In heavy-duty industrial environments, machinery and surfaces are constantly exposed to abrasive forces — whether it’s from flowing particles, impact materials, or mechanical contact. Over time, this wear and tear can lead to surface degradation, equipment failure, production downtime, and costly repairs. Choosing the right abrasion-resistant compounds is not just a preventative measure — it’s a smart investment that extends the life of your assets and improves operational efficiency.
What Is Abrasion? How to Reduce the Effects of Abrasion
Abrasion refers to the mechanical process of scraping, rubbing, or wearing away of a surface due to friction, impact, or the movement of abrasive materials. It is especially prevalent in industries such as mining, construction, power generation, and manufacturing, where equipment faces constant contact with solids or slurries.
One of the most cost-effective and widely adopted strategies is the use of abrasion-resistant wearing compounds, which serve as a protective barrier between the equipment and the abrasive media.
Read in detail: What Causes Equipment Wear & Abrasion — And How to Prevent It
What Are Abrasion-Resistant Compounds?
Abrasion-resistant wearing compounds are engineered protective coatings made from high-performance resins and aggregates. These compounds are designed to be applied onto metal, concrete, or other surfaces to resist abrasion, impact, and even chemical exposure.
They are typically used in areas prone to wear, erosion, or mechanical damage and are available in different formulations to meet various performance requirements. These compounds form a sacrificial and durable layer that protects the underlying structure — dramatically reducing downtime and extending service life.
Two of the most commonly used types include epoxy-based coatings and polyurethane-based coatings.
Abrasion-Resistant Epoxy Coatings
Epoxy coatings are thermosetting polymers known for their superior adhesion, mechanical strength, and chemical resistance. When formulated with specific inorganic fillers, these epoxies become highly resistant to abrasion — making them ideal for environments exposed to intense wear and mechanical stress.
These coatings can be applied in single or multiple layers, depending on the required level of protection.
Key Features:
- High compressive and tensile strength
- Excellent bonding capability to a wide range of surfaces (concrete, steel,…)
- Excellent resistance to sliding abrasion
- Suitable for dry or wet environments
- Long service life with minimal shrinkage
Common Applications:
- Processing tanks and equipment
- Pipelines and elbows carrying slurry
- Structural steel in factories or warehouses
- Concrete floors in high-traffic industrial areas
Abrasion-Resistant Polyurethane Coatings
Polyurethane coatings offer a flexible and impact-tolerant alternative to epoxies, while still delivering exceptional abrasion resistance. Their resilient structure — built on highly flexible molecular backbones — allows them to withstand constant friction, erosion, and mechanical impact. They are particularly effective in resisting fine particle erosion and wet abrasion.
Key Features:
- Excellent flexibility and elongation
- Good resistance to impact and gouging
- Ideal for dynamic or flexing surfaces
- Fast return-to-service cure times
- Available in various colors, offering both functional and aesthetic versatility
Polyurethanes are frequently used as a final protective layer over primers or epoxy base coats, enhancing surface durability. However, they’re also effective as standalone solutions in applications where abrasion is the primary concern — such as on infrastructure, storage tanks, or processing machinery.
Common Use Cases:
- Marine equipment and coastal infrastructure
- Chutes, hoppers, and conveyors
- Machinery in mining, cement, or aggregate plants
- High-impact zones exposed to vibration or dynamic loads
Featured Abrasion-Resistant Compounds Products
| Devcon® Brushable Ceramic Blue is a low-viscosity, alumina-filled epoxy compound designed to provide a smooth, protective barrier against wear, abrasion, corrosion, erosion, and chemical attack. |
 Devcon® Brushable Ceramic Red 11760 | Devcon® Brushable Ceramic Red is a low-viscosity, alumina-filled epoxy compound designed to create a smooth protective barrier against wear, abrasion, corrosion, erosion, and chemical attack. |
| Devcon® Carbide Putty is a silicon carbide-filled epoxy putty designed to provide economical protection against wear and abrasion. It is ideal for applications that involve handling particulate less than 1/16″ (1.6mm). |
Choosing the right abrasion-resistant compound can make all the difference in your plant’s performance, safety, and operating costs. Ready to protect your equipment? Contact us to discuss your needs!
