Mining industry is one of the toughest because it is abrasive and corrosive. It is also a huge potential market for composite materials. The mining industry is interested in a solution to corrosion, particularly in iron and copper mines, potash mines or locations near saltwater. Corrosive environments can reduce the life of a steel roll by 60% or more. Traditional steel rolls have to be replaced frequently because of excessive rust, as frequently as every two weeks in severe cases. This results in more frequent downtime, repeated capital expenditures for replacement rolls and a lot of labor costs for maintenance. Conveyor suppliers have tried coating steel rolls to extend their lives and have replaced them with unreinforced plastic rolls, but coatings can delaminate easily from the steel roll body, and plastic rolls aren't as strong as steel rolls.
Corrosion-resistant composite conveyor rolls are being introduced for improved materials handling. RS Technologies, together with partner FMC Technologies Inc. is in the process of developing a composite idler roll � a tubular roller, 5-7 inches (125-175 mm) in diameter and up to 72 inches/1.85m long that would replace mild steel roller components on mining conveyor belt systems that can be many miles in length. These rollers can perform under highly abrasive, highly acidic and extreme temperature conditions and save mine owners significant repair and maintenance costs compared to steel as reported in Composites Technology. The benefits of the composite rolls over steel rolls include:

• much less susceptibility to abrasion and corrosion.
• from 30 to 50 percent lower weight than steel and the same strength at identical size, making it easier for workers to lift and install them.
• a lower coefficient of thermal expansion (CTE) and resulting lower expansion and contraction, which means less chance for the roll to go out of round, become unbalanced and put uneven loads on the bearings.
• the ability to bear higher belt speeds and rotation rates with less noise because of their lower weight.
• compliance with mining regulations for static and flame resistance, which makes them appropriate for both aboveground and underground installations.