Fabrication of Abrasion Resistant Steel

Brown McFarlane supplies abrasion resistant steel in the form of gas or plasma cut profiles to exacting tolerances or as formed, drilled, or machines parts. It is of course also available as plate straight from our stocks.

Utilised in applications such as tipper bodies, cutting edges, crushing machinery, and excavator buckets abrasion resistant plate from Brown McFarlane is sourced from Western European steel producers and is available in 400, 450, and 500 Brinell hardness, in thicknesses from 3 mm to 150 mm, and up to 12 metres by 3 metres in plate size.

Brown McFarlane stocks Abrazo plates manufactured by Tata Steel as well as proprietary brands from other steel plate manufacturers.

While abrasion resistant steel plate can be easily welded and fabricated, its high hardness and strength compared with mild steel means that it should be treated with some caution. The following information is intended as a basic guide to various fabrication methods. If you require advice on welding, machining, or forming then please contact any one of our offices.


400 Brinell steel can be welded under normal conditions using MMA, MOG, and SAW without preheat, up to a combined thickness of 60mm, provided hydrogen controlled electrodes are used.  Consumables should be dried in accordance with scale ‘D’ of BS 5135. 500 Brinell steel can be welded in the same way provided that preheat and hydrogen controlled electrodes are used. In both cases consumables should be chosen on the basis of whether or not the weld metal is exposed to wear conditions.


Machining or drilling is more difficult due to hardness and should be done with care. For 400 Brinell use high-grade cobalt HSS E drilling tools and for 500 Brinell hard metal drilling tools are necessary.   


Abrasion resistant steels can be readily cold formed. Compared with steels of lower yields, three factors should be considered:

  1. Higher press forces
  2. A greater bend radius is required
  3. Spring back.

Flame Cutting

Material can be cut using conventional flame cutting practices without the need for preheat at ambient temperature.  The following cutting parameters are recommended:-

(LPN mm)
Cutting O2
Heating O2
12.5 10-25 45 40 18 450 
15.0 10-25 50 40 10 490 
25.0 25-40 60 40 20 400 
40.0  40-60  70  40  10  310 
50.0  40-60  75  40 10  300 
65-80  60-100  71  31  13  239 

Please note the above parameters also apply to 500 Brinell steel.

It should be noted that care must be taken to achieve a good quality, defect-free flame cut edge. Any gouges should be smoothly dressed by grinding immediately after cutting.


Abrasion resistant steel can be machined by milling. The following recommendations are given for general guidance:-

Steel Hardness Cutting Speed (mm/min) Feed (mm/tooth)
400 Brinell* 100 0.10-0.15

 * For further information on 450 Brinell and 500 Brinell please contact us.

Cold Bending

Where possible, cold bending should be carried out with the bend axis perpendicular to the rolling direction, this being the less onerous of the two directions. The following table contains guidelines for bending to a 90°angle.  In general however, bending radii should be as generous as possible.

Bending direction (bend axis) Minimum inside
Bending radius
Minimum die
Perpendicular to rolling direction 3t 8.5t
Parallel to rolling direction 4t 10t

Contact Us

For more information and for details of price and availability contact any of our sales teams. You can get their details by clicking here.

Brochure Download

Abrasion Resistant Steel PlateAvailable in 400/450/500 Bhn in thicknesses 3-150mm in plates up to 12m x 3m. 

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