Abtrex rubber systems and suppliers

ABTREX INDUSTRIES INC.
LININGS FOR ABRASION AND CORROSION
FABRICATORS • MANUFACTURERS •
APPLICATORS
AND MORE……
www.Abtrex.com Abtrex Inc. 800-959-0125

ABTREX HISTORY
1969 - Harold Byars starts Abtrex in metro-Detroit with partner, Jim
Graham
Abtrex serves the electroplating industry providing vulcanized plating
equipment including cathodes and tanks
1980 – Abtrex purchases American Fiberglass Fabricators in Elkhart,
Indiana
1985 –Abtrex opens Pittsburgh (Leetsdale, PA) facility
Located on a rail spur, Abtrex enters into bulk material transport industry
1985 – Abtrex buys Blastco (abrasive blasting company) in South Bend, IN
Entire Indiana operation is relocated from Elkhart to South Bend
2009 – Abtrex opens railcar lining operation in Cleveland, TX
Located on UTLX property, Abtrex installs state-of-the-art robotic water blaster
to strip old linings from railcars
2011 – Abtrex acquires KSF Chemical Processes in Cambridge, ON
KSF owned intellectual property for Wean United Acid Recovery
Systems

ABTREX INDUSTRIES’ FACILITIES
South Bend, Indiana
50,000ft², 30 employees
Metal & Plastic Fab, Linings & Coatings

OUR QUALITY

OUR SAFETY
ABTREX SAFETY
• Experience Modification Rate (EMR):
0.81
• No recordable incidents this year
• No lost days for 3+ years

CAPABILITIES
• Engineering Services
• Corrosion and Abrasion Resistant Linings
• Tank and Vessel Fabrication
• Metal
• Plastic
• Fiberglass
• Pipe Fabrication
• Rubber-lined Steel Pipe and Fittings
• Fiberglass Reinforced Plastic (FRP) Pipe
and Fittings
• Field Installations, Maintenance &
Repairswww.Abtrex.com Abtrex Inc. 800-959-0125

DESIGN AND BUILD SERVICES
Engineering and Design Tools
Solidworks 3D CAD design Software
SIEMENS Unigraphics PLM
Software
Autodesk AutoCAD Software
• 3-D Modeling Software:
• General FEA (Finite Element Analysis)

DESIGN AND BUILD SERVICES
Electro-Galvanizing Roll

RUBBER COMPOUNDS & MANUFACTURERS
COMPOUNDS
• Natural (NR)
• Styrene Butadiene (SBR)
• Neoprene (CR)
• Nitrile (NBR)
• Butyl (IIR)
• Bromobutyl (BIIR)
• Chlorobutyl (CIIR)
• FDA-Approved
• Non Staining
• Hundreds more
MANUFACTURER
S

RUBBER MANUFACTURING
• Natural Rubber is tapped from trees
much like maple syrup
• Countries of origin:
• Malaysia
• Liberia
• Indonesia
• India
• Brazil
Synthetic Rubber was developed in 1942 due to shortage of material and costs related to WWII

• Raw materials are combined per
compound recipes
• Ingredients are blended in Banbury
mixers
• Some linings need extra mixes to
breakdown
• Rubber is cross linked by sulfur and
carbon black
Rubber Mill
Banbury Mixer
Carbon Black and
Sulfur

Calender Process
• Blended rubber material is processed
through a series of hard pressure
rollers to create a smooth sheet of
rubber
• Heat is applied during calendering
process to ensure maximum ply
adhesion
• Extruder & Inverted Cracker help to
breakdown rubber
• No heat memory generated
• Helps maintain proper cure

PRE-CURED VS. UNCURED RUBBER
Uncured
Advantages:
• Most Suitable for Shop work
• Superior Bond in an Autoclave
• Ease of Application
Disadvantages:
• Special (Cold) storage needed
• Potentially higher cost to cure
in field
Pre-Cured
Advantages:
• Most Suited for field service
• Can be used on large diameter
vessels when steam is not available
• No special storage needed
Disadvantages:
• Lower bond strength
• Can be difficult to apply
ELASTOMER SELECTION

ELASTOMER SELECTION
Common Rubber Lining Materials
(Higher durometer rubbers generally help reduce water permeation)
Lining Type Optimum Conditions Max Temp. Limitations
Natural Rubber 60 Duro. Sliding abrasion 160°F Heat, solvents, oil
Natural Rubber 40 Duro. Impingement abrasion 170°F Heat, solvents, oil
SBR Synthetic Rubber High abrasion 180°F Heat, Oil & Gasoline
Neoprene Oil & Heat resistant 220°F Solvents
Nitrile Hydrocarbon solvents. oil 220°F High abrasion
Chlorobutyl Chemical Resistant 230°F Oil & Gasoline
Bromobutyl Acid, caustic & Heat resistant 260°F Oil & Gasoline

ELASTOMER SELECTION
Recommended Lining Thickness

APPLYING RUBBER – ABRASIVE BLAST
Surfaces to be lined are blasted to an SSPC-SP5 /
NACE 1 White Metal Blast Cleaning profile

