Wear Tracking

Wear Tracking Services

Rayner Engineering provides specialised wear tracking, wear analysis, condition monitoring, and remaining life assessment services for mining & civil equipment, refineries, smelters, bulk materials handling systems, and industrial plants. We help clients understand how fast components are wearing, when they are likely to require replacement, and how to reduce unplanned downtime.

Our wear tracking services use practical inspection methods such as 3D scanning & ultrasonic thickness testing, supported by statistical wear-life mathematical modelling to ensure safer maintenance planning, improved OEE, and better asset reliability.

Wear Tracking & Condition Monitoring

  • Working with clients condition monitoring teams to gain pinpointed data analytics

  • 3D scanning to track wear, material loss, dimensional change, and component deformation

  • Ultrasonic thickness testing for wear monitoring of liners, chutes, pipework, and high-wear components

  • Statistical modeling to determine remaining wear-life with a defined confidence level

  • Conveyor belt, conveyor pulley, chute, liner, and material handling component wear tracking

  • Crusher liner, screen component, transfer chute, and process plant wear analysis

  • Ground engaging tool (GET) wear tracking for mining and civil equipment

  • Dense phase pneumatic conveying system wear monitoring and erosion analysis

  • Wear tracking for high-use/contact industrial and commercial equipment, such as hotel garbage chutes

  • Wear reporting to support shutdown planning, maintenance scheduling, and replacement forecasting

Wear-Life Improvement & Upgrade Design

  • Design of wear-resistant upgrades using harder-wearing materials such as BISALLOY and other abrasion-resistant steels

  • Replaceable liner design for feeders, screens, chutes, bins, hoppers, transfer points, and other material handling equipment

  • Design optimisation based on wear analysis to simplify maintenance, reduce manufacturing costs, and extend component replacement times

  • Engineering support for safer access, maintainability, and compliance with relevant Australian Standards

  • Practical recommendations to reduce downtime, improve reliability, and extend component service life

Rayner Engineering helps mining, civil, refinery, smelter, and industrial clients make better maintenance decisions by turning wear data into practical engineering outcomes. Our wear tracking and upgrade design services help improve safety, reduce downtime, increase OEE, and save clients time and money across critical plant and equipment.