A refractory campaign that ends 200 heats early costs $300,000 in unscheduled downtime and emergency reline labor at 3× planned cost. A campaign pushed 150 heats past its safe limit risks a breakout — and a single BOF or EAF breakout costs $6M in equipment damage, production loss, and environmental remediation. The steel plants that operate precisely at the right campaign length — neither short nor long — do it with a live campaign register that tracks every heat, every gunning repair, every thickness measurement, and every hot spot detection against the vessel's expected wear curve. This free editable refractory campaign register template, integrated with ladle life tracking and Oxmaint's CMMS, gives your refractory engineer the full-fleet visibility to make that call confidently.
Oxmaint · Free Template · Steel Plant Refractory Campaign Register
Free Steel Plant Refractory Campaign Register — BF / BOF / EAF / Ladle / Tundish
Editable Excel, Word, and PDF formats. Tracks heat count, hot spots, gunning repairs, thickness measurements, and campaign end projections for every vessel type. CMMS-ready for Oxmaint integration.
$6M+
Average cost of a single BOF or EAF refractory breakout — equipment damage, production loss, remediation
5 Types
Vessel registers in this template: BF lining, BOF vessel, EAF shell, ladle fleet, tundish campaign
95%
Campaign end prediction accuracy when laser scan data + heat count are tracked in Oxmaint CMMS
30%
Average refractory cost reduction through optimized campaign end scheduling vs. time-based reline
What the Template Tracks — By Vessel Type
VESSEL TYPE COMPARISON TABLEREFRACTORY CAMPAIGN REGISTER — FIELDS BY VESSEL TYPE
Vessel
Campaign Heat Range
Key Wear Zones
Measurement Method
Register Trigger
Blast Furnace
10–15 years / full campaign
Stave coolers, tuyere zone, hearth
Thermal imaging, stave temp trending
Temperature exceedance
BOF Vessel
3,000–8,000 heats
Charge pad, trunnion, slag zone
Laser profile every 100–200 heats
80% design life heat count
EAF Shell
300–800 heats
Hot spots, tap hole, water-cooled panel
Thermal camera per heat; laser periodic
Hot spot above 250°C shell temp
Steel Ladle
60–150 heats per campaign
Slag line, side wall, bottom nozzle
Visual + gauge per cycle; laser periodic
Zone heat limit (slag line first)
Tundish
1–20 heats (campaign)
Working lining, weir/dam, nozzle
Visual per sequence; weight check
Sequence end or visual trigger
Campaign Lifecycle — The 5 Phases Every Register Must Track
HORIZONTAL LIFECYCLE FLOWREFRACTORY CAMPAIGN LIFECYCLE — PHASES AND OXMAINT TRIGGER POINTS
Phase 1
Installation & Cure
New lining installed. Cure schedule logged. Baseline thickness recorded. Campaign opened in register.
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Phase 2
Early Campaign
First 20% of design life. Wear rate calibration. First laser scan. Baseline wear curve established.
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Phase 3
Mid Campaign
50–70% of design life. Stable wear. Periodic scans. Gunning repairs tracked. Reline window calculated.
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Phase 4
Late Campaign
80–95% heat count. Increased scan frequency. Hot spot monitoring daily. Reline scheduled in CMMS.
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Phase 5
Campaign Close & Reline
Campaign closed. Final heat count recorded. Wear analysis logged. New campaign record opened automatically.
Template Download Formats — What's Included
FORMAT CARDSExcel (.xlsx)
5 tabbed worksheets — one per vessel type. Auto-calculated wear rate, campaign % complete, projected end heat, and hot spot flag columns. Configurable design life inputs per vessel.
Download Excel
Word (.docx)
Narrative campaign record format. Campaign summary sections, hot spot log, repair history, measurement record table, and sign-off blocks for refractory engineer and operations manager.
Download Word
PDF (Printable)
Laminated-ready shop floor format. One page per vessel per campaign. QR code links to Oxmaint CMMS digital record. Designed for melt shop and refractory bay notice boards.
Download PDF
Oxmaint Live (CMMS)
Import directly into Oxmaint. Heat-count auto-update from Level 2, automated reline work order generation at campaign threshold, and 5-year campaign archive for compliance export.
