Solving Wear, Buildup, and Downtime in Aggregate & Concrete Processing

The Challenge 

Across aggregate and concrete processing facilities, abrasive materials and moisture create constant wear and buildup problems in material handling equipment. 

Common trouble areas include: 

• Intake hoppers 

• Cement hoppers 

• Transfer chutes 

• Conveyor beds 

• Processing hoppers 

Over time, these steel surfaces begin to: 

• Wear down from abrasion 

• Develop material buildup 

• Cause flow interruptions 

• Require frequent manual cleaning 

In many cases, operators must shut down equipment to scrape hardened material from steel surfaces, which increases maintenance labor and reduces plant productivity. 

Application 1 

Concrete Truck Intake Hopper Liners 

At one Midwest concrete operation, steel intake hoppers on cement trucks required 45–60 minutes of washout time after each load due to material sticking to the hopper walls.  

Because trucks typically complete several runs per day, this cleaning process significantly reduced driver productivity. 

Solution 

A prefabricated liner system was installed inside the hopper to create a low-friction surface that allows cement to be released more easily. 

Results 

• Washout time reduced to approximately 5 minutes 

• Increased number of daily truck runs 

• Reduced equipment wear 

• Hopper lifespan potentially doubled 

The success of the liner installation led the operation to specify liners for all new trucks and retrofit existing fleet equipment.  

Application 2 

Cement Hopper Flow Improvements 

At a large cement processing facility, operators were dealing with cement hardening along the sides of large hillside hoppers, eventually blocking material flow entirely.  

Maintenance crews spent significant time manually clearing the buildup. 

Solution 

A custom liner system was designed to improve flow and prevent material adhesion to the hopper walls. 

Results 

• Reduced hopper blockages 

• Improved material flow 

• Lower labor requirements for cleaning 

• Successful performance through harsh winter conditions 

Following the initial installation, additional hoppers were scheduled for lining. 

Application 3 

Rock Conveyor Wear Protection 

In another processing facility, rock conveyors handling pebbles, stones, and boulders ranging from ¼ inch to 8 inches in diameter were experiencing excessive wear and buildup on steel conveyor beds.  

Mud and debris also accumulated on the conveyor surface, increasing strain on the equipment. 

Solution 

A polymer liner was installed on the conveyor bed to protect the steel structure and improve material movement. 

Results 

• Reduced wear on the conveyor bed 

• Less buildup from mud and debris 

• Improved overall conveyor performance 

• Liner added to future conveyor builds as a standard design feature 

Application 4 

Debris Buildup in Processing Hoppers 

Processing facilities handling heavy material often experience mud and debris buildup inside hopper systems. 

In one case, operators previously required a backhoe to remove hardened buildup, which frequently damaged existing liners.  

Solution 

A seamless liner system was installed to eliminate gaps where debris could accumulate behind the liner. 

Results 

• Significant reduction in buildup 

• Material could be cleared with simple tools instead of heavy equipment 

• Improved durability and easier maintenance 

Why Polymer Liners Work in Aggregate Processing 

Polymer liners provide several advantages in abrasive material handling environments: 

• High abrasion resistance
  • Low coefficient of friction for improved material flow
  • Reduced material sticking and buildup
  • Protection of steel equipment
  • Reduced maintenance downtime 

These characteristics help keep plants running efficiently while lowering maintenance costs. 

How Cope Plastics Supports Aggregate & Concrete Producers 

Cope Plastics works with processing facilities across multiple industries to solve wear and flow challenges with liner solutions. 

We support customers with: 

• Raw sheet materials for in-house installation 

• Precision cut liner components 

• Custom fabricated liner systems 

• Engineering support for complex wear applications 

With decades of experience in performance plastics, our team helps facilities extend equipment life and improve plant productivity. 

Ready to Improve Your Material Flow? 

If your facility is experiencing: 

• Hopper buildup 

• Conveyor wear 

• Flow interruptions 

• Frequent cleaning shutdowns 

Our team can help evaluate your application and recommend a liner solution.