Loctite® Solutions for MiningMaintenance, Repair, Rebuild and Protect

This guide has been designed to provide quick and easy assistance to the specialists who service mining equipment and look for reliability, longevity and cost reduction.

Mining engineers know about the importance of equipment reliability and predictability. They must keep the machinery running 24 hours a day, 7 days a week without downtime. Henkel offers a wide range of Loctite®, Fixmaster® and Nordbak® products to help maintenance engineers keep the downtime short and find the best solution for any specific maintenance or repair problem.

With the help of this guide, you can:

• Easily select the right products to help you service and maintain mining equipment

• Proactively prevent wear of new equipment

• Pinpoint the most suitable solution for servicing worn parts

• Determine the best product for your particular maintenance or repair problem

Our commitment to the mining industry:

• Dedicated mining maintenance program

• “Hands-on” application advice and technical support

• On-site product and maintenance training

• MRO Solution Guide

• National distribution network

Ask about our customised on-site maintenance training!

Loctite® Mining Solutions

Loctite® is the world’s #1 brand of engineering adhesives & sealants

• Global Leadership: Loctite® is the global technology leader with a wide product range sold through an extensive sales and distributor network.

• Cost Savings and Reliability: Loctite®

solutions are more cost effective compared to conventional mechanical methods.

• Value-Added Partnership: Our large, experienced team of engineers provide documented design and application support.

• Superior Product Performance: Loctite® adhesives and sealants are recognised as the best performing products in the industry.

• End-User Training: We provide professional training programs to customers that help them identify opportunities for improving process efficiency, quality and costs.

TABLE OF CONTENTS

INTRODUCTION ....................................................... 2

LOCTITE® PRODUCT RANGE ................................... 4

LOCTITE® INDUSTRY TRAINING ............................. 5

OPEN CAST MINE l Loctite® Solutions ................................... 6 l Case Histories ......................................... 8

UNDERGROUND MINE l Loctite® Solutions ................................. 10 l Case Histories ....................................... 12

CONCENTRATOR FACILITY l Loctite® Solutions ................................. 14 l Case Histories ....................................... 16

SMELTING FACILITY l Loctite® Solutions ................................. 18 l Case Histories ....................................... 20

Core Technologies & Surface Engineering Products

Loctite® Product Range

Threadlocking

• Prevent loosening, corrosion and seizing of nuts, bolts, studs and other threaded parts

Pipe & Thread Sealing

• Prevent leaks from hydraulic, air, coolant, oil or other threaded fi ttings

• Replace tapes, hemp & paste - Loctite® Threadsealants do not creep, shrink or block systems

Instant Bonding & Joining Structural Parts

• Instant adhesives for rapidly joining different materials or bonding parts temporarily during positioning or repair

• Structural adhesives for making strong, durable, tough and resilient bonds to a wide variety of materials

Metal Rebuilding & Wear Resistance

• Rebuild, restore, repair metal parts and assemblies

• Prevent erosion, sliding abrasion, wear and corrosion

• Protect against cavitation and chemical attack

Grouting, Floor & Concrete Repair

• Mounting of heavy equipment or setting anchor bolts

• Restore old concrete or cracked fl oors

• Create barriers against chemical attack

• Guard against slippery pedestrian or vehicular areas

Rubber Repair & Protection

• Achieve permanently fl exible, impact and vibration-resistant assemblies of different materials

• Join parts that have large gaps or are subject to high temperatures

Lubrication & Anti Seize

• Combat wear and seizing caused by friction

• Resist high temperatures and tough operating conditions

Cleaning Parts and Hands

• Clean parts prior to using adhesives / sealants

• Remove cured residues of adhesives / sealants, old gaskets, etc.

• Clean hands gently and effectively – with or without water

Retaining

• Solve common problems of loose bearings on shafts, worn housings and fretting corrosion

• Join keyed or splined assemblies to make them stronger and prevent backlash

Gasketing

• Seal and mate fl anges to prevent leaks, prevent bolts from loosening as gaskets relax, and stop movement between fl anges

Loctite® Maintenance Reliability Workshop and Surface Engineering Workshop

The Maintenance Reliability and Surface Engineering Workshop is a practical hands-on training program on the use of Loctite® products in maintenance, repair and overhaul environments. Planning, production and maintenance engineers learn reliable methods to reduce worn parts replacements and increase equipment effi ciency and reliability.

Diameter of opening Air loss (l/min) Energy loss (kW) Additional energy

(mm) costs* ($/year)

1 72 0.3 330

3 666 3.1 3408

5 1854 8.3 9125

Leakage rate Loss per day (litre) Loss per year (litre) Annual costs* ($/year)

1 drop in 10 sec 0.56 204 422

1 drop in 5 sec 1.12 409 844

1 drop per sec 5.62 2049 4225

Line pressure at 6 bar. * based on 8000 operating hours / year and energy costs of $0.14/kWh

*price for hydraulic fluid: $2.06/l Source: Bavarian Environmental Protection Agency, guideline ”Druckluft im Handwerk”

Ask also about the Loctite® Industrial Pumps Assembly and Maintenance Workshop.

