Mining Industry

In an industry that often has production facilities located in areas that are not easily accessible, and where repair versus replacement will directly affect downtime and impact the bottom line, Belzona repair products and application technology offer a proven alternative to conventional repair methods.

Our products have been used in mines though out the world to repair and rebuild components of heavy duty equipment including:

  • Worn Bearing Housings
  • Rebuilding worn or oversized Bushings
  • Repairing cracked or damaged Casings
  • Conveyor Belts repairs
  • Repairing Drive Shafts in place
  • Rebuilding and protecting Fans, Housings Chutes, Pumps, and Tanks damaged by Erosion / Corrosion.
  • Many more

Talk to a Technical Consultant Now

  • CUSTOMER: BULK TERMINAL OPERATOR, North Vancouver, BC.
  • APPLICATION DATE: June 1988
  • PROBLEM: Bush housing holding articulating hydraulic arm would wear constantly requiring welding and line boring. Construction of bearing also presented a problem when inserting into housing. Because of the tight tolerances it would easily deform.
  • PRODUCTS:
    Belzona® 1111 Super Metal
  • SUBSTRATE: Mild steel
  • APPLICATION METHOD: Application carried out in accordance with Belzona® Know-How Leaflets MPT-8
  • BELZONA FACTS: Using Belzona® eliminated the distortion problem ensuring that the bearing was not damaged during fitting. This ensured a longer life.

  • CUSTOMER: COAL MINE, British Columbia, Canada
  • APPLICATION DATE: August 1996
  • PROBLEM: Cable stayed belt would develop cracks over a period of time.
  • PRODUCTS:
    Belzona® 2311 SR Elastomer
  • SUBSTRATE: Rubber
  • APPLICATION METHOD: Application carried out in accordance with Belzona® Know-How Leaflet SHM-1
  • BELZONA FACTS: Because of its rapid set up time coupled with as quick development of mechanical strength, Belzona® 2311 SR Elastomer allowed repairs to be made to the belt during unscheduled or short shut downs

  • CUSTOMER: Coal Mine, British Columbia
  • APPLICATION DATE: 1996
  • PROBLEM: The splitter of this cast iron Worthington split case sludge pump had broken away. The mine engineers had originally discarded the “Belzona fix” and insisted that a new cast section be made and welded into place. This was duly done at great expense. The new splitter was “fared in” with Belzona® 1311 and the pump internals coated. After operating for only a few weeks the pump started producing a rattling sound and on further inspection it was found that the new splitter had come adrift and the only thing keeping it in place was the Belzona® product used to “fare it in”. Because there was no replacement, it was decided to go ahead with the Belzona® repair originally suggested but turned down.
  • PRODUCTS:
    Belzona® 1311 Ceramic R Metal
    Belzona® 1321 Ceramic S Metal
  • SUBSTRATE: Cast Iron
  • APPLICATION METHOD: Application carried out in accordance with Belzona® Know-How Leaflet CEP-1,3
  • BELZONA FACTS: After the 2nd repair using the Belzona solution the pump was returned to service and operated for 2 years at which stage it was removed to replace bearings and packings. An inspection revealed that the fabricated splitter was still in first rate condition and that coating applied to the pump to protect it from sliding abrasion was still in perfect condition. After the overall the pump was returned to service.

  • CUSTOMER: Mining Company, Tumbler Ridge, BC
  • APPLICATION DATE: 1996
  • PROBLEM: Cast iron pump splitter had broken away.
  • PRODUCTS:
    Belzona® 1311 Ceramic R Metal
    Belzona® 1321 Ceramic S Metal
  • SUBSTRATE: Cast Iron
  • APPLICATION METHOD: Application carried out in accordance with Belzona® Know-How Leaflet CEP-1
  • BELZONA FACTS: Pump casing had already been consigned to the scrap yard when Belzona repair solution was accepted.

  • CUSTOMER: Heavy duty equipment operator
  • PROBLEM: Repairing cracked and leaking transmission housing
  • PRODUCTS:
    Belzona® 1111 Super Metal
  • SUBSTRATE: Cast Iron
  • APPLICATION METHOD: Application carried out in accordance with Belzona® Know-How Leaflet MPT-1
  • BELZONA FACTS: A Belzona repair allowed casing to be repaired with the minimum amount of disassembly and downtime.

