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Also see wear notes and projects.
Monitoring wear and when to turn or replace panels
Inspect screen panels at least once per shift in hard rock plants, or daily in sand or recycle applications. Look for wear at the discharge end and sites of pegging or blinding. PU and rubber panels can often be rotated end-to-end to extend life, but wire mesh should be replaced when wires are thinned by half or there are visible breaks. Use a wear card or gauge to check aperture against original spec. If the panel is below spec, swap it out before it affects your final product.
Planning the next change-out and stocking spares
Run a campaign calendar for your screen deck, noting average panel life in operating hours or tonnes. Keep at least one full set of critical panels on site, especially if you run in remote areas or during Eskom power cuts that delay deliveries. For plants in high-wear areas or with unpredictable feed, hold extra top deck and mid deck panels. Communicate your forecast so we can reserve stock in Germiston or advise on next cast window.
- Track panel life in hours/tonnes
- Hold spare panels for top and mid decks
- Notify us early for long-lead items
Common causes of early failure
Panel movement, loose clamps, and over-tensioning are the top culprits for premature screen media failure. Running with broken or missing panels risks damage to support rails and downstream crushers. In Karoo and coastal plants, blinding from sticky fines or salt crust is common, regular cleaning and correct aperture selection helps prevent this. Avoid mixing different panel materials on a single deck, as this can cause uneven wear and vibration.
If you see unusual wear patterns, send photos and a description so we can help troubleshoot and recommend a better match for your next campaign.
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