Loctite® Industry Training

Hands-on Maintenance Workshops help to drive costs down

• Suitable for staff at all levels in the organisation

• Customised to your specifi c requirements

• All training materials will be supplied

This program will provide your workforce with the knowledge and tools to:

• Improve safety and reliability

• Reduce downtime

• Reduce fl uid consumption

• Reduce energy costs

• Save time

• Save money

• Plant survey to identify maintenance needs

• Tailor-made hands-on training to fi t your specifi c needs & reliability goals

• Conducted on site

• Review of common causes of failure and prevention

• In-plant follow-up and support

Open Cast MineLoctite® Solutions

MOBILE PLANT

1 OVERBURDEN REMOVALCHALLENGE SOLUTION

Maintain Equipment in Harsh Conditions Loctite® Threadlockers

Loaders, Forestry Equipment, Bulldozers, Backhoe, etc.

Loctite® Anti-Seize ProductsLoctite® Threadlockers

2 DRILLING AND BLASTINGCHALLENGE SOLUTION

Drill Rig Maintenance Loctite® Maintenance Reliability Workshop

Preventing Vibrational Fastener Loosening Loctite® Threadlockers

Locking / Sealing Cylindrical Drilling Hardware Loctite® Retaining Compounds

Hydraulic Line Sealing Loctite® Thread Sealants

Hydraulic Pump Gasketing Loctite® Gasket Eliminator Flange Sealants

Extreme Environment Lubrication Loctite® Anti-Seize Products

Corrosion Protection Loctite® Anti-Seize ProductsLoctite® Nordbak® Brushable Ceramic

Seizure of Drilling Rig Slides Loctite® Moly Dry Film ACH3

3 DRAGLINES, EXCAVATING & TRANSPORTCHALLENGE SOLUTION

Excavator, Dragline & Mobile Plant Maintenance

Loctite® Maintenance Reliability Workshop

Preventing Vibrational Fastener Loosening Loctite® Threadlockers

Wear Prevention on Sliding Metal Surface Loctite® Nordbak® Chemical Resistant Coating

Reclaiming Equipment Belt Repairs Loctite® Fixmaster® Rapid Rubber RepairLoctite® Fixmaster® Flex 80 Putty

Bonding of O-Rings Loctite® Instant Adhesives

Dragline Running Gear & Link Arm Bush Assembly

Loctite® 635 Retaining Compound

Dragline Cable Pulley Bearing Assembly Loctite® 635 Retaining Compound

Gearbox Flange Sealing Loctite® 587 Blue High Performance RTV Gasket Maker

Link Pin Assembly & Seizure Loctite® Heavy-Duty Anti-SeizeLoctite® 232 Wheelmount

FIXED PLANT

4 MINE ENGINEERINGCHALLENGE SOLUTION

Day-to-Day Operations Loctite® Maintenance Reliability WorkshopLoctite® Surface Engineering Workshop

5 CRUSHINGCHALLENGE SOLUTION

Secure Backing Crusher Plates into Cone Crusher

Loctite® Nordbak® Crusher Backing Material

Secure Backing Crusher Plates in Extreme Hard Rock Crushing Applications

Loctite® Nordbak® High Impact Crusher Backing Material

Prevent Equipment Fasteners from Vibrational Loosening

Loctite® Threadlockers

Secure Crusher Bolts and Ancillary Devices Loctite® Fixmaster® Magna Crete

Wear Abrasion to Output Trough Loctite® Nordbak® Wearing Compound

ACH2 Conveyor Belt Wear or Failure Loctite® Fixmaster® Rapid Rubber Repair

Backing Wear Plates in Grinding Mills Loctite® Nordbak® Crusher Backing Compound

Excessive Screen Wear Loctite® Nordbak® Brushable Ceramic

ACH5 Hydraulic Leaks Loctite® Thread Sealants

Hydraulic Fluid Containment Loctite® Nordbak® Chemical Resistant Coating

Secure Crusher Bushing Loctite® 609 Retaining Compound

6 SCREENINGCHALLENGE SOLUTION

Screen Deck Gap Sealing Terostat® MS 939 Polymer Sealant

Secure Fasteners from Vibrational Loosening Loctite® High Strength Threadlocker

Screen Slump Corrosion and Erosion Loctite® Fixmaster® Flex 80 Putty

Sliding Abrasion Wear of Inlet and Outlet Chutes

Loctite® Nordbak® Wearing Compound

Wear Abrasion to Output Trough Loctite® Nordbak® Wearing Compound

7 STACKING / RECLAIMINGCHALLENGE SOLUTION

Bucket Wheel Reclaimer Wear Loctite® Nordbak® Wearing Compound

ACH1 Bucket Wheel Excavator Face Wear Prevention Loctite® Nordbak® Wearing Compound

Repair of Ceramic Composite Liners Loctite® Fixmaster® Flex 80 Putty

ACH4 Impact Chute Wear Loctite® Nordbak® Pneu Wear

Conveyor Pulley Gearbox Flange Sealing Loctite® 587 Blue High Performance RTV Gasket Maker

Conveyor Belt Damage and Wear Loctite® Fixmaster® Rapid Rubber RepairLoctite® Fixmaster® Flex 80 Putty

Open Cast MineLoctite® Case Histories

Protection of Bucket Wheel Excavators

Permanent and Cost Effective Repairs

PRODUCT:Loctite® Nordbak® Wearing Compound

CHALLENGE:Bucket reclaimers are subject to excessive wear caused by the abrasive process of excavation. In particular, the inner wheel face (or diaphragm) and outer bucket walls are problematic, requiring protection to prevent structural failure.Standard bucket reclaimer repair methods include welding, hard facing and wear liners, but all are time consuming to fabricate.

