Tag: Ceramic Brushable Blue

Case Study Data

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Site
Landscaping materials supplier warehouse
Location
United Kingdom
Repair Type
Metal repair and protection
Defect
Metal pallets damaged and worn by storage of abrasive, heavy materials

Products Used

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Ceramic Brushable Epoxy Coating
Epoxy coating reinforced with silicon-carbide which protects metal surfaces against wear, abrasion and impact

Case Study PDF

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Case Study Details

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As one of the biggest suppliers of landscaping materials in the United Kingdom, the company had a vast central warehouse storing items which were then sent to distributors around the country.

These materials included driveway paving, garden slabs, kerbs, edges, porcelain, natural stone and bricks. All were stacked and stored on metal pallets.

The weight of these materials, their abrasive nature and the impact from moving them on and off the metal pallets meant that over time, the metalwork began to show visible signs of wear.

Removing all existing pallets from the warehouse and installing replacements would have been a time-consuming and expensive task.

The landscaping company therefore contacted a mechanical engineering specialist who used and distributed Sylmasta products for advice. They suggested Ceramic Brushable Blue Epoxy Coating to repair the metal pallets in the warehouse.

Ceramic Brushable is reinforced with silicon-carbide for hardness and an ultra-smooth finish. It is painted onto parts and surfaces to create an outer layer with extreme resistance to abrasion, corrosion, chemical attack, cavitation, erosion and pitting.

Two coatings of Ceramic Brushable were applied to the top part of the pallets which the landscaping materials sat on. It cured to form a hardened shell, protecting the original metalwork against abrasion and impact damage caused by the materials.

Initially, only a few pallets were treated as a trial run to test the performance of Ceramic Brushable. Six months later and there were no visible signs of damage to any of the coatings applied during the trial.

Satisfied with the performance of Ceramic Brushable, the landscaping company purchased 10kg to repair and protect more metal pallets throughout the warehouse.

They are also now considering opting for a two-layer wear indicator coating, whereby a topcoat of Ceramic Brushable Green or Black is applied over the existing Blue.

When the Blue layer begins to show through, it will indicate a new topcoat of Green or Black is required to maintain suitable protection levels for the pallet.

Having a clear system showing when to reapply Ceramic Brushable will help the company continually extend the lifespan of its metal pallets for years to come.

Case Study Data

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Repair Type
Abrasion Protection
Defect
Worn aluminium barrels in pug mill putty extruders

Products Used

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Ceramic Brushable Blue Epoxy Coating
Ceramic-filled epoxy coating painted onto surfaces and parts to create a smooth, abrasion resistant layer

Case Study PDF

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Case Study Details

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Silica-filled putty was extruded from the pug mills via aluminium barrels. Over time, the silica in the putty had caused abrasive wear to the surface of the barrels as it passed through.

This wear combined with the initial rough cast finish of the aluminium had caused the flow rate of putty from the pug mills to slow dramatically, impacting on efficiency.

To help the extruders run more efficiently, a means of improving the flow rate through the barrels by filling in existing damage and creating an ultra-smooth finish was sought.

After researching cost and ease of repair, machining the barrels was ruled out as it would have been difficult, expensive and too time consuming.

Instead, it was decided to paint the aluminium barrels in every putty extruder with a low friction coating for increased extrusion rate. The coating used in the repair also needed to be abrasion resistant to protect the aluminium from further wear.

Ceramic Brushable Blue was the obvious solution. It is ceramic-filled and reinforced with silicon carbide for ultimate hardness. It is used on both new and old machines and parts in highly abrasive environments.

Coating new surfaces with Ceramic Brushable Blue provides a toughened, reinforced layer of protection from wear, extending the lifespan of parts.

When used on older machine parts and surfaces such as the putty extruder barrels, Ceramic Brushable Blue repairs damaged areas as well as offering protection against abrasion.

Ceramic Brushable Blue was easy to apply. The parts were mixed and then the coating painted on using a conventional paintbrush. The 90 minute work time allowed larger quantities of epoxy to be mixed and applied in one go without the threat of premature curing.

It took one day to coat every pug mill putty extruder barrel with the required amount of Ceramic Brushable Blue. A full cure was achieved 24 hours after the final coat, meaning that there was minimal disruption to production.

The non-stick, smooth finish of Ceramic Brushable also enabled quicker and easy cleaning of the barrels. Less time needed for the maintenance of the extruders resulted in even greater efficiency for the pug mills.