Overview

The cement and mining industries operate in some of the most demanding environments in the world. Equipment is continuously exposed to highly abrasive materials, heavy impact loads, corrosive chemicals and extreme temperatures — all of which cause rapid deterioration of critical assets such as mills, crushers, conveyors, pumps, pipes and structural concrete.

Belzona's range of solvent-free polymer composites, ceramic-filled coatings and elastomeric materials provide fast, in-situ repair and long-term protection of plant and equipment, significantly reducing replacement costs and unplanned shutdowns.

Abrasion and Wear Protection

Abrasion is one of the primary causes of equipment failure in mining and cement plants. Slurry pipelines, pump casings, fan blades, chutes and hoppers are subject to constant particle impingement and sliding wear that rapidly reduces wall thickness and causes premature failure.

Belzona ceramic-filled composites such as Belzona 1311 (Ceramic R-Metal) and Belzona 1321 (Ceramic S-Metal) provide outstanding resistance to abrasion, erosion and corrosion, restoring worn surfaces to their original profiles. For rubber-lined equipment such as hydrocyclones and slurry pumps, Belzona 2111 (D&A Hi-Build Elastomer) and Belzona 2131 (D&A Fluid Elastomer) offer excellent abrasion and impact resistance with strong adhesion to both metal and rubber substrates.

Pump and Pipe Repair

Slurry pumps and pipelines are critical assets in mining operations, constantly transporting abrasive ore, slurry and process chemicals. Erosion-corrosion causes rapid deterioration of pump casings, impellers, volutes and pipe interiors, leading to efficiency loss and eventual failure.

Belzona repair composites allow in-situ rebuilding of worn pump components to original dimensions without the need for disassembly or hot work. After repair, protective coatings such as Belzona 1341 (Supermetalglide) can improve hydraulic efficiency while providing long-term erosion and corrosion protection. For pipework suffering from external or internal corrosion, Belzona SuperWrap II provides a compliant composite wrap repair in accordance with ISO 24817 and ASME PCC-2 standards.

Concrete Repair and Protection

Cement plant floors, foundations, containment bunds and structural concrete are subject to severe chemical attack from alkalis, acids and process chemicals, as well as heavy mechanical loads and thermal cycling. Spalling, cracking and surface degradation are common problems that compromise structural integrity and create safety hazards.

Belzona's Magma Polymer range provides high-strength, chemical-resistant repair and protection solutions for concrete in cement and mining facilities. Belzona 4111 (Magma-Quartz) repairs spalled and damaged concrete surfaces to a smooth, hard-wearing finish, while Belzona 4311 (Magma CR1) and Belzona 4361 (Magma CR2) provide long-term chemical resistance coatings for floors, bunds and containment areas exposed to aggressive chemical environments.

Conveyor and Solids Handling Equipment

Conveyor systems, chutes, hoppers, screens and other solids handling equipment are in constant contact with abrasive bulk materials. Impact from falling rock, ore or cement clinker causes denting, cracking and rapid wear of metal surfaces, while fine particle abrasion gradually erodes surfaces over time.

Belzona ceramic composites provide tough, impact and abrasion resistant linings for these surfaces, greatly extending service life. Where elastomeric protection is preferred, Belzona 2000 Series rubber repair materials offer a flexible, impact-absorbing lining that mimics the performance of vulcanized rubber but can be applied cold, without the need for curing equipment or hot work.

Other Application Areas

• Crusher and mill liner repair and protection
• Fan blade erosion repair and protective coating
• Silo and storage vessel repair and lining
• Structural steel corrosion protection
• Gearbox and mechanical drive component repair
• Secondary containment area protection against chemical spillage
• Shaft and bearing housing repair without disassembly
• Anti-corrosion coatings for process vessels and tanks