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BDIExpress Knowledge Base
Mining / Cement / Aggregate - Industry Articles
Special Heating Equipment for Extra Large Workpieces - 5311
Viewed 130 time(s) since Aug 15, 2018 - Bearings
The exhaust gas fan failed in the processing facility of a chemical plant. The plant operator was forced to replace the rolling bearing quickly due to the toxic gases and the resulting explosive atmosphere that occurred in the chemical production pro... Read More
Reliable Diagnosis of Damage in Vibrating Screens - 5309
Viewed 108 time(s) since Aug 15, 2018 - Bearings
Vibrating screens are central to the production process. Any unplanned stoppage of this equipment, and the associated loss of production, incurs considerable costs for the operator. In order to increase the availability of its own vibrating screens a... Read More
Professional Bearing Mounting in Tube Mill - 5306
Viewed 93 time(s) since Aug 15, 2018 - Bearings
The customer purchased a used tube mill which was delivered in single pieces. The delivery contained – amongst others – four new FAG spherical roller bearings with an outer diameter of more than 1,5 meters. The mounting of such bearings is very compl... Read More
Advanced Bearing Solutions-Mineral Extraction and Processing - 5292
Viewed 46 time(s) since Aug 15, 2018 - Bearings
At Pilbara Iron’s Dampier Port Operations replacing the bearings on the bucket wheel excavator drive was a maintenance nightmare. The standard unsplit FAG SGC Pillow Block housing was difficult to access. Normally it would have taken 72 hours t... Read More
Premature Bearing Failure in Autoclave Bogie Wheel - 5241
Viewed 35 time(s) since Jul 30, 2018 - Bearings
A customer was experiencing constant bearing failure within an Autoclave bogie wheel assembly utilizing Deep Groove Ball Bearings. The failures resulted in damage of surrounding hardware (housings and axles) creating high labor and replacement parts ... Read More
Repeated Failures on Automated Production Line - 5240
Viewed 34 time(s) since Jul 30, 2018 - Bearings
A market-leading manufacturer of insulation products for the construction industry had completed commissioning of a new automated production line. However, production was reported as being erratic due to repeated failures of bearings used on the blad... Read More
Roof Tiles Were a Re-Greasing Mess - 5239
Viewed 43 time(s) since Jul 30, 2018 - Bearings, Chemicals
A premium roof tile manufacturer was using considerable labor resources on a weekly basis to re-grease the ball sliders on handling machinery. These issues were occurring in multiple areas within the factory, resulting in high maintenance costs and i... Read More
Mechanized Bolting Jumbo Had Bearing Failure - 5238
Viewed 38 time(s) since Jul 30, 2018 - Bearings
A mining and metal company was experiencing repeated failures on their fully mechanized bolting jumbo. Bearings were being exposed to water and abrasive particles. Short life of only two months was realized in their deep groove ball bearings used in ... Read More
Concrete Floor Machine was Constantly Down - 5237
Viewed 39 time(s) since Jul 30, 2018 - Bearings
A customer was experiencing regular bearing failure on a concrete floor manufacturing machine. This caused extensive downtime with associated lost production with high maintenance costs. This was of serious concern for management and an urgent soluti... Read More
Mining Conveyor Application was Causing Headaches - 5236
Viewed 80 time(s) since Jul 30, 2018 - Bearings
A Quarrying and Mining Company were having reliability issues with a conveyor application. Bearing inserts were operating in a very harsh environment, exposed to water and abrasives particles. Located just 5 meters above the ground, inspection and ma... Read More
Conveyor Tail Drum Take Up Unit Had Stopped Taking Up - 5235
Viewed 43 time(s) since Jul 30, 2018 - Bearings
A quarrying company was experiencing short service life on its conveyor tail drum take-up unit. Located in an inaccessible area beneath a shaker screen, the unit´s bearings were subjected to particularly arduous conditions due to elements in th... Read More
Vibrating Drum was Having Reliability Issues - 5234
Viewed 48 time(s) since Jul 30, 2018 - Bearings
A Quarry & Mining company was having frequent reliability problems with bearing units assembled in a vibrating drum. Bearings were exposed to large amounts of sand, which often covered the units completely. Due to the nature of the application an... Read More
Vibrating Screen Manufacturer Looking for Improved Performance - 5233
Viewed 27 time(s) since Jul 30, 2018 - Bearings
A Vibrating Screen manufacturer was having difficulties with consistent mounting of bearing in their shaker box assembly. In addition, they were looking for opportunities to save manufacturing cost and improve the overall performance of their machine... Read More
Split Bearings Simplify Bearing Replacement in Conveyor Belts - 5312
