FRP Strengthening System and Ultra Ceramik, Ultra Mix SVS Lining Systems
In today's conditions of mill operation, the importance of protecting and restoring their casings is becoming increasingly significant. Weartech offers innovative solutions for reinforcing and protecting mill casings, ensuring the durability and reliability of the equipment. The use of advanced technologies allows for significantly reduced repair and maintenance costs, as well as extending the service life of the mills.
FRP System Strengthening System
Weartech's FRP System for mill casing strengthening is designed for the structural reinforcement of metal structures. It includes special composite materials that possess high tensile and elongation strength. Thanks to high adhesion, the system works monolithically with the reinforced structure, eliminating the possibility of delamination.
The main component of the system is the Mapewrap C Uni-AX carbon fiber, which has the following characteristics: tensile strength of at least 4850 N/mm² and modulus of elasticity of at least 230,000 N/mm². Laboratory tests have shown that a single layer of carbon fiber with a thickness of 0.333 mm significantly increases the strength of the structure, reducing the maximum deflection under load to 3.97 mm.
Key Components of the FRP System
1. Weartech Primer 1 high-adhesion primer for polymer systems.
2. High-strength mastic for protecting carbon fiber in two layers.
3. Medium-viscosity epoxy adhesive for bonding carbon fiber.
4. Epoxy impregnation of carbon fiber to provide strength and hardness to the system.
5. High-strength mastic coating for the reinforced system to protect the fiber.
Advantages of the FRP System
Using Weartech's FRP System significantly increases the tensile bearing strength. A single layer of the system (with a total thickness of up to 3 mm) increases strength by 48-50%. The system is not prone to defects such as delamination or separation under increased mechanical loads.
An important advantage is that the system allows repair work to be carried out without the use of fire methods, which significantly reduces equipment downtime and repair costs. All application operations are performed manually, allowing regular personnel to carry out the work without additional training.
Ultra Ceramik Lining System
Weartech's Ultra Ceramik lining system includes plates based on zirconium and aluminum oxides. These plates have high resistance to abrasive, corrosive, and chemical impacts. The plate size is 20x20 mm, and the thickness varies from 4 mm. The small size allows for even distribution of dynamic and impact loads across the entire lining surface, reducing the risk of system damage.
The plates are attached using a special thixotropic adhesive mixture, providing high adhesion to polymers, ensuring the monolithic nature of the lining coating. This system reliably protects mills from aggressive environments and mechanical damage.
Ultra Mix SVS Lining System
Weartech's Ultra Mix SVS lining, made from ultra-high-molecular-weight copolymer, provides resistance to high impact and vibration loads due to the plasticity and damping properties of the coating. The system includes high-adhesion adhesive mixtures and mechanical fastening with standard bolts.
The system's feature lies in the multi-component casting, which allows creating a 3D molecular grid to ensure resistance to high mechanical loads. This significantly increases the lining's service life and reduces the need for frequent repairs and replacements.
Advantages of Strengthening and Lining Systems
✓ Carrying out repairs in the shortest time without the use of fire methods, saving costs and equipment downtime.
✓ Reinforcement and protection of the casing increase the service life compared to traditional overlay welding repair technology. Overlay welding does not predict the restoration of bearing capacity, only increasing the residual thickness of the casing wall, maintaining a high risk of re-wear.
✓ The simplicity of the work allows regular personnel to carry out the operations without additional training. All operations are accompanied by detailed technological instructions.
| Reinforcement | Modulus of Elasticity [GPa] | Thickness [mm] | Width [mm] | Cross-Section Area [mm²] | Tensile Strength [N/mm²] | Tensile Load [KN] |
|---|---|---|---|---|---|---|
| A500 | 210 | 14 | 154 | 500 | 76.97 | |
| A600 | 210 | 14 | 154 | 600 | 92.36 | |
| A500 | 210 | 16 | 201 | 500 | 100.53 | |
| Mapewrap C Uni-AX 300 | 252 | 0.333 | 100 | 33.3 | 4900 | 163.17 |
| Mapewrap C Uni-AX 600 | 252 | 0.666 | 100 | 66.6 | 4900 | 326.34 |
| Mapewrap C Uni-AX 300 HM | 390 | 0.333 | 100 | 33.3 | 4100 | 136.34 |
| Mapewrap C Uni-AX 600 HM | 390 | 0.666 | 100 | 66.6 | 4100 | 329.6 |
Weartech provides reliable protection and reinforcement of mill casings by offering innovative FRP System and Ultra Ceramik and Ultra Mix SVS lining systems. These solutions significantly extend the service life of the equipment and increase its reliability, as confirmed by successfully implemented projects. The company also provides high-quality materials and services that ensure the durability and efficiency of equipment operation in various operating conditions. Weartech is your reliable partner in equipment protection and restoration.