Case study

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Hail Creek

Challenge

The maintenance team at Hail Creek Mine needed more than just high wear resistance. During the trial, the site informed us they required not only durability and a high polish, but also flowers that presented a smooth side.

Solution

KCL supplied shafts designed for high wear, then adapted their design mid-trial. After making metallurgical changes to the Chevrons and refining the flower design, the result was a part with outstanding wear qualities, self-polishing properties, and cleaner surfaces that reduced sticking and fouling.

Results

  • Improved wear life and reduced clay build-up.
  • Cleaner shaft surfaces with minimal post-cleanup required.
  • Cost-saving measures implemented, including extended bearing life and reduced need for carrying multiple critical spares.

Sedgman

Challenge

Sedgman faced extremely hard material passing through the circuit causing excessive shock loading, leading to cracking on the chevrons and shaft jewellery becoming loose.

Solution

In collaboration with Sedgman, KCL developed and trialled an alternative shaft design built to withstand the harsh operating conditions.

Results

  • Shaft wear life increased from 3-5 months to more than 12 months.
  • Reduced breakdowns and maintenance interventions.
  • Lower downtime, improving overall plant efficiency.
  • Partnership with Sedgman continues after 8 years, built on trust, performance, and innovation.

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