BULK
HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH l
m LIFTING VIA RADIO REMOTE CONTROL m BULK HANDLING m VULCANISATION PROCESS OPTIMISED m TODAY
T O D A Y Feb 2014
February 2014
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BULK HANDLING TODAY
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T O D A Y
BULK
HANDLING Endorsed by: February 2014l SAIMechE l SAIMH l CMA l LEEASA
Feb 2014
Contents On The cover: BMG Hydraulics Tel: (031) 576-6221 www.bmgworld.net
CMA 5
Stockyards
From the Chairman’s Desk
29 Use of Castellated Sections under Static and Semi-Dynamic Loads
Cover Story 6
Forklifts
Setting Standards
34 Easier with Forklift Attachments
Earthmoving
9 Excavators Engineered for Bulk-work 13 Celebrating 50 Years in South Africa
Beltcon
15 Optimisation of the Vulcanisation Process
Routing & Scheduling 37 Vehicle Monitoring Over the Border 38
Endorsing Bodies •
Project Management
21 New Player in Projects •
Boilers
23 By Word of Mouth
•
Lifting Equipment
25 Radio Remote Control for Lifting Machinery
Sucess Story
Market Forum
• •
CMA (Conveyor Manufacturers Association) LEEASA (Lifting Equipment Engineering Association of South Africa) SAIMechE (SA Institute of Mechanical Engineering) SAIMH (SA Institute of Materials Handling) also mailed to members of the RFA (Road Freight Association)
27 Climbing the Ladder to Success
Copyright
The monthly circulation is 3 673
All rights reserved. No editorial matter published in “Bulk Handling Today” may be reproduced in any form or language without written permission of Proprietor Publisher: m PROMECH PUBLISHING m LIFTING VIA RADIO REMOTEand CONTROL the publishers. While every effort is made to ensure accurate reproduction, Tel: (011) 781-1401, Fax: (011) 781-1403 m VULCANISATION PROCESS OPTIMISED m the editor, authors, publishers and their employees or agents shall not be E-mail: bulkhandling@promech.co.za www.promech.co.za responsible or in any way liable for any errors, omissions or inaccuracies Managing Editor: Susan Custers Editor: Kowie Hamman in the publication, whether arising from negligence or otherwise or for Advertising Sales: Surita Marx any consequences arising therefrom. The inclusion or exclusion of any DTP: Zinobia Docrat / Jacqueline Nene product does not mean that the publisher or editorial board advocates or Subscriptions: Please email us at accounts@promech.co.za rejects its use either generally or in any particular field or fields. if you wish to subscribe to “Bulk Handling Today” at R475,00 (excl postage and VAT) per year; R1 190,00 per year for Africa/Overseas. Our e-mail address is
bulkhandling@promech.co.za
Visit our website on www.promech.co.za
Printed by: Typo Colour Printing, Tel: (011) 402-3468 FSC (Forestry Stewardship Accreditation)
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CONVEYOR MANUFACTURERS ASSOCIATION
From The Chairman’s Desk Dear CMA Members I’m delighted to say that we now have our 76th CMA member! Collisen Engineering has joined the CMA and we hope to have many years ahead working with them. Another busy year lies ahead for us, and we’ve outlined the events planned for the next 12 months. A highlight that we are currently working on, is Safecon – the committee is putting together a very
exciting and relevant seminar, and you’ll all hear about it once the details are in place. Here’s to another year of sharing ideas, working together and having pride in our Association’s achievements in the execution of our mission – to promote the excellence of belt conveying. Till next time, Simon Curry
Simon Curry
2014 Calendar of Events, Functions & Meetings MONTH
EVENT
DATE
DAY
VENUE
April
Members meeting
8
Tuesday
Bryanston cc
May
Diploma Course
05 to 12
Monday - Monday
Ferndale Lodge
Gala Dinner
28
Wed
Bryanston cc
Members meeting
10
Tuesday
Bryanston cc
3-Day Conveyor Certificate Course 23 - 25
Mon - Wed inclusive
Ferndale Lodge
August
AGM and Interact Weekend
Fri - Sun
TBA
September
3-Day Conveyor Certificate Course 08 - 10
Mon - Wed inclusive
Ferndale Lodge
(Electra Mining)
15 - 19
Mon - Fri
NASREC
Diploma Course
06 to 13
Mon to Mon
Ferndale Lodge
Members Meeting
14
Tuesday
Bryanston cc
SAFECON
TBA
TBA
TBA
June
October November
29 - 31
Membership as at February 2014 All members subscribe to the CMA Code of Ethics ABB Industry Actom Afripp Projects Atlanta Manufacturing Bauer Bearings International Belt Brokers Belt Reco Belting Supply Services Bibby Turboflex BMG Bonfiglioli Power Transmissions Bosworth Brelko Conveyor Products Conveyor Watch Collisen Engineering CPI Technologies CPM Engineering CT Systems David Brown Gear Industries Delras Engineering DRA Mineral Projects DRA Mining (Pty) Ltd Dunlop Belting Products Dymot Engineering Company
ELB Engineering Services Facet Engineering Fenner Conveyor Belting (South Africa) Flexible Steel Lacing SA FLSmidth Roymec Hägglunds Drives South Africa Hansen Transmissions SA Hatch Goba Africa Horne Hydraulics Hosch - Fördertechnik (SA) International Belting & Marketing Iptron Technology Lesa Mining Equipment and Conveyor Belt Lorbrand M & J Engineering Martin Engineering Megaroller Melco Conveyor Equipment Moret Mining MS Conveyor Pulleys SA Nepean Conveyors NSK South Africa (Pty) Ltd OE Bearings Oriental Rubber Industries SA Osborn Engineered Products Pegasus Industrial Services cc
PH Projects Holdings Protea Conveyors Read Swatman & Voigt Regal Beloit South Africa Rema Tip Top South Africa Renold Crofts RSV ENCO Consulting Rula Bulk Materials Handling Sandvik Materials Handling SA Schaeffler South Africa SENET SEW Eurodrive Shaft Engineering Shaw Almex Africa SKF South Africa Sprag Components cc Tenova Takraf ThyssenKrupp Materials Handling Timken South Africa (Pty) Ltd Transmission Components Transvaal Rubber Company TWP Projects Veyance Technologies Africa Voith Turbo Zest Electric Motors
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COVER STORY
Setting Standards With a track record spanning 85 years in southern Africa, Fenner power transmission products continue to set the standard in diverse industries for quality and reliability.
“
The Fenner range fits perfectly into the BMG stable, alongside some of the world’s most trusted brands of engineering components and equipment that keep the wheels of industry turning,” says Dave Russell, BMG’s marketing director. “Fenner belt drives, chain drive couplings and gear drives are skillfully combined with other drive train elements by BMG engineers, to draw out the true operational value for southern African industry and mining.
With the right approach, the goals of energy efficiency and equipment dependability tend to merge Perfecting solution
“Take for example, the ubiquitous Fenner Shaft Mounted Speed Reducer (SMSR) drive assembly. Updated recently to handle higher shock loads and
Dave Russell
perform with greater reliability, BMG engineers set about perfecting a solution around the improved SMSR design which would deliver tangible operational efficiency benefits for its customers. “With the right approach, the goals of energy efficiency and equipment dependability tend to merge. The first focus area was the v belt drive, which supplies power and speed into the SMSR and gives the drive package its versatility and flexibility.” Fenner v belt drives are renowned for their durability, but not even these quality items can compensate for maladjustment and the inevitable operational wear. Misaligned and incorrectly tensioned belt drives not only create an exponentially accelerating wear condition, culminating in drive failure, but also are hugely energy inefficient. The solution was found by incorporating the OST self tensioning motor base into the drive train. Once installed, this patented device maintains the belt drive in optimum tension, to consistently achieve 98% energy transfer efficiency and minimum belt and pulley wear.
BMG’s technical design team innovate productivity-enhancing industrial solutions
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Fenner taper lock bushes, which are precisely machined to mate with Fenner pulleys, permit ease of axial adjustment for pulley
COVER STORY
alignment, which can be accurately set using laser equipment, also available from BMG. Incorrectly tensioned and misaligned v belt drives have been proven to lose an average of 15% of the supplied input energy. This factor alone provides an attractive reason to insist on this BMG solution; notwithstanding the reliability gains that are just as impactful when seeking to maximise productivity.
Quality control
The second focus was the prime mover – the electric motor. The superior features of the BMG Synergy series premium efficiency motors are founded in the design concepts developed by BMG electric motor designers and held to precise standards by meticulous quality control.
In today’s reality, the competitive imperatives of operational efficiency and maximised productivity mean it is no longer enough to simply be a supplier of industrial equipment Not only do these motors optimise the use of energy, but they are designed to be unaffected by the harshest environments, which ensures operational reliability. Supplied in an IP66 enclosure as standard, these SABS certified Synergy Series motors also feature Class H high temperature insulation, over-temperature protection with PTC thermistors, preparation for condition monitoring, oversized terminal box with removable gland plate and regreasable through flush bearing lubrication. These attributes are targeted at enhancing competitive advantage for BMG’s customers.
Customised
The operationally efficient Fenner drive solution is one of thousands of engineered solutions offered by BMG, which are customised to suit specific requirements. This service is supported by the company’s highly-skilled on-site installation and maintenance teams. “In today’s reality, the competitive imperatives of operational efficiency and maximised productivity mean it is no longer enough to simply be a supplier of industrial equipment,” says Dave. Innovative, value delivering solutions are required, which provide effective counter-measures against today’s economic headwinds.
Effective solution
Supply companies need to deliver effective technical solutions that go far beyond the capabilities of the items of equipment alone. Only those organisations, that have aligned their solutions with the productivity and employment enhancement initiatives of commerce and government, can truly claim to be part of the economic solution. “While the Fenner range firmly provides the cor-
nerstone for reliability, it is BMG’s ingenuity that transforms quality products into great solutions,” Dave concludes. BMG, Veronique van Niekerk, Tel: (031) 576-6221 Email: veroniquv@bmgworld.net, www.bmgworld.net
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EARTHMOVING
Excavators Engineered for Bulk-work Specialist excavator manufacturer, Sumitomo, has engineered its range of excavators to perform tirelessly in back-breaking mining and processing environments where the highest levels of productivity and reliability are required. Desmond van Heerden of ELB Equipment
I
ts entire range of excavators from lightweight 7.5-ton machines through to its heavyweight 80-ton contender is built with around-the-clock productivity requirements in mind. As a result, the machines have found a niche in the toughest applications worldwide, where ordinary construction type excavators simply cannot perform adequately.
Aims to outperform and outlast its peers in every application In South Africa the machines have become especially popular with smaller and medium-sized mines, as well as with mining contractors and processing plant operators who value the exceptional efficiency and
reliability of the excavators. Service and support of the highest quality is also required in this type of operation and has been successfully undertaken by ELB Equipment for more than two decades.
Tough contender
According to Desmond van Heerden of ELB, Sumitomo excavators showcase the best of Japanese engineering in a product that aims to outperform and outlast its peers in every application. Their reputation for productivity and reliability is exemplary and has contributed to the brand’s growing popularity throughout the region. “Typically, our clients in mining and industrial applications require machines to work at full capacity BULK HANDLING TODAY
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EARTHMOVING
chines are also critical and an important focus of Sumitomo’s engineers in order to achieve best-inclass performance from every model in its range. The company has found that the advantage of being a multi-brand supplier is that they can select the best product brand for particular applications. As a result they do not have to promote machines from a particular stable that are less competitive or unsuited to sub-Saharan African conditions.
