Abstract: A method of repairing a refractory brick wall in a furnace that includes: (a) identifying a refractory brick wall or portion thereof that requires repair/reconstruction, pre engineering construction dimensions and accommodating various battery oven designs and oven heating systems; (b) demolishing the refractory brick wall or wall portion thereof identified in step (a); (c) installing outer reusable forms in situ, defining a new wall or portion thereof; (d) installing inner consumable forms defining one or more passageways within the new wall or portion thereof; and (e) pouring castable material into one or more areas bounded by the outer forms; (f) curing said castable material; and (g) removing the outer reuseable forms.