Electrowinning cells are installed through a carefully planned, safety-driven process that ensures precision alignment, stability, and long-term performance. It involves expert handling, leveling, and gap-filling techniques-all supervised by certified professionals. At PRS, we don't just supply high-quality electrowinning cells; we provide end-to-end installation expertise tailored to hydrometallurgy operations like copper electrowinning.
In this blog, we break down the key steps of installing electrowinning cells-from storage and lifting to leveling and sealing-so you can see how a systematic approach minimizes risk and maximizes operational efficiency. Whether you're planning a new workshop or upgrading existing infrastructure, understanding these procedures will help you appreciate the engineering rigor behind durable, corrosion-resistant electrowinning systems.
Why Installation Matters More Than You Think
Improper installation can lead to cell misalignment, leakage, or premature wear-costing time and resources. That's why our methodology, developed through years of serving global mining and smelting clients, prioritizes safety, accuracy, and durability. Every step is guided by international standards and tailored to your site's geological and structural conditions.
Step 1: Certified Team & Site Preparation
Before any equipment arrives, the installation team-trained in safety and technical protocols-verifies site conditions. The team inspect support beams (typically concrete with anti-corrosion surfacing) and confirm workshop dimensions. All lifting tools, cranes, and slings are certified for load capacity, and work begins only after client approval.
Step 2: Safe Handling and Storage
When electrowinning cells arrive, they are placed on a flat, stable surface using forklifts. Each cell must rest evenly on all four feet to avoid uneven stress points. The client needs to ensure proper storage conditions to prevent damage before installation.
Step 3: Precision Lifting with Specialized Equipment
Cells are moved into the workshop using cranes equipped with U-shaped slings and a cell lifting beam-designed to distribute weight evenly and prevent tilting. We can guide your team carefully moves each cell onto its support beam, with constant communication to ensure safety and control.
Step 4: Leveling and Alignment
Using adjustable PVC shims (hard and soft varieties), we fine-tune the height of each cell to a tolerance of ±1mm. The first and end cells are positioned according to project drawings, and their alignment is approved by the client's supervisor before proceeding. Intermediate cells are installed sequentially, with continuous checks to maintain straightness and level.
Step 5: Gap Filling with Polymer Mortar
Once all cells are aligned, the gaps between them are filled with polymer mortar-a corrosion-resistant material that enhances structural integrity. We use foam rods and custom hoppers to pour and shape the mortar, ensuring a tight seal without surface residue.
Step 6: Final Touches-Capping Boards
Capping boards are installed according to cell type (end or intermediate). After placement, the inspection team verify overall installation accuracy to ensure everything meets design specifications.
What We Never Do During Installation and Operation-Because Safety Comes First
- Never lift cells without a lifting beam.
- Never stack cells or place them on uneven surfaces.
- Never allow impact between cells or with structures.
These rules protect the cell's anti-corrosion layers and ensure operational safety.
Partner with Experts Who Care About Your Success
At PRS, we combine qualified products (like our patented enhanced strength structure design) with field-tested installation practices. Our clients across the copper and zinc sectors trust us for solutions that reduce downtime and extend asset life.
Need a reliable partner for your electrowinning plant?
Contact us today for a consultation or request a detailed installation manual!
