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Avoid 3 Common Mistakes Installing Chrome Carbide Wear Plate

Chrome Carbide Wear Plate is normally the best choice for combating Abrasion applications.

Throughout this article we will use the term CCO, which stands for Chrome Carbide Overlay plate.

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CCO is made by machine welding hardfacing on a mild steel base plate.

Some people may have had difficulty using CCO.

Evaluating comments over many years, we see most issues can be traced back to 3 common installation mistakes.

Here we will review the three most common installation errors, and what you can do to prevent them from happening in your applications.

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This photo shows two primary causes of CCO wear plate failure.

The RED ‘A’ shows how the joining weld has worn away. This is caused by not hardfacing a cap over the joining welds. This issue will result in a premature failure and unplanned downtime.

The YELLOW ‘B’ shows what happens when the edge of the CCO plate is exposed to the abrasive elements. The mild steel backing plate is not hard and will quickly wear away. Without the base for support, the carbide surface falls away; leaving no abrasion protection, results in premature failure and unplanned downtime.


A. Not hardfacing or capping the structural welds retaining the overlay plate.

This is the primary cause of most CCO failures. It is important to understand joining welds are NOT HARD LIKE THE OVERLAY surface. This means the weld joint does not have the same abrasion resistance as the CCO deposit. The abrasion material flow is now able to get behind the wear plate and create a hole through the equipment structure.

DO THIS for a successful installation:

After all welds have secured the wear plate, apply a hardfacing alloy to cover all joining welds. This will protect the joining weld deposit keeping your steel plates in position.

B. Allowing the edge of CCO to be exposed.

NEVER allow the edge of a CCO plate exposed to abrasive elements. The mild steel backing plate for the CCO deposit is not hard and wears away rapidly.

The Chrome Carbide Overlay is there only for wear resistance. This means the overlay has no structural integrity by itself. That is the overlay’s only job. When the softer mild steel base plate has worn away, there is no support for the overlay.
Like a violent flood causes a river bank to fail; the carbide surface will tumble into the abrasive flow. This leaves you with zero protection, resulting in another premature failure and unplanned downtime.

DO THIS for a successful installation: More critical than the weld joints, ALL exposed CCO plate edges MUST be covered by a compatible hardfacing alloy. Preferably the same deposit as the overlay; covering all edges of the CCO wear plate

C. Not fully supporting the CCO plate.

It is important to remember the overlay has no structural strength by itself. If you are installing a ¾” thick CCO plate, this means the structural mild steel is 3/8” thick with another 3/8” of CCO deposit. As a result CCO cannot withstand being supported only by widely spaced support beams. Any flexing will result in failure of the mild steel base plate, leading to shear failure often seen as ‘chunking out’.

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This piece of CCO was not adequately supported, allowing a large chunk to fall out of the plate.

DO THIS for a successful installation: Have any CCO plate fully supported underneath. The best prevention against flexing is to secure the plate using enough plug welds.

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Starting from the center of the plate, weld the holes to secure the wear plate in an expanding outward circle. Have no distance greater than 18” between the plug welds or plate edges.

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Use this chart to determine the proper size of your plug weld holes, based on the CCO thickness plate you are installing.

NOTE: Only after welding all the plug weld holes do you weld the edges of any wear plate.

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These plug weld holes were not capped, and the joining weld wore away; allowing the welds retaining the CCO plate to flex until it failed. This unplanned breakdown required extensive repairs.

Remember to cap all the plug welds with hardsurfacing so they do not wear away, allowing the plate to flex; leading to failure.
JADCO Mfg., wants your investment in the finest wear resistant CCO material to last as long as possible. This is why we want you and/or your contractor to know exactly how to install these plates.

For your unique applications, JADCO now features five different versions of CCO plates; made on site in our factory 30 minutes North of Pittsburgh, PA:

Chromeweld 600 – Chrome Carbide; high carbide concentration for most applications
Chromeweld Nb Plus – Chrome and Niobium Carbides; for fine particles and high velocity
Chromeweld Ti – Chrome and Titanium Carbides; for abrasion with impact
Chromeweld Complex – Chrome, Niobium and Vanadium Carbides for extremely demanding applications including high heat.
Chromeweld W – Chrome and Tungsten Carbides; RECENTLY INTRODUCED BY REQUEST TO COMBAT YOUR most aggressive wear challenges.

Uncertain which CCO wear resistant plate is the best for your application?

Click Here to listen as JADCO’s president Sam Anderson explains these four different CCO plates; allowing you to determine which one is best for your unique application.

We understand you don't buy wear plate because you need wear plate.

You buy the correct wear plate to provide longer equipment life for your unique application.

Unlike other steel salespeople, we are not simply trying to get an order today.

JADCO sales professionals focus on delivering results FOR YOUR APPLICATIONS.

We ask more questions than most vendors, to make certain we do not duplicate an already failed attempt at longer life.

Our mission is to improve your performance and deliver better results. No excuses – period.

By focusing exclusively on delivering longer life and consistent value for our customers over the last 40 years; JADCO is able to deliver greater performance in your applications.

Remember, the only thing you have to lose by not working with JADCO, are your profits.

Allow us to help you by calling (724) 452-5252, or email sales@jadcomfg.com today.
We will schedule a meeting with one of our local wear plate specialists at a time that best fits your schedule requirements.