Wear Plate & Block. Our Innovation. Your Advantage.

Transcription

1 Wear Plate & Block

2 Introduction Overview Overview The aim of the Wear Plate & Block division of Bradken is to supply technically advanced solutions to the global market. The Wear Plate & Block team are focused on developing products and services to meet customers aspirations. We provide a range of engineering services and have sufficient capabilities to develop and manufacture a solution for any project. Our vast products range is continuously expanding to provide total wear solutions. Our products include: Duaplate Chromium carbide clad wear plate manufactured in Australia and marketed worldwide. Duaplate is well suited to fixed and mobile plant equipment associated with the construction, mining and resource industries; particularly iron ore, coal, cement and steel applications. Q&T Steel Quench and tempered wear resistant steel plate providing an economical solution to an abrasive and impact prone environment. Bradken s Q&T Steel is easily fabricated and has many applications in the construction, mining and process industries. Duablock Range of products based on a composite white iron wear surface metallurgically bonded to a weldable mild steel backing plate. Duablock is fixed to the surface of fixed and mobile plant equipment, such as mining buckets and chutes, where protection from severe abrasion is required. NiHard Abrasion and high impact resistant product. NiHard is a white iron, alloyed with chromium and nickel, to provide a tough wear resistant material. NiHard is often cast into billets and liners and used extensively in the mining, construction and mineral processes industries, particularly in bulk handling situations. Duaceramic Bradken s newest addition to the Wear Plate & Block product range. Duaceramic combines hard abrasion resistant alumina ceramic blocks with an impact resistant polyurethane elastomer. Duaceramic is used in the most extreme abrasive environments found in the mineral processing industry. Whatever the application or situation, Bradken has the material and technical experience to tailor design a solution to your wear problems. For more information, please visit bradken.com.au 2

3 Wear Resistant Products Bradken has always been considered at the forefront of supplying quality, abrasion resistant products to the market place. Bradken has strived to improve existing technologies and develop new products to provide maximum protection for fixed plant and mobile equipment against the effects of wear. Our research and development has lead to Bradken providing a range of chromium carbide based technologies that outperform traditional quench and tempered steels and high alloy castings. The diagram below represents a comparison of common wear resistant materials to AS mild steel. The materials have been tested under the ATSM G65-04 dry sand rubber wheel test standard for low stress sliding abrasion. The number next to each product represents the factor by which the product will outlast AS mild steel. For example, Duablock will last 42 times longer then mild steel in a similar low stress abrasion situation. The chart is only intended as a guide and does not incorporate design advantages such as rock boxes, which can greatly enhance product life. Chromium Carbide Technology High Alloy Castings Q&T Steels Structural Steels D D duaplat D80 35 duaplat D60 6Mn - 1Mo Alloy Cr Alloy 500HB Q&T Steel HB Q&T Steel 6 250HB Q&T Steel 3 AS Steel Mn Alloy 9 450HB Q&T Steel 4 360HB Q&T Steel 2 Stainless Steel The numbers indicate the factor by which the product will outlast AS steel Bradken has recently released our Duaceramic composite liners into the market place. Duaceramic liners incorporate high alumina ceramic blocks, fixed in a polyurethane elastomer and are designed for service in the most extreme abrasive environments found in bulk handling. Initial reports from Duaceramic liners in service indicate a service life several times that of wear plates based on chromium carbide technology. 3

4 Table Of Contents Table Of Contents Introduction Overview...2 Table Of Contents...4 Duaplate Introduction...5 The Chromium Carbide Solution Flyer...6 Duaplate D60 Flyer...8 Duaplate D80 Flyer...10 Duaplate D90 Flyer...12 Duaplate D100/D100XP Flyer...14 Duaplate Smooth Flyer...16 Duaplate Catalogue...18 Q&T Steel Introduction...19 Q&T Steel Flyer...20 Duablock Products Introduction...22 Block Products Flyer...23 Block Products Catalogue...25 NiHard Products Introduction...37 NiHard Products Catalogue...38 Duaceramic Introduction...45 Duaceramic Flyer...46 Duaceramic Catalogue...48 Contact Information Bradken Offices

5 Duaplate Introduction Duaplate is a chromium carbide composite cladding, that is fusion bonded to a backing material. Duaplate is renowned for being one of the most abrasive resistant surfaces available. Duaplate has been proven to outlast quench and tempered steel by up to 10 times in high abrasion and impact applications. The standard backing material for Duaplate is AS mild steel, however, this can be changed to suit your operating environment. The backing plate acts as a ductile base, which allows Duaplate to be formed and shaped without damage to the overlay material. The backing plate can also be used for structural support, allowing entire hoppers and chutes to be created using only Duaplate. Duaplate is available in four different grades to suit a range of operating conditions: D60 - Suited for applications involving high abrasion with moderate to high impact. D80 - Suited for applications involving high abrasion and high impact. D90 - Suited for applications involving severe sliding abrasion or fine particle abrasion with low impact. D100/D100XP - Suited for applications requiring high abrasion resistance at elevated temperatures up to 800 o C. Duaplate can also be produced with a smooth or polished surface finish to minimise the coefficient of friction. This Duaplate smooth overlay is specifically designed to reduce material hang up and to maximise flow properties. Duaplate smooth provides a low friction solution to your bulk handling problems without the design or wear performance penalties. 5

