Award Winning Work & Team
63 Stove Project – Iron Producing
The industrial landscape witnessed a remarkable feat of engineering and craftsmanship with the demolition and rebuild of the #63 stove. Originally constructed in 1946, this major reline and reconstruction project has now been recognized with the prestigious 2025 BAC Craft Award for Best Refractory Project.
Project Overview
Spanning a rigorous five-month timeline and requiring an investment of approximately $11.7 million, the #63 stove reline was a monumental task. A total of 35 highly skilled BAC local force Indiana/Kentucky members dedicated themselves to the success of the project, ensuring it was executed with precision, safety, and efficiency.
Demolition and Reconstruction Challenges:
- The project required the demolition of the existing refractory material, which contained asbestos (ACM – Asbestos Containing Material), necessitating careful abatement procedures and the construction of a large containment area at the stove’s base.
- The original stove shell, measuring 26” in diameter and 123’-6” tall, was completely removed and replaced with a new shell extending to 132’ tall.
- The newly installed dome is self-supporting, eliminating the need for additional structural reinforcement.
- To facilitate the rebuild, a crane was strategically positioned in the ore field with a pick radius of 273’. The heaviest lift involved a staggering 192,000 lbs, including all rigging components.
- All existing utilities had to be rerouted to accommodate the new stove design.
- Extensive internal construction included new columns, grids, girders, insulating brick, hard brick, and checkers.
Operational Considerations:
- Despite the large-scale demolition and construction efforts, the #6 Blast Furnace, along with stoves #61, #62, and #64, remained fully operational throughout the duration of the rebuild.
- The project adhered to a 2-10-6 schedule, with two shifts working 10-hour days from Monday through Saturday, maximizing efficiency without compromising quality.
Safety and Execution Excellence
A project of this magnitude demands rigorous safety protocols, and the reline of the #63 stove delivered exceptional results with over 95,000 craft manhours completed without a single lost-time incident or OSHA recordable. This achievement underscores the unwavering commitment to safety, planning, and execution demonstrated by the team.
Recognition and Industry Impact
The exemplary work has set a new industry standard in refractory projects. The skill, precision, and adherence to best practices has earned Songer the distinguished 2025 BAC Craft Award for Best Refractory Project. This accolade serves as a testament to their expertise and the enduring impact of their contributions to industrial infrastructure.
The successful reline of the #63 stove is more than just a technical achievement—it is a showcase of engineering excellence, innovation, and unwavering dedication to craftsmanship. As a benchmark for future industrial projects, this award-winning rebuild stands as a proud accomplishment in the realm of iron production and refractory construction.