In the mining industry, equipment isn’t just exposed to tough conditions—it’s under constant attack. Chutes, tanks, pipelines, and other systems face relentless wear from abrasive materials, high-impact rock loads, and fast-moving slurry that erodes surfaces from the inside out. Without proper protection, even the most durable mining equipment can wear out quickly, leading to costly repairs and unscheduled downtime.

That’s where rubber lining equipment for mining comes in.

Rubber is a proven solution that absorbs impact, resists abrasion, and seals against corrosion and slurry erosion. In this blog, we’ll explore how rubber lining works, where it’s most effective, and why it’s the go-to choice for mining operations that demand durability and uptime.

The Harsh Realities of Mining Environments

Mining operations are some of the most demanding industrial environments on the planet. From the moment raw material is extracted to the point it’s processed and transported, equipment faces an intense combination of forces that can cause rapid degradation.

Common Threats to Mining Equipment:

• Abrasion: Constant contact with sharp, coarse material grinds down surfaces over time.
• Impact: Heavy rocks and materials drop from significant heights, striking chutes, hoppers, and bins with force.
• Slurry Erosion: Slurries (mixtures of fine solids and water) flow through pipelines and tanks at high speeds, gradually eating away at unprotected surfaces.
• Corrosion: Exposure to water, chemicals, and minerals can corrode unlined metal components.

Mining Equipment at Risk:

• Chutes and Hoppers: Handle large volumes of falling rock and aggregate.
• Pipelines and Slurry Lines: Transport abrasive mining slurry at high velocity.
• Tanks and Process Vessels: Store and mix corrosive materials and abrasive solids.
• Mill Feed Boxes and Cyclones: Constantly exposed to high-energy slurry flows.

The Cost of Equipment Damage:

• Unplanned Downtime: Unexpected failures bring operations to a standstill.
• Repair and Replacement Costs: Frequent repairs drive up maintenance expenses.
• Lost Productivity: Idle equipment delays production and shipment schedules.

In such a hostile environment, standard materials simply don’t hold up. Without specialized protection, even high-strength steel components can fail prematurely, and that’s where rubber lining proves its value.

Why Rubber Lining Works in Mining Applications

Rubber lining is an engineered solution designed to handle the harshest conditions the mining industry can throw at it. From high-impact rock drops to abrasive slurry flows, rubber lining creates a flexible, durable barrier that protects equipment from premature wear and failure.

Here’s why rubber is so effective:

• Exceptional Impact Absorption
  Rubber’s natural elasticity allows it to absorb shock and deformation without cracking. That flexibility makes it ideal for chutes, hoppers, and other high-impact areas where rigid materials like steel or ceramic might shatter or dent. 
• Superior Abrasion Resistance
  Rubber can withstand continuous scraping and grinding from coarse materials. It wears down slowly and evenly, providing long-term protection for equipment carrying or processing abrasive media. 
• Seamless Protection Against Slurry and Corrosion
  Properly applied rubber linings form a watertight seal that prevents slurry infiltration and moisture-induced corrosion — two of the most damaging forces in slurry-based operations. 
• Chemical and Temperature Resistance
  With various rubber  compounds available, linings can be customized to resist specific chemicals or handle extreme temperature fluctuations. Whether you’re dealing with acidic slurries or hot, abrasive ore, rubber has a formulation for the job. 
• Long-Lasting Performance Under Stress
  Rubber linings remain bonded and functional even under repeated flexing, vibration, and movement (conditions that often cause rigid linings to crack or break apart).

In short, rubber lining adapts to the unique mechanical and chemical challenges of mining operations, helping preserve critical components and extend equipment life.

Key Applications of Rubber Lining in the Mining Industry

Rubber lining plays a vital role in mining equipment, particularly where abrasion, impact, and slurry erosion are most intense. By applying the right type of rubber lining to the correct component, mining operations can dramatically increase equipment lifespan and reduce unplanned downtime.

Chutes and Hoppers

These components are constantly bombarded by falling rock and ore. Rubber lining absorbs the energy from impact, reducing surface damage and minimizing the risk of cracking or denting. It also helps prevent material hang-up, allowing for smoother material flow and reducing clogs.

