Wear Sensors

2C-Probe — pipeline and wear liner monitoring

The 2C-Probe is 2Censor’s original patented design for internal pipe wear monitoring, now also used in wear plates, tiles and liners across chutes, hoppers and bins. The probe is installed through a 6–8 mm hole at known points of failure, plugging the hole and becoming part of the liner. Its sacrificial element is manufactured to wear at the same rate as the liner it monitors, measuring each millimetre of wear — no manual thickness-testing rounds, no guesswork between inspections.

2C-Mill and 2C-Strip — SAG and ball mill liner monitoring

For grinding mills, liner-integrated options embed sensor tracks into OEM liners or wear plates using liner bolts or slim strips, providing 24/7 liner thickness data while the mill runs. That live wear profile supports smarter reline scheduling and fewer unplanned stops.

How the system works

1. Probe — installed into the wear lining at known high-wear points, in multiple lengths to suit the liner.
2. Sensor — measures each millimetre of wear, protected by an application-specific casing.
3. Transmitter — reports over LoRaWAN, a secure low-power wide-area radio protocol using country-compliant frequencies. Battery powered; no cabling.
4. Dashboard — live condition displayed per millimetre of wear, with AI-assisted forecasting of time-to-failure and alarms to your maintenance team. You own 100% of the data, and it can feed directly into your own reporting systems instead of ours if preferred.

Proven results on Australian sites

Conveyor feed and reject bin (35 mm lining): a 60 mm probe at the high-wear choke point measured 1 mm of wear per 1.5 weeks and consistently forecast failure at 40 weeks from install. The liner was changed on a scheduled maintenance day, with inspections, working-at-heights and confined-space entries eliminated. Sensor project cost: $35,000. Measured saving over the asset’s life: $138,000.

Coal tailings pipeline (2 × 5 km, 280 mm HDPE): probes in rotating pipe spools extended pipe life from 6 months to 2 years — a $1.5M saving on supply spend, with zero environmental incidents and unplanned outages eliminated (estimated $1.2M/year).

Why choose 2Censor

• Millimetre-level resolution with wireless reporting — early, unmissable wear alerts
• Sacrificial element wears with the asset, giving a direct read on remaining life
• Battery-powered LoRaWAN reporting — simple to scale across sites and assets
• Predictive maintenance alarms with lead time to order and plan replacements
• Proven in abrasive service from tailings pipelines to SAG mill liners

Frequently asked questions

What assets can 2Censor monitor?

Slurry and tailings pipelines (steel or HDPE), chute and hopper wear liners, wear plates and tiles, and SAG/ball mill liners.

Does installation damage the liner?

No — the probe installs through a small 6–8 mm hole and plugs it, becoming part of the liner and wearing with it.

Do we need 2Censor’s software?

No. You own the data outright, and the system can deliver it straight into your existing reporting platform.

Ask us about 2Censor wear sensors →

Related: Kombo Washer mill liner sealing · CUMI ceramic lined pipe · Chute liners