matrox lining e

Matrox®

Lining systems for optimizedbulk material handling

Thermoplastics

01/2014

Matrox® gives you a lead!

Economic advantagesCompared to steel, Matrox® has considerableeconomic benefits.

• Lower costThe cost for lining an existing bin withMatrox® is only about one third of the cost forconstruction steel.

• Lower weightFor example, for the refurbishment of a 200m2

steel bin, re-lining it with Matrox® wouldachieve a reduction in weight of almost threetons compared to the standard method ofwelding steel sheets (S235JR) (see table).Matrox® reduces the load on the structure andmakes installation work much simpler.

• Longer life spanThe life span of Matrox® is substantially longerthan that of conventional construction steel.In the sand-slurry wear test, Matrox® achieveda value of 80 which is 46% better than that ofsteel at 150 (S235JR).(See p. 9 Estimated wear life).

The Matrox® range are polymer engineeringplastics that solve the problems of friction,wear and the flow of material in many sectorsof the industry.An exceptional low friction surface, outstan-ding wear resistance, high impact strength,excellent chemical resistance and superiorperformance in demanding applicationscharacterize the key properties of the product.

Röchling –outstanding competenceRöchling Engineering Plastics is a world-wideleader with more than 90 years of experiencein the development and production of semi-finished products made of engineering plasticsfor the capital goods industry.In close co-operation with our customers wedeveloped a range of Matrox® grades that aretailored to the different lining applications withspecific requirements.Highly qualified employees, superior materialdevelopment, state-of-the-art productionfacilities, laboratories and a certificated qualitymanagement system are the basis for the highquality and economic efficiency of the products.Our excellent reputation among the world’sleading flow consultants and engineeringexperts in the field of bulk solids flow has beenachieved by earning respect based on providingthe industry with unmatched consistent,reliable solutions to flow problems.

Matrox®

The new formulation of Matrox® has specificallybeen developed for the bulk material hand-ling and mining industry to reduce the typicalflow problems of bulk solids in bins, hoppers,chutes, truck beds and other applications.However, every application makes its ownspecial demands on the lining material. In orderto meet these, Röchling Engineering Plasticshas cooperated closely with specialists andusers in modifying tried and tested plasticmaterials for widely varying fields of use.The products of the Matrox® range combinethe best surface friction qualities with abrasionresistance not only to promote bulk materialflow but also to withstand the abrasionresistance of flowing bulk materials in ruggedapplications under different environmentalconditions.The Matrox® grades are based on a specificformulation of Ultra-High-Molecular WeightPolyethylene (PE-UHMW/PE 1000) that hasbeen developed for the use as a lining-materialeither in new construction or as a retrofit.

2 | Röchling Engineering Plastics

Material Specific gravity Weightthickness thickness g/cm3 for 200 m2 [kg]

Steel 3 mm 7.85 4,710

Matrox® 10 mm 0.93 1,860

Weight reduction with Matrox® 2,850 kg ~ 60%

Typical applications

Relative volumetric wear accordingto the sand-slurry process

In the sand-slurry test, a mixture of sand andwater is used to test the resistance to abrasionof a test sample compared to a defined referencematerial of PE-UHMW with a molecular weightof 5 million g/mol to which a fixed value of100 is assigned. The volume lost by the testsample during the test is then stated as an

index compared with that of the referencematerial. The lower the value achieved, thebetter the resistance to abrasion.

Röchling Engineering Plastics I 3

The products of the Matrox® range are usedin a wide variety of industries that handlebulk materials from the mining level up to andincluding the final processing or use of theproduct. Changes in moisture and particle sizeaffect the product’s flowability. Traditionalsteel surfaces become rough or corrodedcausing the bulk material to stick to the steel.The problems deteriorate and productivity andquality control are compromised.

