Mining ROM
Secunda Gyratory Mantle
Campaign planning pack with our contact form handoff.
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Secunda primary Crusher facing mantle wear
A mining operation on the Highveld was running an ageing gyratory crusher as their ROM primary. Operators noticed an uptick in uneven wear and excessive spider arm drop, with the mantle profile showing classic signs of feed misalignment and choke interruptions. Maintenance teams struggled to maintain an even closed side setting and the chamber required more frequent attention. Power draws were inconsistent and fines built up under the spider, increasing cleaning downtime. The plant’s campaign planning flagged the mantle for intervention.
Regular Eskom power cuts and haul-truck scheduling made quick turnarounds essential. The team needed a reliable supply of the correct profile mantle, specific to their OEM design, matched to chamber volume and target throughput. Safety was a concern, especially with lifting procedures and potential tramp metal events.
Supply of matched Gyratory Mantle and changeout process
Crusher Consumables assembled a campaign planning pack with the correct profile mantle, matching the OEM geometry and material grade for aggressive ROM rock. We included lifting lugs certified for safe handling, new liner bolts with torque spec sheets, high strength backing compound, a new set of spider rim liners, and lockout tags. The pack also covered checklists for nip angle monitoring and torque verification, all handed over through our contact form for clear tracking.
The changeout was planned for a shift window to avoid production overruns during power cuts. Our parts yard at Sunnyrock dispatched the components via bakkie to site. The plant team used the supplied lifting lugs and took readings of the chamber before and after, ensuring correct seating and torque on fasteners. The old mantle was safely lifted out and the new one installed with fresh backing compound, while maintaining OEM guidelines for fitment and cure time.
- Matched OEM profile mantle
- Certified lifting lugs and liner bolts
- Backing compound and lockout tags
- Torque and nip angle checklist
Post-Changeout monitoring and continuous improvement
After the changeout, the plant team kept up regular wear profiling using chalk and ultrasonic thickness gauges. They recorded closed side setting trends and monitored mantle seating after thermal cycles. Feed was redistributed to balance the chamber, aiming for even wear and reliable throughput.
For future campaigns, we would recommend a pre-shutdown inspection with the plant’s rope access team to map wear development and check for any stress cracks around the spider or rim liners. A full shadow stock of critical fasteners and a pre-mixed batch of backing compound on site would help cut downtime. Sharing more targeted feedback after each campaign lets us refine the pack for the site’s specific ore, crew, and maintenance realities.
- Ongoing wear profiling and CSS checks
- Feed distribution to even wear
- Consider pre-shutdown rope access mapping
- Keep critical spares and compound on site
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