Wear Solutions
Wear Protection Solutions for Heavy-Industry Plant Equipment
In steel plants and other heavy industries, equipment components face abrasion, impact, heat and corrosion every day. By matching hardfacing, composite wear plates and roll rebuilding to the actual wear mechanism and operating conditions, we help extend component life and reduce unplanned downtime.
Wear Mechanisms
The Right Solution Starts with the Right Diagnosis
Wear rarely has a single cause — several mechanisms usually act together. We identify the dominant mechanism on each component and select the overlay alloy or material that resists it.
Abrasion
Hard particles such as ore, sinter, coke and slag cut away the surface. Common on chutes, hoppers and liners.
Impact
Falling lumps and heavy blows cause deformation, chipping and cracking — a key issue for crushers, grizzly bars and scrap grabs.
Metal-to-Metal Wear & Rolling Fatigue
Contact and sliding between metal parts such as rolls and guides lead to wear, galling and spalling.
Erosion
High-velocity gas or fluid carrying fine particles erodes fan blades, ducts and pipe elbows.
Heat & Thermal Fatigue
Repeated heating and cooling cause heat checking and high-temperature oxidation on caster rolls, off-gas hoods and other hot-zone parts.
Corrosion
Cooling water, scale and molten zinc attack the surface — and speed up material loss when combined with wear.
Our Solutions
Four Approaches, Matched to Each Component
After reviewing the wear pattern, material and operating temperature, we propose the most suitable method and material — from new wear-resistant parts to rebuilding worn ones.
Hardfacing
Worn parts are rebuilt to their original shape by weld overlay and protected with a wear-resistant alloy. Hardfacing can also be applied to new parts as preventive protection. Chromium carbide, complex carbide, martensitic and stainless alloys are selected according to the wear mechanism.
- Crusher rotors & teeth
- Grizzly bars
- Scrap grabs
- Screw flights
- Fan blades
- Pipe & elbow bores
- Dummy bar heads
Composite Wear Plates
A mild or stainless steel base plate with a wear-resistant alloy overlay welded onto it. Supplied as flat plates, cut and formed parts, or fabricated liners and chutes made to your drawing or sample.
- Liners
- Chutes & hoppers
- Feed boxes
- Transition pieces
- Screen panels
- Feed & suction tubes
Roll Cladding & Rebuilding
Continuous casting rolls and mill rolls are rebuilt with overlay alloys chosen for each roll position. After cladding with controlled heat input and dilution, rolls are machined and inspected to restore the original dimensions, profile and surface condition. Where roll bodies and journals are within repairable limits, rebuilding is usually faster and more economical than buying new rolls.
- Foot rolls
- Segment rolls
- Straightening & withdrawal rolls
- Work rolls
- Grooved rolls
- Pinch & coiler rolls
Coatings & Refurbishment for Heat and Corrosion
Parts exposed to thermal fatigue, high-temperature oxidation or attack by molten metal are protected with thermal spray coatings or corrosion-resistant cladding. Secondary cooling nozzles can be refurbished by cleaning, spray-pattern inspection and a wear-resistant coating.
- BOF off-gas hood tubes
- Zinc pots for galvanizing
- Secondary cooling nozzles
Applications
Typical Applications Across the Steel Plant
From raw material handling to rolling and coating, we propose protection for the areas where wear is most severe.
01Raw Materials & Preparation
- Scrap handling grabs
- Crushers
- Coke oven components
- Sinter crushers
- Grizzly bars
02Ironmaking & Steelmaking
- Blast furnace charging chutes
- Distribution chutes
- Bells & bell seats
- Hopper seats
- BOF off-gas hood tubes
03Continuous Casting
- Secondary cooling nozzles
- Foot rolls
- Segment rolls
- Bending, straightening & withdrawal rolls
- Dummy bar heads
04Rolling, Finishing & Coating
- Work rolls
- Backup rolls
- Grooved rolls (long products & sections)
- Pinch & coiler rolls
- Zinc pots for galvanizing lines
Across all processes: handling & dust-collection equipment
- Chutes & hoppers
- Screw conveyors
- Fan blades & casings
- Ducts
- Pipes & elbows
- Screens
Beyond steel plants, we also welcome enquiries about wear parts for cement, mining and quarrying, power generation and recycling equipment.
Composite Wear Plates
Composite Wear Plates: Structure and Types
A composite wear plate combines a weldable, easy-to-work base plate with a hard, carbide-rich overlay. It is fixed by welding or bolting on the base side, while the wear face is protected by the high hardness of the overlay.
