Featuring new technology and options For

industrial wear control

an innovative approach For applying wear studs on areas exposed to high abrasion

state oF the art hardFacing technology

tuFFstudds are carbide-laden, wear resistant alloy studs

>rc hardness is between 50-60

tightly applied patterns create a “dead bed” eFFect which Further enhances wear resistance applied via arc weld onto alloy castings or plate

especially designed For heavy mining or construction operations

overview

beneFits convenience:

simple controls, automatic sequencing oF the welding cycle smokeless operation horizontal, vertical and overhead position capability minimal distortion due to heat build-up repair capability on previously studded surFaces

speed:

application rates oF up to Four sq. Ft. per hour * deposit rates over 20 pounds per hour *

* rates are dependent on coverage surFace area and stud size

beneFits long liFe:

up to three times longer liFe reduces equipment downtime and overall costs oF replaceable components

savings: less equipment costs less downtime less labor expense on repair and idle time less overall cost For replacement parts

the tuFFstudds wear protection system saves money and increases your bottom line!!!

applications

dozer blades: proven method oF protecting dozer blades. applied to blades and push arms multiple applications on original wear plate pattern becomes embedded with mineral debris creating dead bed eFFect

applications

packer tips: eFFective method oF protecting packer tips and blades tips retain packing edge longer, allowing more eFFective packing action wear on blades is minimized increasing liFe oF part

applications

shovel buckets: excellent wear protection For all types oF shovel buckets.

high-wear areas such as lips, cutting edges and tooth adaptors attain maximum liFe when protected with tuFFstudds.

dragline buckets: protect worn bucket components.

wing shrouds and drag hitch areas all beneFit From tuFFstudd protection.

applications

grapple clam tips/arms cage mills breaker plates

augur Flights edges compactor wheels

world oF asphalt

overview

the total asphalt business in the north america is estimated at 24.0 billion dollars annually

the asphalt paving industry is estimated at $14.15 billion dollars annually

approximately 475 companies have sales in excess oF $100,000 annually

1% - $14.15 million dollars are spent on maintenance annually

asphalt plant maintenance

there are two types oF asphalt plants pug mills (batch plants) For small paving jobs; parking lots, driveways, side walks drum (continuous Flow) For large paving jobs, mainly highways.

2006 pug mill test program

6 ton asphalt pug mill

hanson - glen mills, pa

wear on shank arms aFter 200k+ tons oF material or 1 year oF service. Feb 06

test program on new pug mill shanks

march 2006, hanson glen mills installed tuFFstudds to 40 new mixing arms prior to start oF 2006 season For 6 ton pug mill

typically arms are replaced each year aFter average season oF 200k-300k tons oF material are run through mill

there is a signiFicant amount oF labor involved in changing arms each year in additional to cost oF new parts

objective oF test is to increase the wear liFe oF arms to 2 seasons

test program on new pug mill shanks

tuFFstudds are applied to the critical wear areas oF the shank arm: under paddle and around base For bolt

goal is to evaluate tuFFstudds shanks total length oF service.

test oF plant will be conducted in spring-summer oF 2006

results oF tuFFstudd test program

tuFFstudds are not showing any signs oF wear aFter 80k tons oF material through mill. photos From june 2006.

material is embedded between studs on shanks creating the dead bed eFFect

initial results show tuFFstudds appear to be extending the arm liFe

results oF tuFFstudd test program

tuFFstudds arms showing minimal signs oF wear aFter 180k tons oF material through mill (photos sept 30, 2006)

material is still embedded between studs on shanks creating the dead bed eFFect

results show tuFFstudded arms will make second season

results oF tuFFstudd test program

comparison shot oF tuFFstudded arms vs. weld overlay arms

tuFFstudd arms have 180k tons season to date.

Sept 06 2005 Season

updated results oF tuFFstudd test program

there are a total oF 44 paddles contained within the machinery.

only 12 paddles are being replaced during this service period!

these paddles have lasted almost 5 years and have had approximately 1.5 million tons oF material run through them.

previous liFe expectancy was 200k tons which translates into a liFe extension oF 7 times For the studded pug mill paddles.

single or double barrel drum mixer

single barrel drum mixer

tuFFstudds would be applied on the inside diameter oF the drum at the discharge end oF aggregate Feed. in addition there may be paddle arms that could also have tuFFstudds applied

tsa-68 (3/4”-19mm) or tsa-78 (7/8”-22mm) would be used as it would be the same as welding downhand on the inside radius.

on a typical 8 Foot drum diameter by 8 Foot length oF the aggregate Feed area to protect For wear the area to be covered would be:

25.4 Foot circumFerence x 8 Foot long section equals: 203.2 square Feet

using the max tuFFstudd diameter: tsa-78 (7/8” -22mm) with 70 studs per square Foot, it would require 14,225 tsa-78 tuFFstudds (approx.) dollar value $$29,925 usd

double barrel drum mixer

the aggregate discharge would be on the outside oF the inner barrel - outside radius

this makes For a more diFFicult installation – requires weld position slightly overhead.

only tsa-68 (3/4”-19mm) are recommended

using the same dimensions as For the single drum would require 203.2 square Feet oF coverage

203.2 square Feet x 100 per square Foot will require: 20,320 tsa-68 dollar value (approx.) $34,125 usd

in addition there may be paddle arms that could also have tuFFstudds applied

wear plates with tuFFstudds

speciFications

tuFFstudds are available in 3 diFFerent sizes 5/8”,3/4” and 7/8” diameters.

tuFFstudds are graded in 2 diFFerent grading to maximize perFormance ( i ) For low impact, high abrasive conditions ( a ) For higher impact conditions.

application speeds oF up to 200 studs per hour.

best results occur by tightly packing tuFFstudds in patterns that minimize “wash-out” between stud rows.

sales manager: steve swartz e-mail: steve@newagestudwelding.com phone: 888-889-3833 Fax: 856-218-3806 oFFice location:

11 enterprise court sewell, nj 08080

authorized distributor For

For product demo at your site or For additional inFormation on tuFFstudds please contact: