Construction Machinery ME April 2021

Page 1

ISSUE 112 APRIL 2021

PLUS

KING OF SPPIDLEURSS BRINGS SPIDER GGEST IN THE BI ER CR ANE MINI SPID

LONG HAUELCH AND

NEW T S RAISE L E D O M I V IT Y NEW T C U D O R HAULER P

G N I R E G AU L L E W

QUE R O T R E G AU

ION T A T U P E R T’S S I L A I C E P NT S E OF M E G H C N A A T R T E A L D A I N W THE O I D G N E A R E TY I H L T A R U O Q F R S TS W N FO E E N M G D E O S O G G TOOLS IS CTION AND MININ CONSTRU


CONGRATULATIONS SDLG FOR WINNING

Top Quality Awards in the world, The Only & First Chinese Construction Equipment Brand, The leader in China’s Construction Equipment Industry.

SDLG won ARE-QP Award (Asian Quality Award for short) in 2017, which was granted by Asian Network for Quality (ANQ).

AMTRAC- Lebanon

Genserv - Oman

COMAT Tunisia

Al Zwetina General Trading Llc- Libya

AMTRAC Bldg - Blvd. Naher El Mott Jdeidet el Maten P.O.Box: 80-1000 Beirut, Lebanon Tel: +961 70 222131/141

P.O. Box: 2690 Ruwi Postal Code 112, Sultanate of Oman Tel: +968 244 90 755 Fax: +968 244 93 327

ADD: Route de Gabès KM1 Sfax 3003 Tunisia Tel: +216 74 468 710 Cell: +216 98 410 508

POST BOX 28086, DUBAI – U.A.E (For Libya market) Cell: 00218926776070

Al-Futtaim Auto & Machinery Co. LLC, KSA

Ghabbour - Egypt

NECST Motors Kenya Ltd- Kenya&Tanzania

Kilo 6 Makkah Road , P.O. Box 1700 , Jeddah, Saudi Arabia, 21441 Tel: +966 12 680 4444

KM3 - Cairo / Alex Agricukltural Road, Egypt Tel: +20 2 214 6646

Place Four Forty Six, Mlolongo, Machakos County Cell: +254 727 534 593

Address: 5 Mozambique Road, Addis Ababa, Ethiopia +251 114 34 16 11/12

Al-Futtaim Auto & Machinery Company, UAE

Jamil Odeh & Sons Co - Jordan

National Industrial Group - Yemen

P.o.box 473 Abu Alanda 11592 Amman, Jordan Tel.: +962 6 4160409

SBMH- Morocco

Republic of Yemen- Amran Province, the principal Sana’a Street Tel: +967 -7-600359- 602693 Cell: +967 - 711644550 - 777773540

Rue 8 Lotissement Al Assam Nº 10, Kenitra, Morocco Tel: +212 5 37371236

Darb Albehar Construction Machinery Co.Iraq

SMT- Algeria

Alwaha-Bridge Alwaha Area City - Al Nasiriyah, Iraq Tel: 00964 7819553440

Lot n°267, Voie B - ZI Roubia Rouiba 16012 Alger, Algeria Tel: +213 23 87 38 77

Al Swality Al Rasheedy Investment Co .LTDSudan

Kuwait China Cooperation Gen. Trading Co.Kuwait

ADD: MANDANI ST. NEAR TO BASHAIR GAS STATION KHARTOUM - Sudan TEL: 00249964044444

Plot B-131, Al Ramoul - Rashidiya PO Box 5502, Dubai, United Arab Emirates Tel: +971 4 2135100

Arabian Agencies Company - Qatar New Industrial Area; Street #43 P O Box 22329, Doha, Qatar Tel: +974 44600506 / 44500925 / 44500926

Ascendum Makina - Turkey Fatih Mah. Katip Çelebi Cad. No: 43 PK 34956 Tuzla / İstanbul, Turkey Tel: +90 216 581 80 00

Elite Motors - Georgia GEORGIA - Elite Motors 48 Apt., 8B Kandelaki Str.0160 Tbilisi, Georgia Tel: +995 32 215 50 00

Panasonic Tower, Room No. 1804 Kuwait Tel: +965 25414357 Cell: +965 69901305

Tana Engineering Plc. - Ethiopia


CONTENTS APRIL 2021

6_NEWS The latest news from across the region and further afield.

14_EYE IN THE SKY Acciona explains how drone technology has come on in leaps and bounds in recent times and is now an integral part of construction.

18_FUTURE PERFECT The first part of CMME’s series on the equipment needed to build Dubai’s iconic Museum of the Future looks at Wolffkran’s contribution in the project.

22_KING OF SPIDERS CMME witnesses one of the first lifting projects in the region of the UNIC 1006 mini spider crane, Spider Plus’ new introduction in its fleet.

26

10 SPOTTED Y AN e IN GEallR-teM rrain cran

26_AUGERING WELL Auger Torque’s quality and wide range of tools and attachments is good news for the Middle East’s construction and mining sectors.

R E W O RAW P R E L E A SE S

10

Tadano build Tesla fleet helps y in double gigafactor quick time

achinery. struction m W n E co f N o _ d 2 rl 3 the wo leases from The latest re

f OTR tyres.

o EN d longevity e safety an 36_TOP T to maximis Ten steps to

follow

. UL LONG HA e productivity and safety stakes E H T R O 38_SET F in dumpers and haulers up th ts Advancemen THE PISTEr major Alpine ski event. S E R A P E R ady fo HI P the venue re 44_HITAC vators make ers and exca Wheeled load

38

14

22

18


2

EDITORIAL APRIL 2021

GROUP MANAGING DIRECTOR RAZ ISLAM raz.islam@cpitrademedia.com +971 4 375 5471 MANAGING PARTNER VIJAYA CHERIAN vijaya.cherian@cpitrademedia.com +971 4 375 5713 EDITORIAL EDITOR ANIRBAN BAGCHI anirban.bagchi@cpitrademedia.com +971 4 375 5715 DEPUTY EDITOR PAUL GODFREY paul.godfrey@cpitrademedia.com

PROJECTS, PROJECTS This month, CMME covers two projects. One is a recent iconic addition to Dubai’s landmarks, the other a pointer of things to come. Dubai residents driving along the main stretch of Sheikh Zayed Road these past several months have noticed a strange structure taking shape. Fringed by three red tower cranes rising straight up tall, their spindly metallic bodies standing free without support, a lattice work of metal was being built, seemingly like a honeycomb. In time, that latticed framework of metal started being covered by a unique metal façade, itself stencilled with cut-outs of Arabic letters. The Museum of the Future was rising in the present. Now, with the museum complete and the three red tower cranes taken down, we talk in this issue to Wolffkran Arabia, the providers of the cranes, to look at how the equipment worked at the project, the challenges involved in planning, execution and delivery. The other project we cover this month is a lifting job for the UNIC 1006 URW mini spider crane, the biggest of its kind in the world at a lifting capacity of 10t on a 14t overall machine weight. Brought to the region for the first time by Spider Plus, the Dubai-based mini crane rental specialist, the 1006 could be the solution numerous lifting jobs were looking for that were either too small or inaccessible for large cranes and too big for the typical mini crane with just a couple of tons of lift capacity. At a job in a Jebel Ali warehouse, the 1006 first proved its compactness by squeezing through a 5m-by-4m doorway, then proved its strength by lifting and placing two massive tanks while proving its suitability for indoor lifts by dealing with a 10m ceiling for an underhook space of only 4m to the suspended load, then proved its speed by executing the two back-toback lifts withing two hours, while proving it

versatility with all the other things it collectively proved in the course of the morning of the job. While the Museum of the Future is an icon for the ages, the UNIC 1006 is a harbinger of the way lifts such as the ones it did will be increasingly done in the future – with mini spider cranes whose compact sizes belie their capacities and whose use has suddenly taken off in the region, as Spider Plus can testify. While the rise of the spider crane is a new development in the region, the venerable old dump truck trudges on at its mines, quarries and construction sites. Well, not really. With such exciting stuff afoot as autonomous hauling, electrification through catenaries and real-time payload sensing, this sector, venerable as it may be, is not old anymore. In our cover story this month, we look at the rigid and articulated dump trucks from Hitachi, Komatsu, Cat, Volvo, Doosan, et al, and note how the mule has progressed into a connected, robust and sophisticated beast, to add to the power it always had. But projects and sites are where the action is. And as spring rolls into an early summer’s Ramadan, we look forward to bringing you more reports in the coming issues of the projects we’ve been galivanting in during the cool weather. Ramadan Kareem!

ADVERTISING SALES MANAGER BRIAN FERNANDES brian.fernandes@cpitrademedia.com +971 4 375 5479 DESIGN ART DIRECTOR SIMON COBON simon.cobon@cpitrademedia.com DESIGNER PERCIVAL MANALAYSAY percival.manalaysay@cpitrademedia.com MARKETING ADMINISTRATION EXECUTIVE ZAARA KHAN zaara.khan@cpitrademedia.com +971 4 375 5470 CIRCULATION & PRODUCTION PRODUCTION MANAGER VIPIN V. VIJAY vipin.vijay@cpitrademedia.com +971 4 375 5713 DISTRIBUTION MANAGER PHINSON MATHEW GEORGE phinson.george@cpitrademedia.com +971 4 375 5476 WEB DEVELOPMENT ABDUL BAEIS SADIQ SIDDIQUI FOUNDER DOMINIC DE SOUSA (1959-2015) PUBLISHED BY

The publisher of this magazine has made every effort to ensure the content is accurate on the date of publication. The opinions and views expressed in the articles do not necessarily reflect the publisher and editor. The published material, adverts, editorials and all other content are published in good faith. No part of this publication or any part of the contents thereof may be reproduced, stored or transmitted in any form without the permission of the publisher in writing. Publication licensed by Dubai Development Authority to CPI Trade Publishing FZ LLC. Printed by Printwell Printing Press LLC.

Anirban Bagchi Editor, CMME

CPI Trade Media. PO Box 13700, Dubai, UAE. +971 4 375 5470 cpitrademedia.com © Copyright 2021. All rights reserved.


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Mobile and crawler cranes


4

ONLINE APRIL 2021

MOST POPULAR

FEATURED

CONSULTANT

SHEIKH MOHAMMED DECREES ESTABLISHMENT OF INHERITED PROPERTY DISPUTE TRIBUNAL

Egis completes acquisition of Kuwait’s Projacs International

CONSTRUCTION

Abu Dhabi Airports to pull MTB contractors’ bonds over project

EXPERTS Digital twins show the way towards a net-zero emissions construction sector

CONSTRUCTION

DEWA commissions $153m 400/132kV substation at MBR Solar Park

CONSTRUCTION

Grundfos bounces back after COVID-19 revenue slump

CONSULTANT

EMPC appoints Arab Architects to Reef Mall refurbishment

READERS’ COMMENTS

ANALYSIS The tech to enhance collaboration and transparency

The question of inheritance all too frequently unravels the bonds of families and can leave many lives in tatters. The importance of this intervention by His Highness Sheikh Mohammed bin Rashid Al Maktoum, Vice President and Prime Minister of the UAE and ruler of Dubai therefore cannot be overstated. The establishment of a special tribunal to resolve disputes between heirs in relation to the sale of inherited residential property provides clarity to both home owners and the real estate market in general in the UAE. The move to protect the rights and interests of all concerned parties, especially the elderly, minors, femes sole, divorcees, widows and people of determination closes a loop hole and provides protection to these vulnerable groups. The decision to move the tribunals away from Dubai Court is an interesting initiative and in many ways it is a return to the spirit of personal dispute resolutions that were conducted many years ago in Dubai. My main hope is that this will provide speed and certainty to many and allow them to continue with their lives as soon as possible. Name withheld by request



S W NE 6

MATERIAL HANDLING ASSETS

ADNOC L&S EXPANDS FLEET WITH ACQUISITION OF SPEEDY HIRE

JECTS, O R P W E N OFFICES, W E N , S E HIN AROUND K O NEW MAC O L E IVES – W T A MONTH I T S I I N H I T W E NE W WHAT’S N T A N O I G THE RE SKYJACK

The Abu Dhabi National Oil

LAUNCHES MICRO

Company’s (ADNOC) shipping and

SCISSOR

maritime logistics arm, ADNOC

Skyjack has

Logistics & Services (ADNOC

introduced its

L&S), has announced that it has

first new “micro

acquired all of the UAE-based

scissor” with

assets of Speedy Hire PLC (Speedy),

quiet electric

consolidating the position of

drive for low-

ADNOC L&S as the largest integrated

level access work,

logistics provider in the GCC

designed to easily

by adding over 2,000 pieces of

fit through tight

material handling equipment.

spaces and low

Mammoet crane fleet expands in MEA region Mammoet has expanded its crane fleet in the Middle East, Africa and Caspian (MEA) region with the addition of eight new units comprising crawler cranes and rough-terrain and all-terrain models. The world’s largest engineered heavy lifting and transport service provider said the new models in the regional fleet are a 600t crawler crane, two 250t all-terrain cranes as well as one each of 400t and 100t capacity all-terrain cranes, along with three 35t rough-terrain cranes. Mammoet said the expansion increases its capacity in the region, complementing its diverse fleet of equipment for projects and day rental jobs, adding flexibility and greater availability for work in several high-demand geographic areas. The cranes will support Mammoet’s range of engineered heavy lifting work – from small construction sites to handling complex lifts in industrial plants.

