Customer: West Coast-based aggregate operation focused on the production of concrete aggregate mixtures.
Problem: Corrosion and Abrasion in Steel Aggregate Hoppers
The customer was having severe problems with constant corrosion and abrasion on their steel aggregate hoppers.
The company used bolted-down plastic liners to protect its hoppers. The plastic liners provided some marginal life to the steel hoppers; however, they had their problems. Since the liners were bolted in place, aggregate and moisture would get trapped behind them, allowing for continued corrosion.
In turn, the liners began to sag and deform where the aggregate impacted the liner, causing them to break off and fail. In the long run, bolted-on plastic liners proved to be a very expensive non-solution.
Solution: Rhino Linings® TUFF STUFF® for Corrosion and Abrasion Resistance
After realizing that their current strategy was insufficient, the company looked to Rhino Linings® for a longer-lasting, more reliable way to protect their aggregate hoppers. Rhino Linings® TUFF STUFF® was chosen because of its remarkable resistance to wear and corrosion. A two-layer protective system was advised to provide both maximal protection and long-term monitoring.
The following steps were undertaken to ensure a comprehensive and durable solution:
1. Surface Preparation
After a complete sandblasting, the new steel aggregate hopper was polished to an industry-standard SP5 or SP10 finish, which removes rust, mill scale, and other surface impurities. This process was important to guarantee the coating’s robust adherence to the steel substrate. A clean, profiled surface would provide the necessary texture for the Rhino Linings TUFF STUFF to bond effectively.
2. Priming the Steel Surface
After sandblasting, the surface was primed using Rhino Linings Primer 251. This primer acts as a bonding agent between the steel and the protective coating, thereby ensuring that the Rhino Linings TUFF STUFF application will bond properly and effectively to the hopper. The primer also helps prevent moisture penetration, adding an extra layer of corrosion resistance.
3. First Layer – Wear Indicator
First, a red Rhino Linings TUFF STUFF, ¼” (0.635 cm) thick, was used as a protective layer. This layer worked as a wear indicator, enabling the business to monitor the hopper’s wear and tear over time visually. Any visible exposure to the red layer would indicate the need for reapplication of the protective coating, serving as an early warning system.
4. Second Layer – Main Wear Layer
Over the wear indicator layer, a ¾” (1.91 cm) thick layer of black Rhino Linings TUFF STUFF was applied. This layer acts as the primary protective barrier, providing robust protection against the continuous corrosion and abrasion caused by the aggregate material. In addition to offering complete protection, the two-layer method makes it simple to determine the liner’s performance.
The TUFF STUFF material is tack-free and fully cures in less than a minute, allowing the applicator to move quickly through the application process. Although the product cured rapidly, a full 24-hour cure time was allowed to ensure complete cross-linking of the material, maximizing its physical properties such as tensile strength, tear resistance, and adhesion.
Results: Long-Term Corrosion and Abrasion Resistance Performance
Two years later, an inspection of the lining showed no visible wear to the 1” (2.54 cm) thick Rhino Linings’ TUFF STUFF application on the company’s aggregate hopper. This is due to the exceptional wear characteristics of TUFF STUFF and the monolithic adhesion of the product as a uniform application to the steel. Traditional ASTM pull tests show TUFF STUFF to exceed 2,000-psi pull standards.
Since the success of the initial application on its hoppers, the company has utilized Rhino Linings in several other applications, including standard aggregate hoppers and aluminum discharge chutes attached to the company’s mix trucks.
Applying Rhino Linings’ TUFF STUFF to the discharge chutes prevented the concrete from adhering to the walls of the chute and provided an easy-to-clean surface.
Frequently Asked Questions (FAQs):
What is the difference between corrosion and abrasion? Corrosion is the chemical breakdown of materials due to environmental exposure, while abrasion is the physical wear of surfaces caused by friction or rubbing.
What is abrasion resistant? Abrasion resistance is the ability of a material to withstand wear caused by friction, scraping, or contact with rough surfaces, preventing surface damage.
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