Pre-Cast & Pre-Fired refractory shapes — cast and fired at Chakan.
We already manufacture PCPF shapes in-house. Burner blocks, lance heads, ladle inserts, well blocks and fully custom forms come off our Chakan plant pre-fired and ready to install — skipping the on-site dry-out that delays cast-in-place linings. A state-of-the-art expanded PCPF facility is under construction, adding capacity, larger shape range and tighter tolerance control.
In-House
Cast & Fired at Chakan
8+
Standard Shape Families
Custom
Built-to-Drawing
Upgrade
New Facility in Build
Why PCPF
Why pre-cast & pre-fired beats cast-in-place
A castable cast on site is only as good as the on-site curing and dry-out schedule. PCPF shapes arrive at your plant already cured, dried and fired — ready to install and heat up to operating temperature on the next campaign cycle.
Talk to us about your shape01
Skip the on-site dry-out
No multi-day controlled heat-up to drive off chemical and physical water. Shape arrives pre-fired. Production downtime drops materially.
02
Higher density, lower porosity
Vibration-cast in steel moulds under controlled conditions — denser and more uniform than a hand-cast on a furnace floor.
03
Predictable performance
Every shape is fired to a known schedule. Wear behaviour stops being a roll of the dice depending on which crew cast which lift on which day.
04
Fewer skill dependencies
Installation reduces to setting blocks and grouting joints. No on-site mixing, vibration, formwork or curing supervision.
05
Repeatable for relining
A drawing approved once becomes a reorder line item. Each subsequent reline is dispatched in days, not negotiated as a fresh project.
06
Custom geometry that's hard to cast in-situ
Burner cones, lance noses, complex ports and hot-spot inserts — shapes a hand-cast won't do well. We mould them in-house.
Shape Range
Standard PCPF families we manufacture
Standard families below. Custom shapes built to your drawing — talk to us.
Burner Blocks
Burner quarls and burner blocks for fired heaters, reheating furnaces, glass tank ports and reformer combustion zones. High-alumina and mullite-bonded grades.
Lance Heads & Tips
Oxygen-lance noses, side-lance heads and injection-lance tips for steelmaking and aluminium casthouse use. Pre-shaped, no field carving required.
Ladle & Tundish Inserts
Ladle bottom inserts, impact pads, well blocks, dam & weir blocks and tundish furniture. Shaped, cured and pre-fired ready to drop in during the reline window.
Well Blocks & Tap-Hole Blocks
Well blocks for ladle slide-gate systems and tap-hole blocks for furnace and ladle drainage. Tight tolerance on bore and seat geometry.
Runner & Spout Sleeves
Iron runners, launders, casthouse spouts and aluminium transfer-trough segments. Sized to drawing, with optional SiC-rich grades for abrasion-prone zones.
Kiln Nose-Ring Segments
Pre-cast nose-ring segments for cement and lime rotary kilns. Replaces the failure-prone hand-cast nose-ring lift with a drop-in modular set.
Hot-Spot Inserts
Pre-cast hot-spot blocks for known wear zones — converter knuckles, EAF roof delta sections, ladle slag-line panels. Replaces only what wears, not the whole lining.
Custom — built to drawing
Send us a drawing, a sketch or a photo of the worn-out original. We will quote a mix design, mould plan and pre-fire schedule. First-off shapes typically dispatch in 4–8 weeks.
Mix Design
PCPF mix families — pick by service condition
Indicative properties only. Final specification is set per application after we review your operating envelope.
| Mix Family | Bond System | Al2O3 Range | Service Limit | Typical Application |
|---|---|---|---|---|
| High-Alumina LCC | Low-cement, calcium-aluminate | 60–80% | 1500–1650 °C | Burner blocks, ladle inserts, kiln nose rings |
| Mullite-Corundum | Ultra-low-cement | 75–90% | 1650–1750 °C | Reformer burner blocks, glass-tank ports, hot-spot inserts |
| SiC-Bonded Castable | Low-cement, SiC-enriched | 15–55% (with 25–60% SiC) | 1450–1550 °C | Aluminium runners, incinerator hot face, abrasive zones |
| Magnesia-Spinel | Phosphate / cement bonded | — | 1700+ °C | Steel ladle bottom inserts, BOF tap-hole blocks |
| Insulating Castable | Lightweight aggregate, cement | 35–55% | 1100–1300 °C | Backup PCPF blocks, casing thermal-bridge breaks |
Datasheets for each mix family available on request. Send us your specification and we will email the matching datasheet PDF.
