Best Maintenance Practices to Reduce Downtime in Mining

In mining operations, every hour of unexpected downtime can translate into lost productivity and significant costs. Effective maintenance strategies not only keep your equipment running smoothly but also enhance your efficiency and overall operational effectiveness. 

Here, we’re outlining best practices and state-of-the-art products for equipment maintenance in the mining industry, focusing on proactive approaches to maximize the reliability and performance of your equipment.

Best Practices for Equipment Maintenance

Proactive equipment maintenance strategies can help you minimize costly downtime and keep your operations running smoothly. Consider adopting these maintenance best practices to help you maintain productivity and minimize costs:

Implement Predictive Maintenance:

• Use condition monitoring tools such as wear sensors, vibration analysis, and oil analysis to predict equipment failures before they happen.
• Collect and analyze historical data to anticipate potential issues and schedule proactive maintenance.

Adopt Preventive Maintenance Programs:

• Establish a regular maintenance schedule based on manufacturer recommendations and your typical equipment usage.
• Perform routine inspections and servicing tasks to address wear and tear before it leads to equipment failure.

Develop a Comprehensive Maintenance Plan:

• Create detailed plans for maintaining each piece of equipment, outlining tasks, frequencies, and procedures.
• Include emergency response plans for unexpected breakdowns to minimize downtime.

Standardize Maintenance Procedures:

• Develop standard operating procedures (SOPs) for maintenance tasks to ensure consistency and efficiency.
• Use checklists and standardized documentation to streamline processes and reduce errors.
• Your SOPs should also outline the use of preferred products like Armor Plate wear-resistant coating and maintenance products.

Perform Root Cause Analysis: 

• Investigate the root causes of equipment failures to address underlying issues and prevent them from recurring.
• Implement corrective actions based on your findings to improve your equipment reliability.

Optimize Parts and Product Inventory:

• Maintain an organized inventory of critical spare parts to reduce downtime associated with parts shortages.
• Use basic inventory management practices to forecast demand so the critical parts and products you need are always available.

Invest in Long-Term Performance: 

• Focus on improving the reliability and durability of your equipment through ongoing upgrades, modifications, and quality improvements.
• Invest in high-quality components, technologies, and maintenance products that offer better performance and longevity.
• The right maintenance products—like Copps’ line-up of solutions—can prolong equipment lifespan by providing superior protection against erosion, corrosion, and wear. 

Prioritize Safety and Operational Integrity:

• Promote a safety-first culture to ensure your maintenance practices align with regulatory standards and prioritize operational safety requirements.
• Invest in training to equip your team with knowledge of proper maintenance techniques and enhance their ability to troubleshoot problems.

Armor Plate Wear-Resistant Coating and Maintenance Products

Copps Industries provides a full range of wear-resistant and maintenance epoxy products to protect your equipment from deterioration over time. Our Armor Plate products feature abrasion- and corrosion-resistant epoxy compounds designed to repair, rebuild, and extend the life of equipment in industries ranging from mining to aggregate and more. 

Our Armor Plate products can be used to repair and reinforce:

• Pump casings
• Cyclones
• Pipe elbows
• Slurry lines
• Vibrating screens
• Castings
• Shafts and propellers
• Chutes
• Screw conveyors

Copps Industries: Your Partner in Maintenance Excellence

At Copps Industries, our epoxy systems are engineered to help your equipment reach its full lifespan and deliver optimal performance. Used as a part of your proactive maintenance plans, our solutions can help you reduce equipment downtime, enhance productivity, and improve your overall operational efficiency. 

Our line-up of ceramic and metal epoxy solutions protects a broad range of equipment from abrasion and wear, and we can provide custom solutions that effectively mitigate damage in nearly any application. For more information about our tailored solutions, contact us and request a quote.

Industrial Strength Solutions for Heavy-Duty Applications

In industrial maintenance and repair—especially in the demanding mining industry—there’s a critical need for reliable, high-performance materials. Whether you’re dealing with heavy machinery, critical structural components, or equipment exposed to extreme conditions, the right epoxy systems can make all the difference.

Copps Industries offers a full lineup of epoxy products designed to meet the toughest challenges, providing durability, rapid strength development, and exceptional protection against erosion, corrosion, and wear.

Here, we’re looking at four standout products from our lineup: REDBAC Deep Pour 3CE Grout, Maximum Performance Pumpable Grout, Armor Plate High-Performance Brushable Ceramic, and Armor Plate – Steel – Fast. From deep grouting large machine bases in mining operations to protecting pumps and impeller blades, these epoxy systems are engineered to deliver unmatched performance and longevity.

