Archimedes Screw Repair with 202 Ceramic Repair Fluid

4th April 2025

An Archimedes screw repair was carried out at a mineral processing facility after the equipment suffered from severe erosion and corrosion. Continuous exposure to abrasive slurries had degraded the screw surface, risking reduced efficiency and potential failure. The equipment was removed from site and transported to a workshop for full surface preparation and protective coating.

Operating Conditions & Repair Challenges

The screw operated in a demanding environment, facing continuous wear from abrasive solids and aggressive process flows. Welding was ruled out due to the risk of heat distortion and potential for cracking in the large structure. Replacing the unit was not a viable option due to its high cost and the long lead times, which would have resulted in significant operational downtime and disruptions.

Surface Preparation & Coating Application

Once removed from service, the screw was cleaned and mechanically abraded using grinders to ISO 8501/4 ST3 (SSPC SP3 ST3) to ensure a clean, keyed profile. Two coats of 202 Ceramic Repair Fluid were applied by brush, each at 300 microns wet film thickness. The full 600 micron system provided a dense, erosion resistant barrier suitable for continuous operation in mineral processing environments.

Performance Improvements & Benefits

Extended asset life by several years, avoiding full replacement
Long term protection against erosion and corrosion in abrasive service
Minimised risk of unplanned downtime or reactive maintenance
Significant cost savings compared to sourcing and installing a new unit
No hot works required, avoiding additional safety procedures and reducing shutdown risk
Returned to service with a high build, industrial grade protective system

Large Scale Repair in a Controlled Environment

The scale of the Archimedes screw required a controlled repair environment to ensure full access and precision during surface preparation and application. Working off-site allowed the team to deliver consistent film build and complete coverage across the entire screw flight. The use of 202 Ceramic Repair Fluid provided a robust solution suitable for the demands of heavy duty mineral processing equipment.