Quarry products.pdf - Johnson Screens

JOHNSON SCREENS:
Delivering Innovation Quality and
Strength to the Quarry Industry

JOHNSON SCREENS®:
Introduces you to the world’s best
screening systems and the team that
will help you monitor them to ensure
peak performance.
ONLY JOHNSON SCREENS OFFERS THE
COMPLETE RANGE OF SCREENING MEDIA
As the premier manufacturer of stainless steel, polyurethane, rubber
and woven wire screening systems, Johnson Screens offers the most
comprehensive and innovative range of screen surface media in the
industry.
Vee-Wire ®
• Fully welded Centrifugal
Screen baskets
• Flat Panels
• Sieve Bends
• Custom Screen Panels
• Water Intake Screens
• Water Well Screens
Polyurethane
• Pipo Two ® modular screen system
• Pipo Three ® modular system
• Continuous Slot
• Tension mat
• Trommel Screen panels
• Custom designed panels
• Koko ® modular systems
Combination and
s p e c i a lt y p r o d u c ts
• Poly-Vibe ®
• TIRO ®
• Pipo ® Perf
• Pipo Vee-Wire
Woven Wire
• High Carbon
• Stainless Steel
• Exotic Materials
Rubber
• Punched rubber tension mats
• Moulded modular screening systems
Perforated plate
• Available in round, square, hexagon,
slotted slots and rectangular aperture.
• Plate thickness from: 1.2mm - 6.0mm
• Available in Pipo Two modular, Bolt-In
panels and tensionable screens forms.
2

THE JOHNSON SCREENS®
TEAM
JOHNSON SCREENS:
innovatiON, engineering,
manufacturE, QUALITY,
installation AND CHANGE OUT
SERVICE, CONDITION MONITORING
AND TECHNICAL ASSISTANCE
Johnson Screens mission is to provide
fast and effective response to all our
clients on our complete range of products,
where ever you may be, whatever you may
need.
HOW CAN JOHNSON SCREENS
HELP YOU
Johnson Screens will provide on-site
technical assistance during installation,
maintenance or repairs at your quarry.
Specialised services we provide include;
• Process optimization
• Specialty product development
• Audit of screening surfaces
• Installation of new screening
systems and components
• Identify abnormal wear patterns
• Recommend corrective action
• Analysis of product performance
• Technical assistance
• 24hr on call assistance
• Apertures list available
3

WOVEN WIRE
SCREEN CLOTHS
JOHNSON STOCKS A WIDE RANGE OF
WOVEN WIRE SCREEN CLOTHS SUITABLE FOR
THE QUARRY
A screen cloth is a generic term for the
most versatile and common of all
screening mediums, within the quarry
industry. Subject to individual
applications, woven wire screens are
supplied in standard aperture sizes from
0.063mm to 125mm with various wire
sizes and weaving patterns.
Typical aperture / weave combinations
include square, long slot, double chute
and triple chute, agavibe/ polyvibe and
piano wire screens.
Broken down into two distinct groups
largely due to the method of
manufacture.
1. FINE MESH SCREENS
Manufactured in 304ss or 316ss
2. WOVEN WIRE SCREENS
Manufactured in Hi-Tensile wire
‘AGATEX’, 304ss or 316ss
4

SPECIFICATIONS FOR ORDERING
WOVEN WIRE
Follow these easy steps below to
specify when ordering your woven
wire cloths:
1. QUANTITY
hook strip
hook strip
hook strip
hook strip
2. DIMENSIONS
‘A’ over hooks
‘B” overall length
‘C’ length of hooks (if overlap)
3. APERTURE
a. Whether Square or Rectangular
b. Indicate preference for particular
type of crimp
c. If rectangular aperture
i. Width
ii. Length
“B”
SLOTS “SP”
Slots parallel
to Hookstrip
SLOTS “RA”
Slots right angles
to Hookstrip
“C”
4. WIRE DIAMETER
5. METAL
e.g. Agatex or Stainless Steel
“A”
“A” = over hooks
“B” = overall length
“C” = length of hooks (if overlaps)
Important
Remember to tension your screen cloths to drum head tightness and keep
them at this degree of tightness for maximum performance
and long life.
5

