Middletown, Ohio

No. 3 Blast Furnace Hearth Replacement

Client / Owner

AK Steel




Graycor Industrial

Project Scope

Graycor Industrial’s team replaced the No. 3 Blast Furnace’s hearth bottom refractory and installed a new bosh cooling stave system. Graycor also assisted in scope development and constructability.

Scope of work included performing bottom tap; 100-ton salamander removal by lancing; demolition of refractory in the lower stack, bosh and hearth down to the foundation; installation of two rows of staves, hearth and tuyere refractory; shotcrete to the furnace; conversion of the furnace cooling water from tongue plates to staves; replacement of the furnace proper thermocouple system; and shell modifications.

Graycor Industrial performed the 65-day reline utilizing a 2-10-5 schedule which helped the project achieve a cost-efficient project that under-ran its budget and reached completion on time.