®

Extreme protection for extreme applications

 ® SUPER-BLOCK
Wearalloy Super-Block is designed to protect your equipment from impact and high abrasion
damage and to cut equipment downtime by quickly replacing worn and shattered parts.
Wearalloy Super-Block is a combination of high chromium white iron metallurgically bonded
into a mild steel backing plate. The white iron has a hardness of at least 700 Brinell giving incredible
abrasion resistance to your equipment. The mild steel is weldable with a minimum of preparation or
can be machined or studded. The mild steel also cushions the white iron enabling it to handle impact
and abrasion from even extreme applications.
Wearalloy Super-Block is available in standard sizes and styles (subject to stock and availability)
and can be used in combinations to protect most impact and high abrasion areas. Also, certain
Wearalloy Super-Block products can be cut or bent, prior to welding, to help customize the
protection on the machine.
Long-life Wearalloy Super-Block gives you extreme protection for extreme applications and lets
you work harder longer.

Applications TECHNICAL SPECIFICATIONS

Dragline Bucket Protection Lamination of chrome moly white iron met-
Shovel Bucket Protection allurgically bonded to a mild steel backing
Loader Bucket Protection plate achieving a high strength joint.
Excavator Protection White iron: modified As2027 15/3 Cr Mo
Conveyor Chute Liners with finished minimum hardness of 700 BHN
Feeder Deck Plates (63 Rc) and containing primary carbides up
Quarry and Mining Grizzly Screens to 1500 HV.
Gyratory and Jaw Crusher Liners
Tub Liners

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 FABRICATION AND WELDING PROCEDURES

WEARALLOY SUPER-BLOCK® RECOMMENDED WELDING PROCEDURES

STUD-BOLTING FEATURE READ ALL PROCEDURES COMPLETELY!
 nsure that the surface to which Wearalloy Super-Block will be attached is as
1. E
Stud-bolting is a common practice for creating a continuous wear assembly
flat as possible and the area to be welded is clean.
surface, without exposing a nut or bolt to the wear activity.
 lamp and tack weld Wearalloy Super-Block
2. C (Fig. 1)
into position.
WHIT
IRON E
3. S
 titch weld, laying 2” (51mm) max length on each MILD
STEEL
run, alternating ends or similar to minimize heat input.
Do not deposit weld within 2mm from the joint line
between white iron steel backing plate (Fig. 1).
4. If a complete peripheral weld is required, use stitch
weld method as per step 3.
 ELDING RODS – W
5. W  E RECOMMEND LOW HYDROGEN WELD RODS OR
GAS COVERED CORED WIRE.
Gas shielded solid MIG wire -3/64” (1.2mm) dia. max.
Flux cored wire -1/16” (1.6mm) dia. max.
Low hydrogen electrode -1/8” (3.25) dia. max.

WELDING PROCEDURE OVERVIEW

1. READ PROCEDURES COMPLETELY
2. TACK AND WELD INTO POSITION
3. STITCH WELD WITH 2” (51MM) MAX. LENGTH ON EACH RUN
4. MAINTAIN 2MM GAP BETWEEN WELD AND JOINT LINE
5. COMPLETE PERIPHERAL WELD IF REQUIRED
CAUTION! TOO MUCH HEAT INPUT MAY CAUSE CRACKING AND SEPARATION

RECOMMENDED CUTTING PROCEDURES FOR RECOMMENDED BENDING PROCEDURES FOR

WEAR BARS and “CHOCKY” BARS ONLY “CHOCKY” BARS ONLY
High pressure abrasive water cutting is preferred cutting method when available. READ ALL BENDING INTRUCTIONS COMPLETELY!
If not available, cutting by abrasive disc is recommended. NOTE: for extreme curves (radii less than
READ ALL cutting PROCEDURES 12”[35mm]). or inside curves, it is advisable to
COMPLETELY! notch the mild steel backing plate opposite the
“v” to assist bending (fig A) (Fig. A)
Cutting “chocky” bars
1. C lean the surface to which “chocky” bar will be
1. Place “chocky” bar in vise/clamp.
welded. (Fig. 1)
2. Cut through to white iron bond area (Fig. 1). (Fig. 1) 2a. F
 or outside curves: Tack weld one end of “chocky
3. Wrap “chocky” bar with a rag and
bar (per welding procedures) in at least 3 places
carefully hit it with a hammer. The
using at least 15mm of weld in each deposit (Fig.
piece should break cleanly at the
1). Hammer down unwelded end of bar so that the
notch.
bar bends and follows the curve (Fig. 2).
Cutting WEAR bars Make notch parallel
to cut in mild steel 2b. F
 or inside curves: Tack weld one end of “chocky bar
1. Place wear bar in vise/clamp.
backing. Cut notch a
minimum of 1/8” deep. (per welding procedures) in at least 3 places using at least
2. Cut through to white iron bond area 15mm of weld in each deposit (Fig. 3a). Starting in
(ref. Fig. 1). the center strike bar so that the bar bends and follows the
3. Cut a notch in the white iron a min. (Fig. 2) curve (Fig. 3b). (Fig. 2)
of 1/8” deep and parallel to the cut 3. S titch weld (per welding procedures)
in the mild steel backing (Fig. 2). until bar is firmly in place.
4. Wrap wear bar with a rag and carefully hit it with a hammer. The piece should (Fig. 3a)
NOTE: White iron may
break cleanly at the notch. NOTE: The deeper the notch in the white iron the
crack during bending.
cleaner the break. (Fig. 3b)
This is normal.
Ford Steel recommends you always use a soft-face hammer and
ANSO-approved (Z87.1) eye protection during cutting and bending
procedures.
3
 CHOCKY BARS
• With notched backing, easy to cut and conform to
different specifications
• Bending ability to offer protection on
a contoured surface
• Variability in size
See page 3 for instructions on bending and cutting