Our machines to be more than 10% more fuel efficient than comparable Japanese machines Ongoing improvement
Yu Han, assistant manager international sales Sumitomo Construction Machinery
for long hours. Excavators in particular, need to be reliable as they are usually at the centre of operations and are pivotal to the smooth operation of a plant,” Desmond says. He adds, that speed and productivity of the ma-
Close cooperation exists between the two companies to ensure that machines destined for African soil meet all local operational, safety and health requirements. Feedback from customers in Southern Africa is also used for continuous improvement to underwrite reliability and performance. “In recent benchmark tests in Japan we found our machines to be more than 10% more fuel efficient than comparable Japanese machines and up to 30% more efficient than American equivalents.In addition, our machines have faster swing speeds
SKF South Africa - Celebrating 100 Years of Innovative Solutions
Power Transmission Solutions SKF Power Transmission is a product line that provides a complete range of high quality belts, chains, couplings, pulleys, sprockets, bushings and hubs. Required in virtually every industry, power transmission components enable processes to run by connecting moving parts in machinery. By choosing SKF Power Transmission products, customers are investing in high quality, high performance products that enable machinery to run more efficiently. SKF South Africa is celebrating 100 years of innovative solutions during 2014. Drawing on five areas of competence and application-specific expertise (bearings and units, seals, lubrication systems, mechatronics and a wide range of services), SKF brings innovative solutions to OEMs and production facilities in every major industry worldwide.
The Power of Knowledge Engineering SKF South Africa (Pty) Limited Tel: +27 11 821 3500, Fax: +27 11 821 3501 Email: sales.za@skf.com, Web: www.skf.co.za
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EARTHMOVING
and are engineered to be more productive in the applications that they are designed to work in,” says Desmond. “For example, the design of the Space5 engine and hydraulic system allows the machine to work more quickly, smoothly and efficiently. The controls are also ergonomically designed for fast, efficient operation and provide operators with a comfortable and more productive environment,” adds Yu Han, regional manager, international sales Sumitomo Construction Machinery.
Careful engineering
He points out that the company has almost exclusively specialised in building excavators for more than 50 years. In addition Sumitomo has a 400-year history originating from copper mining in Japan, the company understands better than most, the challenges and importance of productivity and reliability in these kinds of applications.
The company also pays particular attention to the overall efficiency of its machines and its SH210-5 excavator recently became the first earthmoving machine to win the Japanese government’s award for energy conservation. Similarly, all the other machines in the range return similarly low fuel-consumption figures and are class-leaders in terms of overall fuel consumption and overall cost of ownership.
A battery of tests and checks to ensure it is ready for operation anywhere in the world Smart choice “Sumitomo excavators should be a natural choice for operations that require around the clock reliability and productivity from an excavator. They represent exceptional value-for-money as a premium quality brand at a price that is in line with other Japanese brands. “The efficiency, durability and legendary productivity of our machines put them in a league of its own,” Desmond concludes. ELB Equipment, Desmond van Heerden, Tel: (011) 306-0722, Email: desmondv@elbquip.co.za, www.elbequipment.com
V13792
“At the point of design of every Sumitomo machine we pay careful attention to the structural strength of the machines, mechanical performance and overall reliability of every component. Each part is manufactured and carefully assembled according to the strictest standards and is subjected to a battery of tests and checks to ensure it is ready
for operation anywhere in the world.”
Protect Your Belt Conveyors with Voith Fluid Couplings. They have been in service for decades under the toughest conditions and have proven themselves worldwide. Voith fluid couplings protect belt conveyors and drive components by providing smooth acceleration and torque control allowing for frequent loaded starts with the least amount of stress on the drive and belt. In multi-motor drives they ensure precise load distribution. Result: fewer downtimes and the service life of the belt and the drive components are increased. The latest product innovation is the Voith TurboBelt 780 TPXL. Tel: +27 11 418 4000 info.vtza@voith.com www.rsa.voithturbo.com
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EARTHMOVING
Komatsu parts distribution centre
Celebrating 50 years in SA record of a sale reveals that the company sold a Komatsu D50-11 dozer to the Department of Bantu Administration and Development on 29 October 1963, and so began a long history of service to the country’s public sector. Apart from the introduction of various other bulldozer models D60, 80 and 120 that followed in the 60s, Illings introduced the Komatsu GD37 motor grader in 1964 and the HD180 dump truck in 1969.
Mike Blom, managing director
Fifty years since the first Komatsu machine was sold into the South African market, the brand has become synonymous with quality and productivity on construction sites and mines across the sub-continent.
T
he family-owned Illings (Pty) Ltd, based in Pinetown, KwaZulu-Natal, first concluded an agreement to bring a limited selection of Komatsu machines to the country. The plan was initially to market them mainly to the farming and construction industries. Shortly after the conclusion of the agreement, the first viable
The company demonstrated the capabilities of the machines at the annual Rand Easter Show, sparking a fair amount of interest from potential customers around the country. In quick order (following the sale of the first machine) the rest of the consignment was sold and orders were placed for more. Positive reports soon began to circulate about the Komatsu machines which led to the then Transvaal Provincial Administration buying more machines for road construction.
Growing up tough
As a result, this enterprising firm caught the attention of Anglo American, which bought the company in 1967. By 1970, sales in the sub-region had raised a flag at Komatsu Ltd in Japan which then took a strategic decision to set up a liaison office in South Africa to deal with local issues and to ensure enough attention was being paid to localising the range of equipment. The 70s saw a further consolidation and acceptance of the brand as a leader in the market. By BULK HANDLING TODAY
February 2014
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EARTHMOVING
Spreading wings
By the 1990s, Komatsu Ltd was growing and it needed to increase its range of mining equipment, so it procured Haulpak in the USA and Demag of Germany. These products where marketed by Komdresco. Major supply contracts for electric drive dump trucks, like those to Sishen (Iscor) iron ore mine and Grootegeluk coal mine were some of the biggest of the time, and firmly positioned the company as a market leader in South Africa.
Current position
Investments across borders have also led to farreaching benefits for the company. The recent awarding of a multi-million Rand tender to Komatsu Southern Africa for the supply of 23 Komatsu 960E dump trucks and supporting equipment to Husab Uranium Mine in Namibia is a perfect example.
Reman centre
now the range had expanded to include HD320, 460 and 680 dump trucks, the W70, 90 and 120 wheel loaders, the WS23S motor scraper and the introduction of the D155 and D355 bulldozers. In 1981 the equipment division was renamed KSA Equipment (Pty) Ltd and marked the beginning of exclusivity with Komatsu equipment. The introduction of the PC 200 excavators, the legendary HD785-1dump truck, the D455 bulldozer, GD623 motor grader and the JV100 rollers were added to the range of equipment over the next decade.
D275 dozer
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Looking towards the future, Komatsu Southern Africa is determined to hold onto its vision as a leading supplier in the industry offering reliable high quality products paired with exceptional customised after sales service. Investments in a state-of-the-art parts distribution centre (PDC) promises to improve parts delivery dramatically, and remanufacturing facilities will soon give customers the ability to extend service lives of their machines. Komatsu, Tel: (011) 923-1210, Email: antonyt@komatsu.co.za
BELTCON
Optimisation of the Vulcanisation Process Belt conveyors are used to enable high flows of bulk materials. The use of steel cord conveyor belts is appropriate where goods have to be transported over long sections or there are great differences in altitude.
H
owever, due to handling and transport restrictions, only limited segment lengths of these belts are produced. The individual segments are then spliced on site in a time-consuming operation. The splicing process includes preparation and implementation of hot vulcanisation using special vulcanising devices. Hot plates positioned above and underneath the conveyor belt splice apply heat and pressure si-
The combined heating method for hot vulcanisation of steel cord conveyor belts described below uses the steel cords, which are embedded in the conveyor belt
Pressure equalising plate
multaneously to the splice. The combined heating method for hot vulcanisation of steel cord conveyor belts described below uses the steel cords, which are embedded in the conveyor belt to act as tension members, as an additional source of heat. In this way, the duration of the vulcanisation process can be substantially reduced, while delivering the same splice strength.
State-of-the-art of devices for the hot vulcanisation of conveyor belt splices
As well as personnel, tools, materials and supplies, suitable vulcanising devices are vital for a hot vulcanised conveyor belt splice. Together with the type of construction, these devices are classified according to their temperature and pressure application. In addition to modular vulcanising devices that Pressure pad can be taken apart and are based on cross beams, a fully integrated compact design is also used.
Heating and pressure plate
Conveyor belt Cross beam
Tension bolt
Figure 1: Pressure pad in a cross beam design vulcanising device Phase 1
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111
Temperature
Vulcanisation temperature Phase 1: Heating
Another option is the use of hydraulic cylinders to generate pressure. They are inserted into the cross beams of the vulcanising device at equal distances and hydraulic fluid is supplied to them via a parallel circuit. Irrespective of the type of construction and temperature and pressure application, the conveyor belt vulcanisation process and their splices is shown in Figure 2.
Phase 11: Vulcanising Cooling limit temperature
Phase 111: Cooling
In most cases, heating coils or ceramic Positive Temperature Coefficient (PTC) heating elements are built into the pressure plate of the vulcanising presses to apply the required heat. To exert the necessary pressure, air-filled or waterfilled pressure pads are frequently used. As shown in Figure 1, the pressure pad is integrated in a sandwich-type structure between the pressure equalising plate and the heating plate.
Vulcanisation time Figure 2: Schematic diagram of the vulcanisation process of conveyor belts and their splices (Ziller, 2010)
This idealised vulcanisation process is in reality subjected to major inhomogeneity’s due to the thickness of the conveyor belt splice and the thermal properties of the elastomer, particularly in phases I and III. The low thermal
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BELTCON
conductivity and the high thermal capacity of the elastomer show the complexity of these thermally dynamic phases I and III. In the area in contact with the vulcanising device heating plates, the cover plate material has already been heated by the start of phase I and hence also already vulcanised, while the core of the conveyor
Belt thickness in mm
The decisive factor is in particular, the inhomogeneous heat distribution over the cross-section of the conveyor belt splice due to the limiting thermal properties of the elastomer
Conveyor belt
belt splice is still at the starting temperature. The inhomogeneous heating of the conveyor belt splice in phase I results in an unevenly distributed state of cure in phase II. This effect is not new, it is seen in the production of new belts and occurs even under optimal conditions. The state of cure curve over the conveyor belt cross-section shown in Figure 3 adjusts in a conveyor belt (type ST 4500) with a cover plate ratio of 16/8 after 31.5 minutes in phase II. The cover plate in direct contact with the heating plates of the vulcanising device reaches a state of cure of 100% after 31.5 minutes, while the state of cure of the core material around the steel cords is about 55%. Different vulcanising presses are used to splice conveyor belts and the splices are subject to this effect which is based on physical principles. Location related influences also affect the splice by increasing the inhomogeneity’s shown.
A combined heating method for the vulcanisation of splices for steel cord conveyor belts
State of cure in %
Steel cord
Figure 3: Local curve of the state of cure in the conveyor belt after 31.5 minutes in phase II (Engst, 1993)
Tension member Length L 100mm Width W 70mm Heigth H 40mm Tension member 10mm Pitch 20mm
The technical parameters governing the vulcanisation of splices of steel cord conveyor belts indicate the complexity of the procedure. The decisive factor is in particular, the inhomogeneous heat distribution over the cross-section of the conveyor belt splice due to the limiting thermal properties of the elastomer. Therefore, an additive heat input into the core of a conveyor belt splice presents potential for optimisation as it enables homogenisation of the heat distribution over the cross-section of the conveyor belt splice.
A concept for additive heat input into the core of the conveyor belt splice based on inductive heating of the steel cords Elastomer was described by Schulz, Overmeyer and Ziller (2011). Such a heat source Figure 4: Three-cord belt sample examined in theory and in experiments installed in addition to the heating plates (Keller, 2001) takes into account the thermal properties of the Conventional heating method elastomer. It has been shown that, for example, in a steel cord, diameter of 9.2 mm, the heated surface in direct contact with the elastomer can Core layer be enlarged by about 62% by using the steel Critical Combined heating method temperature zone cords as an additional heat source.
