Choosing the Right Wear-Resistant Material for Your Industry Needs

In industries like mining, aggregate, and construction, equipment doesn’t just work hard—it takes a beating. Constant exposure to abrasion and corrosive elements—think of the environment in cement plants—can lead to excessive wear, costly downtime, and frequent repairs. That’s where wear-resistant materials play a crucial role.

Selecting the right wear-resistant material isn’t just about protecting your equipment—it’s also about extending service life, reducing maintenance, and ensuring your operations run efficiently and cost-effectively.

Understanding Wear-Resistant Materials

Wear-resistant materials are engineered to endure punishing, high-friction environments, whether from sliding, scraping, or abrasion. Their purpose is twofold: to reinforce equipment before damage occurs and to simplify repairs (to get you back up and running faster) when wear sets in.

These materials are critical in operations exposed to:

• Abrasion (from dust, sand, or minerals)
• Corrosive environments (chemicals, acids, moisture)
• Extreme temperatures (found in kilns, dryers, and crushers)

Common wear-resistant options include epoxies, ceramics, hardened steels, polyurethanes, and composite materials—and each type comes with different advantages depending on the application.

Explore some of the most popular wear-resistant coatings in our blog, Popular Types of Wear-Resistant Coatings.

Industry-Specific Needs and Considerations

Every industry faces unique wear challenges, so wear-resistant material choice varies across sectors:

Mining

• Constant exposure to abrasive ore, chemicals, and high-speed flow
• Requires resistance to both mechanical wear and chemical attack

Aggregate

• Materials like gravel and crushed stone cause impact and wear from friction
• Durability and corrosion resistance in harsh environments are key

Construction

• Equipment needs to be cost-effective, durable, and easy to maintain
• Must perform in unpredictable outdoor and job site conditions

How to Choose the Right Material

Selecting the right wear-resistant material begins with a detailed understanding of your operating environment. Here are three simple steps to choosing the right wear-resistant material for your industry needs:

1. Assess Your Conditions

• Are you dealing with wet or dry abrasion?
• Is there constant impact or sliding friction?
• What temperatures or chemicals are present?

2. Evaluate Material Properties

• Consider the hardness, toughness, corrosion resistance, and high- or low-impact performance
• How easy is it to apply or repair?

3. Balance Longevity and Cost

• Long-lasting materials may have a higher upfront cost but lower total cost of ownership
• Look for products that minimize downtime and simplify labor needs

Copps Solutions in Action: Armor Plate Wear Compound

At Copps Industries, we’ve formulated a line of Armor Plate Wear Compounds specifically for industries facing extreme wear conditions. One standout product is our Armor Plate Wear Compound – FC-K-038, a two-component, ceramic bead-filled epoxy system built for high abrasion and chemical resistance.

Common Uses:

• Pump casings
• Slurry lines
• Pipe elbows
• Chutes and cyclones
• Coal breakers and pulverizers

Key Advantages:

• Outstanding slide and impact resistance due to bead matrix design
• Broad chemical resistance
• Non-sagging application for vertical and overhead surfaces
• Easy to mix and apply with a fast cure time
• Competitive pricing for cost-effectiveness

• Best for time-sensitive applications where quick curing is critical.

An Example of Customer Success: Fluid Bed Dryer Repair

One of our customers in the frac sand industry, running production 24/7, was struggling with excessive wear on the feed end of their fluid bed dryer.

Previous Fix: Cutting and welding AR plate—time-consuming and labor-intensive

Copps Solution: Applied Armor Plate High Temp Ceramic directly to worn surfaces. The fast-curing epoxy was easy to mix and trowel into place, significantly reducing labor time and getting the equipment back online faster.

Copps Industries: Your Source for Wear-Resistant Solutions

Whether you’re operating in mining, aggregate, or construction, selecting the right wear-resistant material can make or break productivity at your plant or job site. At Copps Industries, we understand the demands you face in extreme environments and offer proven solutions that reduce downtime, extend equipment life, and support efficient maintenance.

Not sure which material is right for your operation? Reach out and we’ll help you find the best solution to meet your wear-resistance needs in any industry.

The Future of Composites in Construction: Innovations to Watch

The construction industry is evolving, but when it comes to composites, innovation isn’t just about new materials—it’s also about better applications. While composites have been used in construction for decades, the industry continues to optimize their use for greater durability, efficiency, and sustainability.

Composite solutions like structural reinforcement and pipe repair are helping extend the lifespan of infrastructure, minimize material waste, and improve cost-effectiveness. In this blog, we’re exploring cutting-edge applications and highlighting how composites continue to revolutionize the industry.

