Powerful Steel Protection for Hardworking Mining Equipment

The strength of steel is put to the test in many settings, but there are few more challenging than Australia’s mining industry. The steel used to manufacture industrial mining equipment is often exposed to extreme weather conditions, atmospheric salts, chemical splash, knocks, scrapes and vibration from moving parts.

A conveyor company commissioned their partners to deliver a new conveyor belt winder, setting up the bulky components in their painting shed for coating. The equipment has been designed for long-term use on various mining sites and required a high-performance coating system for essential protection from all environmental challenges.

Showcasing the benefits of a proven system

Dulux® Protective Coatings Technical Sales Representative, Wes Brew consulted the project partners, recommending a three-step coating system to deliver superior corrosion protection and a vibrant gloss finish. The following PUR4 three coating system meets Australian Standards AS/NZ 2312.1:2014 for the protection of steel against atmospheric corrosion:

• 1st coat: Dulux® Zincanode 402 @ 75-microns (µm) DFT with Cold Cure hardener

• 2nd coat: Dulux® Durebild STE @ 150-microns (µm) DFT with Quickturn hardener

• Topcoat: Dulux® Weathermax HBR @ 100-microns (µm) DFT in new Caterpillar Yellow, with Golden Yellow on handrails and Signal Red on lifting points.

Zincanode 402 is an economical zinc-rich epoxy which provided galvanic corrosion protection to the steel. Easy to apply, this primer achieves relatively high film builds without mud cracking and has a rapid dry time. The intermediate coat of Durebild STE bolstered the corrosion protection, providing a barrier to moisture, oxygen and ions.

Durebild STE can be tinted in a wide range of colors and used as a topcoat, especially when used with Quickturn hardener for faster drying time in Victoria's Autumn temperatures. External assets like the conveyor belt winder require a topcoat of Weathermax HBR for a durable, UV resistant finish. This high build polyurethane topcoat has been designed to retain gloss and colour over extended service periods, even in severe industrial or marine environments.

This proven coating system is expected to secure the service life of the asset, with the potential to exceed the current estimate.

Smart solution for fluctuating temperatures

“One of the key challenges we faced during the application process was low overnight temperatures,” Wes explains. “The use of Cold Cure Hardener and Quickturn addressed this issue. These temperature-adaptable hardeners allowed for subsequent coats to be applied the next day without any extended delays, keeping the project on track.”

Achieving excellent coverage with easy application

The applicator used a Graco Merkur X48 airless pump to apply the coatings, effortlessly achieving high builds and efficient, accurate application. A two-litre pressure pot and gun were used for the handrails and lifting lugs.

“This was the first time the applicator had used this system, and the feedback was very positive,” Wes continues. “In particular, the user-friendly nature of Zincanode 402 made this product the preferred choice over others. The whole system was easy to apply and resulted in excellent colour coverage and an impressive gloss finish that exceeded expectations.”