A state-of-the-art PCPF facility — under construction at Chakan
We are commissioning a new, expanded PCPF manufacturing facility on our Chakan site. Larger casting bays, additional firing kilns and tighter dimensional control. The objective: shorter lead times on custom shapes and a step-change in capacity for OEM and EPC customers.
- Expanded casting capacity for larger blocks and longer runs
- Additional firing kilns — faster turnaround, parallel batches
- Tighter dimensional control for slide-gate plates and well blocks
- Dedicated capacity for OEM and EPC supply contracts
Commissioning schedule and capacity numbers available on request as construction progresses.
Pre-book capacity at the new facility
Let us know what you'd want to source from the upgraded facility. We are taking expressions of interest from OEMs and EPC integrators ahead of commissioning so we can plan our shape range and grade portfolio around real demand.
Submit an expression of interest →How We Quote a PCPF Shape
From drawing to dispatched shape
-
01
Share the drawing
PDF drawing, IGES/STEP file, sketch or even a photo of the worn-out original — whatever you have. Plus operating temperature and atmosphere.
-
02
Mix design & mould plan
We pick the mix family, agree the mould approach (steel re-usable vs. one-shot wood) and confirm tolerance bands. You sign off on the drawing.
-
03
Cast, cure, fire
Vibration cast in our shop, controlled cure, then fired to the documented schedule. Dimensional QC and visual inspection on every shape before despatch.
-
04
Dispatch & install
Crated for transport. Dispatched same-day across the Pune belt, by road or rail pan-India, by sea under our active IEC for export customers. Optional install supervision by our crew.
Frequently Asked
PCPF questions, answered
Are Chaneyco PCPF shapes manufactured in-house?
Yes. PCPF shapes are cast, dried and pre-fired at our Chakan plant. A state-of-the-art expanded PCPF facility is under construction to add capacity, larger shape range and tighter tolerance control.
What types of PCPF shapes do you make?
Burner blocks, lance heads & tips, ladle and tundish inserts, well blocks, tap-hole blocks, runner sleeves, kiln nose-ring segments, hot-spot inserts — plus fully custom shapes built to drawing.
What is the lead time for a custom PCPF shape?
Lead time depends on shape complexity, mix selection and firing schedule. Standard shapes typically dispatch within 2–4 weeks; first-off custom shapes within 4–8 weeks. Subsequent reorders run materially faster because the mould and fire schedule are already qualified.
Do PCPF shapes need on-site dry-out?
No. The defining advantage of PCPF over cast-in-place castables is that the shape is already pre-fired. You skip the multi-day on-site dry-out, recover production time and avoid shape failures from rushed heat-up. A normal furnace heat-up to operating temperature is all that is required.
Can you supply PCPF shapes for export?
Yes. We have held an active DGFT-issued IEC since 2012 (IEC 0311071333). We export PCPF shapes and other refractories to plants across Africa, the Middle East and South-East Asia, with export-grade crating and documentation handled by our Chakan despatch team.
Do you supply documentation for QA approval?
Yes. Each batch is shipped with mix data, fire schedule, dimensional QC and visual inspection records. Our ISO 9001:2015 quality system (Cert. No. 11553, AQSR / USAC accredited) covers design, manufacturing, supply and installation, valid through September 2027.
Talk to a PCPF Engineer
Tell us about your shape
Share what you know — furnace type, operating temperature, the shape you need, ideally a drawing. Our PCPF engineer responds within one working day with mix recommendation, mould approach and indicative lead time.