Composite Strengthening Systems (CSS)

Aging infrastructure is a growing concern across many industries. Composite Strengthening Systems (CSS) provide efficient and effective solutions for reinforcing and retrofitting aging, damaged, or overloaded concrete, masonry, steel, and timber structures. Instead of costly demolition and reconstruction, CSS extends the lifespan of structures, reduces material waste, and minimizes downtime for businesses and municipalities.

Why Use Composite Strengthening Systems?

Compared to traditional reinforcement methods, CSS offers:

• Structural Reinforcement: Composite strengthening systems deliver significant flexural, axial, or shear strength gains without adding weight or bulk.
  
• Speed & Ease of Installation: These systems are lightweight and easy to apply, making repairs significantly faster.
• Cost Savings & Minimal Downtime: Composite strengthening systems can often be installed without taking structures out of service, which reduces prep and labor costs and minimizes downtime.
• Real-World Application: Restoring Concrete Pillars Without Disrupting Operations

Many cities and businesses face challenges with aging parking structures, bridge supports, and load-bearing beams. Consider a parking deck experiencing wear and corrosion due to increased vehicle loads. Traditionally, reinforcement would require costly demolition and extensive downtime. Not anymore. Now, crews can use carbon fiber wraps to strengthen critical pillars, allowing the structure to remain open while its integrity is restored

Carbon Fiber Pipe Repair & Manufacturing

Across the globe, millions of miles of pipelines transport water, crude oil, gas, and more. Over time, these critical infrastructures deteriorate due to corrosion, cracking, and manufacturing flaws. Instead of never-ending maintenance and repair, advancements in carbon fiber reduce costs, minimize downtime, and deliver more effective solutions.

Why Use Pipeline Carbon Fiber Wraps?

Carbon fiber is a cutting-edge solution that offers:

• Cost-Effective, Long-Term Repairs: Unlike metal repairs, which are susceptible to rust and degradation, carbon fiber materials offer long-lasting corrosion resistance.
  
• Cost Savings & Minimal Downtime: Every day a pipeline is down represents a potential loss of $2 million or more in revenue. Carbon fiber repairs allow for faster application and reduced downtime compared to traditional metal replacements.
  
• Customizable Solutions: Carbon fiber wrap materials can be tailored based on pipe pressure, temperature requirements, and external environmental factors.

Beyond maintenance, carbon fiber has also been integrated into new pipeline manufacturing. Compared to traditional metal piping, carbon fiber offers lighter, stronger, and corrosion-resistant solutions. Each composite pipe is customized based on industry requirements, including:

• High-Temperature Performance (High Tg Materials): High Tg epoxy solutions are capable of withstanding extreme heat without requiring oven curing, allowing for safer, more efficient field repairs.
• Regulatory Compliance: Composites deliver the tailored solutions many industries require to meet safety and performance standards.

Solutions from Copps Industries

Copps Industries provides high-performance structural strengthening solutions that enhance the durability and longevity of critical infrastructure.

Fast Structural Strengthening TB-A-018.B-425

• Best for time-sensitive applications where quick curing is critical.
• Ideal for load-bearing structures that require reinforcement while keeping operations running.
• Works with carbon fiber fabric to provide high-strength adhesion, ensuring long-lasting structural integrity.

Slow Structural Strengthening TB-A-018.B-435

• Designed for applications requiring extended working time, allowing for precise placement and saturation.
• Provides exceptional bond strength and durability, making it a go-to solution for structural repairs.

Tailored Solutions from Copps Industries

• In addition to these off-the-shelf solutions, Copps specializes in custom resin systems designed to meet the unique needs of each customer and your specific industry applications and requirements.

The Long-Term Benefits of Composites in Construction

Beyond delivering speed and ease in specific applications, composites offer long-term advantages that benefit the construction, transportation, and energy industries.

• Reducing Material Waste: Rather than tearing down and rebuilding, composite repairs extend the lifespan of existing structures. Less demolition means lower environmental impact, less downtime, and cost savings.
• Energy Efficiency & Lightweight Construction: Composites are lighter than traditional materials like concrete and steel, lowering transportation and installation costs.
• Improving Safety in the Field: New solvent-free composite solutions reduce hazards for workers, improving overall health and safety conditions on job sites.

Copps Industries: Your Partner in Innovation

While the use of composites in construction isn’t new, their applications continue to evolve and improve efficiency. With composite strengthening systems, advanced pipeline repair solutions, and high-performance epoxy formulations, composites are making construction faster, stronger, and more cost-effective.

The future of construction isn’t about discovering the next material—it’s about taking the materials we have to the next level. At Copps Industries, we provide custom epoxy solutions for nearly any application. For more information about our existing line-up of solutions or tailored formulations, contact us and request a quote.