Pipelines and Slurry Transport Lines

Slurry (a high-velocity mix of fine solids and water) can wear down unlined metal pipes within months. Rubber lining creates a smooth, resilient barrier that resists both abrasion and chemical attack, extending the life of pipelines transporting mining slurry.

Tanks and Process Vessels

Rubber-lined tanks are used to store and process various corrosive and abrasive materials. Lining these tanks with rubber protects the vessel’s structural integrity while reducing contamination and simplifying maintenance.

Rubber Lining Equipment for Mining vs. Alternative Materials

While several options exist for lining and protecting mining equipment, rubber stands out for its unique combination of flexibility, durability, and cost-effectiveness. 

Let’s take a closer look at how rubber compares to other commonly used lining materials in the mining industry:

When Rubber Is the Best Choice:

• When equipment is exposed to both impact and abrasion (ex. chutes, hoppers).
• When handling abrasive slurry that causes internal pipe wear.
• When chemical resistance is needed.
• When downtime must be minimized, rubber is easier to repair on-site.

When Other Materials Might Be Considered:

• For extreme abrasion with minimal impact (ceramic).
• Where the budget allows for specialized installations (ceramic or steel).
• When dealing with non-impact dry materials, and cost is a priority (plastic).

Long-Term Benefits of Rubber-Lined Mining Equipment

Investing in rubber lining doesn’t just solve short-term wear problems; it delivers long-term value across your entire operation:

1. Extended Service Life for High-Wear Assets

Rubber linings form a durable, flexible barrier that withstands the harshest operating conditions. Equipment lined with rubber lasts significantly longer than unlined or poorly protected components, especially in high-impact or abrasive applications.

2. Reduced Maintenance Frequency and Costs

With rubber-lined systems, repairs are less frequent; when needed, they’re easier and faster to complete. This minimizes labor costs and eliminates the need for full equipment replacements.

3. Fewer Unplanned Shutdowns

Downtime is one of the biggest profit-killers in mining. By preventing premature wear, rubber linings help reduce unexpected breakdowns, keeping operations running smoothly and consistently.

4. Lower Total Cost of Ownership Over Time

While the upfront cost of rubber lining is often lower than that of other materials, the real savings come in long-term performance. Longer equipment life, fewer repairs, and minimized downtime all contribute to a significantly lower total cost of ownership.

Upgrade Mining Equipment Protection with Rubber Lining from US RUBBER

If you’re relying on inefficient equipment for mining, it might be time to reevaluate. US RUBBER offers expert guidance and custom rubber lining solutions designed specifically for the mining industry. We’ll help you choose the right rubber compound, lining method, and application strategy to match your equipment and operational goals.

Contact US RUBBER today to learn more, request a consultation, or schedule an inspection. Let’s protect your equipment — and your bottom line — with proven rubber lining solutions.

Rubber linings protect industrial equipment against corrosion, abrasion, and chemical damage. They also protect storage tanks, pipes, or process vessels, extend equipment life, and keep operations running safely and smoothly.

But even the most durable rubber lining isn’t immune to failure. Lining materials can break down over time, or due to improper installation or exposure to harsh conditions. When they do, minor issues can quickly escalate into major problems like leaks, contamination, or unplanned downtime.

This blog will walk you through six of the most common rubber lining failure modes—what they look like, what causes them, and how to respond quickly to prevent costly damage and keep your business running. 

6 Signs of Rubber Lining Failure to Keep an Eye Out For

From rubber cracking to chemical attacks, below are six of the most common signs of failure—and what to do if you spot them.

1. Rubber Cracking

What it looks like:
Cracks may appear on the surface of the rubber or run deeper into the lining, creating a brittle or flaky appearance. These are especially common in older linings or areas exposed to the elements.

Common causes:
Rubber cracking is often caused by prolonged exposure to UV rays, ozone, or high temperatures. It can also result from chemical incompatibility, oxidation, or simply aging rubber at the end of its service life.

How to respond:
Cracks are a clear warning that your lining is no longer providing full protection. At the first sign of cracking, remove the equipment from service and assess the extent of the damage. In most cases, a rubber lining professional should evaluate the material and recommend either spot repair or a full reline, depending on severity.

2. Debonding

What it looks like:
Debonding occurs when the rubber lining lifts or peels away from the substrate. You might notice visible gaps, curling edges, or bubbles forming beneath the surface. In severe cases, entire sections of the lining may detach.

