The coal mining process creates an extremely corrosive environment that accelerates the breakdown of steel from rust. CONSOL Energy, the largest producer of high-Btu bituminous coal in the United States, needed a durable protective coating system for parts of their coal mine steel infrastructure. Replacing sections of steel is a very expensive process, costing approximately £330 per metre, not including labour and safety expenses.
It was essential to minimise any fumes and maintain internal air-quality. The project using a fast curing protective lining that would not interrupt 24/7 mine operations, and could withstand power washing to remove daily coal residue build-up.
SPI’s Polyshield HT™100 polyurea coating was selected for its corrosion resistance, high elongation and rapid curing properties. This elastomeric protective coating provides a seamless, flexible membrane that conforms to virtually any substrate shape.
Polyshield HT™100’s hydrophobic, fast-set properties allow application in high moisture environments. In addition, this advanced polyurea coating contains 100% solids, has zero VOCs and is odorless after application. The steel substrates were cleaned and sand-blasted to provide a 159 micron anchor profile for adhesion purposes. Next, the applicator spray-applied 2mm of Polyshield HT™ with AE-4 (adhesion enhancer) to the steel surface. Using AE-4 eliminated the extra step of applying a primer, saving time and money.
CONSOL Energy are highly satisfied with the performance of Polyshield HT™100. Mine maintenance personnel are able to power wash the anti-corrosion coating to remove coal residue and dust. 7 years on, the protective coating is as effective as ever, and promises to extend the service life of their multi-million dollar investment, while lowering their eco footprint.