Case
DRS 160 Wheel Block Upgrade in a Turkish Steel Plant
DRS 160 Wheel Block optimized for the extreme conditions of Turkish steel mills, featuring a robust enclosure against salt spray and dust.
1. Industry Background
Steel plants in Türkiye predominantly utilize Electric Arc Furnace (EAF) technology. In this environment, overhead cranes operate 24/7 with high-frequency cycles to transport scrap metal and molten steel ladles. The wear and tear on travel mechanisms in such conditions is 2 to 3 times faster than in standard environments.
The plant’s original localized welded wheel blocks performed poorly under the following challenges:
High-Frequency Vibration: Intense vibrations from high-current smelting and relentless start-stop cycles.
Coastal Salt Spray Corrosion: Located near the Mediterranean, the saline air caused standard bearing housings to rust and seize rapidly.
High-Temperature Dust: Metallic dust generated during scrap melting posed a severe threat to the wheel block seals.
2. The Solution
To combat these harsh conditions, the maintenance department standardized the trolley wheel blocks on their core production line to the DEMAG DRS 160-MA45-A-65-K-X-X.
Five-Sided Machined Housing: The fully enclosed design of the DRS 160 housing creates a sealed bunker for the internal bearings, completely blocking out Mediterranean salt spray and conductive dust.
MA45 Lateral Mounting Flange: Given that many Turkish steel lines are aging and prone to minor foundation settlement, the MA45 connection allows for precise alignment via bolt-hole adjustments. This significantly reduces lateral wear caused by uneven tracks.
Wear-Resistant Tread: The 65mm wide tread combined with the Type-A flange ensures exceptional power transmission stability during frequent acceleration and emergency braking.
3. Application Results
Maintenance Efficiency: Replacing a traditional welded wheel previously required a welder and a mechanic working for 8 hours. Utilizing the DRS modular system, a single technician can now complete the task, slashing downtime from 8 hours to under 2 hours.
Spare Parts Standardization: By stocking this single standard reference, the plant achieved unified management of spare parts across multiple cranes, reducing inventory carrying costs by 20%.
Extended Service Life: In high-salinity and high-heat environments, the service life of the DRS 160 is 2.5 times longer than that of non-standard components.
From 8 Hours to 2 Hours: Can Your Crane Maintenance Be Faster? In the high-output steel mills of İskenderun, every minute of downtime translates into significant financial loss. Switch to the Demag Modular Wheel Block System to achieve standardized components and lightning-fast replacements. Contact Us Today
