Industries · Cement

Welding solutions for every stage of the cement process

A cement plant runs flat out between shutdowns, and every stage of the process — crushing, grinding, burning, cooling — wears metal away in a different manner. Abrasion, impact and heat rarely arrive on their own. Pick an area of the plant on the map to see which components fail, how they fail, and the STANVAC range that puts them back in service.

33
Components mapped
7
Plant areas
500+
Authorised distributors
Isometric view of an integrated cement plant on one site — a quarry face and crusher house at the back, a walled stockpile yard worked by a stacker and loaders, the raw mill shed, a preheater tower and rotary kiln firing into the clinker cooler and its storage silo, the cement mill and silos, and a rail yard loading wagons.
Integrated cement plant 33 components mapped Click a numbered pin on the plant
Plant area

All plant areas

Every mapped component across the plant.

Component Base metal Wear factor Plant area Recommended solution
Hammer (New) Mn. Steel Impact/Abrasion Crusher STAVITRODE A 18 (opens in a new tab) Hard Surface Electrodes
Hammer (Old) Mn. Steel Impact/Abrasion Crusher STAVITRODE A 71 (opens in a new tab) Hard Surface Electrodes
Hammer Arms & Shafts Alloy Steel Friction/Impact Crusher STAVITRODE A 24 (opens in a new tab) Repair - Joining Electrode
Jaw Crusher Plate & Eccentric Shaft Alloy Steel Friction Crusher STAVITRODE A 11 (opens in a new tab) Repair - Joining Electrode
Cylinder Mill Teeth & Crusher Bar Austenitic / Mn. Steel Impact/Abrasion Crusher STAVITRODE A 24 (opens in a new tab) Repair - Joining Electrode
Toggle Bearing Plate Mn. Steel Abrasion Crusher STAVITRODE A 46 (opens in a new tab) Hard Surface Electrodes
Diaphragm Mn. Steel Impact Crusher STAVITRODE A 46 (opens in a new tab) Hard Surface Electrodes
Mill Head/Journal Cast Steel Impact Raw Mill & Kiln Feed STAVITRODE A 11 (opens in a new tab) Repair - Joining Electrode
Mill Gear Drive Pinion Cast Steel Friction Raw Mill & Kiln Feed STAVITRODE A 11 (opens in a new tab) Repair - Joining Electrode
F.K Pump Shaft Bearing Carbon Steel Friction Raw Mill & Kiln Feed STAVITRODE A 24 (opens in a new tab) Repair - Joining Electrode
Slurry Pump Shaft Carbon Steel Corrosion/Friction Raw Mill & Kiln Feed STAVITRODE A 24 (opens in a new tab) Repair - Joining Electrode
Elevator Rim/Drum Mild Steel Abrasion Raw Mill & Kiln Feed STAVITRODE A 11 (opens in a new tab) Repair - Joining Electrode
Kiln Tyre Cast Steel Friction Kiln STAVITRODE A 57 (opens in a new tab) Hard Surface Electrodes
Kiln Support Roller Cast Iron Fatigue/Friction Kiln STAVITRODE A 11 (opens in a new tab) Repair - Joining Electrode
Girth Gear Drive Pinion Cast Steel Fatigue/Friction Kiln STAVITRODE A 11 (opens in a new tab) Repair - Joining Electrode
Girth Gear Teeth (Broken Tooth) Cast Steel Fatigue Kiln STAVITRODE A 11 (opens in a new tab) Repair - Joining Electrode
Burner Nozzle Stainless Steel Heat/Abrasion Kiln STAVITRODE A 22 (opens in a new tab) Repair - Joining Electrode
Clinker Inlet Alloy Steel Heat/Abrasion Kiln STAVITRODE A 22 (opens in a new tab) Repair - Joining Electrode
Inlet Neck/Body Cast Iron Heat/Abrasion Kiln STAVITRODE A 42 (opens in a new tab) Cast Iron Welding Electrodes
Cooler Plates Alloy Steel Heat/Abrasion Clinker Cooler STAVITRODE A 87 (T) (opens in a new tab) Hard Surface Tubular Electrodes
Scooping Liner Plates Mild Steel / Mn. Steel Abrasion Cement Mill & Separator STAVITRODE A 24 (opens in a new tab) Repair - Joining Electrode
Lifting Arm & Roller Mild Steel Friction Cement Mill & Separator STAVITRODE A 11 (opens in a new tab) Repair - Joining Electrode
I.D. Fan Blades Mild Steel Friction Cement Mill & Separator STAVITRODE A 82 (T) (opens in a new tab) Hard Surface Tubular Electrodes
Drag Chain Sprockets Carbon Steel Friction Material Handling STAVITRODE A 25 (opens in a new tab) Cladding & Die Build Up Electrodes
Sprockets Alloy Steel Friction/Impact Material Handling STAVITRODE A 71 (opens in a new tab) Hard Surface Electrodes
Idler, Guides & Track Rollers Carbon Steel Impact/Friction Material Handling STAVITRODE A 11 (opens in a new tab) Repair - Joining Electrode
Coal Pipe Bends Cast Steel Abrasion Material Handling STAVITRODE A 71 (opens in a new tab) Hard Surface Electrodes
Crane Grab Mild Steel Abrasion Material Handling STAVITRODE A 74 (opens in a new tab) Hard Surface Electrodes
Loco/Crane Wheels Cast Steel Friction Material Handling STAVITRODE A 11 (opens in a new tab) Repair - Joining Electrode
Pump Housing Cast Iron Impact Material Handling STAVITRODE A 43 (opens in a new tab) Cast Iron Welding Electrodes
Cylinder Block Head Cast Iron Impact Material Handling STAVITRODE A 43 (opens in a new tab) Cast Iron Welding Electrodes
Shovel Bucket & Lip Mn. Steel Abrasion/Impact Mobile Equipment STAVITRODE A 24 (opens in a new tab) Repair - Joining Electrode
Track Link & Shoes Mn. Steel Impact/Abrasion Mobile Equipment STAVITRODE A 18 (opens in a new tab) Hard Surface Electrodes
Showing 33 of 33 components Confirm the grade with our application engineers before welding
How cement plant components fail
  1. Abrasion

    Limestone, clinker and raw meal cutting into liners, chutes, bends and grabs.

  2. Impact

    Crusher hammers, jaws and mill teeth taking repeated shock until edges collapse.

  3. Heat

    Burner nozzles, clinker inlets and cooler plates cycling through temperature until they scale.

  4. Friction & fatigue

    Kiln tyres, support rollers, girth gears and pinions worn or cracked under load.

Send us the component.
We’ll send the procedure.

Base metal, wear factor and a photograph — an application engineer comes back with the consumable, the parameters and the expected life gain.

Contact Stanvac

Quick enquiry

Tell us what you need. Our team will be in touch.

By submitting, you agree to be contacted about your enquiry. Privacy Policy.