CSN Mineração Saves R$ 4M with Acoem Eagle Sensors at Casa de Pedra Mine

Country: Brazil
Customer: CSN Casa de Pedra – CSN Mineração
Application: Mining

EXECUTIVE SUMMARY

Thanks to the early detection of critical vibration levels on excavator ES-5503’s motor, CSN Mineração avoided a costly and unexpected breakdown at its Casa de Pedra iron ore mine. By acting proactively, the team saved approximately R$ 4 million, showcasing the power of Acoem’s Eagle wireless predictive monitoring solution.

The Challenge

Operating in a demanding mining environment, CSN relies on large-scale excavators for daily production. In early 2025, abnormal vibration was suspected on one of the key machines (ES-5503), indicating potential bearing failure in motor 01.

Potential consequences: Sudden breakdown, extended downtime, and the loss of a critical motor valued at R$ 4 million.
Business impact: Production delays, costly emergency repairs, and reduced operational reliability.

The Solution

Implemented solution: Online monitoring of vibration and temperature using Acoem Eagle wireless sensors on GP excavators.
Why Acoem: Real-time monitoring, wireless flexibility, and actionable insights made Acoem the preferred choice for proactive maintenance.
How it helped:
- The sensors detected critical vibration levels on motor 01.
- A spectral analysis indicated early-stage failure in the front bearing.
- A maintenance request was immediately issued, and the motor was replaced preventively in May 2025, following continuous monitoring.
- Post-repair, the sensors were reinstalled and reconfigured, with vibration levels returning to normal.

The Results

- R$ 4 million saved by avoiding a critical motor failure
- Zero unplanned downtime
- Sustained production continuity and reliability

Customer feedback: “This proactive action prevented an unexpected failure… proving the value of predictive monitoring.”– A Senior Maintenance Specialist at CSN.

The Impact

This case clearly demonstrates the transformative impact of predictive monitoring, even when applied to a single component of one machine.

The success has reinforced the customer’s commitment to scaling Acoem’s technology across more assets. It also strengthened the collaborative relationship between the maintenance teams and Acoem Reliability, positioning both partners to drive operational excellence further.