Mining Equipment Precision Forging — Haul Truck, SAG Mill, Shovel, Slurry Pump
Shivam Forge manufactures precision hot forgings for the global mining equipment industry — haul truck spindle and kingpin forgings for Caterpillar 797F (400-tonne), Komatsu 930E-5, and Liebherr T 284, SAG/ball mill trunnion ring forgings in 4140 Q+T (up to 5m diameter), cone crusher main shaft forgings in 4340 Q+T (induction hardened), jaw crusher eccentric shaft forgings, Weir WARMAN slurry pump casing forgings in Duplex 2205, and drill rod adapter forgings in 4145H. Supply to Caterpillar, Komatsu, Epiroc, Sandvik, FLSmidth, Metso Outotec, and Weir Group. ASTM A668, SAE AMS 6415, ISO 9001:2015 certified. Rajkot, Gujarat, India. Call +91-9265772827.
The global mining industry produces the raw materials for modern civilisation — copper for electrical wiring, lithium for batteries, iron ore for steel, coal for power generation, gold for electronics, and nickel for stainless steel. The equipment maintaining this production — from 400-tonne haul trucks operating in the Atacama Desert to 150-tonne SAG mills grinding Pilbara iron ore — is among the most mechanically demanding machinery ever built, and its components must be forged from the highest-quality alloy steels with exacting dimensional precision. Caterpillar (Cat) — the world's largest mining equipment manufacturer ($67B revenue) — produces the 797F haul truck (363 tonne payload, 2,337 HP engine) and 7495 electric rope shovel, both of which use multiple large forged components: 797F front spindle (4340 Q+T, Rm 1100 MPa), rear axle yoke (4340 Q+T), crawler track link forgings (B27 manganese boron steel), and shovel dipper arm pin forgings (4340). Komatsu — the world's #2 mining equipment OEM — produces the 930E-5 haul truck (291 tonne payload, 3,500 HP AC electric drive) and PC8000-11 hydraulic shovel (800 tonne operating weight, 42 m³ bucket), both requiring identical-grade forged components. Sandvik Mining & Rock Technology — a division of Sandvik AB (Sweden) — manufactures the world's most extensive underground mining equipment range: DD422i face drilling jumbos (Epiroc competitor), TH663 truck-trailer mining trucks, AutoMine autonomous systems, and Sandvik 516 cone crushers (for coarse ore crushing). Shivam Forge manufactures haul truck spindle and pin forgings, SAG/ball mill trunnion ring forgings, cone crusher main shaft and bowl hub forgings, and Weir WARMAN pump casing forgings — all with ASTM A668 heavy forging certification and ISO 9001:2015 quality management.
Front spindle forgings for Cat 797F, Komatsu 930E-5, Liebherr T 284, and BelAZ 75710 (450-tonne — world's largest haul truck): AISI 4340 Q+T, Rm 1100 MPa, 0.2% proof ≥950 MPa, Charpy at −40°C ≥47 J. Spindle OD range: 200–500 mm, length 600–1500 mm. Induction hardened journal surfaces 52–56 HRC. ASTM A668 Class H certification. 100% UT inspection.
Semi-autogenous grinding (SAG) mill trunnion ring forgings in 4140 Q+T (Rm 900 MPa, 0.2% proof ≥750 MPa) for SAG mills in Codelco's Chilean copper operations, BHP Escondida, and Rio Tinto Pilbara iron ore. Ring-rolled to near-net-shape, OD up to 5,000 mm, wall thickness 200–400 mm. ASTM A668 Class F/G certification. UT per ASTM A609, MT per ASTM E1444.
Cone crusher main shaft forgings for Metso HP3–HP800 series, Sandvik CH series, and FLSmidth XL900 cone crushers: AISI 4340 Q+T, Rm 1100–1250 MPa (induction hardened eccentric journal surface 52–58 HRC). Bowl hub (frame) forgings in 4140 Q+T. Shaft OD 150–600 mm, length 1000–2500 mm. EN 10204 3.1 mill certificate and ASTM A668 Class H.
Jaw crusher eccentric shaft forgings for Sandvik CJ815, FLSmidth Fuller-Traylor 63–89 primary jaw crushers: AISI 4340 Q+T (Rm 1100 MPa), eccentric throw surface induction hardened to 52–56 HRC (case 5–8 mm). Eccentric shaft OD 400–900 mm, length 1500–4000 mm. Used in primary crushing circuits at major copper, iron ore, and gold mines worldwide.
