Extend Service Life in Abrasive Piping Systems with CastoTube
Industrial piping systems that transport abrasive materials are among the most maintenance-intensive assets in process industries. Premature wear, reduced flow capacity, and unplanned shutdowns are common challenges for maintenance managers seeking long-term, reliable solutions.
This case study from a cement plant illustrates how upgrading to an engineered wear-resistant piping solution significantly improved reliability, flow, and long-term performance.
The Challenge
A cement producer operating an alternative fuel transport line was facing repeated failures in a 6" Schedule 80 piping system with a ½" rubber lining. The rubber lining wore rapidly under abrasive conditions, leading to frequent repairs and difficult replacements.
At the same time, the lining reduced the pipe’s internal diameter, causing material buildup and clogging. Clearing blockages or replacing pipe sections often took several hours or an entire shift, resulting in unplanned downtime and rising maintenance costs.
The Solution
After evaluating the wear mechanisms and flow constraints, Castolin Eutectic implemented a CastoTube® internally wearfaced piping system.
CastoTube is a steel pipe internally clad with engineered, abrasion-resistant alloys designed to withstand severe wear in demanding material transport applications. Unlike rubber linings, the metallurgically bonded wear layer delivers long-term protection without sacrificing internal diameter.
By replacing the rubber-lined pipes with CastoTube, the system gained more than ½ inch of internal diameter, improving material flow while dramatically increasing wear resistance. The flanged piping design also allowed for efficient installation and simplified future maintenance.
The Outcome
The CastoTube system eliminated wear and abrasion as primary causes of failure while resolving chronic clogging issues. Improved internal diameter reduced material buildup and stabilized flow through the line.
After more than two years of continuous operation with no maintenance-related disruptions, the plant confirmed a substantial extension of service life and a measurable reduction in downtime. Based on these results, the cement producer committed to converting additional alternative fuel pipelines to CastoTube.
Why This Matters for Maintenance Managers
For industries relying on abrasive material transport—cement, mining, power generation, waste processing, and bulk handling—this case demonstrates that extending piping service life is not only about wear resistance. Optimizing internal diameter, maintaining flow efficiency, and reducing maintenance frequency are equally critical.
Engineered wear-resistant piping solutions like CastoTube offer a proven path to longer service life, fewer shutdowns, and more predictable maintenance planning—key priorities for maintenance managers responsible for asset reliability and production continuity.
Take the next step toward longer service life and reduced downtime. Connect with Castolin Eutectic to review your piping challenges.