LOCTITE® SOLUTION:Loctite® Nordbak® Wearing Compound provides a superior sacrifi cial surface that can be easily applied and re-applied as required. The non-sag characteristics of this product results in simple, fast application to vertical surfaces. Downtime and

project planning cost shrink signifi cantly as hot work permits and specialised labour are no longer required. Also, the reclaimer bucket requires less power and shows a longer service life due to the superior wearing properties of Loctite® Nordbak® Wearing Compound which features a compressive strength of 16,000psi.

PRODUCT:Loctite® Nordbak® Rapid Rubber Repair

CHALLENGE:Repairing conveyor belt was costing a coal mining company thousands of dollars a week. Each torn belt meant at least fi ve hours of downtime while the belt repair adhesive cured, more hours cleaning up spilt coal and expensive contract labour.

LOCTITE® SOLUTION:After the belt is abraided with a wire brush and cleaned, the etching agent is applied and allowed to dry for 30 minutes. Loctite® Fixmaster Rapid Rubber Repair is then applied. After two hours of curing time and a light buffi ng, the belt is recommissioned.

RESULTS:Loctite® Rapid Rubber Repair sealed the fabric of the valuable belt, preventing rotting. The improved splice durability extended the lifespan of the belt and reduced the inventory cost for replacements and prevented from sudden downtime. Overall, the productivity of the entire conveyor system has been enhanced.

ACH 1

ACH 2

Drill Rig Slides

Zero Oil Filtering in Drills

Impact Chute Wear

PRODUCT:Loctite® Moly Dry Film

CHALLENGE:Drill rig slides. Nylon slides are used to allow the head to travel smoothly up and down the mast for drill rigs. Dust and dirt, however, builds up on the slides which cause sticking and seizure. Traditional greases and anti-seize attract further dust which leads to component wear and seizure.

LOCTITE® SOLUTION:Loctite® Moly Dry Film is an easy-to-apply aerosol product

which leaves a dry lubricant on the surface, preventing slide seizure and dust build up.

RESULTS:After application of the Loctite® Moly Dry Film, the drill rig now runs smoothly without the need for additional maintenance. The same solution has been used on grader circle drives and can be applied to any sliding surfaces where dust can be an issue.

PRODUCT:Loctite® 567 PST® Thread Sealant or Loctite® 577 High Pressure Pipe Sealant

CHALLENGE:Oil leaks through high-pressure junctions on hydraulic hoses in horizontal and vertical drills, which may cause non-scheduled oil replenishment, pressure losses in the system and retightening, resulting in malfunction of the rammers.

LOCTITE® SOLUTION:Loctite® 567 PST® Thread Sealant or Loctite® 577 High Pressure Pipe Sealant effectively seals the threaded joints on hydraulic hoses that leak due to equipment and hydraulic system vibration. This eliminates losses through

threaded fi ttings, reduces oil replenishment and retightening, and increases the lifetime of hydraulic hoses, which are burned by oil at high temperatures.

EASY TO USE:Clean the fi tting threads, eliminating oil residues, then apply Loctite® 567 PST® Thread Sealant or Loctite® 577 High Pressure Pipe Sealant and tighten the fi ttings. The equipment can be restarted in operation 2 hours after sealing. Product recommended for diameters up to 50mm.

PRODUCT:Loctite® Nordbak® Pneu Wear

CHALLENGE:After building impact chutes, there were small gaps of up to 25mm between the wear plates remained. These are areas where ore can chase between the plates causing excesseive wear of the plate edges and steel frame. This can lead to increased downtime, costly repairs and even catastrophic failure of the chute structure.

LOCTITE® SOLUTION:Henkel engineers specifi ed Loctite® Nordbak® Pneu Wear to fi ll these gaps. The small alumina beads in the epoxy matrix results in excellent sliding wear resistance for fi ne ore, while

also allowing the product to fi ll small gaps.

RESULTS:The mine site was impressed with the ease of application and wear resistance of the Loctite® Nordbak® Pneu Wear and have continued to use the Nordbak® range for ongoing applications in their planned and reactive maintenance schedules.

ACH 3

ACH 5

ACH 4

Underground MineLoctite® Solutions

MOBILE PLANT

1 DRILLINGCHALLENGE SOLUTION

Vibrational Fastener Loosening Loctite® Threadlockers

Locking / Sealing Cylindrical Drilling Hardware Loctite® Retaining Compounds

Hydraulic Line Sealing Loctite® Thread Sealants

Hydraulic Pump Gasketing Loctite® Gasket Eliminator Flange Sealants

Extreme Environment Lubrication Loctite® Anti-Seize Products

Corrosion / Chemical Protection Loctite® Nordbak® Chemical Resistant Coating ACH2

