Bulk Handling Today February 2016 by Promech Publishing

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH l

T O D A Y

February 2016

AdvAnces in FlAme RetARdAnt Belting lARgest tOWeR cRAne FOR tHe gAUtRAin PROJect

T O D A Y

BULK

HANDLING February 2016

Contents

On the cover: BMG Tel: (011) 620 1500 www.bmgworld.net

SAIMH News 5 CMA News 6 Leeasa News Cover Story

Ports

25 Infrastructure Projects

Earthmoving

27 A Happy and Productive Operator

Measurement and Assessment

Power Transmission 12 Taking the Sweat Out of Procurement

Lifting

14 Gautrain Station Project Managers 16 Conserving Marine Life 19 Setting the Pace 22 Advances in Flame Retardant Belting and the Future

All rights reserved. No editorial matter published in “Bulk Handling Today” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

Our e-mail address is bulkhandling@promech.co.za Visit our website on www.promech.co.za

Market Forum

Endorsing Bodies

B-BBEE Compliance

29 Get-rich-quick Scheme 31

11 On Indian Soil

Safecon

Whistle Blowers

•

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)

The monthly circulation is 3 673

Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401, Fax: (011) 781-1403 E-mail: bulkhandling@promech.co.za www.promech.co.za Managing Editor: Susan Custers Advertising Sales: Lin Patricio DTP: Lindy Fobian / Anne Rotteglia Subscriptions: Please email us at accounts@promech.co.za if you wish to subscribe to “Bulk Handling Today” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/Overseas. Printed by: Typo Colour Printing, Tel: (011) 402-3468 FSC (Forestry Stewardship Accreditation)

BULK HANDLING TODAY

February 2016

The South African Institute of Materials Handling

Sample

The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions. The SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who volunteer their time to execute the SAIMHâ&#x20AC;&#x2122;s objective. The main aim is thus to promote the advancement of the art, science, theory and practice of the Bulk Materials Handling principles and techniques.

Company Affliates as at February 2016 Afripp Projects cc Brelko Conveyor Products (Pty) Ltd Bulkcon CPM Engineering CT Systems cc Conveyor Watch (Pty) Ltd David Brown Gear lndustries (Pty) Ltd ELB Engineering Services (Pty) Ltd Engicon Systems (Pty) Ltd Facet Engineering cc Flexco (SA) (Pty) Ltd

Hagglunds Drives SA (Pty) Ltd Hansen Transmissions SA (Pty) Ltd Hatch Goba (Pty) Ltd lllustech J & A Engineering Services Kimrae Engineering Prolects Loadtech Load Cells (Pty) Ltd MacsteelVRN Martin Engineering Melco Conveyor Equipment Morris Material Handling SA (Pty) Ltd

Osborn Engineered Products (Pty)Ltd PD Engineering Services cc PH Projects Holdings (Pty) Ltd Rio Carb (Pty) Ltd Sandvik Materials Handling Africa Screw Conveyors & Material Handling Senet SEW Eurodrive Spar Western Cape SSAB South Africa (Pty) Ltd Tenova Zest Electric Motors (Pty) Ltd

4 BULK 2016 Tel: (011)HANDLING 867-0902TODAY l Fax:February (011) 867-0036 l Email: saimh@global.co.za l www.saimh.co.za

CONVEYOR MANUFACTURERS ASSOCIATION

From The Chairman’s Desk As mentioned in the January article, the four issues that are affecting industry are of primary focus at the moment and the work being done will prove to be a huge advantage to industry. These are Nip Guards, Pull Keys, Directional Rollers and testing of Flame Retardant Belting. In setting up the Working Group to address Nip Guards and Pull Keys, the buy-in from industry is demonstrated by the fact that end-users have seconded some of their most experienced and senior personnel to the Working Group. End-users include Anglo Platinum, Anglo Coal, Sasol, Lonmin and Aquarius. CMA member companies (Cedotech, Flexco, ThyssenKrupp, and Afripp) have similarly responded by supplying their expertise, making this probably one of the most experienced working groups that can be assembled for addressing the issues at hand. Specifically, these are the nip guard and pull key

Simon Curry

issues. The group is chaired by one of our honorary members, Alan Exton. Of similar importance is the Group established to review the issues pertaining to uni-directional rollers. The idler manufacturers have been approached to make their brains trust available to the Working Group. Once the work has been completed, the Nip Guard and Pull Keys Working Group will have sight of the recommendations for finalisation. To complete the process, Industry will receive all outcomes from the two Working Groups at an Industry Indaba which will be scheduled for later this year. Simon Curry - Chairman

Membership at February 2016 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 Brevini Power Transmission SA (Pty) Ltd CedoTech cc Collisen Engineering Conveyor & Engineering Equipment Conveyor Watch CPM Engineering CT Systems David Brown Gear Industries DRA Projects SA (Pty) Ltd Dunlop Belting Products

Dymot Engineering Company ELB Engineering Services Facet Engineering Fenner Conveyor Belting (South Africa) Flexco SA (Pty) Ltd FLSmidth Roymec Hägglunds Drives South Africa Hansen Transmissions SA Hatch Goba Africa 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 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 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 Industrial Solutions South Africa (Pty) Ltd Timken South Africa (Pty) Ltd Transmission Components Transvaal Rubber Company Veyance Technologies Africa Voith Turbo WorleyParsons RSA Zest Electric Motors

BULK HANDLING TODAY

February 2016

ENDORSER OF “BULK HANDLING TODAY”

LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SA

LEEASA, formed in 2003, is a division of the Chamber of Engineering Technology (COET), a non-profit organisation. The association’s objectives include, but are not limited to: the transfer of knowledge and training within the field of the Lifting Industry, to improve safety, promote the use of standards and to promote Professional and Ethical practices.

t is represented on the Engineering Council of South Africa (ECSA) and a number of ECSA committees as well as on various task teams at the South African Bureau of Standards (SABS).