- 1Wear-resistant overlay (hard alloy containing carbides)
- 2Fusion line (where the overlay is fused to the base plate)
- 3Base plate (mild steel, stainless steel, etc.)
- 4Fine stress-relief cracks (normal — not a defect)
- Thickness
- Chosen as base + overlay (e.g. 5+3, 6+6, 10+10), from thin plates of about 4 mm total up to heavy plates.
- Standard sizes
- 1,500 × 3,000 mm, 2,000 × 3,000 mm, etc. The overlaid area is slightly smaller than the plate.
- Base material
- Structural steel (S235 / SS400 class) as standard; wear-resistant, stainless or heat-resistant steels on request.
- Supply forms
- Flat plates, cut parts, bent and rolled parts, and fabricated liners and chutes made from drawings or samples.
Main Types and How to Choose
| Type | Features | Typical hardness / max. temperature | Typical applications |
|---|---|---|---|
| Chromium carbide | The versatile standard for high abrasion with low to moderate impact | HRC 62–64 / up to 300 °C | Mill liners, dump truck liners, loader buckets, grinding components |
| Chromium + niobium carbide | Higher toughness for severe abrasion | HRC 62–64 / up to 450 °C | Dragline buckets, coke hammers, rippers, sizing screens, crushers |
| Complex carbide | Highest carbide content for top wear resistance; keeps its hardness at high temperature | HRC 62–64 / up to 700 °C | Crushing and screening, blast furnace hoppers and throats, furnace areas, hot exhaust fans |
| Titanium carbide in martensitic matrix | Severe abrasion combined with heavy impact and gouging; fewer surface cracks | HRC 52–55 / up to 200 °C | Augers, scraper blades, mixers, crushers, shovel buckets, slurry pipes |
Variants for Specific Needs
Smooth, low-friction plates
A smooth surface with minimal cracking reduces build-up and blockage with wet or sticky materials in chutes and hoppers. A version for high-impact areas is also available.
Thin, lightweight plates
About 4–6 mm total thickness, reaching high hardness (around HRC 64–66) in a single layer — for weight-critical areas. Not suitable for impact.
Wear-profile reinforcement
Custom carbide overlay patterns designed around each component's wear profile, for the most severe zones such as sinter crushers and crusher decks.
Hardness and temperature are general guide values for multi-layer deposits. Actual values depend on the alloy, number of layers and base material — we will propose the specification that suits your application.
Fabrication & Installation
Getting the Most from Composite Wear Plates
Plates with a hard overlay can crack or spall if they are processed like ordinary steel. The key points:
Cutting
- Plasma cutting is the most economical; use laser or waterjet where tight tolerances are needed
- Cut inner shapes such as holes and windows first, the outer profile last
- Pierce from the overlay side and deburr after cutting
- Keep offcuts separate from ordinary steel for recycling
Bending & Rolling
- Bend with the overlay on the inside, perpendicular to the weld beads
- Respect the minimum bend radius — with the overlay outside, at least double the radius is needed
- Use a sacrificial plate to protect the rolls when rolling
- For pipes needing an external overlay, overlaying a pipe of the right diameter is more reliable than rolling plate
Welding & Fixing
- Make all structural welds on the base plate only
- Overlay alloy mixed into the weld metal makes it brittle; where there is a risk, use a stainless (307-type) filler
- Cap joints and bolt heads with hardfacing to protect them from wear
- Fixing options: fillet welds, plug welds, studs, weld nuts, countersunk bolts
Orientation & Handling
- Where fine particles travel at high speed (fan blades and casings, pneumatic conveying pipes), lay the weld beads perpendicular to the flow
- Beads parallel to the flow let the valleys between beads wear first
- Lift with clamps or forklifts — not with magnetic lifters
Information That Helps Us Propose a Solution
Send us photos of the worn part and its replacement interval, and we will identify the wear mechanism and come back with a proposal and quotation.
- 01Part name with drawing or photos
- 02Current material and replacement interval
- 03Wear condition (location, amount, photos)
- 04Material in contact (ore, coke, scrap, etc.) and particle size
- 05Operating temperature, impact and corrosive conditions
- 06Required quantity and target delivery date
Discuss Your Next Sourcing or Manufacturing Project with Us
Send us your drawings or 3D data and our team will guide you through the technical review.