Mining• Off-road truck bed liners• Shovel liners• Hopper liners• Chute liners• Scrapers• Stacker/Reclaimer bucket liners• Dragline bucket liners• Front-end loader buckets

Transportation• Ship holds• On-road truck bed liners• Railcars

Storage and Handling• Silos, bins, bunkers• Reclaim hoppers• Truck dump hoppers• Rail dump hoppers• Vibratory feeder pans• Receiving Hoppers• Dozer Blade Liners• Slider beds• Skirting• Belt scrapers

Processing• Day bins• Surge bins• Batch hoppers• Storage silos and bins• Hoppers• Chutes• Feeders• Screw conveyors

Bulk Materials handled• Coal• Iron Ore• Copper Concentrate• Clay• Limestone• Soda Ash• Chemical Powders• Nickel Ore• Peat• Synthetic Gypsum• Kaolin Clay

• Potash• Salt• Silica Sand• Soap Detergent• Wood Chips• Zinc Concentrate• Phosphate• Dust• Talc• Bauxite

Matrox®

Abrasion index350

300

250

200

150

100

50

0Steel S235JR Aluminium


The Matrox® range of products

Matrox®

Matrox® is the classic lining materialin our range and has general charac-teristics of a very high standard.Matrox® has a very low coefficient ofsliding friction which is particularlyimportant for the bulk transportand storage of glutinous or tackymaterials.

In the field of lining technology, the name Matrox® stands for highestquality with regard to resistance to wear and low sliding friction.In order to meet the demanding requirements of the bulk-goods industry,Röchling Engineering Plastics KG has cooperated with bulk-goods

experts and users in developing more lining materials which are ideal foruse in many different fields of application. These members of the Matrox®

product family are: Matrox®, Matrox® U 110, Matrox® SE, Matrox® EX 60,Matrox® SI 12, Matrox® X, Matrox® FC and Matrox® PUR.

Characteristics• Very low coefficient of sliding

friction• Very high resistance to wear and

abrasion• High notched-bar impact strength• Very low water absorption• High resistance to chemicals• High resistance to temperature

Fields of application• Transport industry• Truck bed lining• Bin and hopper linings

Matrox® U 110This material has the characteri-stics necessary for transporting hotbulk goods such as tar or asphalt.Matrox® U 110 contains a number ofadditives which allow the materialto be used for longer periods oftime at temperatures up to 190°C.When planning linings for bulksolids with temperatures as highas this, the thermal expansion ofthe material has to be taken intoaccount at thedesign stage.

Characteristics• Very high temperature stability• Low coefficient of sliding friction• High resistance to abrasion• Contains additives which inhibit

oxidation• Good resistance to chemicals• Very low moisture absorption

Fields of application• Truck beds• Bulk-solid containers• Bin linings• Conveyor ducts• Hoppers

Matrox® SEMatrox® SE is recommended for usein areas where it is advisable orobligatory to use materials whichare hardly inflammable. This liningmaterial represents an excellentcombination of good slidingcharacteristics and high resistanceto wear and also possesses flame-inhibiting qualities of class V0according to the international testprocess UL94.

Characteristics• Flame-inhibiting (UL94, class V0)• High resistance to wear• High impact strength• Good sliding characteristics• UV-resistant• Anti-static

Fields of application• Mining• Truck beds• Hoppers

Matrox®: Lining material for glutinous bulk solids

Matrox® U 110: The ideal material for hot bulk solids

Matrox® SE: Ideal (among other things)for linings in the mining industry


Matrox® EX 60Because of its permanently anti-static quality, Matrox® EX 60 isespecially suitable for applicationsin areas where there is a risk ofexplosion. The material also has ahigh impact resistance and excellentUV stability. This means that itis ideal for outdoor use, e.g. inopen-cast mining.

Characteristics• Permanently anti-static• High resistance to wear• High impact strength• UV resistant

Fields of application• Open-cast mining• Truck beds• Excavator-shovel liners• Conveyor ducts• Hopper lining

Matrox® SI 12The good wear and slidingproperties of Matrox® SI 12 areideal for use with certain typesof bulk solids such as peat orsand.

Characteristics• Good resistance to wear• Good sliding characteristics• Suitable for outdoor use

Fields of application• Port construction• Conveyor and installation

technology• Wood transport

Matrox® XCoarse-grained solids with sharpedges make extreme demandson the lining material. That is whywe have developed Matrox® X.This is our premium product andpossesses at optimum slidingproperties the highest hardnessand resistance to wear of all themembers of the Matrox® productfamily.

