Mining & Quarry - Discarder washer- Stirring blades - Stationary equipment - Germany - +34% lifetime

Objective

Assess the performance of Creusabro^® 4800 compared to 450 HBW water-quenched steel in stirring blades used in a washer/discarder unit, with the goal of increasing wear life and reducing maintenance interventions in wet, abrasive conditions.

Test Conditions

• Location: Quarry site in Germany

• Environment: Continuous stirring and washing of aggregates at 80 tonnes per hour, under constant abrasion and moisture exposure.

• Function: Stirring blades inside the washer, exposed to rotating contact with aggregates, sand, and water — leading to aggressive abrasive wear.

• Original material: 450 HBW water-quenched steel

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

Results

• The 450 HBW blades achieved a service life of 590 hours before needing replacement.

• The Creusabro® 4800 blades lasted 790 hours, representing a +34% improvement in wear life.

• The replacement used standard cutting and drilling processes, with no modification to design or assembly required.

Value Delivered

• +34% Longer Service Life: Reduced maintenance downtime and increased equipment availability.

• Optimized for Wet Abrasion: Excellent resistance to combined abrasion and moisture, maintaining integrity in harsh conditions.

• Operational Efficiency: Fewer replacement cycles improved plant productivity and reduced overall operating costs.

• Ease of Integration: Fully compatible with existing fabrication methods and equipment design.

Conclusion

By switching to Creusabro® 4800, Wesser Beton and Abraservice implemented a more durable and reliable solution for their washer stirring blades — achieving a 34% gain in service life in a highly abrasive and humid environment.

Creusabro® 4800 confirms its relevance as a high-performance steel for wet and abrasive quarrying applications, ensuring longer uptime and lower maintenance costs.

Comparative test