Protecting Critical Hoses with SYSTEM7 XT™
Industry
Sand & Aggregate
Project Overview
Sand and aggregate operations are inherently abrasive and demanding, with heavy equipment, haul traffic, and loose aggregate materials creating challenging ground conditions. In these environments, large-diameter hoses are often routed across active work areas and gravel access roads to support material processing and site operations.
Because the hoses must remain in place while equipment continues to operate around them, protecting them from mechanical abrasion and excessive point loading is critical to maintaining system reliability and minimizing unplanned downtime.
Challenge
Large-diameter hoses were positioned across gravel surfaces and active work areas. Direct contact between the hoses and sharp, irregular aggregate created continuous abrasion and the potential for premature wear of the hose exterior.
In addition, equipment and vehicle traffic operating in the surrounding area could create concentrated loads and movement that increased the risk of hose damage.
The operation required a durable ground-protection system that could be installed beneath the hoses to create a physical separation between the hose and abrasive gravel while providing a stable surface capable of supporting heavy equipment traffic.
Solution
SYSTEM7 XT™ from Spartan Composites was installed directly on the ground beneath the hoses, creating a durable protective interface between the hoses and the underlying gravel.
The composite mats eliminated direct hose-to-gravel contact, reducing exposure to sharp aggregate edges and abrasive surfaces. The high-strength composite construction also provides load distribution across the mat surface, helping reduce localized ground pressure in areas subject to equipment and vehicle traffic.
Rather than placing the protection over the hoses, the SYSTEM7 XT™ mats functioned as a protective foundation beneath the hoses, isolating them from the rough ground conditions that could accelerate exterior wear.
Implementation
SYSTEM7 XT™ mats were strategically installed along hose routes and at locations where hoses crossed gravel work areas and active traffic zones.
The installation process created a continuous, durable surface beneath the hoses without requiring excavation, permanent ground modification, or extensive site preparation.
Once installed, the hoses were positioned directly on top of the composite mats. This configuration provided:
- A physical barrier between the hose and abrasive gravel.
- A smoother, more stable contact surface for the hoses.
- Reduced exposure to sharp aggregate and protruding rock.
- Improved separation between hoses and contaminated or uneven ground.
- A reusable ground-protection system suitable for changing work areas.
Results
The use of SYSTEM7 XT™ provided a significant improvement in hose protection and ground conditions around critical hose routes.
- Reduced abrasive wear: The mats prevented direct contact between the hoses and sharp gravel, reducing the potential for exterior hose abrasion.
- Extended hose service life: Minimizing mechanical wear can help reduce premature hose replacement and associated maintenance costs.
- Improved operational reliability: Protecting critical hoses helps reduce the risk of damage, leaks, and unplanned interruptions.
- Load isolation: The composite mat system provided separation between the hoses and ground conditions exposed to equipment traffic.
- Improved job-site conditions: The mats created a more controlled and stable surface around hose routes.
- Reusable protection: SYSTEM7 XT™ can be removed, relocated, and redeployed as site conditions and hose routing requirements change.
Why SYSTEM7 XT™
SYSTEM7 XT™ is engineered for demanding industrial and heavy-duty ground-protection applications where high strength, durability, and load distribution are required.
Its robust composite construction is resistant to moisture, corrosion, and harsh environmental conditions. Unlike traditional timber mats, SYSTEM7 XT™ will not rot, absorb water, or splinter, making it well suited for abrasive and continuously changing work environments.
For hose-protection applications, the mat’s role extends beyond ground stabilization. By creating a durable separation layer between critical hoses and abrasive aggregate, SYSTEM7 XT™ helps reduce mechanical wear while providing a stable surface capable of supporting demanding site activities.
Conclusion
By installing SYSTEM7 XT™ beneath critical hoses, the operation created an effective protective barrier between the hoses and abrasive gravel conditions.
The solution reduced direct hose-to-ground contact, helped minimize abrasion and mechanical wear, and provided a reusable protective surface capable of withstanding demanding industrial traffic. For sand and aggregate operations where hose integrity and uptime are critical, SYSTEM7 XT™ provides a practical, durable approach to hose protection and ground management.