6 BRADKEN PRODUCTS The Chromium Carbide Solution There is a common misconception that the higher the hardness of a material, the better the wear resistance. Unfortunately, this approach does not take into account the differences in microstructure, which has a significant impact on wear characteristics. Although Duaplate has similar bulk hardness to abrasion resistant (AR) steels, the wear characteristics of Duaplate are vastly superior. Duaplate is a clad plate, manufactured by welding an abrasion resistant overlay to a steel base. This overlay is in fact a dual phase alloy, or composite, consisting of hard chromium carbides in a supporting matrix. On the other hand, AR steels are single phase alloys consisting of quenched and tempered (Q&T) martensite. The final hardness of Q&T steels is a function of temperature hence the variety of hardness grades available. Typical Duaplate microstructure depicting carbides The two graphs below demonstrate how the presence of chromium carbides in the matrix is responsible for wear resistance and not the bulk hardness of the material. The graphs clearly show that as the volume fraction of carbides (VFC) increases, the wear resistance increases, whilst the hardness has a minimal effect on reducing abrasion loss. The Chromium Carbide Solution Flyer 2008 BRADKEN 6

7 BRADKEN PRODUCTS The Chromium Carbide Solution Cat 994 Loader bucket lined with Duaplate D60 required properties for an application, from a combination of components. In the case of the Duaplate overlay, the presence of tough chromium carbides in the matrix allow for enhanced wear resistance, whilst the backing plate allows for formability, ductility and ease of fabrication. The diagram below represents a comparison of common wear resistant materials to AS mild steel. The materials have been tested under the ATSM G65-04 dry sand rubber wheel test standard for low stress sliding abrasion. The number next to each product represents the factor by which the product will outlast AS mild steel. For example, Duaplate D80 will last 39 times longer then mild steel in a similar low stress abrasion situation. Duaplate D60 slurry pipes Chromium Carbide Technology High Alloy Castings Q&T Steels Structural Steels D D duaplat D80 35 duaplat D60 6Mn - 1Mo Alloy Cr Alloy 500HB Q&T Steel Mn Alloy 9 450HB Q&T Steel 400HB Q&T Steel 6 250HB Q&T Steel 3 AS Steel HB Q&T Steel 2 Stainless Steel Duaplate D80 impact wall The chart is only a guide and does not incorporate design advantages such as rock boxes. Regardless, it is clearly illustrates the benefits of Bradken s Duaplate and white iron products over traditional high alloy steel and Q&T steel. For more information contact Bradken at wpbsales@bradken.com.au 3 BKM SP MKT Rev. 1 Issue date Oct BRADKEN 170 Railway Parade Bassendean WA 6054 Australia T F W bradken.com 7

8 BRADKEN PRODUCTS Duaplate D60 D60 microstructure at 100x magnification Base Material Duaplate is a clad plate manufactured by welding an abrasion resistant material to a steel base. The standard base material is an impact resistant mild steel. This can be changed to suit your operating environment. Overlay Material The D60 overlay material is an austenitic chromium carbide iron that is based on AS The microstructure consists of primary M 7 C 3 carbides in a carbide austenite eutectic matrix. The high abrasion resistance is a provided by the hard chromium carbides that protect the matrix from abrasive wear. Typical Properties Typical D60 finish Bulk Hardness: 650 HV 50 Carbide Hardness: 1500 HV 0.5 Volume Fraction Primary Carbides: 30% Welding The base material can be welded with standard mild steel or low hydrogen welding consumables with no pre-heating required. However, care should be taken to avoid contacting the overlay material. Duaplate D60 lined dozer blade Duaplate D60 Flyer 2008 BRADKEN 8

9 BRADKEN PRODUCTS Duaplate D60 D60 microstructure at 1000x magnification Cutting, Forming and Fabrication Plasma cutting is the recommended method for cutting Duaplate. It is preferable to cut Duaplate from the backing plate side to ensure a clean edge and to prevent carbide contamination. Duaplate can also be easily cold formed into almost any shape that mild steel can, by pinch rolls or hydraulic press brake. The steel backing plate provides Duaplate with structural integrity, thus entire structures can be fabricated from Duaplate. Bradken has the capabilities to manufacture such structures or to supply cut and formed, ready-to-go wear liners. Duaplate D60 dredge pipe Services & Applications Duaplate D60 is suited for use in general wear applications involving high abrasion and medium impact. Typical uses include: Crusher main frame liners Grizzly bars Earth moving buckets liners Chute liners Bin and hopper liners Slurry pipes and bends, Sugar harvesting equipment. Duaplate D60 lined chute For more information contact Bradken at wpbsales@bradken.com.au 3 BKM SP MKT Rev. 1 Issue date June BRADKEN 170 Railway Parade Bassendean WA 6054 Australia T F W bradken.com.au 9

10 BRADKEN PRODUCTS Duaplate D80 D80 microstructure at 100x magnification Base Material Duaplate is a clad plate manufactured by welding an abrasion resistant material to a steel base. The standard base material is mild steel; however, this can be changed to suit your operating environment. Overlay Material The D80 overlay material is a complex chromium carbide iron that is based on AS The microstructure of this material consists of primary M 7 C 3 carbides in a complex carbide austenite matrix. The toughness of the material is improved by the formation of nodular complex carbides leading to a reduction in the size of acicular M 7 C 3 type carbides and inter-carbide spacing. Duaplate D80 sheet ready for delivery Typical Properties Bulk Hardness: 620 HV 50 Typical Carbide Hardness: 1500 HV 0.5 Volume Fraction Primary Carbides: 30% Welding The base material can be welded with standard mild steel or low hydrogen welding consumables with no pre-heating required. However, care should be taken to avoid contacting the overlay material. Truck bed lined with Duaplate D80 and Bradken Q&T Duaplate D80 Flyer 2008 BRADKEN 10

