Repair or Replace? Our Recommendations for a 12-Year-Old Cyclone

18 September 2015,
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When it comes to evaluating aging or depreciated heat processing equipment, the “repair or replace” conversation is common. “Can we squeeze more life out of it? Or should we bite the bullet and incur the capital cost?” Sometimes it’s a cut-and-dried decision, and sometimes it’s not so clear. The following case study is a good example of the evaluation process…Read More ›


Proper Anchor Selection

10 August 2015,
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Proper anchor selection and installation is one of the foundations to help assure a successful refractory installation project. Over 60% of structural monolithic refractory failures are caused by the contractor’s (or design engineer’s) lack of understanding of proper anchor design and installation. A Brief History of Refractory Anchors The early twentieth century monolithic refractories were commonly plastic. At that time…Read More ›


Case Study: Mobilizing a 100-Man Job in 24 Hours

5 August 2015,
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Recently, we completed one of the most challenging projects – if not the most challenging project – that we’ve encountered over the past decade in our Knoxville office. The job started out pretty straightforward. Our customer was taking down two rotary kilns for some routine maintenance – small repairs and gunning work in the kiln and fines chute. Based on…Read More ›


Rebuilding a Bell Kiln

28 July 2015,
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Here at F.S. Sperry, we are very proud of our Resource Center. We’ve been collecting this vast library of prints, schematics and diagrams since 1946. This wealth of resources often means we have the knowledge to service older heat processing equipment that no other refractory contractor in the country may have! Some of you have been asking for examples of…Read More ›


Expansion Joints for Installation of a Castable

6 July 2015,
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If you’re having a castable installed, your refractory contractor’s ability to properly calculate for expansion is essential to obtaining the expected life of the refractory. It’s never fun to learn this the hard way (like the engineers did in the above photo) – improper calculations can force you to replace material far too soon after installation and incur downtime and…Read More ›