Viewed 81 time(s) since Aug 15, 2018 - Bearings
In the past, a failure of the standard roller bearings in the conveyor belt would have caused downtimes of at least 22 hours, as replacing these bearings causes a lot of work and takes a considerable amount of time. Thus – although the solution they ... Read More
Concrete Pipe Slotting Machine Bearing Failure - 5188
Viewed 69 time(s) since Jul 27, 2018 - Bearings
A cement customer was experiencing repeated bearing failure on the blade support of a concrete pipe slotting machine. The failures were occurring every 2-3 months, causing 8 hours downtime per failure. NSK Engineers examined the application and deter... Read More
Paving Producer Experiencing Bearing Failure - 5187
Viewed 71 time(s) since Jul 27, 2018 - Bearings
A paving producer in Poland was experiencing frequent breakdowns due to bearing failures in a vibrating thickener machine. The bearings were mounted in an electric motor which supported unbalanced weights providing the vibration. In a period of 4 mon... Read More
Gates Belt Drive for the Aggregate Mining Industry - 5159
Viewed 78 time(s) since Jul 17, 2018 - Mechanical Power Transmission
Roller chain drives need replacing every year, and that comes at a cost. Switching to a belt drive saved $40,450 in parts, labor, and the elimination of downtime over three years for this application.This article is available in English Only. Read More
Rexnord Power Transmission Solutions for Mining Applications Overview - 2490
Viewed 176 time(s) since Mar 7, 2017 - Bearings, Material Handling, Mechanical Power Transmission
Rexnord Power Transmission Solutions for Mining Applications Overview. Read More
Rexnord Power Transmission Products Solutions for Cement Processing - 2489
Viewed 207 time(s) since Mar 7, 2017 - Bearings, Material Handling, Mechanical Power Transmission
Rexnord Power Transmission Products Solutions for Cement Processing Read More
Automatic Lubrication simalube in the Manufacture of Magnesium - 2328
Viewed 211 time(s) since Jan 20, 2017 - Chemicals
Magnesium manufacturing creates adverse conditions for bearings and other moving parts; DUST, WATER and HEAT. simalube automatic lubricators keep the process moving..  Read More
Product Availability When It Matters Most - 2116
Viewed 270 time(s) since Sep 28, 2016 - Bearings
When an Aggregate manufacturer went down due to a large split block bearing failure on a Sunday morning, PTI was able to overcome obstacles and had the manufacturer up and running by Monday morning.See the attachment below for details. Read More
Heavy-Duty Drum Pulleys Produce Heavy-Duty Savings - 1634
Viewed 332 time(s) since Mar 11, 2016 - Mechanical Power Transmission
Martin manufactures Heavy-Duty Pulleys which offer maximum protection in harsh environments. See the documented cost savings of over $123,000 in the attachment below associated with these Heavy-Duty Drum Pulleys. Read More
Cement Operations Require Tough Steel - 1396
Viewed 379 time(s) since Oct 23, 2015 - Electrical Power Transmission, Bearings
A cement plant was experiencing premature bearing failure due to contamination in their slurry pumps. NSK recommended angular contact bearings and technical training.See the attachment below for more details.  Read More
Mining Hose Safety - 1184
Viewed 238 time(s) since Jun 26, 2015 - Pneumatic - Hydraulic
 This video presents Hose Safety tips for the Mining industry.  Read More
BDI Provides Sand and Gravel Customer Alternative to Vulcanizing - 1293
Viewed 606 time(s) since Aug 21, 2015 - Material Handling
 A sand and gravel company customer was having trouble with the conveyor belt on its pug mill. The belt’s head pulley had a very aggressive scraper, leading the customer to assume that vulcanizing was the only option for belt replacement. Howev... Read More
Large Gearboxes Require Maintenance and Lubrication - 1153
Viewed 379 time(s) since Jun 8, 2015 - Mechanical Power Transmission
A gearbox uses mechanical advantage to increase output torque and reduce RPM. A motor's shaft is fed into the gearbox and through a series of internal gears, providing torque and speed conversion. Gearboxes are available in a variety of sizes an... Read More
Shaft-Mounted Gear Reducer Solves Dual Problem for Limestone Quarry - 442
A limestone quarry customer was experiencing a high rate of catastrophic gear reducer failures, causing costly downtime.  Rexnord proposed a solution that reduced the total cost of ownership while also addressing the downtime issue. For detailed info... Read More
Incorrect Bearing Replacement Type Can Cause Premature Failure - 274
Viewed 258 time(s) since Nov 10, 2014 - Bearings, Electrical Power Transmission
When roller crusher bearings are failing on a regular basis, use of the wrong replacement type could be the culprit.Roller crushers are regularly subject to harsh conditions. Heavy loads, along with abrasive dirt and extreme weather, can take a toll ... Read More