Tag: WearShield

Case Study Data

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Site
Copper mine
Location
Bulgaria
Repair Type
Pump housing repair
Defect
Heavily damaged metalwork

Products Used

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Ceramic Brushable Epoxy Coating
Epoxy coating reinforced with silicon carbide which sets to an ultra-smooth finish for sealing and protecting parts and surfaces

WearShield Epoxy Paste
Epoxy paste heavily filled with alumina beads used to create an impact resistant shell to protect metalwork in abrasive environments

Case Study PDF

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Case Study Details

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The pump housing was part of a system which extracted water from a nearby river and transported it around the copper mine, where it was then used in a number of different processes.

Sand, silt, dirt, stones and other debris were all present in the water as it passed through the pump housing. Following years of exposure to the river water, the housing was now suffering from severe corrosion, abrasion and wear damage.

As it appeared the pump housing was beyond repair, the mine sought quotes for fabrication and installation of a replacement part from several companies. When these were deemed too expensive, it was decided to attempt refurbishment.

The mine contacted Sylmasta’s approved supplier in Bulgaria. The supplier had recently spent several days completing a comprehensive product training programme at Sylmasta HQ in the United Kingdom, including a module on restoring damaged metalwork.

They recommended using Ceramic Brushable Epoxy Coating and WearShield Epoxy Paste in conjunction to both repair the existing damage and protect the pump housing from further deterioration.

Ceramic Brushable is a ceramic-filled epoxy coating reinforced with silicon carbide. It seals and protects parts, machinery and surfaces by forming an ultra-smooth, hardened layer of protection.

WearShield is an epoxy paste heavily filled with alumina beads and a high resin content. The dense alumina structure of the cured material enables it to offer the ultimate resistance against all types of impact in the most abrasive environments.

The pump housing was taken apart and thoroughly cleaned to remove as much rust, dirt and grime as possible. An initial coating of Ceramic Brushable Blue was painted all over the metalwork using a brush, sealing the original surface.

Once Ceramic Brushable had cured, WearShield was applied on top with a spreader. The composition of WearShield makes it easy to build significant, dense layers of protection quickly. In this case, WearShield cured to form a 30mm thick alumina-reinforced shell over the pump housing.

Because the alumina beads make cured WearShield a slightly rough material, it was decided to topcoat with more Ceramic Brushable. The ultra-smooth, low-friction finish provided by Ceramic Brushable would improve flow through the pump housing, making it more efficient once it went back into service.

Completing the repair took just two days and saved the mine a substantial amount of money, The pump housing will remain in service for many more years thanks to the significant protection provided by WearShield and Ceramic Brushable.