Common causes:
Debonding typically stems from improper surface preparation during installation, moisture or contamination under the adhesive, or incorrect adhesive selection or application. It can also result from corrosion forming beneath the lining, compromising adhesion over time.

How to respond:
Debonding creates pathways for chemicals, moisture, and abrasion to reach the equipment surface, putting your system at risk. If you notice signs of separation, stop operation immediately and have the area inspected. A rubber lining expert can assess the substrate condition and reline the area using proper surface prep and bonding techniques to ensure long-term performance.

3. Blistering

What it looks like:
Raised, bubble-like formations under the rubber surface indicate blistering. These blisters are often soft to the touch and may contain air, liquid, or gas. In some cases, they can rupture and expose the substrate below.

Common causes:
Blistering usually results from trapped air or solvent during the lining installation process. Over time, permeation of process media—especially under pressure or heat—can also lead to blisters forming beneath the surface.

How to respond:
Blistering may indicate more than just a surface issue. In many cases, it signals hidden corrosion or delamination beneath the rubber. A lining professional should cut into the blister to evaluate its depth and determine if localized repair or complete removal and reapplication is required. Acting quickly helps prevent the problem from spreading and compromising more equipment.

4. Liner Erosion or Wear

What it looks like:
Signs of erosion include visible thinning, grooves, or worn patches in the rubber lining, especially in high-flow areas or zones exposed to abrasive materials. In severe cases, the substrate beneath the lining may become exposed.

Common causes:
Constant impact from slurries, solids, or abrasive particles can wear down high-performance linings. Other contributing factors include the use of rubber with insufficient hardness for the application or poor system design, which creates excessive turbulence or concentrated wear zones.

How to respond:
Erosion reduces the lining’s ability to protect your equipment and can quickly lead to leaks or structural damage. If you notice signs of wear, evaluate the rubber hardness and thickness in affected areas. Upgrading to a more abrasion-resistant formulation or redesigning the system to reduce wear (such as adding baffles or redirecting flow) can help extend the lining’s lifespan.

5. Chemical Attack

What it looks like:
If rubber appears swollen, softened, sticky, or cracked, it could indicate chemical attack. This is especially common in areas exposed to aggressive chemicals. Depending on the extent of chemical exposure, damage may be localized or spread across broader surfaces.

Common causes:
Chemical attack occurs when the rubber lining isn’t properly matched to the process media. Exposure to incompatible acids, solvents, or caustics (especially at elevated temperatures) can break down the rubber’s structure over time.

How to respond:
Stop the process at the first sign of chemical degradation and identify the chemical exposure. A lining expert can test the rubber and recommend a more chemically resistant formulation. 

6. Undercure or Overcure

What it looks like:
Undercured rubber feels unusually soft, tacky, or weak, sometimes with a gummy texture. Overcured rubber, on the other hand, is tough, brittle, and prone to cracking. Both conditions compromise the lining’s protective properties.

Common causes:
Improper vulcanization during installation is the leading cause of this condition. Other causes include incorrect temperature or cure time, poor placement in the autoclave, or inconsistent heating across the lined surface.

How to respond:
Cut and test sample sections to determine the degree of cure. If undercure or overcure is confirmed, the lining may need to be reprocessed or replaced entirely. Working with experienced rubber lining professionals helps ensure proper cure cycles and consistent quality control, preventing premature failure.

Why Fast Action Matters

Rubber lining failures rarely fix themselves. Even minor issues can spiral into major problems if ignored. Cracks can deepen, blisters can rupture, and worn areas can quickly expose the substrate to corrosive or abrasive materials. The longer you wait, the greater the risk of equipment leaks, contamination, and unplanned shutdowns.

Catching signs of failure early and taking swift action can save thousands in repair costs and prevent costly downtime. Regular inspections and partnering with a trusted rubber lining provider are key to staying ahead of potential failures and extending the life of your equipment.

Don’t Wait—Get Expert Help with US RUBBER 

Not all rubber lining failures are easy to spot or fix. That’s why it pays to have a trusted partner who knows what to look for and how to respond.

At US RUBBER, we bring decades of experience in diagnosing, repairing, and replacing rubber linings across a wide range of industrial applications. From on-site inspections and lab testing to full tank relining and preventative maintenance, we protect your equipment and productivity.

