comes to us Noturolly

is our Asset

WEAR PLATES
TOWARDS TOTAL WEAR SOLUTION

EN
Wear & Tear is one of the major and Common Problem in Power, Cement, Sugar, Mining and
Mineral processing industries. AContinuous research and development process has concluded in

using various Wear Resistance methods. Prabhu Rockshape Machinery Pvt. Ltd. has developed

'ROCKSHAPE Wear Resistant Plates to flght wear & tear problems, resulting in reduced-plant shut
downs, frequent repairs & mainlenance of machinery and ultimately, reducing heavy losses
lndigenously developed 'ROCKSHAPE Wear Resistant Plates are manufactured with a ,1 r r
combination ol alloy wires and alloy metals, blended simultaneously, resulting a heavy layer ol
highly wear resistant alloy.
4 r\',
To cater the needs of valious types of wear solutions, 'ROCKSHAPE' Wear Resistant Plates are
manufactured with a comblnation of different alloys for different purposes. with a various combinations

of alloy layers, hardened surface thickness and base plate thickness 'ROCKSHAPE' Wear Resistant
plates have achieved high to extreme abrasion resistance and they can withstand moderate impact and

high velocity erosion resistance.

GRADE FEATURES ALLOY CHEI\4ISTRY HARDNESS IN R. C,

RC_GP High Abrasive resistance combined with moderate applications. Cr. C. NIn. B. V. 55 to 58
Mixer blades, Shovels, Chutes, Bunkers etc.

RC_57 Severe abrasion, moderate impact resistance. Cr., C., lVn, B. V W. 57 to 60

Crusher Hammers, Mandrills, Buckets lifts & Teeth, Liners etc.

RC_62 Severe to extreme wear resistance and moderate impact. 62 to 66

Cement kiln wear parts. shovel teeth. etc.
RC -65 Extreme abrasion and resist fine particle erosion. Temp. Upto 7000 C. Cr., C., lVn., Nb., W. Mo. 65 and above
Sinter breaker, Sinter fans, Diaphragm plates, Fan blades.
RC-58 Resist High Velocity erosion and fine particle abrasion. Cr., Mn., V. B. W. 59 to 65
spl. Clinker Grinding, Coal Feeding Fan & liner plates, etc.

RC_W Extreme High abrasion Cr. C., W, Mo., V 60 to 65

Due to dendritic strength of primary & secondary carbide suspended in . Our welding procedure is by open arc welding using PLC Control
system to form good chromium carbide matrix.
tough wear resistant matrix, 'Rockshape' Wear Resistant Plates can
achieve hardness as required.
'Rockshape' Wear Resistant Plates has smooth & wide bands, fused
Abrasion testing machine as perASTM G-65
togethertoform a flat and continuos surface.
lilicrostructure & Chemical composition
'Rockshape' Wear Resistant Plates can with stand to prolonged impact Hardnesstesting
loadingat 700"Ctemp. Dye Penetration Testing
'RoCKSI|APE Wear Rosistanl Plale ilicro Structure.
Due to concentration of stresses during manufacturing welding process, Hydraullic Testing
cracks develop at right angle to the surface and do not penetrate beyond Universal Testing L4achine
the carbide layer as the fusion between theoverlayand base plate is good. lmpact Testing Machine

These cracks are essential for stress relieving purpose.

Cost effective due to decreasing mdintenance & plant down time and
increasing productivity and efficiency.
Shows good results in comparison with other conventional hard facings.
We have CNC machineforcutting ofplates as perrequired size accurately.
 LIFE EXPECTANCY OF ROCKSHAPE PLATES IN

Usually it is recommended to make the wear prone part ofthe equipmentor complete

equipmentfrom the wear resistant plate in the plant installation stage. However, ifit is
notpossible, we atPRABHU ROCKSHAPE MACHINERYPvt. Ltd., can helpyou with
our state of art application engineering services by suggesting the best solution to
tackle your problem of ftequent replacement ofwear prone parts.
05

0
ROCKSHAPE HARDENED IVIN,5TEEL NiHARD H|CHROMI M.S.PLATE
I\,I,5. PLATE PLATE PLATE CASTING
PLATES aT 700 4

MATERIALS

CUTTING - Standard procedure for wear resistant plate cutting is by air plasma arc.
Abrasive Wheels can also be used in rarecases.

