Industry Overview
The sand and gravel aggregate industry is one of the largest consumers of wear parts in the world. Billions of tonnes of aggregate are produced annually for concrete, asphalt, road construction, and building foundations. From river gravel to blasted rock, aggregate materials vary enormously in hardness, abrasiveness, and shape — and every crushing and screening operation needs the right wear parts to maximize throughput and minimize cost per tonne.
Zhili provides comprehensive wear solutions for the aggregate industry — from primary jaw crushing through secondary and tertiary cone/VSI crushing to final screening and conveying. We serve fixed crushing plants, mobile crushing contractors, quarry operations, and recycled aggregate processors across the globe. Our metallurgy is tailored to each crushing stage and material type, delivering measurably lower cost per tonne of finished aggregate.
Related Products for Aggregate Industry
Jaw Plates
Manganese steel jaw plates for primary crushing of river gravel, limestone, and blasted rock. Custom tooth profiles optimized for feed material gradation and desired product shape.
Cone Crusher Mantle & Bowl Liners
Precision-cast cone crusher liners with optimized wear profiles for consistent product shape. Available for all major brands — Metso, Sandvik, Telsmith, Cedarapids, and Chinese OEM models.
Crusher Blow Bars
High-chromium blow bars for horizontal shaft impact crushers (HSI) in secondary and tertiary crushing. Optimized for maximum wear life in specific aggregate types — limestone, granite, basalt, or recycled concrete.
Crusher Hammer Heads
Vertical shaft impact (VSI) and hammer crusher rotor assemblies for sand making and fine crushing. Tungsten carbide insert options for ultra-abrasive granite and quartzite applications.
Vibrating Screen Media
High-frequency screen decks, polyurethane screen panels, and rubber screen media for classification screens. Optimized aperture geometry for maximum throughput and minimum blinding in sand and gravel applications.
Wear Liner Plates & Chute Liners
Chute, hopper, and feed bin liner plates with high-chromium bimetal composite surfaces. Custom-formed to match your specific geometry for quick, accurate installation.
Core Material System for Aggregate Industry
The universal material for primary jaw plates, gyratory concaves, and cone crusher liners in aggregate crushing. Austenitic manganese steel work-hardens rapidly under impact — initial hardness of ~200 HB increases to 500-550 HB at the worn surface during service. This self-protecting mechanism makes it ideal for high-impact primary crushing of irregular rock lumps.
| Grade | Mn18Cr2 (ASTM A128 / GB 5680) |
| Initial Hardness | 170-220 HB |
| Work-Hardened Surface | 480-550 HB |
| Impact Toughness | ak >= 150 J/cm2 |
| Application | Jaw plates, gyratory concaves, cone liners |
For secondary and tertiary impact crushing (blow bars, impact plates, VSI rotor parts), high-chromium cast iron is the standard. Zhili's HCrCI alloys with Cr 18-28% and optimized Mo-V-Nb microalloying create a refined M7C3 carbide network that delivers exceptional abrasion resistance at HRC 58-63, while maintaining sufficient toughness for impact loading.
| Grade | HCrCI-EX (Zhili Proprietary) |
| Hardness | HRC 58-63 |
| Carbide Type | M7C3 eutectic network |
| Impact Toughness | ak >= 8 J/cm2 |
| Application | Blow bars, VSI rotor parts, impact plates |
For chutes, feed hoppers, and vibrating screen deck panels in aggregate plants, high-chromium bimetal composite (HRC 60+ wear surface metallurgically bonded to structural steel backing) delivers the highest wear life at the lowest weight. UHMWPE and rubber screen media are used for wet screening and anti-blinding applications.
| Wear Surface | HRC 58-63 (HCrCI, Cr 18-22%) |
| Thickness Range | 4+20mm to 10+30mm |
| Bond Strength | > 350 MPa shear |
| Screen Media Options | Bimetal, PU, rubber, steel wire |
| Application | Chute liners, screen decks, feed hoppers |
For wet screening, anti-blinding applications, and noise-sensitive environments, polyurethane and rubber screen panels provide superior performance to steel wire screens. Polyurethane screens offer 3-5x longer life than steel, excellent release properties for sticky materials, and significantly reduced noise.
| Material Options | Polyurethane (PU), Natural Rubber, Steel |
| Wear Life vs. Steel | PU: 3-5x, Rubber: 2-3x |
| Noise Reduction | PU/Rubber: 10-15 dB lower than steel |
| Aperture Range | 1mm to 100mm (modular panels) |
| Application | Wet screening, sand washing, fine classification |
Typical Application Scenarios
Primary Jaw Crushing
Jaw crushers processing large river gravel or blasted rock (up to 1,000mm feed size). Extreme impact loads and severe abrasion from angular rock fragments require maximum toughness — Mn18Cr2 austenitic manganese steel is the optimal choice.
Mn18Cr2 Jaw PlatesSecondary/Tertiary Cone Crushing
Medium to fine crushing producing 0-40mm aggregate. Sliding and rolling abrasion from rock particles between concave and mantle at high pressure — requires excellent wear resistance plus good shape control.
Mn18Cr2 Cone LinersHorizontal Shaft Impact (HSI) Crushing
Secondary and tertiary impact crushing for manufactured sand and shaped aggregate. Blow bars and aprons experience high-velocity impact with severe abrasive wear from fine rock particles — HCrCI is the standard solution.
HCrCI Blow BarsVSI Sand Making
Vertical shaft impact crushers for manufactured sand production from -40+5mm feed. Rock-on-rock or rock-on-iron configurations with extreme particle velocity (60-80 m/s). Tungsten carbide inserts on rotor parts for quartzite and granite.
VSI Rotor Parts / TC InsertsVibrating Screens & Classification
Multi-deck vibrating screens classifying 0-5mm sand, 5-10mm, 10-20mm, and 20-40mm aggregate fractions. High-frequency screening at 800-1,000 rpm with abrasive rock causing rapid wear on screen media and deck frames.
PU/Rubber Screen MediaConveying & Stacking
Radial stacking conveyors, transfer chutes, and collection bunkers handling high volumes of abrasive aggregate. Chute liners and belt cleaner blades experience severe sliding and impact abrasion — bimetal composite is the proven solution.
Bimetal Chute LinersSuccessful Cases
Jaw Plates — Primary Limestone Crushing
VSI Rotor Parts — Manufactured Sand Production
Blow Bars — C&D Waste Recycling Plant
Polyurethane Screen Decks — Wet Sand Washing
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