Wear & impact protection for the mining sector
Optimize equipment service life
Increase transport productivity
Overcome severe boulder impact and high-friction ore abrasion with through-hardened Hardox 500 TUF steel and super-hard Kalocer ceramic liners
Identify the right impact mechanism, select the right lining material
Mining and mineral processing operate under some of the harshest conditions. Equipment is continuously exposed to destructive impact from large falling rocks combined with severe sliding abrasion from sharp ore particles
INCORRECT APPROACHES
- Increasing the thickness of standard carbon steel such as 16Mn or Q345 to improve wear resistance. Increasing plate thickness adds unnecessary deadweight, increases fuel consumption, and reduces useful payload. Standard carbon steel also lacks sufficient impact toughness, causing rapid denting and structural cracking under heavy ore impact
- Using conventional ceramics or hardfacing in heavy-impact ore zones. Standard ceramic liners are extremely hard but brittle. Large rocks falling from significant heights can fracture ceramic tiles, while hardfacing layers may delaminate under repeated surface fatigue
- Purchasing wear plates and fabricating them without specialized procedures. High-hardness steels can crack during bending or develop hydrogen-induced cracking in the Heat Affected Zone (HAZ) if incorrect cutting, bending, or welding procedures are applied
SOLUTION SELECTION PRINCIPLES
- Use high-toughness wear steel for severe impact zones. Materials such as Hardox 500 TUF provide both high hardness and exceptional impact toughness, minimizing floor deformation and cracking under repeated loading
- Match ceramics to sliding and slurry-wear applications. Use Kalocer or Kalcor ceramics in areas dominated by high-speed sliding abrasion or fine-slurry erosion, where direct heavy impact is limited
- Fabricate through an authorized Hardox Wearparts Center. GAC follows certified low-hydrogen welding, controlled heat-input, and cold-bending procedures according to SSAB specifications to preserve the original mechanical properties of the steel
Mapping high-impact & sliding-abrasion hotspots in mining operations
GAC optimizes equipment service life by specifying the right material for each zone handling coarse ore and fine slurry
Heavy-duty mining truck bodies
Heavy dumping of iron ore or granite tumbles onto standard 16Mn steel beds, causing severe denting, floor bowing, and weld failures within months.
Solution: Line the floor and side plates with Hardox 500 TUF backed by Perform 700 high-strength structural beams. Proven at Than Cao Son coal mine on CAT 777E dumper trucks: standard 16Mn wore out at 1.44mm/month, whereas Hardox 500 TUF wore only 0.45mm/month (yielding a 4.47x life extension) while keeping the bed perfectly flat.
Slurry hydrocyclones & coal-beneficiation pipelines
Silica sand and copper ore slurry create intense centrifugal hydro-abrasive erosion on cyclone inner cones and steel transport elbows, cutting through bare steel rapidly.
Solution: Line interior walls with 15–25mm-thick Kalocer Alumina Ceramic Tiles or Kalcor Zirconium Corundum Tiles bonded with high-bond Kalfix adhesives, preventing sliding friction wear from fine-grained slurries.
Ore transfer chutes & receiving hoppers
Large ore blocks dropping from conveyor discharges >3m slam directly into hopper walls, causing continuous metal tearing and structural failures.
Solution: Apply combined lining engineering: line the direct impact zone with 20–25mm Hardox 500 TUF plates secured by countersunk bolts for easy swap-out, and shield the surrounding sliding walls with weld-on Kalocer ceramic tiles.
Magnetic separators & wet screen drums
Continuous sliding of abrasive wet ore slurries erodes steel drum shells, threatening expensive internal magnet assemblies.
Solution: Line the drum shells with UHMW-PE sheets or custom wear-resistant elastic polymers to prevent ore sticking, eliminate slide-wear, and avoid any magnetic interference
From field survey to fabrication, installation, and performance warranty
GAC provides an end-to-end solution based on actual operating conditions, helping mining plants reduce maintenance costs per ton of product
On-site geomechanical diagnostics
We measure material drop heights, evaluate maximum rock sizes, analyze mineral grain hardness (Mohs/Brinell), and map impact angles
Dual-material lining simulation
We generate 3D CAD lining maps separating impact zones (protected by Hardox 500 TUF) from sliding-abrasive slurry paths (protected by Kalocer)
Precision cold-fabrication
We perform underwater plasma cutting to prevent localized tempering, and execute cold bending using certified heavy-press dies at our Hung Yen factory to maintain the steel's mechanical integrity
Specialized on-site installation
GAC certified crews install mechanical weld-on ceramics with protective plug covers or bolt down Hardox plates with custom edge-beveling to prevent ore hang-ups
Operational monitoring & performance warranty
We hand over original European CO/CQ documents, conduct periodic wear inspections every 3 to 6 months, and back the system with a 12-to-24-month written performance warranty
Plants successfully using Gia Anh's solutions
Wear protection project for a coal mill
In May 2021, Gia Anh Investment Trading Co., Ltd. carried out a wear protection project for the coal mill at VICEM Tam Diep Cement Plant. The scope of work covered...
