Loy Yang B, Basalt Tiling Works
Traralgon, VIC Australia
MATERIALS USED
Basalt Tiles – 30mm
Metz Cleaner
Metz 6NF Epoxy novolac grout and primer
Metz 17 Epoxy Adhesive
Metz 33EN-VG Corrosion resistant epoxy novolac render
PROJECT SUMMARY
Loy Yang B is Victoria’s newest and third largest thermal power station, supplying around 17% of the state’s electricity and employing nearly 200 local workers.
As a respective long term client of Metz, we are often called upon to replace the basalt tiles in the 2 scrapper units which have a life span of normally 5 years. It is critical to maintain the performance of the scrappers as the process consists of cleaning, crushing, and sizing the coal to ensure efficient and consistent burning, ultimately contributing to the power stations electricity generation capacity.
During a planned shutdown, we were invited to replace Scrapper Unit 2, a task with a demanding 7–8 day window for demolition, surface preparation and installation. This required 10-hour shifts and up to 10 Metz employees on site throughout the project. In addition to the long hours and demanding timeline, coordination with other work groups—such as welders and fitters—was essential, as they also needed access to the unit to carry out their tasks.
Accessing the main section of the scrapper unit requires the use of small jackhammers due to the confined space. The existing basalt tiles had been worn down to almost nothing as a result of constant coal scrapping. To allow access for tile removal, all tracks and steel scrappers were first removed. Once the tiles were demolished, the remaining adhesive (Metz 25) needed to be removed. The most efficient method for this is using 9” grinders connected to industrial vacuums, which provides a quick and clean solution.
The scrapper unit consists of two vertical sections: one is exposed and open, while the other wraps around beneath and is significantly tighter and more difficult to access. Both areas require thorough preparation and the installation of new basalt tiles, despite the challenging working conditions in the lower, confined section. Any repairs needed in the vertical sections was done with Metz 33EN-VG, as the base is not steel rather a high strength screed with wire mesh throughout.
Once demolition and steel grinding are complete, an inspection by an Alinta representative is required to assess the scrapper unit for any damage to the steel. This serves as a hold point for Metz, though it is typically not a lengthy process. Upon receiving approval from Alinta, work can proceed. The steel surface is then blasted and primed with Metz 6NF and broadcasted to enhance adhesion of the new tiles. This surface preparation is carried out by Vincent’s Painting and Blasting, a subcontractor with the necessary training and site approval.
With surface preparation complete, the installation of the basalt tiles can begin. The tiles are laid using Metz 17 epoxy adhesive and installed at a 45-degree angle to minimize contact and potential damage from the steel scrapper. Since the scrapper runs directly on the tile surface, it’s critical to ensure a flush installation with no lips, as any unevenness can lead to tile damage and potential downtime for the facility.
Prior to this project, I was called to site to repair a section of the scrapper unit where tiles had detached. Based on the inspection, it appeared the failure was due to poor bonding between the basalt tiles and the Metz 25 adhesive. As a result, Metz 17—an epoxy-based adhesive—was selected for this installation to ensure improved adhesion and long-term performance.
Once all tiles are installed, the joints are grouted using Metz 6NF Chemical Resistant Epoxy Grout. However, the grouting process varies depending on the section of the scrapper unit. In the flat, confined areas, traditional hand-trowel application is not feasible due to the limited space. Instead, the 6NF grout is mixed to a softer consistency, poured over the tiles, and worked into the joints by “squidging” it across the surface. This method ensures proper joint filling while accommodating the challenging access conditions.
Minimal grout cleaning is required, provided the surface is smooth and free from excess grout buildup. Once the scrapper is reinstalled and running over the tiles, any minor residue is quickly worn away, effectively self-cleaning the surface. Despite the challenging nature of these projects—particularly the tight spaces and short turnaround times—Metz has consistently delivered successful outcomes. Projects have been completed within the scheduled time frames, on budget, and to the satisfaction of the client.
Technical Data Sheets for materials installed on this project
METZ CLEANER
SOLVENT CLEANER FOR WASHING EPOXY ETC
METZ 6NF
EPOXY NOVOLAC GROUT & MORTAR
Typical Uses : Acid plants,CIP Rooms,Fertiliser plants,Food and Beverage facilities,Mineral Processing,Oil Refineries,Secondary Containment Areas
METZ 17
EPOXY TILE ADHESIVE
Typical Uses : Bathrooms,Breweries,Commercial Kitchens,Dairy Product Processing,Food Processing plants,Soft Drink & Fruit Juice manufacturing,Swimming Pools
METZ 33EN-VG
CORROSION RESISTANT EPOXY NOVOLAC RENDER
Typical Uses : Acid plants,CIP Rooms in Food & Beverage plants,Food Processing plants,Oil Refineries,Poultry & Meat plants,Secondary Containment linings,Steel Mills,Water Treatment & Sewerage Plant Infrastructure