Wear note
Button maps beat guesswork
Wear buttons only work when the bounce map is written down.
By Mr Thabo Molefe, Parts manager
Thabo Molefe manages all parts operations at Crusher Consumables’ Sunnyrock yard, making sure the right crusher and screen spares reach the right place at the right time.
AuthorWhy this matters on the plant
If you are running jaw crushers on the Highveld or down in the Lowveld, you know how essential it is to keep control of wear on your hard-facing buttons. Guessing when and where to weld on new buttons simply wastes time and money, and can cost you a set of jaw plates if you miss a hot spot. In my years at Crusher Consumables, I have seen too many good liners scrapped early just because nobody mapped the bounce.
Start with a proper bounce map
To get the most value from wear buttons, you need to document exactly where material is bouncing or abrading the jaw faces hardest. I have visited plants from the Karoo to Gqeberha where welders guessed placement from memory, and the results showed in uneven wear, cracks and early liner failures. The right way is to build a simple map: after every ten shifts, open up the crusher with proper lockout and chalk where you see the deepest wear tracks or impact marks. Be systematic, working from the feed end to discharge end, left to right, every time.
We often recommend taking quick measurements with a depth gauge at each chalk mark, writing the millimetres down on a site copy. Over several inspections you will see patterns. This is your bounce map. It is the only way to know where buttons are actually needed, not just where they have always been placed.
Key mistakes with button placement
One common mistake I see on sites is the overuse of buttons, especially in low-wear areas. This happens when there's no map and crews try to cover the whole face 'just in case'. This is wasteful and actually leads to poor nip angle and reduces crusher efficiency. Another issue is welding buttons on old manganese that has already work-hardened poorly, which can cause spalling or cracking around the welds.
Always check liner thickness before any button welding, and consult the OEM manual for minimum thickness. If you see a wear zone moving, update your map. A static map is only useful if your feed and chamber profile stay unchanged, which is almost never the case after a blast or new product mix.
Button mapping in South African plant conditions
Power cuts and Eskom outages make planning inspections and welding a challenge, especially on remote sites running on generators or in KwaZulu-Natal humidity where welds cool slower and can draw moisture. That is why I recommend using a printed bounce map kept in the control room bakkie, updated by whoever does the inspection.
If you are running a multi-shift operation or contract crushing, make it part of your handover programme. Record the date, shift, feed type, and any Eskom interruptions. This way you avoid missing a high-wear event caused by out-of-sequence feeding or a temporary surge in feed size.
Best practices for button wear management
Over the years, the plants that get the best life out of their jaw plates do a few things right every time. They keep bounce maps updated, use only approved backing compound and follow liner bolt torque specs as per the manual. They never weld buttons on without checking for cracks around the weld area after cooling.
Remember, button wear management is not just about saving money on liners. It is about keeping your chamber geometry correct, nip angle tight and reducing the risk of tramp metal damage. Consistency beats guesswork every shift.
- Inspect and chalk wear points every ten shifts
- Measure wear depth accurately at each mapped point
- Update your map after every blast or major feed change
- Store bounce maps where all shifts can access
- Always check for cracks after welding buttons
Related parts: Jaw Plate Set. You can also browse all parts and plant guides.
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