Job Role

The Furnace Liner is responsible for the safe and effective relining, patching, maintenance, and inspection of furnace crucibles to ensure continuous production operations. The role involves removing worn refractory linings, installing new furnace linings using ramming mass, conducting wear inspections, and maintaining lining integrity in accordance with operational, quality, and safety standards. The ideal candidate is safety-conscious, physically fit, detail-oriented, and capable of working in high-temperature industrial environments.

2. PURPOSE OF THE ROLE

• Ensure furnace crucibles are lined and maintained to the required operational standards.
• Support safe and reliable furnace performance by preventing refractory failures.
• Maximize furnace lining lifespan through proper installation and maintenance practices.
• Maintain compliance with plant safety, quality, and operational procedures.
• Support uninterrupted production through timely relining and patching activities.
• Promote housekeeping, equipment care, and efficient use of refractory materials.

3. DUTIES AND RESPONSIBILITIES

A. Furnace Lining Removal

• Break out and remove worn or damaged furnace linings after approved furnace isolation and cooling.
• Clean furnace coil areas and surrounding workspaces during relining activities.
• Inspect coil grout and furnace structures for signs of wear, cracking, or damage.
• Report any abnormalities or damage to the Furnace Supervisor before relining begins.

B. Furnace Relining Operations

• Install insulation materials and position furnace formers according to specifications.
• Apply and compact ramming mass in uniform layers to achieve required density and thickness.
• Operate relining tools and equipment safely and effectively.
• Follow approved sintering and heating schedules during commissioning of new linings.
• Ensure all relining activities meet quality and operational standards.

C. Furnace Maintenance, Patching & Inspection

• Perform routine patching of furnace spouts, tops, and other worn lining sections.
• Conduct lining wear inspections and monitor refractory condition.
• Identify and report lining deterioration and recommend relining requirements.
• Assist in extending lining life through proactive maintenance practices.
• Record lining condition, heat counts, and refractory consumption data.

D. Material Handling & Housekeeping

• Verify ramming mass and insulation materials are clean, dry, and suitable for use.
• Store refractory materials in designated conditions to prevent contamination.
• Maintain cleanliness and organization of relining tools, equipment, and work areas.
• Ensure all tools and equipment are inspected and maintained in operational condition.
• Support inventory control through accurate usage reporting.

E. Safety & Compliance

• Adhere to Lock Out Tag Out (LOTO), confined space, and plant safety procedures.
• Wear and maintain required Personal Protective Equipment (PPE) at all times.
• Follow safe working practices when handling refractory materials and equipment.
• Participate in safety briefings, toolbox talks, and safety improvement initiatives.
• Report unsafe conditions, incidents, and near misses promptly.
• Promote a culture of safety and operational discipline within the melt shop.

F. Operational Coordination & Team Support

• Work closely with furnace operators, supervisors, maintenance personnel, and production teams.
• Support shutdown and maintenance schedules to minimize operational downtime.
• Communicate furnace lining status, maintenance requirements, and operational issues during shift handovers.
• Assist in achieving departmental production and maintenance objectives.
• Contribute to continuous improvement initiatives within furnace operations.

Qualification

4. QUALIFICATIONS

• KCSE Certificate or equivalent qualification.
• Technical training in refractory work, furnace operations, or industrial maintenance is an added advantage.
• Minimum 1–2 years' experience in furnace lining, refractory installation, ladle lining, or related industrial environments.
• Experience in steel manufacturing, foundry operations, or heavy industrial facilities is preferred.

5. COMPETENCIES

• Ramming mass application and compaction techniques
• Refractory maintenance and patching
• Furnace inspection and wear monitoring
• Safe operation of relining tools and equipment
• Material handling and storage procedures
• Safety compliance and LOTO awareness
• Record keeping and operational reporting
• Attention to detail
• Physical stamina and endurance
• Teamwork and collaboration
• Accountability and reliability
• Problem-solving ability
• Discipline and adherence to procedures
• Ability to work under pressure and in demanding environments

Working Conditions

• Shift-based work, including shutdown and maintenance periods.
• Exposure to high temperatures, refractory dust, industrial noise, and heavy lifting.
• Use of PPE, respiratory protection, and other safety equipment as required.
• Work conducted in and around furnace crucibles within a steel manufacturing environment.