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Also see wear notes and projects.
Monitoring wear and knowing when to rotate or replace
Regular inspection is key to getting the full value from your wear buttons. Check high-impact zones weekly for signs of flattening, cracking or spalling. If you notice buttons have worn to under half their original height, or the backing is exposed, it’s time to plan a change. On apron feeders and chutes, uneven wear often means feed is off-centre or there’s a hang-up. Rotate or flip reversible tiles at mid-life, if your layout allows, to balance wear.
Mark the date of each inspection and note which buttons are wearing fastest. Photos taken over time help spot trends and signal when a bigger maintenance window is coming.
Planning your next change-out and keeping spares
Change-outs should be scheduled before the buttons wear right through. For plants with tight campaign schedules, keep at least one full set in stock, especially if you rely on a cast window for non-standard patterns. If you run multiple lines or have variable feed, stagger your ordering to avoid running short during peak Eskom power cuts.
Hold spares in a dry, clean location. For coastal plants, keep buttons coated in rust inhibitor until they’re needed. Organise your grid maps and fit notes in your maintenance file for easy reference.
- Keep one set minimum in stock
- Stagger orders for campaign plants
- Store with rust prevention where needed
Common failure causes and how to avoid them
Premature failure of wear buttons is usually due to over-welding, improper seating, or missing backing on composite parts. Excessive heat during fitment can crack the wear face, especially on white iron or ceramic composites. Running with loose bolts or missed welds leads to buttons popping off during high-impact shifts.
Always defer to OEM manuals for torque and welding guidelines. Monitor feed alignment: if one corner always wears out first, adjust material flow to get full use from every button. Early intervention stops the parent liner from wearing through and saves patchwork welding at shift end.
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