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FAIRFLUX

 ISO 9001:2008
30+ Years · Industrial Excellence
ISO 9001:2008 Certified
Ancillary to SAIL — Bhilai Steel Plant

Engineering Reliability for the Steel Industry

Fairflux Pvt. Ltd. delivers high-performance refractory and flow-control solutions trusted by steel manufacturers for over three decades — including our Cold Board Ladle Lining System, engineered to cut costs and boost production.

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"Cast Steel With Smile"

30+

Years Experience

100+

Steel Plants

5000+

Successful Projects

Pan India

Operational Network

Heat No. 01 — Who We Are

A Legacy Built on Performance

An ancillary unit of Steel Authority of India Limited — Bhilai Steel Plant, Fairflux was established in 1991 and has grown into a trusted metallurgical products partner for the steel and foundry industries.

Backed by a dedicated team of metallurgical engineers and a close working relationship with SAIL — Bhilai Steel Plant, we maintain rigorous quality control on every batch and continually develop newer products to meet evolving plant requirements.

  • 1991 Founded as an ancillary to SAIL — Bhilai Steel Plant
  • ISO 9001:2008 Certified quality management system
  • Rajnandgaon Manufacturing unit, ~25 Kms from Bhilai, with a standard in-house laboratory testing both raw materials and finished goods to specification
Fairflux Tundish Board — collector nozzle and Ar-purged joint assembly for continuous casting

Tundish Board Assembly

Heat No. 02 — What We Offer

Core Solutions

Flagship

Cold Board Ladle Lining

Preheat-free ladle lining system in silica & basic boards, available for 1 MT to 12 MT ladles — and up to 20 Ton on request.

Learn more →

Tundish Board

Cold Tundish Boards of any size or shape for continuous casting, sealing cleanly around the collector nozzle.

Ladle Board

Refractory boards engineered for extreme conditions.

TCC

Tundish casting compounds reducing heat loss.

NFC

Nozzle filling compound ensuring reliable flow.

Sleeves

Insulating & exothermic sleeves, open or blind, improving yield.

Heat No. 03 — Ladle Boards Both In Silica & Basic

Cold Board Ladle Lining System

A preheat-free ladle lining system for bottom-pouring ladles. The scenario in the foundry changes completely once Cold Ladle Boards replace conventional refractory lining — no more ladle preheating, nozzle choking, skull generation, or preparation delays. Boards are available for ladles from 1 MT up to 20 MT.

Best Foundry & Practice 100% Safety For Bottom Pouring Ladle
Cold Board Ladle Lining diagram showing stopper rod assembly, insulation boards, loose sand fill, safety lining and nozzle hole
  • → Stopper Rod Assembly (or Slide Gate)
  • → Insulation Boards
  • → Loose Sand Fill
  • → Safety Lining — Standard Bricks or 1½" Tiles
  • → Joint in Bottom Boards
  • → Groove in Bottom Boards for Fixing Vertical Boards
  • → Nozzle Hole
Cold Board Ladle Lining installed inside a ladle, top view

Installed Cold Board lining, ready for the next heat

Heat No. 04 — Why Switch

Advantages of Cold Board Lining

No Preheating Required

Saves furnace oil / LDO and eliminates the recurring and capital cost of a pre-heater and its space.

Easy Ladle Availability

The melter is relieved from the tension of getting a ladle ready and can concentrate on heat-making.

No Skull Jam

No skull or jamming forms in the ladle, eliminating the need for oxygen lancing.

No Metal Loss

Yield of metal increases as loss due to ladle failure and skull formation is eliminated.

No Use of Refractory

No refractory bricks or mortar needed, keeping steel free of refractory inclusions and dirt.

Less Temperature Drop

Consistent temperature fall from furnace to ladle standardizes tapping temperature every heat.

Very Neat & Clean

100% safe working; the ladle is ready within 3 hours for the next casting, doubling shop production.

100% Safety

Cool, ready-to-inspect ladles reduce risk and make cleaning and inspection straightforward.

Heat No. 05 — How It Works

Description & Method of Use

01

Level & Set Bottom Boards

Two bottom boards are installed first, after leveling the base of the ladle with dry sand. One board has a hole for the nozzle, aligned with the ladle's nozzle hole, then fixed with adhesive paste.

02

Fix Vertical Panel Boards

Twelve vertical board panels are set side by side using the grooves in the bottom boards to complete the circle. All joints are sealed with the adhesive cement paste supplied with the boards.