Wear protection project for the static separator vanes of a coal mill
In January 2021, Gia Anh Investment Trading Co., Ltd. collaborated with Kalenborn to implement a wear protection solution for the coal mill separator guide vanes at VICEM Hai Phong Cement...
Wear protection project for coal conveying pipelines – Vinh Tan 2 thermal power plant
In October 2020, a wear protection project for the coal conveying pipelines was carried out at Vinh Tan 2 Thermal Power Plant. EVNGENCO 3 Power Service Company was responsible for...
Wear protection project for cooling water beam – Hoa Phat steel plant
In September 2021, Gia Anh Investment Trading Co., Ltd. carried out a wear protection project for the cooling water beam at Hoa Phat Steel Plant. The repair work was carried...
Official Authorized Partner of the World’s Leading Brands
Products and services
Specialized heavy-impact, sliding-abrasion, and ore-slurry resistant materials
Genuine Swedish Hardox Wear Plate: Full range of Hardox 450, 500, particularly Hardox 500 TUF engineered specifically to resist falling rock/ore dynamic impact, and extreme-hardness Hardox 550/600 plates.
Kalocer High-Alumina Wear-Resistant Ceramics (Germany): High-density sintered tiles (Al₂O₃ >92%) achieving a hardness of 1,050 HV1, pre-formed as flat plates, cylinders, or customized shapes with mechanical weld-on sockets.
Kalmetall Bimetallic Clad Plates: Premium overlay cladding specifically built to resist coarse-grain scratch sliding abrasion.
Abresist Fused Cast Basalt (Germany): Centrifugally cast spools (20-30mm thick) reaching a hardness of 8 Mohs, glass-smooth interior, and fully chemically inert to acid mine drainage (AMD).
Tivar 1000 & Tivar 88-2 UHMW-PE Sheets: Premium low-friction polymer liners engineered to eliminate clay and wet ore build-up in hoppers.
On-site geomechanical diagnostics & wear simulation
On-site parameter mapping including rock drop heights, peak lump sizes, mineral Mohs/Brinell hardness, clay moisture profiles, and dynamic stress zones.
Application of high-precision 3D Laser Scanning to reconstruct exact geometries of eroded transfer chutes and mill cones for 100% flush-fitted liner design.
Precision workshop mechanical fabrication at Hung Yen facility
Utilizing CNC Underwater Plasma Arc Cutting to shape Hardox plates, maintaining a cooled cut edge to preserve the steel's native toughness and crack resistance.
Heavy-duty hydraulic press-brake cold bending with large-radius dies conforming to SSAB specifications, eliminating welding seams in direct sliding wear paths.
Certified on-site installation & heavy-duty fixation
Executing heavy-duty liner bolting and countersunk stud assembly for mining dumper beds and raw ore hoppers.
Installing mechanical weld-on Kalocer ceramics with integrated plug protection to resist severe vibration on sizing screens and beneficiation drums.
Applying Kalpoxy 150 two-component wear compound for rapid on-site patch repairs.
Key Clients
Frequently Asked Questions
Hardox® 500 TUF combines high hardness (475–505 HBW) with exceptional toughness. Field measurements show that 16Mn steel wears approximately 4.47 times faster than Hardox® 500 TUF and is much more susceptible to cracking and permanent deformation.
GAC uses TIVAR® 88-2 ultra-high molecular weight polyethylene (UHMW-PE), which features an extremely low coefficient of friction (0.08) and zero moisture absorption. It converts material flow into true mass flow, eliminating blockages without the need for hammering that can damage the silo structure.
Hardox® 450 offers significantly higher hardness, better dent resistance, and superior wear resistance than conventional structural steels. It extends equipment service life and allows thinner plates to be used while maintaining structural strength.
GAC classifies industrial wear into four primary mechanisms: adhesive wear, abrasive wear, corrosive wear, and fatigue wear. The evaluation is based on the German DIN 50320 standard, which analyzes the interactions among four key elements: the base material, the counter body, the intermediate medium, and the operating environment (including temperature and corrosion).
ABRESIST cast basalt is ideal for sliding abrasion applications such as ash or wet slag handling. It provides a smooth surface and can withstand temperatures up to 350°C. KALOCER ceramic offers higher hardness (9 on the Mohs scale) and heat resistance up to 1,000°C, making it the preferred choice for severe erosion areas such as cyclones and classifier blades.
Request for solution consultation
Gia Anh's expert will contact you within 24 hours to analyze the problem and provide a suitable solution.
