From guesswork to data work: the future of screen maintenance
In mineral processing, uptime is everything – and yet screen deck maintenance has long relied on inconsistent methods, guesswork, and fragmented data. DeckMapp™ is the evolutionary digital tool from Sandvik that, alongside AI-powered WearApp™ can change that. Together, they empower plant operators to make smarter, faster decisions based on reliable wear data and visual insights – resulting in reduced downtime, fewer errors, and more sustainable maintenance practices.
Screen media maintenance is a high-stakes task. If plans are incomplete, panels are misidentified, or wear data is missing, the result can be severe: unplanned shutdowns, rework, production losses – and even safety risks. Many operations still rely on handwritten job sheets, inconsistent wear measurements, and spreadsheets scattered across personal drives. This approach is prone to breakdowns – both mechanical and operational.
When our line manager left the business, we lost years of maintenance records. Without knowing the deck condition, we couldn’t finish the shutdown on time.
The solution: Digital maintenance from the ground up
DeckMapp™ is an intelligent screening media management platform. Accessible via laptop, tablet, or phone, it creates a shared digital workspace for planning, executing, and analyzing screen maintenance activities. Teams can track wear patterns, view deck history, and collaborate on real-time shutdown plans – no more paper printouts, lost updates, or inconsistencies.
With built-in reporting and revision history, every maintenance action is visible and traceable. From pre-shutdown prep to post-task analysis, DeckMapp™ turns fragmented information into structured, actionable insight.
AI meets wear inspection
As an optional add-on to DeckMapp™, WearApp™ brings artificial intelligence to the field. Instead of manually inspecting every screen aperture, operators simply snap a photo with a phone or tablet. The app assesses wear at aperture level, estimates panel efficiency, and predicts remaining wear life.
The result? Faster inspections, greater accuracy, and smarter decisions about when – and what – to replace. “WearApp™ doesn’t just improve inspection. It fundamentally changes the conversation from ‘How bad is it?’ to ‘What’s the smartest move?’" says Matt Cutbush, Digital Solutions Product Manager at Sandvik.
WearApp™ doesn’t just improve inspection. It fundamentally changes the conversation from ‘How bad is it?’ to ‘What’s the smartest move?’
More sustainable – more productive
By extending the life of screening media, DeckMapp™ and WearApp™ reduce unnecessary replacements – and the resource costs that come with them. They minimize the risk of avoidable shutdowns, support efficient spare parts planning, and eliminate duplicated work. Ultimately, they help operators use what they already have, better. “When screen media management is digital, connected, and data-informed, every task becomes an opportunity to improve – not just performance, but sustainability too”, continues Cutbush.
Connected insights, better outcomes
Whether it’s a shutdown in the Pilbara, or a maintenance round in the Andes, DeckMapp™ and WearApp™ bring screen maintenance into the digital age, one deck at a time. Because when your decisions are powered by insights – your operations keeps moving forward.