11 BRADKEN PRODUCTS Duaplate D80 D80 microstructure at 1000x magnification Cutting, Forming and Fabrication Plasma cutting is the recommended method for cutting Duaplate. It is preferable to cut Duaplate from the backing plate side to ensure a clean edge and to prevent carbide contamination. Duaplate can also be easily cold formed into almost any shape that mild steel can, by pinch rolls or hydraulic press brake. The steel backing plate provides Duaplate with structural integrity, thus entire structures can be fabricated from Duaplate. Bradken has the capabilities to manufacture such structures or to supply cut and formed, ready-to-go wear liners. Duaplate D80 chute Services & Applications Duaplate D80 is suited for applications involving high abrasion and high impact. Typical uses include: Sizing Screens Ball mill liner plates Dump truck tray linings Deflector Screens Chute liners Bin & hopper liners Screw Feeders Screen house lined with Duaplate D80 For more information contact Bradken at wpbsales@bradken.com.au 3 BKM SP MKT Rev. 1 Issue date June BRADKEN 170 Railway Parade Bassendean WA 6054 Australia T F W bradken.com.au 11

12 BRADKEN PRODUCTS Duaplate D90 D90 Microstructure at 100x magnification Base Material Duaplate is a clad plate manufactured by welding an abrasion resistant material to a steel base. The standard base material is mild steel; however, this can be changed to suit your operating environment. Overlay Material The D90 overlay material is a martensitic chromium carbide iron that is based on AS The microstructure of this material consists of primary M 7 C 3 carbides in a carbide martensite eutectic matrix. The material is resistant to fine particle abrasion due to the improved hardness of the matrix. Typical Properties Bulk Hardness: 700HV 50 Typical D90 finish Typical Carbide Hardness: 1500 HV 0.5 Volume Fraction Primary Carbides: 30% Welding The base material can be welded with standard mild steel or low hydrogen welding consumables with no pre-heating required. However, care should be taken to avoid contacting the overlay material. Duaplate D90 cement meal duct Duaplate D90 Flyer 2008 BRADKEN 12

13 BRADKEN PRODUCTS Duaplate D90 D90 Microstructure at 500x magnification Cutting, Forming and Fabrication Plasma cutting is the recommended method for cutting Duaplate. It is preferable to cut Duaplate from the backing plate side to ensure a clean edge and to prevent carbide contamination. Duaplate can also be easily cold formed into almost any shape that mild steel can, by pinch rolls or hydraulic press brake. The steel backing plate provides Duaplate with structural integrity, thus entire structures can be fabricated from Duaplate. Bradken has the capabilities to manufacture such structures or to supply cut and formed, ready-to-go wear liners. Duaplate D90 fan blades Services & Applications Duaplate D90 is suited for severe sliding abrasion or fine particle abrasion with low impact. Typical uses include: Cement chutes Cyclones Fan blades Fan casings Agricultural implements Trommel screen liners Sizing Screens Duaplate D90 trommel screen For more information contact Bradken at wpbsales@bradken.com.au 3 BKM SP MKT Rev. 1 Issue date June BRADKEN 170 Railway Parade Bassendean WA 6054 Australia T F W bradken.com.au 13

14 BRADKEN PRODUCTS Duaplate D100 & D100XP D100 microstructure at 100x magnification Typical D100 finish Base Material Duaplate is a clad plate manufactured by welding an abrasion resistant material to a steel base. The standard base material is mild steel; however, this can be changed to suit your operating environment. Overlay Material The D100 and D100XP overlay materials are complex chromium carbide irons that are based on AS The microstructure of these materials consists of primary M 7 C 3 and MC carbides in a complex carbide austenite matrix. The high temperature abrasion resistance performance is attributable to the presence of refractory elements molybdenum, niobium and tungsten. D100XP contains a higher amount of refractory elements then D100, which results in a greater resistance to abrasion at high temperatures. Typical Properties Bulk Hardness (HV 50 ): Grade Ambient 400 o C 800 o C D D100XP Typical Carbide Hardness: 1500HV 0.5 Volume Fraction Primary Carbide: Duaplate D100 chute in cement plant Grade MC M3C7 D % 22% Duaplate D100XP 10-15% 20% D100/D100XP Flyer 2008 BRADKEN 14

15 BRADKEN PRODUCTS Duaplate D100 & D100XP D100 microstructure at 500x magnification Duaplate D100 panels for a paul wurth chute Welding Duaplate can generally be welded in the same manner as the base material, provided care is taken to avoid contact with the overlay material when laying down structural welds. For further information contact your nearest Bradken branch. Cutting, Forming and Fabrication Plasma cutting is the recommended method for cutting Duaplate. It is preferable to cut Duaplate from the backing plate side to ensure a clean edge and to prevent carbide contamination. Duaplate can also be easily cold formed into almost any shape that mild steel can, by pinch rolls or hydraulic press brake. The steel backing plate provides Duaplate with structural integrity, thus entire structures can be fabricated from Duaplate. Bradken has the capabilities to manufacture such structures or to supply cut and formed, ready-to-go wear liners. Services & Applications Duaplate D100 and D100XP are suited for applications requiring severe abrasion resistance at elevated temperatures. Typical uses include: Duaplate D100 screw feeder segment Sizing screens Ducts Sinter bins Paul wurth chutes Chute liners For more information contact Bradken at wpbsales@bradken.com.au 3 BKM SP MKT Rev. 1 Issue date July BRADKEN 170 Railway Parade Bassendean WA 6054 Australia T F W bradken.com.au 15

