How rotable programs can reduce shutdown exposure, improve maintenance safety and extend the useful life of critical mining equipment Mining operations have traditionally treated liner replacement as an activity performed entirely during a shutdown. Equipment is taken out of service, worn liners are removed, structural repairs are completed, and the replacement lining system is installed, all while production is waiting to restart. A rotable program changes that sequence. Instead of rebuilding the equipment during the shutdown, the mine maintains a spare structure that has already been inspected, repaired and ceramic lined. When the operating structure reaches its planned replacement point, the prepared spare is installed and the removed unit is sent through the next rebuild cycle. The operating strategy is simple: Remove. Replace. Rebuild. Stage. Repeat. What Is a Rotable? A rotable is a repairable asset that moves through a planned cycle of operation, removal, refurbishment and return to service. For a ceramic lined structure, the process typically includes: 1. Monitoring the wear condition of the operating equipment 2. Preparing a fully inspected and ceramic lined spare structure 3. Removing the worn structure during a planned shutdown 4. Installing the prepared replacement 5. Transporting the removed structure to a controlled repair facility 6. Inspecting and repairing the steel structure 7. Installing the new wear lining system 8. Staging the rebuilt structure for the next rotation Rotable programs can be developed for transfer chutes, feed boxes, crusher components, pipe sections and other critical high wear assemblies. Reducing the Work Performed During Shutdowns Conventional onsite relining can require cleaning, demolition, liner removal, steel repair, surface preparation, installation and curing. Unexpected structural damage can further expand the work scope after the shutdown has already started. A rotable program moves much of this work outside the shutdown window. The outage can then focus on safely removing the worn assembly and installing the prepared replacement. The removed structure can be rebuilt without the same production pressure and staged well before it is needed again. This can provide: 1. Shorter and more predictable change outs 2. Fewer rebuild activities on the shutdown’s critical path 3. Less dependence on emergency labor and material deliveries 4. More time for inspection, repair and quality control 5. Improved production and maintenance coordination 6. A replacement assembly that is ready before the shutdown begins The exact time savings will depend on the equipment, lifting access and site conditions. However, the fundamental benefit remains: the mine is replacing a complete assembly instead of rebuilding it while production waits. Reducing Maintenance Exposure Liner replacement can involve heavy components, restricted access, elevated work, cutting, welding, rigging, stored energy and interaction with large equipment. A rotable program does not eliminate these hazards. The structure must still be properly isolated, lifted, removed and installed under an engineered work plan. However, moving liner demolition, steel repair and liner installation away from the operating plant can reduce the number of work hours performed in congested or difficult to access locations. Completing the rebuild in a controlled facility can provide: 1. Better access to all sides of the equipment 2. Improved lighting and ventilation 3. Stable working surfaces 4. Proper lifting and material handling equipment 5. Better control of tools and loose materials 6. Less interaction with operating equipment 7. More time to follow established safety and repair procedures The objective is not to claim that rotables eliminate injuries. The real benefit is reducing worker exposure to certain onsite maintenance hazards and performing more of the work under controlled conditions. Improving Repair and Lining Quality Shutdown pressure is rarely ideal for detailed fabrication and lining work. Multiple crews may be working in the same area, access can be limited, and production is waiting for the equipment to return to service. Removing that pressure allows the structure to be cleaned, inspected and evaluated before repair work begins. A controlled rebuild process creates the opportunity to: 1. Measure and document structural wear 2. Inspect for cracks, distortion and steel loss 3. Repair recurring structural problems 4. Verify critical dimensions and connection points 5. Perform weld quality inspections 6. Review liner layout and attachment details 7. Provide appropriate curing time 8. Complete final quality checks before shipment The rebuilt structure can be reviewed and accepted before it reaches the mine’s installation schedule. Supporting a Circular Economy Across South America, this type of maintenance strategy is increasingly associated with the circular economy. Instead of discarding an entire structure when its wear protection reaches the end of its service life, the mine retains the valuable steel asset, replaces the sacrificial lining system and returns the structure to operation. A rotable program supports circular economy principles by: 1. Extending the useful life of fabricated structures 2. Repairing and reusing assets that remain structurally serviceable 3. Preserving the labor and energy invested in the original fabrication 4. Reducing unnecessary replacement of complete steel assemblies 5. Replacing worn components instead of discarding the entire asset 6. Creating a repeatable refurbishment and reuse cycle This is circularity in practical operating form: preserve the core structure, replace what is worn and return the asset to productive service. Improving Maintenance Planning A properly managed rotable program provides clear visibility into the status of every critical asset. Each structure should have a defined status: 1. In operation 2. Awaiting change-out 3. Under inspection 4. Under repair 5. Being lined 6. Awaiting quality approval 7. Ready for installation This allows maintenance teams to plan labor, materials, transportation, cranes and contractors before the next shutdown. The program should also track: 1. Asset identification numbers 2. Installation and removal dates 3. Tons processed 4. Liner condition and wear measurements 5. Structural repair history 6. Rebuild turnaround time 7. Expected replacement date 8. Cost per operating cycle 9. Total cost per ton Without these controls, a rotable can become an expensive spare sitting in storage. With proper management, it becomes a strategic reliability asset. Corrosion Engineering has the capability to support the entire rotable process at our manufacturing plant in Mesa, Arizona. Our capabilities include: Application review and engineering Detailed chute and equipment design Heavy steel fabrication Structural inspection and repair Custom ceramic lining design Ceramic and rubber lining installation Purpose built transportation and storage stands Dimensional and quality verification Rebuild documentation and asset tracking support Preparation of completed structures for shipment and installation Keeping these capabilities under one roof gives the customer a single point of responsibility for the structure and its wear protection system. Our team can evaluate how the material moves through the equipment, identify high impact and high abrasion areas, select the appropriate lining construction, fabricate the structure and deliver a completed assembly ready for installation. We can also receive removed structures at our Mesa plant for inspection, repair and relining, allowing them to be prepared for the next planned rotation. Building the Right Program Not every piece of equipment needs a rotable spare. The best candidates are critical high wear assemblies where failure, relining or structural repair creates significant production loss, maintenance exposure or shutdown uncertainty. A successful program should include: 1. Standardized equipment dimensions and interfaces 2. Engineered lifting points 3. Purpose-built support and storage stands 4. Defined inspection and repair criteria 5. Approved lining specifications 6. Wear limits and replacement triggers 7. Rebuild responsibilities and turnaround expectations 8. Storage and preservation requirements 9.Asset identification and maintenance records 10. Performance measurements based on downtime, wear life and cost per ton The initial investment should be evaluated against the value of production protected, onsite labor avoided, shutdown time reduced and equipment life extended. More Than a Spare Structure A rotable program is not simply the purchase of an extra chute or feed box. It is a structured maintenance strategy designed to improve readiness, reduce shutdown exposure and keep valuable equipment circulating through multiple operating cycles. For critical high wear applications, the question should not be: “How quickly can we replace the liners once the shutdown starts?” The better question is: “How much of this work can be completed safely and correctly before the shutdown begins?” Corrosion Engineering can help answer that question. From engineering and fabrication to ceramic lining, structural rebuilding and purpose built stands, our Mesa, Arizona plant can deliver complete rotable solutions for demanding mining applications. To discuss a rotable program for your operation, visit www.corroeng.com.