Setting the New Standard in Crusher Repair and Maintenance.
Setting the New Standard in Crusher Repair and Maintenance.
When unplanned downtime isn’t an option, customers around the world turn to CMS Cepcor for trusted, high-quality crusher spares and precision-engineered solutions. In this case study, we explore how CMS Cepcor partnered with a mining customer in North-West Africa to overcome critical challenges, improve equipment reliability, and deliver measurable results. From specialist repair capabilities to expert maintenance and technical support, this is a story of partnership, performance, and industry-leading service.
Why CMS Cepcor?
The copper-mining customer approached the regional sales team for refurbishment of an old used Topshell and Spider they had on site, with a view to having them refurbished and available as rotable spare assemblies to minimise downtime for their Svedala 42x65 Primary Gyratory. Rotable solutions are becoming a keystone of what CMS Cepcor can offer, providing a quicker, more efficient and safer way to re-line. Complete topshells are removed and liners changed off-site – minimising risk and reducing field-based tasks. This in turn reduces downtime and optimises the entire refurbishment process.
This wasn’t a test case either; CMS Cepcor are highly experienced in streamlining preventative maintenance, and had also previously undertaken similar works to this customers’ operational components – successfully carrying out repairs to the exacting standards of OEM specifications. The scale and scope of the project also played to CMS Cepcor strengths – as there were limited crusher specialist companies able to handle the sheer size and weight of the components involved, both in terms of logistics, workshop operations and engineering expertise.
Repair process
The 43-tonne consignment of both the Topshell and Spider arrived at CMS Cepcor Head Office in Coalville, Leicestershire and a full dimensional inspection was carried out utilising FARO coordinate measuring equipment and 3D scanning determine full scope of work and definitive costs.
The Topshell and Spider were then shotblasted and NDT tested prior to commencing repair, with an NDT report provided to the customer at this stage. Following this, the Topshell 5 degree tapers, flange faces and concave seating bands were pre-machined, then overlayed with weld in the workshop on a column and boom welding turntable. Tapers, flange faces and seating bands were finish machined to exacting OEM specifications.
Next up, the Spider 5 degree and spider bush bore were pre-machined ready to be overlayed with weld – and the Elongated 2 1/2” UNC spider stud holes were over-bored ready to accept specially manufactured inserts (an engineered repair solution). Then it was back on the turntable for welding the 5 degree taper and spider bush bore ready for machining – ensuring welded taper and bore were also finish machined to OEM specifications. Engineered inserts were then fitted using cryogenics and were subsequently drilled and tapped.
The Project in Numbers…
During the repair process, more than 1.5 tonnes of welding wire was laid down to achieve required stock for finish machining to required tolerances. In addition, there were 580 hours of welding and 400 hours of machining.
The Topshell and Spider were then repainted and prepared for return shipping to the customer.
The project was completed at a quarter of the cost compared to buying new replacement parts and with an industry-beating turnaround time.
To discuss a better way to maintain your crushing capabilities, reduce unplanned downtime and beat the clock on repair and refurbishment, speak to CMS Cepcor today – The Crusher Parts Specialist.
01530 817 000
Associated Businesses