What’s in it for you:

As an Individual member who is registered as a Lifting Machinery Inspector (LMI), you may qualify for any concessionary fee granted by ECSA (this could save you over R1 000 a year). ECSA registered COET / LEEASA members are awarded one Continuing Professional Development (CPD) credit in category

3 each year. CPD is an ECSA requirement to retain registration. Members obtain a discount on training and seminars validated by the association, especially useful in earning ECSA CPD credits. Members benefit from the collective power of a recognised and established association and collective co-ordination in dealing with authorities in policy making and matters concerning the industry. LEEASA has some 500 members (Individuals and Companies).

Tel/Fax: (011) 787-1302, Email: engineer@netactive.co.za, www.leeasa.mirrorz.com 6

BULK HANDLING TODAY

February 2016

BULK HANDLING TODAY

February 2012

LIFTING GUIDE 2016/17 LEEASA (Lifting Equipment Engineering of SA), has once again joined forces with “Bulk Handling Today” to produce the annual “Lifting Guide”. This is the ONLY guide endorsed by LEEASA. Now in it’s 5th edition, it remains the definitive reference publication for the industry. The guide will advise industry users on how to choose, use and maintain lifting equipment that is ‘tailor-made’ for their specific needs and applications. Generic type of cranes and their specifications are discussed in detail, along with other useful information such as chains, hoists, slings, etc. But any machine is only as good as the person who operates it, so we will also discuss driver training, daily checklists to ensure proper maintenance, health and safety requirements, inspections and much more. The publication is also endorsed by: CMA (Conveyor Manufacturers Association); SAIMechE (SA Institution of Mechanical Engineering) and SAIMH (SA Institute of Material Handling).

LIFTING gUIDE 2014/15 Also publishers of “Bulk Handling Today”

Aside from being posted out with “Bulk Handling Today” (May 2016), extra copies of the guide are given out at: • Electra Mining, • Cape Industrial Show, • KZN Industrial Show, • African Port and Rail, • Various LEEASA functions, • Extra requested copies to EXXARO, • Lonmin asked for extra copies, • Transnet asked for extra copies If you would like your product or service to feature in this definitive lifting guide, I will be happy to provide you with further information so please do not hesitate to contact me. Make sure you’re in this comprehensive reference publication!

If you would like your product or service to feature in this definitive lifting guide, please contact: Lin Patricio Tel: 011 781 1401 / 083 637 7122 E-mail: bulkhandling@promech.co.za BULK HANDLING TODAY February 2016 7

COVER STORY

BMG offers the full portfolio of SPM condition monitoring equipment, from basic hand held instruments, to high level online systems. Included in this range is the entry level VibChecker portable instrument, designed for reliable on-site vibration measurement and assessment.

Measurement and Assessment BMG offers the full portfolio of SPM condition monitoring equipment, from basic hand held instruments, to high level on-line systems. Included in this range is the entry level VibChecker portable instrument, designed for reliable on-site vibration measurement and assessment.

“

The VibChecker requires minimal operator training and supports BMG’s BearingChecker which is used to accurately assess the condition of rolling element bearings during operation in equipment like motors, fans, pumps and gearboxes,” says Carlo Beukes, general manager: Drives Belts & Ironware divisions, BMG – Bearing Man Group.

Periodic vibration checks are easily done and reliable and accurate vibration information is delivered in seconds. Readings are immediately and automatically evaluated according to established ISO standards “The VibChecker gives early warning signs of developing machine problems in order to prevent premature replacement of machine parts. Vibration monitoring is the most widely used preventative maintenance technique for the accurate assessment of the condition of machinery elements – like pump rotors, fan impellors, gearbox gears and housing mountings.

BULK HANDLING TODAY

February 2016

“Both these instruments are instantly usable and require little training for efficient operation.”

Ergonomic design

The lightweight user-friendly VibChecker has an ergonomic design, an easy button operation and user-friendly interface, which make it the perfect maintenance tool for plant mechanics, machine operators and maintenance technicians. With this device, vibration monitoring no longer needs to be a question of cost or expertise. The VibChecker is designed for simple vibration checks and with built in FFT (Fast Fourier Transform) capabilities, it is also an efficient device for troubleshooting. Periodic vibration checks are easily done and reliable and accurate vibration information is delivered in seconds. Readings are immediately and automatically evaluated according to established ISO standards. These standards make the assumption that limited information - obtained easily and at low cost - is

COVER STORY

as useful as a detailed analysis, using expensive equipment and elaborate techniques.

RPM range, including speed applications as low as 0,1 RPM.