Activate in CMMS
Hot Spot Severity Scale — What the Register Uses
HORIZONTAL SEVERITY SCALE BARHOT SPOT CLASSIFICATION SCALE — REFRACTORY CAMPAIGN REGISTER STANDARD
Spreadsheet Register vs Oxmaint CMMS — What You Gain
CAPABILITY COMPARISON — MANUAL SPREADSHEET vs OXMAINT LIVE REGISTER
Manual Spreadsheet
Heat count updated manually after each shift
Hot spot log in separate email chain
No automatic reline work order trigger
No cross-vessel fleet view
Campaign history in shared drive folders
No wear curve projection
Oxmaint Live Register
Heat count auto-updated from Level 2 / SCADA
Hot spot flags generate work orders instantly
Reline work order auto-created at 90% campaign
Full fleet dashboard — all vessels, one view
5-year searchable campaign archive in CMMS
AI wear curve projection with 95% accuracy
"We had a BOF campaign that ran 400 heats past its scheduled reline because the spreadsheet tracker was three days behind on heat counts and nobody saw the slag line reaching critical thickness. After moving to Oxmaint's live campaign register, heat counts update automatically and we've had zero unscheduled relines in 18 months. The register paid for itself in the first quarter."
Refractory Engineer
Integrated Steel Producer, Ohio — BOF Shop, 2.8 MTPA
Frequently Asked Questions
Q1 What fields does the refractory campaign register template include for a BOF vessel?
The BOF template tracks vessel ID, campaign number, installation date, lining material and grade, heat count at campaign start, design life heat target, accumulated heat count per heat day, thickness measurements by zone (charge pad, trunnion, slag zone, bottom) at each laser scan interval, gunning repair records with material quantity and zone, hot spot log with temperature and classification level, and projected end heat with confidence range based on current wear rate.
Q2 How does Oxmaint automatically update heat counts in the campaign register?
Oxmaint connects to the plant's Level 2 production system or SCADA via API to read heat completion events in real time — incrementing the heat counter on each vessel's campaign record automatically at every heat end. No manual entry is required by maintenance or operations staff, eliminating the 3-day lag common in spreadsheet-based tracking and ensuring the campaign register always reflects the true current heat count.
Q3 What is a hot spot and at what temperature should a campaign end?
A hot spot is a localized area of the vessel shell reaching temperatures above the design baseline, indicating refractory thinning or loss in that zone. The register classifies hot spots on a 5-level scale — Level 3 (200–250°C) triggers emergency gunning repair, Level 4 (250–300°C) requires immediate intervention and reline planning, and Level 5 (above 300°C shell temperature) is a campaign end condition requiring immediate shutdown to prevent breakout risk.
Q4 Can the same register template track ladle campaigns alongside BOF and EAF vessels?
Yes — the Excel template includes separate worksheets pre-configured for each vessel type (BF lining, BOF vessel, EAF shell, steel ladle fleet, tundish), each with the specific fields, heat count ranges, and wear zone names appropriate to that vessel. In Oxmaint's CMMS, all vessel types are managed from a single campaign dashboard with per-vessel filtering.
Q5 How does Oxmaint generate a reline work order automatically from the campaign register?
When a vessel's accumulated heat count reaches the configured alert threshold (default: 90% of design life), Oxmaint automatically creates a reline planning work order assigned to the refractory coordinator, pre-filled with vessel ID, current heat count, campaign history, and standard reline procedure reference. A second work order is auto-generated at 100% threshold for execution scheduling, ensuring the reline team has lead time to source materials and schedule the outage window.
Q6 Does the template include a gunning repair record section?
Yes — each vessel worksheet includes a gunning repair log capturing repair date, heat count at time of repair, zone repaired (with zone map reference), material type and quantity consumed, operator/vendor who performed the repair, and pre/post repair thickness estimate where available. In Oxmaint, each gunning event is a work order with the same fields, searchable across the full campaign history and included in the campaign summary report.
Q7 What is the difference between a tundish campaign register and a ladle campaign register?
Tundish campaigns are significantly shorter (1 to 20 heats per sequence depending on steel grade) and use a disposable working lining over a permanent backup lining — so the register tracks sequences rather than extended heat campaigns, with primary attention to working lining weight and condition at end of sequence and backup lining inspection frequency. Ladle registers track individual unit heat count per zone over 60 to 150 heat campaigns, with slide gate cycle records as a separate component history.
Q8 How does the campaign register support NESHAP compliance for BOF and EAF operations?
Refractory campaign records document that emission control equipment (BOF suppression hoods, EAF offgas systems) received the maintenance required to maintain compliance with NESHAP Subpart FFFFF. Oxmaint's campaign register links vessel maintenance records to the associated pollution control equipment PM schedule, creating the traceability chain that EPA inspectors request when reviewing emission control system reliability documentation during air compliance audits.
Download Free. Deploy in Oxmaint in Minutes.
Download the refractory campaign register in Excel, Word, or PDF — or activate the live Oxmaint version with automatic heat-count updating and reline work order generation for your entire vessel fleet.
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