REDBAC Deep Pour 3CE Grout (K-028)

REDBAC Deep Pour 3CE Grout is a three-component, 100 percent solid epoxy resin system designed for pours up to 8″ (20.3 cm). Deep Pour 3CE offers rapid strength development, excellent flow characteristics, and minimal shrinkage. It flows into spaces under machines, fills completely before solidifying, and is self-leveling. It will survive impact and vibration equal to reinforced rubber materials and will not de-laminate under the most severe shock loads. 

Common applications for Deep Pour 3CE include:

• Deep grouting of large machine bases 
• Setting large pumps 
• Setting large sole plates 
• Deep repairs in foundations 
• Use as a concrete alternative for critical machine settings

Maximum Performance Pumpable Grout (K-027)

Maximum Performance Grout is a two-component, 100 percent solid epoxy system designed for wet, underwater, high strength, and rugged, durable service. Its low component viscosity and mixed viscosity allow for efficient, problem-free meter mixing and pump dispensing into voids from 1/2″ up to 2″. Maximum Performance Grout delivers high compressive strength in extreme conditions, making it ideal for water exposure applications, including quoin and miter blocks for lock miter gates. The low viscosity and thixotropy of Maximum Performance Grout allow it to flow into narrow spaces at a rapid rate, shortening application time and assuring solid foundation support. 

Common applications for Maximum Performance Grout include:

• Gyratory bottom shell placement
• Large mining cone replacement
• Pump bases

Armor Plate High-Performance Brushable Ceramic (K-096)

HP Brushable Ceramic is a two-component, high-performance ceramic-filled coating system designed for sealing, protecting, and repairing surfaces subject to high wear. HP Brushable Ceramic allows you to seal and protect equipment exposed to erosion and corrosion effectively. This solvent-free epoxy system has excellent chemical resistance. 

Common uses for HP Brushable Ceramic include:

• Protect pump casings, impeller blades, gate valves, water boxes, and fan blades
• Rebuild heat exchangers, tube sheets, and other water-circulating equipment
• Use as a top coat for exceptionally smooth repaired surfaces

Armor Plate – Steel – Fast (K-081)

Armor Plate – Steel – Fast is a two-component, steel-filled epoxy designed for repairing worn shafts, sheaves, and castings or for use in tool- and die-making applications. It offers excellent corrosion resistance and resistance against a wide range of chemicals. It’s also resistant to shrinkage, expansion, and distortion. Armor Plate – Steel kits are supplied with resin and hardener pre-measured in the correct ratio, which makes for easy measuring and mixing on-site. 

Common uses for Armor Plate – Steel – Fast include: 

• Repairing cracks or holes in engine and pump casings, pipes, tanks, and other equipment
• Resurfacing pitted or damaged metal surfaces
• Repairing shafts and hydraulic rams
• Use as a structural adhesive for metal bonding

Products for Mine Maintenance and Beyond from Copps Industries

At Copps Industries, we offer best-in-class epoxy systems tailored for the rigorous demands of the mining industry and beyond. With standout properties and benefits, our solutions are designed to extend the life of your most critical equipment, minimize downtime, and maximize throughput.

Whether you need to deep grout large machine bases, protect equipment from erosion and corrosion, or perform quick, effective repairs, our line of epoxy products has you covered. Our solutions are engineered to help your equipment reach its full lifespan and deliver optimal performance in the harshest environments. For more information about our industrial strength solutions for heavy-duty applications, contact us and request a quote.

What Abrasion-Resistant Coatings Can Do for You

In industries where machinery and components are subject to extreme wear and tear, the importance of abrasion-resistant coatings can’t be overstated. These coatings serve as a protective shield, preventing damage and ensuring longevity. From protecting mining equipment to road vehicles to heavy manufacturing machinery, abrasion-resistant coatings are indispensable. 

Copps Industries’ hard-working formulas can help you extend the lifespan of your equipment, optimize its performance, and decrease overall maintenance costs. Here, we’re demonstrating how abrasion-resistant coatings work and highlighting their benefits and wide-ranging applications.

How Abrasion-Resistant Coatings Work

Abrasion-resistant coatings safeguard surfaces from wear under harsh conditions. Typically made from durable materials like epoxies or polyurethanes, they work by forming a tough, protective layer over the surface of equipment. Abrasion-resistant coatings safeguard equipment by:

• Creating a Barrier. The coatings form a durable barrier that resists physical abrasion from dust, grit, and other particles. This prevents the underlying material from being damaged by friction and impact.
• Minimizing Friction. The coatings reduce friction between moving parts by providing a smooth surface. This protects equipment from wear and improves its efficiency and performance.
• Chemical Resistance. Many coatings also offer protection against chemicals and corrosion. This is especially important in harsh environments where equipment is exposed to aggressive substances that could degrade the material.
• Thermal Protection. Some coatings can withstand high temperatures, protecting equipment that operates in extreme heat. This thermal resistance prevents the coating from breaking down and ensures longer-lasting performance.
• Impact Resistance. The toughness of the coatings helps absorb energy from impacts, protecting equipment from dents, cracks, and other damage.