This instrument has an internal probe and connector for external ICP transducers. The VibChecker is capable of displacement, velocity and acceleration RMS and ISO 2372/10816 measurement between the 10 and 1000 Hz frequency range.

In addition to HD technologies, BMG offers a range of condition monitoring methods for trouble shooting and root cause analysis.

Accessories include a comfort grip protective sleeve and a small portable MEMS transducer with magnetic foot, convenient for measurement in narrow spaces. BMG’s SPM’s high definition HD technologies is a further development of the Shock Pulse Method (SPM) providing reliable information on the lubrication and mechanical condition of bearings.

These devices are perfectly suited for measurement in a broad RPM range With sufficient forewarning, plant personnel can either perform required maintenance or schedule a planned component replacement, thus minimising repair costs and reducing downtime.

The company’s team of over 140 mobile technicians supports condition monitoring products with a technical skills service, to ensure the highest level of plant output and reliability. Specialist services include installation, adjustment, replacement and maintenance of components, shaft and pulley alignment, balancing, condition monitoring, oil sampling and analysis and critical equipment inspections and lubrication schedules. Maintenance training and fault diagnosis also form an important part of BMG’s field services. BMG – Bearing Man Group Carlo Beukes Tel: (031) 576-6300 Email: carlob@bmgworld.net www.bmgworld.net

Critical information

This condition monitoring system offers continuous bearing and lubrication condition information to complement regular interruptive inspections that are legally required, by giving the responsible certified engineer critical information about the physical health of bearings while in operation. Instant evaluation of bearing condition is given in an easily understood green, yellow and red colour code. With the advanced digital SPM HD technique and RPM based sampling frequency, these devices are perfectly suited for measurement in a broad

BMG’s VibChecker portable instrument is a user-friendly tool, perfect for both the novice and experienced user, for easy measurement of a machine’s condition. The VibChecker supports BMG’s BearingChecker, which is used to accurately assess the condition of rolling element bearings.

BULK HANDLING TODAY

February 2016

Perfect Conveyor Belt Solutions for the Power Generation Industry Requirements in the Power Generation Industry can differ greatly. Conveyor Belts have to stand the test in widely diverse work environments, from ship or train unloading, over internal transportation, storage, incinerator feeding to ash return and desulfurization. ContiTech offers complete solutions in premium quality, from textile, steel-cord, solid woven and special-purpose belts through to service materials and services.

conveying excellence

+27 (0) 11 248 9300 www.contitech.co.za

POWER TRANSMISSION

Global expansion

The JV was set up in 2011 as part of David Brown’s global expansion strategy to serve markets on an international stage, focused on power, mining, hydro, irrigation, defence, cement, rubber, metals and sugar covering both new build and service and repair sectors.

On Indian Soil David Brown Group has increased its shareholding in David Brown Bharat Forge Gear Systems India Limited by buying out its Indian partner, Bharat Forge Ltd. The move will initiate a major programme of investment and forms a commitment to business growth with strong alignment to the ‘Made in India’ initiative, increasing the value of business to $50 million in the next five years. The new business will operate under the new name David Brown Gear Systems India Pvt Limited.

The business also benefits from access to David Brown’s existing installed base for service and repair activities including maintenance, inspection, drop in replacements, overhauls and reverse engineering to deliver greater process availability, reliability and efficiency for its customers’ operations. Venkatesh Subramanyam, MD India comments, “David Brown will continue to build on the sound base established in core markets since 2011. Ongoing investment in manufacturing, people and infrastructure will further expand our capacity to meet local customer needs and leverage low cost supply for customers worldwide.”

Value proposition

David Brown Gear Systems India investments in the short term will focus on developing manufacturing expertise in-house including gear cutting. This will ensure closer control of quality, the flexibility to respond to customer requirements and expansion of the value proposition.

Ongoing investment in manufacturing, people and infrastructure will further expand our capacity to meet local customer needs and leverage low cost supply for customers worldwide

homas Burley, CEO, David Brown Gear Systems comments, “We have a long history in India and are very pleased to be able to build our capability and invest fully in this rapidly growing market. We are tremendously excited by the Indian government’s ‘Made in India’ programme and the encouragement it gives to businesses with advanced engineered products and services such as David Brown to develop a full design and manufacturing capability in country. The fit between India’s needs for advanced transmission technology and David Brown’s products is ideal. “The commitment and capability of Bharat Forge has given us the confidence to take full control of the business and move to this next phase of investment and growth.”

It will also expand the product portfolio in the Indian market to include access to a more comprehensive and sophisticated global product range including proprietary products such as the CX mining conveyor and HX high speed gear technology developed by David Brown centres of excellence located worldwide. David Brown Gear Systems India itself has potential for growth as a low cost manufacturing centre for David Brown globally. Gerry Marshall of David Brown Group comments, “Enhancing our presence in India is a critical step for growth as we continue to develop our worldwide capabilities and customer responsive services.” David Brown Group, www.davidbroen.com

BULK HANDLING TODAY

February 2016

B-BBEE COMPLIANCE

Taking the Sweat Out of Procurement With the changeover to the new B-BBEE codes for all certificates issued from 1 May 2015, LexisNexis South Africa has added a B-BBEE compliance module to ProcureCheck.

s companies develop plans to meet the stringent requirements of the amended codes, the new edition puts all the intelligence required for conducting procurement business professionally and ethically on one platform, facilitating the entire vendor management function. “The new B-BBEE legislation is changing

the way in which a company’s vendor database must comply with BEE codes and standards. Whereas previously only vendors pertaining to 80% of procurement spend had to be BEE compliant, now 80% of the vendor database needs to be compliant and to meet the new quotas. This means more SMEs and EMEs will need to be vetted for companies to comply,” says Greg Brown of Nexis.

