Welding vs Replacing Grousers: Making the Right Choice for Track Maintenance

[MikePhua]

Understanding Grousers and Their Importance
Grousers, the protruding cleats on the tracks of excavators, bulldozers, and other tracked equipment, play a crucial role in providing traction, stability, and efficient movement on rough terrain. Over time, these components wear down due to constant contact with abrasive surfaces, impacting machine performance and safety.
When grousers become excessively worn or damaged, operators face the decision: should they weld to repair them or replace them entirely? Each approach has pros and cons that can affect cost, downtime, and long-term track health.
The Case for Welding Grousers
Welding worn or broken grousers back onto track shoes is a common repair method, especially for extending the life of undercarriage components. Skilled welders can rebuild grousers using compatible steel filler materials, restoring shape and thickness.
This method is often quicker and less expensive upfront than ordering and installing new track shoes or grousers. In situations where replacement parts are hard to source or during busy seasons when downtime is costly, welding offers a practical interim solution.
Operators working in remote locations sometimes rely on welding repairs to keep machines running, sharing stories of emergency fixes on job sites where replacement parts were days away.
Limitations and Risks of Welding
However, welding is not without risks. Improper welding can cause:

• Distortion or warping of the track shoe
  
• Cracking due to heat-affected zones
  
• Weakened structural integrity if wrong filler materials or techniques are used
  

Welded repairs may also not restore the original hardness of the grouser, leading to faster wear. Excessive or repeated welding can compromise the shoe, sometimes necessitating full replacement sooner than planned.
One experienced mechanic recounted a case where poor welding on a bulldozer grouser led to premature failure under heavy loads, costing more in repairs than a timely replacement would have.
When to Choose Replacement
Replacing grousers or entire track shoes is often the best option for heavily worn or structurally compromised components. Modern manufacturing ensures replacement parts meet original specifications for hardness and durability.
Though more expensive initially, replacement provides long-term reliability and reduces the risk of unexpected failures. For heavy-duty applications like mining or quarrying, where equipment faces extreme stress, replacement is typically preferred.
Balancing Cost, Time, and Machine Usage
The decision often hinges on budget constraints, part availability, and operational urgency. For light to moderate use, welding can serve as a cost-effective stopgap. For machines under heavy loads or with extended service expectations, investing in replacements can save money over time.
Industry Trends and Innovations
Advances in metallurgy and welding techniques have improved repair quality. Specialized wear-resistant filler materials now enable stronger welds closer to OEM performance. Some companies offer on-site welding services with mobile rigs, reducing downtime.
Additionally, manufacturers design track components with modular grousers or bolt-on options, simplifying replacement and reducing labor.
Real-World Examples
A forestry contractor shared how welding saved them during a critical harvest season, enabling a tracked skidder to continue working despite several worn grousers. Conversely, a construction firm switched to full replacements after repeated weld failures, noting improved machine uptime and operator safety.
Conclusion
Choosing between welding and replacing grousers is a nuanced decision influenced by machine use, part availability, cost, and repair quality. While welding offers flexibility and immediate savings, replacement often provides superior long-term value and reliability.
Understanding the trade-offs and applying best practices ensures that tracked equipment maintains traction and durability—key factors that keep projects on track and operators safe.