THICKNESS DOES MATTER

THE USE OF THICK LININGS IN INDUSTRIAL APPLICATIONS

Bharat Naik, Director Technical Services
Marty Seigel, Director of Sales
Michael Babiarz, Regional Manager
Phil Kennedy, Regional Manager
Rhino Linings USA, Inc.
Industrial Division
San Diego, California, USA
Abstract: While a coating is typically measured in
mils, a lining typically refers to an application of 1/16
inch or thicker. Certain industrial applications are best
served through the use of a thick lining with unique
physical properties that provide superior resistance
against abrasion, impact, chemicals, and corrosion.

INTRODUCTION TO THICK LININGS

Basic Benefits of Thick Linings Formulations
Although thinner coatings can be effective against
chemicals and corrosion, thick linings exhibit
toughness and flexibility that provides for additional
durability against impact and abrasion. They form a
non-porous monolithic layer that bonds permanently
with almost any substrate, providing abrasion and
impact resistance, corrosion prevention, and chemical
resistance. They will not crack, split, or delaminate
from extensive and repeated flexing of the substrate.
These versatile materials are applied in continuous
coats in order to achieve desired thickness, and
conform to virtually any shape to which they are
applied. There is no limit to the thickness that they
can be applied, and therefore the thickness of the
lining can be tailored to the specific requirements of
each particular application.
Chemical Characteristics of Thick Linings
Formulations
Although there are various formulations of thick
spray-on linings, discussion in this paper will
concentrate on elastomeric polyurethane linings.

Polyurethane refers to materials made with isocyanate

compounds containing the isocyanate (NCO) group.
The number of isocyanate groups distinguishes the
chemicals as mono-isocyanate (one group),
diisocyanate (two groups) or poly-isocyanate (three or
more groups).
In a typical two-component system, the diisocyanate
reacts with a resin that contains reactive hydrogen,
typically an OH group. The reaction forms a solid
polymer that exhibits the fundamental performance
properties of polyurethane linings.
Aliphatic polyurethanes are based on aliphatic
isocyanates (HDI and IPDI) and primarily polyester
and / or acrylic polyols. Aliphatic polyurethanes
provide the best UV resistance and color stability, but
they can be costly for most 100% solids applications.
They are usually used on exterior surfaces or for other
applications in which color stability is of key
importance, such as automotive and aircraft paints.
Aromatic polyurethanes are based on aromatic
isocyanates (MDI and TDI) and mostly polyether
polyols. Aromatic polyurethanes are less expensive
than aliphatic polyurethanes. Depending on their
formulation, aromatic polyurethanes can experience a
certain amount of color change after a few
days/months of UV exposure; however, their UV
resistance is greater than that of common epoxies. The
effect of UV exposure is primarily a surface
phenomenon and has relatively little impact on the
performance of the lining. Most 100% solids
polyurethane linings sold today are aromatic.

A related type of chemistry to polyurethanes that is

recently gaining use in the protective linings market is
polyurea. This material is created by the reaction of
isocyanates and polyamines (-NH2 group). The
isocyanates used for polyureas are similar to the ones
used for polyurethane linings. The extremely fast
reaction between the amine group and the isocyanate
group requires the use of high pressure spray
equipment for these materials. Although this paper
focuses on the use of polyurethane linings, Rhino
Linings has offered both types of chemistries to the
marketplace depending on the application involved.
100% solids polyurethane linings can range from very
soft, rubbery elastomers to rigid, ceramic-like systems.
In the rigid linings, chemical bonds are highly crosslinked, creating hard, dense systems with high
chemical and corrosion resistance. Rigid linings
normally have excellent adhesion and good abrasion
protection. They typically have lower impact
resistance than elastomeric polyurethanes and are
better suited for less flexible surfaces such as metals.
Elastomeric polyurethanes have a linear structure with
much less cross-linking, allowing them to elongate and
be elastic. These systems have superior impact
resistance and are particularly well suited for
protecting substrates that tend to move and flex. In
thinner linings, the chemical and corrosion resistance
of elastomers is typically lower than that of rigid
polyurethanes; however, when elastomers are applied
in thicker coats, chemical and corrosion resistance is
excellent.
The Historical Development of Thick Linings and
Rhino Linings USA, Inc.
The roots of the thick linings business are planted
firmly in the industrial sector, born out of the need for
a tough, resilient lining to protect the heavy equipment
in the mining industry of South Africa. This
equipment was constantly subject to the harshest
environment imaginable.
In the mid 1980s, Rhino Linings pioneered a sprayedon, industrial grade lining that protected this
equipment from corrosion in a wet and caustic
environment, as well as from the constant impact and