16 BRADKEN PRODUCTS Duaplate Smooth The Duaplate Smooth finish Hopper lined with Duaplate Smooth Duaplate is a well established chromium carbide overlay plate, well known for its high abrasion and impact resistance. Duaplate is also available in smooth varieties to maximise material flow and reduce hang-up. Duaplate Smooth provides a low friction solution to your bulk handling problems, without the design or wear penalties. The smooth surface of Duaplate Smooth is a result of using a flux during the overlay process. This smooth finish, along with a slightly modified carbide structure, attributes to Duaplate Smooth s low friction properties. Duaplate Smooth is best employed in situations where mass flow is critical and hangup is a problem, such as in hoppers and load out bins. Several independent laboratory tests have been conducted to compliment the successful service history of Duaplate Smooth. The tests emphasize the shear stress or friction generated when a force or normal stress is applied to a bulk material against a liner material. The lower the shear stress for a given normal stress, the less likely it will be for the bulk material to hang up on the particular liner material. The bulk materials used these tests are typically regarded as some of the worse in terms of their tendency to hang-up. Chute lined with Duaplate Smooth Duaplate Smooth Flyer 2008 BRADKEN 16

17 BRADKEN PRODUCTS Duaplate Smooth Duaplate Smooth coal conveyor feed chute Duaplate - Standard (left), Smooth (Centre) and Polished (Right) As with standard Duaplate, for optimum wear life it is preferable to align any Duaplate Smooth liner or fabrication with the weld beads perpendicular to the material flow. It should be noted that the orientation of the weld beads has a minimal effect on the low friction properties of Duaplate Smooth. Smooth varieties of the Duaplate D60 and D80 are available through the full range of the standard Duaplate overlay thicknesses. D90 Smooth is also available, but only as a 6mm overlay. These three smooth grades allow Bradken to offer a low friction solution to your material handling problems whether it is affected by impact or fine particle abrasion. The graphs highlight the superior low friction properties Duaplate Smooth achieves over mild steel, other clad plate and competitor materials. In addition to Duaplate Smooth, Duaplate Polished, which has an even lower coefficient of friction, can be supplied for extreme bulk material hang-up problems, Duaplate Polished is subject to a minimum order quantity and some conditions apply. For more information on Duaplate in the standard, smooth or polished varieties, contact your local Wear Plate & Block sales representative. For more information contact Bradken at wpbsales@bradken.com.au 3 BKM SP MKT Rev. 1 Issue date July BRADKEN 170 Railway Parade Bassendean WA 6054 Australia T F W bradken.com 17

18 Duaplate Catalogue Standard Dimensions & Weights Standard sheets are marked with an X Plate Grade Overall Weight Type D60 LRG D80 LRG D60 SML D80 SML Thickness (mm) (Kg.m -2 ) 3 on on on 6 X X on on 8 X X X X on 10 X X on 8 X X on on on on on on 8 X X on 10 X X X X on 12 X on on 10 X on 12 X X on 10 X on 12 X X Small Sheet (SML) -1.94m Large Sheet (LRG) m Overlay direction Length m Sheet size and overlay direction Notes: 1. Example - Plate type 5 on 8 has 5mm Duaplate on 8mm of backing plate. 2. Non-standards plate types are made to order with a minimum quantity. 3. Overlay beads run along widths as indicated in the diagram above. 4. Sheet widths can be larger to suit customer requirements. Note this can make plates over-width for transport. 5. D90 and D100/D100XP are made to order and have some manufacturing constraints. 6. Other thicknesses can be manufactured on request. 7. Please discuss any variation from standard with your local sales representative. 18

19 Q&T Steel Introduction Bradken s 450 Q&T steel is a heat-treated, quench and tempered (Q&T) steel designed for applications where shock and severe abrasion are the primary cause of failure. Bradken s Q&T steel provides an economic alternative to more exotic and expansive abrasion and impact resistant materials. Bradken s 450 Q&T steel has mechanical properties compared to mild steel, with a typical hardness of 465HB and a tensile strength of 1480MPa. Bradken s 450 Q&T steel is easily welded, cut and formed for accurate fitting and installation on any application. Bradken s 450 Q&T steel is designed to provide maximum abrasion resistance and impact protection at an economically viable cost. Although 450 is our primary grade of Q&T plate, Bradken can also supply structural grade plates and other abrasion resistant Q&T steel grades. 19

20 BRADKEN PRODUCTS Bradken s Q&T Steel Q&T steel sizing screen Material Information Bradken s Q&T Steel is an abrasive resistant quench and tempered steel plate, heat treated to provide an excellent combination of toughness and wear resistance. Bradken s Q&T Steel is available in a variety of sizes and thicknesses to suit a range of operating conditions. Typical Properties Chemical Analysis Element C P Mn Si S Ni Composition % Element Cr Mo B CE(IIW) PCM Composition % Chute lined with Q&T steel plates Hardness: 465 HB Tensile strength: 1480 MPa Charpy impact: 20J Elongation: 12% Welding Bradken s Q&T Steel can be welded in accordance with AS It is recommended that the plate should be preheated for all thicknesses. No post heating is required. Truck bed lined with Q&T steel and Duaplate D80 Q&T Steel Flyer 2008 BRADKEN 20

