FAQs

GAC utilizes a specialized dual-fixation weld-on ceramic system (weld-on Kalocer). Each Kalocer tile (13 – 25mm thick) features a pre-formed countersunk hole. A metal socket is inserted through the tile and plug-welded directly to the skip car’s steel floor. The socket is then filled with Kalfix adhesive and capped with a matched ceramic plug. This mechanical weld lock, combined with epoxy bonding, prevents the tiles from dislodging under heavy vibrational shocks.

High-moisture iron ore concentrates dropped from Level-5 silos create a highly corrosive, acidic environment. Mild steel rusts and pits rapidly, creating a rough, scale-covered surface that causes material hang-up. Hardox HiAce combines high hardness (425 – 475 HBW) with specialized electrochemical corrosion-resistant properties, extending service life by up to 2.7 times while maintaining a smooth sliding surface.

In pneumatic transport pipelines, centrifugal force concentrates particle impact on the outer radius (back) of the pipe elbow, while the inner radius (throat) experiences minimal wear. GAC’s asymmetric design casts a thicker Kalcret layer on the high-wear outer radius and a thinner layer on the inner radius, optimizing material weight, reducing pipe load, and lowering the procurement cost for the plant.

Kalcret BTX is applied as a jointless, monolithic lining, completely eliminating joint lines and exposed adhesive areas. Furthermore, Kalcret is mechanically anchored onto a 5mm-thick expanded steel mesh welded directly to the casing, ensuring the lining cannot delaminate even under high-velocity dust streams.

This failure is driven by aerodynamic erosion targeting the joint lines between individual ceramic tiles. Fine, high-velocity dust particles blast the soft epoxy adhesive out of the joints. Once the adhesive is eroded, gas pressure forces its way underneath the ceramic tiles, lifting and peeling them off in sheets.

At this location, hot sintered ore from the kiln carries high thermal load. Standard bimetallic plates (like W100) are limited to operating temperatures below 350°C. For these conditions, GAC recommends Kalmetall W145. Formulated with special niobium (Nb) and molybdenum (Mo) alloying elements, Kalmetall W145 maintains its carbide matrix stability and extreme hardness (HV 800) at continuous operating temperatures up to 750°C.

Standard flux-cored wire hardfacing often dilutes carbon and chromium into the steel backing plate during welding, causing carbide concentration to drop dramatically toward the fusion line. This leads to accelerated wear once the top layer is gone. Kalmetall W100, manufactured via a proprietary powder cladding and fast-crystallization process, maintains a uniform distribution of chromium carbides (M7C3, with micro-hardness exceeding HV 1300) from the outer wear surface all the way down to the steel backing boundary, extending wear life by 2 to 3 times.

For standard wear plates, increasing hardness often results in increased brittleness, which can lead to micro-cracking and eventual fracturing under heavy dynamic impacts from excavator bucket drops. Hardox 500 TUF bridges this gap by combining high hardness (475 – 505 HBW) with exceptional impact toughness (Charpy V-notch toughness of 45J at -40°C), completely preventing cracking and structural failure in dumper beds.

Q355B has a low yield strength (~355 MPa), meaning it undergoes permanent plastic deformation (denting and warping) under dynamic loading. Conversely, Hardox 500 is a through-hardened steel with a surface hardness of 475 – 505 HBW and an actual yield strength of 1250 – 1400 MPa. It resists scratch-gouging and springs back to its original flat profile even after absorbing high-impact forces from falling boulders.

GAC’s installation team receives direct technology transfer and technical training under the supervision of specialists from leading international manufacturers such as Kalenborn and SSAB, ensuring installation quality that meets global standards.

Gia Anh provides complete turnkey wear protection solutions, including on-site inspection, failure analysis, engineering design, material supply, fabrication, installation, and final acceptance.

Managing the entire project through a single contractor ensures seamless coordination between materials, design, and installation, minimizing unexpected issues during maintenance. For scheduled shutdown projects, Gia Anh works closely with the plant to prepare materials and installation plans in advance, reducing maintenance time and returning equipment to operation on schedule.