Challenge

A customer required a full deck of 84 Tuff Rail 2’ x 2’ Profile Wire Panels for a 14’ x 24’ Banana Screen. Conn-Weld secured the order over a competitor through proven field testing and the ability to offer chrome panels in the Tuff Rail design with customizable openings.

After receiving the order late in the year, the team faced a compressed timeline to complete design modifications, process chrome, and manufacture all 84 panels before year-end. The panels also had to fit seamlessly into a competitor’s screen deck, leaving no margin for error.

Solution

Conn-Weld quickly aligned engineering and production teams to execute. Panel frame modifications were completed and pushed through to production, while chrome processing and manufacturing were expedited. The order was treated as a priority across departments, ensuring continuous progress despite the holiday timeframe. Critical focus was placed on precision, with each panel built to exact specifications to guarantee compatibility with the existing deck.

Results

All 84 panels were completed and delivered within the required timeframe. The entire deck was installed without a single issue, every panel fitting perfectly. This project highlights Conn-Weld’s ability to combine performance, customization, and execution speed—delivering a complete solution that performs in the field and fits right the first time.

Challenge

In many applications, wear is isolated to specific sections of a deck frame. However, when replacement options are limited, customers are often required to replace the entire frame to maintain operation. This can lead to unnecessary downtime and increased repair costs, even when only a portion of the deck frame requires service.

Solution

An Individual Cross Member Modular Deck Frame that introduces a standardized, modular approach to deck frame construction. Interchangeable cross members deliver faster installation and easier maintenance by addressing wear at its source, streamlining replacement of worn sections, and eliminating the need to remove the entire deck.

Result

The Cross Member Modular Deck Frame delivers measurable improvements in performance, efficiency, and customer value — including reduced maintenance downtime, lower total cost of ownership, faster installation and reconfiguration, as well as greater flexibility for changing deck requirements.

Cardan Shaft: Conn-Weld Cardan Shaft direct drive system, reduces premature bearing failure compared to conventional belts and motor bases. It delivers smooth power transmission and also reduced maintenance compared to traditional belt-driven systems.

Challenge

A customer in the Bahamas was operating a vibrating screen in an extremely corrosive, salt-laden environment—made even more severe by using salt water to wash the processed rock. The existing screen could not withstand the conditions, resulting in frequent failures and heavy maintenance. The customer was forced to replace the drive system annually, along with other major vibrating screen components, creating ongoing downtime and high long-term cost.

Solution

Conn-Weld engineers visited the site to evaluate the process and environmental exposure. Based on corrosion severity, we engineered a long-term reliability solution: an 8′ x 20′ stainless steel Triple-Deck Incline vibrating screen. Designed for corrosive wash-down conditions, stainless steel provides through-material corrosion resistance for true long-term protection.

Result

Since installation, the Conn-Weld stainless steel screen has remained in operation with no major component replacements, delivering long-term uptime and reducing total cost of ownership in one of the harshest operating environments.

Challenge

A customer’s 10′ × 20′ Double Deck Banana Screen was experiencing repeated bolt failures at the deck beam-to-side plate connection, causing ongoing downtime and maintenance issues.

Solution

Conn-Weld’s Engineering team conducted standard diagnostic vibration analysis testing — including 4-Corner, Operating Deflection Shape (ODS), and Impact Testing. The analysis and on-site assessment revealed significant deflection caused by excitation of a natural or “critical” frequency. To address this, a motor sheave change was implemented to slightly adjust the screen speed.

Result

By adjusting the screen to its optimal operating frequency, the root cause was eliminated. Deflection was reduced, bolt failures stopped, and follow-up testing confirmed the screen is now running with low deflection, improved reliability and less unplanned maintenance.

Challenge

Excessive fine material entering the vibrating screen created unnecessary load, accelerated wear, and reduced overall screening efficiency. This led to higher maintenance demands, increased downtime, and diminished screen performance. A solution was needed to improve material flow and protect the vibrating screen without disrupting the existing process.

Solution

Conn-Weld engineered and manufactured a custom sieve designed to fit directly into the customer’s existing chute work ahead of the vibrating screen. The sieve pre-classified material by removing fines upstream, reducing the volume and burden placed on the vibrating screen. By designing the sieve to integrate seamlessly into the current layout, the solution improved performance while minimizing installation time and disruption.

Result

The newly installed sieve resulted in reduced load and wear on the vibrating screen, improved screening efficiency and consistency, lower maintenance requirements and downtime, and extended life of screen media and equipment. No major chute modifications were required. This solution highlights Conn-Weld’s ability to deliver process-driven, custom-engineered solutions that improve performance while working within existing plant infrastructure.

Challenge

The producer’s existing vibrating screen was not processing material properly, causing material buildup on the equipment and inconsistent performance. Analysis showed the location of the units’ drive was the root cause of the problem, impacting vibration efficiency and material flow.

Solution

Our engineering team delivered a redesigned vibrating screen by relocating the mechanism from the top and middle deck to the middle and bottom deck. This redesign restored correct operating balance and performance and improved material flow across the screen. Due to this redesign, new discharge points were established and a rollaway chute was manufactured to accept these discharge points.

Result

Eliminated material buildup and restored consistent processing. Kept the footprint intact — no structural rework required. Simplified installation with a complete screen + chute solution. Reduced customer coordination and downtime risk. A performance-driven redesign that solved the root cause—without creating additional work for the plant.

Challenge

Customer wanted to upgrade from a double-deck screen to a triple-deck screen without major structural rework. In addition, they also needed a customized enclosure for dust control—while still allowing maintenance access.

Solution

Conn-Weld engineers visited the site to evaluate structural constraints and designed a fully customized package. This included an 8′ x 20′ triple-deck incline screen with an extended base, giving the customer added flexibility during installation. A custom enclosure was also engineered around the base of the screen, featuring access doors for easy maintenance.

Result

The triple-deck screen is designed to replace the existing double-deck unit, requiring only minor structural modifications. The upgrade is expected to increase tonnage, improve screening efficiency, and reduce maintenance needs and long-term operating costs.