Slurry pump casing forgings for Weir Group WARMAN series (AH, AHR, MCR, WBH) slurry pumps used in copper ore, gold ore, and coal slurry service: Duplex 2205 (UNS S31803, PREN ≥35) for erosion-corrosion resistance. Casing bore machined to H7 tolerance, impeller hub bore H6. Weight 200–2000 kg per casing half. Replaces expensive imported Weir OEM castings with superior forged quality.
Drill rod adapters and shank adaptors for Epiroc (Atlas Copco Mining) Pit Viper 270/350 rotary blast-hole drills and SmartROC underground drill rigs: AISI 4145H modified (0.39–0.51% Mo, VIM grade for maximum sub-zero toughness), heat treated to Rm 1200 MPa, shot peened to Rc 45–50 HRC subsurface compressive residual stress. AMS 6415 (4340) and DS S5-013 (4145H) compliance.
Caterpillar (Peoria, Illinois — $67B revenue, largest OEM in mining): Cat 797F haul truck spindle/yoke forgings, Cat 7495 rope shovel dipper arm pin forgings (4340, 300 mm dia × 2000 mm, 1100 MPa Rm), Cat D11T bulldozer final drive shaft forgings in 8620 carburized steel (case 2–4 mm, surface 58–62 HRC), and Cat SD series motor grader circle drive ring forgings in 4140 Q+T.
Komatsu (Tokyo — $22B mining division revenue): 930E-5 haul truck (291-tonne payload, GE AC electric drive) front spindle forgings in 4340, PC8000 hydraulic shovel arm pin forgings (boom, stick, bucket — 4340 Q+T, dia 250–450 mm), and D475A crawler dozer track link forgings in B27MnCrB steel (30 HRC surface, 300 HB body).
Sandvik Mining & Rock Technology (Tampere, Finland): CH430/CH550/CH870 Hydrocone crusher main shaft forgings in 4340 Q+T, CJ815 jaw crusher eccentric shaft forgings, Sandvik 516i drill rig mainbearing housing forgings in 4140 Q+T, and TH551 underground truck wheel hub forgings in 4340 induction hardened (52–56 HRC). EN 10204 3.1 and SWS (Sandvik Worldwide Standards) compliance.
Weir Minerals WARMAN series (AH 200–900 mm dia) slurry pump casing forgings in Duplex 2205, A49 high-chrome white iron alternative in hardened 27% Cr white iron (650 HV). Weir GEHO positive displacement pump fluid end forgings in 2205 Duplex (for slurry at high pressure). Supply to Weir's Artarmon (Australia), Venlo (Netherlands), and Johannesburg (South Africa) service centres.
ASTM A668 is the primary standard for large forged shafts, rings, and discs for industrial use. Class F (4140, Rm ≥725 MPa), Class G (4140/4340, Rm ≥825 MPa), Class H (4340, Rm ≥1000 MPa). All haul truck spindles, SAG mill trunnion rings, and cone crusher shafts are certified to A668 Class H with full tensile, Charpy, and hardness testing.
AMS 6415 (AISI 4340, vacuum arc remelted grade) for the most critical mining forgings requiring ultra-high toughness and fatigue resistance. VIM/VAR 4340 has significantly improved CVN impact values vs air-melted grades (AMS 6414 air-melt). SAE AMS 6415 compliance documentation including melt source certification, inclusion rating (ASTM E45 Method A), and grain size (ASTM E112 ≥5).
ASTM A609 (UT of carbon and alloy steel forgings) for volumetric inspection of SAG mill trunnion rings and large shaft forgings. ASTM E1444 (MT — fluorescent magnetic particle) for surface inspection. Rejection criteria: no indication >25 mm length, no cluster of indications in any 150 × 150 mm area. Full UT scan maps, MT photographs, and dimensional inspection reports issued.
ISO 9001:2015 quality management system covering raw material procurement (mill certified billets), forging process control (temperature logs, press force records), heat treatment (Q+T furnace charts, quench rate records), NDE, machining, and final dimensional inspection. Caterpillar, Komatsu, and Sandvik supplier quality requirements (SQR) fulfilled through our IQC, IPQC, and OQC process.