21 BRADKEN PRODUCTS Bradken s Q&T Steel Standard Sheet Sizes Bradken can supply pre-cut and fabricated sections of Bradken s Q&T Steel, or we can provide standard sheets sizes as outlined below*. Q&T steel main frame liners Thickness: Standard Width: Standard Lengths: 6mm, 8mm, 10mm, 12mm, 16mm, 20mm, 25mm, 32mm 40mm, 50mm, 63mm, 75mm 2485mm 4000mm and 8000mm *Other dimensions and thicknesses are available on request. Bucket with Q&T steel strips Services & Applications Bradken s Q&T Steel is suited for applications involving high impact and moderate abrasion. Bradken s Q&T Steel is typical used on: Dump truck wear liners Chute liners Bin and hopper liners Construction and mining bucket liners Mold board liners Scrapper liners Chipper hoods Dozer with Q&T steels tumble bars For more information contact Bradken at wpbsales@bradken.com.au 3 BKM SP MKT Rev. 0 Issue date Oct BRADKEN 170 Railway Parade Bassendean WA 6054 Australia T F W bradken.com 21

22 Duablock Introduction Bradken s block products are a composite material comprising of a chromiummolybdenum, abrasion resistant, white iron casting, metallurgically bonded to a weldable mild steel backing plate. The white iron casting is a superior wear resistant product, containing hard chromium carbides, typically 1500HV, supported in a martensitic matrix. The mild steel backing plate is vacuum brazed to the white iron casting, giving a true metallurgical bond. Other backing plates, such as stainless steel, can also be used to suit the operating environment. The standard backing plate is machined flat for quick attachment by welding or Bradken can supply blocks fitted with studs for easy installation and removal. When welding the backing plate to a surface, no pre heating or post heating is required. A wide variety of standard blocks are available, adapted for specific applications. However, Bradken s block products can be custom designed to meet any situation regardless of size and shape concerns. Bradken can also supply cut and shaped blocks to be strategically placed on equipment so that a unique, high performance wear package can be created to maximise service life. Bradken s Block products offer superior wear life compared to Q&T bars, manganese steel and chrome-molybdenum pearlitic steels. 22

23 BRADKEN PRODUCTS Block Product Solutions Bradken is a leading manufacturer of wear resistant products for the mining, construction and resource processing industries. With over 30 years experience, Bradken has distinguished itself as a provider of quality products that meet customer requirements. Assorted block products Bradken s block products are chromium-molybdenum rich, abrasion resistant, white iron castings that is metallurgically bonded to weldable mild steel backing plate. Bradken s range of block products include: Duablock Microledge Duabutton Duatrap Chocblock Skidblock Grizzlybar Bucket with Duabutton protection Chute lined with Microledge Block Products Flyer The advantages of using Bradken s range of block products: Longer wear life: outlast Q&T steel. Reduced downtime: Bradken s block products improve equipment life and require less maintenance and inspections. Easy to fit: No special qualifications required to weld. As an alternative to welding, studs can be attached on request. Flexibility: Bradken can supply block products for attachment in the field as required, or they can be preattached to equipment at one of Bradken s engineering workshops. Adaptability: Bradken s block products are available in a wide range of dimensions and can be adapted to suit a wide range of operating conditions BRADKEN 23

24 BRADKEN PRODUCTS Block Product Solutions Grizzly bars protected by Duablock Applications of Block Products Bradken s block products can be strategically placed on equipment before it enters service to prolong life in high wear locations. They can also be welded onto equipment during service to rectify wear in unexpected, localised trouble areas. Duablock wear bars offer excellent protection when used as tumble bars or when configured to form a rock-box. They are also used to provide protection to heavy earth moving machinery. Duabutton blocks are extensively used on heavy earth moving equipment, particular on mining and construction buckets and shovels. Loader bucket with Skidblock Chokblock bars are unique block products that can be formed and welded onto flat or curved surfaces. This allows Chokblocks to be used on a range of fixed plant and mobile equipment such as buckets and chute liners. Microledge blocks are attached to chutes to form micro-rock boxes, which virtually eliminates wear to the chute structure. Skidblock pads are used extensively to provide strategic protection on heavy earth moving equipment, particularly on mining and construction buckets and shovels. Duatrap lined impact wall Duatrap liners are used to create a rock-box effect on fixed plant applications such as chutes and impact walls. Grizzlybar cappings used to protect grizzly fingers. For more information contact Bradken at wpbsales@bradken.com.au 3 BKM SP MKT Rev. 3 Issue date Oct BRADKEN 170 Railway Parade Bassendean WA 6054 Australia T F W bradken.com.au 24

25 Duablock Catalogue Standard Dimensions & Weights Part Reference Dimensions (mm) Weight Number Number A B C D E (Kg) BD115X50X50D BD128X50X50D BD150X50X50D BD190X50X50D BD210X50X50D BD300X50X50D BD432X50X50D BD75X50X32D BD100X100X50D BD150X75X75D BD150X100X58D BD152X75X38D BD152X75X50D BD190X50X70D BD200X25X25D BD200X75X75D BD210X50X70D BD230X50X70D BD238X75X75D BD241X100X58D BD300X25X25D BD315X130X75D BD335X130X75D BD340X75X75D BD375X130X75D BD500X130X75D BD600X100X50D Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request BRADKEN MADE IN AUSTRALIA BKX 25

26 Standard Dimensions & Weights Part Reference Dimensions (mm) Weight Number Number A B C D E (Kg) BD75X27D BD90X32D BD115X32D BD150X41D Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request BRADKEN MADE IN AUSTRALIA BKX 26

