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Case Study: Managing Vibrational Loads with Molykote

In this article, we explore a case study about how Molykote BR2-Plus was used to manage vibrational loads in the production of prestressed cellular concrete.

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Case Study: Vibrational Loads with Molykote

In order to understand how industrial experts were able to handle excessive vibrational loads with a Molykote product, we will explore the context, the problem and the way it was solved.

The Client

The client for this project was a company which specialises in solid and hollow-core precast prestressed concrete; they create cellular panels of prestressed concrete called flexicores, which are used in the construction of multi-story buildings. The advantages they provide over on-site concrete flooring include their reduced weight and price. 

The Problem

The panels are manufactured by pouring concrete in casts 16 meters long, half a meter wide and 20 cm thick. Each cast sits on four pedestal vibrators approximately half a meter high. Once a cast is filled, the vibrators shake it for 4 minutes. In this way, all the air is removed and the concrete is consolidated. However, the company realised that the vibration was shaking the grease out of the vibrators’ bearings, causing premature bearing failure.

The Solution

Molykote representatives suggested Molykote BR2-Plus as a solution.

This high-performance grease is composed of highly refined mineral oil, lithium soap and a specific percentage of solid lubricants and additives, molybdenum disulfide (MoS2), in combination with high-pressure additives and extremely effective corrosion inhibitors. 

This product also offers high performance under high loads at high or low speeds and with reciprocating motion. For this reason, it adapts particularly well to the vibratory movement of the machinery.

In this way, Molykote BR2-Plus solves the problem by properly lubricating the vibrator, preventing premature bearing failure.

strescon worker with molykote
A Strescon worker cuts the end of a prestressing wire from a hollow-core precast board.

The Benefits

Molykote BR2-Plus great provides benefits, including:

  • High load-carrying capacity
  • Good corrosion resistance
  • Water-washout resistance
  • Effective, long-term lubrication
  • Wear protection through solid lubricants and EP additives
  • Can function at moderate to high speeds

How Does It Work?

Molykote BR2-Plus is formulated to perform under heavy loads, reducing the coefficient of friction and metal-to-metal contact, minimising wear and improving operating conditions. This helps to deal with the heavy vibrational loads on the gearbox and bearings.

Under load, a boundary lubrication film containing MoS2 is deposited from the grease to the sliding surfaces, allowing emergency lubrication. Unlike the previous material used, Molykote BR2-Plus remains intact and effective through the vibrations, resulting in longer-lasting bearings. The vibrators work 4 out of 8 minutes and are greased every day. The plant supervisor estimates that the bearing life is extended by up to 600%.
Molykote BR2-Plus truly adds value and reduces the downtime required for bearing replacement. The company now uses a 54-kilo barrel of the material each month.
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