FINE MESH
SPECIFICATIONS FOR ORDERING
FINE MESH
When selecting a mesh, the mesh count is
the most important thing to keep in mind.
The mesh count is the open area between
wires and can be expressed as a whole
number, a fraction or as two numbers. A
whole number and fraction indicate the
distance between the centers of both
horizontal and vertical parallel wires. Two
numbers such as 30 x 30 indicate the
actual number of openings per linear inch,
both vertically and horizontally.
25.4mm
To measure the size of the wire a
MICROMETER should be used; a slight
error in the diameter of wire would alter
the aperture considerably.
Key points to consider when
specifying wire mesh:
25.4mm
1. The number of apertures per
lineal 25.4mm.
2. The clear space between the wires
forming the mesh.
6

HARP SCREENS
JOHNSON SCREENS® OFFERS A
COMPREHENSIVE RANGE OF HARP SCREENS
TO SUIT ALL TYPES OF MACHINES
Screens can be supplied from eight
various wire diameters;
• Wire – High Tensile or
Stainless Steel
• Spacers – Metal or Plastic
• Hooks – Galvanized or
Stainless Steel
Harp Screen Type Chart
Aperture Light Duty
Size (mm) Wire Dia (mm)
1.00
1.25
1.50
1.75
2.00
2.50
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
11.00
12.00
14.00
16.00
0.70
0.80
1.00
1.00
1.25
1.25
1.40
1.40
1.60
1.60
1.80
1.80
Standard Duty
Wire Dia (mm)
0.70
0.70
0.70
0.80
1.00
1.25
1.25
1.40
1.40
1.60
1.60
1.80
1.80
2.00
2.00
Heavy Duty
Wire Dia (mm)
0.70
0.70
0.70
0.80
0.80
0.80
1.00
1.25
1.40
1.40
1.60
1.60
1.80
1.80
2.00
2.00
Extra Heavy Duty
Wire Dia (mm)
0.80
0.80
0.80
1.00
1.00
1.00
1.25
1.40
1.60
1.60
1.80
1.80
2.00
2.00
7

WOVEN WIRE AGAVIBE
Second Generation,
Non Blinding Screens ®
Agavibe screens are the ‘traditional’ wire vibe
screens, highly effective with a proven
performance history:
• Staple product for the quarrying
industry.
• Excellent open area.
• Apertures from 2.5 to 32 mm
available, in varying wire gauges.
Agavibe screens can be manufactured
using either round or shaped wires; these
wires are woven forming a wave pattern.
Transverse wire clusters hold the wires
together.
Agavibe
Aperture
Size (mm)
2.5
3
4
4.5
5
6
7
8
10
11
12
14
16
18
20
25
30
32
32
Wire
Diameter (mm)
1.25
1.6
1.6
1.6
2
2
2
2.5
2.5
2.5
3.15
3.15
3.15
3.15
4
4
5
5
6.3
Open Area
(%)
44.0
43.3
45.1
48.5
44.6
47.2
50.1
50.5
54.2
59.6
53.2
57.1
61.2
64.9
54.9
58.1
63.3
75.0
70.0
8

TIRO ® AND
POLY-VIBE ®
TIRO VIBE ‘Tap In Rip Out’
Vibe Screens
TIRO vibe screens are an extension of
the Poly-Vibe, in which smaller panels
are simply snapped on to the support
frame of the screen.
TIRO is a safe, highly efficient,
non-pegging and non-blinding modular
wire screening system
The advantages of such a screen are
obvious: only worn panels need be
replaced; screen panels are much smaller
than fully-hooked screen panels and are
therefore lighter and safer for the
maintenance teams; replacement is
carried out with a leaver and a mallet;
wires are rectangular rather than round
and therefore have improved wear
results and higher open area.
POLY-VIBE: REDUCES BLINDING AND
PLUGGING OF THE SCREEN SURFACE
The most persistent problem in vibratory
screening has been blinding and
plugging of the screen surfaces. To
reduce or eliminate this, Johnson
Screens® has developed screen panels
using non-woven wires bound together
by polyurethane strips.
These strips are located above the bucker
bars, creating a flat surface in which the
wires can move independently.
The flat, more active screen surface,
reduces buildup and increases
throughput, virtually eliminating the
need to shut down for screen cleaning.
The lighter weight screens with
polyurethane edge strips and no sharp
edges are also easier and safer to handle
and faster to install.
Actual field performance comparisons
show that Poly-Vibe screens, on a wet
day, nearly equal dry day production of
conventional woven wire screens.
Poly-Vibe screens are manufactured
with tension hooks and are
extensively used in the sand and gravel
industry.
9