27 Standard Dimensions & Weights Part Reference Dimensions (mm) Weight Type Number Number A B C D E (Kg) BD240X40X23D BD240X40X23D70N BD240X50X23D BD240X50X23D70N BD240X65X23D BD240X65X23D70N BD240X90X29D70N BD240X130X29D70N Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. BRADKEN BKX 1088 MADE IN AUSTRALIA BRADKEN 27

28 Standard Dimensions & Weights Part Reference Dimensions Weight Type Block Size Mount Type Number Number A (mm) (Kg) BD128X50X50D70BKT A 128X50X50 128X65X65X10 ANGLE BD190X50X50D70BKT A 190X50X50 190X65X65X10 ANGLE BD210X50X50D70BKT A 210X50X50 210X65X65X10 ANGLE BD230X50X50D70BKT A 230X50X50 230X65X65X10 ANGLE BD432X50X50D70BKT B 432X50X50 432X65X65X10 ANGLE Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 28

29 Standard Dimensions & Weights Part Reference Dimensions Weight Type Block Size Mount Type Number Number A (mm) (Kg) BD128X50X50D70STD A 128X50X50 M16X35mm STUDS (X2) BD150X75X75D70STD A 150X75X75 M20X50mm STUDS (X2) BD190X50X50D70STD A 190X50X50 M16X35mm STUDS (X2) BD210X50X50D70STD A 210X50X50 M16X35mm STUDS (X2) BD230X50X50D70STD A 230X50X50 M16X35mm STUDS (X2) BD238X75X75D70STD A 238X75X75 M20X50mm STUDS (X2) BD340X75X75D70STD A 340X75X75 M20X50mm STUDS (X2) BD432X50X50D70STD B 432X50X50 M16X35mm STUDS (X3) Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Other stud sizes are available on request. 29

30 Standard Dimensions & Weights Part Reference Dimensions Weight Type Block Size Mount Type Number Number A (mm) (Kg) BD190X50(75)X50STD A 190X50(75)X50 M16X35mm STUDS (X2) BD230X50(75)X50STD A 230X50(75)X50 M16X35mm STUDS (X2) BD432X50(75)X50STD B 432X50(75)X50 M16X35mm STUDS (X3) Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Other stud sizes are available on request. 30

31 Standard Dimensions & Weights Part Reference Dimensions Weight Type Block Size Mount Type Number Number A (mm) (Kg) BD241X100X58BPL2H A 241X100X58 241X150X10 PLATE BD241X100X58BPL B 241X100X58 241X150X10 PLATE BD241X100X58BPL2H A 150X100X58 150X150X10 PLATE BD241X100X58BPL2H A 241X100X58 241X150X10 PLATE Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 31

32 Standard Dimensions & Weights Part Reference Dimensions (mm) Studs Weight Number Number A B C D E F G J K L M (Kg) BDT300X150X50STD M16X40 (X2) 12.9 BDT300X300X50STD M16X40 (X4) 25.9 BDT452X300X50STD M16X40 (X4) 38.9 Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Other stud sizes are available on request BRADKEN MADE IN AUSTRALIA BKX 1108 BRADKEN MADE IN AUSTRALIA BKX 1108 BRADKEN MADE IN AUSTRALIA BKX 1108 BRADKEN MADE IN AUSTRALIA BKX 32

33 Standard Dimensions & Weights Part Reference Dimensions (mm) Studs Weight Number Number A B C D E F G J K L M (Kg) BDT150X150X50STD M16X40 (X1) 6.5 BDT300X150X50STD M16X40 (X2) 12.9 BDT452X150X50STD M16X40 (X2) 19.4 Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Other stud sizes are available on request BRADKEN MADE IN AUSTRALIA BKX 1108 BRADKEN MADE IN AUSTRALIA BKX 33

34 Standard Dimensions & Weights Part Reference Dimensions (mm) Studs Weight Number Number A B C D E F G J K L M (Kg) BDT452X150X50STD M16X40 (X2) 19.4 BDT452X300X50STD M16X40 (X4) 38.9 Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Other stud sizes are available on request BRADKEN MADE IN AUSTRALIA BKX 1108 BRADKEN MADE IN AUSTRALIA BKX 1108 BRADKEN MADE IN AUSTRALIA BKX 1108 BRADKEN MADE IN AUSTRALIA BKX 1108 BRADKEN MADE IN AUSTRALIA BKX 1108 BRADKEN MADE IN AUSTRALIA BKX 34

35 Standard Dimensions & Weights Part Reference Dimensions (mm) Weight Number Number A B C D E F (Kg) BD305X150(141)X50D BD305X141(131)X50D BD305X131(122)X50D BD305X122(113)X50D BD305X113(103)X50D BD305X103(94)X50D BD305X94(84)X50D BD305X84(75)X50D Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 35

36 Standard Dimensions & Weights Part Reference Dimensions (mm) Weight Number Number A B C D E (Kg) BD200X150X45D BD250X150X45D BD250X250X45D Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request BRADKEN MADE IN AUSTRALIA BKX 36

