Patent ID: 8016259

Claim:
A method of constructing a refractory furnace cover comprising: providing a molding form base having a molding surface; providing an outer molding frame on the molding form base; providing at least two substantially parallel inner molding members disposed across and dividing the molding surface into a first molding section, a second molding section, and a third molding section, the inner molding members each having a first molding surface and a second molding surface, the first molding surface having a protrusion located along its length and being located adjacent to and facing the first and second molding sections; shotcreting refractory material in the first molded section of the furnace cover to form a first section; shotcreting refractory material in the second molded section of the furnace cover to form a second formed section; removing the inner molding members, thereby exposing substantially parallel slots formed in the first molded section and the second molded section by the protrusion in the inner molding members; and shotcreting refractory material in the third molded section to form a third formed section in contact with first and second molded sections, thereby forming interlocking keys in the slots of the first molded section and the second molded section.