Mining Industry

On-site machining, wear protection and component refurbishment for mining equipment

Mining and mineral processing equipment operates in some of the most demanding industrial environments.

Abrasive material, heavy mechanical loads, slurry, moisture, corrosion and continuous operation can gradually affect critical components and functional surfaces.

PR Rolls provides on-site machining, industrial coatings, surface restoration and workshop refurbishment for mining and mineral processing equipment.

Our capabilities include:

• On-site machining
• Industrial coatings and surface engineering
• Wear and corrosion protection
• Shaft and journal repair
• Bearing seat and bore restoration
• Grinding and dimensional restoration
• Line boring
• Measurement and alignment
• Field balancing
• Workshop refurbishment
• Dynamic balancing

The objective is to restore valuable equipment where technically appropriate, extend component lifetime and reduce unnecessary replacement.

Maintenance Challenges in Mining & Mineral Processing

Equipment exposed to continuous wear

Mining equipment is continuously exposed to conditions that can accelerate component deterioration.

Typical maintenance challenges include:

• Abrasive wear
• Erosion
• Corrosion
• Combined wear and corrosion
• Shaft and journal damage
• Bearing seat wear
• Worn or misaligned bores
• Surface damage
• Dimensional wear
• Misalignment
• Vibration and imbalance

A worn surface does not necessarily mean that the complete component needs to be replaced.

PR Rolls evaluates what has deteriorated, how much material has been lost and which geometry or surface properties need to be restored.

Inspect → Measure → Repair → Restore → Protect → Verify

On-Site Machining for Mining Equipment

Repair large components where they operate

Mining and mineral processing equipment can contain large components that are difficult, expensive or time-consuming to remove and transport.

PR Rolls brings portable machining technology directly to the mine, processing plant or maintenance site.

Depending on the application, on-site services can include:

• Turning
• Milling
• Line boring
• Drilling
• Grinding
• Grooving
• Honing and precision finishing

On-site machining can reduce the need for extensive dismantling and transportation while allowing damaged geometry to be restored directly at the equipment.

Instead of bringing the component to the machine tool, PR Rolls brings the machine tool to the component.

Wear Protection & Industrial Coatings

Engineer surfaces for abrasive operating conditions

Wear is one of the fundamental maintenance challenges in mining and mineral processing.

Abrasive particles, slurry, mechanical contact and flowing process media can gradually remove material from critical surfaces.

PR Rolls provides industrial coatings and surface engineering solutions for suitable components exposed to wear, erosion and corrosion.

Depending on the application, coating systems can be selected for requirements such as:

• Abrasive wear resistance
• Erosion resistance
• Corrosion resistance
• Combined wear and corrosion protection
• Dimensional restoration
• Application-specific surface properties

Carbide-based thermal spray technologies can provide highly wear-resistant functional surfaces for suitable mining applications.

The coating is selected according to:

Component + Wear mechanism + Process environment + Required surface function

Alternatives to Hard Chrome

Modern carbide coatings for suitable wear applications

Traditional hard chrome has historically been used for wear and corrosion protection on many industrial components.

However, conventional hard chrome electroplating can involve hexavalent chromium, Cr(VI) in the manufacturing process. This has increased interest in alternative surface technologies.

PR Rolls provides carbide-based thermal spray coatings that can be used as alternatives to hard chrome in suitable applications.

Depending on operating conditions, technologies based on HVOF and HVAF spraying can provide dense, hard and wear-resistant functional surfaces.

Potential applications can include:

• Shafts
• Sleeves
• Hydraulic components
• Pump components
• Valve components
• Bearing and sealing areas
• Other precision wear surfaces

The appropriate alternative must always be selected according to the component, operating conditions and required tolerances.

Shaft, Journal & Bearing Area Repair

Restore worn dimensions and functional surfaces

Shafts, journals and bearing areas can deteriorate through wear, corrosion, fretting, bearing failure or mechanical damage.

Replacing the complete component because of localised damage is not always necessary.

PR Rolls can restore suitable areas through a combination of:

• On-site machining
• Grinding
• Metallic coating
• Brush plating
• Dimensional restoration
• Precision finishing

The damaged area can be rebuilt and machined back to the required dimensions.