Seizure of Drilling Rig Slides Loctite® Moly Dry Film

2 EXCAVATING & TRANSPORTCHALLENGE SOLUTION

Excavator Maintenance Loctite® Maintenance Reliability Workshop

Preventing Vibrational Fastener Loosening Loctite® Threadlockers

Bucket Wheel Excavator Face Wear Prevention Loctite® Nordbak® Wearing Compound

Wear Prevention on Sliding Metal Surface Loctite® Nordbak® Chemical Resistant Coating

Reclaiming Equipment Belt Repairs Loctite® Fixmaster® Rapid Rubber Repair

Bonding of O-Rings Loctite® Instant Adhesives

FIXED PLANT

3 MINE ENGINEERINGCHALLENGE SOLUTION

Day-to-Day Operations Loctite® Maintenance Reliability WorkshopLoctite® Surface Engineering Workshop

4 EXCAVATING & TRANSPORTCHALLENGE SOLUTION

ACH4 Hydraulic Pump Gasketing Loctite® Gasket Products

5 CRUSHINGCHALLENGE SOLUTION

ACH3 Prevent Equipment Fasteners from Seizing Loctite® Anti-Seize Products

Locate Equipment Securely On-Site and Reinforce Base Frame to Improve Structure

Loctite® Fixmaster® Magna Crete

ACH5 Secure Crusher Bolts and Ancillary Devices Loctite® Fixmaster® Fixmaster® Magna Crete

Processing Conveyor Belt Wear Loctite® Fixmaster® Rapid Rubber Repair

ACH1 Fixing Crusher Liners Loctite® Nordbak® Crusher Backing Compound

6 SHAFTCHALLENGE SOLUTION

Braking Mechanism Mounting Bolts Loctite® Threadlockers

Braking Mechanism Fasteners from Micro Movement

Loctite® Anti-Seize Products

Hoist Motors and Gearbox Maintenance Loctite® Fixmaster® Magna Crete

Shaft Maintenance Loctite® ThreadlockersLoctite® Anti-Seize ProductsLoctite® Wearing Compounds

Hydraulic Fluid Power Components Loctite® Thread Sealants

Hydraulic Cylinder Rework Loctite® Retaining Compounds

Hydraulic Cylinder Head Ring Loctite® Anti-Seize Products

7 UNDERGROUND MATERIAL HANDLINGCHALLENGE SOLUTION

Hydraulic Pump Sealing Loctite® Thread Sealants

Hydraulic Pump Gasketing Loctite® Gasket Products

Extreme Environment Loctite® Anti-Seize Products

Wear Prevention Applications Loctite® Nordbak® Wearing Compound

Metal Rebuilding Loctite® Fixmaster® Superior Metal

Low Pressure Leaks from Punctures Loctite® Fixmaster® Metal Magic Steel

Fitted Part Seizure Loctite® Anti-Seize Products

Underground MineLoctite® Case Histories

Crusher Backing Compound

PRODUCT:Loctite® Nordbak® Crusher Backing Compound

CHALLENGE:Rock crushing equipment sees some of the largest types of physical impact that any single piece of equipment would ever handle.

LOCTITE® SOLUTION:Loctite® Nordbak® Crusher Backing Compound offers a compressive strength of 106.9 N/mm² (15,500 PSI). Where other materials loosen and crumble, the Loctite® Nordbak® linings maintain their strength to ensure all parts are suffi ciently protected throughout the crusher maintenance cycle. Loctite® Nordbak® Crusher Backing Compounds is sold in 10kg pail formats, allowing for easier application into hard to access locations. Larger formats are available if needed.

BENEFITS:• Loctite® Nordbak® has strong performance data• Small or large packages allow for easy pouring in

compromising locations• Epoxy accelerator available for those working in cold

climates

ACH 1

Eliminate Corrosion in Acid Environment

PRODUCT:Loctite® Nordbak® Chemical Resistant Coating

CHALLENGE:Equipment suffering corrosion and chemical action due to the environment with high concentrations of sulphuric acid and sulphur. A lot of equipment such as pumps and bases were corroded in just 6 months after implantation at the area.

LOCTITE® SOLUTION:Loctite® Nordbak® Chemical Resistant Coating protects the equipment against corrosion.

BENEFITS:After applying Loctite® Nordbak® Chemical Resistant Coating, the equipment shows high level of production with no need for maintenance and non-scheduled stoppages. Durability of application has exceeded 5 years without maintenance.

ACH 2

Seizure Prevention Made Easy

Sealing of Transmission Housing in Front Charger

Secure Crusher Bushings

PRODUCT:Loctite® Heavy Duty Anti-Seize

CHALLENGE:Seized parts require oxy or disc cutting which often needs time-consuming hot work permits and can damage expensive components. An Australian mine with underground operations was trying to address this problem and was seeking a reliable and cost effi cient solution that can also be used on alloy parts. Anti-seize is an essential product for mining maintenance operations to ensure that components can be easily dismantled.

LOCTITE® SOLUTION:Loctite® Heavy Duty Anti-Seize is a metal-free, non-hazardous anti-seize product that is able to be used on all alloys and has a temperature rating of 1315°C.

BENEFITS:The mine is very pleased with the Loctite® Heavy Duty Anti-Seize, and its reliable performance. It addressed this problem and in addition reduced the OH & S risks for the maintenance teams.

PRODUCT:Loctite® 515 Master Gasket Flange Sealant

CHALLENGE:Transmission housing of front charger. When using acetic silicone to perform joint sealing, oxidation on housing faces and oil leaking through joints occurs.

