A complex air classifier. Severe abrasive wear. Strict weight limitations. And a maintenance process that previously required the entire unit to be removed from site.
The site needed a repair solution that could be installed quickly in a restricted access area without drilling into the existing chute or extending the shutdown.
At Fortescue’s Iron Bridge magnetite operation in Western Australia, the air classifier system is exposed to high-velocity air carrying abrasive iron ore fines. Protecting the complex internal geometry presented a significant wear challenge — particularly when the lining solution also needed to remain within a strict 4,100 kg lifting limit.
The existing trowel-applied cementitious lining was labour-intensive to repair and could not be maintained in situ. Routine wear maintenance required the complete air classifier to be removed and replaced with a spare unit, involving heavy lifts and extended planned shutdowns.
Elastotec worked with the project team to develop an alternative using the Magnefast™ Wear System with A95 ceramic liners.
Engineering Wear Protection Around the Asset
Rather than adapting the asset to suit a conventional lining system, the Magnefast™ solution was engineered around the air classifier’s complex geometry and operating requirements.
Using a detailed 3D model, the complete wear panel layout and individual liner designs were developed before installation. The magnetic attachment system allowed the ceramic liners to closely follow the internal profile while keeping the total installed weight below the required limit.
The system also introduced a significant maintenance advantage: individual Magnefast™ panels can be installed, removed or rotated in less than 20 seconds, creating the potential for targeted in-situ maintenance rather than removing the complete air classifier.
What Happened After 14 Weeks?
The first inspection during the planned 14-week shutdown provided an early indication of how the system was performing.
All ceramic liners remained securely in position in the magnetite operating environment. The majority showed little to no measurable wear, with only minor localised wear identified on the leading edges of a small number of liners. The maximum wear recorded was approximately 5mm.
The Results
✓ Meets strict 4,100 kg lifting requirements
✓ Rapid in-situ maintenance
✓ Gap-minimised wear protection
✓ Projected wear life up to 70 weeks
✓ Individual liners can be removed or rotated in seconds
✓ Reduced requirement for heavy lifts, scaffolding and hot work
See the Full Engineering Solution
How do you protect a complex asset against severe abrasive wear without adding excessive weight and make future maintenance significantly easier at the same time?
The full case study explores the engineering challenge at Iron Bridge, the Magnefast™ liner design and installation process, inspection findings after the first 14-weeks and feedback from the site engineering team.
Facing a similar wear challenge in a chute, classifier, transfer point or other difficult-to-access fixed plant application?
Contact Elastotec to discuss how Magnefast™ can be engineered around your application.