Figure 5: Qualitative temperature distribution in the cross-section of the three-cord belt sample in phase I for different heating methods
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In-depth theoretical and experimental examinations are required to enable an assessment of the effects of additive heat input. This is
BELTCON
undertaken using three-cord belt samples as shown in Figure 4. The first period of experiments were carried out on cylindrical tension members which had been treated with a cement to create adhesion with the elastomer.
The advantages of a combined heating method are reflected in the time curve of the difference between minimum and maximum temperature in the three-cord belt sample Theoretical examination of heat distribution in three-cord belt samples
Differential temeprature in oC
A calculation method was developed by the Institute of Transport and Automation Technology (ITA) and applied to investigate three-cord belt samples. This initially examined the theory of temperature distribution in the samples during the vulcanisation process. The effects of this additive heating on the duration of phases I to III can be shown by means of the calculations. The theoretical studies for different heating methods focused on the temperature of the strengthrelevant core layer shown in Figure 5, and the critical temperature zone of a conveyor belt splice arising during the vulcanisation process.
method. After only ten minutes at a heat source temperature of 145째C, the differential temperature drops to below 20째C, while the temperature difference for the conventional method remains at 90째C.
Experimental examinations of the heat distribution in three-cord belt samples
In principle, inductive and conductive methods can be used to examine an additional heat input into the core of a conveyor belt splice under laboratory conditions. The inductive method requires a relatively high equipment expenditure. The same thermal effect can be achieved with less expenditure with the conductive method in which a direct current is fed into the tension members. Therefore this method was used. The respective tests were carried out on three-
Conventional heating method Combined heating method
The design of the inductive heating unit ensures that only the cords inside the splice are heated directly, thus there is no effect on cords outside of the splicing area. There are, obviously, some thermal effects on the belt outside the splicing area in both methods.
Temperature in oC
In the conventional heating method, the critical temperature zone lies within the core layer, but it is outside for the combined heating method. Thus the influence of the critical temperature zone Time in minutes on the core layer is reduced. Moreover, the necessary adhesion between steel Figure 6: Theoretical curve of the difference between minimum and maximum temperature cord and elastomer can build up im- in a three-cord belt sample for different heating methods with ideal heat source characteristics mediately at the start of phase I and does not depend on the heat application by the conventional heating system.
Combined heating method
Measured The advantages of a combined heating method are reflected in the time curve Calculated of the difference between minimum and maximum temperature in the three-cord belt sample (Figure 6). Assuming an ideal heat source characteristic, which is the rectangular function of temperature increase, the differential temperature Time in minutes curve of the combined heating method shows significantly more homogeneous Figure 7: Theoretical and experimental temperature in the core layer of a three-cord belt heating compared to the conventional sample for the combined heating method
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Force
BELTCON
Time Figure 8: Schematic diagram of the force curve for the static pull-out strength of three-cord belt samples (left). Example of fracture pattern of a three-cord belt sample (right)
Heating method
Mean of static pull-out strength in %
Largest positive deviation of static pull-out strength from mean in %
Largest negative deviation of static pull-out strength from mean in %
Conventional
100.0
+4.4
-0.1
Combined
102.8
+9.2
-3.7
Table 1: Test results of the static pull-out strength of three-cord belt samples compared to the conventional heating method
cord belt samples of the type described in this article. The direct current was fed into the tension members via terminals. The temperature inside the core layers of the three-cord belt samples was measured during the vulcanisation process by means of thermocouples. In addition, the heating characteristics of the vulcanising device were recorded and then used as a basis for the theoretical simulation of the core layer temperature curve for the combined heating method. As shown in Figure 7, the temperature curve in the core layer can be precisely simulated using the calculation method developed at the ITA. Hence, the applicability of the calculation method in practice is demonstrated.
Experimental examinations of the strength of three-cord belt samples
In these experiments, the static and dynamic strength of three-cord belt samples using both the conventional and the combined heating method was investigated. The same vulcanisation temperature of 145°C was applied in both heating methods, the only difference being that it was reached using different heating characteristics. Accordingly, the results only show the effects of a different heating phase (phase I). Phases II and III were not changed.
Conventional heating method
In the conventional heating method, the threecord belt samples are vulcanised by means of the heating plates arranged above and underneath the samples. Additional heat input does not take place.
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Combined heating method
Various methods are feasible for the combined heating method and were thoroughly explored in the research project. However, the subject matter of this article is exclusively the method described below in which the heating plates of the vulcanising device are operated with the same heating characteristics as the conventional heating method. In addition, the tension members in the core of the three-cord belt sample are heated to the vulcanisation temperature of 145°C within a defined period of time. As a consequence, different temperature gradients are dependent on the respective defined target heating time. A target heating time of 300 seconds was defined for the tests described here. This time corresponds to about 10% of the duration of phase I when using the conventional heating method.
Static tests
The static tests of the three-cord belt samples were conducted according to DIN 7623. The aim of the tests was to determine the influence of the two different heating methods on the static pull-out strength of a three-cord belt sample. Conforming to DIN 7623, the three-cord belt samples were stressed until fracture by a movement speed of the clamping device of 100 Âą10 mm/min (Figure 8, left). Five test pieces per heating method were examined. In all test pieces, the fracture was in the form of a purely structural interruption in the elastomer (Figure 8, right). Table 1 shows the results including their relative deviations compared to the conventional heating method. Table 1 shows the results of the two heating methods and the deviations from the mean of the static pull-out strength of the conventional heating method. The results do not show a significant influence of the combined heating method in phase I on the pull-out strength of the three-cord belt samples compared to the conventional heating method. The static strength is neither significantly increased nor decreased.
Force
Highest Load
Lowest Load Load Cycle
Relative elongation in %
BELTCON
Elongation at fracture
Elongation at highest load Elongation at lowest load
Time
Time
Figure 9: Schematic diagram of the test load curve for the dynamic test of the three-cord belt samples (left). Example of elongation behaviour of a three-cord belt sample (right)
Dynamic tests
The dynamic tests of the three-cord belt samples were carried out following DIN 22110-3 and AS 1333. The aim of the tests was to determine the influence of the two different heating methods on the finite-life fatigue strength of a three-cord belt sample. Conforming to DIN 22110-3 and AS 1333, the three-cord belt samples were subjected to cyclic loads which are described by a highest load, a lowest load, a ramp rise or ramp fall time and a holding time (Figure 9, left). The lowest load was 4.0 kN in all tests and kept constant at each load cycle for a period of 1 second. The periods of force increase to highest load or force decrease to lowest load were 2 seconds at each load cycle, so that the resulting load cycle period was 5 seconds. The highest load could be chosen freely. The duration of a test depended on the number of load cycles passed until fracture of the three-cord belt sample.
Figure 9 shows an example of elongation behaviour of a three-cord belt sample in a dynamic test. The change of elongation over time, both at the highest load and at the lowest load, is present for the entire duration from the start of the test and the end, due to the fracture of the test piece. The figure shows that an elongation of about 20% occurs when the sample fails under the highest load. The elongation behavior shown is accurately determined by the properties of the elastomer and the design of the three-cord belt sample examined. The elongation behaviour allows further conclusions as to the formation of the sample's dynamic pull-out strength. Four three-cord belt samples were examined for each heating method. In all test pieces, the fracture was in the form of a purely structural interruption in the elastomer. By combining the test results, a finite-life fatigue strength curve was recorded for the test pieces for both heating methods. From these curves, a relative reference fatigue strength is calculated for a pre-determined number of load cycles of 10 000. This strength value is purposely not shown as an absolute value but as a relative value by relating it to the mean of the static pullout strength of the three-cord belt samples tested with the conventional heating method (Table 2).
Heating method
Relative reference fatigue strength in %
Conventional
38
Combined
39
Table 2: Relative reference fatigue strength of the examined three-cord belt samples for different heating methods
According to Table 2, the test results do not show that the heating method has a significant influence on the relative reference fatigue strength. The results of the tests are nearly identical for both heating methods. This means that the dynamic strength is neither significantly increased nor decreased.
Economic importance of the test results
The aim of the following discussion is to determine the effects of the different heating methods on the duration of the heating phase (phase I). To this end, the temperatures inside the core layers of the three-cord belt samples were measured and recorded during the entire vulcanisation process. Figure 10 shows examples of temperature curves for both heating methods and displays the different heating characteristics. In the conventional heating method, the temperature inside the core layer rises slowly and approaches the pre-defined vulcanisation temperature of 145째C asymptotically. The combined heating method is characterised by the fact that the tension members are additionally heated to the vulcanisation temperature within a fixed period. Figure 10 shows this characteristic at the start of phase I. The core layer follows, with a delay, the temperature of the tension member given by the heating method. Once the tension member has reached the required vulcanisation temperature of 145째C, the temperature is kept constant by the regulating algorithm of the combined heating method. This explains the more gradual rise of the temperature in the core layer that occurs after BULK HANDLING TODAY
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BELTCON
Temperature in oC
spect of the duration of the heating process (phase I). The use of the combined heating method can reduce the heating process by up to 45% compared to the conventional heating method.
Since the investigations for the modified heating process Conventional heating method (phase I) already Combined heating method show a considerable potential for time savings, it is intended to address Time in minutes the impact of a modified vulcanisation Figure 10: Temperature inside the core layer of a three-cord belt sample during the vulcanisation phase (phase II) in process for different heating methods future research. This will also focus on the strength of the vulcanised three-cord belt samples and the duration of the The use of the combined heating method can reduce vulcanisation phase.
the heating process by up to 45% compared to the conventional heating method
Since the conductive heating method that made it possible to perform the first period of investigations can be implemented only in a laboratory environment, further tests are necessary using an inductive heating method. Currently, no full scale splices have been done, but investigations on a small scale are still being conducted.
about five minutes, after which the temperature approaches the specified vulcanisation temperature, also asymptotically. With regard to the duration of the heating process until the defined vulcanisation temperature of 145째C is reached, the heating methods examined show substantial differences. Using the combined heating method can reduce the duration of phase I by up to 45% compared to the conventional heating method. This percentage is calculated and based on the conventional heat-up process described.
It thus becomes a prerequisite to develop and construct an appropriate vulcanising device. It will then be possible to compare the conductive and the inductive heating methods, and to verify the practical application of the new combined (conventional and inductive) heating method for vulcanising devices for the splicing of steel cord conveyor belts.
In the studies, test pieces produced with the conventional and the combined heating method were compared to each other in terms of strength. Both the static and the dynamic strength values of the three-cord belt samples showed just marginal differences for the two heating methods. PROMECH PUB p - T, O, G 2/20/11 9:54 PM Page 2 However, a substantial
difference was found in reC
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Composite BULK
HANDLING TODAY
This paper has been condensed due to space constraints. It was first presented at Beltcon 17 in 2013. The authors are Lennart Schulz from Leibniz Universit채t Hannover, Ludger Overmeyer from Leibniz Universit채t Hannover and Thomas Ziller from NILOS GmbH & Co. KG. Copyright is vested with the IMHC. www.beltcon.org.za
February 2014
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CONVEYING
PROJECT MANAGEMENT
New Player in Projects Keen as mustard, your new company has just been launched and you’re raring to go. Only problem, no-one’s heard of you and they’re reluctant to give you a break. But what if the company is a joint venture between two firms that are already well-known in the market? Ardbel is just such a concern. traditional business of the two ‘mother’ companies, but we will be able to draw engineering expertise from them where necessary.”
