Cement & Aggregates - Cement plant - Secondary crusher - Static equipement - Italy - +47% lifetime

Objective

Assess the performance of Creusabro^® 4800 compared to standard 400 HBW water-quenched steel in a secondary crusher application, with the aim of extending wear life and reducing maintenance interruptions.

Test Conditions

• Location: Cement plant in Imola, Italy

• Environment: Highly abrasive cement raw materials processed at a rate of 90 tons per hour, subjecting side wear plates to constant abrasion and impact.

• Function: Side wearing plates in a secondary crusher OMT, critical for maintaining crushing efficiency and equipment uptime.

• Original material: 400 HBW water-quenched steel

• Replacement material: Creusabro® 4800, processed by flame cutting, drilling, and tapping.

Results

• The Creusabro® 4800 plates delivered 1,830 hours of service life, compared to 1,300 hours with the original 400 HBW steel — a 47% improvement.

• The material was easily fabricated and installed, requiring no changes to the processing or assembly methods.

Value Delivered

• Extended Service Life: Nearly 50% longer wear life reduced replacement frequency and maintenance downtime.

• Cost Efficiency: Fewer parts and less frequent interventions translated into lower operational costs.

• Operational Continuity: Improved reliability ensured more consistent crusher performance and minimized production disruptions

• Easy Implementation: Compatible with standard fabrication techniques, simplifying the transition to the improved material.

Conclusion

By adopting Creusabro® 4800, COOP Trasporti and Abraservice achieved a more durable and cost-effective solution, increasing the crusher side plate service life by 47% while maintaining smooth operations.

Creusabro® continues to deliver proven reliability and added value, even in the highly demanding cement industry.

Comparative test