In underground mining, every minute of production counts. Load–Haul–Dump (LHD) loaders, the workhorses of the stope, face some of the harshest operating conditions in the industry. Constant abrasion, impact, and high mechanical stress wear down the bucket’s lip and edges, forcing operators to schedule frequent maintenance interventions. Traditionally, these repairs have relied on welded Ground Engaging Tools (GET) — a method that, while effective in its time, now faces significant limitations in terms of safety, downtime, and cost.

Over the last decade, a new generation of bolt-on GET systems has emerged, redefining how maintenance is performed underground. Among these, Curakit™, designed and manufactured with Hardox® wear steel, has set a new standard for durability and practicality.
 

The limits of traditional welded systems

In a typical underground maintenance routine, replacing worn GET components involves several complex steps.
The process begins by bringing the LHD to surface or to a maintenance bay equipped for welding. The old wear elements must be cut or gouged off, which exposes the bucket lip to heat distortion. New wear parts are then aligned and welded in place — a process that can take hours, requires qualified welders, and introduces the risk of structural weakening due to repeated thermal cycles.

Each intervention results in:

• Extended downtime for critical production equipment.
• Increased safety risks for maintenance crews.
• Additional costs for consumables, gas, filler materials and labor hours.
• Reduced fatigue life of the bucket structure due to heat-affected zones.

For underground mines operating 24/7, even a few extra hours of downtime can translate into thousands of tonnes of missed production and significant financial impact.

The bolt-on revolution

The bolt-on GET concept eliminates welding altogether. Instead, wear components such as shrouds, teeth, and lip protectors are mechanically fastened using high-strength bolts and precision-machined interfaces. This innovation brings multiple advantages that directly affect both performance and cost efficiency.

1. Faster, safer maintenance

Technicians can replace worn parts directly underground, without removing the bucket or transporting the loader to surface.
No welding, grinding, or cutting is required — reducing safety risks related to sparks, fumes, and confined-space hot work. A full Curakit™ replacement can be completed in a fraction of the time compared to welded systems.

2. Consistent geometry and fit

Bolt-on systems maintain the exact original geometry of the bucket lip through every replacement cycle.
Because the contact surfaces are machined and bolted, alignment is repeatable, ensuring optimal bucket penetration and reduced rolling resistance — which directly improves productivity and fuel efficiency.

3. Extended wear life

Curakit™ components are made of Hardox® 550 or 500 TUF, steels renowned for their exceptional combination of hardness, toughness and structural integrity. Field data from copper and zinc operations show up to 70% longer service life compared to conventional welded GETs, thanks to the uniform wear pattern and self-sharpening profile.

4. Reduced operational cost

Shorter maintenance times mean less downtime and higher availability. In addition, operators save on welding consumables, labor, and transport logistics. Over time, these savings compound, delivering a rapid return on investment (Fast ROI) for mining operators.

Engineering excellence behind the design

The performance of a bolt-on system depends on engineering precision. Curakit™ integrates:

• Finite Element Analysis (FEA) to model stress distribution across the lip.
• High-tensile bolts (12.9 grade) with anti-rotation locking to prevent loosening under vibration.
• Optimized wear profiles that maintain a sharp edge through the entire wear cycle.
• Hardox® base plates and Duroxite® overlays for extreme abrasion zones.

This design synergy results in a modular, reliable protection system that performs consistently in the most demanding conditions — from Iberian pyrite belt copper mines to Australian nickel operations.

A new standard for underground maintenance

The mining industry is moving toward safer, more sustainable, and cost-efficient maintenance practices. Bolt-on GET systems like Curakit™ align perfectly with these goals by minimizing energy consumption, reducing steel waste, and extending component life cycles.
By adopting mechanical fastening over welding, operators not only improve productivity but also enhance worker safety and environmental performance.

In the end, the question is no longer whether bolt-on systems work better — it’s how soon your mine can adopt them.

Key takeaway:

Curakit™ represents the evolution of wear protection — faster, safer, and smarter mining maintenance.