Benefits of Applying Abrasion Resistant Coating in Specific Applications

The advantages of using abrasion-resistant coatings go beyond protection. The coatings deliver various benefits that can significantly enhance performance and reduce costs. The benefits of abrasion-resistant coatings include:

• Enhanced Durability and Longevity. Abrasion-resistant coatings offer valuable protection from wear, scuffs, and scratches, improving the durability of your components and surfaces. The added durability safeguards equipment integrity and reduces the risk of premature failure, decreasing downtime and increasing longevity.
• Improved Performance and Efficiency. Abrasion-resistant coatings can reduce your downtime and maintenance costs by decreasing the need for equipment repairs. They can also minimize friction, which enhances energy efficiency, optimizes performance, and ensures smooth operation.
• Increased Safety and Reliability. Abrasion-resistant coatings protect the surface of your equipment and structures to improve their reliability and safety.
• Cost Savings and Return on Investment (ROI). Investing in abrasion-resistant coatings can deliver significant cost savings over the long run. By extending your equipment lifespan and reducing the need for replacements or repairs, these coatings save both time and money.

Applications of Abrasion-Resistant Coatings

Understanding the benefits of abrasion-resistant coatings is only part of the equation; knowing where and how to apply them is just as crucial. Abrasion-resistant coatings have wide-ranging applications across many industries, each with unique challenges and requirements. Some of the most common applications include:

Mining and Quarrying

Equipment and machinery used in the mining industry are regularly subjected to abrasive environments. By applying an abrasion-resistant coating, you can protect these components from wear to increase the longevity and efficiency of the equipment while minimizing downtime. These coatings can be applied to the following types of mining and quarrying equipment:

• Crushers
• Mills
• Screens
• Mining machinery

Manufacturing and Industrial Equipment

Industrial machines and equipment are subject to friction and abrasive materials that can cause continuous wear. Abrasion-resistant coatings can be applied to polymer, concrete, and metal surfaces to protect them from abrasion caused by impact, sliding contact, and moving parts. This will help extend the lifespan of the equipment while ensuring smooth operation. The types of machinery and equipment that benefit from abrasion-resistant coatings include:

• Pump components
• Chutes and hoppers
• Agitators and mixers
• Rollers, gears, and bearings
• Conveyor belts and pulleys

Automotive and Transportation

Vehicles and transportation systems are continuously exposed to sources of abrasion, including road debris, harsh environmental conditions, and even car washes. Without adequate protection, these elements can lead to paint scratches and other types of surface damage. By applying an abrasion-resistant coating, you add an extra layer of protection to preserve the appearance and value of the vehicle. Automotive applications for abrasion-resistant coatings include:

• Railway carriages
• Off-road vehicle components
• Aircraft landing gear
• Truck bed liners
• Automotive body panels
• Cargo holds

Oil and Gas

Equipment and components used in the oil and gas industry are subject to constant exposure to chemicals, abrasive materials, and harsh environmental conditions. Abrasion-resistant coatings can protect against wear and corrosion to ensure the longevity and integrity of:

• Pipes and pipelines
• Offshore platforms and rigs
• Boat decks and pontoons
• Ship hulls and marine vessels

Construction and Infrastructure

Infrastructure such as highways, parking garages, and bridges are subject to wear from environmental factors, mechanical stress, heavy vehicle and foot traffic, and chemical exposure. Abrasion-resistant coatings provide a protective barrier to prevent cracks, erosion, and surface degradation in concrete surfaces and prolong their lifespan. Common applications include:

• Concrete floors and road surfaces
• Pipeline coatings
• Tunnels and underground structures
• Bridge decks and expansion joints

Abrasion Resistant Coatings from Copps Industries

Your success depends on abrasion-resistant coatings when you operate in harsh environments and under abrasive conditions. These protective formulas can enhance the durability, safety, and cost-effectiveness of your machinery, structures, and components. From mining and manufacturing to automotive and construction, abrasion-resistant coatings are critical in extending equipment lifespan and optimizing performance.

At Copps Industries, we offer best-in-class abrasion-resistant coating solutions to meet even the most demanding conditions. Our products are designed to help your equipment reach its full lifespan and deliver the best possible performance. For more information about our abrasion-resistant coatings, contact us and request a quote.