03

Fill & Seal

Coarse, dry sand fills the gap between the boards and the ladle's safety lining, allowing evolved gas to escape freely. The stopper rod is installed in the conventional way.

04

Pre-heat Nozzle & Stopper

Unlike the boards, the nozzle and stopper rod need brief pre-heating — the nozzle is heated from the bottom for 15–20 minutes before the ladle is used.

05

Inspect, Tap & Reline

Heat is removed from the nozzle, the ladle is inspected and tapped normally. After pouring, the nozzle is pushed out and the lining falls out when the ladle is inverted — ready for immediate relining.

Heat No. 06 — Assembly Reference

Ladle, Hot Top & Tundish Assemblies

Whether it's a slide-gate nozzle feeding a mould directly or a stopper-rod bottom-pouring ladle feeding through a hot top and spyout, Fairflux boards and compounds are built to seal each interface cleanly — protecting casting quality heat after heat.

Diagram of slide gate nozzle top pouring and stopper rod bottom pouring ladle with hot top, spyout and refractory bricks

Ladle & Hot Top

Top pouring via slide-gate nozzle, and bottom pouring via stopper rod through a hot top and spyout onto refractory bricks — the two most common ladle-to-mould configurations our boards are built to seal.

Fairflux Tundish Board with collector nozzle, Ar-purged joint and long nozzle for continuous casting

Tundish Board

Cold Tundish Boards of any size or shape for continuous casting, engineered to seal cleanly at the collector nozzle and Ar-purged joint before the long nozzle feeds the mould.

Heat No. 07 — 100 Heats × 2.5 MT (250 T Liquid Steel)

Estimated Cost Benefits

Conventional Refractory-Lined Ladle
Side Arch & Standard Bricks₹10,000
Fire Clay & Grog₹11,000
Metal / Filter Loss due to Skull (1.25 T)₹30,750
Oil Consumption (2,500 Ltrs)₹1,00,000
Extra Electricity Charges (250 T)₹30,000
Extra Manpower₹5,000
Oxygen (100 M³)₹2,000
Metal Loss due to Ladle Failure (2.5 T)₹62,500
TOTAL₹2,51,250
Cold Ladle Board Lining
Cost of Cold Boards₹1,50,000
Loss due to Board Damage etc.₹3,000
Other Miscellaneous Expenses₹10,000
TOTAL₹1,63,000
Net savings of ₹90,000 for 250 T of liquid steel — that's ₹360 per tonne — plus improved casting quality, cleaner steel, and lower fettling cost.
Heat No. 08 — Handling Guidelines

Precautions

Heat No. 09 — Complete Catalogue

Foundry & Steel Division Products

Two dedicated product lines, one quality standard — everything below is manufactured to size, specification, or drawing.

Foundry Division

For Foundry Shops
  • Insulating Sleeves — Open / Blind
  • Exothermic Sleeves — Open / Blind
  • Flexible Riser, Boards and Breaker with Sleeves
  • Hot Topping Compound
  • Anti-Piping Compound
  • Ladle Covering Compounds
  • Cold Ladle Boards for sizes up to 20 Ton Ladles
  • Core Jointing Gum
  • Paints and Coatings in Silica, Magnesite, Zircon and Graphite
  • Wax Sealing Rope or Tube — 3, 6, 10, 20mm Diameter
  • Pattern Releasing Compound

Steel Division

For Steel Melting Shops
  • Mould Coating Powder for Ingot Casting
  • Hot Tops for Forging / Killed Steel — Single & Multi-Piece
  • Anti-Piping Compound
  • Cold Tundish Boards of Any Size / Shape for Continuous Casting
  • Sealing Compound, Rope, Tube of Any Size
  • Ladle Covering Compound
  • Bottom Teeming Fluxes
  • Casting Powder for CCS
  • Ladle Nozzle Opening Compound
  • Stopper Heating Cone or Sleeves
  • Ramming Masses for Furnace and Launder in Basic Refractories
Custom Manufacturing

Send your requirements in terms of size, specification or drawing. Any size or shape, as applicable to specific products, can be manufactured within 10 days of receipt of a technically and commercially clear purchase order. Fairflux ensures timely delivery of quality products.

Partner With a Proven Industry Leader

Talk to our technical experts for customized refractory and Cold Board Ladle Lining solutions.

Contact Fairflux Call +91 97558 44042