SSPC-SP1 Solvent Cleaning
SSPC-SP2 Hand Tool Cleaning
SSPC-SP3 Power Tool Cleaning
SSPC-SP5 / NACE 1 White Metal Blast Cleaning
SSPC-SP6 / NACE 3 Commercial Blast Cleaning
SSPC-SP7 / NACE 4 Brush-Off Blast Cleaning
SSPC-SP10 / NACE 2 Near-White Blast Cleaning
SSPC-SP11 Power Tool Cleaning to Bare Metal

Blasted surfaces are verified per ASTM D4417
Digital Surface
Profile Gauge
Replica Tape &
Micrometer/Thickness Gauge

APPLYING RUBBER – ADHESIVE SYSTEM
Surfaces are prepped post-blast with adhesive system
Three-Part System
1. Primer (Green) -
applied to substrate.
2. Covercoat (Red) –
applied over primer.
3. Cement (Black) –
applied to both
substrate and sheet
rubber.

APPLYING RUBBER – PATTERNS
Surfaces are measured and sheet rubber is cut into
patterns to match the part’s geometry

APPLYING RUBBER – SKIVING
Rubber panels are skived with a 45° up skive on the
bottom and the top has a 45° down skive
Seam Styles: Skive Butt Joint and Overlap

APPLYING RUBBER – STITCHING
Every square inch of rubber is stitched, or pressed
into the blasted and cemented profile

APPLYING RUBBER – LINING PIPE
• Sheet rubber is rolled into a tube and sealed at both ends.
• Rubber bladder is inflated to specified psi.
• Air pressure is used instead of hand stitching to bond rubber
to substrate.

• Strings are run to allow air to escape between lining and substrate

• Collars are bolted to each end of pipe

• Ends are capped with blind flanges.
• One end has an air fitting to inflate bladder.

APPLYING RUBBER – AUTOCLAVE CURE
• Vulcanization Process – pressurized steam cure
• Rubber manufacturer provides specifications for cure temperature and time
(eg. 6 hours at 275°F)
• Autoclave is pressurized to approx. 10 to 30 psi (varies with temperature)
• Data (temperature, time and pressure) for cure is captured on a chart recorder
• Linings for vacuum service will require longer cure times
TEMPERATURES FOR
VARIOUS PRESSURES
Press. Temp.
10psi 240°F (115°C)
15psi 250°F (121°C)
20psi 258°F (125°C)
30psi 274°F (134°C)

APPLYING RUBBER – INTERNAL PRESSURE CURE
• Used for larger parts that cannot be placed in autoclave
• Condensation needs to drain
• Thick steel creates a greater heat sink and requires longer
heat-up times.

APPLYING RUBBER – ATMOSPHERIC CURE
• Used for larger parts that cannot be placed in autoclave
• Requires longer cure times than autoclave
• Slightly lower durometer hardness than autoclave cured linings

TESTING RUBBER LININGS:
HOLIDAY/SPARK TESTING
• Per ASTM D5162-08 - Standard Practice
for Discontinuity (Holiday) Testing of
Nonconductive Protective Coating on
Metallic Substrates
• Detects pinholes in linings before & after
cure
• Methods:
• Method A – Low Voltage Wet
Sponge
• Method B – High Voltage Spark
• Can potentially damage lining
• Test voltages determined by
material thickness (see
table)
High-Voltage Spark Tester Low-Voltage Sponge Tester

• Per ASTM D 429 - Standard Test Methods for Rubber Property—Adhesion to
Rigid Substrates
• Measures static strength of rubber adhesion to metals or other rigid materials
• Eight different methods
• Types of Failure measured:
• R – Failure in the rubber
• RC – Failure in the rubber-cover cement
• CP – Failure in the cover cement-prime cement
• M or CM – Failure in the prime cement-metal interface
ADHESION TESTING
Method B

DUROMETER HARDNESS
• Per ASTM D2240 - Standard Test
Method for Rubber Property —
Durometer Hardness
• Determines indentation hardness of
thermoplastic elastomers, vulcanized
rubber, cellular and gel-like materials
and some plastics
• 12 classifications of rubber
hardness: A, B , C, D, E, M, O, OO,
OOO, OOO-S and RDigital Durometer
Gauge
Gauges are calibrated to
hardness standards
Installed, cured lining being tested

RUBBER LINED SLURRY PIPELINES
• Mineral Concentrates:
• Iron ore
• Gold
• Base Metals (Cu, Ni, Pb,
Zn)
• Rare Earth minerals
• Oil Sands
• FGD (Gypsum)
• Potash
• Tailings

RUBBER-LINED STEEL PIPE
RUBBER-LINED STEEL ABSORBER RECYCLE PIPE
COMPONENTS

I.D. of Absorber Recycle Pipe Header for Duke Energy

48” RUBBER-LINED A/R PIPE WITH AWWA
RING FLANGES AND VERTICAL SUPPORT
BRACKETSwww.Abtrex.com Abtrex Inc. 800-959-0125