LOCTITE® SOLUTION:E Loctite® 515 Master Gasket Flange Sealant replaces acetic silicone, avoiding oil leaking

through joint and avoiding corrosion provoked by acetic silicone on housing faces.

EASY TO USE:Remove all acetic silicone residues with Loctite® Chisel Gasket Remover product. Clean it with grease remover that does not leave residues. After applying Loctite® 515 Master Gasket Flange Sealant, set your assembly. You can operate equipment 12 hours after product application.

PRODUCT:Loctite® 609 Retaining Compound

CHALLENGE:Excessive vibration causes loosening of crusher bushing.

LOCTITE® SOLUTION:Loctite® 609 Retaining Compound is designed to secure and bond cylindrical fi ttings such as bushings, sleeves and bearings to shafts.Before any products were applied, the surface was thoroughly

prepared to eliminate contaminates and maximize adhesion of new coatings.

RESULTS:The bushing is now secured preventing down time and housing wear.

ACH 3

ACH 4

ACH 5

Concentrator FacilityLoctite® Solutions

3 FLOTATION CELLSCHALLENGE SOLUTION

Excessive Impeller Erosion Loctite® Nordbak® Brushable Ceramic

Tank Lining Loctite® Nordbak® Chemical Resistant Coating

Prevent Fastener Seizure from Elemental Corrosion

Loctite® Anti-Seize Products

Enhance Plumbing Reliability Loctite® Thread Sealants

Repair Flooring Abrasion Loctite® Fixmaster® Magna Crete

Skimmer Erosion Loctite® Nordbak® Brushable Ceramic

Piping Reinforcement for Abrasion Resistances Loctite® Nordbak® Brushable Ceramic Loctite® Nordbak® Pneu Wear

Excessive Wearing of Discharge Region Loctite® Nordbak® Wearing Compound ACH3

1 MINING OFFICECHALLENGE SOLUTION

Day-to-Day Operations Loctite® Maintenance Reliability WorkshopLoctite® Surface Engineering Workshop

ACH4

2 CRUSHING/MILLINGCHALLENGE SOLUTION

Secure Backing Crusher Plates Loctite® Nordbak Crusher Backing Compound ACH2

Secure Backing Crusher Plates in Extreme Hard Rock Crushing Applications

Loctite® High Impact Crusher Backing Compound

Prevent Vibrational Loosening of Fasteners Loctite® Threadlockers ACH4

Wear and Abrasion to Trunion Output Chute Loctite® Nordbak® Wearing Compound

Concrete Degradation Loctite® Fixmaster® Magna Crete ACH1

Conveyor Belt Wear or Failure Repairs Loctite® Fixmaster® Rapid Rubber Repair

Backing Plates Wear in Grinding Mills (Ball, Rod, Sag)

Loctite® Nordbak® Crusher Backing Compound

Excessive Screen Wear Loctite® Nordbak® Wearing Compound

Mill Liner Bolt Corrosion Loctite® Heavy Duty Anti Seize

Mill Liner/Wall Seizure Loctite® Moly Dry Film

Mill Discharge Chute Wear Loctite® Nordbak® Wearing CompoundLoctite® Nordbak® Pneu Wear

Mill Feeder Chute High Impact and Wear Loctite® Nordbak® High Impact Wearing Compound

Cyclone Inlet / Discharge Wear Loctite® Nordbak® Pneu Wear

5 VACUUM DRUM FILTERSCHALLENGE SOLUTION

Metal Rebuilding Loctite® Fixmaster® Superior Metal

Bearing Mounting Loctite® Retaining Compounds

6 ROTARY KILNCHALLENGE SOLUTION

Drum Erosion Repairs Loctite® Nordbak® Pneu Wear

7 LOADING HOPPERCHALLENGE SOLUTION

Material Handling Chute Wearing Loctite® Nordbak® Wearing Compound

Wearing Abrasion to Conveyor Belts Loctite® Fixmaster® Rapid Rubber Repair

4 SEDIMENTATION THICKENERCHALLENGE SOLUTION

Excessive Wearing of Discharge Region Loctite® Nordbak® Wearing Compound

Concrete Degradation Loctite® Fixmaster® Magna Crete

Chemical Attack Loctite® Nordbak® Chemical Resistant Coating

Sludge Outlet Erosion Loctite® Nordbak® Pneu Wear

Pulp Waste Pump Recover Flange Loctite® Nordbak® Pneu Wear

ACH5Pulp Pump Volutes Loctite® Nordbak® Wearing Compound

Loctite® Nordbak® Sprayable Ceramic

Concentrator FacilityLoctite® Case Histories

Saving Costly Downtime

No More Bolt Retightening

PRODUCT:Loctite® Fixmaster® Magna Crete

CHALLENGE:Concrete wall in slurry pit below sag mill has been worn and eroded by abrasive slurry. The concrete was worn past the reinforcement steel in the concrete.The structural integrity of the worn wall was a concern if worn back continually. It took four hours overnight to make the total repair, which is not possible with cementitious materials. The shutdown involved a considerably high cost per hour.

LOCTITE® SOLUTION:Loctite® Fixmaster® Magna CreteThe mine will rebuild and resurface this repair to maintain and protect the concrete structure.

