When Vale, one of the world’s largest mining companies, faced critical maintenance issues caused by severe vibration on their equipment, they searched for a fastener that could withstand the extremes of daily operation. At Itabira, Minas Gerais, Brazil, HARDLOCK Nuts were trialed on vibration screens and quickly proved their resilience. After six months of uninterrupted performance, Vale adopted HARDLOCK Nuts across all vibration screen assets.

Following this success, equipment manufacturer Haver & Boecker also integrated HARDLOCK Nuts into their screen designs to ensure long-term reliability and minimize maintenance. Today, HARDLOCK is used in mining operations across multiple continents, from Africa to Australia.

Vale’s operations encountered major issues due to extreme vibration loads:

• Massive Maintenance Burden: 150 vibration screens required monthly re-torquing—over 1,500 hours of lost maintenance time each month.
• Frequent Bolt Breakage: Standard fastening systems could not cope with harsh vibrations, leading to fatigue and breakage.
• Inconsistent Repairs: Multiple nuts, including nylon lock nuts, were stacked in makeshift attempts to extend fastener life.
• Disjointed Maintenance: Lack of coordination between teams led to varied and unreliable maintenance practices.

Vibration screen performance and productivity were significantly impacted by these frequent, inconsistent maintenance demands.

HARDLOCK Nuts offered a permanent solution to persistent vibration problems:

• Initial Trial on Exciter Units: First installed on exciter assemblies, where vibration was most severe.
• No More Monthly Re-Torquing: Eliminated the need to remove heavy exciter covers and re-torque 10+ bolts per screen every month.
• Permanent Stability: The wedge-locking system absorbed vibration loads without losing clamping force or allowing fastener movement.
• Consistent Performance Across All Machines: Once installed, HARDLOCK Nuts required no intervention outside of planned shutdowns.

With HARDLOCK Nuts in place, Vale achieved:

• Elimination of Bolt Failures: No more breakage from vibration-induced fatigue.
• Standardized Fastening Method: Unified system across all machines improved coordination and predictability.
• Substantial Maintenance Reduction: Re-torquing now only occurs during major planned shutdowns, freeing up thousands of hours annually.
• Widespread Adoption: The proven results led manufacturers and mines worldwide to integrate HARDLOCK Nuts in their vibration-prone systems.

HARDLOCK Nuts (HLN) are trusted across the mining and earthmoving sectors for their superior anti-loosening performance in heavy-duty applications. From processing plants to mobile machinery and rail transport, HARDLOCK delivers lasting stability under extreme vibration, impact, and environmental stress.

Main Applications in Mining & Earthmoving Projects

Processing Machinery

• Vibrating Screens: Prevents loosening caused by continuous high-frequency motion.
• Breakers: Secures critical fasteners under repeated shock loads.
• Conveyor Systems: Maintains integrity in high-load, high-speed operations.
• Grid Cars: Enhances safety in ore processing and transfer systems.

Heavy Machinery

• Off-Road Trucks: Ensures safe operation on uneven, high-impact terrain.
• Dozers: Withstands intense vibration during pushing and leveling tasks.
• Bucket Wheel Excavators: Secures large, rotating components in mining operations.

Freight Railway

• Wagons & Wagon Rotators: Prevents loosening during bulk material loading/unloading.
• Fishplates & Crossings: Maintains track alignment and safety in high-load environments.

HARDLOCK Nut solutions help mining and construction operations reduce downtime, extend equipment life, and improve workplace safety—even under the harshest working conditions.