They will be available for customers across all sectors including the power, petrochemical, mining, renewables and civil construction sectors throughout the Middle East, Africa and the Caspian region. Shortly after arrival, all cranes have been deployed on various construction projects: a short termsubstation transformer installation and infrastructure construction activities throughout the UAE. Michel Bunnik, commercial director, Mammoet MEA, said: “We are excited to complement our current regional fleet with these additional cranes in the region as we are continually looking for ways to improve the efficiency of our operations and equipment ready availability for construction and maintenance projects, thus reinforcing our emphasis on service to our customers.”

Speedy Hire is among the UK’s

floor load ratings.

leading rental companies for tools

The company

and equipment used in the oil & gas,

said the new

construction and industrial sectors.

micro scissor

Under the terms of the acquisition,

has two variants

ADNOC L&S has taken ownership of

based on market

Speedy’s equipment, stock and other

regulation: the

fixed assets relating to its Middle

SJ3013 for the

East business, which comprise more

ANSI market, and

than 2,000 pieces of equipment,

the SJ3014 for

including cranes, forklifts, fire trucks

the CE market.

and other high-value machinery

Kristopher

used for offshore and onshore

Schmidt, product

material handling services.

manager, Skyjack,

ADNOC said the transaction

said the SJ3014

includes a Transitional Services

boasts a 14ft

Agreement with ADNOC L&S for

platform height

up to four months, to support the

and a working

transfer of assets. During this time,

height of 20ft

Speedy’s UAE-based employees

while the ANSI

will be on-boarded by ADNOC L&S

SJ3013 has a

at its Mussafah offshore logistics

platform height of

base. Speedy currently has around

13ft and working

600 employees in the UAE.

height of 19ft.

Captain Abdulkareem Al Masabi, CEO, ADNOC L&S, said: “The expansion plan we are pursuing is in line with ADNOC Group’s 2030 growth strategy. Speedy has been an efficient and reliable equipment and manpower services specialist for several years, and their assets and skilled personnel in the region are valuable as we look to expand our offshore logistics operations.”


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8

NEWS ROUND-UP APRIL 2021

CONSTRUCTION AND DEMOLITION

TADWEER RECYCLES 1.9M TONS OF WASTE IN 2020

Hiab, Thor ME renew agreement for GCC

Truck-mounted crane maker Hiab has renewed its distribution agreement with Thor Middle East LLC as its regional importer and distributor in the GCC region. With the renewal Thor continues to be responsible for sales, parts and service support for the UAE, Bahrain, Kuwait, Oman, Qatar and Saudi Arabia for the Swedish truck-mounted crane maker Hiab, which is part of Cargotec. Meanwhile, Thor has recently been acquired by

JLG INVESTS IN MICROVAST JLG Industries has announced a planned investment of $25m by its parent company Oshkosh Corporation, in Microvast, a global provider of nextgeneration battery technologies. JLG aims to use the battery tech in its electric equipment.

Al Shirawi Equipment Co. (Oasis Investment Group), a Dubai, UAE, based conglomerate comprising trading, industrial, distribution, contracting and service industries with 10,000 plus employees. With the addition of Thor Middle East, Al Shirawi will cement its position as the leading ‘One stop’ solution and service provider to the waste management, construction and transportation sectors building on its already

dominant position, said a statement from the company. Thor Middle East will continue to operate as an independent company while being part of the large Al Shirawi group of companies. The move is expected to give Hiab loader cranes, Multilift demountables, Zepro tail lifts, Jonsered recycling cranes and Loglift forestry cranes more visibility and support across the Middle East. Henrik Wittgren, regional business manager at Hiab, says: “It is important for Hiab to have a strong local partner in the Middle East that can closely support our end customers. For this reason, we are very happy to continue to work with Thor Middle East and look forward to developing a strong partnership with the Al Shirawi Group.”

DOOSAN ENT ‘TRANSPARSTEM BUCKET’ SYER SAFETY LOAD e IMPROVES launched th

pe has acore Euro sparent Doosan Infr loader “tran d le ee h w t blind rs fi ators to see industry’s allows oper h ic g the h n w , si u em achine bucket” syst et on the m ck u b use e ca th f s o nt er bucket spots in fro heeled load W . -a b e ca in e h th of the mac monitor in ea in front ar e ew n th s it in n said blind spots fety. Doosa terms of sa in rn f the loader ce o n t n co ages in fro im s rd co ed cameras system re m front-load o tt o b d b an with top es on the ca bined imag m co s w o ed and sh sing a curv real time u monitor in . d o meth projection

NEW EMEA GM AT DPP The Portable Power business of Doosan Bobcat has announced the appointment of Jan Moravec as general manager,

The Abu Dhabi Waste Management

Portable Power, for

Centre (Tadweer) recycled 1,915,724

the EMEA (Europe,

tons of construction and demolition

the Middle East

(C&D) waste in Abu Dhabi in 2020,

and Africa) region.

accounting for 80% of the total

Doosan Portable

C&D waste it handled in the year.

Power said that

Tadweer said the total tonnage

the move is in

of recycled waste is equivalent to

line with “a new

255 domes of the Louvre Museum

global leadership

in Abu Dhabi. The emirate of Abu

structure to

Dhabi also accounted for 2,400,000t

provide the

or 32% of the C&D waste that

company with

Tadweer handled in 2020.

increased

Tadweer added that in order to

efficiencies in

reduce waste resulting from C&D

terms of global

activities across the emirate, it is

operational

implementing various programmes

footprint, global

to enhance its recycling capabilities

product platforms

in accordance with the highest local

and other key

and international standards. This aligns

initiatives”.

with the Abu Dhabi Executive Council’s decision that mandates the use of at least 40% of recycled materials in road and construction projects across the emirate’s three regions. The facilities can produce treated sand and four sizes of recycled aggregate, 0mm to 37.5mm.


9

Atlas Copco gensets for Saudi factory

Atlas Copco has supplied four TwinPowerTM generators for uninterrupted power supply purposes to Saudi Arabia’s Jasmine Water and Beverages Factory Ltd. Co. (JWB) through GCC Olayan, Atlas Copco’s partner in the Saudi market. Atlas Copco said JWB’s plant is in a remote location

in the desert 120km west of Riyadh city, without access to a stable power grid, and was facing frequent power failures, making continuous production difficult. JWB turned to Atlas Copco Power and Flow’s official distributor in Saudi Arabia, GCC Olayan, for

a solution to give them uninterrupted power supply for 24/7 operations with a reliable generator. GCC Olayan recommended four TwinPowerTM generators, which are containerised portable generators that deliver “versatility, fuel economy and twice the

CLIMATE

TECH IMPROVES EFFICIENCY

ZAHID TRACTOR USES INFOR ERP FOR MACHINERY AND VEHICLE OPERATIONS

CERTIFICATION FOR WOLFFKRAN Wolffkran has

amount of on-site power than conventional Independent Power Plants (IPPS)”. According Atlas Copco, the TwinPowerTM is a 20ft, ISO containerised unit housing two compact 500kVA generators powered by compact Scania engines. “This configuration, with an advanced control system, allows the two generators to work independently or in parallel with each other. This makes it ideally suited for applications that have variable power needs, whether due to the time of day or the current usage requirement.” As JWB needed 4,000 kVA to work in synchronisation, Atlas Copco modified the units’ totalisation and distribution panel and fuel systems.

AL MASAOOD, NIDEC LEROYSOMER JOIN FOR SERVICE Al Masaood Power Division has joined forces with alternator heavyweight Nidec Leroy-Somer (NLS) for a one-stop service workshop in the GCC for aftersales support to alternators from the NLS and Kato Engineering brands. The deal expands on their existing partnerships.

Tenderd, EMA agree for joint fleet services

achieved an Saudi Arabia’s Zahid Tractor

all departments, said Infor,

important green

has announced that it has

a global business cloud

credential,

integrated Infor enterprise

software specialist.

becoming

resource planning (ERP)

“The integration of Infor

among the first

systems into its operations for

M3 for Equipment allows

to be certified

construction machinery and

Zahid Tractor to continue

in Germany as a

commercial vehicles supply

to distinguish its customer-

climate-neutral

across the kingdom.

centric offering and

company. The

commitment to excellence

certification was

Zahid Group, is the authorised

across Saudi Arabia’s

conducted by

Saudi distributor for

construction, transportation

Fokus Zukunft

Caterpillar in its Construction

and rental sectors,” said Infor.

GmbH & Co. KG,

Zahid Trctor, part of the

Machinery division, under a

Zahid Tractor originally

an independent

partnership that has been in

depended on a bespoke

sustainability

place for 71 years. It is also the

homegrown ERP solution.

consultancy,

authorised distributor for the

“As the company continued

which evaluated

Volvo Trucks Group under its

to grow, this solution was no

the CO2 emissions

Commercial Vehicles division,

longer feasible.”

at Wolffkran’s

representing brands such as

Infor M3 said it met all the

Volvo Trucks, Renault Trucks

requirements stemming from

and UD Trucks in a 41-year

interface-driven initiatives

partnership so far.

Zahid Tractor has with its

The move to integrate Infor

OEM partners, which help

M3 systems has been done

increase supply chain visibility

with a view to streamline

and improve service levels for

and gain visibility across

their customers.

two German production sites.

Online equipment rental marketplace Tenderd and EMA Lubricants Company (ExxonMobil JV) have announced an agreement to offer maintenance services to equipment fleet owners in order for them to prevent breakdowns, increase fleet productivity and reduce project costs and delays. According to Tenderd, the “breakdown of one single piece of machinery on-site means loss of operation, project delays and extra costs”. Since equipment and on-site work is interdependent, one single breakdown can bring the job site to a standstill. Other equipment and resources

continue to absorb costs while idling by and waiting for the breakdown to be resolved. The single most important issue that causes equipment breakdown is the lack of proper maintenance. The collaboration between EMALU and Tenderd aims to address this problem. Arjun Mohan, founder, Tenderd, said: “It’s very exciting to see our company collaborate with a global player in offering a large scope of different lubrication solutions to fit each client’s needs. With this association, our customers can now enjoy the benefits of using Mobil’s technology and services to protect their equipment and maximise fleet productivity.”


10

KIT SPOTTING APRIL 2016 2021

TADANO ATCS BUILD TESLA’S GERMAN MEGAFACTORY

T

esla is in the process of building its latest Gigafactory near Berlin. And it’s not just the capabilities of the finished factory that are set to be “giga”, as the construction project itself is turning out to be a remarkable undertaking, too. This is where Hellmich Kranservice GmbH is proving to be a vital contributor to the construction and installation of the factory with the help of its four Tadano all-terrain cranes. The Gigafactory BerlinBrandenburg is set to be the most advanced series production facility for electric vehicles in the world, according to Tesla. The Model Y and other subsequent models from the Elon Musk-founded company will be made here. The facility is being built in record time: Construction only began at the start of 2020 and is set to be completed as early as this summer. The

topping-out ceremony for Hall 1 of the factory was celebrated in November. Even the dimensions of the factory are “giga”, with Tesla currently expecting the total area of the industrial site to be over 3m square metres, making it larger than the factory premises of the main Mercedes-Benz plant in Stuttgart. To bring a construction project of this size to fruition in such a short time requires perfect planning and execution. Any delay would have a negative impact on subsequent processes in the chain – something the general contractor for the construction, Goldbeck International Beton und Stahl, is well aware of. This is why the company relies exclusively on partners renowned for their reliability and speed, such as Hellmich Kranservice GmbH from Riedstadt-Erfelden. Hellmich relies on trustworthy crane technology, boasting as many as four Tadano all-terrain cranes in active

use across Grünheide. The two 44m boom-version Tadano ATF 70G-4s and two ATF 110G-5s are now working on getting the Gigafactory ready, with tasks including erecting fire walls and concrete columns as well as lifting steel trusses and panels for the roof. The Gigafactory is being constructed based on the “Lego principle”, explains Carsten Molitor from the Hellmich planning department: “There are four halls in total, each 300m long and 200m wide. to be combined into one large complex at the end.” For Hellmich Kranservice, this means endless lifting of prefabricated parts of various weights and dimensions. The concrete columns that form the basic structure weigh 15-30t, depending on the design. As for the fire walls, these weigh 10t, while the steel trusses and roof panels are around 3t each. The steel girders alone have a total weight of around 5,000t, so it’s an

extreme load for the technology and crane drivers to handle. Molitor says: “When it comes to concrete and steel construction, we prefer to use Tadano cranes. They really are unbeatable in this area on account of the lifting capacities they offer in their respective classes. We also appreciate the flexibility of the machines from Lauf an der Pegnitz. Given the large number of machines on site, space is at a premium. This is when the compactness of the 70 and 110 really pays off. The ATF 70G-4 is only 2.66m wide and less than 12.5m long, while the five-axles are a narrow 2.75m wide and well under 15m long. On projects like this, the 110 also ranks highly with its asymmetrical outrigger base, which allows it to achieve optimal lifting capacities with outriggers extended to different distances. This is another advantage of Tadano cranes on the busy Tesla construction site.