BENEFITS:Loctite® Fixmaster® Magna Crete saved downtime costs overnight.

PRODUCT:Loctite® 263 Best Ever Threadlocker Loctite® 277 Threadlocker

CHALLENGE:Frames subject to high workloads, vibration and impact, cause the loosening of bolts, generating non-scheduled retightening.

LOCTITE® SOLUTION:Loctite® 263 Best Ever Threadlocker or Loctite® 277 Threadlocker, high strength bolt fastener. Both products ensure the bolts remain in place, preventing their loosening and shearing, dedicating lost times to scheduled maintenance.

EASY TO USE:Clean the bolts and apply a few drops of Loctite® 263 Best Ever Threadlocker or Loctite® 277 Threadlocker. We recommend to use this threadlocker on bolts up to 36mm. Pay attention on the fact that the product is anaerobic, hence it hardens in the absence of air and presence of metal. The residues must be removed.

ACH 1

ACH 2

Mill Inlet Wear

Wear of the Cyclone Chamber - No More Abrasion Problems!

Pump Volute Repair

PRODUCT:Loctite® Nordbak® Wearing Compound

CHALLENGE:Large quantities of iron ore circulate in the fl otation process and cause severe wear of the mill inlets. Due to its dimensions, the repair of the part is a complex task that requires a special welding, thus a lot of time.

LOCTITE® SOLUTION:Loctite® Nordbak® Wearing Compound is a fast-dry

two-part ceramic compound, designed to protect, rebuild and repair worn areas. In addition, it reduces downtime and labour cost.

EASY TO USE:Prepare the surface to be repaired, creating roughness and removing detached rubber remains in order to achieve good product anchoring on the fl otation cell region affected. Mix in a homogeneous way Loctite® Nordbak® Wearing Compound and apply on the region affected.

PRODUCT:Loctite® Nordbak® Brushable CeramicLoctite® Nordbak® Pneu Wear

CHALLENGE:Due to the intense fl ow of ore slurry, the internal coating of feed manifold is prone to suffer from severe erosion.

LOCTITE® SOLUTION:Loctite® Nordbak® Pneu Wear is a ceramic bead fi lled two-part epoxy putty designed to protect equipment from fi ne

particle abrasion. It can be applied in situ in vertical condition. In addition, its fast curing properties reduce downtime.

EASY TO USE:Prepare the surface to be repaired and coat the affected surface with Loctite® Nordbak® Brushable Ceramic.Then rebuild the pre-treated area with Loctite® Nordbak® Pneu Wear.

PRODUCT:Loctite® Nordbak® Wearing CompoundLoctite® Nordbak® Sprayable Ceramic

CHALLENGE:Pulp pump volutes are severely worn out due to abrasion, and in some cases need to be replaced in less than 90 days. This involves high costs and considerable downtime.

LOCTITE® SOLUTION:Using Loctite® Nordbak® Wearing Compound and Loctite® Nordbak® Sprayable Ceramic helps in salvaging worn out volutes and extending the life of the same.

BENEFITS:Prevents pump volute from scrapping by repairing them on site, reduces downtime, lowers replacement costs.

ACH 3

ACH 4

ACH 5

Smelting FacilityLoctite® Solutions

1 SMELTING FLASH FURNACECHALLENGE SOLUTION

Conveyor Wear Loctite® Fixmaster® Rapid Rubber Repair ACH4

Hopper Erosion Loctite® Nordbak® Pneu Wear ACH1

Flooring Burns and Erosion Loctite® Fixmaster® Magna Crete

Concentrate Delivery Chute Erosion Loctite® Nordbak® Pneu WearLoctite® Nordbak® Brushable Ceramic

ACH5

High Heat Part Seizure Prevention Loctite® Heavy Duty Anti-Seize

Pipe Elbow Erosion Loctite® Nordbak® Sprayable CeramicLoctite® Nordbak® Pneu Wear

2 CONVERTERCHALLENGE SOLUTION

High Heat Part Seizure Prevention Loctite® Heavy Duty Anti-Seize

Thermal Shock Fastener Loosening Loctite® High Temperature Threadlockers ACH2

High Temperature Gasketing Loctite® Superfl ex® High Temperature Red RTV Silicone Gasket Maker

3 ANODE CASTINGCHALLENGE SOLUTION

Flooring Burns and Erosion Loctite® Fixmaster® Magna Crete ACH3

Threaded Fastener Seizure and Galling Loctite® Heavy Duty Anti-Seize

Corrosion Resistance on Exposed Hardware Loctite® Nordbak® Chemical Resistant Coating

4 REFINING TANKCHALLENGE SOLUTION

Floor & Bund Protection and Coating Loctite® Fixmaster® Floor FillLoctite® Nordbak® Chemical Resistant Coating

5 GAS CLEANER / ACID PLANTCHALLENGE SOLUTION

Floor & Bund Protection and Coating Loctite® Fixmaster® Floor FillLoctite® Nordbak® Chemical Resistant Coating

Acid Erosion of Vessels & Tanks Loctite® Nordbak® Chemical Resistant Coating ACH4

Elevated Rates of Corrosion on Key Equipment Loctite® Nordbak® Chemical Resistant Coating

Exhaust Fan Corrosion and/or Decay Loctite® Nordbak® Chemical Resistant Coating

Exhaust Fan Casing and Impeller Wear Loctite® Nordbak® Brushable CeramicLoctite® Nordbak® Pneu Wear

Smelting FacilityLoctite® Case Histories

Life of cyclone hopper doubled with Pneu Wear

Securing bolts at 300°C

PRODUCT:Loctite® Nordbak® Pneu Wear

CHALLENGE:Corrosion left the cyclone hoppers that transport aluminium fi lings through a smelter with a lifespan of just twelve weeks.

