Screen media may be a small part of your mine or quarry operation, but it can have a big impact on overall production if it malfunctions. It can bring the entire circuit to a standstill and you could lose thousands of dollars due to downtime. That’s why, whether you’re using wire cloth or a synthetic option, periodic visual inspection is needed to make sure there isn’t any extreme or unusual wear.
If you’re using side-tensioned media, during your inspections, you should always make sure your screens are tensioned correctly. Look for clamp bars that have come loose and for blocked apertures in the media, plugged with material or blinded over. While synthetic screen media, either polyurethane or rubber, can last up to 15 times longer than wire cloth, that only reduces the frequency of visual inspection—it doesn’t eliminate it. You’ll still need to regularly inspect your screens to evaluate media condition.
Resist the temptation to use stop-gap solutions to continue running damaged wire cloth. For example, when you install a patch on worn-out sections, or use a liquid urethane to fill in holes, you end up sacrificing screen efficiency. That likely will just make for a bigger mess later.
When replacing modular synthetic media, be sure to clean sand or fines from the frame surfaces and the fastening cavities to ensure a secure attachment to the frame. Make sure side wear plates are tightened down against the screen panels to prevent panels from working loose.
Do not assume that, because synthetic screen media have significantly longer wear life and reduced maintenance requirements, you can put off checking the screens entirely. You could end up with damaged frames, out-of-spec products, and increased costs when you have to rush orders for replacement media.
Make sure to evaluate screen box performance for unusual variations in acceleration, displacement, deflections, and critical frequency. Any one or a combination of these issues can negatively affect screen performance and can even result in structural damage to the support structure. Poor screening performance can often be traced back to the screen box itself being out of spec. If you are not equipped to conduct a screen box analysis yourself, there are industry consultants available to do the analysis and present you with the results.
You need to use a proactive approach to ensure maximum cost efficiency, longer wear life, consistent specification accuracy, and the security of a reliable and sound screening system. Be sure to always monitor quality control procedures, check side wear liners, and ensure there is proper support and tensioning. When you conduct your periodic inspections, maintain maintenance records and follow recommended replacement and installation methods.
As a family-owned, private company whose sole focus is on your screening operation, Polydeck has the systems, experience, and expertise to ensure that, with regular maintenance checkups, your screening operation will produce the results you need for years to come.
Since 1978, Polydeck has been the leading provider of modular polyurethane, rubber, and specialty screening solutions for the aggregate, coal, and mining industries. Our solutions are known for their high-quality construction, high open area, long wear life, and minimal maintenance requirements. No other screen media manufacturer can provide you with the knowledge, application-specific expertise, and industry-leading Performance Guarantee that Polydeck can.
To learn more about our screen media options, visit polydeckscreen.com/screen-media today!