Belzona Applications for the Mining Industry

Welcome to this edition of Industrial Insights, where we delve into the mining industry and highlight how Belzona’s advanced concrete repair solutions can simplify and accelerate maintenance procedures.

The Challenges of Mining Operations:

The mining industry is characterised by its demanding environments, where equipment is exposed to extreme conditions, constant vibrations, and substantial wear and tear. Effective maintenance solutions that can withstand these challenges are essential to minimise downtime and maintain productivity. Concrete repair, in particular, is a critical component of maintaining the structural integrity of mining facilities.

Case Studies:

Primary Crusher Base Repaired with Belzona 4111 (Magma-Quartz)

At a Copper Mine in Marabá, Brazil, the base of the primary crusher had been weakened by vibration and required rebuilding. The primary crusher weighs 336 tonnes and is 9.5 metres (31 ft) high and 5.6 metres (18 ft) wide, contributing further to the amount of stress being put on the foundations.

As one of the largest copper crushers in South America, processing over 3,000 tonnes of copper ore per hour, every hour of downtime can result in nearly $20 million in losses (given that copper is traded at around $6,000 per tonne). This meant traditional concrete was not an option due to the 28-day cure time.

The solution presented was Belzona 4111 (Magma-Quartz) , so the first two layers of concrete were removed to reach the steel reinforcement structure. Belzona 4911 (Magma TX Conditioner) was then applied to ensure an optimum bond between the substrate and repair materials before Belzona 4111 (Magma-Quartz) was used to recreate a foundation at the base of the primary crusher.

The curing time of the system allowed?the assembly of the machine to commence in as little as 4-6 hours after application and a full return to service was possible in approximately 16 hours.?

Belzona Refurbishes Ball Mill Ends:

The ball mill ends were suffering from heavy wear and erosion under the plates. Replacement was not an option as the age of this ball mill meant parts are not available and welding was not possible as it would cause immense heat stress.

Belzona 4111 (Magma-Quartz) was chosen as the optimal solution. First the surface was grit blasted and solvent washed before Belzona 4911 (Magma TX Conditioner) was applied. The Belzona 4111 (Magma-Quartz) was then applied by trowel and hand to push it firmly into the uneven surface. An aluminium guide was then used to check for the proper finish.

By using Belzona 4111 (Magma-Quartz) the application was completed in less than a day, allowed to cure overnight, and shipped to the customer the next day ready to be installed.

Belzona 4111 (Magma-Quartz) is robust and fast-curing, making it an ideal choice for applications where downtime needs to be minimised.

Key Features:

• Rapid Curing Time: Belzona 4111 (Magma-Quartz) cures in as little as 16 hours, significantly reducing downtime compared to traditional concrete, which can take up to 28 days to fully cure. This accelerated curing process allows for quicker repairs and a faster return-to-service, minimising operational disruptions.
• High Compressive Strength: With a compressive strength exceeding 90 MPa, Belzona 4111 (Magma-Quartz) provides a durable foundation repair solution that can handle the heavy loads and vibrations typical in mining operations.
• Excellent Adhesion: This product adheres exceptionally well to surfaces such as concrete, stone and brick, ensuring a solid bond even under the stress of frequent vibrations and operational forces.
• Vibration Resistance: The formulation is designed to withstand vibrations, which is crucial in mining applications where machinery and foundations are constantly subjected to movement and shifting loads.

In the mining industry, where downtime leads to significant financial losses, having reliable, effective repair solutions is crucial. Belzona's concrete repair solutions offer the durability and performance needed to maintain equipment foundations and ensure operational stability.

Check out this episode of the Belzona podcast to hear more about Belzona in the Mining Industry:

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