This approach can preserve valuable shafts and other machine components when the underlying structure remains suitable for continued operation.

Line Boring & Bore Restoration

Restore geometry and alignment in large equipment

Bearing housings, pivot points and other aligned bores can gradually lose their correct dimensions through wear or mechanical damage.

PR Rolls provides on-site line boring and bore restoration for suitable mining and mineral processing equipment.

Applications can include:

• Bearing housings
• Large machine bores
• Pin and pivot bores
• Gearbox-related structures
• Aligned bore systems
• Other large mechanical interfaces

Where necessary, worn areas can first be rebuilt before final machining restores the required geometry.

Pumps, Valves & Slurry-Exposed Components

Restore equipment exposed to wear, erosion and corrosion

Pumps and valves used in mineral processing can operate in environments where abrasive particles and process media place demanding requirements on component surfaces.

Localised wear or erosion can affect the performance of an otherwise serviceable component.

Depending on condition and application, PR Rolls can provide surface restoration for suitable:

• Pump shafts
• Sleeves
• Seal areas
• Bearing areas
• Valve components
• Other precision process components

Repair can combine machining, coating or plating and precision finishing.

The objective is to restore the functional area while retaining the existing component where technically appropriate.

Hydraulic Component Refurbishment

Restore worn surfaces in heavy-duty hydraulic equipment

Hydraulic systems are widely used in heavy industrial machinery.

Piston rods, shafts, bearing areas and other precision surfaces can be affected by wear, scoring, corrosion and seal-related damage.

PR Rolls can evaluate suitable hydraulic components for:

• Machining
• Grinding
• Dimensional restoration
• Functional coating
• Precision finishing

Modern thermal spray coating technologies can also provide alternatives to traditional hard chrome for suitable hydraulic applications.

Grinding & Dimensional Restoration

Restore geometry as well as the surface

A coating alone cannot correct every maintenance problem.

Where wear has affected component geometry or dimensions, machining or grinding may be required before a functional surface can be restored.

PR Rolls can combine:

Measurement → Machining → Grinding → Dimensional restoration → Coating → Precision finishing

This integrated approach is particularly useful when both geometry and surface properties have deteriorated.

Measurement, Alignment & Field Balancing

Identify the cause before repairing the symptom

Not every equipment problem originates from surface wear.

Misalignment, runout and imbalance can contribute to vibration, uneven loading and accelerated component deterioration.

PR Rolls provides measurement, alignment and field balancing for suitable mining and mineral processing equipment.

These services can be used to:

• Determine existing geometry
• Identify alignment deviations
• Establish machining references
• Measure runout
• Support installation and maintenance
• Correct imbalance
• Verify repaired equipment

Combining measurement with machining and surface restoration helps ensure that maintenance addresses the underlying mechanical condition.

Rotating Equipment Maintenance

Restore reliable operation

Mining and mineral processing plants contain numerous rotating components where geometry, surface condition and balance interact.

Depending on the equipment, PR Rolls can combine:

• Inspection and measurement
• Shaft and journal restoration
• Machining
• Grinding
• Surface engineering
• Alignment
• Field balancing
• Workshop dynamic balancing

Addressing these factors together can be more effective than treating individual symptoms separately.

Workshop Maintenance & Refurbishment

Complete restoration for removable components

Not every mining component needs to be repaired on-site.

Suitable removable equipment can be refurbished at the PR Rolls workshop.

Depending on the component, refurbishment can include:

Inspection → Measurement → Mechanical repair → Machining → Grinding → Surface restoration → Coating → Precision finishing → Dynamic balancing

This provides two complementary maintenance routes:

Large or installed equipment → On-site repair

Removable components → Workshop refurbishment

The appropriate method depends on component size, condition, tolerances and maintenance requirements.

Typical Mining & Mineral Processing Applications

PR Rolls' technologies can be applied to suitable equipment throughout mining and mineral processing operations.