Verification

ProcureCheck with B-BBEE Compliance is designed to reduce the cost of compliance, fulfil regulatory requirements, enhance decision-making and protect businesses from fraud and reputational damage. This innovative solution adds the ability to manage B-BBEE compliance including: monitoring the expiry date of your certificate, monitoring your procurement spend, monitoring your suppliers’ progress in terms of B-BBEE to the other capabilities of Procurecheck.

Greg Brown

BULK HANDLING TODAY

February 2016

"In addition it will help you identify Enterprise Development/Supplier Development opportunities to increase

B-BBEE COMPLIANCE

While the system will expose public sector officials, it will also put pressure on companies looking to win government business to comply, to constantly monitor and improve their B-BBEE status, as well as to meet all the requirements of the Public Finance and Municipal Finance Management Acts your scores in this area of the B-BBEE scorecard,” Greg adds. He urges companies to start planning for their next verification on the amended codes, warning that insufficient planning could result in organisations being downgraded. He also highlights that the new edition ProcureCheck is being launched at a time when procurement fraud and corruption have been widely publicised and strict reforms are being introduced.

Central supplier database

In February 2015 Finance Minister, Nhlanhla Nene announced in his budget speech that from April 2015, a central supplier database would be introduced. The database will interface with South African Revenue Services (SARS), the Companies and Intellectual Property Commission and the payroll system. It will electronically verify a supplier's tax and BEE status, and enable public sector officials doing business with the state to be identified. “While the system will expose public sector officials, it will also put pressure on companies looking to win government business to comply, to constantly monitor and improve their B-BBEE status, as well as to meet all the requirements of the Public Finance and Municipal Finance Management Acts,” Greg advises. ProcureCheck links to various data bases including the Companies and Intellectual Property Commission (CIPC), South African Fraud Protection Services (SAFPS), SARS, Value Added Tax (VAT), Judgements and the National Treasury

Restricted Database. It enables supply chain staff to access the information they need anytime, anywhere, to: Combat corruption by identifying potential connections and ownership of property Identify possible fraudulent activity within vendors and employees with the help of South African Fraud Prevention Services and automated or online procurement management systems Establish the business interests of employees within your organisation Look for and recognise conflicts of interest within your organisation and potential supply chain management partners Vet vendors and create a preferred vendor list Monitor vendors on an ongoing basis.

Accountable “Under King III, the CEO of a company can be held accountable for any theft, fraud, corruption and bribery taking place in his business under his watch and should therefore take procurement vetting seriously. Used effectively Procurecheck with B-BBEE Compliance enables users to turn compliance into competitive advantage,” Greg concludes. LexisNexis South Africa Tel: (031) 268-3111 Email: customercare@lexisnexis.co.za, www.lexisnexis.co.za

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February 2016

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Gautrain Station The Gautrain Station platforms at OR Tambo International Airport are to be expanded, enabling passengers to embark or disembark from a full four-car train set, which is currently limited to two cars.

urner & Townsend has been appointed by Bombela Concession Company to manage this prestigious turnkey expansion project. The duration of the construction project is approximately 12 months with anticipated completion by mid-2016. Noluthando Molao, associate director of Turner & Townsend, says construction itself will be carried out with pre-cast elements and with the establishment of a storage area for materials close by, in order to minimise activity on site. An interesting aspect of the project is that the tower crane to be used on site is one of the biggest in the country, which can lift 32 tons at a radius of 27.8m and can pick up a maximum load of 20.6 tons at a radius of 40m. Initially procured for the Medupi Power Station, the crane will be relocated to the OR Tambo construction site. “One of the key challenges of the project is that the trains must be fully operational at all times to ensure there is no disruption to the Gautrain service. Coupled with this, the construction is being carried out at approximately 18 metres above ground level, with the access road directly beneath the construction site needing to remain operational as an airport entry point. What makes the construction more challenging is that the crane can only operate from one side of the viaduct structure and safety will be a key priority.

The access road directly beneath the construction site needing to remain operational as an airport entry point “Furthermore, the close proximity of the City Lodge parking facility right next to the construction site presents another challenge. Noise and

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February 2016

dust will be minimised with most of the work being completed off site and the use of acoustic boards, while construction will only be undertaken during specific times as agreed,” says Noluthando. “Given the issue of cable theft, the safety and security management systems require that the highest security measures are in place at all times.”

