Long-term testing of vibrochute lining PUCEST plate reinforced with perforated steel plate

Deployment: IFE Vibroschurre

1. General:

The plant, located in the Vienna region, belongs to the Salzburger Sand und Kies Group and produces CE-standards verified gravel mainly for the concrete plants of BauBeton GmbH. The material is “Danube gravel”, round grain with over approx. 90% quartz content and is extracted by means of wheel loaders (dry) and since the beginning of 2020 via a bucket chain excavator (wet).

2nd insert:

Via a feed hopper with 10 x 10 cm grate, the mined material is fed to the preparation process via 2 pieces of IFE vibrators. Thus, approx. 200 days per year, 180 tons of material pass over the vibro chutes every hour.

3. problem statement:

Due to the highly abrasive material, the chute bottom must be replaced twice a year. It is not possible to dismantle the vibro chutes, so the exchange of the Wear-resistant steel chute bases has to be carried out laboriously in confined spaces.

3.1 Wear stress:

In vibratory chutes, impact and sliding wear due to feed height, in continuous operation with large individual loads and non-uniform volume flow, occur in a mixed manner.

3.2 Solution approach:

Ing. Wedorn recommended the use of the material PUCEST – a light and easily machinable material with damping properties.

Blanks of PUCEST board reinforced with steel perforated sheet, 65° shore, in thickness s= 20 mm were manufactured.

4. service life:

In the course of follow-up orders in January 2020 at Ing. Wedorn for the annual revision, Mr. Hanak said: “Come to the factory once, I want to show you something ….”.

The plant manager Mr. Hanak and his foreman can still remember well – it was one of the first jobs of his then new foreman – how the chute floors were executed in PUCEST in 2013. Since 2013, after about 2.5 million tons of material mined, the chute floors are still in use and will continue to be used. There is NO appreciable abrasion!

In a personal conversation on 12.03.20 on site with the foreman, Mr. Ing. Wedorn again reassured himself that the first blanks of PUCEST are really still installed.

As explanation for this above-average service life, Mr. Wedorn explained the fine sand layer on the PUCEST slab. This fine film on which the gravel slides, forms an autogenous wear protection. (Material on material)

The fact that the gravel with its high quartz content is wear-intensive can be seen in the pictures below. The step baffles have been installed in the processing plant in downstream transfers since the beginning of 2018:

5. summary:

A service life extension from the steel material of approx. ½ year with changeover to the material PUCEST to more than 7 years. Once again, in this case probably disproportionately, the longevity of the material PUCEST is demonstrated. The examination of the conditions on site and the correct plate thickness and Shore hardness ensure an optimum result.