LOCTITE® SOLUTION:A two-part epoxy putty fi lled with small ceramic beads, Loctite® Nordbak® Pneu Wear protects equipment from fi ne particle abrasion.

The surface of the new cyclone was abrasive blasted to a surface fi nish of 75 microns. The surface was wet in with a smear of Loctite® Nordbak® Pneu Wear, which was then built up with a trowel to a thickness of 8mm. Two hours later, a paint roller was used over plastic to eliminate air bubbles and create a low-friction surface.

BENEFITS:The cyclone has now been operational for six months without replacement. The Nordbak® Pneu Wear was applied in just four hours, generating annual labour savings of 15 days and a week or more of production time.

PRODUCT:Loctite® 2620 High Strength High Temperature Threadlocker

CHALLENGE:Loose bolts in a machine that forms red-hot six-metre steel rods into perfectly round balls were causing massive downtime. The process involves intense vibration and temperatures up to 300°C, which loosen bolts securing the forming inserts. Falling inserts jammed the machine leading to considerably high downtime costs. Even locknuts proved ineffective in the extreme environment.

LOCTITE® SOLUTION:Loctite® 2620 High Strength High Temperature Threadlocker withstands continuous exposure to temperatures of up to

350ºC. The paste is applied with a convenient syringe.

BENEFITS:Treated with Loctite® 2620 High Strength High Temperature Threadlocker, the bolts remain tight, saving the manufacturer time and money.

ACH 1

ACH 2

“The cyclone’s lifespan has been doubled in the four hours it took to apply Loctite Nordbak Pneu Wear.”

Eliminate Corrosion in Chemical Plant

Increased Output Chute Lifetime

No More Bolt Cutting, Easy Dismounting

PRODUCT:Loctite® Nordbak® Chemical Resistant Coating

CHALLENGE:Internal and external tank and vessel surfaces were suffering corrosion and chemical action due to the environment with high concentrations of sulphuric acid and sulphur.

LOCTITE® SOLUTION:Loctite® Nordbak® Chemical Resistant Coating was used as a solution to protect the prematurely corroded tank and vessel surfaces.

BENEFITS:After applying Loctite® Nordbak® Chemical Resistant Coating, the protection coating of both, the external and internal surfaces lasted 1.5 times longer than traditionally used surface treatments.

PRODUCT:Loctite® Nordbak® Brushable CeramicLoctite® Nordbak® Pneu Wear

CHALLENGE:The concentrate delivery chute suffers abrasive wear on the inner lining, causing chute rupture.

SOLUTION:Loctite® Nordbak® Brushable Ceramic creates a smooth, wear

resistant, low friction coating and enhances the output process effi ciency.Loctite® Nordbak® Pneu Wear protects against further wear and abrasion.

BENEFITS:After applying Loctite® Nordbak® Chemical Resistant Coating, the protection coating lasted 1.5 times longer than traditionally used surface treatments.

PRODUCT:Loctite® Nickel Anti-Seize

CHALLENGE:The working environment at pump houses (moisture) produces oxidation and corrosion, thus preventing fast removal of the equipment for maintenance, and the bolts must be loosened by using oxyacetylene cutting, which causes delays and increases maintenance costs, also preventing the reutilization of bolts when reassembling the pump.

LOCTITE® SOLUTION:Once started the pump mounting, take its new bolts and apply the Loctite® Nickel Anti-Seize on the threads, and install them by applying the tightening torque recommended for your equipment. This product has been designed to support

moisture (including water) and high temperatures, which protects the bolts against corrosion and facilitates the equipment removal.

BENEFITS:The utilization of Loctite® Nickel Anti-Seize on bolts prevents corrosion and facilitates the removal of equipment for maintenance, also enabling the reutilization of high percentage of the bolts in the pump cases, enabling maintenance cost savings. Once the equipment is mounted, it can be restarted immediately into operation.

