At first glance, two pieces of equipment may show very similar damage. However, the underlying cause may be entirely different. A chute may lose wall thickness because of continuous contact with ore, a pump may deteriorate because of particle-laden flow, a duct may be affected by chemical agents, and a hopper may sustain damage from repeated impacts.
Correctly identifying the damage mechanism is the first step in defining an effective repair and protection strategy. Once the cause of deterioration is understood, more suitable solutions can be selected, maintenance work can be planned more effectively, and operational continuity at the mine site can be improved.
Why Is It Important to Distinguish Between Damage Mechanisms?
Not all damage mechanisms produce the same type of deterioration or require the same protection strategy. Therefore, before planning a repair, it is important to identify the predominant damage mechanism affecting the component.
1. Abrasion
Abrasion occurs when solid particles progressively remove material from a surface through sliding, rubbing, or continuous contact. It is one of the most common damage mechanisms in mining, particularly in equipment that transports or processes ore, such as chutes, hoppers, and conveyor belts.
Over time, abrasion progressively removes material, reducing component or lining thickness and potentially exposing the underlying substrate.
2. Corrosion
Unlike abrasion, corrosion is not caused by mechanical contact. It results from chemical or electrochemical interaction between the equipment surface and agents such as moisture, chemicals, or other corrosive elements in the operating environment.
This type of degradation can accelerate cracking, material loss, or leakage, particularly when combined with other damage mechanisms such as abrasion or impact.
3. Erosion
Erosion occurs when high-velocity fluids, often carrying suspended solid particles, repeatedly impinge on a surface. Over time, erosion reduces wall thickness and may impair equipment performance.
This damage mechanism is common in ducts, pumps, piping, hydrocyclones, elbows, and other equipment exposed to particle-laden flow.
4. Impact
Impact wear occurs when large rocks or coarse ore repeatedly strike a surface. Repeated impacts can cause deformation, lining delamination, cracking, and premature material loss.
In mining operations, this commonly occurs at ore transfer points and in hoppers, chutes, mills, and crushers.
| Damage mechanism | Main cause | Example equipment |
|---|---|---|
| Abrasion | Continuous rubbing of solid particles. | Chutes, hoppers, conveyor belts. |
| Corrosion | Chemical agents and moisture. | Tanks, ducts, pumps. |
| Erosion | High-velocity particle or fluid flow. | Piping, hydrocyclones, elbows. |
| Impact | Repeated strikes from coarse material. | Hoppers, chutes, crushers. |
In practice, multiple damage mechanisms often act together. Although distinguishing between them is useful, mining equipment is rarely exposed to only one mechanism. The same component may be simultaneously affected by abrasion, impact, moisture, and chemical agents, creating highly demanding service conditions.
Therefore, in addition to identifying the predominant damage mechanism, the full operating context should be assessed before defining a repair or protection strategy.
Selecting the Right Solution Begins with an Accurate Diagnosis
Understanding the cause of deterioration supports better maintenance decisions. Depending on the predominant damage mechanism, substrate, equipment geometry, and operating conditions, the most appropriate repair and protection solution can be selected.
FLEXSOL® provides fast-curing, flexible repair and protection systems for rubber and rubber-to-metal applications exposed to abrasion, impact, vibration, expansion and contraction, and acidic environments.
DURAFAST® provides rigid epoxy systems for metal, ceramic, and concrete substrates exposed primarily to severe abrasion and moderate impact.
These cold-applied, onsite systems can help return equipment to service in approximately one hour, depending on the product selected and the specified application conditions. For DURAFAST®, the 60-minute cure time applies at 25°C.
In addition, our technical team assesses the substrate, equipment geometry, damage mechanism, and operating conditions to support repair planning, product selection, and operational continuity.
Because an effective repair does not begin with the product. It begins with understanding the problem.
We make it simple.
For more information about our repair and wear-protection solutions or technical advice for your operation, please complete the form by clicking the “Contact Us” button. You can also email us at:
- Chile: contacto@bertech.cl
- Brazil: comercialbrasil@bertech.cl
- Other countries: internationalsales@bertech.cl