A B C D E WEIGHT
PART NO.
IN MM IN MM IN MM IN MM IN MM LBS KG
FSCB 25 • 9-7/16” 240 1” 25 19/32” 15 5/16” 8 1-9/16” 40 1.96 .88
FSCB 40 • 9-7/16” 240 1-9/16” 40 19/32” 15 5/16” 8 1-9/16” 40 3.20 1.5
FSCB 50 • 9-7/16” 240 1-31/32” 50 19/32” 15 5/16” 8 1-9/16” 40 4.00 1.9
FSCB 65 • 9-7/16” 240 2-9/16” 65 19/32” 15 5/16” 8 1-9/16” 40 5.40 2.4
FSCB100 • 9-7/16” 240 3-15/16” 100 19/32” 15 5/16” 8 1-9/16” 40 8.20 3.7
FSCB130 • 9-7/16” 240 5-1/8” 130 19/32” 15 5/16” 8 1-9/16” 40 11.0 5.0
• Available with notched backing plate

SKID BARS
• Low center of gravity ideal for bucket
bottom protection
• Variability in size
• Grooves allow for “dead-bedding”

A B C D WEIGHT
PART NO.
IN MM IN MM IN MM IN MM LBS KG
FSDLP 205 11” 279 3” 76 7/8” 25 3/8” 10 10.8 5.0
FSSB 403 8-3/8” 214 4” 101 13/16” 22 7/16” 10 9.8 4.5
FSSB 406 12” 302 4” 101 13/16” 22 7/16” 10 13.8 6.2
FSSB 409 6” 154 4” 101 13/16” 22 7/16” 10 7.2 3.3

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 WEAR BARS
• Strategic placement of wear bars causes “rock box” White Iron
Mild Steel
protection or “dirt on dirt” protection
• Individual components
can be back-welded to
form one continuous A B C D WEIGHT
PART NO.
PART NO. IN MM IN MM IN MM IN MM LBS KG
wear surface
FSDLP 184 5-7/8” 150 3” 76 1-1/8” 29 3/8” 10 7.0 3.2
• Variability in shapes FSDLP 352 8” 206 8” 203 1-3/8” 38 3/4” 30 39 17.1
and sizes FSDLP 619 6” 150 3” 76 1-13/16” 50 3/8” 10 10.8 5.0
FSDLP 995 12” 305 5-7/8” 150 11/16” 18 5/16” 6 19.8 9.0
FSDLP 125 9” 230 2” 50 1-1/2” 38 15/32” 12 9.6 4.3
FSDLP 201A 17” 432 2” 50 1-1/2” 38 15/32” 12 17.8 8.1
FSDLP 753 9-5/8” 274 1” 25 1” 25 3/8” 10 3.0 1.4
FSDLP 270 10” 254 2” 50 3/8” 12 5/16” 8 4.0 1.8
FSDLP 295 6” 152 1-1/2” 38 1” 25 5/16” 8 3.2 1.5
FSDLP 4 12-5/16” 300 1-1/2” 38 1” 25 5/16” 8 6 2.7
FSDLP 453 11-13/16” 300 2” 50 1-1/2” 40 3/8” 10 12 5.5
FSDLP 1191 11-13/16” 300 1” 25 5/8” 15 5/16” 10 3.4 1.5
FSDLP 727 11-1/2” 294 11-1/2” 294 3/4” 20 3/8” 8 40.6 18.4

Thicknesses: 1/4”, 3/8”, 1/2”, 5/8”, 1”, 1-1/2”, 2”

Widths: 48”, 96” Lengths: 120”, 240”, 288”