Characteristics• Excellent resistance to abrasion• Very high surface hardness• Good sliding characteristics• High impact strength• Very good resistance to

chemicals

Fields of application• Mining• Mining vehicles• Truck beds• Hopper linings

Anti-static: Matrox® EX 60 in open-cast mining where explosion risk is high

Matrox® SI 12: Balanced properties for less demanding goods

Matrox® X: The premiumlining for extremeconditions


The Matrox® range of products

Matrox® Matrox® U 110 Matrox® SE Matrox® EX 60 Matrox® X Matrox® SI 12 Matrox® FC Matrox® PUR

Resistance to wear

Impact strength

Sliding characteristics

Antistatic properties

UV resistance

Service temp.-250...80 -250...110 -250...80 -250...80 -250...80 -150...80 -250...80 -40...60° C continuous

Service temp.-250...130 -250...190 -250...130 -250...130 -250...130 -250...130 -250...130 -50...80° C briefly

Matrox® FCWith its official approval,Matrox® FC is ideal as a liningmaterial for contact with bulkgoods in the foodstuffs industry.

Characteristics• FDA-approved• High resistance to wear• High impact strength• Very low coefficient of

sliding friction• Low moisture absorption

Fields of application• Foodstuffs industry• Goods wagons• Bin lining

Matrox® PURThis material is perfect forapplications involving extremewear and tear, impact stress andless demanding sliding require-ments. The combination with otherproducts in the Matrox® rangeallows you to achieve a systemwhich is outstanding for its highresistance to abrasion, excellentsliding characteristics and maxi-mum impact strength at certaindefined points. Matrox® PUR isavailable in a number of hardnessgrades depending on requirement.

Characteristics• Extremely resistant to jolt

and impact stresses• Very high elasticity and

resistance to tearing• High abrasion strength• Sound-absorbing

Fields of application• Lining of concrete-mixing

machinery• Storage bins• Transfer funnels in bulk

conveying systems• Infeed-flow pipes• Crusher plant• Road-construction machinery

Matrox® FC: According to FDA approval, suitable for contact with foodstuffs.

Matrox® PUR: Suitable for applications involving high impact stress and lessdemanding slide requirements.

very good good satisfactory moderate not good

Matrox® coils:Ideal for lining dump-truck beds


Sheet sizes

Matrox® coils

Matrox® coilsMatrox® can also be supplied in rolls.The roll can be cut to specificationand offers cost advantages such as:

• easy installation• less welding work• fewer fixing elements.

Better unloadingWith Matrox® coils it is possible toline virtually any dump truck quicklyand easily. The material is availablein thicknesses from 6.3 to 15 mm, inwidths of up to 5 metres and lengthsup to 14.6 metres and is deliveredon a pallet.

The caking of material, especiallywith older or worn truck beds makesunloading more time-consuming. Itmay also be more dangerous if the

load does not move until thetipping angle is very high andslips out of the bed suddenly andrapidly. Lining with Matrox® ensuresreliable and even mass flow. Inthis way, the load can slide off thebed at a low tipping angle withoutleaving any significant residue.This shortens the time requiredand makes the process safer.

MegaSheetMegaSheet is a sheet formatespecially developed for the liningtechnology. These sheets areproduced in a unique process andhave the largest size currentlyavailable. The MegaSheets canbe utilized either in full size orcut pieces. The large size sheetdimensions allow for fewer seamsand more efficient yield.

Benefits of usingMegaSheet• Size 6,000 x 2,500 mm

(20 ft. x 8 ft.)• Elimination of cost effective

processing-steps• Waste-reduction (better yields)• Significant cost advantages

for the customer

Dimensions Typical thicknesses*

2000 x 1000 mm

3050 x 1250 mm

4000 x 2000 mm 6 – 20 mm

6000 x 2000 mm

6000 x 2500 mm (MegaSheet)

Sheet sizesMatrox® is available in the following sheet sizes:

* If required, also available in thicknesses from 1 to 200 mm.