11

“The cranes are in almost continuous operation for weeks and months on end. This means the machines have to give everything they’ve got, but we know we can rely on our Tadano cranes”


12

KIT SPOTTING APRIL 2016 2021

POTAIN TRIO IN MILAN RENEWAL PROJECT

C

ontractor and developer Cooperativa Braccianti e Muratori di Carpi (C.M.B.) has deployed two Potain MD 208 A tower cranes and a Potain topless MDT 219 for the Symbiosis project in the Ripamonti district of Milan, Italy. The Symbiosis project, led by Covivio, aims to transform a decaying industrial area in the south of the city into a new destination for the service sector, close to the prestigious Fondazione Prada and Bocconi University. The plan is to regenerate the area into a high-tech and environmentally sustainable business district with 125,000sqm of new office space across 10 buildings around a green landscaped square with pedestrian paths, trees and ponds, creating a relaxed atmosphere for workers and citizens. It is hoped the project will serve as a model for sustainable urban planning, using the latest technologies to limit building emissions and promote the use of shared electric transport. The construction of the “D” building began at the site in Ripamonti in February last year but was soon interrupted due to the Covid-19 pandemic. The first two Potain cranes were installed when construction activities resumed in May and C.M.B. decided to install a third crane a few weeks later to speed up progress. The project is scheduled for completion in October.

C.M.B., a Potain customer since the early 1970s, chose the MDT 219 and two MD 208 A for their quality, reliability and productivity. Ivan Catini, responsible for central services at C.M.B, says: “These are high performance cranes which ensure optimal productivity on site and they maintain their value, which makes them easy to relocate on the market. “ The Potain MD 208 A is a popular model for urban job sites thanks to its 10t capacity, 62.5m maximum operating radius, multiple base and hoisting winch options and Ultra View cab, which provides good visibility from its 9m2 glass surface, as well as a comfortable operator environment with joystick-operable commands. The Potain MDT 219 is also a 10t capacity crane and features the CCS (Crane Control System), which offers high comfort, flexibility and ergonomic control. The MDT CSS topless concept enables complex multi-crane installation with shortened phases of assembly, erection, transport and even maintenance. Crane configuration settings are made via the CCS display directly from the cab in only 15 minutes. Without CCS, it would take three hours. “Operator feedback confirms the efficiency of the CCS system, which limits dynamic effects, automatically adjusts speed and acceleration, optimises the load curve and enables operators to lift with total control,” said Marco Arena, jobsite director.


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“These are high performance cranes which ensure optimal productivity on the jobsite and they maintain their value which makes them easy to relocate on the market”


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HARD HITTERS COMMENT APRIL AUGUS 2021T 2019

EYE IN THE SKY

DRONE TECHNOLOGY HAS IMPROVED IN LEAPS AND BOUNDS RECENTLY IN THE CONSTRUCTION SECTOR, WITH THE MACHINE NOW AN INVALUABLE PIECE OF EQUIPMENT TO COLLECT REAL TIME DATA ABOUT PROJECTS TO HELP MANAGERS UNDERSTAND WHAT IS HAPPENING ON SITE, SAYS LUIS CLEMENTE, NEW TECHNOLOGIES MANAGER AT ACCIONA MIDDLE EAST

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rone technology, also known as unmanned aerial vehicles (UAVs), is used for various reasons in the construction industry. As a tool that improves communication and safety, the use of drones in construction can offer many advantages, capturing real-time images from the field. In the last few years, drones have helped make several improvements in construction, from increased accuracy in reporting and improving safety conditions to cutting costs and increasing efficiency. While drones are not used in the actual labour phase of construction, they play a huge role in the planning and analysis process because they can provide an aerial view of a job-site at a cost that is comparatively small in the project outlay. We are

currently using drone technology for various activities in the construction sector, such as photogrammetric flights and photographic reports, both for drafting new bids and works in progress; as well as for volume calculations, structural inspections, monitoring work progress, assessing the environmental impacts associated with a project’s construction, or taking soundings on mountainsides. The use of this technology, which has already been implemented on various company projects in several countries, such as Spain, as part of Acciona’s commitment to innovation and the digital transformation, aims to leverage the benefits of mass data capture to digitise and optimise existing construction processes. The countries where Acciona has already implemented the use of jobsite drones also include Canada, New Zealand, Norway, Denmark and Panama. We love to be one step ahead and have used drones during the tunnel construction phase to

obtain digital models. This technology, which can be used on tunnel projects excavated by conventional methods (explosives, hammers or cutters) as well as on underground mining projects, can be supplemented with photographic resources to regularly monitor a project. In use currently is tripod-based laser scanner systems, supplemented with conventional topography, to obtain digital models of the inside of tunnels under construction. Unfortunately, these methods are time-consuming and not very versatile, which is not very compatible with the production performance of these works, reducing their effectiveness. However, by using drones in tunnels, a regular digital record of the works can be created to analyse any variations against the project’s specifications, such as the volume of material excavated, the consumption of inputs, execution deadlines, incidents, etc.


15 The use of drones to create digital models of tunnels is an alternative solution to conventional systems and responds to the needs of the business. The versatility and efficiency of this technology has made drones an extremely useful tool that can be replicated across all Acciona’s tunnel projects. In addition, Acciona’s Construction Technology Centre, located in Spain, is researching other benefits that this technology can provide in digitisation processes in construction. It is therefore taking part in the Comp4Drones project, a European R&D initiative that aims to provide a useful technological framework for the infrastructure sector, which seeks to develop software and hardware for unmanned aerial vehicles (UAV). The aim is to ensure that the drones are capable of making safe and autonomous decisions, sending reliable information, minimising the design and verification requirements for complex drone applications, as well as ensuring the sustainability and creation of an industry-supported community.

Our role on the project is to study the use of drones in the construction sector, with the aim to improve digitalisation in the project execution process and carry out all the data processing without interfering in tasks done in the workplace. Unmanned inspections seem to be the best alternative to costly and time-consuming traditional methods for inspecting infrastructures, without compromising on the quality of the information. In addition to the business applications, we continue to explore the latest technologies from the Digital Innovation Hub of the Innovation Department. Technologies such as long-distance military drones, underwater drones, efficient point cloud processing software, automatic extraction and modeling - all of these are tested to capture and process data, and generate content that can be used in business applications. Therefore, Acciona is constantly developing innovative applications based on drone technology in order to collect real time data about major

transport projects, which will help their managers to understand what is happening on site. The aerial information will enable to monitor progress and help to detect incidents earlier, before they become costly or slow down the project execution. With the development of technology and the price reduction of these devices, drones are showing great effectiveness in terms of possibility and accuracy: activities that otherwise would be impossible, such as entering through the interior of very deep cavities as we have seen or the ability of these machines to remain motionless in space. In fact, modern drones offer a wide range of possibilities in the construction field. Their versatility, ease of use, economy and precision make them a clearly advantageous option over traditional procedures. With technology improving for drones every year, they look set to help the construction industry even more over the coming years and are already a reality in the daily life of our construction projects in the Middle East region.

“Their versatility, ease of use, economy and precision make them a clearly advantageous option over traditional procedures”


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HARD HITTERS APRIL TECHNOLOGY AUGUS2021 T 2019

LIFTING IN 3D

MAMMOET IS TRANSFORMING THE PLANNING AND EXECUTION OF ENGINEERED HEAVY LIFTING USING DIGITAL TECHNOLOGIES AND MODELLING, MAKING THE PREVIOUSLY CUMBERSOME PLANNING OF A HEAVY LIFT PROJECT SIMPLER AND LIFTS SAFER

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he role of engineered heavy lifting has always been to support the incredible feats of others by offering guidance on the possible and impossible. By establishing early on how loads can be lifted, transported or even divided, decisions can be made that pay out many times over throughout the life of a project. The modern engineer has many tools at their disposal. LIDAR route surveys can establish whether roads have the necessary clearance, during the course of a single drive. Digital mapping integration can establish the shortest overall transport route. On site, load cells will calculate a module’s centre of gravity to minute accuracy - clarifying what is stable and what is not. But things haven’t always been this good. Forty years ago, lift preparations were a painstaking manual process, undertaken using the humble pencil by rows of engineers at drawing boards. Projects

would be mapped out in meticulous detail; each image bespoke, uncontrolled and resource-hungry. Leon van Tiel, director of engineering, Mammoet Europe, explains: “In the 1990s, Mammoet was the first heavy lifting company to develop and use a digital tool to accurately source and draw the most suitable crane in 2D project plans. At the time this was ground-breaking in how all information about crane equipment and performance was stored within the program – allowing quick, accurate plans to be formed at the click of a button, rather than referring to multiple pages of load charts and calculations.” During the last decade, digitalisation has seen many industries using enhanced information modelling to give stakeholders better insights during the design and implementation of projects. In the construction sector, use of digital technologies has allowed for planning to circumvent unstable ground or discoveries of historic or hazardous materials; to better connect projects and teams; and to improve the volume and quality of data being collected.

So, Mammoet explored how the latest 3D technology could help in communicating project plans and align more closely with our customers’ digitalisation work. There are multiple benefits to a 3D approach over the conventional 2D format. Complex projects can be communicated in a much clearer format, avoiding potential misinterpretation and increasing understanding about why a specific method has been selected. Customers can interact directly with the 3D model to explore how different elements would work from multiple viewpoints and timestamps, prompting discussions that can be supported by these clear visualisations. Potential issues can be identified via a virtual tour of the site - and a plan to manage them developed earlier in the process than may otherwise have been possible. Although the potential for 3D project visualisations has been recognised for some time, technology has been a barrier to its introduction. The processing power required to visualise complex heavy lifting and transportation work to a high standard, in real


17 Move3D is a 3D engineering platform combining intelligence, such as crane charts, with Mammoet equipment and client data. The company is rolling it out across its global operations.

time – beyond conventional CAD applications - has not been widely available until recent years. However, in 2018, Mammoet identified that the right technology was now available to make regular 3D project visualisations a reality. A team was formed to develop this exciting possibility and explore how it could be harnessed to help meet and exceed customer requirements. This project became known as Move3D and was led by van Tiel. “Move3D is a 3D engineering platform that combines business intelligence, such as crane charts, with Mammoet equipment and client data. It is independent from crane manufacturers and has been developed with the end-user in mind,” he says. The Move3D system complements customers’ own digital systems and methods. Information including LIDAR scans and point clouds, or thirdparty data such as satellite maps, can be easily incorporated into visualisations for accuracy and consistency with wider project planning. Data from the Move3D system can be exported for use within, for example, Building Information

Modeling (BIM) tools, and can be communicated in a variety of forms. “Offering this practical method to give our customers 3D visualizations of projects is an important way to present and discuss our plans in the simplest, clearest format possible. At the flick of a switch we can show them the details and complexities of our work - from any angle and at any point in the project,” says van Tiel. “Not only does this mean that clients are able to get a more developed picture of how the work will happen, crucially it also gives us the opportunity to identify and discuss any pinch points – quickly addressing anything that might not be clear or may require changing.” The Move3D system has already been used across a number of projects, including for BASF in Germany, with considerable success. Dirk Balzer, BASF project manager, says: “The 3D animation was a useful tool to precisely observe the restricted space conditions impacting on a heat exchanger replacement. Perhaps most impressive of all was that

the live execution of the job matched the animation 100%. We quickly recognized the advantages that Move3D could offer and were very impressed with how easy it made explaining the planned activities to all of our decision makers in BASF.” The system is now being rolled out across Mammoet’s global operations, but the current version is not likely to be the last. With clients adopting more sophisticated digital technology, Move3D will adapt to continue to offer the best possible visualisation of a project as new techniques become available. “An exciting aspect of the system is the ability to offer visualisations in VR. This means that a client can ‘walk’ around the project and see for themselves how we will perform a move. There is even the possibility to put yourself in the cab of the crane to simulate the specific actions involved,” says van Tiel. “We know this ability to view planned work in such detail will also have health and safety benefits – allowing potential issues to be identified and dealt with sooner in the process.”


