Wear note
Sand plant tip maps
Tip maps that travel with the rotor save the next campaign.
By Ms Chloe Naidoo, Showroom coordinator
Chloe Naidoo is the showroom coordinator at Crusher Consumables, keeping plant handovers seamless across the country’s main centres.
AuthorWhy this matters on the plant
In sand plants across the Highveld and Lowveld, packing wear buttons is only half the battle. The real trick is making sure tip maps travel with the rotor, so you avoid repeating the same mistakes next campaign.
Why tip maps matter in South African sand plants
Every time a VSI rotor runs a fresh campaign, local conditions like Durban humidity or the Cape southeaster can throw up surprises. We see that uneven sand gradation, spot wear, or rotor imbalance often comes down to missing or outdated tip mapping. A tip map records where each wear button, block, or edge protector sits, as well as their wear patterns at every shift change or planned stop.
Without a current tip map, the crew puts the next button pack in the same places as last time, even though the chamber profile or feed choke may have shifted. Over one or two months, this doubles the risk of tip breakage, rotor vibration, or even catastrophic throwouts when Eskom cuts the power and a restart tries to spin a badly wearing set.
How to create and update a tip map
Start with a clean, marked-up rotor. Paint, chalk, or a centre-punch mark works: divide the rotor face into numbered quadrants and mark each tip and wear button location. Use a measuring tape and record exact distances in millimetres from the hub to each feature. After a campaign, remove and lay out all used wear buttons in their original orientation.
Use a permanent marker to write the quadrant and position on each removed button. Photograph each segment with a card showing the date and shift. This makes it possible to compare wear across sectors, and plan for heavier-duty buttons or more dense packing where the sand is biting hardest. Every time you change feed material, make a new quick sketch or record changes to the feed chute. This reduces guesswork and keeps the next campaign safer.
- Mark rotor quadrants clearly with paint or punch.
- Record all button positions in millimetres from the hub.
- Label each button and photograph before and after each campaign.
- Update the map if feed material or choke changes.
- Store the map in a rotor-safe folder with the maintenance log.
Common mistakes and how to avoid them
We often see teams who skip mapping because they are pressed for time, especially during Eskom outages or when a bakkie is waiting for the next batch. This leads to lost buttons, mismatched impeller tips, and poor rotor balance. The next campaign starts with guesswork instead of precision.
Another mistake is reusing old maps without checking for changes in liner configuration or feed distribution. Even a small change in screen aperture or a new feed conveyor can shift the sand flow, so the old wear pattern no longer fits. Do not rely on memory or 'the usual', wear is almost never symmetrical, especially in sites with variable moisture or high fines.
Using the right wear button pack for each campaign
Not all wear button packs are the same, and the right map helps you choose the right set. For high-silica feeds, consider stepping up to ceramic-embedded buttons or changing the packing density along the leading edge. Maps make it obvious where the impact is greatest and where extra coverage pays off.
Always check that the new button pack matches your marked positions and that all lifting lugs are clear before torquing bolts. If in doubt, refer to the OEM profile or manual for tightening sequences. A well-updated map, matched with quality wear buttons, means a safer, longer-lasting rotor, and fewer surprises when the next Eskom outage hits.
Related parts: Wear Button Pack. You can also browse all parts and plant guides.
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