Unload better with Matrox®

Results of flow problems• Delayed start-up - increased cost• Limited live storage• Spontaneous combustion

(stagnant coal)• Quality compromised• Segregation• Silo vibrating or shaking• Silo structural failure• Wear of equipment• Process out-of control• Operator intervention

Typical flow patternsFunnel flow is referred to as first-in last-out and is ideal for freeflowing bulk materials. The bulkmaterial discharges from the binthrough a small channel in thecentre of the bin above the outletand the material along the wallremains stationary until the end.

Mass flow is referred to as first-in first-out and is required forcohesive bulk materials. It isdefined as all the material is inmotion whenever any is with-drawn.

Rathole: The centre portion of the bin empties first in the form of a funnel(Photo Courtesy of Solids Handling Technologies, Inc.)

Typical problems: Arches (left) and Ratholes (right) occur whenthe lining material does not promote the bulk material flow

Understandingflow problemsCohesive bulk materials do notflow easily e.g. in chutes andhoppers.They stick to the walls and willaffect productivity. This is a com-mon problem because most binswere designed without a thoroughknowledge of the bulk materialbeing handled. Moisture, storagetime at rest and other factorsaffect the flow properties of thebulk material.

Arching and ratholes are twocommon problems that usuallydevelop when either the outletis too small or when the hopperlining material does not promoteflow due to shallow wall anglesor rough wall conditions causedby corrosion.

Segregation will occur if materialdischarges from the bin in a funnelflow pattern. The center portionof the bin empties first, followedby the material along the walls.This creates segregation becauseas the bin was loaded the finerparticles collect in the center ofthe bin under the charging pointwhile the coarse particles roll tothe periphery of the bin alongthe walls. In order to remix thematerial during discharge a massflow pattern is required tominimize or eliminate segregation.

Matrox® reduces the frictionbetween the bulk material andthe walls of the hopper and thusallows the material to flow outand to empty the hoppercompletely.

Funnel Flow:The flowing material(dark grey) is forminga funnel, while the rest(grey) is sticking to thewalls of the bin


Matrox® was tested againstvarious grades of coal with diffe-rent moisture contents and timeat rest ( > 72 h ). The wall anglesrequired to achieve mass flow varyaccording to the surface friction ofthe lining material on the hopperwall.

In order to create mass flow, thehopper walls must be smoothand steep enough and the outletmust be large enough to preventarching. Please note the differentwall angles required to createmass flow in the following chart.

The following chart shows thedifferent wall angles required tocreate an optimised mass flowfor different lining materials.

EstimatedWear LifeThe following chart shows theestimated life expectancy of a 1⁄2"(12,7 mm) thick Matrox® liner in amass flow circular bin having thefollowing dimensions:• total silo height is 65 ft.

(1,981.2 cm),• hopper section has a 25 ft.

(762.0 cm) vertical height• 25 ft diameter with a 2 ft.

(60.96 cm) diameter outlet.

Summary of wall friction test resultsfrom Jenike & Johanson, Inc., PRBis a sub-bituminous coal mined inthe USA, Degrees measured fromhorizontal

Mass Flow: All the material is inmotion when any is withdrawn

Recommended cone wall anglesto achieve maximum mass flowfor different wall materials

Wall material

Bulk Diameter of Stainless Steelmaterial cone outlet Flow rate Matrox® acc. DIN 1.4301 UHMW-PE

PRB Coalwith 29 %moisture

2 ft.(610 mm)

8 ft.(2,440 mm)

2 ft.(610 mm)

8 ft.(2,440 mm)

continuous

after 3 days rest

continuous

after 3 days rest

continuous

after 3 days rest

continuous

after 3 days rest

56°

60°

55°

59°

59°

65°

57°

62°

81°

81°

78°

78°

88°

90°

76°

78°

62°

63°

60°

62°

64°

68°

58°

63°

PRB Coalwith 36 %moisture

Coal handled Estimated lifeof 1/2" (12,7 mm)

thick Matrox® liner in years

Bituminous > 17

Sub-Bituminous (PRB) > 35

Lignite > 50


Fixing system:Stud weldingIn order to fix linings in position,the sheet is always pre-drilled atthe fixing points using a specialdrill. The distance between theindividual fixing points dependson the geometry and the materialof the container being lined, theoperating conditions and the typeof fixing process selected.

When the sheets are bolted intoposition with bolts and disk nuts,we recommend a distance of150-200 mm. The distancebetween the holes and the edgeof the sheet should not exceed20-30 mm.