37 NiHard Products NiHard is a well-established white iron product alloyed with nickel and chromium to give significant abrasion and impact resistant properties. The structure of NiHard is composed of iron and chromium carbides, fixed in a matrix rendered martensitic by the nickel content. This structure allows NiHard to be utilised in abrasive and high impact conditions found throughout the construction, mining, manufacturing and mineral processing industries. Bradken NiHard products include billets and liner plates that can be made to the customers specification or supplied from our range of stock sizes. Bradken s NiHard products can be custom designed to meet any situation regardless of any size and shape concerns. Bradken can also supply cut and shaped liners to be strategically placed on fixed plant equipment so that a unique wear package can be created, maximising wear life. This makes NiHard the perfect material for chutes, drop boxes, bin and hopper liners. Bradken primarily supplies cast billet and liner plates produced to the NiHard 4 specifications. However, Bradken can produce billets and liner plates from the following alloys on special request: NiHard 1 & 2 27 Chrome Alloy 15/3 White Iron 20/1 White Iron Introduction 37

38 NiHard Catalogue Standard Dimensions & Weights 20mm thick to suit M20 fishtail bolt Part Reference Dimensions (mm) Weight Type Number Number A B C D E F G (Kg) D03779 L D04078 L1S D03786 L D03787 L D03792 L D03798 L Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Liners can be cut to size on request. 4. Bolts are available on request. 38

39 Standard Dimensions & Weights 32mm thick to suit M20 fishtail bolt Part Reference Dimensions (mm) Weight Type Number Number A B C D E F G (Kg) D04064 N D04065 N D04066 N D04067 N D04068 N D04069 N Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Liners can be cut to size on request. 4. Bolts are available on request. 39

40 Standard Dimensions & Weights 50mm thick to suit M20 fishtail bolt Part Reference Dimensions (mm) Weight Type Number Number A B C D E F G (Kg) D02971 B D02972 B D02793 B Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Bolts are available on request. 40

41 Standard Dimensions & Weights 100mm thick to suit M22 fishtail bolt Part Reference Dimensions (mm) Weight Type Number Number A B C D E F G (Kg) D03468 WB D03536 WB Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Bolts are available on request. 41

42 Standard Dimensions & Weights 100mm thick to suit M20 hex head bolt Part Reference Dimensions (mm) Weight Type Number Number A B C D E F G (Kg) DW2875S B DW2874S B Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Bolts are available on request. 42

43 Standard Dimensions & Weights 76mm thick to suit M20 square head bolt Part Reference Dimensions (mm) Weight Type Number Number A B C D E F G (Kg) D00927S 12 BILLET D00926S 18 BILLET Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Bolts are available on request. 43

44 Standard Dimensions & Weights Hollow billets to suit M20 bolt Part Reference Dimensions (mm) Weight Type Number Number A B C D E F G (Kg) DW3012S HB DW3011S HB Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes can be made on request. 3. Bolts are available on request. 44

45 Duaceramic Duaceramic is a new product developed and manufactured in Australia by Bradken. Duaceramic combines exceptionally abrasion resistant alumina tiles, imbedded in an impact resistant polyurethane elastomer, to provide an outstanding wear resistant product. The extremely hard ceramic tiles protect equipment from deterioration, whilst the elastic properties of the polyurethane dampens any impact. Several different modular alumina tile designs are available that are suited for different applications. The hardness of the polyurethane is also available in multiple grades to suit specific material and operating conditions. As one of the hardness materials known, alumina is far superior to steel plate when it comes to protection against abrasion. The Duaceramic range of products are specifically designed to protect against the most extreme abrasive environments. Introduction 45

46 BRADKEN PRODUCTS Duaceramic Liners Duaceramic is a new, dynamic product offered by Bradken s Wear Plate and Block. Duaceramic combines hard alumina ceramic blocks, chemically and mechanically bonded to an impact resistant polyurethane elastomer. Duaceramic is designed for use in the most extreme abrasive environments found in the mining and mineral processing industries. Duaceramic liners with edge protection and backing plate 35mm thick Duaceramic liners for a ship loader 63mm thick Duaceramic chute layout Duaceramic Flyer Duaceramic liners are available in a range of standard thicknesses and shapes. Duaceramic liners can also be customised to provide unique shapes for wear packages. The Duaceramic liners can be manufactured using hexagonal alumina blocks for high abrasion and medium impact or large rectangular alumina ceramic tiles, for extreme abrasion with low impact. Duaceramic Features: Maximum Resistance To Abrasion: The ceramic blocks used in Duaceramic are manufactured from high alumina ceramic to provide maximum resistance to abrasion. Multidirectional: The Duaceramic liners do not require a specific orientation to flow direction. Edge Protection: Leading and trailing edges can be included to protect the ceramic tiles from severe impact on the edges. Noise Reduction: The polyurethane medium not only absorbs impact, but also reduces noise caused by bulk material flow. Backing Plate: A unique, light weight backing plate can be included to provide assistance in the knockout of worn liners. Ceramic Locking System: Each ceramic tile used in the Duaceramic liners comes with a locking mechanism to prevent tile knock out during severe impact. Wear Indicators: Duaceramic Liners can be manufactureed to indicate when 50% or more of the ceramic has been abraded. Unique Chemical Treatment: The ceramic tiles in Duaceramic undergo a unique chemical treatment to provide a superior polyurethane to ceramic bond strength. Customized Liners: Duaceramic can be manufactured into a range of complex shapes with angles and bevelled edges. Australian made: Duaceramic is a wholly Australian developed and manufactured product by Bradken BRADKEN 46