Platform length

The design and construction in terms of the project incorporates a number of aspects which include extending the existing roof canopy, and - with the use of pre-cast concrete slabs - horizontally

LIFTING

Project Managers Legacy

The OR Tambo Station platform expansion is one of a series of projects that Turner & Townsend has recently been involved with Bombela. These include the extension of Gautrain parkades, parking garages and additional parking at Midrand and Rhodesfield Gautrain Stations. At King Shaka International Airport in KwaZulu-Natal, Turner & Townsend were involved as bid managers as well as programme manager and project managers for the pre- and post contract works for this modern ‘greenfield’ development. They also provided procurement advice and training to the building and civil contractor.

increasing either side of the platform as well as extending the platform length by a total of 55 metres. In addition, the concrete parapet wall will be extended and two fire escape towers constructed.

Adds Noluthando, “Not surprisingly, the contractor tender process had a technical requirement for a grading of nine, which is the highest level according to the Construction Industry Development Board. A BEE Level 3 minimum requirement was also stipulated and the successful contractor, Stefanutti Stocks, will have to achieve 80 percent of the scorecard for technical criteria.”

Globally, and with a network of 90 offices, Turner & Townsend has an extensive track record in major projects, and more specifically in the air sector having helped formulate and implement the agreement for the build of British Airways Terminal 5 at Heathrow Airport (the biggest free-standing structure in the UK) and playing an integral role in bringing the project in on time and on budget. Turner & Townsend has also been involved in providing master planning, procurement strategy and risk management services for the development of the new three-runway system at Hong Kong International Airport and delivering cost estimating services, scheduling and risk management for the expansion of Abu Dhabi International Airport. Jacques Jacobs, Turner & Townsend, Tel: 082 334 2148 Bombela Concession Company, Tel: (011) 446-6800

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February 2016

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Conserving Marine Life A jib crane installed on a small island off the South African coast is rendering sterling service to ornithological teams visiting and conserving marine bird colonies which nest and breed there.

Installed with a motorised 360-degree slew on Bird Island, eight kilometres offshore from Woody Cape and 62 kilometres from Port Elizabeth, the Condra crane has been used since 2010 to lift the scientists’ boat from the sea onto a trailer, which is then winched along the jetty into a boathouse for the duration of the visit. The scientific visits are important for the study and restoration of the island’s marine bird colonies.

Success stories include the revival of the island’s population of African penguins from fewer than 100 pairs 75 years ago to well over 10 000 birds today Protected by South African National Parks as part of the Addo Elephant National Park, Bird Island and several smaller rocky outcrops form important habitats for bird life. The 2,4 hectares of Bird Island itself are home to South Africa’s greatest colonies of Cape gannets (65 000 breeding pairs), African penguins, endangered roseate terns (just 250 breeding pairs), Antarctic terns and kelp gulls.

Success stories include the revival of the island’s population of African penguins from fewer than 100 pairs 75 years ago to well over 10 000 birds today, the result of the cessation of guano scraping and the extermination of feral rabbits.

Scientific teams To meet the requirements of the visiting scientific teams, H&M Cranes of Port Elizabeth supplied a Condra jib crane with a 360-degree slew and reach of 4,5 metres, fitted with a single-speed 2,5-ton chain hoist with a 7,5 metre lift. H&M Cranes is the Port Elizabeth agent for Condra products. Although the jib crane came from Condra’s standard range, its components had to be designed in four sections each having a mass under 800 kilogrammes, to allow transport and installation on the island by helicopter. An Alouette helicopter hired by National Parks was used to ferry the crane components to the island in three trips, with a fourth journey being made to bring in the jib.

Condra’s jib crane in use

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LIFTING

The lower two sections of the column were mounted on the foundation plinth of an underwater concrete foundation, bolted together and encased with concrete. The top column section, jib and motor were then installed with the aid of the Alouette, which precisely positioned the motor for fitting and attaching.

Lead time

Gauteng-based Condra offers a range of standard jib cranes with capacities of up to 5 tons and reaches up to 7 metres. These standard designs provide the company with a competitive advantage when short lead times are specified, because most South African crane manufacturers lack a standard range. Condra has also supplied custom designed jib cranes with reaches up to 12 metres. The company is currently manufacturing a standard 5-ton jib crane for Grootegeluk coal mine in Lephalale. Condra (Pty) Ltd, Marc Kleiner, Tel: (011) 776-6000, Email:sales@condra.co.za

An Alouette helicopter hired by National Parks was used to ferry the crane components to the island in three trips

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► EIA Process

► Environmental Risk Assessments

► Geographical Information Systems

► Agricultural Assessment and Advise

► Project Managment

► Wetland and Riparian Services

► Natural Resource Services

► Visual Impact Assessments

► Ecological/Biodiversity Services

► Public Participation Process

► Application Assistance

► Game Ranch Management

► Developement Research, Monitoring and Evaluation

N2 Mnini ECO Duties

Plant rescue

Durban Coal Terminal Site Inspection

Ohlanga Pump station ECO Duties

Freightpak Warehouse Site Audit

Public participation Makhabeleni

Ballito Interchange Botanical survey

Site assessment Sundumbili pipeline

l Tel: (031) 303-2835 l Fax: 086 692 2547 l l Email: info@afzelia.co.za l www.afzelia.co.za l Skills on Site

Septmeber 2012

LIFTING

Setting the Pace Although the majority of contractors see a tower crane as simply another piece of materials handling equipment, this is not how Manitowoc views this vital tool which is a common fixture on most construction sites around the world.