When the pre-drilled lining sheetis positioned in the container it isused as a template for welding.

For stud welding, a threaded boltis welded through a hole in thesheet to the metal surface below.A hexagon nut or an anti-looseningdisk nut is then screwed onto thebolt.

For lining purposes, nuts andthreaded bolts of the size M10have proved to be most suitable.We supply these in variouslengths. For simpler installationon uneven surfaces, we havespecial threaded bolts with pre-determined breaking points.

Advantages:• Easy removal of the sheets

Ideal applications• For thicker sheets

Equipment required• Suitable graduated drill• Stud-welding unit• Threaded bolts (if necessary

with pre-determined breakingpoint)

• Disk nuts• Fixing tool for tightening the

disk nuts.

A bolt-firing tool can also be usedto mount the lining sheets.

Strong fixing: the studis welded to the basethrough the pre-drilledsheet

Stud-welding process: lining a hopper

Fixing technology

Fixing systemStud weld

Fixing systemsMatrox® is installed by mechanically fastening it to the substrate using boltedor welded fasteners. Both types are acceptable and are usually chosen basedon the requirements of the application and the structure being lined.

Röchling is associated with qualified installers around the world that under-stand the complex field of bulk material handling. Proper installation by aqualified distributor or installer is critical to the life expectancy of the liner.


Fixing system:Weld washer

Fixing system:Weld washerWith the so-called "weld-washer"fixing system, a plate-shapedpre-stamped metal disk is weldeddirectly to the base through thehole in the sheet. Only oneoperation is necessary. This fixingsystem can be used for sheetthicknesses of up to 15 mm. Aneven lining surface is then createdby covering the weld washers withmatching Matrox® plastic caps.

Advantages:• Quick and easy installation• Cover caps prevent accumulation

of bulk material at the fixingpoints.

Ideal applications:• Simplest system for mounting

thin lining sheets

Equipment required• Weld washers• Suitable graduated drill• Welding unit (cover gas or

electric welding unit)• Matrox® cover caps

In addition to the systemsdescribed above, alternativemethods are also available onrequest. We would be pleasedto advise you.

Fixing to concreteA system consisting of washers,countersunk head screws, concretedowels and Matrox® cover caps isparticularly suitable for attachingMatrox® sheets to concrete walls ormasonry.

This system creates tolerance spaceswhich help to prevent the formationof bulges at high temperatures. Toprevent material from penetratingunder the sheet, the sheet is sealedby means of a cap. The benefitsof this process are simple attachmentof the sheet and excellent durability.

Fixing toconcrete

Washer

Concrete dowel

Concrete

Matrox® sheet

Matrox® cover cap

Countersunkhead screw

Fixing a hopper liningWith hopper linings, corners andsharp angles often cause undesira-ble accumulations of bulk material.For this reason, the lining sheetshould, if possible, be curved incorner areas. Depending on thethickness, it may be necessary touse a hot-air blower or a rollingunit to achieve the desired curve.

The cavity thus created behind thesheet is then filled with a polymer(epoxy-resin) mortar. Countersunkscrews and expansion dowels areused to fix the lining sheet intoposition.

Laying techniqueWhen lining hoppers and bins, theliner sheets are laid horizontallystarting at the bottom and workingupwards. We recommend off-setting the vertical joints of thesheets. Depending on the type ofbulk solid in question, it may benecessary to improve the materialflow by overlapping the liningsheets. This also prevents fine-grained material from working itsway under the lining.

The diagram shows the methodswhich can be used for the overlap.The direction of flow is indicatedby the arrow. Alternatively, thejoints may be sealed with a specialextrusion welding device.

Fastening of hopper lining

The sheets are laid horizontally from bottom to top in the offset position

Overlapmethods

Concrete lining

R12

Mortar filling

Matrox® sheet


Fixing technology

Bin wall

Edge protectionWhen installing all types of lining, thetop row of sheets must be protectedby a sealing strip to prevent materialfrom working its way under the sheets.The strips may be of aluminium (truckbed) or steel plates as required.

When fixing the strips, ensure thatthe material can expand and contractfreely due to thermal effects.

