary kiln, 138 tons of dense concrete in different units of the plant and 120 tons of our Lite LW 23 AS insulating concrete. The entire ALFRAN-HTR team was congratulated by the client for the prompt and perfect execution of the work. The outcome of a good job is a satisfied customer!

In all work activities, to achieve an acceptable level of safety, it is vitally important to ensure and maintain adequate conditions of order and cleanliness. The lack of order and cleanliness in the facilities is a risk factor that deserves special attention since it is the cause of many accidents, falls due to stumbles or slips, bumps or steps on objects, and deterioration of equipment or facilities, which can lead to results other than those expected.

To achieve the goal of keeping the company “clean and tidy”, all staff must assimilate concepts such as:

1. Eliminate the unnecessary and classify the useful:

– Have the means to eliminate what is useless, prioritizing the elimination according to its usefulness.

– Classify according to utility and collect the useless in containers.

– Separate those elements that should not be in contact with others.

– In the case of flammable products, use metal drums with a fire-resistant lid.

– Machines with possible leaks must have a collection and drainage system.

– Act on the reasons why waste accumulates.

2. Store the material in appropriate places so that it can be easily located:

– Put everything in its place and eliminate what is useless.

– Collect tools on shelves that are easy to locate and identify.

– Designate the locations based on their functionality and speed of placement.

– Delimit and indicate the location of things.

– Classify waste properly.

3. Avoid dirtying and, if it gets dirty, clean immediately:

– Eliminate and control everything that can dirty.

– Cleaning is the means of controlling the state of things.

– Cleaning people must be properly trained and equipped.

– Quickly eliminate residues or substances that can contaminate and cause accidents.

– Avoid slippery floors due to oils or grease. Windows will be cleaned to allow light to enter.

– Keep changing rooms, showers, etc. clean.

– Involve staff in cleaning the environment.

– Control the critical points that generate dirt.

4. Generate work habits aimed at favoring order and cleanliness, etc:

– The characteristics of the floors, ceilings, etc. They shall be such as to allow easy cleaning.

– Standardize procedures by order and cleanliness.

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Since 2007, Refractarios Alfran has been the main player in both the refractory materials supply and installation at Votorantim Cimentos plants, in southern Spain.

Alfran has been the company chosen thanks to its knowledge of the facilities, the quality of its materials and our qualified personnel, mastering all installation methods and knowing perfectly the material requirements in each area, in the different maintenance shutdowns carried out at its plants in Cordoba and Niebla (Huelva).

We must highlight that castables such as ALFRAN CLEAN 85 G, ALFRAN ABR CLEAN, or DRYTECH 70 are commonly used in these cement plants, with exceptional performances.

Wet-mix shotcreting has revolutionized the refractory lining industry, offering an efficient solution for applying concrete in extreme conditions. This method is characterized by high-speed wet concrete spraying using compressed air, allowing for rapid, precise installation with minimal dust generation and reduced material waste. Thanks to these advantages, shotcrete is widely used in industries such as cement, steel, and energy, where high resistance to extreme temperatures and severe mechanical conditions is essential.

Definition and Advantages of Alfranjet® Technology

Alfranjet® is a patented technology by alfran®, backed by over 30 years of experience, designed to enhance the wet-mix shotcreting process. This innovative solution is tailored to maximize the durability of refractory linings in demanding industrial environments, delivering outstanding thermal, mechanical, and chemical resistance. Through this technology, Grupo Aldomer offers operational benefits including improved safety, faster application, long-lasting performance, and minimal environmental impact. The Alfranjet® system also shortens installation times and reduces operational downtimes, resulting in greater efficiency for industrial plants.

Key advantages of Alfranjet® include:

• Safety: The technology requires fewer personnel, significantly lowering the risk of workplace accidents.

• Reduced Installation Time: High application speed enables quick and precise installations, minimizing equipment downtime.

• Minimal Waste and Rebound: Engineered to reduce material loss, the system ensures even application and decreases the amount of concrete that fails to adhere to the surface.

• High Mechanical Strength: Linings installed using Alfranjet® exhibit strong resistance to abrasion, thermal shock, and chemical attack, extending service life.

Wet-Mix Shotcreting Technology

Wet-mix shotcreting involves projecting pre-mixed concrete, including all liquid components, to ensure a consistent blend. The material is pumped to a nozzle where compressed air and specific additives are added, achieving a precise, high-speed application. Unlike traditional methods, wet-mix shotcreting generates significantly less dust, improving workplace conditions.

The Alfranjet® system is specially optimized for superior material compaction, resulting in lower porosity and enhanced mechanical and thermal resistance. This is critical for applications where refractory linings are exposed to extreme conditions, such as in industrial furnaces or cement plants.

Operational Benefits of Alfranjet®

• Safety: Fewer workers are needed during installation, which cuts the accident risk nearly in half compared to conventional vibrocasting.

• Application Speed: Alfranjet® allows for fast and efficient refractory concrete application, reducing downtime in plants with continuous production cycles.

• Durability and Resistance: Linings applied with Alfranjet® withstand abrasion, thermal shock, and chemical attacks, increasing lifespan and lowering maintenance costs.

• Reduced Environmental Impact: In addition to operational advantages, Alfranjet® contributes to a cleaner, safer work environment by minimizing dust and waste during inst

Recently, in the ALFRAN Mexico facilities, a training was carried out for the application of Alfranjet castables in rotary kilns. The training course goal was to promote good practices throughout the installation process of the material, from the preparation of the resources to their proper final application.
The instruction simulated all the on-site operating conditions that occur, which allowed our collaborators to enhance their knowledge for risk analysis, line preparations, material quality control, and correct application techniques, according to our technical procedures. All the objectives set were achieved and the training was a success. ALFRAN is committed to Training and Continuous Improvement!