New 150′ Rotary Hearth Furnace

Onex Construction supplied and installed the refractory materials for a new Rotary Hearth and Mandrel Bar Furnace. The refractory system consisted of pump cast materials along with gunnite and fiber modules. Over 3 million lbs. of material were installed. The project was completed on time with zero incidents or accidents.


181’ x 41’ Walking Beam Reheat Furnace, (2) Hot Dip Galvanizing Lines, (4) Zinc Pots:

Onex Construction performed the refractory installation on a new Walking Beam Reheat furnace as well as a Hot Dip Galvanizing furnace and Zinc Pots. The walking beam furnace consisted of rammed roof and walls with a cast hearth and skids. The waste gas system and 234’ stack sections were lined with gunnite. With adjacent furnaces in operation, all activities were carefully planned to ensure the safety of the crews. The 75’ vertical galvanizing furnaces were insulated with 10 layers of ceramic fiber and protected by stainless steel cladding. Each Zinc Pot was constructed using a combination of brick and castable. Due to the scale and complexity of the project, careful coordination was required to ensure flow of materials to work areas. The project consumed over 4 million lbs. of refractory material, 500,000 square feet of ceramic fiber, and 50,000 square feet of stainless-steel cladding.

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470′ Tunnel Kiln

Onex Construction installed all roof and sidewall joint refractories for a new 470’ tunnel kiln. The kiln consisted of a sprung arch roof design with a MH Dietrick curtain wall design. The project was completed on time and under budget.