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PROJECT REPORT APRIL 2021

Dubai’s iconic Museum of the Futre was built using Wolff tower cranes from Wolffkran Arabia, with the project requiring the units to rise high while remaining free-standing.

“The design of the building was such that it would require very high free-standing tower cranes, as there was no scope to tie the cranes to the building because the structure was too weak...So, they came to us because Wolffkran’s cranes are well-known for achieving high, free-standing heights”


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FUTURE PERFECT

DUBAI’S ICONIC MUSEUM OF THE FUTURE IS AN ARCHITECTURAL LANDMARK AND A BUILDING FOR THE AGES. IN THE FIRST PART OF CMME’S REPORT ON THE CONSTRUCTION MACHINERY INVOLVED IN THE BUILD, WE TAKE A LOOK AT TOWER CRANES FROM WOLFFKRAN THAT MADE THE PROJECT POSSIBLE

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f you drive down the main highway and artery of Dubai, Sheikh Zayed Road, you will instantly be greeted by an architectural marvel - The Museum of The Future. Starting in 2017 Wolffkran Arabia implemented a lifting plan for this project, involving three tower cranes which were erected and then changed to meet the construction needs. The cranes were put up in three phases. Additionally, as a crane solution provider, Wolffkran also provided the base design and procedures to erect and dismantle the cranes safely. They facilitated this process with the SMIE anti-collision system and in-house trained crane operators. The first phase of crane operations started in April 2017 when Wolffkran Arabia erected three main tower cranes in three days. They started off with an arrangement of three saddle jib cranes – Wolffkran 6531.12 models with maximum load capacity of 12t – operating for the first six months. For identification purposes, the cranes were called TC1, TC2 and TC3. The TC1 and TC2 cranes were installed on 2.5m square bases, and the TC3 was installed on a 2.9m square base. Since Wolff crane bases can be exchanged between all its crane models, installing these bases at the start of the project permitted for the jacking of the cranes as well as exchanging the cranes for different units on the same base as construction progressed. The second phase of the crane operations began


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PROJECT REPORT APRIL 2021

in October 2017 when the three saddle jib cranes were switched for two 28t 355B luffing jib cranes which was the new TC1 and TC2 and one 20t 8033.20 saddle jib crane which was the new TC3. At the start of phase 2, the cranes elevated 11–12t panels but, as construction progressed, they were jacked up to lift up to 20t steel parts. The cranes were operated for about 20 hours daily, lifting between 9–15t of steel parts every hour. Phase 2 was the longest stage where the majority of the construction was done. For the third and last phase, the height under hook of the cranes was increased to 67.5m for TC1 and TC2 and 87.7m TC3 with the jib of TC3 being extended from 45m to 50m to facilitate lifting material of up to 4t. The Museum of the Future project required free standing cranes because of the design of the building and its proximity to the Dubai Metro Red line, where the critical zone is 5m. Explaining the project requirements and Wolffkran Arabia’s role in greater detail, the company’s operations director, Jeffrey Watson, says: “The builders came with the blueprint of a project that had never been done before and there were, of course, challenges for the cranes involved. The design of the building was such that it would require very high freestanding tower cranes as there was no scope to tie the cranes to the building because the structure was too weak during construction for any tower crane to be anchored to it. So, they came to us because Wolffkran’s cranes are well-known for achieving high, free-standing heights. Another reason was the quick erection process of our cranes.

The number of Wolff tower cranes on the site at any given time of the build numbered three, with two luffing jib models and one flat-top making up the final trio that saw it to completion.

“There were also other limitations for us, as the project is located right next to the Dubai Metro’s viaduct for the Red Line. This imposed restrictions on free standing cranes as we had an exclusion zone of 5m from the edge of the Metro structure, so the crane radius had to be outside of that. Also, as the building climbed upwards the crane had to climb with it, which required models with very fast climbing processes.” Watson adds that the builder initially had a one-crane plan for the project, using a very

large tower crane model. The actual building itself is based on a concrete structure as the foundation on which the steel works would later be built. The first eight months of the build was only this concrete structure. “In order to save money for the project owners, we suggested using smaller tower cranes during this process of the project when the concrete base was being built. And even when we were planning the erection of the cranes, we had to think about the dismantling process as well in advance, factoring in things like the space required for the mobile cranes doing the dismantling and their clearances from the Metro.” Wolffkran Arabia erected the smaller saddlejob cranes in the beginning, which used less power than the larger cranes that were needed later on for the steel works. However, the foundations for the cranes were made to suit the larger cranes, though these same larger crane foundations were used for the smaller cranes first - which hints at considerable foresight in the planning. “Once the building’s concrete structure was finished, we swapped the cranes used for that with the larger cranes needed for the rest of the build This process had to be quick to prevent delays in the project and it took us just a weekend for each crane.” Watson adds that to select the specific crane models it supplied, Wolffkran Arabia looked at the precise lifting requirements of the project. “The lifting capacities needed were not much initially - about 3-4t of steel - however, the height the cranes had to reach was quite tall. So, for the final build, we went with two luffingjib models on either side of the structure and a large saddle-jib model in the middle of 20t capacity. Importantly, these had to be freestanding and the middle one, especially, had to rise to a height of 87.7m,” he explains. “The vital requirement of the project was not so much lifting capacity as the positioning and height of the cranes and keeping the costs down, as well as adhering to safety requirements and regulations, such as the Metro exclusion zone.” Wolffkran Arabia also used the SMIE crane control system, compatible with all the cranes in the project and a system they’ve been using for a long time as the best fit to work with. “In this project it was used not just for anticollision but especially as a zoning system in order to prevent the crane jibs from swinging over the Metro and the road in front of the Emirates Towers, which is just behind the site. We zoned out the road and the Metro exclusion zone so that it was impossible for the crane operator to go over the boundaries of the project into these areas, thus avoiding the hazards all around,” Watson says.



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HARD HITTER APRIL 2021

KING OF SPIDERS

SPIDER PLUS INTRODUCES THE BIGGEST MINI SPIDER CRANE IN THE WORLD TO THE REGION – THE UNIC 1006 – WHICH MARRIES A WHOPPING 10T IN MAXIMUM LIFTING CAPACITY WITH COMPACT GO-ANYWHERE DIMENSIONS TO MAKE HEAVY LIFTS POSSIBLE IN DIFFICULT-TO-ACCESS AREAS

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he king of spider cranes has arrived in the region. In December 2020, Dubai-based crane and specialised equipment rental major, Spider Plus, brought in the UNIC URW 1006 spider crane, the biggest of its kind built so far, to join its fleet. The model is deceptively small to look ta when folded and stored, but once it spreads out its jointed outriggers and raises its boom, the arachnoid pose it strikes makes it look every bit a giant spider waiting to pounce on a load as if it’s prey and give it a powerful hoist. “This is the first and the biggest mini spider crane not only in the UAE, but also in the region. It is also the biggest one of its kind ever manufactured,” says Eddie Nobrega, regional sales manager at Spider Plus, as he describes the unit. “Among the most important points about the 1006 is that it only weighs 14t but has a lift capacity of 10t.This is a special ability. Cranes with similar capacities in the market usually have much bigger footprints. The beauty of this crane is that at a certain radius and a certain boom length it also works like a pick-and-carry crane. So, while it’s holding

the load up, it can actually crawl with it. This is a huge benefit for the users of this crane.” The UNIC URW 1006 can crawl forward with the outriggers both in and out. If the outriggers are in while crawling then its maximum capacity to pick and carry is only around 700kg up to a radius of 2.5m. Crawling with extended outriggers, however, it can carry around 1.5t at the same radius, or around double the weight compared to when they are in. The outriggers remain just above the ground and act as balancers and stabilisers while the crane crawls on its rubber tracks with the load. This makes it dual-purpose or a multipurpose crane. Aiding that ability for multipurpose application is its compact, go-anywhere dimensions, and Nobrega describes: “This mini spider crane can squeeze through some really tight gaps and access areas where few other cranes can go. Again, within the UNIC brand of cranes there are very versatile models, which in effect fit through most places. Although this is a big capacity crane and not a small one by any means, it’s not a big, bulky crane and you wouldn’t guess its lifting capabilities by looking at its size when it is folded and moving on a job-site. “We got this in into the UAE around December, and among the first jobs it worked on was at a new crate washing plant site being


23 The new UNIC 1006 mini spider crane from Spider Plus is seen here in one of its first jobs in the UAE, lifting and placing two massive steel tanks in the confines of a crate washing factory in JAFZA.

“This is the first and the biggest mini spider crane not only in the UAE, but also in the region. It is also the biggest one of its kind ever manufactured. Among the most important points about the 1006 is that it only weighs 14t but has a lift capacity of 10t”


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HARD HITTER APRIL 2021

set up in a warehouse in Dubai’s Jebel Ali.” The beauty of this crane is that whereas contractors, engineers and project owners are very scared about cranes going over built-up concrete slabs on a structure, this is a machine that lays such fears to rest. This is a 14t crane that worked on a slab with a basement underneath it to lower heat exchanger units for EmPower at the new DMCC tower job-site. “Of course, we had to do some propping and spreading the load on the slab over the beams, but it was completely and easily achievable. And this is something that spider cranes like this one are capable of doing - going inside buildings and on built-up slabs and executing lifting jobs in narrow semi-finished spaces.” The job he refers to is for GLS International, which involves lifting and positioning two enormous cylindrical steel tanks, each with a capacity of 22,000 litres, as part of a filtration unit for a crate washing plant. With CMME in attendance on the day of the lift, Nobrega takes us through the particulars of the job: “The objects we are lifting here today are two 22,000-litre steel tanks for liquids imported from The

SPECIFICATIONS

UNIC URW 1006 MINI SPIDER CRANE Working on a warehouse floor accessible through a 4m-wide doorway and under the constraint of a 10m high ceiling, the UNIC 1006 made light work of raising the 6.2m long 1.8t steel tank.

“We needed a crane with adequate capacity and lift height that was able to come and position itself indoors for the lift”

Total unit weight: 14t Max lifting capacity: 10t Max working radius: 21.9m (24.3m with fly jib) Max lifting height: 22.8m (30.7m with second stage fly jib) Engine and output: Yanmar diesel, 29.8kW

Netherlands, each weighing approximately 1.8t. In terms of dimensions, each tank is a cylinder that is about 6.2m in height and 2.4m across. They came in containers, flat on their side, and that’s obviously why we need the crane to get them upright and also to have them positioned at just the right spot in the warehouse so that GLS International can connect them to their washing plant.” With this being an indoor lift, in a confined environment, several other considerations of the surroundings needed to be taken onboard, such as the space available for the cranes to lift. Explaining this, Nobrega elaborates: “The first thing we did was to measure the height of the warehouse ceiling, which we found to be 10m. We were a bit worried as the original plans said the tanks were 8m in height, which would have only given us a 2m clearance for the crane’s boom to operate, and that would not have been enough. But then GLS confirmed the figure at 6.2m, which gave us a comfortable 4m clearance between the ceiling and the top of the tanks for the crane’s boom and hook to operate.” That confirmation was given by Gerrit Mostert, operations manager, GLS


25 International, who says selecting Spider Plus for the lift was a no-brainer given that the company had the specific crane in its fleet that was needed for the job. “We needed a crane with adequate capacity and lift height that was able to come and position itself indoors for the lift, so you need something that can go through standard warehouse cargo docking doors. Since the lift is happening indoors in a building with a roof on top, you can’t use a construction crane or any other type of crane from outside,” says Mostert. “This building also does not have a ramp wide enough for most vehicles to drive up; the biggest ramp we have here is only 2m wide. So the advantage with Spider Plus was that they had this spider crane that they were able to deliver on a flatbed truck, which aligned with our loading dock and then they were able to drive the crane while it was in a folded condition directly through the loading doors onto the floor, position it at the right spot and start setting up straight away. There weren’t any hassles in trying to get the crane inside and position it. I’ve seen places where they’ve had to break through a wall to get a crane inside or lift the roof. That would have been impossible to do here, from the perspective of the project execution speed we needed as well as from the financial, logistics and all other points of view. “In the lead-up to the lift, the Spider Plus team visited this venue a few times and made sure that all heights, clearances and tolerances were measured and mapped out, based on which the crane choice was finalised and the lift planned. Today they arrived here at 8am. It’s 9am now and the first tank has already been lifted and positioned on its spot. By 10am I expect they will have completed the other lift and the crane would be back on the trailer that brought it here and on its way. So, the service from Spider Plus has also been exceptional.” Analysing the lift after the job’s completion, Nobrega tells CMME: “In the preparation stages of the lift, we ascertained which crane to select for the job based on all necessary information - such as the dimensions of the load, the sort of lift that needed to take place - in this case a top-and-tail lift – and the size of the doorway through which the crane would need to fit to access the lift spot. We measured the roof height accurately to make sure we had the clearance and didn’t hit it. We also took a close look at the units which had been delivered, noting the lifting eyes, and finalised the rigging, making sure we had the right shackles, hooks and all other lifting gear. And then we were ready to bring in the crane and execute the job.