Rubber screening
systems
Rubber Tension Mat, Fully Modular Pipo Two
& Special Heavy Duty steel backed
screen panels
Johnson’s Rubber Screening Systems
compliments woven wire and
polyurethane screens and can be used in
tension mat, modular or special heavyduty
steel backed formats. The fully
moulded modular panels are available
with the Johnson Screens ® patented Pipo
Two ® system and one-foot square
modules.
Benefits of
rubber mats:
• Tough
• Resistance to cutting and gouging
• Ability to perform in extreme hot
and cold conditions
• Resistance to impact
• Resistance to abrasion
• Low noise factor
10

polyurethane
Tension MatS
Polyurethane is recognised as
one of the best AND MOST VERSTILE
MATERIALS FOR SCREENING SURFACES
The use of polyurethane tensionable
mats as a screening surface has
significant advantages provided the
application is appraised correctly:
• Johnson Screens’ advanced design
through sustained research,
development and quality of
manufacture has allowed for the
correct relief angle to be designed
into each application, ensuring
optimum performance.
• As a result ‘pegging’ and ‘binding’ is
minimised, reducing the frequency of
scheduled stoppages
caused by screening surface failure.
• Polyurethane tension mats have a
long life when screening materials
such as quartz; silicon sand,
gravel etc.
• Polyurethane exhibits the
characteristic elasticity of rubber .
• The distinct advantage polyurethane
mats have over rubber is the accuracy
of the cast apertures.
• Polyurethane tension mats, allow for
more precise screening compared to
the punched apertures in rubber.
11

PIPO TWO ® :
The first 2’ x 1’
patented modular
screening system
THE PIPO (PUSH IN, PULL OUT)
MODULAR SCREENING SYSTEM IS
SIMPLE, TOUGH AND EFFECTIVE
• First designed by Johnson engineers
in the late eighties, Pipo is now the
standard format throughout the
world
The ability to combine differing materials
and modules allows the plant manager to
manage the screen as desired. This
“configured deck” concept is another way
that Johnson Screens® can help you to get
the most out of your operation.
The intermediate rail currently used in our
Pipo Two System now incorporates a
deflecting polyurethane skirt eliminating
wear on the support frame rails from the
module and the material being screened.
• Features ease of installation and
shortened maintenance change out.
• Modules are available with varied
configurations including flat, ramp,
cross dam and deflectors
• Apertures are available in square,
slotted, teardrop, hexagonal and splits
• Apertures list available
Pipo Two has the ability to incorporate
other surface media with the lateral
engaging clip design. For example: Pipo
Two Wedge Wire (Stainless Steel Vee
Wire®), Pipo Two Perforated Plate, rubber
panels or high impact panels
incorporating ceramic tiles.
Pipo’s Continuous Slot polyurethane
screen panels offer the highest open area
available in the heavy to medium duty
market.
12

PIPO THREE ®
The next generation
in screening systems
Pipo three Is the MOST
ECONOMICAL CONSUMABLE
IN TODAYS MARKET
Building upon the many proven
advantages of the Pipo systems, the
engineering team at Johnson Screens®
have created Pipo Three, the most
innovative screening system of all
time.
It has been especially designed to
address your business needs and to
further improve:
• Operating costs
• Screen utilization
• Plant Availability
• Ease of maintenance
Pipo Three is unlike any other
modular polyurethane panel. Using a
support structure that clips into Pipo
Two intermediate rails, Pipo Three is a
removable working screening surface.
By separating the internal
reinforcement and the screening
surface, only the top section is
replaced while the structural support
remains in the machine to be used
again, reducing the cost of screen
maintenance.
Pipo Three features separated
reinforcement and skin that give the
mat a ‘live’ surface, reducing or
eliminating blinding entirely. This
means the open area is maximised for
the life of the deck without any costly
and time consuming wash downs.
The Pipo Three two-part modular system
and long life flexible screening panel
provide:
• The lightest replacement screen
element in the industry
• Maximised open area
• The simplest, safest and most cost
effective change-over replacement
process
• Easy interchange with existing
Pipo Two system
• Efficient, accurate screening
from 0.25-25mm
• Low ongoing unit cost
• Screen dimensions can be custom
designed
• Apertures list available
Sticky, moist feeds with high clay can
still be screened. This increases screen
utilisation, thereby maximising
throughput and profitability.
EASY INSTALLATION AND REMOVAL PROCESS
1 2
Screwdriver assists in easy
removal
Flexible design enables the skin
to easily peel out
3 4
Frame slots into position
Skin locks into place
13

