Code: PRJ-2022
Kiln De-Bricking & Refractory Installation
National Cement Plant, Kenya
Scale
KSh 10,000,000
Status
Complete
The Kiln De-Bricking and Refractory Installation project for National Cement demonstrates Civicrete's specialist capability in cement plant maintenance operations. Cement kilns require periodic replacement of their internal refractory brick lining — a technically demanding task requiring execution within tight plant shutdown windows to minimise production downtime. Civicrete's team carried out systematic de-bricking of the worn lining, installation of new refractory anchor studs by welding, and complete installation of new refractory bricks across the kiln cell. The project was completed on schedule and to National Cement's quality specification, restoring the kiln to full thermal efficiency.
Confined Space Operations
All brick installation work was executed inside the kiln shell — a confined space environment requiring full gas-testing protocols, forced ventilation, and buddy-system working procedures throughout.
Shutdown Window Pressure
The entire de-bricking and re-bricking operation was executed within a scheduled maintenance shutdown, creating intense time pressure that required 24-hour working with staggered shift teams.
Weld Quality in Refractory Environment
Anchor stud welds in the kiln shell must achieve specific shear strength values to secure the refractory brick lining against thermal cycling and kiln rotation forces. All welds were tested by pull-out method.
Plant Shutdown Coordination
Work schedule and access plan agreed with National Cement operations team
Kiln Cooling
Controlled cooling protocol to bring kiln shell to safe working temperature
De-Bricking
Systematic removal of worn refractory brick lining using mechanical breaking equipment
Shell Inspection
Visual and dimensional check of kiln shell and existing anchor condition
Anchor Installation
Welding of new refractory anchor studs to the kiln shell at specified centres
Brick Installation
Installation of new refractory bricks with appropriate refractory mortar
Quality Check & Handover
Inspection of completed lining and clearance for plant restart
