Polydeck Screen Media and Screening Solutions
Improve screening efficiency, wear life and maintainability with Polydeck modular screen media, PIPETOP support systems and engineered deck solutions.
Carmaky supports mining and mineral processing operations with application-led product selection, screen media supply and system upgrade opportunities.
Screening Performance Starts with the Right System
Screening performance is influenced by more than the panel material alone. Aperture selection, available open area, wear characteristics, fastening, support structure and operating conditions all affect how effectively a deck performs.
Carmaky works with clients to understand the existing screen, media arrangement and operating objective before recommending a Polydeck solution.
Common issues we can review
- Limited throughput or poor screening efficiency
- Excessive panel wear
- Blinding and pegging
- Restricted effective open area
- Frequent panel or fastening maintenance
- Worn stringers and fastening points
- Need to convert an existing deck to a modular system
Core Polydeck Screen Media
POLYDEX® Polyurethane Screen Media
POLYDEX is Polydeck’s injection-moulded modular polyurethane screen media range. It offers a broad selection of aperture sizes, shapes and configurations for application-specific screening requirements.
Use POLYDEX where the application calls for polyurethane media selected around the required cut, open area, wear conditions and operating duty.
RUBBERDEX® Rubber Screen Media
RUBBERDEX is Polydeck’s injection-moulded modular rubber screen media range. Multiple product configurations support applications where abrasion, gouging, impact, noise or high-throughput separation must be considered.
The correct panel model and rubber formulation should be selected against the actual duty rather than treated as a standard replacement item.
Selection note
The choice between polyurethane and rubber media is application dependent. Carmaky will review the existing media, aperture, feed, product requirement, wear life and operating concerns before recommending a solution.
PIPETOP® Stringers and Screen Support Systems
PIPETOP is an important part of the complete Polydeck screening system. Its narrow stringer arrangement is designed to maximise the available screening area while supporting modular media and replaceable wear components.
More usable open area
A narrower stringer occupies less deck area. This allows the panel layout to make better use of the available screening surface and can support panel designs with greater effective open area.
Protected stringers
Replaceable protection covers the stringers and can be changed when the panels are replaced. Wear is managed through replaceable components rather than being allowed to damage the underlying support structure.
Replaceable fastening inserts
Conventional stringers can require welding, rebuilding or replacement when fastening holes wear or become oval. PIPETOP uses individually replaceable threaded ferrule inserts, allowing the worn insert to be replaced instead of repairing or replacing the stringer.
Practical benefits
Application-dependent design and maintenance benefits.
- Better use of the available deck area
- Replaceable protection over the stringer
- Simpler replacement of worn fastening points
- Reduced need for stringer welding and rebuilding
- Longer useful life of the supporting structure
- A maintainable platform for Polydeck modular panels
Standard Frames, XD Frames and Conversions
Polydeck frames and conversion systems allow the screen media, fastening arrangement, protective components and support structure to be considered as one system.
Standard and XD frame options can be considered for new arrangements or screen upgrade requirements. PIPETOP conversion opportunities can also be assessed where an existing deck is being upgraded from another media or support arrangement.
Standard Frame
XD Frame
The appropriate solution depends on the screen geometry, cross members, available clearances, existing hole patterns and the intended panel layout. Detailed measurements and application information may be required before a conversion can be confirmed.
PROTEX® Protection for PIPETOP Systems
PROTEX protective components help shield stringers and other wear-prone areas within the screen deck. Within a PIPETOP arrangement, replaceable protection helps preserve the supporting structure and simplifies maintenance when worn components need attention.
Replace the wear component, not the supporting structure.
Proven Polydeck Results
Results reported by Polydeck for the named applications; not Carmaky project results or guarantees of performance for another operation.
Bell Creek Gold Mine
Polydeck reports POLYDEX slotted/VR trash-screen panels reduced fibrous-material blinding: 32% higher throughput, over 2.5× drain-rate improvement, enabling secondary-trash-screen bypass.
Pinto Valley Mine
Polydeck reports RUBBERDEX panel selection/deck zoning addressed blinding and bottlenecks: 48,000 to 60,000 tons/day, reduced recirculating loads and improved wear management.
Toquepala Mine
Polydeck reports a media-only retrofit using POLYDEX MAXI top deck and RUBBERDEX bottom deck: plugging fell from 24% to 6.4%, with 3% higher undersize throughput.
Additional Polydeck Solutions
ARMADEX®
Heavy impact, bolt-down panels and protective products are available for demanding applications where additional impact and wear protection is required.
METALDEX®
Modular wire products are available for specialised applications, including duties where plugging, blinding or drainage requirements favour a wire media solution.
Trommels and conversions
Polydeck trommel and conversion requirements can be discussed where they suit the application. These are available on enquiry.
Pins, inserts and accessories
Pins, inserts and associated accessories can be supplied as part of the selected panel or system arrangement.
Improve Your Screening Performance
Speak to Carmaky about your current screen media, wear life, open area, maintenance concerns or deck conversion requirements.
We can help review the application and identify the Polydeck media, support system and associated components best suited to the operating requirement.