Fabrication designed to last

Fabricated parts from ICS are more than just copying what you already have. Due to our expertise in combatting component wear in many different applications, we do more than create replacement parts or slurry pump parts - we create replacement solutions. For many of our clients, we have designed components that last longer and work better than their original parts.

ICS gives you two options:

• Choose from our catalogue of current pattern templates, all of which have been tested in the field. We mark everything we make with a serial number, so we can track field performance; or
• Choose to work with us for a custom-designed pattern precisely matched to your operating conditions. Many of our custom-designed solutions quickly repay the cost of development by giving our clients longer service life and/or greater operating efficiency.

For either option, ICS gives you cost-effective, on-time delivery. We can handle almost any request. Our foundry and machine shop have the capacity to deal with components ranging in size from one pound to 8,000 pounds and can work with a variety of alloys. Available casting methods include centrifugal castings, chrome moly steel, die castings, ductile iron, grey iron, high-chrome white iron (HCWI), lost-wax castings, manganese, resin castings, sand castings, and stainless steel.

For all applications requiring ceramics, rubber, and/or urethane, our team of engineers will take your sample and/or drawing, design a mould and provide you with a custom product built to match your operation. With over 200 years of combined experience in both the underground mining and surface mining sectors, we know you need more than parts. You need solutions that makes your machinery able to withstand the inherent wear factors of your industry, whether that wear is caused by abrasion, corrosion, and/or impact.

Below, we outline two of our many successes in custom fabrication.

Custom Designed Elbow

Shown below is a custom designed elbow, which we created to replace an original equipment part that failed. We redesigned the elbow, modified the wall thickness, and changed the alloy. The result was a component which fit perfectly into the original assembly but lasted 47 per cent longer than the original component.

ICS used this sample from the client to check the composition, critical wall thickness, and hardness of the original component.	The two halves of the pattern created by ICS to fabricate a new, stronger elbow component. ICS also changed the alloy, which added to the component's service life, and modified the thickness of the walls.		The new elbows are ready to ship. Initial results show a 47% increase in service life.

Custom Designed Casting

At a NWT mine, any downtime cost the company more than $10,000 an hour. To reduce unscheduled downtime, ICS created a custom-designed casting of a vibrating grizzly wear bar with a re-engineered, thicker foot. The thicker feet makes the grizzly wear bar better able to withstand impact, thus ensuring continued production and reduced downtime.

The thicker feet on this redesigned vibrating grizzly wear bar, shown above, makes the component better able to handle the vibration of heavier rock falling. The redesign reduced downtime for the client, a NWT mine.

Read more success stories on how ICS Wear Groups develops solutions for our clients.

Contact us to discover how we can help your operation with custom fabrication or replacement parts.