BULK HANDLING TODAY

February 2016

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Bulk Materials Handling Mining | Process Plants | Pit to Port

At the forefront of materials handling systems

“

The speed at which a tower crane can lift and place loads is directly linked to the productivity that a site will be able to achieve on any given day,” says David Semple, Manitowoc VP Sales Middle East & Africa. “Fast track projects have become the standard throughout the world today and being able to build rapidly is a major benefit to any contractor. “There is a significant difference in the speed at which construction can take place based on the amount of materials moved in a single working day. For example, whether you can pour 100 buckets of concrete or 120 buckets can have an impact on the daily build programme,” he adds.

Accessibility to materials

WorleyParsons supports the mining and minerals sectors, offering a scope of engineering and draughting capabilities in conveyors, stockpiles, chutes, hoppers and silo design using the latest software analysis tools. We have expertise in understanding material flow in design and implementation of materials handling systems. - 1,200 local employees - Deep local knowledge - Global expertise - BBBEE Level 2

countries

148

offices

31,400

wprsainfo@worleyparsons.com www.worleyparsons.com

BULK HANDLING TODAY

WP MH ad 90x267.indd 1

In addition to operational productivity, the speed of erection and disassembly of the tower crane is just as important. This also receives attention during engineering as the speed at which the tower crane is erected will dictate the site’s accessibility to materials. Furthermore, the speed at which the unit can be climbed also has an impact, especially where the building being constructed is high rise. “An example where advanced engineering has made a difference is in the tying of the Potain tower crane into a high rise building as it climbs. This can be done in 6 hours as opposed to the conventionally accepted 8 hours with other similar cranes,” David says. Dismantling of the machine is also important as this too is a time-related task. The Potain tower crane has been engineered to facilitate speed of erection as well as dismantling, and its ergonomic design makes it easier for rigging crews and ensures optimal safety during both activities.

people

Productivity of a tower crane could also be compromised if it is not correctly configured as it would then not operate optimally. An example could be where the winch is undersized and the tower crane could then become a bottleneck on site, slowing down materials handling and subsequent construction activities.

February 2016 2015/11/19 12:50 PM

LIFTING

Partner with a reputable supplier

Torre Lifting Solutions, SA French division, is the southern African distributor for Potain tower cranes and Quentin van Breda, technical director says that it is important that contractors partner with a reputable equipment supplier who has the depth of technical skill to appropriately configure a tower crane for a specific application. “Tower cranes should be constructed to maximise productivity without breaching operational performance or safety protocols,” he says. “And this requires the input of experienced people who understand both the technical ability of the crane as well as the actual site requirements.” Potain tower cranes are recognised for their failproof design and excellent lifespan.

Components test Manitowoc operates a Product Verification Centre (PVC) in France where all major components are

tested to ensure structural and operational integrity. Components are subjected to climatic extremes and stress through simulated tests. Manitowoc is the only crane manufacturer that invests to this level to ensure the absolute integrity of its final product.

Tower cranes should be constructed to maximise productivity without breaching operational performance or safety protocols Significantly, Potain has remained the world leader in tower crane production since its inception in France in 1928 and over 120 000 cranes have been manufactured and installed across the globe. Torre Lifting Solutions (SA French Division) Quentin van Breda Tel: (011) 822 8782 Email: quentin@safrench.co.za www.safrench.co.za

BULK HANDLING TODAY

February 2016

SAFECON

Advances in Flame Retardant Belting and the Future Flame retardant belting has been in general use for decades since this stipulation was enforced by the National Coal Board (NCB) when conveyors in industrial coal mining were first used.

his article highlights several improvements that have emerged in flame retardant belting over the past few years, and also comments on likely future developments.

History of flame retardant belting

There is a pronounced difference between ’Flame Resistant’ and ’Flame Retardant’ belting. Flame resistant implies that the object will not burn, whereas flame retardant implies that the object can burn but will retard the flame propagation.

GAS DETECTED

CONCENTRATION FOR 100g OF MATERIAL BURNED (ppm)

Carbon Dioxide

TOXICITY INDEX

227 272

2.271

6 818

1.704

182

0.727

Carbon Monoxide Nitrogen Oxide TOTAL TOXICITY INDEX

4.703

Flame retardant belting is designed to self-extinTable 1. Test results on a typical third generation guish if the flame source is removed. In order for rubber sample any object to burn it needs a fuel source and oxygen. Gas Type Gas Gas Type Gas Concentration (ppm)

First Generation Belts (1905)

The first generation belts were manufactured from cotton carcasses soaked with PVC paste. During the burning process of polyvinyl chlorine (PVC) belting, chlorine gas is emitted which starves the flames of oxygen preventing further burning and thus the belt automatically self-extinguishes.