Potential applications include:

• Shafts and journals
• Bearing seats and housings
• Bores and aligned bore systems
• Drums and rotating equipment
• Rolls and cylinders
• Pumps and pump components
• Valve components
• Hydraulic components
• Sleeves and sealing surfaces
• Large machine components
• Other wear-exposed process equipment

The deciding factor is not simply what the component is called.

The key question is what has deteriorated and which dimensions, geometry or surface properties need to be restored.

Planned Shutdown & Emergency Repairs

Coordinate multiple maintenance operations

Mining operations often depend on planned maintenance windows where several critical repairs need to be completed within a limited timeframe.

PR Rolls can combine multiple specialist services during the same project:

Inspection + Measurement + Machining + Grinding + Surface restoration + Alignment + Balancing

On-site capabilities are particularly valuable when removing and transporting large components would consume a significant part of the available maintenance window.

The same capabilities can support unexpected repairs where component damage needs to be evaluated and restored efficiently.

Repair, Refurbish or Replace?

Make the decision based on actual component condition

Heavy wear does not automatically mean that the complete component has reached the end of its service life.

Depending on its condition, the appropriate maintenance strategy may be to:

Repair – correct local damage.

Machine or grind – restore geometry and dimensions.

Restore – rebuild a worn functional area.

Recoat – provide a renewed wear- or corrosion-resistant surface.

Refurbish – restore the complete component.

Upgrade – change the functional surface for demanding operating conditions.

Replace – when continued restoration is no longer technically appropriate.

This condition-based approach helps utilise the remaining value of existing mining equipment.

Why PR Rolls for the Mining Industry?

Combine machining with surface engineering

Mining equipment problems frequently require more than one maintenance technology.

A worn shaft may require dimensional restoration and grinding. A damaged bearing housing may require line boring. A slurry-exposed component may require both machining and a renewed wear-resistant surface.

PR Rolls combines:

On-site machining + Grinding + Line boring + Industrial coatings + Dimensional restoration + Measurement + Alignment + Field balancing + Workshop refurbishment

This allows the maintenance solution to be designed around the actual component and failure mechanism.

The objective is not simply to repair visible damage, but to restore the geometry and functional surface required for continued operation.

Frequently Asked Questions About Mining Industry Services

What services does PR Rolls provide for mining companies?
PR Rolls provides on-site machining, grinding, line boring, industrial coatings, dimensional restoration, shaft and journal repair, measurement, alignment, balancing and workshop refurbishment for suitable mining and mineral processing equipment.

Can large mining equipment be repaired on-site?
Yes. Where component geometry, accessibility and site conditions allow, portable machining equipment can be used to restore large components directly at the mine or processing plant.

Can worn shafts and journals be restored?
Yes. Suitable shafts and journals can often be restored using machining combined with metallic coating, brush plating or other dimensional restoration technologies.

Does PR Rolls provide wear-resistant coatings?
Yes. PR Rolls provides industrial surface engineering solutions, including carbide-based thermal spray coatings for suitable applications exposed to abrasive wear, erosion and corrosion.

Can PR Rolls provide alternatives to hard chrome?
Yes. Carbide-based HVOF and HVAF thermal spray technologies can provide alternatives to traditional hard chrome plating in suitable applications. The correct coating depends on component geometry, operating conditions and required surface properties.

Does PR Rolls service pumps and hydraulic components?
PR Rolls' surface engineering and refurbishment capabilities can be applied to suitable pump, hydraulic and other process equipment components, depending on the component and required repair.

Does PR Rolls provide field balancing?
Yes. Field balancing can be used for suitable rotating equipment where imbalance contributes to vibration or unreliable operation. Removable components can also be dynamically balanced at the workshop.

Restore Critical Mining Equipment. Extend Component Lifetime.

Mining equipment operates in an environment where wear is unavoidable – but premature replacement is not always the only solution.

PR Rolls combines on-site machining, wear-resistant coatings, grinding, dimensional restoration, line boring, measurement, alignment and component refurbishment to restore suitable mining and mineral processing equipment.

From shafts and bearing areas to pumps, hydraulic components and large rotating equipment, the maintenance strategy begins with understanding the actual condition and deterioration mechanism.

Inspect → Measure → Restore → Protect → Verify → Return to production