The UNIC 1006 not only has a maximum stationary lift capacity of 10t, but can also pick and carry 700kg with its outriggers in and 1.5t with them extended, both at a 2.5m radius.

“On the day of the lift, we drove the crane through the warehouse’s 4m-wide by 5m-high doorway, which was more than wide-enough for the crane to travel through when folded as it is only 2.5m in width and around 3m high. The crane was driven on its tracks right up to the lift spot where the tanks lay on their side and then after all the riggings were hooked up, the lifting process saw the boom head being extended to 9.5m and under it our slings were about 1.5m long. With the actual load being 6.2m tall, the boom around 0.5m of

space to manoeuvre, which was enough. This tight, challenging and precision lifting job in a confined space was made possible because of the unique features of the UNIC URW 1006 spider crane, with which we lifted the huge tanks up and positioned them on the proverbial spot marked by the ‘X’.” However, Spider Plus is more than just a provider of spider cranes. Describing its operations, Nobrega adds: “At Spider Plus, we operate throughout the GCC and provide complete back up and support to users of this crane, as well as our other spider cranes from the UNIC brand. We do this for both our rental customers and for those that buy these cranes from us. So, the servicing is done by us and we look after all after-sales aspects, such as fulfilling warranties. “We also provide the operators for our rental customers and we conduct operator training at no extra cost for those who buy these cranes from us, as well as train the operators of our rental customers who want to use their own operators. Of course, all operators, including our own, are trained to a very high standard where safety and efficiency are concerned. “We are a unique company in the segments that we operate in, given our operational knowledge, our back-up and the auxiliaries that go with the products that we offer. With the inclusion of the URW 1006 into our fleet, our range of cranes spans from 10t to less than a ton in lift capacities.” And, of course, ruling the web is the new king of spiders – Spider Plus’ UNIC URW 1006 mini spider crane.


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COVER STORY APRIL 2021

“From Auger Torque drilling attachments and Kinshofer buckets and tilt rotors to sleeper laying attachment and tampers from RF in the railways segment, and from Demarec hydraulic crushers to Hammer hydraulic breakers – the expert companies that comprise our group together offer customer a one-stop-shop solution”

Auger Torque has one of the widest ranges of attachments in the industry for the construction, mining, quarrying and infrastructure segments, all ready for use with small to large excavators.


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AUGERING WELL

WITH TOOLS FOR A VARIETY OF JOBS IN THE CONSTRUCTION, DRILLING, PIPE-LAYING, MINING AND QUARRYING SEGMENTS, AUGER TORQUE, WITH ITS GROUP COMPANIES SUCH AS KINSHOFER, NOW ALSO HAS THE ON-THE-GROUND BACK-UP IN THE REGION TO MAKE IT A ONE-STOP SHOP FOR ALL ATTACHMENT NEEDS

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typical construction equipment fleet includes the mandatory group of excavators of various sizes, the backhoe loaders, the large loaders and the smaller compact and skid-steer loaders. But equipped with just the usual bucket, the range of tasks these machines can do is extremely restricted. This is where attachments come into play – implements such as hammers, drills, augers, trenchers, cutters and such others – enabling the machines to do the complex jobs they are required for. When it comes to attachments, Auger Torque is a name that is respected and sought after worldwide, as well as in the Middle East. The specialist attachments manufacturer produces a comprehensive line of tools for the major earthmoving machines across all manufacturers and for use in a variety of segments, such as construction, infrastructure, mining and quarrying. Speaking exclusively to CMME, Rohan Saldanha, international business development manager at Auger Torque Europe Ltd., and responsible for the Middle East, says that among the key advantages customers can

derive from working with Auger Torque and Kinshofer, the group it is a part of, is the synergy of the group companies, providing them a wide array of quality specialist attachments to get a variety of jobs done quickly, easily and efficiently. “From Auger Torque drilling attachments and Kinshofer buckets and tilt rotors to sleeper laying attachment and tampers from RF in the railways segment, and from Demarec hydraulic crushers to Hammer hydraulic breakers – the expert companies that comprise our group together offer customers a one-stop-shop to access various solutions from a single group entity,” Saldanha says. In the Middle East, the company has made a mark with its attachment solutions for applications such as dewatering, predrilling for sheet piling, micro piling, deep trenching in hard rock, solar panel foundations and fencing, he adds. The company first started supplying to the region in 2010 but saw real growth in 2016 and 2017 with the introduction of local stock from Jebel Ali, a growing dealer network and Dubai-based staff. “The opportunities in the Middle East were always clear but it wasn’t until a solid infrastructure was put in place in 2016 with stock in Jebel Ali, a dedicated business development team locally and a growing dealer network, that these opportunities could be exploited. Today, we are closer


28

COVER STORY APRIL 2021

to customers, understand the challenges they face and provide suitable and workable solutions. Working closely with R&D, we develop new fit-for-purpose products or adapt existing ones to meet customer challenges,” Saldanha explains. “While we were selling products to customers before, it was in 2016 when we decided to establish an active presence and service customers across the Middle East. It was quickly understood that product availability was a key element that customers demanded and stock on the ground was swiftly deployed. In 2017, Auger Torque Middle East was launched and United Motors was signed up as the UAE dealer. “Also in 2017, Techno Qatar purchased both the 50000 MAX and XHT 250, our largest screw pile driver, for marine applications and were extremely happy. In 2018 Riham General Trading and Contracting expressed interest in marketing products and services in Kuwait and have been our representative there since then. “In 2020, Qatar Tractors Company in Doha effectively took on the dealership for Kinshofer/Auger Torque products and services in the country with eight units of our KDC 45 deployed for 1.2m-wide by 10m-deep trenches. Subsequently, they’ve ordered another two units for this year. Also in 2020, GB Equipment & Solutions requested dealership in the UAE and has started marketing our products and services. Our focus for 2021 is the deployment of the Hammer hydraulic breakers KFX line into the GCC and surrounding markets while also

Auger Torque has seen good success in the Middle East recently by putting stock on the ground in the region and building up a dealer network for product support to customers.

introducing Auger Torque’s latest earth drill launch - the 100,000 Max.” Elaborating on Auger Torque’s customercentric market philosophy, Saldanha adds that among the company’s key attributes is to be true to its core corporate values of being “Global, Nimble and Open”, through which it seeks to be transparent, honest and committed to providing customers with quality products and solutions. “In order to achieve this, in interactions with dealers or clients, we look at what they want to achieve, the parameters they

have to work with and what is the best cost-effective solution that we can provide within a reasonable time. Putting ourselves in the shoes of a customer gives a different perspective of the issues they face. “A prime example of this consultative approach was with Dubai-based Action Dewatering. The customer had an ABI drilling mast with a broken drilling head. They tried to source spare parts from Germany, but it was extremely cost prohibitive and with a long lead time. Due to time constraints and project commitments, the customer approached Auger Torque to see if we could assist. Our product specialist went to the site, evaluated the existing drill rig, conducted flow and pressure tests, discussed with our R&D team and then recommended the right product from among those we had ready in stock, thus solving the customer’s issue efficiently and quickly.” Coming to the Auger Torque family of products, Saldanha highlights certain categories that the company excels in and which are in demand: “We specialise in the manufactures and supply of various drilling heads that can be fitted on any carrier machine and powered by just the auxiliary hydraulic line without any need to modify the parent machine. Thus, any client can effectively use their carrier machine to drill/ auger or install screw pile/helical pile without the need of any specialised equipment. “Screw piles or helical piles are used by mining and quarrying customers for applications such as ground stabilisation or

BREAKERS AND CUTTERS

KINSHOFER EXPERTISE DELIVERS VALUE Kinshofer offers has two hydraulic breaker offerings – the KSB series and the KFX series. The KSB series covers carrier classes from 0.5-12t

and the KFX from 12-200t, which forms the main product focus for mining and quarrying. The KFX series has some key attributes which include completely sealed, dust-proof systems for the breakers that enable them to work in dusty environments or underwater. They also have automatic greasing for the chisels to remove one of the main factors that cause breakdowns and downtime. The KFX series also comes with hydraulic systems that prevent blank firing using a regenerative oil circuit that stops the hammering ram from hitting the piston when the breaker is not in

contact with a surface. The unique attribute of Kinshofer drum cutters is the reduction gear ratios used. “Most people assume the higher the power input, greater will be the output; this is far from the truth. Whatever the input, in any gear box it’s the reduction ratios of the gears that convert the RPM from the hydraulic motor into the torque that is needed to power the drums to chip and grind the surface,” explains Rohan Saldanha. “The more appropriate the reduction ratios, the greater the torque amplified. Thus, we can use lower motors and lighter drum cutters to generate

the same torque, if not more, than most of the competition. This, coupled with high-quality gears and German engineering, effectively makes the Kinshofer Schaeff cutters an attachment that delivers value.”


29 building of retaining walls. Utilising Auger Torque drill heads in conjunction with screw piles provides the effective level of torque required to drive helical piles into the ground. The advantage to customers is the speed at which a pile can be set into the ground and loaded. Further, if there is an error in the verticality of a screw pile it can be removed out and reset without any issue. Screw piles can also be installed with virtually no noise or vibrations emitted to surrounding structures.” Mining and quarrying are among the important sectors where Auger Torque products are used extensively. Saldanha adds that in this high-productivity driven segment, customers tend to look for products and services that have “high quality and exceptional performance level in adverse application conditions”. “We offer hydraulic breakers, drum cutters, flip screen screening buckets and earth drills and hard rock drills for common jobs within this segment. Drilling in a mining or quarrying operation happens on a regular basis mainly for two reasons: exploration to assess the various rock formation strata that will be encountered during the extraction process, and secondly to facilitate ore extraction. Alternatively, they are used for building or fastening structural elements that help process the extracted ore or for safety retaining walls in a quarry. “In either case, conventional systems involve using dedicated rigs which are expensive and have high mobilisation costs. There may also be space restrictions on site, preventing the use of conventional drilling rigs. In such cases, clients tend to utilise excavators with earth drills with rock augers mounted on them. Auger Torque’s hard rock augers are tapered and mounted with C23 pic teeth. The tapered head is mounted with a pilot bit and is hard faced. In addition, the tapered ends facilitate the fracture of the rock. The pitch of the flights is flatter, which enables more spoil to be carried onto the flights during the drilling process. A combination of the earth drill and the hard rock auger system makes the drilling process more efficient and less time-consuming.” Saldanha also informs that Schaeff cutters - drum or transverse cutters - are used extensively in tunnelling, mining and quarrying. Drum cutters use a hydraulic motor to power a gear box to rotate a horizontal shaft to which drums with teeth are fitted on either side. These drums chip and grind the surface. “For the mining segment they are used to profile the rock/mine face and unlike blasting or hydraulic breaking, the operator is in control of profiling the surrounding structure of the mine. They are also used

KEY PROJECTS

AUGER TORQUE IN THE GCC • Abu Dhabi: Khalifa B Project - Light pole foundation • Abu Dhabi: Khalifa port expansion - Micro piling, Casing installation • Dubai: Sustainable city solar project – Helical pile application with Earth drills • Kuwait: KNP Sulphur Cracker unit – Earth drills/300mm auger 18m depth • Oman: Muscat WWTP – Predrilling sheet piling • Oman: Ibri Highway Street light Drum cutters / Earth drills – Hard rock Augers • Saudi Arabia: Aramco Jazan refinery Onshore – Fencing work – Earth drills and 1.2mØ / 5m depth Auger system • Dewatering application: Various customers – Earth drill 150mm / 6m deep

in civil construction for trenches to lay industrial pipes, sewers or rain wastewater lines. In quarrying, some customers use them to chip the stone from the quarry rather than blasting large sections, breaking the rock into manageable pieces and then transporting them to crushers for aggregate. Kinshofer offers a wide array of KDC drum cutters: the KDC 04, 06 and 08 are for 2-8t mini excavators while the KDC 15, 20 and 30 are used with 9-30t excavators and the KDC 35, 45 and 60 extend that range all the way to 60t-plus excavators.”