abrasion resulting from the rigors of the mineral

extraction process.
From those industrial roots, Rhino Linings expanded
into the US consumer market, ultimately becoming the
de-facto leader in the industry in pickup truck bed
linings. Rhino Linings has an international presence
with offices in Canada, Mexico, Germany, Japan, and
Australia, with customers in over 80 countries
worldwide. Over the past decade, Rhino Linings has
expanded the companys focus and has developed
unique formulations with specific physical properties
to address the rigorous and diverse requirements of the
commercial and industrial marketplace.
Rhino Linings manufactures and markets a complete
solution for thick linings applications, and is the
largest and most widely recognized manufacturer of
sprayed-on polyurethane linings in the world. Based
upon a rigid quality control process, Rhino Linings has
earned the ISO-9001 certification.
Rhino Linings currently serves industries such as
petrochemical, mining, manufacturing, material
handling, and foundries. The company also
participates with various military contracts on both the
OEM and application side of the industry. Rhino
Linings products contain no solvents or VOCs, and
the 100% solids formulation sets up completely inert,
making them environmentally friendly.
Thick Linings Classes
Polyurethane linings formulations are adjusted in order
for the lining to achieve the desired physical properties
for the specific application. Rhino Linings has
developed several classes of lining products which
provide excellent, long-lasting protection, and cover a
vast array of requirements for applications in the
industrial market. However, each class possesses
specific physical properties geared to satisfy different
service requirements of specific applications.
Class A
Class A polyurethane is the least cross-linked and has
the greatest elastomeric and elongation properties. It
is the most versatile and widely used class. It is used
to protect vehicles, building materials, equipment,
flooring, machine components, manufactured
products, secondary containment, storage facilities,

material processing components and countless other

surfaces.
Class A is the most flexible class, maintaining its
integrity under repeated flexing, regardless of film
thickness. It has excellent impact, abrasion and
corrosion resistance and provides the highest level of
skid resistance, sound deadening and vibration
absorption.

Class B Secondary Containment Application

Utility Vehicle Bed Lined with Class A Polyurethane

Class B
Class B polyurethane is slightly more rigid with higher
cross-linking than Class A. Its surface is slightly less
skid resistant, and although less than Class A, still
provides a reasonable level of impact and abrasion
resistance. It has better chemical resistance than Class
A and is effective as a sound reduction layer.
Class B is an ideal general purpose lining for
processing equipment and tanks requiring high
hydrolytic stability. It is also used as a protective lining
system for tanks, storage and other applications in
which a seamless flexible system is essential. It is a
very effective lining in food processing and
commercial kitchens, as well as a variety of secondary
containment applications.

Class C
Class C polyurethane is designed specifically for
chemical resistance. Although it has some flexibility,
it is the most rigid class with the highest cross-linking.
It is typically sprayed onto metal and concrete
surfaces, but can adhere to most substrates. The lining
provides excellent corrosion resistance and will not
deteriorate from most chemical attacks. Typical
applications include wastewater pipelines, wet wells
and treatment tanks.

Acid Tank Lined with Class C Polyurethane

THICK LININGS SELECTION CHOOSING THE

RIGHT LINING FOR THE JOB

Different Applications, Different Linings

The suitability of a specific type of lining for a
particular application can be determined by asking a

straightforward question: Do the physical

characteristics of the lining meet the performance
requirements of the application?
As such, a careful evaluation of the application
environment is required in order to prioritize and
balance the importance of the various physical
characteristics among lining choices. Products that are
produced with higher cross-linking result in a tighter
molecular structure, translating into greater material
hardness as measured with a Durometer on the ShoreD scale.
Physical
Property
Hardness (Shore D)

Class
A

Class
B

Class
C

35 5

55 5

75 5

1700-1900

2100-2200

3000-3500

325-375

50-80

15-20

783

n/a

n/a

10 -15

25 - 30

53

Tear Resistance (pli), Die C

140-150

200-250

170 - 180

Water Absorbtion (%)

< 1.6 %

< 1.6 %

< 0.5 %

Tensile Strength (psi)

Elongation (%)
Compressive Strength (psi)
Taber Abrasion Resistance (mg loss/1000 cycles)
CS17 Wheel; 1000 grams weight

Chart A - Physical Properties Vary Based Upon the Amount of

Cross-Linking. Cross-Linking increases from Class A to Class C.

