Mining & Quarry - Secondary crusher - Screening - Stationary equipment - Sweden - +140% lifetime

Objective

Evaluate the performance of Creusabro^® 8000 as a more durable alternative to 450 HB steel in a screening application on a secondary crusher, with the aim of extending wear life and optimizing plant uptime.

Test Conditions

• Location: Quarry operation in Sweden

• Environment: High-abrasion environment within a secondary crusher, where screens are used to control granulometry and are continuously exposed to stone flow and impact from 0/80 mm material.

• Function: Screening plate that separates crushed material based on particle size; exposed to sliding wear and dynamic loads.

• Original material: 450 HB steel, 16 mm thick

• Replacement material: Creusabro® 8000, increased to 20 mm thickness, processed by plasma cutting

Results

• The 450 HB steel screening plate processed 105,000 tonnes before reaching wear limit.

• The Creusabro® 8000 screening plate processed 210,000 tonnes, achieving a +100% increase in wear life, with 140% gain in wear volume efficiency thanks to the thicker, more homogeneous material.

• The change in thickness was accepted by the end-user as it did not negatively impact equipment performance or screening efficiency.

Value Delivered

• +140% Wear Volume Efficiency: More than double the tonnage processed with consistent wear performance.

• Controlled Lifetime Extension: Thicker plate fully utilized thanks to Creusabro®'s homogeneous through-thickness wear resistance.

• Reduced Shutdowns: Less frequent replacement increased operational continuity and crusher availability.

• Simple Processing: Plasma cutting enabled precise fabrication and easy implementation into the existing setup.

Expert Insight

In this case, increasing the plate thickness allowed the full benefit of Creusabro® 8000's homogeneous microstructure to be realized. Unlike steels focussed only on hardness, Creusabro® wears uniformly through its thickness — enabling predictable performance over time. When equipment design allows, thickness increase becomes a strategic lever to maximize uptime and minimize intervention costs. The customer manage to keep the granulometry constant over time.

Conclusion

By switching to Creusabro® 8000 and increasing plate thickness, KEWAB and Bergsmekaniska implemented a robust, high-efficiency solution for secondary crusher screening — achieving a 140% improvement in wear performance and doubling the processed material.

Creusabro® proves once again to be a strategic upgrade for critical wear parts in crushing and screening operations.

Comparative test