Weld seam

Z-sheet

Steel base

Matrox® sheet

Steel base

Weld seam

Stainless-steel edgeprotector

Matrox® sheet

Edge strips prevent penetrationof material beneath the liner sheet


Project examples


Truck-bed liningsDepending on their shape, truckbeds have number of differentproblem areas. Material sticks inthe corners, the flow is impededand the bed is exposed to additio-nal wear. Depending on the designof the bed, the shape, grain-size,moisture content and temperatureof the bulk solid, we recommendthe following products:

Matrox®

Matrox® U 110Matrox® EX 60Matrox® X

For applications involving heavyimpact stresses, we can alsosupply a combination of the aboveMatrox® types and polyurethane.

Strongly anchored:Installation ofMatrox® sheets ina funnel-shapeddump truck usingthe stud-weldingprocess

Professional lining:Z-sheets attached to thetruck bed prevent materialfrom drifting under thelining sheet

Comparison between Matrox® and steel.The material adheres to large areas ofthe unlined steel surface. The area linedwith Matrox® is almost completely free

Mining vehicle. Matrox® X-lined truckbed for ore transport in Australia

Lining is a matter of experienceThe choice of lining material depends on a number of factors such as thetype of bulk solid, the geometry of the object being lined as well asother factors affecting the flow of material and amount of wear. RöchlingEngineering Plastics KG has a wealth of experience in lining technology

going back over 40 years. This experience is at your service. We canadvise you on the right type of lining material and fixing technologyfor your application. Our priorities are the durability and efficiency ofthe lining.


Hopper and silo liningOne of the main challenges inlining hoppers and silos is the highamount of wear caused by theimpact of material falling from aheight. The funnel-shaped outletcauses problems with regard tocore and mass flow. Special safetyregulations or, for example, thehandling of foodstuffs, createadditional demands.

We recommend:

Matrox® EX 60Matrox® SEMatrox® SI 12Matrox® FC

Here too we can supplycombinations of Matrox® andpolyurethane for applicationsinvolving high impact stresses.

Hopper lining with weld washers.The distribution of fixing points canbe clearly seen

Emptying a bin:The Matrox® lining ofthe bin ensures evenand undisrupted loadingof the bulk material

View into a hopper frombelow. With large-grainedbulk goods, which may causeserious localised wear,lining the exposed parts withMatrox® may considerablyprolong the life span of thehopper

Coal hopper in a power stationlined with Matrox® EX 60.Operating reliability andundisrupted infeed of rawmaterial are essential in thepower industry


Wagon liningThe universal use of goods wagonsfor all kinds of bulk solids requiresa fine balance between protectionfrom abrasion and low frictionto promote flow. For hopper,cradle or standard-type wagonswe recommend the use ofMatrox® SI 12. For some typesof bulk goods, special liningsmay be necessary. We would bepleased to advise you.

Welding work for lining a goodswagon. The Matrox® lining is weldedat the angled edges of the jointsto prevent material collecting inthe corners

Universal in application:Because of their variousfields of use, the liningof goods wagons must besuitable for all types ofmaterial

Wagon lining with Matrox® SI 12:The clean and easy emptying of each wagonensures rapid unloading of entire goods trains

Expertise on site: Our experienced installation partners are at your service

We supply your systemsolution, consisting of:

• The optimum lining materials for thespecific requirements

• Sheets cut to size• Fastening materials such as bolts,

nuts, drills, cover caps, and (on hire)stud-welding equipment

Our experienced installation partnersare at your service on site worldwide.

In our development and trainingcentre in Haren, Germany, we alsoorganise workshops for our customer'semployees to familiarise them with allaspects of lining technology, includingdifferent welding techniques andfastening systems.

Theory and practice:At the Röchling training centre, ourcustomers learn the fundamentalsof lining technology

System partner in lining technology

In addition to high-quality liningsheets, Röchling Engineering Plasticsalso supplies fastening systems forpermanent installation as well asthe required advisory and supportservices.


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Röchling Engineering Plastics KG

Röchlingstr.149733 Haren/GermanyTel. +49 5934 701 - 0Fax +49 5934 701 - [email protected]

matrox lining e

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