In determining the appropriate lining for a particular

application, there is typically a trade-off. For example,
in order to obtain greater hardness and chemical
resistance, one must trade off flexibility and impact
resistance. In order to gain a softer, more non-slip
surface, one must trade off some level of chemical
resistance.
Lets review a case study of a particular application
and the methodology for choosing the appropriate
lining to meet the job requirements.
Granite Rock Quarry
A rock quarry was suffering significant maintenance
expenditures due to aggressive aggregate wear, erosion
and corrosion of their metal material chutes, sand
screws, end loader/dump beds, augers and conveyors.
Case Overview
Due to the extremely abrasive nature of granite rock as
well as the granite sand and dust resulting from the
mining process, it was affecting their equipment
anywhere materials were transported and/or changed
direction. Due to the high cost of these metal

components, their annual equipment replacement costs

ran well into six figures. In addition to the
replacement expense, there was significant downtime
while an equipment component was replaced. The
company estimated their down time and lost
productivity costs at a minimum of $800.00 per
minute.
Solutions Considered
The quarry had considered alternative solutions such
as mechanically fastened UHMW, rubber or
polyurethane sheet stock. These possible solutions
were eliminated as they lacked the ability to prevent
corrosion with a permanent bond and involved
significant time to repair or replace. The company
conducted an analysis of the costs of the UHMW
solution, and compared these costs to a thick linings
solution. The results of this analysis are shown in
Chart A.
Rhino Linings Tuff Stuff

Rubber alternative

No removal required. Clean, abrade, prime and

spraycast

Removal of worn rubber = 2 workers

approximately 1 hour or $50.00 / ft2

Not applicable; able to SprayCast onto any

object form no modifcation of object or
material required.

Attach new rubber stock (measure, cut, drill

mechanical attachment holes, lift and hold into
place).

Material = $108/ft2 @ 2 thick

Material = $36/ft2 @ 2 thick

Area = 2 ft2 / plate X 7 plates/chute X 6 chutes

Area = 2 ft2 / plate X 7 plates/chute X 6 chutes

Replacements / year = 3 (max)

Replacements / year = 15 (min)

Labor = $50.00 / hour X 2 workers

X 4 hours / chute
X 6 chutes
X 3 replacements / year (max)

Labor = $50.00 / hour X 2 workers

X 3 hours / plate
X 7 plates / chute
X 6 chutes
X 15 replacements / year (min)

Downtime @ $800 / minute = $48,000 / hour

Downtime 216 hours (allows 24 hours / 2
chutes)

Downtime @ $800 / minute = $48,000 / hour

Downtime = 1,890 hours (only accounts for
straight working time)

Chart B Cost Analysis Class A Lining to UHMW

Due to the extreme high volume of granite aggregate

handled in this plant, impact and abrasion were
considered the primary issues to address with the
solution.

Flotation is an important technique for separating and

concentrating valuable minerals and precious metals.
This technique is accomplished in many companies
through the use of a flotation cell, which is a chamber
that allows certain substances to bubble froth to the top
of a mineral suspension, while other materials settle
out of the bottom of the colloidal mixture. Chemicals
such as oils, limes, and sulfides are used in the
flotation process and act as collectors and frothing
agents to separate and concentrate the minerals.
11,000 Tons of Granite/day pass through Quarry Chutes

Choice of Lining for the Application

Since primary concerns were to address the impact and
abrasion of metal equipment, Class A polyurethane
lining was chosen for this application. The lining was
cast with a red wear layer on the bottom of the
metal, with a 1 black layer cast on top for a total
protective thickness of two inches.

Flotation Cell used in Mining and Mineral Processing

Red Wear Indicator Layer is Showing, indicating need to re-apply

the sacrificial top layer of polyurethane lining.

The resulting thick lining has provided excellent

protection against the aggressive abrasion from granite
rock and has maintained a seal over the metal
substrate, preventing the onset of corrosion.
As the sacrificial lining material wears down, the red
wear layer shows through, giving the plant operators
adequate time to prepare for re-application.
Flotation Cell Lining
Lets contrast the previous example with another
application from the mining and mineral processing
industry. In this case, we move from granite mining to
the precious metals mining industry.

The slurry material contained within a flotation cell is

not only caustic, but very abrasive, exposing bare
metal and thus making corrosion a significant problem.
Chemical wear is a problem for flotation cells as harsh
chemicals are often used in slurry to help separate fine
solids.
A thick lining provides positive return on investment
when considered against the alternative of a
mechanically fastened application or replacing the
base metal of the cell, which is constructed of
extremely expensive steel. In this companys case, a
flotation cell was prepped and lined with class B
polyurethane because of its wide spectrum of
properties that include both higher cross-linking as
well as durability against corrosion, abrasion, and
chemical wear.

much faster than a thick polyurethane lining. An

abrasion resistant thick lining was needed to guard
against both abrasion and chemical wear.

