How Hoverdale's Ultraclad Wear Plate saved 3,000 man hours & 75 days of production over an 18-month period

Tata Port Talbot Hard Metal Case Study

The Situation

Screen decks made from punched mild steel plate were big used and because of the high volume of abrasive material (made up of iron ore, coke & lime stone) the mild steel panels were completely worn out in one week. It took a team of 4 men 10 hours to change them.

The Client's Objectives

The client’s objectives were to find a better material/product to improve machine availability and reduce operating costs.

Our Solution

Our Ultraclad 800 material was plasma cut to produce screen panels. A complete set were installed and to everyone’s amazement they lasted 18 months saving 3000 man hours in maintenance and giving 75 days extra production.

Their Measures for Success

The company’s main criteria for success were:

  • Longer life from the screens
  • Reduce downtime
  • Increase plant availability
  • Increase screening efficiency

Our Work

We manufactured screen panels from Ultraclad 800 – a bi-metallic material with a mild steel base overlaid with 6mm of chromium carbide rich alloy. The screen panels were cut from the mild steel side which took advantage of the natural kerf angle (4 degrees) of the plasma cut to give holes with coneicity which improves screening efficiency and prevents ‘blinding’.

The Timing

The need for improvement was pressing and we were able to manufacture and supply a hearth layer screen deck complete in 5 weeks.

The Value to the Customer

There were a number of ways in which the customer felt that this was valuable to them:

  • Dramatic improvement in life
  • Dramatic reduction in maintenance costs
  • Significant increase in screening efficiency
  • Dramatic increase in machine availability

Total savings: 3000 man hours and 75 days extra production

“This is a fantastic result that we couldn’t believe possible’ – Eddie Booker Sinter Plant Engineer


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