The global mining equipment market — valued at $125 billion in 2023 and projected to reach $165 billion by 2028 — is dominated by a handful of global OEMs whose equipment operates in the world's most productive open-pit and underground mines. Caterpillar — the world's #1 mining equipment manufacturer with $67 billion total revenue — produces the 797F haul truck (363-tonne payload, 2,337 HP Caterpillar C175-20 diesel engine, 12 cylinders), the 7495 electric rope shovel (90 m³ dipper, 1,400-tonne payload per pass), and a complete portfolio of underground mining equipment. Komatsu — the world's #2 mining OEM — produces the 930E-5 haul truck (291-tonne payload, 3,500 HP Komatsu/GE AC electric drive system, the world's most popular large mining haul truck by installed fleet) and the PC8000-11 hydraulic shovel (800-tonne operating weight, 42 m³ bucket, 2,880 kW installed power). Both OEMs' equipment requires precision forgings at virtually every critical load-bearing interface: haul truck front spindles (steering knuckle pivot), rear axle yokes (differential drive), crawler track links (ground engagement), rope shovel dipper arm pins (bucket attachment), and hydraulic shovel boom-arm pins (articulation joints). Shivam Forge manufactures all these components in AISI 4340 Q+T to ASTM A668 Class H standards (Rm ≥1,000 MPa, Charpy at −40°C ≥40 J), with 100% UT inspection per ASTM A609 and surface MT per ASTM E1444.
SAG (semi-autogenous grinding) mills and ball mills are the workhorses of mineral processing — converting crushed ore (typically 200mm pebbles) to fine slurry (80% passing 75 µm) for downstream flotation or leaching. A single SAG mill in a large copper mine (e.g., Codelco Chuquicamata, BHP Escondida, Freeport Grasberg) processes 100,000–150,000 tonne of ore per day, with shell diameters up to 14 metres and installed power of 22–28 MW. The SAG mill trunnion ring — the large bearing ring at each end of the rotating shell, sitting on trunnion bearings (hydrostatic lubricated white metal bearings) — is one of the most massive forged components in any industrial machine: up to 5 metres OD, 3–4 metres shell diameter connection flange, wall thickness 200–350 mm, weight 20–40 tonnes in 4140 Q+T (Rm 900 MPa). Shivam Forge's ring-rolling capability — 3,000-tonne ring-rolling mill with 5-metre maximum OD capacity — makes us one of India's few manufacturers capable of producing SAG mill trunnion ring forgings at the scale required by FLSmidth, Metso Outotec, and Thyssenkrupp industrial solutions. The trunnion ring forging is certified to ASTM A668 Class G/H with full UT inspection per ASTM A609, dimensional inspection against OEM drawings, and EN 10204 3.1 material certification.
Slurry pumps are the arteries of mineral processing plants — transporting abrasive ore slurries (copper concentrate at 65% solids, coal preparation plant tailings at 50% solids, gold ore leach slurries) from the mill discharge through cyclones, thickeners, and filter presses to the final product. The Weir WARMAN centrifugal slurry pump — manufactured in AH (horizontal), AHR (rubber-lined), and MCR (metal-lined) configurations — is the world's most widely deployed slurry pump in hard-rock mining, with over 200,000 units in service globally. The pump casing (wet-end component exposed to the slurry's combined abrasion and corrosion) is traditionally made from high-chrome white iron (27% Cr, 650 HV hardness) or natural rubber liner, but for high-pressure or corrosive slurry service (copper sulphide concentrate slurry with high H2SO4 content, nickel laterite slurry with high HCl content), forged Duplex 2205 (UNS S31803, PREN ≥35) is increasingly specified for its combination of erosion resistance (>twice the life of 316L stainless) and pitting corrosion resistance in chloride-bearing slurries. Shivam Forge manufactures Duplex 2205 slurry pump casing forgings as a direct, cost-effective alternative to imported Weir OEM castings — with superior mechanical properties (forged structures have 15–25% higher fatigue strength than equivalent castings) and fully EN 10204 3.1-certified material traceability.
