Featuring New technology and options for Industrial Wear Control
OVERVIEW An innovative approach for applying wear studs on areas exposed to high abrasion State of the art hardfacing technology TuffStudds are carbide-laden, wear resistant alloy studs >RC hardness is between 50-60 Tightly applied patterns create a dead bed effect which further enhances wear resistance Applied via Arc Weld onto alloy castings or plate Especially designed for heavy mining or construction operations
Benefits Convenience: Simple controls, automatic sequencing of the welding cycle Smokeless operation Horizontal, vertical and overhead position capability Minimal distortion due to heat build-up Repair capability on previously studded surfaces Speed: Application rates of up to four sq. ft. per hour * Deposit rates over 20 pounds per hour * * rates are dependent on coverage surface area and stud size
Benefits Long Life: Up to three times longer life reduces equipment downtime and overall costs of replaceable components Savings: Less Equipment Costs Less Downtime Less Labor Expense on repair and idle time Less overall cost for replacement parts The TuffStudds Wear Protection System SAVES money and INCREASES your bottom line!!!
Applications DOZER BLADES: Proven method of protecting dozer blades. Applied to blades and push arms Multiple applications on original wear plate Pattern becomes embedded with mineral debris creating dead bed effect
Applications Packer Tips: Effective method of protecting packer tips and blades Tips retain packing edge longer, allowing more effective packing action Wear on blades is minimized increasing life of part
Applications DRAGLINE BUCKETS: protect worn bucket components. Wing shrouds and drag hitch areas all benefit from TuffStudd protection. SHOVEL BUCKETS: excellent wear protection for all types of shovel buckets. High-wear areas such as lips, cutting edges and tooth adaptors attain maximum life when protected with TuffStudds.
Applications Augur Flights Edges Compactor Wheels Cage Mills Breaker Plates Grapple Clam Tips/Arms
WORLD OF ASPHALT
OVERVIEW The total Asphalt business in the North America is estimated at 24.0 Billion dollars annually The Asphalt Paving Industry is estimated at $14.15 Billion Dollars annually Approximately 475 companies have sales in excess of $100,000 annually 1% - $14.15 Million Dollars are spent on maintenance annually
ASPHALT PLANT MAINTENANCE There are two types of Asphalt plants PUG MILLS (batch plants) For small paving jobs; parking lots, driveways, side walks DRUM (continuous flow) for large paving jobs, mainly highways.
2006 Pug Mill Test Program 6 Ton Asphalt Pug Mill Hanson - Glen Mills, Pa Wear on Shank Arms after 200k+ tons of material or 1 year of service. Feb 06
Test Program on New Pug Mill Shanks March 2006, Hanson Glen mills installed TuffStudds to 40 new mixing arms prior to start of 2006 season for 6 ton pug mill Typically arms are replaced each year after average season of 200k-300k tons of material are run through mill There is a significant amount of labor involved in changing arms each year in additional to cost of new parts Objective of test is to increase the wear life of arms to 2 seasons
Test Program on New Pug Mill Shanks TuffStudds are applied to the critical wear areas of the shank Arm: under Paddle and around Base for Bolt Goal is to evaluate TuffStudds Shanks total length of service. Test of plant will be conducted in Spring-Summer of 2006
Results of TuffStudd Test Program TuffStudds are not showing any signs of wear after 80k tons of material through mill. Photos from June 2006. Material is embedded between studs on shanks creating the dead bed effect Initial results show TuffStudds appear to be extending the arm life
Results of TuffStudd Test Program TuffStudds arms showing minimal signs of wear after 180k tons of material through mill (Photos Sept 30, 2006) Material is still embedded between studs on shanks creating the dead bed effect Results show Tuffstudded arms will make second season
Results of TuffStudd Test Program Sept 06 2005 Season Comparison shot of Tuffstudded Arms vs. weld overlay arms Tuffstudd arms have 180k tons season to date.
Updated Results of Tuffstudd Test Program There are a total of 44 paddles contained within the machinery. Only 12 paddles are being replaced during this service period! These paddles have lasted almost 5 years and have had approximately 1.5 MILLION TONS of material run through them. Previous life expectancy was 200k tons which translates into a life extension of 7 times for the studded pug mill paddles.
SINGLE OR DOUBLE BARREL DRUM MIXER
SINGLE BARREL DRUM MIXER TUFFSTUDDS WOULD BE APPLIED ON THE INSIDE DIAMETER OF THE DRUM AT THE DISCHARGE END OF AGGREGATE FEED. IN ADDITION THERE MAY BE PADDLE ARMS THAT COULD ALSO HAVE TUFFSTUDDS APPLIED TSA-68 (3/4-19MM) OR TSA-78 (7/8-22MM) WOULD BE USED AS IT WOULD BE THE SAME AS WELDING DOWNHAND ON THE INSIDE RADIUS. ON A TYPICAL 8 FOOT DRUM DIAMETER BY 8 FOOT LENGTH OF THE AGGREGATE FEED AREA TO PROTECT FOR WEAR THE AREA TO BE COVERED WOULD BE: 25.4 FOOT CIRCUMFERENCE X 8 FOOT LONG SECTION EQUALS: 203.2 SQUARE FEET USING THE MAX TUFFSTUDD DIAMETER: TSA-78 (7/8-22MM) WITH 70 STUDS PER SQUARE FOOT, IT WOULD REQUIRE 14,225 TSA-78 TUFFSTUDDS (Approx.) Dollar Value $$29,925 USD
DOUBLE BARREL DRUM MIXER THE AGGREGATE DISCHARGE WOULD BE ON THE OUTSIDE OF THE INNER BARREL - OUTSIDE RADIUS THIS MAKES FOR A MORE DIFFICULT INSTALLATION requires WELD POSITION SLIGHTLY OVERHEAD. ONLY TSA-68 (3/4-19MM) ARE RECOMMENDED USING THE SAME DIMENSIONS AS FOR THE SINGLE DRUM WOULD REQUIRE 203.2 SQUARE FEET OF COVERAGE 203.2 SQUARE FEET X 100 PER SQUARE FOOT WILL REQUIRE: 20,320 TSA-68 Dollar Value (approx.) $34,125 USD IN ADDITION THERE MAY BE PADDLE ARMS THAT COULD ALSO HAVE TUFFSTUDDS APPLIED
Wear Plates with TuffStudds
Specifications Tuffstudds are available in 3 different sizes 5/8,3/4 and 7/8 diameters. Tuffstudds are graded in 2 different grading to maximize performance ( I ) for low impact, high abrasive conditions ( A ) for higher impact conditions. Application speeds of up to 200 studs per hour. Best results occur by tightly packing Tuffstudds in patterns that minimize wash-out between stud rows.
Authorized Distributor for For Product Demo at your site or for additional information on Tuffstudds please contact: Sales Manager: Steve Swartz E-mail: steve@newagestudwelding.com Phone: 888-889-3833 Fax: 856-218-3806 Office Location: 11 Enterprise Court Sewell, NJ 08080