Outlast the Grind: Why Wear-Resistant Pipe Systems Are Revolutionizing Material Handling

Discover How SureAlloy® Fabricated Pipe and CLADPIPE Hardfaced Cladded Pipe Deliver Unmatched Durability, Performance, and ROI in the Toughest Industrial Environments

​In industries where materials are subjected to extreme wear and abrasion, selecting the appropriate piping solutions is crucial to ensure operational efficiency and longevity. Two notable advancements in wear-resistant piping are pipes fabricated from SureAlloy® Premium Carbide Overlay Plate and those cladded with hardfacing materials, such as CLADPIPE by Cladtec. These solutions offer significant advantages over traditional induction-hardened or standard metal pipes.​

SureAlloy® Premium Carbide Overlay Fabricated Pipes

Pipes constructed from SureAlloy® Premium Carbide Overlay Plate are designed to withstand severe abrasion and impact. The fabrication process involves metallurgically bonding a composite of chromium-iron carbides to a mild steel substrate, resulting in a highly abrasion-resistant overlay material. This combination provides exceptional durability, often lasting up to 30 times longer than mild steel and up to 20 times longer than manganese steel in high-wear applications. ​

Key Benefits:

• Extended Service Life: The carbide overlay significantly enhances the pipe's resistance to wear, reducing the frequency of replacements and maintenance.​
• High Flow Efficiency: The smooth, low-friction surface minimizes material buildup, ensuring consistent throughput and reducing energy consumption.​
• Custom Fabrication: Pipes can be tailored to specific system requirements, accommodating various diameters, lengths, and complex configurations.​
  
  

CLADPIPE by Cladtec: Hardfaced Cladded Pipes

CLADPIPE represents a high-performance composite wear-resistant pipe with an internally cladded inner diameter lined with premium hardfacing materials. Manufactured in the USA using advanced automated cladding technology, CLADPIPE ensures consistent quality and durability. ​

Manufacturing Highlights:

• Base Pipe: Typically utilizes extra heavy-walled A53 Grade B, with other alloys available upon request.​
• Inner Diameter Range: From 5.5” up to 26” finished ID, with special runs up to 30” depending on wall thickness.​
• Length Options: Pipes up to 40 feet in length, based on specifications.​
• Cladding Configuration: Circumferential weld bead pattern with bead widths of 1/4”.​
• Cladding Thickness: Ranges from 1/8” to 1/2”, depending on the material.​

Advantages:

• Superior Wear Resistance: The hardfacing materials provide exceptional protection against abrasion and erosion, extending the pipe's operational life.​
• Precision and Consistency: Advanced manufacturing techniques ensure tight tolerances and high-quality standards.​
• Customization: Pipes can be engineered to meet specific application requirements, offering flexibility in design and performance.​

Applications of Wear-Resistant Pipes

These advanced piping solutions are particularly beneficial in industries where materials are transported under harsh conditions:​

• Mining and Quarrying: Handling abrasive ores and aggregates.​
• Power Generation: Transporting coal ash slurry and limestone slurry in flue gas desulfurization systems.​
• Cement Production: Conveying raw materials and clinker.
• Steel Manufacturing: Moving sinter and other abrasive materials.​
• Pulp and Paper: Transporting wood chips and other fibrous materials.​

Comparison with Induction-Hardened and Standard Metal Pipes

While induction-hardened pipes offer improved wear resistance over standard metal pipes by creating a hardened inner surface through a heating and quenching process, they may not match the durability and customization options provided by carbide overlay or hardfaced cladded pipes. For instance an induction-hardened pipe, lasts up to six times longer than mild steel pipe. However, carbide overlay and hardfaced cladded pipes can offer even greater longevity and performance in extremely abrasive environments.​

Key Differences:

• Wear Resistance: Carbide overlay and hardfaced cladded pipes typically exhibit superior wear resistance due to the hardness and composition of the overlay materials.​
• Customization: These pipes can be fabricated to specific dimensions and configurations, accommodating complex system designs.​
• Impact Resistance: The combination of a tough base material with a hard overlay provides a balance of impact and abrasion resistance with custom material blends.​
  
  

Return on Investment (ROI)

Investing in wear-resistant piping solutions like those fabricated from SureAlloy® or CLADPIPE can lead to significant cost savings over time. Although the initial investment may be higher than standard or induction-hardened pipes, the extended service life and reduced maintenance requirements result in a lower total cost of ownership. For example, a chemical plant reported saving $2 million annually by switching from lined to cladded pipes in hydrochloric acid service.

ROI Considerations:

• Reduced Downtime: Longer-lasting pipes mean fewer shutdowns for maintenance or replacement.​
• Lower Maintenance Costs: Enhanced durability reduces the need for frequent inspections and repairs.​
• Improved Efficiency: Maintaining optimal flow rates and reducing energy consumption contribute to operational savings.​

In conclusion, selecting wear-resistant pipes fabricated from SureAlloy® Premium Carbide Overlay Plate or cladded with hardfacing materials like CLADPIPE™ offers substantial benefits in terms of durability, efficiency, and cost-effectiveness, particularly in demanding industrial applications. The SAS SureAlloy Pipe and Cladtec CladPipe can also be refurbished for continued use after a typical service life, providing a key benefit for those seeking an extended return on investment.

Additionally, both options can be custom-manufactured with varying levels of overlay. From standard chrome carbide to complex overlays engineered for the most extreme wear environments, ensuring the right solution for every application. These advanced systems deliver industry-leading performance and long-term value, making them the smart choice over traditional induction-hardened or standard piping that can't be refurbished.