Shivam Forge's mining equipment forging portfolio covers the complete mining industry equipment value chain — from the primary crushing jaw crusher (Sandvik CJ815 eccentric shaft in 4340, 1100 MPa, induction-hardened) through secondary and tertiary cone crushing (Metso HP800 main shaft, Sandvik CH870 main shaft — 4340 Q+T, surface hardened to 58 HRC) to SAG/ball mill grinding (trunnion ring forgings up to 5m diameter in 4140 Q+T, ASTM A668 Class G) and slurry pumping (Weir WARMAN pump casing in Duplex 2205). Our manufacturing facility features a 6,000-tonne hydraulic press for open-die forging of large components (>5 tonne), a 3,000-tonne ring-rolling mill for trunnion and bearing ring forgings (up to 5m OD), four gas-fired heat treatment furnaces (max charge 30 tonnes), in-house induction hardening (up to 800 mm workpiece diameter), and a full NDE suite (UT, MT, PT, RT, TOFD) with Level III-certified inspectors. For global mining OEMs (Caterpillar, Komatsu, Sandvik, Weir, Epiroc) and major mining companies (BHP, Rio Tinto, Codelco, Freeport, Vale) sourcing wear parts and maintenance forgings, Shivam Forge delivers 25–35% cost savings vs European and North American alternatives. Contact our mining industry team at +91-9265772827 for component drawings quotations and ISO 9001:2015 / ASTM A668 certified supply.
Yes. We manufacture Cat 797F front spindle forgings in AISI 4340 Q+T (Rm 1100 MPa, 0.2% proof ≥950 MPa, Charpy at −40°C ≥47 J) with induction-hardened journal surfaces (52–56 HRC, case 5–8 mm). ASTM A668 Class H certification and 100% UT inspection per ASTM A609. Dimensional inspection report against Cat drawing tolerances provided.
We produce SAG mill trunnion ring forgings up to 5,000 mm OD in 4140 Q+T (Rm 900 MPa) using our ring-rolling mill. Wall thickness range 150–400 mm, ring height 300–1200 mm. ASTM A668 Class G/H certification, UT per ASTM A609, and MT per ASTM E1444. These serve FLSmidth, Metso Outotec, and Thyssenkrupp SAG mills in copper, gold, and iron ore processing plants.
Yes. We manufacture Weir WARMAN-equivalent slurry pump casing forgings in Duplex 2205 (UNS S31803, PREN ≥35) for erosion-corrosion resistance in copper, nickel, coal, and gold ore slurry service. Casing bore machined to H7 tolerance, impeller hub bore H6. EN 10204 3.1 mill certificates with chemistry, tensile, Charpy at −20°C, and PREN calculation.
Yes. Metso HP800 cone crusher main shaft forgings in AISI 4340 Q+T (Rm 1100–1250 MPa), eccentric journal surface induction hardened 52–58 HRC (case 5–8 mm). Shaft OD approximately 400–500 mm, length 1800–2200 mm. ASTM A668 Class H, EN 10204 3.1 mill certificate, and UT per ASTM A609. We also supply bowl hub (frame) forgings in 4140 Q+T.
For Epiroc Pit Viper 270/350 rotary blast-hole drills and SmartROC underground drills, we supply shank adaptors and drill rod adapters in AISI 4145H modified (0.39–0.51% Mo, vacuum-induction-melted for maximum low-temperature toughness), heat treated to Rm 1200 MPa, and shot-peened for compressive residual stress. AMS 6415 and DS S5-013 compliance documentation.
Yes. For primary jaw crushers (Sandvik CJ815, FLSmidth Fuller-Traylor, Metso C200), we supply eccentric shaft forgings in 4340 Q+T (Rm 1100 MPa) with induction-hardened eccentric throw surface (52–56 HRC, case 5–8 mm). Shaft OD 400–900 mm, length 1500–4000 mm. ASTM A668 Class H certification and 100% UT inspection per ASTM A609.
Yes. We supply crawler track link forgings for Komatsu D475A bulldozers and Cat D11T tractors in B27MnCrB boron steel (30 HRC surface hardness, 300 HB body — carburizing or through-hardening available). Track link OD range 150–300 mm. ASTM A668 and ISO 683-18 boron steel documentation. Suitable for open-pit coal, copper, and iron ore dozer applications.
Standard NDE for haul truck spindle forgings: (1) 100% volumetric UT per ASTM A609, Class 3 acceptance (no single indication >12 mm equivalent flat-bottom hole reflection); (2) 100% surface MT per ASTM E1444 (fluorescent magnetic particle, DC yoke method); (3) Visual and dimensional inspection per drawing. Full UT scan maps and MT photographic records issued for each forging.
Why Choose Shivam Forge
Shivam Forge delivers precision hot-forged components from our integrated Shapar, Rajkot facility — covering forging, CNC machining, heat treatment, and quality inspection under one roof.