Trommel ScreenS
JOHNSON SCREENS® SPECIALISES
IN THE CONSTRUCTION OF
CUSTOM DESIGNED CYLINDRICAL
TROMMEL SCREEN SYSTEMS.
Plant managers should investigate the
advantages of using the Johnson
Screens Pipo Two ® modular screening
system for their Trommel screens:
• Custom designed for individual
applications.
• Johnson Screens engineers will
assist in determining the appropriate
screening media; polyurethane,
rubber, woven wire or Vee-Wire ® .
• Suits wet or dry applications.
• Successfully screens Mineral Sands,
Sands, Coal, Phosphate and Gravel.
• Aperture opening sizes and designs
can be varied depending upon the
application.
• Panels can be custom designed
and sized as required.
• Polyurethane portholes protect the
trommel frame.
• Vee-Wire Trommels and Cylinder
screens feature high open area
and accurate classification.
• Johnson’s full ranges of Vee-Wire
shapes are available for most
designs.
• All of the virtues of our other
polyurethane screening systems are
incorporated in our special trommel
screen mats and modules.
• Panels are steel reinforced as
required.
• Lightweight screen modules are
manufactured with innovative fixing
mounts that protect the trommel
and facilitate quick installation.
14

PLASMA CUT METALS
AND PERFORATED PLATE
Whenever profile holes are
needed, we can put them where
you want them in a wide choice of
material specifications and finish
With our availability of plasma cut metals
and perforated plates there are almost no
limitations to the design, shape and
material type that can be provided.
PERFORATED METALS INCLUDE:
• Mild Steel
• Stainless Steel
• Aluminium
PLASMA CUT METALS INCLUDE:
• Mild Steel
• Stainless Steel
• Wear Plates
PROFILE SHAPES INCLUDE
• Round
• Square
• Rectangular slots
• Obround slots
• Hexagon and diamond apertures
15

Providing over 100 years of experience,
innovation and customer satisfaction.
Contact us today.
OUR WIDE RANGE OF PRECISION
ENGINEERED EQUIPMENT IS
SUITABLE FOR MORE
APPLICATIONS THAN EVER.
Turn to Johnson Screens® to help
maximise your operational efficiency
and find long-term, trouble-free
solutions. Discover our ever expanding
range of products, designed with your
needs in mind:
MINERAL AND AGGREGATE
PROCESSING
Vee Wire ® centrifuge baskets
Sieve bends, flat panels
P/U modular screening systems
P/U and Wire combination screens
Rubber Screening systems
HDPE pipe, P/U lined pipe
SAG and Ball Mill liners
Rubber Ceramic Wear Liners
Woven Wire and perforated plate
Screens
ARCHITECTURE &
CONSTRUCTION
Column covers
Urban furniture
Frontages
Floor grating
Ventilation grids
Sun-control screens
Custom lighting
Furniture
Wall partitions
GENERAL INDUSTRIAL
Flat panels
Sieve bends
Cylindrical screens
Centrifugal baskets
DSM screens
Trommels
Vibrator screens
Diffuser screens
Pressure screens
PETROCHEMICAL AND REFINING
Centerpipes
Outer baskets
Scallops
Support grids & beams
Outlet collectors
Laterals
Distributor trays
Nozzle systems
Scale traps
PULP AND PAPER
Screen baskets
Extraction plates
Rotors
Filtrate cleaning
Fiber recovery
Refurbishing services
WATER PROCESS
HeadWorks
Dissolved Air Flotation (DAF)
Belt Presses
Progressing Cavity Pumps
Triton Underdrains
Intake Screens
Ultra-Filtration
CoMag ®
WATER WELL
Wellscreens (Stainless steel & PVC)
Riser pipes
Sand spears
Environmental monitoring screens
Drilling fluid
Nu-Well ® rehabilitation chemicals
ON-SITE SERVICES
Installation
Inspection
Repair
Assistance
Supervision
A Weatherford Company
Johnson Screens
TEL.: +27 11 864 2773
FAX: +27 11 864 6069
EMAIL: salesasiapacific@johnsonscreens.com
4 Chris Street, Alrode, Alberton, South Africa
PO Box 123771, Alrode 1451
www.johnsonscreens.com
Copyright ©2009 All rights reserved to Johnson Screens (Australia) Pty Ltd