Archimedes Screw Repair: Mining Facility, South Africa

4th April 2025

Industry: Mining
Location: South Africa
Application: Mineral Processing
Products: 202 Ceramic Repair Fluid

The Challenge

A large Archimedes screw used in a mineral processing facility was experiencing widespread surface degradation due to continuous exposure to abrasive slurry. The aggressive combination of erosion and corrosion was compromising performance and posed a high risk of unplanned downtime. With welding ruled out due to distortion risks, and full replacement deemed too costly, the client sought a rapid, long lasting repair method that could extend the equipment’s life without introducing heat stress.

The Application

The component was removed from site and transferred to a controlled workshop environment for complete refurbishment. Surface preparation was carried out using mechanical grinders to ISO 8501/4 ST3 (SSPC SP3 ST3) standard, creating a clean, textured profile ideal for coating adhesion.

Two layers of 202 Ceramic Repair Fluid were applied by brush across the full screw surface, including the helical flights. Each coat was applied at 300 microns, producing a total dry film thickness of 600 microns. The high performance barrier provided protection against both mechanical wear and corrosive slurry flow.

The Solution

Off-site repair ensured consistent surface preparation, controlled film build, and an even finish across the full component. As a solvent free, brush applied system, 202 Ceramic Repair Fluid eliminated the risks associated with welding and hot work. The product’s dense ceramic filled matrix delivered long term resistance to erosion, abrasion, and chemical attack in demanding slurry applications. The refurbished screw was returned to service with an extended operational lifespan, avoiding replacement costs and reducing the risk of future downtime.