Lowveld line
Nelspruit Apron Buttons
Button map on an apron feeder bounce zone.
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Chronic wear at the apron feeder transfer
At a major Lowveld operation near Nelspruit, the apron feeder’s bounce zone had become a persistent headache. This was the area where the loading dropped onto the first few pans, and despite using standard liner plates, the site team was constantly patching up gouges and replacing worn-through steel. High impact from boulders and varying feed rate made the apron’s surface an ongoing maintenance hotspot, especially with the humidity and fine dust typical of the region.
The uneven wear patterns pointed to a need for targeted sacrificial protection. Downtime for repairs was a real risk due to the plant’s tight production targets, and stockpiling apron pans was not economical. The site maintenance team wanted a solution that was quick to install, easy to replace in sections, and would absorb punishment without constant attention.
Installation of hardened wear buttons
Crusher Consumables mapped out the apron’s bounce zone and recommended our locally-cast, high-chrome apron buttons. These were installed in a grid pattern across the high-impact area, following a site walkdown to mark out the bounce footprints. Working with the plant’s fitters, we supplied buttons with integral weldable bases for straightforward on-site fitting.
The installation was handled during a scheduled shut. Each button was welded in place with controlled heat input to avoid warping the pans, and spacing was set to allow for easy inspection and replacement. No change to the feeder drive or settings was needed, keeping things simple. We supplied a set of spares for quick swaps, keeping downtime to a minimum.
- Apron buttons made from high-chrome iron
- Weldable base for fast field repairs
- Pattern mapped for optimal coverage
- Spare sets included for future changeouts
Results and future approach
After installation, the apron pans in the bounce zone showed far less scarring and pitting during routine checks. The crew adopted a practice of replacing individual buttons as needed during scheduled stops, using an impact hammer and portable welder. The buttons proved easy to track for wear profiling, and the original liner plates lasted significantly longer as a result.
If we approached this project again, we would add more detailed wear mapping using a laser profile before starting, to refine button placement even further. We would also review the apron’s feed distribution to see if flow could be evened out upstream, reducing peak impacts. For torque and welding advice, we always recommend following the OEM manual and consulting with a qualified fitter. Want to discuss a feeder upgrade? Get in touch through our contact form.
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