Shotcrete cement plant Gmunden
An international client was looking for a method to install over 400 tonnes of high-quality refractory concrete in a cement plant in Austria as quickly as possible.
400 tonnes of refractory concrete in minimal time
The Rohrdorfer Group, an international cement producer with plants in Austria, needed a method to install over 400 tonnes of high-quality refractory concrete in their cement plant in Gmunden — as quickly as possible and within a scheduled shutdown. The scale of the project was exceptional: 400 tonnes is an enormous quantity of material that normally takes weeks to process.
The time pressure was immense: a longer shutdown than planned would directly lead to production losses that were unacceptable to the client. At the same time, high quality requirements were set for the refractory material: it had to meet the most demanding requirements for heat resistance in a cement kiln. Only a specialist with the right equipment and experience could achieve this.
International deployment with the right technique
VTG mobilised the necessary equipment and personnel to Gmunden, Austria. The logistics were a challenge in themselves: pumps, hoses, mixing equipment and hundreds of big bags of refractory material had to be on site on time. In collaboration with the client, a detailed work plan was drawn up with a tight hourly schedule.
VTG worked in shifts to make optimal use of the time window. Each shift had a clear assignment and a production target that had to be met. Through the use of ultra-high-pressure piston pumps and experienced operators, productivity could be kept at a consistently high level. By the end of the shutdown, the cement plant was fully fitted with a new refractory system — ready for a new production cycle.
400 tonnes of refractory concrete within a single shutdown
Using the wet shotcrete system and advanced mixing equipment, VTG installed more than 400 tonnes of refractory sprayed concrete within the available shutdown. Ultra-high-pressure piston pumps ensured a constant supply of material, while big bags of refractory material were mixed on site for maximum freshness and quality.
By spraying large layer thicknesses per pass and working in shifts, the enormous quantity of material was processed on time. The certified wet spraying method guarantees a low rebound rate of less than 5%, which makes material use efficient and cost-effective. An achievement that underlines VTG's international reputation as a specialist in refractory applications.
Arjan de Waard
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