47 BRADKEN PRODUCTS Duaceramic Liners 35mm Duaceramic liners for an apron feeder Comparison With A Competitor Duaceramic offers a superior replacement for competitor ceramic/polymer composites. The following is a comparison between a competitor liner and the equivalent Duaceramic liner: Feature Duaceramic Competitor Backing Plate (BP) Optional Compulsory Edge Protection Optional Optional Angled & Bevelled Edges Yes Yes Wear Indicator Optional No Locking Mechanism Yes No Multidirectional Yes No Medium Material Polyurethane (PU) Styrene Butadiene Rubber (SBR) Complementary Products In addition to our Duaceramic liners, Bradken can also provide: Polyurethane impact liners Ceramic to metal fabrications Unique Duaceramic light weight backing plate Duaceramic tile showing key design features For more information contact Bradken at wpbsales@bradken.com.au 3 BKM SP MKT Rev. 2 Issue date Oct BRADKEN 170 Railway Parade Bassendean WA 6054 Australia T F W bradken.com 47

48 Duaceramic Catalogue Standard Dimensions & Weights Hex liners with backing plates Part Dimensions (mm) Weight Type Studs Number A B C D E (Kg) (+0/-2) (+0/-2) (±1) (±1) H1-63BP LRG HEX M16x50 (x8) 35.2 H2-63BP LRG HEX M16x50 (x4) 17.1 H3-63BP LRG HEX M16x50 (x2) 8.6 H1-53BP LRG HEX M16x50 (x8) 28.7 H2-53BP LRG HEX M16x50 (x4) 14.2 H3-53BP LRG HEX M16x50 (x2) 7.2 H1-35BP SML HEX M16x50 (x8) 17.4 H2-35BP SML HEX M16x50 (x4) 8.5 H3-35BP SML HEX M16x50 (x2) 4.4 Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes and custom shapes can be made on request. 3. Other stud sizes are available on request. 48

49 Standard Dimensions & Weights Hex liners without backing plates Part Dimensions (mm) Weight Type Studs Number A B C D E (Kg) (+0/-2) (+0/-2) (±1) (±1) H1-63 LRG HEX M16x50 (x8) 32.5 H2-63 LRG HEX M16x50 (x4) 15.9 H3-63 LRG HEX M16x50 (x2) 8.0 H1-50 LRG HEX M16x50 (x8) 25.2 H2-50 LRG HEX M16x50 (x4) 12.7 H3-50 LRG HEX M16x50 (x2) 6.4 H1-32 SML HEX M16x50 (x8) 14.0 H2-32 SML HEX M16x50 (x4) 7.1 H3-32 SML HEX M16x50 (x2) 3.5 Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes and custom shapes can be made on request. 3. Other stud sizes are available on request. 49

50 Standard Dimensions & Weights Tile liners with backing plates Part Dimensions (mm) Weight Type Studs Number A B C D E (Kg) (+0/-2) (+0/-2) (±1) (±1) T1-63BP TILE M16x50 (x8) 36.2 T2-63BP TILE M16x50 (x4) 17.9 T3-63BP TILE M16x50 (x2) 9.0 Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes and custom shapes can be made on request. 3. Other stud sizes are available on request. 50

51 Standard Dimensions & Weights Tile liners without backing plates Part Dimensions (mm) Weight Type Studs Number A B C D E (Kg) (+0/-2) (+0/-2) (±1) (±1) T1-63 TILE M16x50 (x8) 33.2 T2-63 TILE M16x50 (x4) 16.7 T3-63 TILE M16x50 (x2) 8.3 Notes 1. Please contact your local sales office for pricing and availability. 2. Other sizes and custom shapes can be made on request. 3. Other stud sizes are available on request. 51

52 Contact Information Bradken Offices Adelaide, SA 80 Cromwell Road Kilburn SA 5084 T F Brisbane, QLD 54 Bonemill Road Runcorn QLD 4113 T F Emerald, QLD 3/23 Hospital Road Emerald QLD 4720 T F Gladstone, QLD 177 Old Ten Chain Road Calliope QLD 4680 T F Kalgoorlie, WA 142 Cunningham Road Kalgoorlie WA 6430 T F Mackay, QLD 2 Commercial Avenue Paget QLD 4740 T F Mt Isa, QLD Lot 3, 5 Northridge Road Northridge Industrial Estate Mt Isa QLD 4825 T F Port Hedland, WA M Mt Thorley, NSW Lot Woodlands Road Mt Thorley NSW 2330 T F Melbourne, VIC 32 Business Park Drive Notting Hill VIC 3168 T F Newcastle, NSW 2 Maud Street Mayfield West NSW 2304 T F Orange, NSW 2/87 Byng Street South Orange NSW 2800 T F Perth, WA 170 Railway Parade Bassendean WA 6054 T F Townsville, QLD Dalrymple Road Garbutt QLD 4814 T F Wundowie, WA 52 Hawke Avenue Wundowie WA 6560 T F Bradken Offices Bradken Resources Pty Limited ABN Wear Plate & Block Head Office 170 Railway Parade Bassendean WA 6054 Australia PO Box 51 Bassendean WA 6934 Australia T F E wpbsales@bradken.com.au W bradken.com Bradken Head Office 2 Maud Street Mayfield West NSW 2304 Australia PO Box 105 Waratah NSW 2298 Australia T F E bradken@bradken.com.au W bradken.com Bradken Bradken, Duaplate, Duablock and Duaceramic are registered trademarks of Bradken Resources Pty Limited. Wearalloy is a registered trademark of Ford Steel Company. Bisalloy is a registered trademark of Bisalloy Steels Pty Limited. Hardox is a registered trademark of SSAB Oxelosund AB. Creusabro is a registered trademark of Creusot Loire Industrie. (Ref: 3 BKM SP MKT WPB Booklet - Oct 2008)