DONUT & WEAR BUTTONS

• Donut hole al-
lows for “Dead-
Bedding”
• Notching for • Ideal for smaller areas requiring wear resistant
easy cutting and material
versatility • Requires less welding time and material
• “Economical” • Variability in size
wear button
• Variability in size A B C WEIGHT
PART NO.
IN MM IN MM IN MM LBS KG
FSWB 60 2-3/8” 60 3/8” 20 3/8” 10 .9 .4
FSWB 75 2-3/4” 75 5/8” 20 3/8” 10 2 .9
FSWB 90 3-1/2” 90 13/16” 20 3/8” 10 2.4 1.1
FSWB 115 4-1/2” 115 3/4” 20 1/2” 12 5.7 2.6
(Dotted line indicates inside of donut) Diameter in inches
FSWB 150 5-7/8” 150 15/16” 25 5/8” 16 12.3 5.6
DLP 1920 = 3” • DLP 1921 = 4” • DLP 1994 = 4”

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 STANDARD GRIZZLY CAPS
50mm
[2”]

DLP 2067 DLP 2068 DLP 2069 DLP 2070 DLP 2071 DLP 2072 DLP 2073 DLP 2074

150mm 2440mm
[6”] [96”]
50mm
305mm [2”]
[12”] 12mm
[0.5”]

A B

20mm
38mm [0.8”]
[1-1/2”]

A B WEIGHT
PART NO.
IN MM IN MM LBS. KG
DLP 2067 6” 150 5.4” 137.5 30.0 13.6
DLP 2068 5.4” 137.5 4.9” 125 27.5 12.5
DLP 2069 4.9” 125 4.4” 112.5 24.7 11.2
DLP 2070 4.4” 112.5 3.93” 100 22.05 10.0
DLP 2071 3.93” 100 3.45” 87.5 19.4 8.8
DLP 2072 3.45” 87.5 2.95 75 16.5 7.5
DLP 2073 2.95” 75 2.46” 62.5 13.9 6.3
DLP 2074 2.46” 62.5 2” 50 11.2 5.1

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 75mm
[3”]

DLP 2075 DLP 2076 DLP 2077 DLP 2078 DLP 2079 DLP 2080 DLP 2081 DLP 2082

150mm 2440mm
[6”] [96”] 50mm
305mm [2”]
[12”] 12mm
[0.5”]

A B

20mm
[0.8”]
38mm
[1-1/2”]

A B WEIGHT
PART NO.
IN MM IN MM LBS. KG
DLP 2075 6” 150 5.5” 141 30.4 13.8
DLP 2076 5.5” 141 5.2” 131 28.4 12.9
DLP 2077 5.2” 131 4.8” 122 26.2 11.9
DLP 2078 4.8” 122 4.5” 113 24.5 11.1
DLP 2079 4.5” 113 4” 103 22.3 10.1
DLP 2080 4” 103 3.7” 94 20.3 9.2
DLP 2081 3.7” 94 3.3” 84 13.3 8.3
DLP 2082 3.3” 84 3” 75 16.3 7.4

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 We Are Ford Steel
LEADERS . . . When we were founded in 1945, we worked with construction and mining companies to
combat wear problems with their equipment. Now, we are a global leader, carrying thousands of tons of
Wearalloy and Mangalloy steel used in a wide variety of applications. We are committed to being the best in
our industry, and you will find we have a wealth of expertise and physical resources.

PARTNERS . . . We work with you to improve your business by providing high quality wear-resistant
products, excellent service, competitive pricing, and prompt delivery. Our highly trained sales representatives
are available to provide a proven solution to your specific wear problems. With our warehouses and
distribution centers stocked and managed throughout the world, our skilled and experienced professionals
can help you avoid unnecessary downtime.

EXPERTS . . . We are experts in solving the challenges associated with heavy equipment and plant
maintenance. With extensive drawings on file, and AutoCAD® capability, we will help you find the solution
you need on everything from crusher to truck bed liners, and more. We are proud of our achievements, and
would like to work with you to solve your abrasion and wear problems. Please contact us today.

“We Measure Up”

Ford Steel Products & Services

• Wearalloy 400, 450, 500 Plate WARRANTY
• Wearalloy 400 Bars
• Wearalloy Nickel Chrome Plate Ford Steel Company warrants its products
• Wearalloy Super-Clad Overlay Plate against defective material, which will either be
• Wearalloy Tungsten-Clad replaced or credited to the customer’s account
• Wearalloy Super-Block after an investigation by the St. Louis office.
• Wearalloy Super-Hard Chrome
• Mangalloy Plates and Bars We are not responsible for incidental or
• Wearalloy Slip -On and Custom Made Cutting Edges consequential damages.
• Sure Grip Grouser Bar
• Fabrications

P.O. Box 54, 2475 Rock Island Blvd. • St. Louis, Missouri 63043 USA
(314) 567-4680 • Toll-Free (800) 325-4012 • Fax (314) 567-5762
E-mail: sales@fordsteel.com
Branch Office and Warehouse:
Elko, Nevada • (775) 738-8883 • Toll-Free (800) 939-3673 •Fax (775) 738-0155

www.fordsteel.com
Printed in U.S.A. 10/10