Auger Torque’s attachments are used in civil construction for trenches to lay industrial pipes, sewers and water lines, as well as in quarrying to chip and break stones before crushing.

He adds that Auger Torque is expanding availability of its KDC drum cutter range in the Middle East, adding more stock on the ground. In earth drills, it is also bringing in its 100,000 Max and 150,000 Max models, and expanding the KFX hydraulic hammers range. “For users in the Middle East, a problem when purchasing products from international companies can be the availability of stock when required and lack of access to technical expertise and aftermarket services. Many GCC companies tend to look for products that will improve their productivity and enhance operational excellence but are afraid to invest because there is no one to advise them technically or they cannot access aftermarket services in case of breakdowns, or the servicing costs are too high. “At Auger Torque, what differentiates us is that our customers have access to a wide array of high-quality attachments from our entire group, comprising things such as tilt rotors, crushers, compactors and others. We provide stock on the ground so that customers get products whenever need arises. Our technical resources are available locally with access to qualified persons from the company. With us, customers also have access to our R&D resources for quick development of bespoke items for applications in the region, as well as a proactive supply chain that can react from anywhere in the world,” Saldanha signs off.


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Digitalisation, remote monitoring and diagnostics. Increasing uptime and productivity 19 – 20 April 2021, Online

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Technology in CM Summit

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In a world where the average smart phone now has more computing power than some super computers of just a few decades ago, the world of construction machinery has not been left behind either in this smart revolution. The Technology in Construction Machinery Summit looks at the transformative effects of IT on the equipment that builds our modern landscapes. From operator-less, autonomous machines, linked fleets and remote monitoring to productivity tracking, eliminating downtime with pre-emptive maintenance, training and improving job-site safety, experts will discuss the latest data-driven approaches to using equipment.

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31

R E W O P RAW E E D TO N U O Y G N I EVERY TH

KNOW

36

32_NEW RELEASES The latest releases from the world of construction machinery.

TOP 10: TR TYRES TIPS FOR O nd longest st work a Get the safe s our OTR tyre life out of y c steps. with 10 basi

38_SET FOR THE LONG HAUL Large dump truck makers focus on safety and savings, with diverse models sporting advanced features and technology aids to improve customers’ bottom lines.

44_HITACH ON PISTE Loaders and diggers prepare the slopes for Alpine ski championship.


32

NEW RELEASES APRIL 2021

CAT UPGRADES ELECTRIC MINING SHOVELS WHY GET IT? NEW FEATURES AND COMPONENT ENHANCEMENTS ON 7495 AND 7495 HF IMPROVE EFFICIENCY AND REDUCE COST OF MATERIAL MOVED PER TON Caterpillar has upgraded its 7495 and 7495 HF Electric Rope Shovels (ERS), with the 2021 models combining multiple new standard feature improvements to increase operating efficiency up to 10% reduce cost per ton of material moved by as much as 15%. Cat said the improvements had been brought about by component enhancements, increased frame durability and enhanced serviceability, all of which the company drew from more than a century of rope shovel innovation. Dan Wyatt, ERS product value stream manager at Cat, said: “Consistently, our customers tell us machine availability and productivity are primary contributors to their operation’s success. From the full adaptive control system for HydraCrowd™ to more innovative technology and data security, the advances made to the 2021 electric rope shovels reflect our commitment to meeting their needs. Many of these improvements are compatible with shovels in the field, so customers can realise these gains through upgrades to their existing fleets as well as new machine purchases.” According to Cat, a new propel gear case for the 7495 and 7495 HF models nearly doubles

the life of propel gear cases in some extreme operating conditions. Precise adjustments to gearing geometry and advancements in tooth hardening enhance gear case durability and productivity. The result is lower total cost of ownership as much as $8 per hour when the drive system is replaced at one scheduled time. Additionally, an ecology drain simplifies oil draining and enables kidney-loop flushing, which reduces abrasion-causing contaminants and oil change frequency. Updates to the 7495 AC electric drive system deliver greater reliability, improved maintenance access, enhanced safety, and expanded high-altitude and temperature capabilities. A liquid-cooled motion regulator cabinet efficiently dissipates heat generated by electrical components and enables operation at 50 degrees Celsius and altitudes as high as 5,250m without derating. A faster propel transfer switch cuts lag time by 75% to improve productivity, while common motors in multiple applications means fewer parts to stock, improved parts availability and simplified maintenance. SPECIFICATIONS

CAT 7495 & 7495 HF Electrical drive: IGBT Acutrol drive system Peak power: 3778kW Max dipper payload: 109t Dipper capacity: 30.6-62.7m3

ENERPAC’S NEW HMT SERIES TORQUE WRENCHES WHY GET IT? MODULAR PARTS ELIMINATE NEED FOR SEPARATE TOOLS FOR NEW DESIGN WHICH COMPANY CALLS THE “ONE WRENCH TO RULE THEM ALL” Enerpac has introduced its new HMT series modular torque wrenches, designed to be flexible, two-in-one tools that can be used with a low-profile hex or square drive cassettes with built-in interchangeability with a wide range of hydraulic torque wrenches and cassettes on the market. According to Enerpac, the HMT series is the “one wrench to rule them all” and its modular parts eliminate the need to select and purchase separate tools, thus helping reduce the cost of ownership. The ATEX and CE approved Enerpac HMT torque wrenches are the most durable wrenches in their class, the manufacturer claims, with up to a 2.5X longer life expectancy than other leading tools. “Housed in lightweight alloys, the HMT provides strength and versatility to a variety of bolting applications, all in a single tool. When it comes to speed, Enerpac HMT torque wrenches have best-in-class efficiency and are up to 25% faster than competitor torque wrenches. It’s low maintenance too, with only three moving parts; all of which are enclosed, minimising pinch points,” said Enerpac in a statement. Features and benefits of the new Enerpac torque wrench include 30 degrees of stroke allowing up to 25% faster bolting than other known brands, while the tool’s fine tooth ratchet prevents it from locking on, thus speeding up the bolting process. Supplied with an ergonomic safety handle as standard, the Enerpac HMT torque wrenches include a push button, quick release, reversible square drive, while the HSQ square drive reaction arm has a single dial lock for rapid change.


33

LIEBHERR INTRODUCES WORLD’S FIRST BATTERY-POWERED CRAWLER CRANES WHY GET IT? EMISSION-FREE AND LOW NOISE LIFTING WITH FOUR-HOUR OPERATIONS ON 2.2H HOUR CHARGE TIMES Liebherr has introduced the world’s first battery-powered crawler cranes, with the duo of LR 1200.1 unplugged and LR 1250.1 unplugged driven by electric engines with a system performance of 255kW. The manufacturer said the two models make “no compromises regarding performance or availability when compared with the conventional versions”, with the LR 1200.1 offering a maximum lifting capacity of 200t, while the LR 1250.1 can lift 250t. According to Liebherr, thanks to the duo’s zero emission and very low noise levels, they bring huge advantages in areas sensitive to noise and also for the people working on the job-site. The cranes can

be recharged on a conventional jobsite electric supply at 32 amps and 63 amps in 4.5 hours and optionally with 125 amps in 2.25 hours. The battery capacity is designed for four hours of lifting operation. In accordance with their names, the cranes can be operated without a cable - thus “unplugged” thanks to the battery-electric drive design. The cranes have a blue accent in the colour composition of their livery, which, Liebherr says, “lends a distinctive look to the unplugged series, symbolises the electric solution representing an advanced technology”. The cranes achieve a happy combination of operator benefit, efficiency and environmental sustainability, the manufacturer added. Gerhard Frainer, MD for Sales at LiebherrWerk Nenzing GmbH, said: “The year 2020 has shown that one must be open-minded

and bold to break new ground. With our unplugged cranes we offer our customers an alternative drive design. As we have already seen with the LB 16 unplugged, the first battery-powered drilling rig, the strategy is a complete success. Strict requirements regarding environmental sustainability in tenders for construction projects increase the demand for advanced technologies. For us, it was clear that we extend and successfully establish the design in further product groups.” SPECIFICATIONS

LIEBHERR LR 1200.1 & LR 1250.1 Engine power: 255kW Max lift capacities: 200t & 250t Recharge times on 32 & 63 amps: 4.5 hours Recharge time on 125 amps: 2.25 hours


34

NEW RELEASES APRIL 2021

CAT INTRODUCES NEW STAND-BY GENSETS WHY GET IT? EXPANDED RANGE OF CAT GC DIESEL GENERATOR SETS FOR GLOBAL ELECTRICAL CONTRACTOR MARKET IN 50HZ AND 60HZ APPLICATIONS Caterpillar has announced the launch of 31 new models of Cat GC diesel generator sets, the company’s new range of value-engineered standby power solutions specifically targeted for the global electrical contractor market. Now available for 50Hz and 60Hz applications worldwide, Cat GC generator sets simplify the specification process, substantially reduce quotation and delivery times, while helping to meet the tight budget requirements of the vast majority of stationary standby power applications in this power range. Apart from 11 specific models from 40-200kW for 60Hz applications in North America the 31 new models now available include 11 with power ratings from 33400 kVA for 50Hz applications globally as well as nine from 30-175 W for 60Hz applications outside North America. According to Cat, select models with commonly specified power outputs and configurations are stocked at its larger dealer locations for immediate pickup and delivery. Jason Kaiser, vice president for Caterpillar Electric Power, said: “The electrical contractor market is responsible for commissioning the largest share of standby power solutions for small- to medium-sized standby applications. We have specifically configured Cat GC generator sets with electrical contractors in mind and we have now designed a product that offers Caterpillar’s renowned performance at an exceptional value.”

AMCO VEBA EXPANDS ‘NEW GENERATION’ TRUCK-MOUNTED CRANE LINE WHY GET IT? ACCURATE AND SAFE OPERATION WITH REDUCED RISK OF TRUCK CAPSIZE Truck-mounted crane brand Amco Veba has expanded its ‘New Generation’ line of cranes with the addition of the 19-21tm family, which joins the other models in the line that offer 9tm and 13-16tm lift capacities. With the introduction of the new family of truck-mounted cranes, the Amco Veba range now spans from 1-165tm and offers solutions for industries and applications ranging from mining to maintenance, construction to car recovery, said the manufacturer. Giuseppe Bevacqua, the company’s product manager, Cranes, said: “Our ‘New Generation’ crane line offers excellent lifting capacities and a wide variety of configurations. The eyecatching design together with new hydraulics and electronics, offer choice, improved performance, safety and ease of use throughout the range.” Amco Veba added that the new family cranes offer enhanced stability, ergonomic working positions and userfriendly interfaces, which combine to

deliver accurate and safe operation with reduced risk of truck capsize. A variety of radio remote controls and stabiliser configurations are available. The models offer features such as Dynamic Load Diagram (DLD) and Magic Touch (MT), which improve driver attention and can save time and increase productivity. DLD, totally new in the truck-mounted crane industry, allows verification in advance of the crane lifting capacity based on the actual truck stability; and MT allows the driver to open the crane automatically from transport position to working position and back to transport position when required. The new 19-21 tm class comprises 12 models and five different boom configurations, comprising the 821NGT and 824NGT Series T telescopic boom cranes; the 821NG & 824NG Series 800 articulated boom cranes; the 921NG, 922NG, 924NG and 925NG Series 900 high-performance articulated cranes with double linkage boom systems; the 921NGC and 924NGC Series 900 short boom articulated cranes with double linkage boom systems; and the VR23NG and VR26NG Series VR endless slewing cranes with double linkage boom systems. SPECIFICATIONS

AMCO VEBA “NEW GEN” TRUCK-MOUNTED CRANES Number of new models: 12 Lift capacity range: 19-21tm Available boom configurations: 5 Lift management: Dynamic Load Diagram



36

TOP TEN APRIL 2021

02 01

INSPECT BEFORE OPERATION The operator or maintenance staff should visually inspect all tyres on the equipment daily before starting work for the day. Check the condition of valve stems and valve caps. Look for cuts, cracks, and irregular wear on both the tread and tyre shoulders. It’s important to find issues early, as lesscostly repairs may be possible at this time rather than using a tyre with issues. A major problem may result, requiring replacement.

