Western Refractory Construction Services

Professional Refractory Construction In The United States | Western Refractory Construction

Boilers

Refractory issues caused by physical wear, abrasion, extreme temperatures, and rapid expansion, can sometimes leave your operation at a standstill. Western Refractory’s team of professionals specializes in boiler refractory repairs and ensuring your system is back up and running as quickly as possible. By quickly assessing the issue and providing solutions, you will recognize that our decades of experience in boiler repairs and maintenance make us the perfect partner for your operation. Talk to one of our professionals about your next project today.

Precast

Western Refractory’s Precast shape facility located in Salt Lake City, UT allows us to rise to the demanding needs of the industry and offer our clients a wide range of precast shapes and sizes. With a fully functioning dry-out oven on-site, we are not only capable of meeting the drying and firing needs of our customers, but we are also able to supply:

Burner Rings
Tap Out Blocks
Seal Blocks
Bull Nose
Many Other Precast Items

Fireproofing

Western Refractory’s experienced professionals are able to provide the application of industrial fireproofing materials for your project. Our team has the expertise to install cementation products by various methods including troweling, sprayed, and even formed and poured options to meet your specific needs. Our quality control standards, dedication to safety, and a highly skilled team of professionals that will give you peace of mind knowing you chose the best partner for your project – no matter how big or small. Talk to one of our professionals about your next project today.

Brick Work

Western Refractory is home to some of the best bricklayers in the industry. Our professionals are able to lay brick in almost any type of environment and perform advanced interlocking patterns to meet our client’s needs. Whether it’s interlocking roofs, kiln brick placement, or more, Western Refractory will ensure your project is executed at the highest quality and safety standards. Talk to one of our professionals about your next project today

Refractory Inspections

Western Refractory’s API 936 certified inspectors are the professionals you need to ensure your facility is operating at its full potential. We are able to function as a third party inspection service or even work with you on developing a detailed repair plan for your facility. Some of the most common services our inspectors perform are:

Pre-qualification of materials
Pre-qualification of the crew
Compliance data determination

Hold points

Mapping of installation batches

Production sampling

Final reports

Brokk Demolition

Sometimes spaces are either too tight or too dangerous for a human to perform complex demolitions in. Meet Brokk…Western Refractory’s very own remote-controlled demolition robot! Brokk’s ability to work in tight spaces and remain agile allows our team of professionals to make the most difficult projects look easy. Our clients often require demolition in places like kilns, vaults, dams, and the cleaning of ladles. Because Brokk is an unmanned remote-controlled piece of equipment, Western Refractory’s professionals are able to be extremely effective while maintaining a high level of safety.

Castables

Western Refractory has the capability to provide our clients with a wide range of castables to meet their needs. Made of quality materials that have low thermal conductivity and conservation of heat energy, Western Refractory’s castables can either be casted or pumped in place. From insulating to dense products, our team is able to supply a full line of castable refractories and no cement castables using various bonding systems.

Gunnite / Shotcrete

Western Refractory has a world-class team of professional nozzle men who are second to none in the industry. Our many years of experience have allowed us to develop our skills, system, and processes to a level that minimizes waste and saves our clients time and money.

Plastics / Ram

When castables and brick are simply too complicated, or bulky and formwork is unavailable, refractory plastics are a great solution. Because of its excellent strength, high density, abrasion, slag, and spall resistance, refractory plastics can be used for a wide array of applications. The most common settings this is found are:

Boiler Work
Forge Furnaces
Ladle Linings
Burner Blogs
Patch Work

Coatings / Mortar

Refractory coatings have to be resistant to thermal shocks and high temperatures with melting points up to 1830 degrees Celsius. Western Refractory’s team of professionals are able to provide coatings and mortar that fit the needs of our clients from being resistant to abrasion, gases, or slag attacks depending on the intended application.

Welding

Western Refractory is home to some of the best welders in the nation. Our team of professionals is capable of working at very high levels of efficiency and allows us to save our clients money by executing projects quickly and correctly. Our welders are experts in processes including GTAW, GMAW, FCAW, and SAW. In addition, Western Refractory’s welders can perform a number of codes, including ASME Section I, B31.1, B31.3, and R Code Stamps and Certifications. As a member of the NBIC, we hold a valid R-Stamp which is required for ASME code repairs.

Pipelines

Western Refractory’s team of professionals work on pipelines all year long from Colorado to Wyoming and wherever your next project may be. No matter what your needs are, Western Refractory will be your experienced partner to be with you every step of the way from reclamation to installation.

