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Also see wear notes and projects.
Wear monitoring and rotation schedules
Regularly check your blow bars for edge rounding, cracking at the mounting points, and visible loss of profile. A weekly wear log, even just with a tape measure and chalk, helps spot trends and decide when to rotate or flip bars, if your chamber allows. Some alloys, like martensitic with ceramic inserts, need more frequent checks due to unpredictable fracture, especially on rebar-rich feed.
- Track leading and trailing edge wear
- Inspect mounting faces for spalling
- Schedule checks by shift or weekly
Change-out and campaign planning
Change bars before the wear limit approaches bolt heads or seat faces, as a dropped or fractured bar can ruin the rotor. Always have a spare set on site, especially when running high-wear campaigns on quartzite or during the rainy season when downtime bites hard. Plan for Eskom outages by doing changeouts during daylight and keeping the job short and safe. Rotate your stock to use the oldest bars first, and keep new kits off the damp floor.
- Don't run past wear limit (bolt level)
- Hold at least one kit on site
- Rotate stock to avoid rust
Common causes of blow bar failure
Most premature blow bar failures in SA come from incorrect alloy selection, neglected rotor balance, or skipped bolting torque checks. Feed with unspotted tramp iron or unchoked operation also shortens life fast. Regular profile checks, safe fitting, and clear communication with our parts team make the difference. Send wear photos with each kit reorder to help us advise if your alloy choice needs an update.
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