OVERVIEW: Faced with severe wear from coke breeze and past coating failures, a leading mineral processing plant turned to Chemcote to restore and protect a 1.7 m OD steel duct. Operating under temperatures up to 110°C and heavy particulate exposure, the site needed a high-performance solution that could withstand extreme abrasion and extend service life. Chemcote deployed a robust multi-layer coating system featuring Chem-tect™ RB 364CS, alumina tiles, basalt fibre reinforcement, and a durable RC 500GTC topcoat — all applied with minimal downtime.
INDUSTRY
Mining and Mineral Processing
ENVIRONMENT
Normal operating temperature is 50 DegC.
Excursions have ranged up to 110 DegC semi regularly. Coke breeze (sharp granules) causing wear and tear after 25 years in service.
SUBSTRATE
Mild Steel
CHALLENGE
Prevent water mixing with the material causing
blockages. All areas with change in direction have holed through and previous contractor’s attempts have delaminated within two years.
SOLUTION
Alumina tiles, using RB364CS and basalt fibre
SCOPE
- Install sheet metal to allow composite repairs to commence
- Prepare surfaces by abrasive blast and fibreglass patch holes, whilst offline for 4 hours
- Application of Chem-tect™ RB 364CS in a 75mm band from weld down onto the conical section
- Installation of 6mm hex alumina tiles in the high wear areas
- Application of Basalt Fibre in two layers to obtain a thickness of 6,000μm DFT
- Topcoat using a RC500GTC (Green) in one coat
OUTCOME
Chemcote delivered a game-changing solution engineered for longevity. Nearly three years post-application, the coated system remains fully intact with zero delamination or leakage — proving its value as a high-durability, low-maintenance solution expected to last up to 15 years. This project is a testament to Chemcote’s ability to turn critical wear zones into long-term assets through smart material technology and expert application
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