Rubber Lining Services
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Rubber Hot Lining
Rubber HOT Lining refers to the process of applying uncured (raw) rubber sheets onto a metal surface and then vulcanizing (curing) it under heat and pressure to form a seamless, bonded, and durable protective layer.
This process is primarily used in industries where equipment needs to be protected from abrasion, corrosion, and chemical attack, especially in mining, power plants, steel, cement, and chemical industries.
Purpose of Rubber HOT Lining
- Protects metal surfaces from wear, corrosion, and chemical damage
- Extends equipment life and reduces maintenance cost
- Provides high resistance against impact, abrasion, and thermal shock
- Ideal for handling slurries, wet ores, chemicals, or abrasive materials
Rubber HOT Lining Process Steps
- Surface Preparation – Grit blasting or shot blasting the metal surface to clean it and create a rough profile for bonding.
- Primer & Adhesive Application – Application of a special rubber adhesive/primer system to enhance bonding strength.
- Rubber Sheet Application – Uncured rubber sheets are manually laid over the adhesive-coated surface.
- Vulcanization (Curing) – Heat and pressure are applied using an autoclave, pressure bag, or hot water/steam system to cure the rubber and create a permanent bond with the substrate.
- Inspection & Testing – Spark testing, tapping test, and visual inspection are performed to ensure the lining is free of voids or blisters.
Types of Rubber Used in HOT Lining
In HOT lining applications, various types of rubber materials are selected based on their unique properties to ensure maximum protection and durability in demanding environments. Natural Rubber (NR) is highly valued for its excellent abrasion and impact resistance, making it ideal for ore chutes, bins, and cyclones handling abrasive materials. Neoprene (CR) offers strong oil and chemical resistance, making it suitable for oil lines and storage tanks in chemical processing facilities. Butyl Rubber (IIR) is known for its outstanding acid resistance and gas impermeability, which is why it is commonly used in acid tanks and chemical vessels. EPDM provides superior weather and chemical resistance, making it ideal for external tanks and environments with prolonged exposure to sunlight, ozone, and moisture. Nitrile Rubber (NBR) excels in oil and fuel resistance, making it perfect for fuel tanks and refinery applications. Hypalon (CSM) stands out for its resistance to chlorine, ozone, and acids, making it the preferred choice for chemical reactors, pickling tanks, and other corrosive environments. This careful material selection ensures that HOT linings deliver long-lasting performance, even in the most aggressive industrial conditions.
Commonly Rubber-Lined Equipment
- Slurry pipes & elbows
- Hoppers, bins & chutes
- Storage tanks (chemical/acid)
- Cyclones & hydrocyclones
- Pulley drums & impact zones
- Agitator vessels & reactors
Advantages of HOT Rubber Lining
- Seamless & high-strength bond
- Longer service life than cold bonding
- High performance in aggressive environments
- Withstands thermal cycling and pressure
- Customizable rubber grade based on usage
Limitations / Considerations
- Requires skilled labor and specialized vulcanizing equipment
- Curing time and setup can be lengthy
- Equipment must be shut down for installation
Rubber Cold Lining
Rubber Cold Lining is a method of protecting equipment surfaces by bonding pre-vulcanized (cured) rubber sheets onto a substrate using special cold adhesives without the need for heat or pressure.
This technique is ideal for on-site repairs, limited access areas, or equipment that cannot be dismantled. It is commonly used in industries requiring moderate chemical and abrasion resistance.
Purpose of Cold Rubber Lining
- Protect equipment from corrosion, abrasion, and chemical attack
- Extend the service life of tanks, pipes, chutes, and bins
- Provide a quick and cost-effective lining solution
- Ideal for maintenance and repair applications
Cold Lining Process
- Surface Preparation – Surface is cleaned and blasted to near white metal finish (Sa 2.5) for optimal adhesion.
- Primer Application – Special metal primer is applied to enhance adhesion.
- Adhesive Application – Cold bonding adhesive (e.g., chloroprene-based or epoxy-based) is applied on both the substrate and the rubber.
- Rubber Sheet Application – Pre-vulcanized rubber sheets are carefully placed and rolled to eliminate air pockets.
- Curing Time – Adhesive is allowed to cure at ambient temperature (may take 24–72 hours depending on system).
Advantages of Rubber Cold Lining
- Fast and cost-effective for on-site application
- No special heating or curing equipment needed
- Ideal for maintenance and emergency repair
- Applicable in confined or remote areas
- Lightweight and adaptable
Limitations
- Bond strength is generally lower than hot lining
- Not suitable for very high temperatures or aggressive abrasion
- Proper surface preparation is critical
- Curing time depends on ambient conditions
Industries Using COLD & HOT Rubber Lining
- Mining and mineral processing
- Steel and metal industries
- Cement plants
- Chemical and fertilizer plants
- Thermal and hydro power plants
- Oil & gas refineries
- Pulp & paper industries
HOT vs COLD Rubber Lining
| Feature | HOT Lining | COLD Lining |
|---|---|---|
|
Rubber Type |
Uncured (raw) |
Pre-cured |
|
Process |
Cured with heat and pressure |
Adhesive bonding without heat |
|
Equipment Needed |
Vulcanizing press or autoclave |
Hand tools and adhesives |
|
Site Flexibility |
Workshop based |
Can be done onsite |
|
Bond Strength |
Stronger, integrated bond |
Moderate, relies on surface prep |
|
Repair Suitability |
Not ideal for small-scale repair |
Perfect for quick repairs and patches |
|
Installation Time |
Longer due to curing setup |
Shorter, easier setup |
|
Cost |
Higher equipment and labor cost |
More economical for small/medium jobs |
|
Service Temp Limit |
Up to 150°C |
Typically up to 85°C |
