Benefits of Hot-tek™ Online Refractory Repair

The fast, safe, and reliable way to repair fired heater refractory damage online. Avoid expensive emergency shutdowns to make a conventional repair. Continue full production until the next planned turnaround. Hot-tek™ teams, with more than 20 years of online work experience, can tackle most refractory lining problems.

Multiple Hot Repair Technologies Available

Existing access points in the heater steel shell may be used, or access is made at the point of damage to insert specially designed components to support the repair material.

Fast Payback

Quick ROI compared to the costs associated with conventional repairs which require the heater be shutdown.

Maintain Production & Avoid Costly Shutdowns

Hot-tek™ safely repairs refractory whilst the heater is online, with no interruption to production, avoiding the need for an emergency shutdown to make a conventional repair.

Rapid Worldwide Mobilization

With Hot-tek™ technicians and equipment strategically placed worldwide, we can mobilise rapidly to meet your requirements.

Online Furnace Refractory Repair Testimonial

I wanted to take a moment to express my sincere gratitude for the great job you and your team did on our Furnace roof while the furnace was still online. This was the first time we attempted this type of repair in our plant.

We were impressed by your team’s level of skill, precision, and professionalism. At first, we were hesitant about the safety and the method of repair while the furnace was online, but your team’s experience and expertise made the process seamless and efficient.

The repair was completed successfully without disrupting our production schedule, which is a testament to your team’s hard work and dedication. I also appreciate your patience and willingness to answer our questions and concerns throughout the process. Your guidance was invaluable and helped us understand the repair process better.

– Head of Maintenance, Oman Oil Industry Company

Hot Refractory Repair FAQ

Safe and Proven Online Refractory Maintenance

At IGS, our Hot-tek® services are designed to keep fired heaters and process units operating safely and efficiently, all without the need for costly shutdowns. Below, our experts answer the most frequently asked questions, drawing on decades of real-world experience across refineries, petrochemical plants, and power facilities worldwide.

How safe is hot refractory repair?

Safety is our top priority. IGS has developed intrinsically safe procedures and performed dozens of successful repairs around the world – all without safety incidents.

Do you need to reduce the heater duty for Hot Refractory Repair?

No production impact is required. Hot Refractory Repair can be performed safely without impacting production on heaters with negative pressure.

How reliable is this solution?

Extremely reliable. Many of our hot refractory repairs have remained in service for more than 15 years. Typically, the repaired refractory is inspected at the next turnaround and plant internal procedures are followed concerning the inspection and replacement.

Can you repair any refractory material or configuration?

Yes. IGS has solutions for every type of refractory lining – including concrete, brick, and ceramic fiber.

What if the original refractory is made up of multiple materials/layers?

This is of no concern; we have repaired refractory hot spots on several heaters with multiple materials/layers.

Does the thickness of the refractory matter for the repair procedure?

The thickness of the refractory is not a concern for hot repair; if necessary, we can extend the length of the handle to reach further into the repair area.

Is the basket exposed to real heat? Will it oxidize away?

Yes, the repair basket is directly exposed to the real heat. The basket is constructed of a high-alloy stainless steel and can withstand up to 1,250°C of continuous exposure, ensuring durability even in extreme furnace conditions.

Will the hot refractory repair survive in areas of high flue gas velocity zones?

Absolutely. We have performed numerous successful repairs in high-velocity environments, with long-lasting performance results.

How are large refractory hot spots repaired?

For extensive areas, our technicians overlap multiple repair baskets or plates over the intact surrounding refractory. This creates a new internal wall which is backfilled with pumpable refractory as the repair progresses.

Is repair possible with wall-mounted (single-fired) process tubes?

Yes, our approach works effectively even on single-fired wall-mounted tube configurations.

Does IGS perform calculations on the rigidity/stability of the panel you’re cutting into?

Yes. Prior to beginning a repair, we work closely with the plant engineers and develop a site-specific plan that includes additional exterior support if required.

What PPE is used when working with open furnaces in relation to the temperature?

All IGS personnel use high-temperature personal protective equipment (PPE) that complies fully with local safety regulations and site requirements.

Technical Content Reviewed by: Larry Emch, Sr. Director, Energy Efficiency Solutions, IGS
Expertise: Reliability & Asset Life Extension | Energy Efficiency | Ceramic & Metallurgical Claddings

Trusted Online Maintenance Without Shutdowns

IGS Hot Refractory Repair has been trusted by refineries and process plants worldwide to restore integrity without interrupting operations. With intrinsically safe procedures, high-alloy repair materials, and decades of field experience, our teams deliver lasting results where downtime isn’t an option.