Cement & Minerals • St.Genevieve, MO, CA
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Overview
The competitor over built 4 OK Mill Tables by 25mm. WA Integra Team was able to come up with a solution on the fly to set up a Automated Gouging set up using WA D-2 equipment.
Industry
Cement & Minerals
Location
St.Genevieve, MO, CA
Component/Workpiece
VRM Table Repair
Business Type
Integra - On Site
Job Type
Repair
OEM
Flsmidth
Type of Wear
Base Metal
Hi Chrome
General Dimensions (mm)
3.6m Table
The challenge the customer was facing
The problem was the competitor overbuilt all 4 tables by 25mm. Learning how to automate gouge not only a table but a radiused one in-situ was a steep task given this was a process the crew was new to.
Previous Service Life
2mo
Competitor
Alabama Wear Services
How WA solved the challenge
WA Integra used GW-O (3.2) D-2 millkits with air knives attached to torches angled downhill on radius allowing them to gouge/cut the 25mm of overbuild in 48hrs. The table was then rebuilt using Mill 415.
Product Category
Integra Services
Product Description
For Gouging Repairs - GW-O (3.2) For Welding Repair - Mill 415 (3.2) Build Up
Job Duration
1w 6d
Technical Advantages
WA Gouging Solution allowed for the team to rebuild 4 OK Mill tables that otherwise could not continue to grind clinker efficiently. I see this as a HUGE Technical Advantage as NO one in the Hardfacing US Cement Market is doing this or has the equipment to do such work.
Service Life
1y
Photos and visuals for this case study
Annual Cost Before
$400,000.00
Annual Cost After
$156,666.67
Annual Savings
$243,333.33
60.0% reduction
Annual Cost = (A × E) + (E − 1) × (F + G + H)
Where: A = Cost of Part, E = Parts/Year, F = Maintenance, G = Disassembly, H = Downtime
Now that the existing over built material has been removed by gouging the tables have been brought back to OEM profile allowing for better cement production. The removal of the old material also gave solid base materail to rebuild on which should allow a much better wear life.
1 layer(s) documented
Contributor
Ian Turner
ian.turner@welding-alloys.com
Created
April 1, 2026
Submitted
April 1, 2026
Approved By
Bastien Gerard
April 1, 2026