For many bulk handling operations, transfer chute maintenance is an unavoidable part of every shutdown. Wear liners require constant attention, temporary repairs consume valuable labour, and maintenance teams are often forced to focus on keeping assets operational rather than improving long-term reliability.
One major iron ore export port in Western Australia faced exactly this challenge.
A critical transfer chute, which had been in operation for more than 30 years, required ongoing maintenance at every 14-week shutdown. Originally fitted with studded Ni-Hard liners, the chute had become increasingly maintenance-intensive over time. Due to the limited duration of planned shutdowns, maintenance teams relied heavily on ceramic filler repairs to address wear damage and keep the chute operational.
While these repairs provided a short-term solution, they required rework during every shutdown, consuming valuable maintenance resources and exposing personnel to the safety risks associated with working inside transfer chutes.
Breaking the Cycle of Temporary Repairs
Seeking a more sustainable solution, the site replaced the existing chute with a new steel chute body fitted with Magnefast™ 95% aluminium oxide ceramic liners. The system was specifically selected to:
- Extend liner service life
- Reduce maintenance frequency
- Simplify future liner replacements
- Eliminate hot work requirements
- Improve shutdown efficiency and safety
An additional advantage of the Magnefast™ system is the ability to quickly rotate or reposition wear panels, allowing maintenance teams to maximise liner life without major intervention.
Performance After 6 Million Tonnes
After processing 6 million tonnes of material, the Magnefast™ lining system was inspected during a planned shutdown and showed exceptional wear performance. The highest wear areas recorded only 3–4 mm of wear, while the majority of the chute exhibited less than 1 mm of wear.
Further inspection confirmed no visible corrosion on the chute wall and no signs of deterioration within the magnetic fastening system, highlighting the durability and long-term reliability of the solution.
Key results include:
✅ 600% Increase in Service Life
✅ Maintenance-free Operation for Six Shutdowns
✅ Quick and Easy Panel Replacement in Under One Hour
✅ Reduced Shutdown Duration and Maintenance Costs
Rethinking Transfer Chute Maintenance
The result wasn’t the wear performance itself, but the ability to redirect shutdown time away from recurring chute repairs and towards higher-value maintenance activities.
If you’re still patching chutes every shutdown, it may be time to rethink the system. Contact Elastotec to learn how Magnefast™ wear panels can help extend service life, reduce shutdown time and improve maintenance safety.
