In mining, downtime is not just an operational halt; it is a direct loss of productivity, efficiency, and profitability. In operations where equipment works under extreme conditions of abrasion, impact, and chemical exposure, even a minor failure can quickly escalate into an unplanned shutdown.
In practice, these factors translate into recurring failures at specific points in the production process. Understanding this relationship is key to approaching maintenance from a more
strategic perspective.
Below, we present five causes identified at Bertech that explain a large portion of unplanned shutdowns in the mining sector, and how to achieve fast and effective repairs through the use of high-performance linings.
- Continuous abrasion in process equipment
Abrasion is one of the main wear factors in mining, resulting from constant contact with hard abrasive particles. In operation, this directly leads to failures in equipment such as screens, chutes, and mill components, where wear on walls and surfaces eventually causes material loss, leakage,
and unplanned shutdowns. An effective strategy is to incorporate high-adhesion industrial anti-abrasion linings, such as those developed in the Durafast® line, designed to withstand wear from both coarse and fine particles. This type of solution protects the surface, extends asset service life, and reduces corrective maintenance. - Wear and friction in material handling systems
The combination of abrasion and constant friction heavily impacts material handling systems. This is reflected in failures in conveyor belts and drive pulleys, where loss of lining, surface wear, and traction issues can result in a complete system shutdown. The application of flexible linings designed to resist wear and improve adhesion, such as the Flexsol® line, helps extend the service life of these components and reduces the risk of unexpected failures. - Impact and load in mining equipment
Components such as wheel loader buckets, as well as structures associated with excavators and haul trucks (CAEX), are exposed to constant impacts, heavy loads, and severe abrasive conditions.
Repeated impact and high mechanical loads are critical factors in loading equipment, where surfaces suffer deformation, cracking, and material loss.
In these cases, mining linings with flexible properties and high mechanical resistance allow impact energy to be absorbed and reinforce the most exposed areas.
- Corrosion and wear in aggressive or wet environments
In wet environments, the combination of chemical agents and operational condition accelerates corrosion and material degradation processes. This is commonly seen in failures in chutes and other exposed surfaces, where loss of material integrity can affect flow continuity and lead to shutdowns. The use of chemically resistant linings helps isolate surfaces from aggressive environment and extend their operational lifespan. - Extreme wear in comminution stages
Secondary and tertiary crushing processes operate under conditions of intense wear, where abrasion and impact act simultaneously. In practice, this results in failures in crushers, which require frequent interventions to maintain performance. Protecting these surfaces with advanced industrial linings allows operating conditions to be maintained for longer and reduces the frequency of shutdowns. Towards more efficient downtime management While technical causes explain a large portion of downtime, the time required to execute repairs remains a key factor in operational continuity. In this context, the ability to apply solutions directly on-site, without dismantling and with reduced recovery times, becomes essential to minimize downtime windows and optimize operations.
At Bertech, this approach is addressed through mining lining solutions, including:
- Durafast®: designed for areas with high abrasion and severe wear, providing protection for steel, ceramic, and concrete surfaces across various processing and transport equipment
components, such as chutes, hoppers, pump casings, and pipe supports. - Flexsol®: designed to repair and rebuild rubber or metal surfaces, enabling fast on-site interventions and rapid operational recovery. With high resistance and flexibility, it is applied in conveyor belts, splices, and pulleys, among others. These solutions help reduce maintenance time and enable operations to resume more quickly, with curing times of approximately one hour. They also reduce equipment replacement needs and spare parts costs.
Today, the challenge is not only to repair, but to do so with solutions that sustain operations over time, reduce failure recurrence, and minimize the impact of shutdowns. For more information about our lining solutions or technical support for your operation, you can complete the form by clicking the “Contact Us” button