Flotation Cell prior to Lining Application

This specific company, as do many other companies,

originally lined their cells with urethane-lined steel
plates. The company would purchase these plates and
then weld them to the bottom of their flotation cells.
The weakness of the urethane-lined steel plate solution
is that the abrasive material being stirred around would
gradually corrode the steel welds holding down the
plates. Slurry would then make its way under the steel
plates and begin corroding the cell itself, rendering
their steel plate solution useless.

The company decided upon a thick spray-on

polyurethane lining for their flotation cell. The
application was specified to spray Class B
polyurethane at approximately 3/8 thick. This thick
polyurethane lining solved the companys wear
flotation cell wear problem. The company reported
that, as a result of applying the polyurethane lining,
maintenance costs and downtime were significantly
reduced. Based on extremely positive payback from
the lining implementation, the company specified
Class B spray-on polyurethane linings to be sprayed on
every flotation cell in their operation.
Frac Tank Lining
A frac tank is used in the oil drilling industry to open
new channels in the formation surrounding a
production well. Frac fluids (such as distillate, diesel
fuel, crude oil, dilute hydrochloric acid, water, or
kerosene) are pumped and forced out into the ground
under extremely high hydraulic pressure.
The pressure causes cracks to open in the underground
formation, and the fluid penetrates the formation
through the cracks. Sand grains, aluminum pellets,
walnut shells, or similar materials (propping agents)
are carried in suspension by the fluid into the cracks.
When pressure is released at the surface, the fracturing
fluid returns to the well but leaves behind the propping
agents to hold open the formation cracks to facilitate
the oil drilling process.

Flotation Cell during Application of Formula B

The company decided that a new solution was required

to protect this cell from corrosion and abrasion in the
flotation process. At first, they considered coating the
cell with a thin protective layer of epoxy. It was
determined however that a thin coating may require
several re-coatings per year and would not withstand
the abrasion that occurs within the flotation cell. Thin
coatings may have held up against chemical wear
alone, but with the added abrasion would wear down

The chemicals contained in frac tanks can be very

corrosive. Thick linings are a necessity for frac tanks
as these tanks can be very expensive to replace or
repair. In this case, Class C polyurethane was chosen
because of its high cross-linking and resulting
durability. Class C polyurethane is most chemical
resistant.
The picture below depicts a company that sprayed
their frac tank with Rhino Linings Class C
polyurethane. At the time, the tank was brand new.
Polyurethane was sprayed on at a thickness of 1/8. It
has been 2.5 years since the application was done and

the tank still has its original polyurethane. No reapplications have been needed.

to be the most practical and economical long term

solution for many applications.
Thick linings can extend the useful life of equipment;
reduce down time, and save money by reducing the
need for frequent repeat applications. When reapplication is necessary, it can be accomplished
efficiently with a minimum of downtime and labor
expense by limiting the re-application specifically to
the areas that show wear.
Finally, by matching the correct class of specific and
appropriate lining to the requirements of the
application, results are optimized and return on
investment is maximized.

Frac Tank Application of Class C Polyurethane

In another Rhino Linings frac tank application, Class

C polyurethane was sprayed onto the interior of their
frac tanks 6 years ago and has experienced a zero level
of failures. No re-applications have been needed on
their tanks. This shows the long lasting benefit of thick
coatings, as some thin epoxy coatings may have only
lasted 9-15 months in this application.
To test the strength of Rhino Linings thick
polyurethane linings, one company performed a pull
test. The company was unable to break the adhesion of
the polyurethane even after applying a 3,000 psi pull
test.
In both cases, sprayed on thick polyurethane linings
have helped to maximize business profitability by
making their tanks more reliable and less resistant to
chemical damage and corrosion.
SUMMARY & CONCLUSION
There are particular applications where, because of
specific requirements, a thick lining is the preferred
solution when compared to a thin coating. In these
types of applications, although both coatings and
linings may provide an adequate level of corrosion and
chemical resistance, thick linings protect the substrate
longer and provide better abrasion and impact
resistance than thin coatings. As illustrated by the
three case studies above, thick linings have been found

REFERENCES
(1) ANALYSIS OF FLOTATION FROTH
APPEARANCE
BY DESIGN OF EXPERIMENTS
Vesa Hasu, Jari Htnen, Heikki Hytyniemi
Control Engineering Laboratory, Helsinki University
of Technology
P.O.Box 5400, FIN-02015 HUT, Finland
tel. +358 9 451 5226, fax +358 9 451 5208,
E-mail: vesa.hasu@hut.fi
(2) Rhino Linings USA, Inc. Website
www.rhinoliningsindustrial.com
(3) U.S. Department of Labor Occupational Safety &
Health Administration www.osha.gov