  • CUSTOMER: Mining Company
  • APPLICATION DATE: 1992
  • PROBLEM: The base of the rotating block had worn unevenly creating an uneven mounting surface.
  • PRODUCTS:
    Belzona® 1341 Supermetalglide
  • SUBSTRATE: Cast Iron
  • APPLICATION METHOD: Application carried out in accordance with a modified version of Belzona® Know-How Leaflet GSS-1
  • BELZONA FACTS: The use of Belzona® 1341 Supermetalglide enabled the mine to create an uneven shim between the two metal surfaces saving many hours of downtime.

  • CUSTOMER: Mining Company
  • APPLICATION DATE: 1992
  • PROBLEM: The 16 inch diameter bores on the final drive of this P&H Shovel were badly worn.
  • PRODUCTS:
    Belzona® 1111 Super Metal
    Belzona® 9411 Release Agent
  • SUBSTRATE: Cast steel / Bronze
  • APPLICATION METHOD: Application carried out in accordance with Belzona® Know-How Leaflet MPT-1
  • BELZONA FACTS: This repair remained in service until the closing of the Shirley Basin Uranium Mine. Estimated savings in downtime and replacement costs were $125,000.00

  • CUSTOMER: Mining operation
  • APPLICATION DATE: September 2005
  • PROBLEM: A large hole had formed in this conveyor belt stopping production
  • PRODUCTS:
    Belzona® 2311 SR Elastomer
  • SUBSTRATE: Belzona® 2311 SR Elastomer
  • APPLICATION METHOD: Application carried out in accordance with Belzona® Know-How Leaflet SHM-1
  • BELZONA FACTS: The use of Belzona® 2311SR Elastomer enabled maintenance to make the necessary repairs incurring minimum amount of downtime and loss of production.

  • CUSTOMER: Coal Mine, British Columbia
  • APPLICATION DATE: June 2009
  • PROBLEM: This 8” diameter shaft carries the head pulley of a large conveyor belt. The bearing seat on the drive end was heavily scored worn more than ¼” undersize.
  • PRODUCTS:
    Belzona® 1321 Ceramic S Metal
  • SUBSTRATE: Belzona® 1321 Ceramic S Metal
  • APPLICATION METHOD: Application carried out in accordance with Belzona® Know-How Leaflet MPT-2. A split mould is machined to size, and coated with mould release agent. The seat area on the shaft is prepped with an angle grinder, and the mould clamped in place. Belzona® 1321 Ceramic S Metal is then mixed and injected into the mould. When the mould is removed, the cured Belzona material forms the new bearing seat.
  • BELZONA FACTS: Belzona® materials do not shrink during cure; this type of repair is extremely accurate, yet will carry the weight of this conveyor shaft which supports a 10-ton counterweight. This Belzona® repair was completed in less than 24 hours.

  • CUSTOMER: Coal Mine, Elkford, BC
  • APPLICATION DATE: March 2010
  • PROBLEM: Mine maintenance would normally weld a “Wear Protection Package” of specially hardened steel plates over the fan blade faces to protect the mild steel fan from erosion. This required a minimum of 2 days downtime. To get this done the fan would have to be removed from its position and transported to the welding shop.
  • PRODUCTS:
    Belzona® 1311 Ceramic R Metal
    Belzona® 1391 Ceramic HT
  • SUBSTRATE: Hardened Steel
  • APPLICATION METHOD: Application carried out in accordance with Belzona® Know-How Leaflet FBC 1
  • BELZONA FACTS: The original Belzona coating lasted just short of 2 years. Payback for the mine was considerable. The Belzona application required only 5 hours to complete

  • CUSTOMER: Zink Smelter, Trail, BC
  • APPLICATION DATE: May 2010
  • PROBLEM: Due to age, shear, and chemical degradation, the rubber bellows had developed splits and holes, which reduced the efficiency of the fans by allowing air to enter the gas stream.
  • PRODUCTS:
    Belzona® 2121 D&A Hi-Coat Elastomer
  • SUBSTRATE: Rubber
  • APPLICATION METHOD: Application carried out in accordance with Belzona® Know-How Leaflet HEX 13b
  • BELZONA FACTS: These bellows were slated for replacement during a rare whole-site shutdown—but the replacement bellows were found to be incompatible. Given less than one week lead time, the local Belzona Consultant arranged, contracted, and delivered this application as a turnkey repair during the 2-day shutdown, on time and under budget.