PIPELINE WEAR FACTORS
Material Being Handled
Particle size
Particle shape
Particle Hardness
Chemical composition
Lining material
Abrasion resistance
Chemical ressistance
Temperature resistance
Impact resistance
Thickness
Design
Flow velocity
Impact velocity
Impact angle
Bend radius
Piping Layout

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
PVC
Mild Steel
HDPE
Alumina
HCWCI
Rubber
PU
Wear Rate (mm³/hr.)
Figure 16 -- Olengorsky Iron Ore18
(25 NB Pipe, 18% vol. concentration, 3.7 m/s velocity)
Material
PIPELINE WEAR RATES
Ref. SME Paper
Combating Pipeline Wear by N.R. Stewart

PIPE FLOW VELOCITY
Minimum velocity to avoid settling (Wilson)
Example: 250mm pipe, 0.5mm, 3.8 sg gives 4.5 m/s.

GENERAL GUIDELINES FOR LINED PIPING SYSTEMS
 Select optimum flow velocity
 Maximum 10 m/s for elastomer linings
 Use 3D/5D Elbows – 3 to 5 times pipe diameter
(as opposed to standard long radius elbows which are 1.5 times pipe
diameter)
 Avoid inclined pipe runs
 Vertical or Horizontal piping preferred
 Avoid direct impingement on tank walls and bottom
Direct impingement is preferred to angular impingement
 Use “rock box” tank design if possible
 Launder bottom slope 10-15%

OUR CUSTOMERS

REFERENCES
Corn Sweetener
Archer Daniels Midland Company (ADM) Contact: Darryl Munsinger
400 West Erie Rd Phone: 507-537-2511
Marshall, MN 56258-2744
Cargill Inc. Contact: Ms. Adebola Durosawo
3201 Needmore Rd Phone: 937-237-2561
Dayton, OH 46414
Field Erected Tanks
M.L. Smith Jr., Inc. Contact: Moe Hansen
2330 Farmerville Hwy Phone: 318-255-4474
Ruston, LA 71213-1717
Kennedy Tank Contact: Paul Bolin
833 East Sumner Avenue Phone: 317-780-3528
Indianapolis, IN 46227

REFERENCES
Plating/Galvanizing
Walbridge Coatings Contact: David Swemba
30610 E Broadway Phone: 419-661-5952
Walbridge, OH 43465
Lacks Enterprises Contact: Ben Wesley
5460 Cascade Road SE Phone: 616-443-6087
Grand Rapids, MI 49546
IN Tek/IN Kote (Areclor-Mittal) Contact: James McGranahan
30755 Edison Road Phone: 574-654-1733
New Carlisle, Indiana 46552
Steel Processing
Steel Warehouse Contact: Jerry Czajkowski
2722 West Tucker Dr. Phone: 574-236-5100
South Bend, IN 46619
US Steel Contact: Samer Aweidah
600 Grant Street Phone: 412-433-5833
Pittsburgh, PA 15219 sraweidah@uss.com

REFERENCES
Power Plants
Duke Energy Contact: Russ Steinmetz
6293 Beaver Rd Phone: 513-467-4839
Rabbit Hash, KY 41091 russell.steinmetz@duke-energy.com
EON-US Contact: Charles Ransdell
820 W. Broadway Phone: 502-627-3299
Louisville, KY 40232
Hitachi America Limited Contact: William Knowles
50 Prospect Phone: 914-524-6700
Tarry Town, NY 10591
Big Rivers Electric (Coleman Station) Contact: Christa Lucas
4982 River Rd Phone: 270-844-6983
Hawesville, KY 42348
Duke Energy Progress Contact: Reggie Clay
1700 Dunnaway Rd. Phone: 336-597-6116
Semora, NC 27343 Reggie.Clay@pgnmail.com

REFERENCES
Mining Equipment
FLSmidth Salt Lake City Contact: Mark Nielsen
7158 South FLSmidth Drive Phone: 801-871-7936
Midvale, Utah, USA 84047 mark.nielsen@flsmidth.com
Weir Minerals Contact: Debra Switzer
2701 S Stoughton Rd. Phone: 970-665-9149
Madison, WI debra.switzer@weirminerals.com
Metso Minerals Industries, Inc. Contact: Betsy Day
240 Arch St. Phone: 717-849-7201
York, PA 17403
Eriez – Flotation Division Contact: Kris Barnes
7168 Honeyman St. - Unit 1 Phone: 604-952-2300
Delta, BC Canada V4G 1G1
URS Contact: Michelle Rodriguez
8181 E. Tufts Avenue Phone: 303-796-4719
Denver, CO 80237 michelle.rodriguez@urs.com

THANK YOU!
Doug Hardy, Sales Engineer • 800.959.0125 • DougHardy@Abtrex.com
Chuck Groom, Project Manager • 800.959.0125 • ChuckGroom@Abtrex.com
Keith Byars, President • 800.959.0125 • KeithByars@Abtrex.com
Please contact us for more information or questions
about today’s presentation.
www.Abtrex.com

Abtrex rubber systems and suppliers

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