AVOID OBSTACLES It’s important for operators to understand that even though they’re running a large machine designed for work in the off-road environment of quarries and mines, the tyres are not invulnerable to debris and sharp objects. Tyre chains can provide a significant measure of protection against damage-causing obstacles, but the chains themselves will cause some tyre wear, require maintenance and add weight to the machine that increase drivetrain load.

: N E T P O T E K A M O WAYS T R E G N O L T S A L S TYRE , DIGGERS AND DUMPERS

DERS THESE W O L YOUR LOA L O F . S F THEM R TYRE O T T O U N O O T L S L E RO ET THE B G O T S P E SIMPLE ST

03

MATCH PRESSURE TO MATERIAL The default tyre pressures in your operator’s manual may not be right for the material you’re loading. Refer to your tyre manufacturer’s load/pressure tables or contact your equipment dealer for proper inflation pressure by application. Proper inflation provides a high level of traction and longer tyre life by maintaining the optimal contact area between the tyre and ground.

AVOID G INNIN ct TYREleSd P ru st in , loaders

For whee chine’s use the ma to rs to ra e op rial when wd the mate on the ro c to s lic u hydra g mainly t cket. Relyin ll the bucke filling the bu motion to fi rd a n o rw ti fo c a ’s tr e machin of losing e likelihood accelerated increases th resulting in s, re ty g in n the throttle and spin pers, apply m u d n O r. o much wea to prevent to ly e iv ss re g pro ls on loose g the whee in n in sp r e h pow ditions, whic ground con s tyre wear. again cause

04


37

06 05

LIMIT WET CONDITIONS Removing water from operating surfaces can be tough to accomplish but limiting the amount of water your loaders or dumpers run in can improve tyre life. Water acts as a lubricant that makes it easier for objects to cut or puncture tyres. Try to limit using your wheeled equipment in wet conditions, or where that is not possible, try to set up a job-site where water drains away and does not accumulate.

MAINTAIN PROPER PRESSURE Incorrect tyre pressure will slow your equipment down in its work cycle. On loaders, low front tyre pressures promote excessive side-to-side motion as the boom is raised, leading to slower cycle times. Higher-than-required rear tyre pressures contribute to poor fore-aft stability and slow cycle times. On dumpers, low tyre pressure will increase the contact patch area, leading to more wear and tear, as well as higher fuel consumption.

DOWseNem SLOW down may

Slowing eed can tive, but sp c u d ro rp te he faster coun t tyre life. T c e ff a ly e v ti on tyres, nega her the toll ig h e th o g ater, higher you load. Like w r e d n u lly from fast especia mperatures te re ty l a s can make intern n work area mage e e tw e b g to da runnin susceptible tyres more separation. d a s and tre le c a st b o w the from eds also allo e sp r e w lo S see ore time to operator m bstacles. and avoid o

09 08

JOB-SITE SET-UP Planning operations and equipment set-up on a site properly can do a lot to preserve tyres and machines. Set up your operation with tyre preservation in mind. Minimise transport distances between work areas and eliminate the need to make sharp turns wherever possible. Keeping roadways on the job-site groomed properly will also benefit tyre life.

DIFFERENTIAL LOCKS Differential locks can significantly increase traction when one wheel encounters a slippery surface or momentarily loses contact with the ground, increasing tyre life by reducing wheel spin. However, locked differentials can contribute to tyre wear during turns. Engage differential locks only when required.

07 10

USE TELEMATICS Today’s telematics products can help you manage tyres remotely. Most OTR tyre makers have their own tyre monitoring systems to keep constant tabs on tyre pressure via an Internet interface or mobile app. Tyre temperature along with differential lock and spin control utilisation can be viewed, too. Many OEM telematics packages also have similar systems. Use these to monitor your tyres and prolong tyre life.


38

COVER STORY APRIL 2021

SET FOR THE LONG HAUL

MANUFACTURERS OF THE LARGE DUMP TRUCKS ARE BRINGING IN CONSTANT NEW TECHNOLOGICAL INNOVATION, ADVANCED FEATURES AND DIVERSE MODELS TO SUIT CUSTOMER REQUIREMENTS FOR VARIOUS JOB-SITES AND OPERATIONAL NEEDS, WITH A FOCUS ON SAFETY AND SAVINGS

A

lthough a fairly niche product used almost exclusively for the large mining and quarrying applications, the dump truck sector is a competitive one, with every brand vying to gain market share by constantly refining its machines, introducing new models and adding new features - such as increased payloads and capacities, higher safety, greater reliability and length of operation, as well as new technologies for autonomous and electrified operations. At Volvo CE, perhaps the first name that comes to mind in the field of articulated dump trucks (ADT), a key recent development has been its entry into the rigid hauler market last year with its own Volvobranded units. Volvo says it had markets such as the Middle East in mind for its new rigid hauler range, where it was made available even before the more advanced global markets. The development of the new four-model range has relied heavily on the longstanding rigid hauler expertise of Volvo CE’s subsidiary Terex Trucks, combined with the technological strength of the Volvo Group. The range in the Middle East consists of the 40t R45D, 54t R60D, 65t R70D and the flagship 95t R100E. At Volvo’s last customer outreach event in its base in Eskilstuna, Sweden, it was the R70D and R100E that were on centre stage, with the R100E piloted into the demonstration by none other than company president Melker Jernberg, who says: “The E-Series R100E is a completely new Volvo CE 100t rigid hauler that combines a wealth of market and customer knowledge with proven components, new technologies and a striking new design – all providing a cost-effective

and productive solution to fulfil the needs of today’s mining and quarrying customers.” Based on the existing and well-proven Terex Trucks TR-Series, development of the D-Series R45D, R60D and R70D Volvo rigid haulers followed in-depth engineering reviews, ensuring the machines met the standards expected from Volvo products in their target markets. Improvements include greater visibility and safety systems, along with Volvo technical support. Volvo’ rigid haulers build on the company’s expertise in the ADT segment, in which it has been one of the pioneers and best-known exponents. Volvo’s reputation in the ADTs has been bolstered in the region with several important projects under its belt over the years. These include the Saudi-Oman Landbridge in the Rub Al Khali desert and the Al Maktoum Airport in Dubai, where Volvo ADT fleets numbering 68 units and 37 units respectively made these projects possible. At Japanese giant Komatsu, the dump truck is an integral part of the company’s product offering. Jehad Jayyousi, assistant manager, Marketing, Komatsu Middle East, says the company’s dump trucks are divided in terms of frame into the rigid and articulated, while the rigids are further divided into mechanical and electrical power trains. “We have six popular models of rigid dump trucks in the Middle East. These are the HD325-7R with a 36.5t payload, the HD405-7R with a 40t payload, the HD4657R with a payload of 55t, the 63t HD605-7R, the 91.7t HD785-7 and the HD1500-8 offering a payload of 141.7t. In our ADT range we have the HM Series of models with the 41t HM400-3R important for the region. “Globally, Komatsu dump trucks are also further divided at the higher end into the E models, which have electric powertrains with payloads from 181.4–369.4t. The E models, such as 830E, 960E and 980E, have not been introduced into our region as yet as there


39 Already known for its articulated dump trucks, Volvo CE introduced its rigid hauler line a couple of years ago, comprising four models for the Middle East with payloads from 40.8t to 95t.

“The E-Series R100E is a completely new Volvo CE 100t rigid hauler that combines proven components, new technologies and a striking new design for a cost-effective and productive solution for today’s mining and quarrying customers”


40

COVER STORY APRIL 2021

is little demand for such class sizes. However, on a global level, these models are testimony to Komatsu’s expertise in building the most advanced and useful dump trucks.” In terms of market performance in the region, Jayyousi says the demand for dump trucks has been stable through the last 2-3 years in the Middle East. Describing Komatsu’s position, he says: “We enjoy a very healthy market share in the region. In dump trucks, productivity, availability or uptime, durability and quality are the main choice drivers for customers and Komatsu excels in all of them. When it comes to dump trucks, the importance of total cost of ownership (TCO) is clearly higher compared to smaller equipment such as wheeled loaders for which a low initial price has a bigger role.” Responding to the Middle East market demands, Komatsu’s latest addition to its dump trucks range in the region is the HD1500-8, a 141.7t-payload model. This is now among Komatsu’s highest payload-capacity models available in the region and was introduced because a demand for it was spotted over the last few years. The biggest demand for a Komatsu dump truck, however, comes from the smaller sizes such as the rigid HD325 and the ADT HM400-3R, with payloads of 36.5t and 41t respectively. Jayyousi says this is because the biggest requirement for dump trucks in the region are from quarries and small-scale mining, and not large-scale mining operations where Komatsu’s HD1500 or even bigger models are the requirement. Not only does Komatsu look at the commercial aspects of a market when tailoring its product offering, more importantly, it also looks at the working conditions and the jobs-site requirements when developing the products themselves. Jayyousi explains: “We develop and introduce all our models after detailed studies of the region they are intended for. In the Middle East, all models are designed and made specifically for areas with severe conditions, like the hot and sandy ones here, as well as keeping available fuel quality in mind. For our region, models are equipped with such features as our Hot Area Arrangement, Sandy Area Arrangement and Poor Fuel Arrangement. Each of our models here has several modifications incorporated over the original machines in line with our commitment to quality and reliability.” In keeping with preparing the right machine for a particular market or application, Komatsu has also brought in the required technological features into its dump trucks that take the brand’s quality and reliability goals further. “The Komatsu-designed electronically controlled transmission, called Komatsu Advance Transmission with Optimum

“All models are designed and made specifically for the severe hot and sandy conditions here, as well as keeping available fuel quality in mind”

Komatsu has over six models of rigid haulers and artiuclated dump trucks in the Middle East. The company sees the highest demand for its smaller sizes, such as the HD325 and HM400-3R.

Modulation Control System (K-ATOMiCS), has been a success in Komatsu’s rigid dump trucks. The electronic clutch modulation system ensures proper clutch pressure when the clutch is engaged. The total control system controls both the engine and the transmission by monitoring the vehicle conditions. This high technology system assures smooth shifts without shock and maximises the power train life,” explains Jayyoussi. “Also, Komatsu has developed various shoe/ wheel slip control technologies, including

traction control systems in bulldozer and Automatic Spin Regulator (ASR) for rigid dump trucks. These technologies are combined and upgraded to the evolutionally advanced traction control system for our ADTs. Our KTCS system allows easy travel on soft ground and slippery roads for our dumpers simply by operating the accelerator. This also makes for much better turning performance than the conventional differential lock-up or the limited slip differential.” Meanwhile, Komatsu’s technological advancements as a global company also go into autonomous equipment operations, especially when it comes to haulers. Jayyousi points out that mining companies across the world have now hauled more than three billion metric tonnes of materials leveraging Komatsu’s Autonomous Haulage System (AHS), which marks another industry-first for autonomous haulage. “Working closely with customers, Komatsu developed the first commercially available autonomous haulage system to help mines move material more efficiently. First deployed in 2008 at Codelco’s Gabriela Mistral (Gaby) copper mine in Chile, AHS brings together some of the world’s best-selling, ultra-class dump trucks with our Modular Mining Systems’ DISPATCH Fleet Management System. Today, our FrontRunner system operates round the clock, hauling copper, iron ore, oil sands and coal at 11 customer sites across three continents. At the end of June 2020, there were 251 trucks in operation, with an additional 100 - mainly from installing AHS retrofit kit - planned for deployment within the year.” As Komatsu approaches a milestone in its history this year, Jayyousi puts recent developments into perspective, saying: “Since Komatsu’s founding 100 years ago, we’ve


41 held true to our initial purpose - providing sustainable growth for people, businesses and communities. We work with all our stakeholders to develop sustainable solutions to help move society forward. In the dump trucks space, this means that wherever the machines are required you will find us. In the Middle East that includes the UAE, Saudi Arabia, Egypt, Oman and Jordan, where we see the highest demand for smaller sizes, such as the HD325 rigid hauler and the HM400-3R ADT.” Korean company Doosan Construction Equipment has launched upgraded new versions of its DA30 and DA45 ADTs for the Middle East and Africa market, with the former sporting a payload of 28t and the latter 41t. In 2018, the previous version of the DA30 was upgraded with features such as a new cab, new self-levelling front suspension and new tandem bogie system, which are all incorporated in the latest DA30 model. A similar process has been followed for the new DA45 machine, with a new cab and a semilevelling front suspension that adjusts itself independently based on operating conditions to ensure a comfortable operator environment. The cabs on these ADTs have new comfortable

hand grips and footrests and an improved layout for the display, which is easier to use even for tired eyes. Doosan adds that the new models also offer other features, one of the most eye-catching being a new design for the front frame and bonnet components on the trucks, created by the Doosan Design Team in accordance with the latest market trends. The manufacturer says the new dynamic look given to the ADTs reflects the high performance, power and robustness of Doosan’s range.

