For mining and mineral processing operations, planned shutdowns are some of the most important and expensive days of the year. Every hour a plant is offline costs production, so the work done during a shutdown has to be planned precisely. Wear liners in chutes, hoppers, tanks, pumps and pipes are among the most common shutdown jobs, and how well that work is planned has a big effect on how long the shutdown takes and how long the plant runs afterwards.
Here is how operators can approach wear liner inspection and replacement so shutdowns finish on time and equipment stays protected until the next one.
Start With Good Wear Data
The best shutdowns begin months before the plant stops. Reliable wear data tells planners which liners need replacing, which can wait and which have failed faster than expected.
Useful sources of data include:
- Ultrasonic thickness readings on pipes, tanks and chutes
- Wear indicator holes or embedded markers in liners
- Photographs and measurements from previous shutdowns
- Records of leaks, failures and unplanned repairs
- Throughput and ore hardness data, which affect wear rates
Tracking wear rates over time lets teams predict when each liner will reach its limit, rather than relying on guesswork.
Prioritise the Work
Not every liner needs replacing at every shutdown. Classify components by risk:
- Critical: failure would stop production or create a safety or environmental hazard. These must be addressed.
- High: wear is advanced and failure is likely before the next shutdown.
- Monitor: wear is within limits and can be checked again next time.
This approach keeps the scope realistic and focuses resources where they matter most.
Order Materials and Prefabricate Early
Lead times for rubber sheet, ceramic tiles, bonding agents and fabricated spools can be long. Ordering early avoids last-minute substitutions. Wherever possible, prefabricate lined components off site before the shutdown. Spools, chute sections and wear panels that arrive ready to install save hours compared with lining equipment in place.
Choose the Right Lining for Each Area
A shutdown is a chance to improve on what was there before. If a liner wore out much faster than expected, consider a different compound, a thicker lining or a combination system such as rubber-backed ceramic. Getting advice from Industrial rubber lining experts Perth plants already work with can help match lining materials to particle size, impact, temperature and chemical exposure, so the next campaign lasts longer.
Plan the Sequence and Access
Detailed job planning is what keeps shutdowns on schedule:
- Map out the order in which equipment will be isolated, opened, relined and returned to service.
- Plan scaffolding, cranes and confined space access in advance.
- Make sure isolation and permit-to-work processes are clear.
- Allow time for surface preparation, curing and inspection, which cannot be rushed.
- Identify tasks that can run in parallel.
On-Site Lining Work
Some lining work must be done in place, particularly in large tanks, thickeners and fixed chutes. Cold-bonded rubber systems allow on-site installation without an autoclave. Quality still depends on the basics: thorough abrasive blasting, controlled humidity and temperature, correct adhesive application and careful rolling to remove air.
Inspection and Quality Assurance
Before equipment returns to service, every new lining should be inspected:
- Spark testing to detect pinholes in rubber linings
- Hardness and thickness checks
- Visual inspection of joints, edges and seams
- Documentation and photographs for future reference
Good records make the next shutdown easier to plan.
Safety First
Shutdown work often involves confined spaces, work at height, heavy lifting, solvents and abrasive blasting. Clear safety planning, trained crews, gas testing and proper ventilation are essential. A shutdown that finishes early but leaves someone injured is not a success.
Review After the Shutdown
Once the plant is running again, review what went well and what did not. Were materials on time? Did any jobs run over? Were there surprises inside equipment? Feeding these lessons into the next plan steadily improves shutdown performance.
The Bottom Line
Efficient wear liner replacement comes down to preparation: accurate wear data, a prioritised scope, early material orders, prefabrication, careful sequencing and thorough quality checks. When these pieces come together, shutdowns finish on time and equipment stays protected until the next planned stop.