Process Piping

Western Refractory has the necessary experience, qualifications, and a world-class team to weld and install process piping for your project. Our team’s ability to operate at very high levels of efficiency allows us to keep costs low and satisfaction high.

Boiler Repairs

Tank Work

Our team of experienced professionals are capable of performing everything from cleaning, sandblasting, repairs, and painting of entire tanks. We are also capable of performing hot taps on ‘in-service’ thanks. This eliminates the need for the tank to come out of service.

Pressure Vessels

Western Refractory can perform all of your pressure vessel repair needs from exchangers to storage tanks. We are certified to repair all types of vessels and can perform a variety of repairs as required by the specific vessel code. Some examples:

Investigate the repair that is required
Prepare a repair plan that includes hold points for the Authorized Inspector (AI)
Identify the weld procedure to be used
Identify the welder to be used and verify his/her qualifications
Retrieve all engineering drawings and plans
Specify all non-destructive testing that is required
Specify any final inspection requirements
Specify any Post Weld Heat Treat requirements
Specify the type and range of any pressure test that is required
Prepare a nameplate
Prepare applicable R Form
Perform the repair as stated in the repair plan
Perform testing as required by the NBIC
Sign off on the appropriate documentation

Industrial Plant Maintenance

Our clients oftentimes prefer to contract their plant maintenance to a team of professionals that are capable of minimizing downtime and executing maintenance tasks at a very high level. Let’s talk about how we can put your plant maintenance on auto-pilot and free up your time to focus on the priorities that are most important to you.

Thermal Lancing

Sometimes your demolition needs require us to turn up the heat. Western Refractory offers our clients thermal lancing for those projects that require us to cut through thicker steel along with brick and concrete by using a process that is similar to a torch but reaches much higher temperatures.

Concrete Slabs / Foundations

Big projects require big concrete and our team of professionals have the experience and knowledge to make sure we make you look good. From large complex slabs to common structural elements for buildings, Western Refractory has the capability to ensure your project is a success.

Piers / Pedestals

Western Refractory is no stranger to support. Our team uses piers and concrete pedestals to provide the support you need when you need it.

Site Grading

Ensuring a solid foundation starts with Western Refractory’s professional Site Grading. Our team specializes in adjusting the slope and elevation of the soil around a home or building and doing complete soil tests and surveying of the land. We not only perform site grading for new projects but even existing buildings to improve drainage.

Hazardous Excavations

Western Refractory’s professionals are highly experienced in performing hazardous excavations at the highest levels. Unknown hazards such as hidden underground lines, benzene exposure, live lines, or unknown soil conditions require a team of experienced professionals that are equipped with the correct knowledge and equipment to safely perform the excavation.

Right Of Way Maintenance

Pipeline projects often require us to assist our clients in their complementary objective of protecting the integrity of the pipeline. Right-of-way clearing promotes the safe and efficient operation of the pipeline and also allows for an effective response to emergency situations. Western Refractory also offers reclamation of land.

Hydro Excavations

Sometimes an excavator isn’t capable of the precision digging needed for your project out of fear of damaging underground obstacles. Western Refractory is able to facilitate complex hydro excavation for our clients and get around all of those underground obstacles by using high-pressure water to cut the earth away and a pump that works to simultaneously remove the water from the excavation area.

Steel Fabrication / Erection

For over 30 years, Western Refractory has performed steel erection projects of all sizes and at the highest levels. Our team is capable of meeting all your needs from pipe support racks to the modification of existing structures.

Module Assemblies

Thanks to its cost-effectiveness, ease of transport and time-saving attributes; offsite modular assembly is quickly becoming the preferred method of construction in industrial development. The highly efficient process eliminates the barriers typically associated with tight project schedules, changing site conditions and availability of skilled field labor. WRC can construct a wide range of modular assemblies using the latest in design techniques. In addition to custom pre-fabricated pipe spools, our modules can be packaged to improve project delivery and can incorporate a broad range of components including valves, instrumentation, cable trays, equipment, structural supports. By WRC adding modular construction capabilities, this adds another dimension to the services they offer.

Equipment Installation / Removal

Western Refractory works with our clients to set and install their new equipment from tanks, exchangers, pumps, and much more. Our team of highly trained professionals can perform their jobs in any environment. Once the new equipment is set, Western Refractory will remove and dispose of any old equipment no longer needed.

Structural Welding / Repairs

Western Refractory has some of the best welders in the industry and can repair or modify all of your structural needs.

