When standard rubber or steel plates wear out in a matter of weeks, and each downtime due to a breached lining threatens to disrupt the production schedule, a solution that lasts much longer is needed. Polyurethane lining offers wear resistance 10 times greater than rubber, maintains functionality in a range from -60 to +100 °C, and provides economic benefits by reducing repair frequency. In this article, we explore why polyurethane lining has become the industry standard for abrasive units, how to correctly select hardness and design, and which units can be effectively protected with polyurethane plates.
Why Polyurethane Lining is the Optimal Choice
Polyurethane lining combines high wear resistance (10 times that of rubber) with elasticity, which absorbs impacts and resists abrasives. Thanks to the material’s resilience, particles are deflected rather than cutting into the surface, minimizing groove and micro-crack formation.
In real-world applications, such as chutes or hoppers where abrasive materials pass through, polyurethane lining retains its shape and function many times longer than rubber or steel counterparts. Traditional materials either wear out quickly or transmit impacts to the metal structure, causing vibrations and noise.
Hardness for lining is selected in the range of 80-95 Shore A: this provides sufficient rigidity to resist wear while maintaining essential elasticity. For units where geometric stability is crucial, polyurethane with hardness up to 70 Shore D is used, but under abrasive conditions, Shore A remains the standard. This ensures polyurethane protects the unit from chipping, corrosion, reduces noise, and extends maintenance intervals in challenging conditions, from metallurgy to mining.
Comparison with Rubber, Steel, and Caprolon: Figures and Performance
According to the DIN 53516 abrasion test, polyurethane (TIMOL) has a rating of 20-45 mm3, while SBR rubber is 100-200 mm3, caprolon is 30-90 mm3, and steel suffers significant wear under abrasives, though it lacks a standardized abrasion rating. Notably, even specialized rubber (NBR, EPDM) falls short of polyurethane in resource efficiency when working with quartzite, ore, sand, or grain.
| Material | Abrasion (DIN 53516), mm3 | Working Temperature, °C | Density, g/cm3 | Tensile Strength, MPa | Hardness (Shore) |
|---|---|---|---|---|---|
| Polyurethane (TIMOL) | 20-45 | -60…+100 | 1.05-1.25 | 25-60 | 50A-70D |
| SBR Rubber | 100-200 | -40…+80 | 0.94-1.1 | 8-20 | 40A-80A |
| NBR Rubber | 80-150 | -30…+100 | 1-1.3 | 10-25 | 40A-90A |
| Caprolon (PA6/PA66) | 30-90 | -40…+100 | 1.13-1.15 | 60-85 | 75D-85D |
| Structural Steel | , | -40…+500 | 7.7-7.9 | 370-700 | 120-250 HB |
| Wear-resistant Steel Hardox | , | -40…+250 | 7.8-7.85 | 1250-1600 | 370-540 HB |
Polyurethane not only reduces repair costs but also protects units from corrosion and chipping. In practice, rubber loses thickness 3-5 times faster (100-200 mm3 compared to 20-45 mm3 for polyurethane), and steel inserts, especially in screens or gravity pipes, quickly wear out and require replacement due to local defects. Caprolon may outperform in some abrasion cases (30-90 mm3) but lacks the elasticity of polyurethane, which is critical for units with dynamic impacts.
Where Polyurethane Lining is Used
Polyurethane plates, sheets, and special parts are used in 12 real industries, including mining and metallurgy, mechanical engineering, oil and gas, railway transport, pipe manufacturing, food, and light industry. The most in-demand units are chutes, hoppers, gravity pipes, screens, and screening parts, lining plates for support surfaces, concrete mixer scrapers, and conveyor belt protection.
In the mining industry, polyurethane lining is installed on chutes that transport rock with a lot of dust and abrasives, hoppers for ore or coal where material falls from great heights. In metallurgy, in gravity pipes and chutes for aggressive slurries. In the food industry, for transporting bulk products (sugar, grain) where inertness to most chemicals and the absence of product contamination are required.
Plates are mounted with bolts, embedded plates, or adhesives with high adhesion to metal. For units with increased vibration, flexible mounting schemes are used, allowing the plates to “play” with the structure, preventing delamination and chipping.
Check out the list of typical lining products in the polyurethane products catalog.
How to Choose the Hardness and Design of Lining
For units under abrasive wear, polyurethane with a hardness of 80-95 Shore A is recommended. This range provides a balance between wear resistance and elasticity, allowing the material to absorb impacts and deflect abrasive particles, reducing wear depth. Using rigid grades (Shore D) offers no advantages in wear resistance, as the material loses elasticity and chips under abrasives.
The thickness of the lining is determined by the type of flow, frequency of impacts, abrasive fraction, and unit geometry. For chutes and hoppers, typical plate thickness ranges from 10 to several tens of millimeters; for screens and sieves, thinner sheets that adapt to the working load. Installation is carried out on a cleaned and degreased surface, which is critical for the longevity of the adhesive layer.
Engineer’s Tip: For hoppers with strong abrasive flow, always choose polyurethane with a hardness of 85, 95 Shore A. Do not aim for maximum rigidity; resilient polyurethane absorbs impact and lasts longer than rigid plastics or steel, which chip under load.
In conditions where the lining is subjected not only to abrasion but also to aggressive environments (oils, acids), polyurethane maintains property stability across the entire working temperature range, from -60 to +100 °C. This allows its use in transport units outdoors, in port facilities, and elevators.
Manufacturing Technology of Lining at TIMOL Factory
The production of polyurethane lining at the TIMOL factory is carried out by the free casting method. This technology allows for the production of parts of any complexity, from standard plates to products based on individual drawings or unit samples. The customer can provide a technical task with dimensions and mounting points, and the factory will produce both single and serial batches.
Free casting results in seamless products with uniform density and no pores. This is critical for lining, as even a minor defect in the material quickly becomes a point of failure under abrasives. At the TIMOL factory, modern equipment is used for casting plates, scrapers, sheets, gravity equipment, as well as conveyor parts, wheels, and rollers. All stages, from surface preparation to final mechanical processing, are performed under the technologist’s control. For customers without ready drawings, the factory can measure the unit or develop a project for the task.
Learn more about the material and technology in the reference information section.
Practical Aspects of Operation and Maintenance
Operating polyurethane lining significantly simplifies the technical maintenance of units. There is no need for weekly thickness checks, as with steel, or monthly plate replacements, as with rubber. A periodic visual inspection is sufficient, and replacement is only done at points of maximum wear. In case of local damage, repairs are made by replacing individual plates or lining sections, reducing downtime and maintenance costs.
A longer service life is achieved not only through the properties of polyurethane but also through the correct selection of thickness, hardness, quality installation, and adherence to surface preparation technology. In most cases, lining lasts 10 times longer than rubber, allowing maintenance to be planned on a quarterly or even annual basis.
A wide selection of sizes and shapes (plates, sheets, scrapers, custom parts) ensures full compatibility with the unit, and the TIMOL factory manufactures products according to drawings or samples.
Conclusion: How to Order Polyurethane Lining for Your Unit
Polyurethane lining is a real way to reduce repair costs and equipment downtime. The material is used in 12 industries, has wear resistance 10 times greater than rubber, withstands temperatures from -60 to +100 °C, and is suitable for both standard and unique units. The TIMOL factory will manufacture lining according to your drawing or sample, help select the hardness and design, and suggest the optimal installation method. Contact us through the contact form or view the product catalog for consultation, calculation, and ordering.