Ken Bromfield, MD of Ardbel
S
temming from a joint initiative between ELB and DRA, both well-respected project houses in the mining industry, this specialist bulk materials handling company has recently been established in South Africa to address specific needs. “Bulk Handling Today” speaks to managing director, Ken Bromfield.
Local backing
“Ardbel is a joint venture formed through the collaborative efforts of the DRA Group and ELB Engineering Services, with the specific purpose of re-defining large scale materials handling and infrastructure engineering services to the mining industry,” he says. “Drawing from the specialist skills of these two well-established engineering companies in Africa, we intend offering project management solutions backed by the wealth of experience and the financial stability of these two firms.”
Ardbel will get involved in taking material from the run of mine point of generation, pre-conditioning it by crushing, screening and sorting and transporting it to the actual process plant. Being DRA’s field of business, they will not get involved in the process plant itself, but will step in again when it comes to taking material from the process plant, usually in two streams. Ken explains, “One stream is a beneficiation product which we will take to a stockyard which we’ll ensure is designed and operated correctly in order to preserve the integrity of the material. The other stream will be waste which needs to be transported to the residue facility.
Both ends
“Subsequently we will design and build the loading systems for the stockyard material, be it by train, truck or any other means to enable us to get the material to port. At the export end, we will be responsible for designing
Drawing from the specialist skills of these two well-established engineering companies in Africa, we intend offering project management solutions backed by the wealth of experience and the financial stability of these two firms Although both companies manage projects for mining developments, they recognised that neither covered large scale bulk handling as a dedicated speciality. “Ardbel now makes it feasible to get into the very big bulk handling projects which both ELB and DRA have missed out on in the past,” Ken explains. Since making the decision to go ahead with the joint venture, Ardbel has been registered as a company, competition commission issues have been sorted and it’s ready for business.
Pit-to-port
“Our pit-to-port materials handling solutions for large projects will not affect the BULK HANDLING TODAY
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PROJECT MANAGEMENT
the stockyard and handling systems including the stacking – reclaiming and shiploading equipment.” Although both parent companies have operated internationally for many years, they are no slouch when it comes to working in Africa which is a major advantage for Ardbel which does not have to re-invent the wheel as far as local conditions and challenges go. In fact, the company can access the project management and engineering skills of over 1 400 engineers, technologists and draughtsmen through their association with the two founding companies.
The company can access the project management and engineering skills of over 1 400 engineers, technologists and draughtsmen through their association with the two founding companies For Africa
“There are many significant projects happening in Africa right now, not only on a Greenfields basis but also in terms of the expansion of existing mining operations,” Ken notes. “Being able to relatively quickly mobilise a fair-sized project team by pulling resources from our parent companies is a huge advantage. Over time, however, we will build up sufficient expertise to operate independently as a project house in our own right.” Given the financial backing of the ELB Group, which listed on the Johannesburg Stock Exchange in 1951, and the DRA Group which is a large-scale, privately-held engineering business, Ardbel is able
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to offer clients flexible contracting arrangements which include Lump Sum Turn Key (LSTK), Engineer Procure Construct (EPC), or Engineer Procure Construct Manage (EPCM) contracts.
Operator
In time to come, Ardbel intends to penetrate the mining market on a long-term basis by also operating mines on behalf of owners. “Through an associated company, Minopex, we can offer the full range of services in commissioning, operations and maintenance to our clients,” Ken says. “Currently Minopex operates and maintains a total of 20 mineral processing plants in Africa alone. This includes diamond, coal and platinum beneficiation as well as chrome and gold processing where they’re responsible for plant operations in terms of general metallurgical, engineering and quality management of the beneficiation plant and the associated materials handling systems of the entire operation.” The general reaction to a new player in the market has been warm and billed as filling an important gap. “We’ll be operating in a space where we can freely select equipment which will be appropriate for our clients,” Ken remarks in conclusion. “We don’t have a flag to fly for any particular supplier of equipment which will allow us to provide our clients with a unique solution for their particular requirements.” Ardbel, Ken Bromfield, Tel: (011) 032-1150 Email: kenbromfield@ardbel.com, www.ardbel.com
BOILERS
By Word of Mouth South African engineers working for international companies tend to migrate back and forth between various countries, often taking local technology and solutions along with them. This is a major advantage for South African manufacturers as their products are introduced to new markets they’ve not played in before.
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ransmission Components in Kempton Park is one such manufacturer. Enquiries for their products have steadily increased from Europe as well as Australia without them actually marketing specifically in these regions. “We have just extended the patent on our Tru-line rigid flange coupling to Europe and Australia because of the many enquiries we’ve received,” says marketing manager, Rudi Jeggle. “We deduced that the enquiries stem from engineers who used our systems in South Africa and are now working on projects in Australia where they must have spread the word about the coupling’s superior features.
Patents
“Until now, our patent only covered South Africa, but since the principle of our design is fairly new technology to the Australian market, we’ve had to ensure our design is protected there as well,” he adds. “Even with patent protection locally, there still are people who have tried to copy our design, but since many mines now specify our product, this threat has been reduced somewhat.”
This cost saving is passed onto the customer and it also means that only the toothed grid elements on the larger sizes of this type of coupling have to be replaced when they become worn To surmount the problem of copying products so that they resemble the real thing, Kurt Jeggle, the managing director of Transmission Components, used clever engineering to re-design the locking element of the company’s well-known rigid flange coupling by adding subtle improvements and then patenting the design.
More versatile
“The Tru-line rigid flange coupling design has undergone some changes to make it more versatile than before,” Rudi explains. “We’ve made alignment easier and the coupling can now be re-used over and over because there’s no possibility of damage when it’s removed as was sometimes the case in the past.” With the new changes in the design, the company decided to patent the design to ensure that it can’t be copied outright. “The product can be used on any application where two shafts are joined, but our target market is mainly in conveyor applications
where true alignment and re-usability of the coupling is important,” says Rudi.
Manufacturing
However, it’s not only the new features which have made this coupling a huge success, the manufacturing and quality control processes in place at Transmission Components make a world of difference in terms of precision-fit components. “From the experience we’ve gained in exporting to Germany over the years, we’ve learnt that you have to work to very fine tolerances consistently, not only dimensionally but also when it comes to surface finishing,” says Rudi. “If you don’t, your product will just not be good enough for the international markets.” All Transmission Component products are certified and records are kept in order to have full traceability of each component manufactured. Rudi adds, “Although we manufacture this range of couplings in all the standard general sizes, we have come across a couple of applications where we’ve had to either make a custom size, or devise a special adaptor plate in order to make the coupling fit properly.”
Backstops
The company is doing well in backstops for conveyor system, also partially manufactured locally. “A backstop is a heavy piece of equipment to import so we came to an agreement with the OEM, Ringspann, and now only import certain components,” Rudi explains. “This has allowed us to cut BULK HANDLING TODAY
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BOILERS
The Ringspann backstop
costs considerably as we only import the internal parts and manufacture everything else around these items in-house with full approval of the OEM.
We’ve made alignment easier and the coupling can now be re-used over and over because there’s no possibility of damage when it’s removed
“Similarly we often get involved in developing specific locking-element solutions for clients with new coupling applications and will even machine parts of their designs for them,” he adds. “A well-known European brand of locking element, for example, is wholly manufactured by us.”
Cost savings
At this company, innovation is an on-going thing. For example, in terms of imported grid couplings, they have made some changes to the design, also to reduce import costs. “On large couplings, the toothed part is the core but importing the whole assembly adds up to a big chunk of steel,” says Rudi. “Now we only import the toothed part of the grid coupling in the form of a ring. This toothed ring is then bolted onto a hub which we manufacture here under licence to the OEM in France.” The company, therefore, no longer has to pay freight for the weight of the hub which, together with the toothed ring, makes up the component. This cost saving is passed onto the customer and it also means that only the toothed grid elements on the larger sizes of this type of coupling have to be replaced when they become worn. Therefore the customer does not have to pay for all that extra steel as was the case in the past. Couplings and locking elements form an integral part of a conveyor system and to incur downtime costs because of inferior quality couplings just doesn’t make sense. “Always ensure that you’re dealing with a reputable company that has been around for a while, otherwise you may end up with a cheap copy,” Rudi warns in conclusion. “In the end it always costs you more when you have to replace and what’s more, you simply won’t be able to re-use the coupling unless you specify a prime product from a company that know its oats.” Transmission Components, Rudi Jeggle Tel: (011) 394-1830, Email: rjeggle@transmission.co.za
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LIFTING EQUIPMENT
Radio Remote Control for Lifting Machinery Controlling lifting machinery remotely via radio frequency on a handheld console is almost standard practice nowadays, especially in situations where the safety of the operator is at risk.
they’re now introducing to the local market. “Since going to market a while back, the local sales of the 2.4 GHz technology consoles have increased steadily,” he says. “For high RF traffic areas, HBCradiomatic in Germany developed an intelligent frequency management system which now allows safe, convenient and hassle-free machine control without frequency conflicts.” This RF technology comes in the form of a highfrequency module, the TC240, which brings about a whole set of advantages. The cumbersome tracking and logging of frequency lists is no longer required because the 2.4 GHz technology module is a fully-automatic, intelligent frequency management system.
Paul Barcelos, director of HBC-radiomatic South Africa
W
ith only 69 separate channels allocated to remote-controlled frequencies, chances are that a site with many remote control units, will cause interference rendering the units inoperable. This age-old problem requires someone to tediously list and keep track of all the frequencies of the units on the same site, until an outside unit arrives on site to throw a spanner in the works.
No interference
This problem is now a thing of the past. “Bulk Handling Today” speaks to Paul Barcelos, An intelligent frequency director of HBCmanagement system radiomatic South which now allows safe, Africa, about the convenient and hassle-free frequency clashfree remote conmachine control without trol technology frequency conflicts
Paul adds, “For example, let’s say a truck arrives on a site where there are many RF units, chances are good that with the old technology, the remote control for the crane on the truck may interfere with one of the frequencies already in use on the site. If this situation arises now our unit will ‘sense’ that there is another radio already using that specific frequency and simply switch to another frequency which is not in use at the time. Also, the channels have been bumped up from 69 to 79. “The 2.4 GHz technology is available with all HBC radio control systems, except cubix,” Paul adds. “From compact hand-held transmitters to high-end joystick controllers, customers now have even more possibilities when it comes to selecting a radio control system from us, and the TC240 is characterised by a very strong and secure radio link, even under the most demanding conditions.”
Seeing the whole picture
Brand-new from Germany, and now available in South Africa, is a video monitor built into the remote console, allowing the operator to see what he’s doing from a variety of angles on a TFT colour screen. “We can plug in up to eight live video streams from cameras mounted at various angles onto the workplace so that the operator can switch between the various camera angles on the remote console by simply flicking a switch,” Paul explains. “Each camera has a transmitter which sends a live stream to the console continuously.
“The cameras are day/night with infrared vision,” Paul states. “As soon as the illumination levels We can plug in up to eight live video streams from cameras mounted at in the working area fall below a various angles pre-determined value, the cameras BULK HANDLING TODAY
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LIFTING EQUIPMENT
automatically activate several infrared LEDs so that the operator can see in dark areas or work at night. Most important of all though, is that this feature further enhances the safety aspect around lifting because the operator has such a wide view of everything in and around the workplace.”
Operators are much more responsible because they know abuse can be traced back to them
The user ID system
Lifting control
Another innovation also currently being introduced to the South African market is a crane operator identification system built into the remote console. “The user identification system allows for the activation of the radio control system through the use of a convenient login card which we call the HBC Smart Card,” Paul elaborates. This not only provides protection from the danger of unauthorised use, but the system has features such as operator
identification and individual user level settings. “In order to start up the remote controller, the operator is given a personal card which he swipes over the console,” explains Paul. “Apart from switching the console on, it also logs the date, the time and who logged in. It also carries all details of the operator’s licence so he or she is unable to start-up if he has reached the expiry date.”