Doosan has launched the upgraded versions of its DA30 and DA45 ADTs for the Middle East and Africa markets, with the models offering 28t and 41t of payload respectively.

The new Doosan ADTs are equipped as standard with a real-time payload measuring system with a light indication for excavator operators to help them place optimal loads for higher productivity and low fuel consumption. The electronic and hydraulic systems in the new trucks have also been upgraded for improved performance with extended functionality and new technology. Among the functional changes are those that improve safety, comfort and serviceability, including a repositioned diesel tank, which is now much lower than before to make ground-level filling possible for operators. The greasing system has also been relocated to make it easily accessible from ground level. Space has been provided above the standard automatic lubrication system for additional grease cartridges and a filling pump. In addition, the transmission filters are installed close to the greasing system, making them easier to access. All of these systems are protected to ensure that excess oil/grease is collected and can be removed during service and maintenance. Doosan says the aim with the improved maintenance access was to help operators perform daily checks faster

VOLVO ARTICULATED DUMP TRUCKS

DRIVING THE AL MAKTOUM AIRPORT EXPANSION A fleet of Volvo machines, including 37 Volvo A35F ADTs, was involved in the expansion project at Dubai’s Al Maktoum Airport, the new sevenmillion-passengers-a-year air traffic hub at the heart of Dubai’s future plans. The first phase of the mega expansion will see this leap to 26 million passengers a year, with plans to up capacity to around 140 million – making it by far the largest aviation infrastructure in the world. The entire ground preparation operation for the expansion was done by a single company, Tristar Engineering and Construction,

a veteran Abu Dhabi-based infrastructure contractor. The scale of the work was daunting - out of the 140km2 total area of Dubai South, 50km2 needed preparation as part of the expansion. Tristar fleet manager Mohammed Amer says: “You can call it a megaproject; it is not at all ordinary. I think there have been very few similar projects in the UAE with such quantities of material moved.” Dubai’s desert landscape is a mix of rising dunes and sunken depressions where the sea water seeping through the porous mineral below has glued

the sand together, making it as hard as rock. Amer continues: “We have some areas where we are simply loading the trucks with excavators, but we also have hard material that is like rock where the excavators first have to break the material up with hydraulic hammers before loading it into the haulers.” The cutting and filling of 170 million cubic metres of sand and rock over an area of 50km2 in just two years required Tristar’s 37 A35F haulers to work 10 hours a day to meet the tight schedule and dizzying production targets.

Ambient temperatures were often over 50°C in summer, with a fine suspension of desert dust almost always in the air. The A35F haulers were prepared for the conditions, thanks to both their fully enclosed axles, which guard against the dust and circulate cooling lubricant, and their threestage filtration system, ensuring no airborne dust enters the engine. “The most important thing about the Volvo machines is their extremely low downtime. All of our haulers have exceeded 10,000 working hours, and we are still happy,” notes Amer.


42

COVER STORY APRIL 2021

and more safely. Both new machines have additional external round handrails to prevent accidents and hazards. Inside the cab, there is a new additional grip on the righthand side for increased operator safety. Doosan says the developments in the new DA30 and DA45 have resulted from intensive market analysis, customer visits, interviews with operators and additional feedback gathered by its ADT Product and R&D teams at its Norway plant. The new models also feature Doosan’s articulation hinge positioned behind the turning ring to provide equal weight distribution to the front axle even during maximum steer articulation. This, combined with a free-swinging rear tandem bogie, ensures equal distribution of weight to each wheel and guarantees permanent six-wheel contact and drive for equal power distribution and performance, particularly on difficult terrain such as soft ground, uneven surfaces, steep slopes, tight turns or their combination. Collectively, the forward turning point, the unique tandem bogie and the sloping rear frame result in what Doosan claims is “best in class” rough- and soft-terrain capabilities.

Doosan’s new ADTs tackle rough and softer terrain better, with improved load distribution leading to more traction, while a standard real-time payload measuring system optimises loading.

The unique body shape and sloping frame ensure equal load distribution on all wheels, making these machines well suited for softterrain work. The design of the articulation also provides equal load distribution on the wheels on both the left and righthand sides when turning, important for traction and stability. At Hitachi, the Japanese heavyweight well known for dump trucks, customers get the flexibility to choose engines suited to their particular operations in the company’s three rigid dump truck models for the Middle East.

TA 230 LITRONIC ADT

LIEBHERR LAUNCHES NEW GENERATION ARTICULATED DUMP TRUCK Liebherr recently unveiled the first representative of its new generation of articulated dump trucks, showing off the TA 230 Litronic, which has been redeveloped from scratch on the basis of comprehensive market and customer analyses. The new TA 230 Litronic has been developed specially for challenging off-road applications. New designs in the front-end create maximum ground clearance for better off-road performance. For example, in the TA 230 Litronic the powershift transmission is positioned safely and compactly under the operator’s cab and the exhaust gas aftertreatment is safely installed behind the operator’s cab in a space-saving manner, whereby a large slope angle could be generated. The newly designed, solid articulated swivel joint creates excellent off-road

capability: It allows independent movements of front and rear end, thus ensuring maximum manoeuvrability. The robust and positive-locking swivel joint with tapered roller bearing is perfect for the shear stresses arising during use, withstands maximum loads and provides optimal force distribution. The front and rear axles of the machine are secured via sturdy A-rods at the articulated swivel joint and at the rear end.

A powerful six-cylinder construction machinery engine with 12l displacement and 360hp power output powers the new TA 230 Litronic, Mated with an automatic eight-speed powershift transmission it provides optimal force distribution and also sports actively controlled longitudinal differential locks. automatic traction control is also available for the TA 230 Litronic, which deals with wheel slip in any axle by transferring the torque to the axle or axles with traction. The TA 230 Litronic is designed for a 28t payload. Improvements for quick and efficient loading and unloading include a straight trough front with low sills so that loading with a wheel loader, for example, is easily possible across the entire length. A standard weighing system shows the current payload during loading on the display in the operator’s cab.

Piet van Bakergem, general manager, Hitachi Construction Machinery Middle East, says: “In the Middle East, we are offering three models: the EH3500AC-3, which has a 180t-class payload capacity; the EH4000AC-3, with a 220t-class payload capacity; and the EH5000AC-3, offering 300t-class payload.” The specifications of the Hitachi dump truck models make it clear that the company has aimed at the high-capacity end of the regional market, which requires the sort of expertise in building some massive and robust machines that Hitachi has acquired and exhibited over several decades. The three Hitachi models in the Middle East all come with a choice of engines, and van Bakergem explains: “Based on customer preference, each of these models can be equipped with either a Cummins or MTU engine, while other aspects, such as truck components and performance, remain the same. In some territories, customers already have a relationship with one of these OEM engine brands. So offering the choice of these engines gives customers the freedom to choose their engine OEM with reference to their market.” Hitachi’s sales record in the wider Middle East includes selling 10 units of the EH3500AC-3 to Turkish coal mining customer Celikler and another 10 units of the EH4000AC-3 to Tuprag, another Turkish customer, for gold mining and van Bakergem points out that the units have notched up 14,000 hours and 25,000 hours respectively of seamless, reliable work with the two customers. Attributing the performance to the quality, features, technology and safety devices crammed into Hitachi’s dump trucks, he explains: “All Hitachi’s AC-3 dump trucks are fitted with our unique Drive System Control, consisting of pitch control, slip slide control and side skid control. These unique Hitachi features offer better performance with increased controllability and hence increased operational safety during truck hauling. “To increase safety, we developed another system called ‘Aerial Angle’, which consists of Peripheral Vision and Object Detect Assist functions. When the truck is stable, these functions continuously check the surroundings and warn the operator if any moving object is detected around the truck, such as a mechanic or any other machine. During hauling, by using our Millimetre Radar Wave system, Aerial Angle detects the moving objects in front of the truck and based on the distance, the system generates a warning sound for the operator. “In addition to these, Hitachi dump trucks are continuously monitored by our in-house monitoring system, called ConSite, which enables dealers and mining customers to


43 observe their trucks’ performance, diagnose errors and get the production data.” Such technology features amply illustrate Hitachi’s constant innovation drive, which is further reflected in the future technologies and green initiatives the company offers on its haulers, such as ‘Trolley Drive’. “A trolley drive truck in surface mining is a diesel-electric drive truck that has an option installed to enable a secondary means to power the wheel motors. When activated, diesel generated power to the wheel motors is cancelled and overhead catenary power is connected and diverted to the wheel motors through the inverters,” says van Bakergem. “On a mine site, trolleys are placed on the slopes where the truck is burning the highest amount of fuel in a cycle. By utilising the trolley, more production can be achieved with less fuel consumption. Our figures point to a 30% decrease in fuel consumption observed in one cycle. This contributes to major decreases in operational costs with reduced truck fleet numbers. Based on our studies and estimation, fuel makes up 45% of the total life-cycle cost of a truck. In the Middle East, customers are looking for every opportunity to decrease their operational costs. So, in order to decrease this further, the trolley application can become the most dominant and effective solution.” Hitachi has also rolled out other technologies globally, such as its Autonomous Haulage System (AHS), which enables unmanned, autonomous operation, improving safety and boosting productivity by autonomously controlling dump trucks through a Fleet Management System (FMS), he adds. “Being under the Hitachi umbrella, our trucks’ component and drive systems are all designed, developed and produced by Hitachi Limited. Compared to other brands, in case support is needed for a component or software, rather than going to another brand, we get the required support in a very short time from our sister company. And, of course, Hitachi has a very dedicated support team that attends to customer needs 24/7.” Meanwhile, at global equipment leader Caterpillar, the Middle East line-up of heavy trucks is divided into the quarry and construction truck (QCT) and the ADT ranges, each comprising seven models. Samer Ismail, product manager, Earthmoving & Excavation, at Al-Bahar, the Cat dealer for the GCC excluding Saudi Arabia, details the models as the 770G, 772G, 773E, 773G, 775G, 777E, 777G in the QCT range and the 725, 730, 730EJ, 735, 740EJ, 740GC, 745 in the ADT range. Apart from the fully built-up trucks, the Cat ADT line-up also includes bare-chassis-only versions and Ismail explains: “The articulated truck bare chassis can be leveraged for a variety

of final machines, including water trucks, fuel and lube trucks, coal haulers, service trucks, container and waste trucks, tow tractors, etc.” Some of the features and advantages that the Cat ADTs provide are “manoeuvrability, the ability to tackle poor underfoot conditions and steep inclines”, says Ismail. Coming to the Cat QCTs, he adds: “These are ideal for hauling at high speeds, with superior braking systems enhancing safety. They have a wide loading target for fast and efficient loading, and various body and liner options. All in all,

Hitachi’s rigid dump trucks available in the Middle East offer high payloads and are providing economical performance in coal mines and gold mines in the wider region.

Cat QCTs provide some of the lowest costs per ton of material moved.” Ismail says that the most popular Cat dump truck models in the region are the 770G and 775G among the QCTs and the 740 in the ADT range. Among Cat’s more recent introductions in the Middle East are the 745 and 740GC in the ADTs and the 777E in the QCT range. “We are leading the market in the dump trucks. Driven by the UAE, that market has seen a gradual expansion in the last few years. Also in favour of Cat dump trucks are our technology aids such as Truck Production Management System (TPMS), Cat Detect with Stability Assist and Link Technology, which help increase productivity and savings.” Cat is also among the pioneers of autonomous haulers worldwide and hit a significant global milestone in spring last year, achieving two billion tonnes hauled autonomously using Cat MineStar Command. While this technology is not yet offered in the Middle East owing to its lack of relevance here as of now, it does point to Cat’s overall expertise and track record as a leader in the haulage sector. With the dump truck - whether rigid or articulated - playing a unique and crucial role in the mining and quarrying as well as infratructure and construction segments, the big global manufacturers of the machine continue to be on the ball in the Middle East market with their model ranges, technologies and services, keeping their wheels rolling while being set for the long haul.

“In case support is needed for a component or a software... Hitachi has a very dedicated team that attends to customer needs 24/7”


44

THE LAST WORD APRIL 2021

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