Building Erections

No matter what you’re building, our team at Western Refractory can bring your project to life. From arched canvas sided buildings to a steel building with metal siding, we’re able to execute the job to perfection.

Turnkey Turnarounds

Over the last 30 years, Western Refractory has built a team of highly trained professionals that have helped our clients with their successful turnarounds. Some of our clients even prefer a complete turnkey solution that includes planning, scheduling, cost tracking, and the final installation. Our professionals understand the importance of time and accuracy on these projects and they have the experience to perform at the highest levels of the industry. During turnarounds, our team has performed work on:

FCCU equipment: Cyclones, Diplegs, Flapper Valves, Riser Lines, Wyes, Air Grids, Steam Rings, Plenums, Regen/Reactor Heads, Flue Gas Lines, Transfer Lines, 3rd Stage Separators, Pressure Vessels, API Tanks, Stacks, Transfer Lines, Equipment, Pipe Spools & Ducting: Custom Metal Fabrication, Refractory (Hexmesh, Anchor) Lined, Inconel/Stainless Lined and Non-Lined Equipment. Exterior insulation and painting.
SRU Equipment:Waste Heat Boilers, Condensers, Converters, Reactors, Sour Water Strippers, Columns, In-Line Burners and Refractory Lined Ducting and Piping All equipment.

Project Management

Western Refractory’s world-class project management team is second to none. Our professionals bring a unique focus to project management shaped by the goals, resources, and schedule of each individual project and its needs. By focusing on the following ten areas, our team is able to focus on the core values of project management that will make your project a success:

Integration
Scope
Time
Cost
Quality
Procurement
Human Resources
Communication
Risk Management
Stakeholder Management

Scheduling

Over the years our team has successfully planned multiple projects for our clients on top of the day to day projects they manage for our company internally. From turnaround size projects to ones that only last a few weeks, Western Refractory will give you peace of mind knowing that everything is executed proficiently from pre-planning through completion. Our team is proficient in both Microsoft Project and Primavera.

Estimating

When your primary focus is getting fully operational, our team will make it their focus to meet your estimating needs quickly competitively, and accurately. With some of the best estimators in the business, we’re able to offer fast turnarounds backed by industry experience and deep understanding of the industries we serve. Western Refractory offers free estimates and our team is capable of meeting all deadlines with competitive prices.

Critical Lifts

Over the years, our team of highly experienced professionals has successfully performed numerous critical lifts from vessels, towers, tanks, and everything in between. With a strong focus on safety, we’ve developed a track record of success that echos throughout every project we touch.

As-Built Drawings

Throughout the life of a project, there are going to be changes and unforeseen circumstances that require slight alterations. When this happens, our team of professionals is capable of providing you with ‘As-Built Drawings’ for review in order to keep the project moving forward and preventing the need to re-engineer the plans.

Cost Tracking

Our ability to ensure projects stay on budget allows Western Refractory to maintain competitive pricing for our clients and provide peace of mind.

QA / QC Monitoring

In addition to providing our clients with the highest quality of craftsmanship and materials, Western Refractory offers our clients a wide range of quality control services both in-house and through our third-party contractors:

PWHT Services
Hydro Testing
Liquid Penetrant (pt)
Magnetic Particle (mt)
Vessel Closures
PMI Reports
MTR’s
Welding Log
Non-Conformance Reports
Many more

Emergency Response Service

In most cases, Western Refractory can assemble our team anywhere in the United States within 24 hours and we’re available to our clients 24 hours a day, 365 days a year. In other words, your emergency is our emergency and we’ll make it our priority to get your plant back up and running to prevent the least amount of lost revenue as possible.

Discover how our process makes us stand out from the rest.

Featured Project

Wyoming Refinery: Newcastle, Wyoming

Western was awarded the bid in January 2016 to provide Wyoming Refining a new Benzout unit. This new unit contained over 14,000 feet of pipe, over 1200 valves, towers ranging from 50k to 100k lbs., and multiple vessels and pumps.

Western Refractory was responsible for the assembly of the structural steel, fire proofing, installation and hydo of all process piping, setting of towers and pumps as well as assisting the plant in start up of the unit. This project was a huge success Western came in under budget and right on schedule. Wyoming Refining we thank you for allowing us to perform this project for you.

Discover how our process makes us stand out from the rest.

WR “Safety First Initiative”

A History Of Success
Built on Safety

WR “Safety First Initiative”

Colorado Headquarters

Salt Lake City Branch

California Office

Nebraska Office