Second Generation Belts (1950)

Carbon Dioxide Carbon Monoxide

100 000 4 000

February 2016

250

Hydrogen Cyanide

150

500

Acrylonitrile

400

Hydrogen

100

Ammonia

750

500

Sulphur Dioxide

400

150

Hydrogen Sulphide

750

250

Phosgene

Figure 1. Attributes of belt flame resistant safety

BULK HANDLING TODAY

Nitrous Oxides

Formaldehyde

The cotton carcass in first generation Fluoride belts absorbed moisture easily resulting Hydrogen in reduced belt strength as the cotton rot- Chloride ted. Synthetic fibers such as polyester and Hydrogen nylon were then introduced to overcome Bromide this problem. This enabled manufacturers Phenol to construct much stronger belts which Table 2. Gases and their made possible much longer belt installa-

Concentration (ppm)

fatality limits

SAFECON

Figure 2. The Carbon Monoxide (CO) levels reduced by 60%

Figure 3. The Hydrogen Chloride (HCL) levels have reduced dramatically to almost zero

tions. The flame retardant properties were still obtained through the use of PVC as the saturate. Unfortunately PVC also releases highly toxic fumes in large quantities coupled with high smoke densities. Examples of the toxic gases are NO, CO, CO2, HCl and SO2 There are still, however, many mines that use this type of belting, mainly due to the low associated cost.

Third Generation Belts (1980)

Multi-ply rubber covered belts were developed and introduced in the 1980s. The rubber contained high levels of chlorinated paraffin that was used to starve the fire of oxygen. These belts also released highly toxic fumes in large quantities associated with high smoke densities. The toxicity index is calculated from the summation of the ratios of these concentrations to the concentrations causing fatality to an individual after a 30- minute exposure time. Gases and their fatality limits, as defined in UK Naval Engineering Standard NES 713, are shown in Table 2.

Fourth Generation Belts (1992)

The introduction of the â&#x20AC;&#x2DC;Gallery Testâ&#x20AC;&#x2122; forced manu-

facturers to increase the flame resistance of belts. The Gallery Test simulates a belt burning underground in a confined space with an air draft. This is a fairly severe test and generation one to three belts did not comply. As a consequence, belt manufacturers reduced the potential fuel sources usually added to the rubber, and also examined the type of rubber used. This resulted in an increase in the belt cost but a much safer belt. Unfortunately, highly toxic fumes and high smoke density remained a problem. Earlier versions of flame retardant belting specifications focused purely on the self-extinguishing properties of the belt and not the toxicity levels or smoke density generated by a burning belt.

Fifth Generation Belts Most of the rubber belts currently supplied, excluding PVC belts, incorporate non-halogenated products to achieve the required self-extinguishing properties. Basically, a mixture of chemicals is added to the rubber, which during the combustion process, release water which extinguishes the fire. Chlorine was thus eliminated from the rubber formulation and toxicity reduced. BULK HANDLING TODAY

February 2016

SAFECON

Figure 4. The smoke density levels have reduced dramatically

These modifications were still, regrettably, insufficient in lowering the remaining high levels of toxic fumes coupled with high smoke density during combustion.

The latest generation of fire retardant belting

To date, the focus of all the conveyor belt specifications have been on the ’flame’. There are no regulations or guidelines for the smoke density or gas toxic levels. The belt evaluation laboratory test (B.E.L.T.) also known as the ’Gallery Test’ does not measure or control the smoke properties. Conveyor belt manufacturers have now developed flame retardant belting with a much lower toxicity and also drastically reduced smoke density. Figures 2 - 4 illustrate the reduction in the toxic gas levels and also the improved drop in smoke density.

Conclusion

Generation two, three, four and five belts are all currently used in South Africa. All of the above complied with the requirements of SANS 971 up until the latest revision of 2013 where changes were introduced to reduce the belt flame propagation properties in line with the best global specifications. Without sacrificing on belt performance, the latest generation of flame retardant belts will ensure a much safer environment compared to older generation belts. The major reduction in toxic gas levels coupled with the improved drop in optical density will most definitely result in a safer environment in the event of a fire starting. This paper was first presented at Beltcon 17 in 2013. The author is Ben-Piet Terblanche, National Technical Sales Manager, Veyance Technologies, Inc. and copyright is vested with the IMHC. www.beltcon.org.za

THE POWER OF EXPERIENCE Turboflex SA (Pty) Ltd. Part of the

A complete range of industrial and high performance couplings together with a comprehensive selection of torque limiting products available from a single source.

Altra Industrial Motion Group

Turboflex Couplings

Gear Couplings Marland Backstops Grid Couplings Rotofluid Couplings Unit 11. Middle Park, Cnr.Craig & Dormehl roads, Anderbolt, Boksburg. PO Box 16524, Atlasville, 1465 Tel: +27 11 918 4270 • Fax +27 11 918 4240 • Email: sales@bibbyturboflex.co.za

BULK HANDLING TODAY

February 2016

Svendborg Brakes

Infrastructure Projects

PORTS

The ports industry is in a state of radical change and uncertainty, which requires flexible and adaptable port planning and design. This is according to Phyllis Difeto, Transnet National Ports Authority’s (TNPA) Chief Operations Officer.

“

The impact of the global economic downturn is a daily reminder to ports of the need to change ‘business as usual’. Innovative techniques are required to adapt to the pressures of integrating the global supply chain, the need for greater

port expansion and the immediate requirement to preserve natural resources,” she says. Phyllis outlines the South African port authority’s strategic direction and key projects from 2015 to 2022. Transnet’s Market Demand Strategy – which aims to enable the effective, efficient and economic functioning of an integrated port system to promote economic growth – is in its third year of implementation. Transnet has invested R92.8bn to date, of which port investments amount to R5.78bn. TNPA’s investment in the South African port system over the next 10 years will be R 56bn, of which R320m will be spent in the 2015/16 financial year. “The South African government’s focus on the Oceans Economy under its Operation Phakisa initiative will be a major driver to invest in the port system. A total of around R2bn will be spent over the next five years to refurbish existing repair facilities, while we will invest an estimated R13 to 15bn to create new repair facilities at the South African ports,” she adds.

