The main characteristic of Hardox is its combination of high hardness and high toughness.

1. High Hardness: Hardness is measured on the Brinell (HB) scale and typically ranges from 400 HB to 600 HB. This means the steel’s surface is extremely resistant to penetration, scraping, and abrasion from materials such as iron ore, rock, sand, and scrap metal.
2. High Toughness: Despite its hardness, Hardox has excellent impact resistance and does not shatter or crack easily. This property is crucial in dumpsters subjected to heavy material drops and constant vibration.

Benefits of Hardox Bucket Lining

Replacing common carbon steels or low-alloy steels with Hardox brings significant operational and financial advantages:

1. Extended Service Life

The main benefit is the drastic increase in bucket lifespan. In abrasive environments, a Hardox coating can last two to five times longer than standard structural steel, reducing the frequency of equipment replacement.

2. Weight Reduction (Increased Payload)

Because Hardox is much stronger, it’s possible to use thinner plates to achieve the same or even greater wear resistance than thicker plates of conventional steel. A lighter bucket allows:

• Increased Payload: The truck can transport more material per trip.
• Lower Fuel Consumption: With less dead weight, energy efficiency improves.

3. Less Maintenance and Downtime

The coating is more resistant to dents and holes, reducing the need for frequent repairs. Less maintenance time results in higher equipment uptime and, consequently, higher productivity.

4. Better Material Flow

Some Hardox plates, such as the “Tuf” line, have a surface that may be less adherent to wet or clayey materials, facilitating the flow of the material during tilting (the so-called “Hardox effect”).

Common Types and Applications

Hardox is offered in several hardness classes to meet different needs:

Bucket Lining Applications:

• Mining: Transportation of high-density ore and explosive rocks.
• Heavy Construction: Loading and transportation of aggregates and demolition.
• Recycling and Scrap: Dumpsters that handle metals, glass and other highly abrasive waste.

Installation Considerations

The installation of a Hardox coating must be carried out by professionals, as it requires specific machining and welding techniques due to the high hardness of the material:

• Welding: Requires preheating and the use of specific consumables (usually low hydrogen) to maintain material integrity.
• Mechanical Attachment: In some cases, the liner is bolted to the main body of the bucket to allow for quicker replacement in the future.
• Thickness: Choosing the ideal thickness (gauge) depends on the type of material being transported, the drop height, and the bucket volume. The goal is to use the minimum thickness that guarantees the necessary wear resistance to save weight.

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Our discs are made entirely from HARDOX Steel, a high-performance material, recognized worldwide for its superior properties:

1. Extreme Abrasion Resistance: HARDOX has unparalleled hardness, making the discs highly resistant to wear caused by constant friction with hard materials such as ores and rocks.
2. Alta Tenacidade: Mantém a integridade estrutural mesmo sob alto impacto, comum em operações VSI (Vertical Shaft Impactor), prevenindo trincas e quebras prematuras.
3. Maior Vida Útil: Ao utilizar um material superior, garantimos que seus componentes durem muito mais tempo, reduzindo a frequência de paradas para manutenção e a troca de peças.

Custom Manufacturing

We understand that each piece of equipment and application has unique specifications. Therefore, our main differentiator is custom production:

• Custom Design: We manufacture discs according to technical drawings and the exact dimensions of your equipment and the type of material processed.
• Performance Optimization: Perfect adjustment ensures maximum efficiency of your VSI crusher, minimizing clearances and vibrations that accelerate wear.
• Meeting Needs: We don’t provide an off-the-shelf product, but rather a solution designed and engineered according to our customers’ needs, ensuring the best cost-benefit and operational performance.

Key Advantages for Your Business

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The main difference between Hardox steel lies in the balance between hardness and toughness, which are often opposing characteristics in traditional metals.

Definition in the Hardox Context
Benefit in the Mining Shell

Ability to absorb energy and undergo plastic deformation before fracture.

The most common grades used in mining are Hardox 450 and Hardox 500, where the number refers to the average Brinell hardness.

2. Operational and Economic Advantages

Replacing carbon or low-alloy steels with Hardox in mining shells offers direct benefits that impact the total cost of ownership (TCO).

1. Increased Service Life

Hardox’s superior abrasion resistance results in significantly longer shell life, with durability up to three to four times greater than that of standard steels.

1. Payload Gain

Due to Hardox’s high strength and hardness, it is possible to use thinner sheets (less thickness) in the shell construction while maintaining or exceeding structural strength. This results in:

1. Lighter Shell: The dead weight of the equipment is reduced.
2. Increased Payload: The equipment can carry more material per cycle, increasing productivity.
3. Better Fuel Efficiency: The engine has less mass to move, reducing fuel consumption.

1. Less Downtime

A longer-lasting shell requires fewer replacements and welding repairs. This minimizes machine downtime, crucial in 24/7 mining operations.

1. Better Material Flow

The smooth surface and high hardness of Hardox help reduce friction and adhesion of sticky materials (such as clay or wet ore), improving the pouring angle and discharge speed.

3. Strategic Application in Shells

Hardox steel is typically used in the areas of the shell that experience the most wear:

• Cutting Edge: The front part that comes into direct contact with the material to be excavated.
• Wear Plates: Used on the inside bottom and sides of the bucket to protect the main structural steel.
• Side Reinforcements (Side Cutters): Protect the sides of the shell and aid in material penetration.
• Heel Shrouds: Protect the lower back, which suffers constant abrasion when turning and dragging on the ground.

The combination of structural steels (for the shell skeleton) and Hardox plates (for the contact surfaces) results in a component optimized for maximum performance and durability.

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