Data logging
In addition, every single function that the operator then performs during a shift can be recorded. “In combination with an HBC data logger, the radio system fitted with the operation ID system can store several operational data sets for each user,” Paul adds. “This includes the operating hours of the unit or the number of drive commands given. A very important aspect of the user ID system is the ability to set limitations for different operators. If an operator’s licence, for example, only allows him to work within certain weight limits, the system won’t allow him to lift anything heavier than the set limit. For this, additional crane hardware may be required.” Finally we ask Paul whether all these bells and whistles don’t make the console more vulnerable to damage by the operators? “On the contrary, operators are much more responsible because they know abuse can be traced back to them. Furthermore, all these features have been developed with better safety in mind. South African companies are increasingly becoming aware of the importance of safety, especially when it comes to lifting. Steadily the bells and whistles are becoming necessary requirements.” Paul Barcelos, HBC-radiomatic South Africa, Tel: (011) 421-0004/25, Email: paul@radiomatic.co.za
Book Now! MAR 2014 • Conveying • Crushers, screens, chutes, liners • Harbours, ports, shipping & railways • Trucking & Transport APR 2014 • Power Transmission • Lifting equipment • Underground mining equipment • Earthmoving & plant hire
Contact Surita Marx on Tel (011) 781-1401, Fax: (011) 781-1403 or E-mail: bulkhandling@promech.co.za to book your advertising space
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SUCCESS STORY
Climbing the Ladder to Success Every morning when Esther Hobongwana takes the first step up the ladder to the top of her massive tower cranek, she is taking another step towards building a successful career in construction.
ing course being offered in Durban that teaches people to become crane operators I gathered all my money and took the decision to resign from work.
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he is a woman who doesn’t let fear get in the way of her dreams and never lets an opportunity slip by her without giving it her best try. But, even for a strong-willed person like Esther, it took years for her to realise her worth and start to become the courageous woman that she is today. Just a few years ago she was a single mother of twins living in a tiny room in Johannesburg. Her only income was from a waitressing job where she worked long, hard hours just to make enough money to pay rent and buy meagre food and clothing for her and her children. She felt trapped, but was inspired by the many women working in construction jobs on the Gautrain project.
Big decision
“There and then I decided to change my life and follow my dreams. When I found out about a train-
“I travelled down to Durban, completed the course and walked away with a smart certificate in my hands. But, I found that the crane operator’s certificate wasn’t an easy ticket to getting a job,” Esther says. She tells “Bulk Handling Today” that it was tough walking the streets from company to company trying to convince people that she was able to do the job. Some of the men on these sites were sceptical saying that they were not sure she could cope, while supervisors raised concerns that the men on site would not be able to work with her.
Changing lives
Her fortunes changed however when she met a contracts manager for Stefanutti Stocks Building at a construction site in Rivonia. Noticing her determination, he gave her the details of the company’s then HR Director and suggested she talk to him.
Crane operators get a good view of the construction projects
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SUCCESS STORY
Investing in people
Ian’s judgement and Stefanutti Stocks’ trust in Esther have paid off and to date Esther has never had a single incident involving her crane. Her safety record is unblemished and despite initial scepticism of many of the male workers she has become the most trusted crane operator on the company’s sites. “Esther has shown us that she is capable of great things. As a crane operator she is gaining an overall view of how construction projects unfold and how it works. This will stand her in good stead in future and I predict that with her drive and determination she will go far within our company,” Ian says.
Ian Holmes with Esther Hobongwana
“I was sitting at my desk when this young woman walked in clutching a certificate and asking for a job as a crane operator. Although it is not unusual that people ask me for work, this time it was different, there was a determination in her eyes that I have seldom seen in my 39 years in the construction business,” explains Ian Holmes, Stefanutti Stocks Building.
But, at the moment Esther is still too busy enjoying her job to be seriously thinking about changing. “I love my job and every day I learn new things. I made the right move going for a career in construction and I know that the sky is the limit when it comes to my career with Stefanutti Stocks,” she concludes. Stefanutti Stock Building, Ian Holmes, Tel: (011) 244 0311, Email: Ian.Holmes@stefstocks.com
He continues that in his profession he has learned to read people’s body language and could immediately tell that Esther was not only determined, but also confident and genuine. He decided to try and find a position for her and spent the next few days phoning around. The breakthrough came when he found an opening at the company’s stock yard. Here Esther would be required to operate a small tower crane used to move and store heavy stock items for use by the contracts division.
Proving herself
“We were immediately impressed with her passion and soon noticed that she was the first person on site in the mornings and the last to leave in the evenings. She happily worked overtime when we had to work late and was always prepared to stay on to finish an urgent job.” Her hard work and determination paid off and when the company began work on a multi-storey parking garage at OR Tambo, Esther was paired with the company’s most experienced and respected crane operator. “I learned so much from this guy. He mentored me and taught me all the things I needed to know to be a good crane operator,” adds Esther. Soon afterwards and after a long and successful career, Esther was given the opportunity to take over her mentor’s role. In the months before his retirement he had let Esther operate the crane on her own. After his departure and based on her abilities, the company’s managers did not hesitate to put her on some of the most demanding crane operator jobs the company had.
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Esther Hobongwana has mastered the skill of operating a tower crane
STOCKYARDS
Use of Castellated Sections under Static and Semi-Dynamic Loads Despite their excellent strength to mass ratio, castellated beams are not commonly used for dynamically or semi-dynamically loaded structures on stockyard machines. This can primarily be attributed to the greater complexity of load assessment and strength calculation procedures when compared with hot rolled sections or plate/ box girders.
T
his article deals with the basic problems of sizing castellated beams subjected to dynamic and semi-dynamic load conditions, highlights economic benefits in using this type of construction and provides examples of applications where castellated beams were used successfully. Only recently, as fabrication methods have become more automated and the steel prices have increased much faster than inflation, more and more companies started looking more closely at using this type of member for the construction of light and medium duty statically loaded structures. The use of the castellated beams for dynamic or semi-dynamic applications is still not considered by many structural engineers.
Castellated and cell/smartbeams
Initially castellated beams were fabricated by
cutting the web of the standard hot rolled section in a regular alternating pattern. Both halves were subsequently offset until the high points were aligned and the web was then rejoined by welding, leaving a series of hexagonal openings. To increase the depth and improve the sectional properties even more, square plates were inserted between high points of the web. This type of castellated beam is usually referred to as increment castellated beams. Steel companies also developed a further variation of this concept which was called the smart beam or cellular beam. These beams can be recognised by their circular openings instead of the original castellated beam’s hexagonal or the increment beam’s octagonal shape.
Background It is worth noting that the maximum normal stress (bending) is a combination of the primary bending stress (due to that bending moment) and secondary bending stress (due to shear force – the Vierendeel effect) and it may occur at any point along the length of the beam above or below the opening. The basic modes of failure in castellated beams are: • Formation of a flexure mechanism – failure of the member due to the yield of the T-section above and below the opening due to the primary bending moment only,
Majuba Power Station ash spreading system
• Formation of Vierendeel’s mechanism – failure of the member due to the yield of the T-section above and below opening due to Vierendeel’s bending caused by the shear force, • Lateral – torsional buckling – similar to the hot rolled or plate girder lateral – torsional buckling, • Shear of the weld in the web post – caused by the action of the horizontal shear force in the web post, • Shear buckling of the web post – caused by the horizontal shear, • Compression buckling of the web post – caused by the concentrated load applied directly above un-stiffened web post,
Catoca open pit diamond mine
• Fatigue – due to the stress concentration in the opening corners the castellated beams are more BULK HANDLING TODAY
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STOCKYARDS
sensitive to develop the fatigue cracks than the beams with the solid webs,
• approximately 15% for castellated beams with low web increment ( ≤ 200 mm),
• Vibrations of the web.
• approximately 20% for castellated beams with high web increment ( > 200 mm).
The last two modes of failure are typical for members subject to dynamic load conditions and can be neglected for static load applications. Another matter, which is still subject to research, concerns the stability and performance these sections under critical load (eg, postbuckling behavior of the web).
A few simple rules to size castellated sections
The detailed analysis of castellated beams is more time-consuming than the sizing of regular hot rolled beams or plate girders. Below are a few simplified rules for the selection of suitable castellated beam sections.
Stress calculation
The stress calculation for these members is based on Vierendeel theory and will not be treated here in detail. A number of commercial software packages are available on the market that can also assist the designers in dealing with this particular facet.
Lateral-torsional buckling
It has already been mentioned that the lateraltorsional buckling of castellated beams is similar to that of hot rolled sections and plate girders. Research has shown, however, that some form of correction needs to be applied when calculating the critical bending moment for the section as a whole. The critical elastic bending moment for the hot rolled section is given as:
For castellated beams this value should be modified by introducing a castellation factor (Cc) and a bending coefficient (Cb). The critical elastic bending moment of the castellated beam can now be calculated as follows:
Deflection The deflection of castellated beams is similar to the deflection of the hot rolled sections or plate girders. Therefore, for a simply supported beam with a point load in the middle, the following formula applies for calculation of the maximum deflection:
The castellation factor for beam types IPE and UB is approximately Cc = 1.056. The bending factor coefficient (Cb) depends of the size of the section and type of load. The following bending coefficients have been recommended: Pure bending: Cb = 1.0 b C • Uniform distributed load on the top flange:
where
P - point load, l - beam span, E - elastic modulus. Due to the non-uniform cross section of the castellation, the equivalent moment of inertia is a function of the moments of inertia of the cross-section with and without openings. Some publications suggest using the following approximation of the moment of inertia to calculate a deflection of the castellated beams:
where: I - moment of inertia of castellated beam which can be used for deflection estimation,
• Point load in the centre: Cb = 1.756 L - length of member, K - effective length factor, ry - radius of gyration of the member about its weak axis.
Shear buckling of the web
Since buckling of the web usually involves inelastic behavior, the ultimate limit state approach was revised to take this action into account. The web moment and shear resistance criteria can be expressed:
I1 - moment of inertia of the section at the opening, I2 - moment of inertia of the section without the opening In addition, for a castellated beam with web increments, the deflection value should be increased by:
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Mr - moment resistance, Vr - shear resistance. The test results show that the values k = 2 and
STOCKYARDS
Figure 1. Sample of FE linear analyses of the stacker structure and enlarged view on the castellated beam used for the stacker boom design
m = 2 can be used for engineering calculations. The shear resistance can be expressed using similarity to: • Moment resistance:
- correlation between the theoretical and test results approximately 11.3%, or • Axial compression resistance: - correlation between the theoretical and test results approximately 16.6%. l is interpreted as For standard castellated beams, as described in the South African Steel Construction Handbook 7th edition, the coefficient n=4 can be used.
Vpl and Vcre refers to the plastic and elastic buckling shear capacity.
Fe analyses and interpretation of the results
Due to the nature of the castellated beams it is advisable that the designer should exercise caution and be aware of possible discrepancies between the results obtained through FEA, the results obtained by analytic method and the actual behavior of the castellated section.
Linear analyses
The FE linear analyses give a very limited idea of the stress distribution, buckling and the dynamic behavior of the members. Due to the disregard of inelastic action within the castellated member, the results will be “very conservative” (stress pattern obtained from the linear analysis are higher than from the non-linear model). This difference between linear and nonlinear analysis may be as high as 60%. The FE linear analyses can still be found in older
Figure 2. Comparison of the stacker boom FE results using linear (left) and non-linear (right) analyses
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STOCKYARDS
Figure 3. SoMat eDAQ-lite field computer and tri-axial accelerometer used for measurements during dynamic test of the container crane
publications but they are not recommended due to their inaccuracy.
