The formation of metastable alumina phases due to the oxidation of commercial FeCralloy (R) rods (0.5 mm thickness) at various temperatures and time periods has been examined. This structured layer acts as an anchor to bind additional coatings of alumina via wash-coat techniques, thereby improving the layer thickness and increasing adhesion of the catalytic surface. Optimisation of the layer thickness and catalytic properties were conducted, using a range of analytical systems [scanning electron microscope (SEM), energy dispersive X-ray (EDX) and X-ray diffraction (XRD)]. The modified FeCralloy (R) rods were tested in a fixed bed reactor rig to assess the impact on yield for the dehydrogenation of methylcyclohexane. (C) 2014 The Chemical Industry and Engineering Society of China, and Chemical Industry Press. All rights reserved.