ACH 4

ACH 5

ACH 3

22

Product Index by Product Name

Product Description Pack Size Part number IDH codeLoctite® 232 Wheelmount Medium Strength Threadlocker 250ml 44324 1381765Loctite® 243 Best Ever Medium Strength Threadlocker 50ml 44092 1311321Loctite® 243 Best Ever Medium Strength Threadlocker 250ml 44094 1311323Loctite® 2422 Medium Strength High Temp Threadlocker 30g 1134601 1389695Loctite® 263 Best Ever High Strength Threadlocker 50ml 44130 1331618Loctite® 263 Best Ever High Strength Threadlocker 250ml 44131 1331536Loctite® 2620 High Strength High Temp Threadlocker 30g 1138282 1383415Loctite® 277 High Strength Threadlocker 50 ml 27750 232658Loctite® 277 High Strength Threadlocker 250 ml 27770 286777Loctite® 515 Gasket Eliminator Flange Sealant 50ml 51531A 473169Loctite® 515 Gasket Eliminator Flange Sealant 300ml 33530 265605Loctite® 55 Sealing Cord 150m 31899 473136Loctite® 567 PST Thread Sealant 50ml 56747A 473168Loctite® 567 PST Thread Sealant 250ml 56741 234453Loctite® 577 High Pressure Pipe Sealant 50ml 19259 229930Loctite® 577 High Pressure Pipe Sealant 250ml 34112 281823Loctite® 587 Blue High Performance RTV Silicone Gasket Maker 95g 34848 332651Loctite® 587 Blue High Performance RTV Silicone Gasket Maker 300ml 34888 333949Loctite® 5900 Heavy Body Silicone Flange Sealant 300 ml 20166 212184Loctite® 609 Retaining Compound 50ml 30015 234551Loctite® 609 Retaining Compound 250ml 30014 234549Loctite® 638 Retaining Compound 50ml 63830 1559812Loctite® 660 QuickMetal Retaining Compound 6ml 66010A 473167Loctite® 660 QuickMetal Retaining Compound 50ml 66040 473166Loctite® 7649 Primer N 100ml 22410A 991076Loctite® 7649 Primer N 3.78L 24063A 990024Loctite® Chisel Gasket Remover 510g 79040 642664Loctite® Fixmaster® Fast Set Steel Putty 453g 39917 219293Loctite® Fixmaster® Flex 80 Putty 1lb 97423 209821Loctite® Fixmaster® Flex Etching Agent 85.2ml 99626 902325Loctite® Fixmaster® Floor Fill 4.5kg 99361 1581469Loctite® Fixmaster® Magna Crete 3.78L 95551 235572Loctite® Fixmaster® Magna Crete 18.9L 95555 235573Loctite® Fixmaster® Rapid Rubber Repair 400ml 96675 1232303Loctite® Fixmaster® Rapid Rubber Repair Kit 400ml 96677 1265768Loctite® Fixmaster® Superior Metal 408g 97473 209822Loctite® Fixmaster® Superior Metal 4kg 40900 1581467Loctite® Heavy Duty Anti-Seize 510g 51606 209758Loctite® Heavy Duty Anti-Seize Stick 20g 944870 944870Loctite® Metal Magic Stick 113g 98853 645440Loctite® Moly Dry Film 340g 39895 473134Loctite® Nickel Anti-Seize tube 28g 28182A 472902Loctite® Nickel Anti-Seize tub 500g 39163 641488Loctite® Nordbak® Brushable Ceramic Grey 1kg 42087A 978759Loctite® Nordbak® Brushable Ceramic Grey 2kg 42076A 978758Loctite® Nordbak® Brushable Ceramic White 1kg 42372A 1050263Loctite® Nordbak® Brushable Ceramic White 2kg 42377A 1050599Loctite® Nordbak® Chemical Resistant Coating 5.43kg 96092 661982Loctite® Nordbak® Crusher Backing Compound 10kg 36123 408041Loctite® Nordbak® High Impact Wearing Compound 11.35kg 1174109 1214823Loctite® Nordbak® Pneu Wear 10kg 42089 979698Loctite® Nordbak® Sprayable Ceramic 900ml 43269 1308499Loctite® Nordbak® Wearing Compound 10kg 41782 912251Loctite® Superflex Red High Temperature RTV Silicone 80ml 59630 135507Loctite® Superflex Red High Temperature RTV Silicone 300ml 59675 198817Teroson® Terostat® MS 939 Black 570ml n/a 100145Teroson® Terostat® MS 939 Grey 570ml n/a 197363Teroson® Terostat® MS 939 White 570ml n/a 212653

Unexpected downtime?We can fi x that.

Everytime your equipment goes down, or springs a leak, your profi ts do too. There’s no more compelling reason to enroll your staff in the Loctite® Maintenance Workshop.• Reduce downtime• Reduce costs• Increase reliability• Reclaim worn parts• Save Money!

After just two hours of training, your staff will be applying the skills they’ve just learned – Immediately and with confi dence.• Practical hands on training• Product application technique• Customized content - aimed at trouble shooting,

eliminating key problems within your plant• Conducted at your facility

THE LOCTITE® MAINTENANCE WORKSHOP…INDUSTRY TESTED. CUSTOMER APPROVED.

Henkel – Your partner worldwide

The data contained herein is intended as reference only. Please contact your local Henkel subsidiary for assistance and recommendation on speci�cations and applications of these products. ® All trademarks, except where otherwise noted, are the property of or used underlicense by Henkel Corporation. Nordberg trademark is property of its respective owner. ©Copyright 2011, Henkel Australia Pty Ltd. All rights reserved ART0973 IDH 1468392

Henkel Australia Pty Ltd.135-141 Canterbury RoadKilsyth, Victoria 3137, AustraliaTel: +61 3 9724 6444Fax: +61 3 9761 4539www.loctite.com.auwww.henkel.com.au

Henkel New Zealand Ltd.2 Allens Road, East TamakiPO Box 58 493, Greenmount 1730Auckland, New ZealandTel: +64 9 272 6710Fax: +64 9 272 6735www.loctite.co.nzwww.henkel.co.nz