Non-linear analyses Due to the several inelastic actions: • yielding at mid span of the T-section and mid depth of the web post, • inelastic web buckling, etc non-linear FEA is recommended for performing computer simulations of castellated beams. The stresses obtained by non-linear analysis are substantially lower than those obtained from the linear simulation and the difference has been found to be as high as 60%.
The non-linear analysis results correlate with the results obtained from the test. The correlation between non-linear analyses and the test results depends mainly from the geometry of the section (geometry of the opening, width and thickness of the web post, length of the T-section) but also the stress level.
Dynamic load
One of the most challenging tasks that most designers face during sizing the structure under dynamic loads is a dynamic load assessment. There are a number of publications and standards that allow the designer to establish the magnitude and time history of the load under dynamic conditions for many applications. However, it should always be kept in mind that these values are general approximations and might not be suitable for the specific application. It is therefore advisable in certain cases to perform field measurements on a similar application. This exercise, though costly and time-consuming, generally pays for itself in terms of steel mass saving and avoiding costly repairs or other more serious consequences. Figure 3 shows typical equipment used for the transient response measurements of a container crane. The collected data allows not only compare the theoretical calculations with the behavior of the real structure but also to create a dynamic load data library that can be further developed into typical dynamic loading patterns for the No
Figure 4. Comparison of theoretical and boom response spectrum and frequency content (red line – theoretical graph, blue line – measured values)
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BULK HANDLING TODAY
February 2014
Type of girder
Cost
1
Castellated beam without increments
100 %
2
Castellated beam with increments
89 %
3
Lattice girder
129 %
4
Bent plate channel girder
120 %
5
Plate girder
167 %
Table 1: Girder cost comparison
STOCKYARDS
specific applications. Figure 4 shows a comparison of the crane boom response spectrum, in its transient state, measured on site and theoretical values calculated analytically based on the data obtained from the author library. The difference between the values calculated and measured on site is approximately 3%.
Economics
Castellated beams are approximately 50% deeper and their strength is approximately 50% higher than original members. However, the fabrication cost, due to the cutting and rejoining is also higher. A detail fabrication cost study (table 1) was performed for different types of girders to establish the most economical solution. The case study was for a 35 m long stacker boom supporting a 2.2 wide conveyor belt. Due to the operation requirements the girder was 800 mm deep with walkways on both sides of the conveyor. The figures given in the table include cost of: material, making a jig, girder assembly, welding, blasting and painting.
Medupi Power Station coal stockpile stacking system
It can be clearly seen that the castellated beams with increments is the most cost-effective solution. It should be also pointed out here that the fabrication cost ratios (ZAR/kg) are not constant and depend on the relationship between cost of the steel and labour.
Conclusions
• The cost study of different sections used for the stacker boom design shows that the castellated beam is the most cost-effective solution, • The Vierendeel’s girder theory gives a good approximation of the stress level assessment and can be successfully used in engineering practice, • There are a number of publications dealing with the local inelastic behavior of castellated beams, providing a simplified calculation methods of this event, • The non-linear FE analyses give a high accuracy between obtained results and the test results. Due to the local inelastic actions in the castellated beams, the linear FE are not recommended. www.thyssenkrupp-materialshandling.co.za Presented at the Structures for Mining and Materials Handling Conference, October 2012, Vanderbijlpark, South Africa SA Institue of Steel Construction, Tel: (011) 726-6111, www.saisc.co.za
Kusile Power Station coal stockpile stacking system – fabrication phase
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FORKLIFTS
Easier with Forklift Attachments Little room remains for human beings in automated materials handling environments other than operating machines that improve the efficiency of processes and minimise errors.
I
n today’s environment more hands, mean more complication and slow work. As a result, companies are seeking intelligent solutions to handle goods more quickly, safely and correctly without turning to a labour force to accomplish the same work. Stan Contat, managing director of Benoni-based Micron Engineering tells “Bulk Handling Today” that the trend locally is towards fitfor-purpose machinery to handle products that were either handled manually or badly in the past. He adds that the South African market is slowly aligning itself with global best practice and a move towards increased efficiency.
Machines do it better
“South Africa is a tale of two worlds where the top-end of our market makes use of some of the most sophisticated equipment in the world, while the lower end of the market still makes use of manual Mark Tucker, Stan Contat and Dustin Graham of Micron Engineering with a labour or inappropriate technology. newly-delivered telescopic fork attachment
Fit-for-purpose machinery to handle products that were either handled manually or badly in the past “That is why we have adapted our range of forklift attachment to meet the needs of both ends of the market. On the one end of the scale we have big business that is constantly looking for technologies to improve efficiencies. On the other we have smaller businesses that want to be less reliant on manpower and are turning towards varying degrees of automation.
Micron Engineering’s new pallet inverter
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Forklift attachments provide customers with solutions to do dedicated or specialised jobs with a fit-forpurpose machine. It also provides the flexibility to simply detach and use the forklift for other purposes or even to attach other types of work tools and perform different tasks with the same machine.
FORKLIFTS
An innovative tyre handler attachment
Popular solutions
At present the major sellers supplied by the company are attachments that are used as productivity boosters. These include multi-pallet handlers that are used in bulk applications where pallets of different types are handled simultaneously.
Micron Engineering has been manufacturing, customising and importing forklift attachments for over two decades. During this time the company has seen the expansion of the range of attachments worldwide from basic mostly mechanical units, to sophisticated pneumatic and computer-driven equipment for specific applications.
Popular choice
Fork-positioners are also a popular addition to enhance productivity especially in tight spaces
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February 2014
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FORKLIFTS
or where precise alignment is difficult to achieve. In some instances the addition of fork-positioners can double or treble productivity purely as a result of less time spent picking-up each load. Similarly, telescopic forks are becoming increasingly popular as they provide operators with far greater flexibility especially when dealing with double-deep racking or more commonly to unload trucks from one side only. Although these are just some of the popular choices of forklift users at the moment, Stan explains that similar solutions exist for almost every other application and can be tailor-made to enhance productivity and ensure safety when handling goods.
Make end-user deliveries a less complicated and faster experience
The new easy-to-attach container handler
“Some South African companies are world leaders when it comes to materials handling and the use of technology to facilitate their processes.”
Around the world
The company manufactures a range of forklift attachments at its factory in Benoni. These are mainly mechanical units and custom-made attachments according to unique specifications. In recent years, however, the company has also begun importing fit-for-purpose attachments from top manufacturers around the world to ensure customers have access to the very best equipment available globally. “We don’t want to reinvent the wheel every time a customer wants a specific attachment. Instead we have agencies around the world that specialise purely in making attachments for certain applications and, in many instances, we prefer to bring in ready-made equipment that is tailor-made to our clients’ specifications. “Whether we are supplying attachments to reduce labour, work more effectively in tighter spaces, or to handle goods more carefully and efficiently, we always strive to supply the appropriate equipment to get the job done right,” concludes Stan. Micron Engineering, Stan Contat, Tel: (011) 421-0738, Email: stanc@microneng.co.za, www.microneng.co.za
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ROUTING & SCHEDULING
Vehicle Monitoring Over the Border Numerous industries across Africa can ensure that their fleets are safely and cost-effectively managed anywhere on the continent, by making use of the QIC-Fleet GSM fleet management solution developed by QCIC.
P
Brian McKenzie
retoria-based QCIC utilises unique telemetry solutions and services to meet the fleet management requirements of clients operating in the transport, earthmoving, consumer and security industries. QCIC director Brian McKenzie notes that the QICFleet solution enables fleet owners to effectively and affordably manage numerous variables related to the location and performance of individual vehicles by transmitting relevant data on the GSM network, via a preferred network partner. Sub-Saharan Africa is well covered by a GSM network at the moment which enables telemetry solution providers to supply clients with sophisticated GSM solutions that can connect to preferred networks and deliver near real-time data to the end-user. Coupled with Hybrid Satellite hardware, the asset is never out of the communications reach of the owner.
Enabling the fleet owner to monitor the vehicle or asset at a flat rate when it enters countries in sub-Saharan Africa Cosy connection
Brian points out that the preferred supplier agreement enables the QIC-Fleet solution to essentially 'piggyback' on the GSM Network’s and their partners, thereby enabling the fleet owner to monitor the vehicle or asset at a flat rate when it enters countries in sub-Saharan Africa such as Namibia, Botswana, Zimbabwe, Mozambique, Tanzania, Kenya, Malawi, Zambia and the Democratic Republic of Congo. "In the past, GSM was not a viable option for fleet management, as network providers would charge high data rates for roaming when the vehicle entered a new country, and the devices did not have the ability to connect to a preferred partner in that country. QIC-Fleet now has the ability
to do exactly that and at a fraction of the cost�. The product is fitted to the client's vehicles free of charge, and comes standard with the required mapping software, and GSM airtime. It boasts numerous benefits, including: vehicle and driver ID, GPS location, trip duration, highest speed for trip, trip distance odometer, accumulative odometer, fuel consumption, engine hours and start and end times of trips. These are just some of the functions the system can perform.
Essential data
What's more QIC-Fleet enables the client to take proactive measures to avoid accidents, or to establish the cause of an accident, should one occur. "The device records essential data such as RPM, speed and braking, and warns the driver to take necessary action before failure occurs." Should the driver fail to take the necessary action that was prompted, the crash analysis feature makes all recorded data, 10 seconds before and five seconds after the incident, available to the relevant fleet manager. "These recordings provide valuable insight in determining the circumstances surrounding the cause of the accident, and what action the company should take moving forward. It is also invaluable for insurance purposes, as the information is captured and recorded, and eliminates any conflicting versions from the various parties involved in the incident."
Crossing borders
As continued investment in the African marketplace directly results in the increase of commercial delivery vehicles crossing borders, Brian is optimistic that they can measurably increase market share through QIC-Fleet in the short-term future. "Fleet owners demand the peace of mind in knowing that their driver, vehicle and its load are safely crossing borders in an efficient, safe and costeffective manner. By adopting our solution, they will have full and uninterrupted access to their fleet on an around-the-clock basis," he concludes. QCIC, Brian McKenzie, Tel: (012) 682-1621/3, Email: brian.mckenzie@qcic.co.za, www.qcic.co.za
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MARKET FORUM
Another Successful Year Mobile harbour cranes (LHM) once again contributed strongly to the overall success of Liebherr Maritime Cranes. The 2013 year ranks among the most successful ever. Various highlights characterised the year, including a remarkable order intake for the 600 series in Latin America and the launch of the Liebherr maritime cranes simulator range. In 2013, Liebherr delivered almost 80 mobile harbour cranes across the globe and achieved a turnover of 280 million Euro. Having a closer look at the geographical distribution, Europe (including Russia) is still the main region for Liebherr mobile harbour cranes accounting for more than 40% of the annual deliveries. The African market was ranked second in 2013 with nearly 14%, showing a 7% drop compared with its 2012 share. However, the order backlog for this region indicates that this is just a temporary downturn. Strong signals came from Australia (10%) and North America (7%). Also in the Middle East the demand for LHMs rose significantly. Further deliveries to Latin America, India and Asia complete the picture.
Metso’s latest generation Lokotrack ST2.4 mobile screen combines high capacity performance with fuel-efficient operation to provide the lowest cost per tonne in its class, thanks in part to the optimised hydraulic design and state- of-the-ar t process steering automatics.
