Ceram Core® Pipes from FSI: The Ultimate Solution for Abrasive Environments

Ceram Core Piping System

Introduction

In industries such as mining, power generation, and chemical processing, pipelines often carry highly abrasive materials like slurries, bottom ash, or mine tailings. Standard metallic pipes quickly succumb to wear and tear, leading to costly replacements, frequent downtime, and lost productivity.

Fibreglass Solutions Inc. (FSI) has a solution that redefines performance in these challenging environments—Ceram Core® pipe from NOV Fiber Glass System. This advanced piping system combines the lightweight, corrosion-resistant benefits of fiberglass-reinforced plastic (FRP) with the exceptional abrasion resistance of a high-alumina ceramic liner. The result? A pipe built to outperform and outlast conventional alternatives.

 

Benefits of FSI’s Ceram Core® Pipes

1. Unmatched Abrasion Resistance

The defining feature of Ceram Core® is its high-alumina ceramic liner, made from 3.3 mm (0.13") ceramic beads embedded in epoxy. This liner acts as a protective shield, dramatically reducing wear from sharp, angular particles common in abrasive flows such as:

  • Bottom ash
  • Sand lines
  • Ore slurries
  • Mine tailings

This construction ensures the pipe interior withstands extreme abrasion—delivering years of service in applications that typically destroy steel or cast iron in a fraction of the time.

2. Proven Field Performance

Real-world case studies highlight the unmatched durability of Ceram Core®:

  • Idaho mining facility: A Ceram Core® spool in zinc slurry ran for 21 months without failure, compared to steel pipe replacements needed every month.
  • Wisconsin plant: After 19 months in high-abrasion service, Ceram Core® showed minimal wear—far outperforming carbon steel’s 6–12-month lifespan.
  • Georgia power station: Used in a bottom ash line, Ceram Core® has already exceeded 30 months of operation and is projected to last over 17 years, compared to cast iron’s typical 3 years.
  • Duffin Creek WWTP: Ceram Core® piping has been installed and operating in ash incinerator lines for 13 years without failure.

These results speak for themselves: Ceram Core® consistently delivers 5x–20x longer service life than conventional piping.

(Explore more high-performance products on FSI’s Products page).

3. Lightweight, Yet Structurally Strong

One of the major advantages of FRP-based systems is weight reduction. Ceram Core® weighs a fraction of steel or cast iron—making it easier to handle, transport, and install.
For example, a 10″ Ceram Core® pipe section weighs about 9.8 lb/ft (14.6 kg/m)—compared to 358 kg/m for a similar length of cast iron.

This lighter weight means:

  • Faster installation times
  • Lower labour costs
  • Reduced need for heavy lifting equipment
  • Safer handling on job sites

4. Reliable Pressure & Temperature Capabilities

Ceram Core® pipes are designed for working pressures up to 225 psig (15.5 bar) and temperatures up to 200 °F (93 °C), making them suitable for a wide range of demanding industrial conditions.

5. Superior Jointing & Corrosion Resistance

The system uses precision flanged joints with self-aligning flanges, ensuring perfect alignment of the ceramic liner. This design minimizes turbulence and wear at joints—common failure points in metallic systems.

Additionally, the FRP body provides inherent corrosion resistance, ensuring performance even in environments where steel would suffer from rust, scaling, or chemical attack.

Real-World Applications

FSI’s Ceram Core® pipes are the go-to choice for severe abrasion service, including:

  • Power plants: Bottom ash and fly ash handling systems
  • Mining operations: Ore slurry, tailings, and concentrate pipelines
  • Sand and gravel facilities: Sand slurry transport
  • Industrial & wastewater processing plants: High-solid-content waste lines

In each of these scenarios, Ceram Core® dramatically extends maintenance cycles, reduces unplanned outages, and lowers total operating costs.

(To learn more about FSI’s application-specific solutions for different industries, visit our Markets page.)

Long-Term Value & Sustainability

Choosing Ceram Core® isn’t just about immediate performance—it’s a long-term investment:

  • Lower lifecycle costs: Longer lifespan means fewer replacements and less downtime.
  • Environmental benefits: Reduced need for replacement pipes lowers material waste and resource use.
  • Consistent performance: Predictable wear patterns and extended maintenance intervals help avoid costly disruptions.

By combining durability, lightweight design, and corrosion resistance, Ceram Core® supports sustainability goals while enhancing operational reliability.

 

Conclusion

In abrasive service environments, the choice of pipe material can mean the difference between constant maintenance headaches and years of trouble-free operation. Ceram Core® pipe delivers unmatched performance where it matters most—abrasion resistance, longevity, and ease of installation.

From mining slurry lines to wastewater plant ash systems, Ceram Core® is proven in the field to last up to 20 times longer than traditional steel or cast iron. And with FSI’s decades of expertise, you can count on the right solution—tailored to your project’s unique challenges.

Ready to reduce wear, cut downtime, and boost efficiency?
Contact Fibreglass Solutions Inc. today to learn more about integrating Ceram Core® into your next project.