Is your lining failing? Contact US RUBBER today to schedule an expert inspection or discuss your repair options.

Understanding durometer ratings is one of the most critical factors in selecting industrial rubber lining. A durometer measures the hardness of rubber, which directly impacts how well it performs under stress, resists abrasion, absorbs impact, and stands up to harsh environments.

Rubber hardness is critical for meeting spec requirements, ensuring long-term performance, protecting valuable equipment, and minimizing costly downtime. Whether your application involves chemical exposure, mechanical stress, or abrasive materials, the correct durometer rating can make all the difference.

In this blog, we’ll explain how durometer ratings are measured, what different levels mean, and how to match the right hardness to your specific needs.

What Is a Durometer Rating?

A durometer rating is a standardized measurement of a material’s hardness, specifically, its resistance to indentation. In industrial rubber applications, durometer ratings help engineers and maintenance teams evaluate how soft or hard a rubber compound is and whether it’s suitable for a specific environment or mechanical demand.

For most rubber lining applications, hardness is measured using the Shore A scale, which is designed for flexible, semi-rigid materials like elastomers. The scale assigns a number from 0 to 100 based on how much a calibrated device (called a durometer) penetrates the rubber’s surface:

• A lower value (e.g., Shore A 40) indicates softer rubber that absorbs shock and conforms to irregular surfaces.
• A higher value (e.g., Shore A 90) indicates harder rubber that offers greater resistance to abrasion and mechanical wear.

Hardness testing is standardized under ASTM D2240 to ensure consistency and accuracy across applications. At US Rubber, we perform durometer testing as part of our quality control process—both during manufacturing and after curing—to confirm that each lining meets its required specifications.

What Durometer Ratings Indicate in Real Applications

Different durometer ratings affect how rubber responds to stress, impact, and environmental challenges. Here’s a breakdown of what various Shore A ranges typically mean—and where each performs best.

Soft Rubber (Shore A 40–60)

• Flexible and elastic
• Absorbs vibration and shock
• Ideal for tight seals, vibration damping, and irregular surfaces

Medium Rubber (Shore A 60–75)

• Balances flexibility with strength
• Suitable for general-purpose linings
• Common in moderate-wear environments

Hard Rubber (Shore A 75–90+)

• Rigid and durable
• Resists tearing and abrasion
• Best for high-impact or high-pressure environments

Now let’s connect these characteristics to specific industrial applications:

Abrasion Resistance

Harder rubber (Shore A 80–90) withstands repeated wear, making it ideal for chutes, hoppers, and material-handling systems.

Chemical Exposure

While the compound matters most, mid-range durometer rubber (60–75) offers a good balance of flexibility and resistance in chemically aggressive environments.

Impact & Mechanical Stress

Softer rubber (40–60) performs better in shock-absorbing roles, such as vibrating screens or mobile equipment.

Complex Shapes & Surfaces

Lower durometer materials are more pliable and easier to install around bends, curves, and fittings.

Choosing a durometer that’s too hard or too soft can result in poor performance, increased wear, or even lining failure. That’s why material selection must match the real demands of your operating environment.

Why Durometer Isn’t the Only Critical Factor

While durometer ratings provide essential insight into rubber hardness, they’re just one part of the equation. The overall performance of a rubber lining also depends on:

• Rubber formulation, which affects chemical resistance, temperature tolerance, and tensile strength
• Cure systems, which influence final hardness and bonding properties
• Substrate preparation, which impacts how well the rubber adheres to surfaces
• Environmental factors like thermal cycling, pressure, and chemical exposure

Even with the right durometer, a poor fit for any of these elements can lead to premature failure. That’s why it’s important to take a holistic view—and work with a partner who understands how to optimize all the variables.

Work with US Rubber for the Right Material Selection

At US Rubber, we bring decades of experience in evaluating every aspect of your application environment, including chemical exposure, temperature extremes, mechanical stress, and abrasion levels.

Our team works closely with you to recommend the optimal durometer rating and rubber compound for your needs. And when off-the-shelf solutions won’t cut it, we can customize rubber linings to meet your exact operating conditions and performance standards.

Need help finding the right durometer rating for your lining? 

Contact US Rubber today for expert guidance or to request a quote. We’re here to help you protect your equipment, reduce downtime, and get the job done right the first time.