Multi-product Screening
The Lokotrack ST2.4 processes a diverse range of feed materials, from the prescreening of the coarsest gravel to fine classifying and processing of natural sands, or any demanding recycle materials. Three clean end product sizes can be produced in one process due to the ST2.4’s two-stage screen set-up. A variety of screen media can be fitted, from steel meshes to rubber and polyurethane materials. All the conveyors are folded
hydraulically and secured mechanically. “You just set up the screen angle, lift the feeder up and start screening,” says Kimmo Anttila, product manager for Metso mobile screens. (Barloworld Equipment is Metso Mobile’s southern African distributor.) Barloworld Equipment, Alastair Currie Tel: 011-929-0000 Email: acurrie@barloworld-equipment.com
Local Apron Feeders FLSmidth has introduced a locallymanufactured and supported apron feeder under its Buffalo product line that effectively extends the focus of this equipment brand beyond the coal sector and into the hard rock arena. “There’s a major demand for apron feeders in the African mining industry and establishing a manufacturing and aftersales support hub for this equipment in sub-Saharan Africa will greatly reduce lead times,” Johan Fourie, FLSmidth’s Buffalo operations director, says. “This line of equipment will be fully supported by field service teams, technical know-how
The outlook for 2014 is impressive. Order backlog is at a record level and is much higher than in 2012, which still represents the most successful year for the company. The total order backlog is well above 150 million Euro.
An FLSmidth Buffalo feeders and sizers installation
BULK HANDLING TODAY
The FLSmidth apron feeder offering includes horizontal and inclined units for extracting bulk materials from under a dump hopper or regulated feed to a crusher. Raw material is dumped directly into a reinforced feed hopper and extracted by the apron feeder ensuring a steady flow of material to the next stage of the process, typically a crushing plant. The rugged and reliable construction of these feeders makes them easy to operate and maintain, with minimum operator attention required. They are designed for uninterrupted service and only need to be stopped for the occasional replacement of wear parts. Worn aprons and chains are accessed from the take-up end of the feeder for easy replacement and sprocket wheels feature bolted-on tooth segments which can be interchanged or replaced. Impact rollers are lubricated by a central lubrication unit, while the chain rollers are lubricated manually with a grease gun.
Liebherr, Tel: (011) 365-20 00 Dobler Joachim Joachim.Dobler2@Liebherr.com www.Liebherr.com
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and spares from our facility at Ferrobank, eMalahleni, with additional backup from the greater FLSmidth Group globally.”
February 2014
Flsmidth, Terence Osborn Tel: (0100 210-4820 Email: marinda.kerr@flsmidth.com
MARKET FORUM
Full Mobility Most Fuel-efficient Econz Wireless and RuggedPhones have announced their partnership to provide businesses operating in tough environments with a full set of mobile applications from employee tracking, to time-and-attendance and payroll integration. The suite of mobile apps will enable employers in environments like construction, manufacturing, distribution, and government to not only track their employees while in the field via GPS but to give them a full time and attendance record of who is on site and when. Fully integrated with their own accounting and payroll system, this gives employers accurate records in real time. The Titan range of Android phones has ratings from IP-67 to IP-68 for the Titan 5R and 7R. IP-68 is the toughest rating that can be awarded to smartphones and means that the Titan range will operate just about anywhere – in wet or dry and dusty conditions. All phones are full-featured smart phones/tablets, compliant with US military standard, MIL-STD-810G, which assesses the viability of a product across a broad range of environmental conditions. Econz Wireless, Thomas Marshall Tel: 082 535 1255, www.econz.co.za Email: thomasm@econz.com
Driver
The Volvo Drivers’ Fuel Challenge is open to all professional truck drivers, irrespective of brand. The final will take place in Sweden on 19 September 2014. The Drivers’ Fuel Challenge has been arranged in different forms – global or regional –annually since 2009. This is the first time that a South African driver has a guaranteed spot in the world final in Sweden. “Fuel cost is a heavy burden for most haulage companies. However, an improved driving style can result in considerable cost
Energy Absorption Specialist engineering company, Horne, reports positive market acceptance of its improved Technogrid energy absorption system, widely used for arresting failed conveyor belt counterweights, runaway gantry cranes, mine cages in over-wind or under-wind conditions and runaway underground trains.
The improved product, introduced in 2011 as a development of the original South African design, is smaller and lighter, with a higher energy absorption per unit mass. Recent sales have included several hundred units to platinum mines in South Africa, with further orders received from mines in Mongolia and Mexico. Technogrid functions by absorbing a moving body’s kinetic or potential energy through deformation of a metal grid of known design and characteristics. The product comprises a series of multi-bar units connected in a staggered grid shape which, upon impact, allow the metal bars to yield and deform under double curvature bending, opening up the units and absorbing the impact energy through strain hardening. Horne Group, André du Preez Tel: (011) 974-1004 Email: andre@horne-group.com
savings. With the Drivers’ Fuel Challenge we want to highlight this fact and encourage truck drivers to adopt a more fuelefficient way of driving,” says Philip Phasha, project manager for the Drivers’ Fuel Challenge 2014 in South Africa. The potential benefits of driving in a fuel-efficient way are considerable. Volvo Trucks’ own research shows that by using accredited services for individual follow-ups on fuel consumption, together with driver training, it is possible to reduce fuel consumption by around ten percent. The Drivers’ Fuel Challenge participants will not only be tested on actual fuel consumption but also on fuel-affecting driver behaviour such as anticipation, braking, as well as engine and gearbox utilisation. It will all be done in realistic conditions in which the drivers have to maintain productivity and where they also need to show that they utilise the truck in a safe and responsible way. The South African rounds will take place on the following Saturdays: 24 May in Cape Town, 7 June in Durban and 14 June in Johannesburg. The national competition will be held 21 June and will also take place in Johannesburg. Participants may register until 30 March 2014 Volvo Trucks, Valentia Hobbs Tel: (011) 842-5000 Email: Valentia.Hobbs@volvo.com www.volvo.com
Technogrid energy absorption system
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MARKET FORUM
New Hoist Safety Course
Getting Liners Right
Phakamisa Safety Consultants was established 15 years ago to provide specialised lifting equipment training, consulting and auditing as well as lifting equipment inspection registers to mines and industry. Essentially Phakamisa assists its clients in implementing and maintaining a safe lifting programme in the workplace which is legally compliant with all issues pertaining to lifting equipment use, inspection and compiling written operating procedures. The LTI or lifting tackle inspection course has been successfully attended by over 5 500 candidates over the last few years, assisting users, suppliers and service providers to conduct onsite lifting tackle inspections. Candidates are provided with a comprehensive training manual as well as a register to record their inspections. A new training course entitled “The correct use, operation and inspection of hoists” is being launched in March this year for users, inspectors, artisans,
Combinations of different liners for separate tasks within a bulk materials processing plant can drastically improve the serviceable lifespan of equipment and boost the overall performance of a plant tenfold. Rubber, steel, ceramics and engineering plastics have outstanding suppliers, safety and engineering staff. The content will be presented by Piet Otto and Jan Marx who together have over 55 years experience in the lifting equipment industry. The course is unique as it is generic and not conducted by a specific hoist supplier aimed at promoting the features of their specific products. Although most training is conducted on site, public courses will also be arranged for individuals or small groups. Phakamisa Safety Consultants, Piet Otto Tel: 082 372 4595 Email: potto@icon.co.za
Crushing Results High Power Equipment (HPE) Africa - the sole Southern African distributor for crushing, screening and recycling equipment manufacturer McCloskey International - continues to gain market share through the range. HPE Africa has sold a total of 15 McCloskey machines across Africa since becoming an official local distributor in January 2013. Sales and marketing manager Alan Straw credits the success of the McCloskey range to the fact that the machines are easily adaptable to the harsh African climate and terrain. “These machines have been designed to withstand extreme variances in temperatures and terrain for some of the most remote parts of the world, and therefore have to be reliable, operator friendly and easy to maintain, which make them ideal for African conditions.”
range of equipment from existing and potential customers, and it looks set to continue as the market increasingly requires machinery that is durable and reliable, while remaining affordable.” HPE Africa, Alan Straw, Tel: (011) 397-4670 Email: alan.straw@hpeafrica.co.za
Alan says that the future outlook for HPE Africa and McCloskey is positive. “The McCloskey range of equipment from HPE Africa is competitively priced, but this does not compromise on the power or the quality of the machines. We have had several enquiries into the McCloskey
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performance in certain conditions, but have weaknesses in other areas. However, by combining appropriate liners at different points within a process, it is possible to obtain the best possible performance in terms of product movement and durability. Wayne Johnstone, product manager at Tega Industries South Africa says, “As a single source supplier we provide the entire solution from start to finish, which means that the customer deals with a single contact point. If technical problems arise, ours technical team is the only team on site and will quickly and professionally sort the issues out. “It happens all too often that multiple contractors install different liners at a site. When problems occur the blaming starts and the customer may find it very difficult to pinpoint the actual cause. With a single-source supplier the customer has one guarantee that covers all the liners installed on site,” Wayne concludess. Tega Industries South Africa Vishal Gautam, Tel: (011) 421-9916 vishal.gautam@tegaindustries.co.za www.tegaindustries.com
MARKET FORUM
Recapitalisation Programme A R240-million recapitalisation programme is being implemented at DCD Rolling Stock to further consolidate its reputation as a leading manufacturer and supplier of locomotives, wagons and bogies to railway, mining and industrial operations. Due to its large-scale nature, the company's recapitalisation programme will be rolled out over a three to five-year period. Phase 1 involves a R100-million investment in the regaining and upgrading of its 42 000 m2 manufacturing facility and its manufacturing equipment. DCD Rolling Stock General Manager Petrus Mulaudzi says, "The DCD Group has invested a total of R80-million to regain this facility from our sister company DCD Protected Mobility, which has moved to a new purpose built manufacturing plant in Isando, Gauteng. An additional R10-million was spent on the installation of four robotic welding cells in October 2013, while the balance was spent on repairs."
Petrus believes that Africa in particular holds the greatest potential for the company's growth into the future. "Underdeveloped countries with burgeoning mining industries, such as Mozambique, Zambia and Tanzania, will serve as the catalyst for railway development, due to the fact that an increasing number of mines will require a link to a port for export purposes." DCD Rolling Stock manufacturing man-
ager Frank Ramage indicates that the implementation of Swedish-engineered Motoman automated robotic welding cells will increase production volumes, in addition to more efficiently utilising the skills of experienced manual welders. DCD Phillip van der Westhuizen Tel: (011) 306-8311 Email: phillip@dcd.co.za www.dcd.co.za
Milestones Melco continues to consolidate its reputation as an industry frontrunner, following a year of measurable achievements and successes to date. The company's most recent industry
breakthrough was the August 2013 introduction of a new range of Rulmeca TOP return rollers to the South African market. Rulmeca is a worldwide group of companies that specialises in the production of rollers, idlers, motorised pulleys, fabricated pulleys and other components for worldwide bulk handling industries. Marketing and sales director Craig Warmback notes that the TOP range is a light to medium duty high-density polyethylene (HDPE) roller that is ideally suited for quarrying and cement applications, which was previously not available as a return roller.
