Project Overview
At a hard rock quarry in Gippsland, Victoria, the primary feed hopper and grizzly feeder handle a constant flow of large, angular rock mixed with fines. This heavy, high-impact loading places extreme stress on the feeder floor. The quarry’s maintenance team had previously installed 450 grade hardened steel liners to protect the floor, but over time, these had become damaged and worn out.
When the worn steel liners were removed, the team discovered a more serious issue, the underlying structural supports had also been damaged by the constant impact of rock. This required structural repairs before any new liners could be installed. The site’s maintenance manager approached Reglin Rubber for an alternative solution that could provide effective wear protection while also absorbing impact energy to prevent further structural damage.
Solution: Custom Made Steel Backed PP Rubber Wear Plates
Reglin supplied 100mm thick steel backed PP Rubber Wear Plates featuring a 10mm heavy duty steel backing plate designed for high-impact and abrasive applications. Unlike hardened steel, the premium-grade SAR 60 Rubber compound absorbs impact energy from the large rocks, reducing transmitted forces to the supporting structure. The fully vulcanised steel
backing plate provides the rigidity needed for secure mechanical fastening to the recently repaired structure and ensured the liners remain stable under heavy load conditions.
The customer specified that they were willing to replace the liners on a regular schedule if it meant preventing costly structural repairs. While the life expectancy of rubber liners in a primary ore environment was initially unknown, the benefits of reduced impact and vibration made the trial worthwhile.
Results
The liners, which were custom made to suit the existing feeder design, were installed successfully, providing a smooth, protective surface on the feeder floor. They immediately reduced impact forces, minimised noise, and improved material flow through the grizzly.
Two years later, the original liners were still performing well, showing only moderate wear and no signs of underlying structural damage. The trial proved that steel-backed rubber wear liners could deliver long-term protection in the most demanding quarry conditions, with the added benefit of preventing costly structural repairs
Key Benefits
- Impact absorption – Protects feeder structure from heavy rock drop
- Long service life – Still performing after two years in primary ore duty
- Reduced vibration and noise – Improves operator environment
- Secure fastening – Vulcanised steel backing allows easy installation and stability
Conclusion
This installation demonstrated that Reglin PP Rubber Wear Plates are a highly effective solution for protecting high-impact, high-abrasion areas in quarry equipment. By absorbing impact energy and preventing structural damage, the liners delivered long-term performance while reducing maintenance costs and downtime. Even in the challenging conditions of a primary ore feed, the liners exceeded expectations, proving their value as a durable and reliable wear protection option.
