India’s No.1 in stainless steel welding consumables — by far
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 SUPERON range that puts them back in service.

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
33
Components mapped
7
Plant areas
500+
Authorised distributors

Plant map

Click any area — the photo above and the table below both update

33 components mapped  ·  7 plant areas Click an area to narrow
Component Base metal Wear factor Plant area Recommended solution
Hammer (New) Mn. Steel Impact/Abrasion Crusher Hard surface electrodes
Hammer (Old) Mn. Steel Impact/Abrasion Crusher Hard surface electrodes
Hammer Arms & Shafts Alloy Steel Friction/Impact Crusher Hard surface electrodes
Jaw Crusher Plate & Eccentric Shaft Alloy Steel Friction Crusher Cladding & die build-up
Cylinder Mill Teeth & Crusher Bar Austenitic / Mn. Steel Impact/Abrasion Crusher Hard surface electrodes
Toggle Bearing Plate Mn. Steel Abrasion Crusher Hard surface electrodes
Diaphragm Mn. Steel Impact Crusher Hard surface electrodes
Mill Head/Journal Cast Steel Impact Raw Mill & Kiln Feed Hard surface electrodes
Mill Gear Drive Pinion Cast Steel Friction Raw Mill & Kiln Feed Cladding & die build-up
F.K Pump Shaft Bearing Carbon Steel Friction Raw Mill & Kiln Feed Cladding & die build-up
Slurry Pump Shaft Carbon Steel Corrosion/Friction Raw Mill & Kiln Feed Cladding & die build-up
Elevator Rim/Drum Mild Steel Abrasion Raw Mill & Kiln Feed Hard surface electrodes
Kiln Tyre Cast Steel Friction Kiln Cladding & die build-up
Kiln Support Roller Cast Iron Fatigue/Friction Kiln Cast iron electrodes
Girth Gear Drive Pinion Cast Steel Fatigue/Friction Kiln Cladding & die build-up
Girth Gear Teeth (Broken Tooth) Cast Steel Fatigue Kiln Cladding & die build-up
Burner Nozzle Stainless Steel Heat/Abrasion Kiln Nickel & Inconel grades
Clinker Inlet Alloy Steel Heat/Abrasion Kiln Cladding & die build-up
Inlet Neck/Body Cast Iron Heat/Abrasion Kiln Cast iron electrodes
Cooler Plates Alloy Steel Heat/Abrasion Clinker Cooler Cladding & die build-up
Scooping Liner Plates Mild Steel / Mn. Steel Abrasion Cement Mill & Separator Hard surface electrodes
Lifting Arm & Roller Mild Steel Friction Cement Mill & Separator Cladding & die build-up
I.D. Fan Blades Mild Steel Friction Cement Mill & Separator Cladding & die build-up
Drag Chain Sprockets Carbon Steel Friction Material Handling Cladding & die build-up
Sprockets Alloy Steel Friction/Impact Material Handling Hard surface electrodes
Idler, Guides & Track Rollers Carbon Steel Impact/Friction Material Handling Hard surface electrodes
Coal Pipe Bends Cast Steel Abrasion Material Handling Hard surface electrodes
Crane Grab Mild Steel Abrasion Material Handling Hard surface electrodes
Loco/Crane Wheels Cast Steel Friction Material Handling Cladding & die build-up
Pump Housing Cast Iron Impact Material Handling Cast iron electrodes
Cylinder Block Head Cast Iron Impact Material Handling Cast iron electrodes
Shovel Bucket & Lip Mn. Steel Abrasion/Impact Mobile Equipment Hard surface electrodes
Track Link & Shoes Mn. Steel Impact/Abrasion Mobile Equipment Hard surface electrodes

Cylinder Mill Teeth & Crusher Bar

Crusher
Base metal Austenitic / Mn. Steel
Wear factor Impact/Abrasion
Hard surface electrodes

Slurry Pump Shaft

Raw Mill & Kiln Feed
Base metal Carbon Steel
Wear factor Corrosion/Friction
Cladding & die build-up

Scooping Liner Plates

Cement Mill & Separator
Base metal Mild Steel / Mn. Steel
Wear factor Abrasion
Hard surface electrodes

Idler, Guides & Track Rollers

Material Handling
Base metal Carbon Steel
Wear factor Impact/Friction
Hard surface electrodes

Cylinder Block Head

Material Handling
Base metal Cast Iron
Wear factor Impact
Cast iron electrodes
Showing 33 of 33 components Grade-level recommendation issued after component inspection
How cement plant components fail

Abrasion

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

Impact

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

Heat

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

Friction & fatigue

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

The range

What a cement plant buys from us

Stainless steel electrodes India's best-selling SS welding consumable range. Hard surface electrodes Overlays for abrasion, impact and friction wear faces. Hard surface tubular electrodes High deposition on large, heavily worn surfaces. Cast iron welding electrodes Cold repair of cracked housings, beds and pump bodies. Cladding & die build-up Rebuilding shafts, dies and tooling back to size. Repair & joining electrodes Dissimilar and unknown-steel joints made on site. Nickel & Inconel grades Heat-resistant service on grills, elements and doors. Abrasives Cut, grind and finish on the same line.
Other industries
Steel Marine Mining Sugar Transport Railway Oil & Petrochemical Power

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.

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