Mining equipment faces extreme wear, impact, abrasive dust, moisture and corrosion. Without effective coatings, components fail early – increasing downtime, maintenance costs and safety risks.

When properly applied, protective coatings play a critical role in extending equipment life and improving ROI.

At SCT, we don’t offer coatings. We specialise in supplying spray systems and fluid transfer equipment, including solutions for the mining industry. Below we offer an objective guide to the types and uses of protective coatings for mining applications, with best practices for applying them.

Why protective coatings are essential in mining

Anyone who has spent any time at a South African mine knows why protective coatings are essential. Few environments are harsher. It’s hard on man and equally hard on machines. Equipment and structures are constantly exposed to brutal conditions that frequently result in wear and breakdowns.

This poses a high financial burden for businesses. When equipment breaks, downtime losses are vast. When it’s damaged beyond repair, replacement costs are huge.

Common equipment challenges in mining

This harsh environment constantly exposes metal equipment to challenges that cause failure and fatigue, including:

• abrasion and erosion from rocks, ore, dust, and constant friction
• corrosion from water, acidic compounds and chemicals
• thermal cycling from extreme temperatures
• impact damage from exposure to friction, force and materials
• UV degradation from South Africa’s harsh sunlight.

Types of coatings for mining applications

These constant threats to mining equipment can be alleviated through the use of high-quality, high-build barrier coatings. They increase efficiency, lengthen equipment life, and reduce unplanned outages.

When choosing a wear-resistant technology, it’s essential to choose the correct specialist coating, which include:

• ceramic coatings for abrasion protection
• epoxy coatings for durability and chemical resistance
• enamel and PVA coatings for maintenance and aesthetic improvement
• polyurethane coatings for extreme impact, weather resistance and UV stability
• high-build barrier coatings for corrosion protection.

Best practices for coating mining equipment

The key to successful coating of mining equipment lies in choosing the appropriate coating, thorough surface preparation, correct coating sequence and proper application techniques.

Thorough surface preparation is critical. Surfaces must be cleaned of all contaminants and the profile properly prepared to allow the coating to anchor. This typically involves sanding, degreasing, shot or sand blasting or chemical pre-treatment. At SCT, we can assist by supplying high-quality pneumatic sanders, if required. Once prepared, the surface must dry thoroughly.

For proper coating application, a specialised spray system for thick or high-solids coatings should be used. The more viscous the coating material, the more powerful the spray machine needs to be. SCT offers a range of pneumatic-, petrol- and electrically-operated spray systems for any application – no matter how remote or inaccessible the mining equipment may be.

How coatings reduce overall costs

Investing in protective coatings helps reduce overall costs in a number of ways.

• Longer component life. Protective coatings increase the lifespan and reliability of mining equipment exposed to abrasive and corrosive materials.
• Fewer shutdowns. Properly specified protective coatings reduce the risk of unplanned and costly stoppages.
• Lower total cost of ownership (TCO). The TCO is reduced because protective coatings help reduce costly stoppages, the frequency of parts replacements, and the labour costs of repairs.
• Improved safety. Structural weaknesses in mining equipment put workers at risk. Protective coatings help maintain equipment integrity and create safer working conditions.
• Optimised operational efficiency. Coatingsreduce costs from production and processing  inefficiencies caused by equipment degradation by maintaining optimal performance and reduced energy consumption.

How SCT can help with mining equipment maintenance and costs

SCT can supply the right coating application equipment and systems designed for heavy-duty mining environments, helping reduce maintenance costs and improve performance.

Speak to us for tailored coating and application solutions for mining operations. We also offer a large range of diaphragm pumps for fluid transfer and other applications, such as dewatering and slurry removal, in the mining industry.