Craig reveals that this new offering incorporates a steel inner tube coupled with a modified and castellated HDPE tube. "This ensures that TOP return rollers are now up to 50 per cent lighter than similar rollers of the same length," he continues. Melco product manager Bryan Krynauw als highlights the fact that Melco supplied the first-ever 250 kW motorised pulley at the Kriel Coal Mine in Mpumalanga in mid-2013. The 250 kW Rulmeca 1000HD motorised pulley weighs 4980 kg, and is ideally suited as a belt conveyor drive solution for large volumes of bulk material for coal mining applications. "This particular model of motorised pulley is 1 000 mm in diameter with a 1800 mm face length. It has a belt speed of 4-m-per-second, 3 000 Nm of torque and a belt pull of 58 800 Nm – making it the fastest and most powerful motorised pulley in the international market," he explains. Melco, Gavin Hall, Tel: 087 806 3160, Email: gavinh@melco.co.za, www.melcoconveyors.com
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MARKET FORUM
Substantial Value
Professional consulting services provider GMC Global, which was acquired in 2012 by engineering consulting firm SMEC, has established a local office in Johannesburg South Africa, to expand its geographical footprint. GMC Global recently assisted an internationally recognised mining client in increasing its revenue by more than US$17-million through the implementation of a custom designed maintenance improvement programme. In addition to providing a measurable increase in revenue, the implementation of the maintenance programme also provided the client with a 600% return-oninvestment - while increasing plant availability by 16%; obtaining a 5% improvement in plant throughput and achieving 66% completion of planned maintenance strategies. GMC Global, Schalk Prinsloo Tel: (011) 369-0600, www.gmcglobal.com
Modern Belt Monitoring Systems A large-scale project is now underway internationally with the ContiTech Conveyor Belt Group delivering conveyor belts and belt monitoring systems for the development and expansion of a Chilean copper mine in El Teniente, which is run by mine operator Codelco. More than 20 kilometres of steel cord belts are to be installed between 2013 and 2017. The conveyor belt specialist received this latest order via Tenova Takraf from Leipzig. The steel cord belts from ContiTech are manufactured with an XLL compound, a special, energy-optimised rubber composition. Since this rubber compound significantly improves visco-elastic properties, the indentation rolling resistance on the conveyor belt system is minimised. In comparison with conventional conveyor belts, this enables energy consumption during the transport of raw materials to be cut by up to 25%. Alongside energy-optimised steel cord belts, the ContiTech Conveyor Belt Group is supplying innovative electronic conveyor
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BULK HANDLING TODAY
belt monitoring and inspection systems. Conti Protect monitoring systems protect conveyor belt systems against serious damage, thereby making a major contribution to enhanced operational reliability by reducing the number and length of malfunction-related downtimes. ContiProtect Splice Elongation Measurement is designed to monitor larger conveyor belt systems and uses magnetic markers to detect irregularities in splice length. On conveyor systems with ever more stringent safety factors and ever increasing conveyor belt strengths, monitoring the splice increases operational reliability. ContiProtect Belt Rip Detection uses conductor loops vulcanised into the conveyor belt to detect longitudinal slits as early as possible. With improved conductor loops and low susceptibility to electromagnetic interference, the belt monitoring system prevents error messages and, in turn, costly conveyor downtime.
February 2014
ContiProtect Belt Rip Detection increases process reliability
ContiInspect systems provide data that can be used to derive reliable forecasts about the remaining service life of the conveyor belt, allowing operators to estimate investment costs more accurately. Contitech, www.contitech.co.za
MARKET FORUM
Go with the Flow DEM Solutions in the USA has launched the Edem BulkSim bulk material flow simulation software enabling EPCM companies and conveyor system OEMs to optimise the design, performance and reliability of production critical conveyor transfer equipment in mine operations. BulkSim allows engineering teams to design bulk materials handling equipment that is more reliable, delivers greater material throughput and improves operational efficiencies. “Often considered only a relatively lowcost part of a mine’s bulk materials handling system, transfer points can easily become a costly bottleneck and maintenance overhead,” states Dr John Favier, CEO and founder of DEM Solutions. “Out of 100 engineers involved in mine operations surveyed at the Iron Ore 2013 Conference in Perth, Australia, over 50% experienced chutes and transfer points as being the most problematic and causing the most maintenance problems, while Asset Care Specialists added that 60% 70% of downtime in iron ore processing is for maintenance of transfer chutes.
“With Edem BulkSim, engineering and equipment suppliers can more effectively address the performance challenges of conveyor transfer equipment and reduce the risk of unscheduled downtime for mine operators.” This software helps them to reduce the costs related to unforeseen equipment malfunction, and increase the productivity and energy efficiency of ore handling and processing plants. It also helps in estimating the service life of equipment
Advanced Diagnostics Two innovative and unique devices have been introduced into the South African market by global crane giant Konecranes. RailQ is an alignment survey technology developed to provide faster, safer, and more accurate analysis than any other type of rail survey available worldwide. RailQ uses precise survey techniques with specific software to accurately measure straightness, elevation, rail-to-rail elevation, and the span of the rails. The result is a precise, reliable runway analysis that provides cost-effective solutions for any rail system and for all makes and models of cranes. It also takes a fraction of the
and systems, and in effective planning of maintenance schedules. This high-performance bulk material flow simulation software is used by engineers designing bulk materials handling equipment in mine operations and minerals processing plant, such as conveyor transfer points, stockpile reclaimers, and material feed and discharge chutes in comminution circuits. DEM Solutions, www.dem-solutions.com. Email: info@dem-solutions.com
time to conduct as compared with traditional rail surveys. RailQ uses proprietary visualisation technology and a remote-controlled robot trolley which runs along the rail collecting data via Bluetooth technology before transferring the data to a total station to determine tracking issues and misalignments. At the total station, survey software processes the data for straightness, span, elevation, and rail-to-rail elevation. RailQ inspection methods can also verify the geometry of the crane structure and components, identifying problems that can result from geometric deficiencies. Konecranes, John Macdonald Tel: (011) 864-2800 John.macdonald@konecranes.com www.konecranes.co.za
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MARKET FORUM
Mining Air Hoists In 2012 the King Mine-Air series of SANS 1638 & SANS 3077 compliant pneumatically-powered chain hoists designed for the South African mining industry was introduced onto the South African market. The series was in design and prototype testing for four years prior to the highly successful market introduction and after presentation, testing and approvals, the hoists have been in operation underground with great success since June 2012.
Materials Handling Solutions
Searle Hoist & Tool, Robert Darby Tel: (011) 882-2000 Email: rjd.esjhb@mweb.co.za
n Bulk Solids Flow Laboratory Testwork
www.promech.co.za
n Design Audits n On-site Troubleshooting and Investigations n Rapid Response Consulting for Engineering Design to ISO 9001 With a reputation for excellence in Materials Handling Design and a successful minerals projects track record, Greentechnical specialises in advanced material flow technologies for Mining, Agriculture and Industry. We support testwork results with consulting services and functional design requirements for material handling systems. Our collaborative agreement with Tenova Mining & Minerals’ laboratory provides access to this testwork facility, an industry leader for more than 30 years.
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HANDLING 2014
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enquiries@greentechnical.co.za www.greentechnical.co.za l Conveying l Crushing l Trucking l Storage l Lifting l
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Some of the unique features of the hoist design are the automatic, factory-filled, long life, anti-corrosion, lubrication system inside the air motor (no external filters or lubricators necessary); chain guide roller system for horizontal pulling; dual braking system; and overload prevention regulator. This product is supplied and serviced by the King OEM, Searle Hoist & Tool Pty Ltd and their authorised trained distributors and service centres countrywide.
Solving Materials Handling Problems through Innovative Design using Advanced Material Flow Technologies n Materials Handling Systems Design
The design and performance criteria are based on: product and operator safety [fos 6:1]; durability and low maintenance; performance at low air pressure from 3 – 6 bar working air pressure; suitable for horizontal pulling and vertical lifting; consistent quality three performance and load tests during the factory to customer supply process; and product range 2t, 3t, 4t, 7,5t, 10t wll models.
February 2014
MARKET FORUM Through its Centre for Mechanised Mining Systems (CMMS), Wits university is offering a wide variety of courses and post-graduate degree programmes designed to empower the next generation of mine bosses to look beyond traditional man-machine management techniques to a systemsbased approach. In recognition of the future role of mechanisation in narrow reef hard rock mining operations in South Africa, Sandvik Mining was instrumental in establishing and funding the centre to train management staff. As a result, today, Wits is the only university globally to offer a Masters Degree in Mechanised Mining.
Mechanised Mining
The University of the Witwatersrand continues to train an all-new breed of mine man-
According to centre direc- agers able to embrace modern technology. tor, Prof Jim Porter, the last decade has seen a massive increase in efforts to introduce in terms of productivity – particularly in mechanised mining and automation in narrow reef hard rock operations. a more proactive manner. In countries Commenting on progress made by the such as Australia, USA, etc where the centre in the years since its establishment, uptake is strongest, mines are booming founding sponsor and key mechanised and production volumes skyrocketing. mining equipment supplier Sandvik MinSimultaneously, despite facing more ing’s Rod Pickering says that in certain treacherous and difficult mining condi- sectors our mines are marginal and are tions, South Africa’s slow uptake has not as profitable as they could be. In resulted in the country falling far behind others, there are reserves that cannot be
reached by people and in these instances mechanisation holds the key. “In some sectors such as underground coal mining, mechanisation of local mines is comparable to the best in the world and these mines are being run competitively.” Sandvik Mining, Alice Ward Tel: (011) 929 5400, www.mc.sandvik.com/za Email alice.ward@sandvik.com
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Subdued Performance in 2014 The performance of the South African truck market surpassed all expectations during 2013. Sales increased by 11.12% on 2012’s full-year results, reaching a noteworthy 30 936 units despite a number of key challenges posed by the local political and economic environment. Sales in the Medium Commercial Vehicle (MCV) segment increased by 14.66% to 11 585 units, while the Heavy Commercial Vehicle (HCV) segment showed a 9.94% growth to conclude the year on 5 477 units. The Extra Heavy Commercial Vehicle (EHCV) segment experienced significant growth of 10.39%, selling 12 828 units during 2013.
or SIPs identified by government.”
challenges due to the improvement of the country’s rail infrastructure and capacity, as well as a slowdown in mining production. Last year, a total of 1 202 trucks were exported by South African manufacturers, an increase of 11.71% when compared to 2012’s figures. During 2013, UD Trucks comfortably retained its fourth position in the market, and was once again the top selling HCV brand with a 24.16% share of the market. The company also made significant inroads in the EHCV segment, growing sales of its Quon range by 18.57% to capture an 8.76% market share. According to Rory Schulz, general manager of corporate planning and marketing at UD Trucks Southern Africa, “Government’s New Development Plan, although met with mixed reactions, has also now for the first time been included in the state budget and bodes well for the development of a number of the Strategic Infrastructure Projects
TRANSMISSION COMPONENTS Another transport segment that made a significant contribution was ULK HANDLING TODAY - FEB 2014 (CMA 40th) demanding long-haul (29.82%), which is usually a high xvolume 130mm (height) 85mm (width) segment but faced some growth
The SIPs include 18 projects ranging from geographically-focused developments, to social infrastructure, knowledge, water and sanitation. Most of these projects require heavy involvement by the transport industry, which could once again have a positive impact on the potential growth of the market. “While we expect interest rates to remain basically unchanged during 2014, one also has to consider the impact of the national elections and labour on the performance of the country’s economy,” explains Rory. UD Trucks expects total truck sales to increase by 4.93% during 2014 to reach an expected 32 550 units. This forecast includes an increase in sales across all the segments. UD Trucks, Rory Schulz Tel: (012) 564-9500 www.udtrucks.co.za
Index to Advertisers Bibby Turboflex 96 Plane Road Spartan / Kempton Park Tel: (011) 394 1830 Fax: (011) 975 6504 www.transmission.co.za
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BMG
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ELB 12 Engineer Placements
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Horne 20 ILS 8 John King Chains
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SKF 10 Tega
Quality Industrial Power Transmission
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Transmission Components
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Voith Turbo
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TOTAL : Solution
Tega offers value added consultancy services and solutions
TM
in Mineral Beneficiation, Bulk Solids handling, Wear and Abrasion customised to suit specific applications. With focus on core engineering applications in the Mining and Mineral Processing Industry, Steel plants, Power, Port and Cement Industries.
Tega Industries (South Africa) Pty Ltd P.O Box 17260, Benoni West, 1503, South Africa, Phone: (011) 421 - 9916/ 7, 421 - 6714, 421 - 6761, Fax: (011) 845 1472, Email: info@tegaindustries.co.za, www.tegaindustries.com
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February 2014