FORMING - Forming of Wear Resistant Plates has some Iimitations. Further, Wear
plate can not be formed in two planes. Such problems can be sorted out by our expert
e
application support engineers by studying the shape ofwear prone parts, it's location
and application in the equipmentand theycan suggest the best solution.

FIXING -'ROCKSHAPE'Wear Resistant Plate used as a structural component as the

case may be keeping theforming limitations in mind.

'ROCKSHAPE'Wear Resistant Plate with it's M. S. Base plate can be welded directly
to mother plate by low hydrogen electrodes.
'ROCKSHAPE' Wear Resistant Plate finds its use in nearly
Studs can also be welded to 'ROCKSHAPE Wear Resistant Plate on base plate side all the plants where material is transferred in bulk quantities.
forfixing thesame byproviding appropriate holes on the mother plate. CEMENT PLANT
Clinker Discharge for Raw Mill / Cement Mill inlet &
'ROCKSHAPE'Wear Resistant Plate can be provided with predetermined CSK holes Discharge Chute.
forfixing the same byon to mother plate by CSK Bolts/ Nuts. Outlet Duct Bend for Coal Mill.
Liners for Crusher Discharge Hopper.
By using Cotter Pins pegging of'ROCKSHAPE'Wear Resistant Plate can be achieved
Damper Blades.
for high abrasivewearon inclined surfaces.
Louver Plates.
Redler/ En-masse Conveyor, Bucket Elevator Chute.
Cyclone Casing Plates.
'ROCKSHAPE' Wear Resistant PIates are available in wide range of base
Conveyors.
plate thickness and overlaythickness to suit the specificapplications.
Housing for L. S. Crusher lmpactor.
CoverAssly. for Coal Mill Roller.
Base Plate: Overlay:
Coal Mill material Feed Pipe.

From 6mmthk. To 16mm thk. 4mmto6mmthk Feed llopper & Chute.

From 16mm thk. To40mm thk. 4mm togmm thk D S M Screen.
Standard Size: 11Sbmm X 4900mm Polycom lmpeller Separator
1150mmX3000mm
Coal Crusher Liners.
Formed and cutaccording tocustomeis need and also preJabricated parts
Coal Mill Dynamic Separator.
thereof. Cooler Exh. Fan Blade Liners.
Liners for Crusher.
DEALERS NETWORK: lnlet Cone for Cement Mill.
l\.4aharashtra, Gujarat, Rajasthan, UttarPradesh, [,4adhya Pradesh, Andhra lmpeller Blades.

Pradesh, Tamilnadu, Delhi, Orissa. Liners for Raw l,4ill Fan Vanes.
 STEEL PLANT .t

Sinter Plant : Feed Drums, Screens, Fan Blades,

Fan Casings, Sinter Cooler Parts,
Louver PIates.
. Blast Furnace: Skip Body, Skip Track Liners.
MINING
COAL FACE (Open Cast)
Line Pan Scraper: Scraper Blades.
Sheerer Drum: Drum Face.
Strata Bunker: Liner Plates.
Skip Liners : Liner Plates

POWER GENERATION
Collector Pan.
Liner for Mill Elbow Plant.
Coal Feeder
Liners for Coal Feeder
Outlet Ventury CollarAssly.
P A. Fan Casing.
Flue Gas Duct.
Strips for Screw Conveyor.
lnlet / Discharge Chutes.
Vibro Feeder Trough.
Coal Mills Applications.
Classifier Blades.
Guide Vanes.
Fan Runners.
Fan lmpeller.

COAL PREPAMTION
Raw Coal Bunker: Bunker Liners,
Weigh Feeder: Liners,
Scrapei: Chain Tracks, Sprocket Teeth.
Separating Bath: Launder Chute Liners.
Middling Crusher: Crusher Cone.
Sizing Screens :

Primary Screens: Screen Decks.

Recovery Screens.

MATERIAL HANDLING
Transfer Chutes.
l-eeder Irays.
Ski( Plates. PRABHU ROCKSHAPE MACHINERY PVT. LTD.
Bucket Liners. (An ISO - 9001 : 2008 Company)
Ducts / Bends. A- 188, lV. I. D. C. , CHINCHOLI, SOLAPUR - 413 255. Maharashka, (lNDlA)
Spiral Chutes. Tel.0217 - 2733230,2733233,2357226.|Fax: 0217 - 2357477 .
Deflector Plates. E.mail : spchitte@hotmail.com / spr chittesp@sancharnet,in
www.prabhurockshape.com