#55 Steel Rusts in
2–3 Days
FerroMax® Anti-rust Screens: Engineered for extreme mining conditions to eliminate frequent replacements and costly shutdowns.
FerroMax® Anti-rust Screens: Engineered for extreme mining conditions to eliminate frequent replacements and costly shutdowns.
Low-carbon steel screens fail rapidly in mining environments, creating operational and financial burdens.
#55 low-carbon steel screens develop red rust within 48–72 hours, creating a cascade of operational issues and financial losses for mining operations.
"We were forced to shut down the machine twice a month to replace the screens. The labor cost for screen replacement alone was ≥$2,800/month."
The true cost of #55 steel corrosion extends far beyond replacement parts.
For #55 steel of the same specification in an environment with 40°C, 75% RH, and Cl⁻-containing dust:
If the mesh aperture is enlarged by 20%, the screening efficiency will suddenly drop by 30%.
Corrosion pits combined with vibration reduce fatigue limits by 60%, leading to a 15% annual risk of sudden fracture.
Each downtime loss is ≥$7,000, with an annual hidden cost exceeding $140,000.
Engineered for Extreme Mining Environments to Eliminate Corrosion Issues
FerroMax® screens outperform conventional #55 steel in all critical performance metrics, delivering exceptional durability in harsh mining environments.
| PERFORMANCE METRIC | GRADE #55 STEEL | FERROMAX® SERIES |
|---|---|---|
| Indoor storage anti-rust period | 10–15 days | ≥ 365 days |
| Actual anti-rust period in mines | 5–10 days | 3–6 months |
| Annual corrosion rate | 0.39–0.65 mm | ≤ 0.05 mm |
| Fatigue life | 1.2×10⁶ cycles | ≥ 4.5×10⁶ cycles |
| Annual replacement frequency | 12–24 times | 4–6 times |
"Since implementing FerroMax® screens, our downtime has decreased by 75%, saving us over $200,000 annually."
— Project Manager, Australian Iron Ore Operation
Our proprietary technology combines advanced materials science with innovative engineering.
Zn-Al-Mg rare earth alloy coating + nano-sealing film + passivation and sealing, with porosity < 3% and 90% reduction in Cl⁻ permeability.
65Mn, quenched & twice isothermal-drawn, achieving a tensile strength of 1600–1800 MPa. The coating forms a metallurgical bond with the substrate, resisting impact and preventing peeling.
Patented "double-lock" weaving nodes reduce the stress concentration factor from 3.0 to 1.4, lowering the probability of fatigue crack initiation by 60%.
FerroMax® has passed rigorous 1000-hour salt spray testing, confirming its superior corrosion resistance. The unique combination of materials and manufacturing processes delivers 275% longer fatigue life compared to #55 steel.
"FerroMax® screens demonstrated exceptional performance in our accelerated corrosion testing, outperforming all conventional alternatives."
— Independent Materials Testing Laboratory
Saving $25,000 per year per screening machine
The economic benefits of FerroMax® extend beyond reduced replacement frequency, impacting multiple cost centers in your operation.
PRODUCTION LINE SAVINGS
An entire production line with 8 machines can save approximately $200,000 annually
(Data from a cobblestone quarry project in China)
| ITEM | MONTHLY REPLACEMENT | BI-MONTHLY REPLACEMENT | ANNUAL SAVINGS |
|---|---|---|---|
| Screen usage | 12 pieces | 6 pieces | 72 pieces |
| Price per piece | $110–$170 | $110–$170 | — |
| Screen procurement cost | $1,320–$2,040 | $660–$1,020 | $660–$1,020 |
| Replacement labor cost | 12 × $550 = $6,600 | 6 × $550 = $3,300 | $3,300 |
| Shutdown loss | 12 × $3,500 = $42,000 | 6 × $3,500 = $21,000 | $21,000 |
| TOTAL ANNUAL SAVINGS | — | — | $24,960–$25,320 |
Average ROI period: 1.2 months
CHOOSE FERROMAX® = CHOOSE HIGHER EFFICIENCY AND LOWER COSTS
Experience the FerroMax® difference with our no-risk trial program
A 1m×2m FerroMax®-AR40 (40mm square holes, 8mm wire diameter) will be delivered this week for on-site testing.
Our engineers can bring handheld corrosion thickness gauges to record rust differences at 7, 30, and 90 days.
If the trial is successful, an annual framework agreement can be signed, with 5% safety stock reserved to ensure delivery within 48 hours.
Take the first step toward eliminating corrosion-related issues and saving thousands annually. Request your free FerroMax® sample today.
REQUEST FREE SAMPLE