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Mining Giant Machine KU800 - PRODEKO a.s., Bílina
Client
PRODECO, a.s. is a company focused on providing supplies and services primarily for surface mines in the energy sector. In addition to delivering its own giant machines and other equipment for surface mining, it offers thorough and comprehensive services tailored to customer requirements.
Problem
Water Leakage Through Roof Details of the High-Voltage Switchgear Roof on the Mining Machine During Rainfall
Detailed Description:
The roof covering consists of sheet metal panels with standing seam joints. Protruding above the roof surface are structures such as safety railings, technologies, ventilation penetrations, and access hatches. Rainwater drainage is sloped towards the edges of the roof covering.
Defects:
The roof exhibited various types of defects that compromised its integrity and led to water infiltration. Different types of leaks were primarily identified in areas where steel structures were embedded into the substrate. These areas lacked the original coating and were significantly affected by corrosion. Across the entire roof surface, areas with peeling original paint and varying degrees of corrosion were found, ranging from surface corrosion (powdery rust) to deep corrosion (pitting). Some standing seam joints were so severely damaged by corrosion that they caused substantial water leakage in these areas.
Solution
The client approached us in 2016 requesting a possible technical solution for repairing the roof of the high-voltage switchgear during the planned shutdown and maintenance of the mining giant machine.
The proposed repair process involved preparing and cleaning the substrate from all contaminants, particularly the layers of industrial grease that accumulate on the roof during the machine's operation.
The PLASTONIT REFLEX technology was used. This process begins with the application of an anti-corrosion coating with high adhesion as the first layer. In complex details and at points where the structure is embedded in the substrate, lamination technology was utilized. This involved placing a glass-lamination mat between two layers of PLASTONIT SILVET coating.
Result
This technical solution successfully prevented water leakage into the roof and significantly extended the lifespan of the metal panels by passivating corrosion products. The reflective final coating reduced thermal stress on the steel structure and minimized the dilation of the high-voltage switchgear roof. This also resulted in a reduction in internal temperatures within the switchgear.