  • CUSTOMER: Bulk Handling Facility, North Vancouver, BC
  • APPLICATION DATE: August 2010
  • PROBLEM: A large gap between the fabricated sections of this bulk handling facility needed to be filled.
  • PRODUCTS:
    Belzona® 2211 MP Hi-Build Elastomer
  • SUBSTRATE: Stainless Steel
  • APPLICATION METHOD: Application carried out in accordance with modified version of Belzona® Know-How Leaflet FPA-6
  • BELZONA FACTS: The need to seal this gap between the two fabricated sections of this facility was urgent as wash water was penetrating behind the steel plates and causing a contamination problem in a facility that handled a number of very different bulk commodities. Welding was an option but would have taken weeks to complete as the gap was more than a ¼ wide.

  • CUSTOMER: Zink Smelter, Trail, BC
  • APPLICATION DATE: August 2009
  • PROBLEM: An unexpected shutdown allowed several maintenance projects to proceed ahead of schedule including the replacement of this gasket. Unfortunately the replacement gaskets were not due for several weeks. The expansion gaskets, which isolate the dryer fan housing from the inlet duct had developed cracks in multiple locations due to embrittlement, allowing outside air to enter the inlet duct reducing suction
  • PRODUCTS:
    Belzona® 2121 D&A Hi-Coat Elastomer
  • SUBSTRATE: Rubber
  • APPLICATION METHOD: Application carried out in accordance with a modified version of Belzona® Know-How Leaflet FBC-6
  • BELZONA FACTS: This application was done on very short notice and was inspired by the success of similar application completed in another section of the plant. The rebuilt components were reinstalled after 24hours and are functioning perfectly.

  • CUSTOMER: Zinc Smelter, Trail, BC
  • APPLICATION DATE: October 2010
  • PROBLEM: The molten slag is dripped into water spray which cools it to form granules much like grains of sand. The slag is removed and the water is then cooled and re-used in a closed cycle
  • PRODUCTS:
    Belzona® 1391 HT Ceramic
  • SUBSTRATE: Mild Steel
  • APPLICATION METHOD: Application was carried out using Belzona System Leaflet HEX 1 using tapered EPDM plugs in the tubes. The Belzona 1391 HT Ceramic was injected into and allowed to flow around the EPDM plugs forming a new “ceramic base” the plugs were removed after the material had cured.
  • BELZONA FACTS: This tube sheet was horizontally situated and contained 2300 tubes. Operating at 80˚C it was decided to use Belzona 1391 HT Ceramic. The use of tapered EPDM Plugs meant that each tube opening is conical and easy to remove once material had cured.

  • CUSTOMER: Zinc Smelter, Trail, BC
  • APPLICATION DATE: October 2010
  • PROBLEM: The acid plant produces Sulphuric Acid from a gaseous sulphur dioxide which is transported into the plant via ductwork and blowers. Moisture in the gas stream reacts with the Sulphur Dioxide to form Sulphuric Acid which condenses inside the blower volutes attacking the gasket face of the support flange.
  • PRODUCTS:
    Belzona® 1311 Ceramic R Metal
    Belzona® 4341 CR4
  • SUBSTRATE: Mild Steel
  • APPLICATION METHOD: Application was carried out using a modified form of Belzona System Leaflet FBC-5. A laminate faced plywood former was used to create a true gasket surface on the flange. The voids were rebuilt with Belzona 1311 and allowed to partially set up. The repaired area and the formers were coated with Belzona 4341 and clamped into place and allowed to set up overnight before removal.
  • BELZONA FACTS: Flange damage was discovered during a plant shutdown. On the basis of prior repair successes in this plant Belzona was called. The damaged flanges were repaired and ready for reassembly the following day.