Phyllis Difeto, Transnet National Ports Authority

“We are addressing current challenges in the Port of Durban where depth restrictions demand an urgent programme of dredging and berth deepening. In Richards Bay we will create additional container handling capacity through the short term installa-

SKF Mining Industry Solutions Harsh operating and market conditions make the mining industry a tough customer. SKF’s advanced range of products and services in the SKF Life Cycle Management approach - SKF’s proven approach for reducing Total Cost of Ownership for machinery at every stage, from specification and design to operation and maintenance, can help! SKF solutions assist with increased productivity and profitability, improved worker safety, reduced environmental impact, cutting energy consumption and reducing unplanned downtime.

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

BULK HANDLING TODAY

February 2016

PORTS

tion of mobile cranes and a medium term expansion for the port to handle up to 100 000 TEUs of containerised cargo.”

Major projects

TNPA’s anticipated major port infrastructure projects between 2015/16 and 2021/22 include:  Two projects to create additional capacity and deeper berths at the Durban Container Terminal, namely the Pier 2 berth deepening and lengthening project, and the Pier 1 Phase 2 project, also known as the Salisbury Island Infill project  Operationalising the Port of Ngqura

Developing our suppliers and trying to ensure that the ports provide opportunities to local suppliers and the previously disadvantaged  Creating bulk capacity at the Port of Ngqura through a new 16mtpa manganese terminal and a tank farm at berth A100 supported by roads, port entrance and service. Additional bulk capacity will also be created at the Port of Richards Bay through a new LNG terminal and additional bulk liquid berth.  Creating break bulk capacity through the reconstruction of sheet pile quay walls at the Durban Maydon Wharf precinct’s berths 1-2 and 13-14.  A fleet management programme for all ports including the acquisition of tug boats, pilot boats, launchers and dredgers.  Acquiring new helicopters for Durban and Richards Bay.  Operation Phakisa infrastructure developments

BULK HANDLING TODAY

February 2016

at the Ports of Durban, Saldanha, Cape Town, East London and Port Elizabeth, aimed at supporting the oil and gas sectors as well as the ship repair and building industries. Phyllis adds, “We have made solid progress. We have digitised our eight ports through our Integrated Port Management System (IPMS), and are monitoring port efficiencies while implementing performance operating standards for all operations – at the terminal, marine, haulier / road and rail interfaces. We are also in the process of establishing Joint Operations Centres (JOC) across the port system.

Complement rather than compete

“Within the parameters of our economic regulatory environment we are striving to improve the sustainability of the port system. Transformation of the port system is another priority and all new port projects, contracts and leases are subject to strict transformation criteria. We are developing our suppliers and trying to ensure that the ports provide opportunities to local suppliers and the previously disadvantaged,” she emphasises. TNPA’s port framework plans are reviewed annually and adjusted to suit the economic, policy, trade and technology environment. The port plans allowed TNPA to manage land use and optimise its investments. TNPA is landlord of eight commercial ports around the South African coastline. Transnet’s integrated system of regional ports and rail corridors aim to complement rather than compete with each other, Phyllis concludes. Transnet National Ports Authority, Richard Vallihu, www.transnetnationalportsauthority.net

EARTHMOVING

A Happy and Productive Operator

The latest backhoe loaders are all about the operator, Desigen Naicker, Building Construction Products marketing manager for Barloworld Equipment Southern Africa, tells “Bulk Handling Today”.

aving produced more than 300 000 of these machines that are working globally, the latest generation F2 series is improved and impressive. While doing more work faster forms a big part of the new offering, the machine is setting industry standards for operator comfort. Desigen tells us, “While the leader is far more modern- looking, essentially it was designed with the operator in mind with improved controls, enhanced visibility and just all round better comfort. Let’s face it – a happy operator is a productive operator.”

We are adamant that we will not just replicate Western solutions The machine is the product of ongoing collaboration and partnering with customers to tailor-make a backhoe loader that best suits their needs. “New designs no longer take place in a vacuum. We make a point of consulting with our customers to get a close up and personal account of what they would like to see in new generation equipment,” Desigen comments. “The North American landscape where Caterpillar has a large presence is very different from Africa and so it’s an ongoing process to deliver to local customers machines that have been refined to address the unique aspects of working in Africa. “This is a key driver for us and we are adamant that we will not just replicate Western solutions.”

Pioneering success

The first Cat backhoe was produced in 1985 in Leicester, England at a manufacturing plant for the assembly of forklift trucks. Since its inception the

machine with its distinct and unique features has been an industry success. The introductory units of the A series were immediately recognisable by the distinctive curved boom design, narrow loader tower and divergent loader arms. These lift arms remain unique to Cat loaders to this day. The same goes for the curved boom design that is also an industry exclusive. Launched with an operating weigh of approximately 6 087kg and a lift capacity at full height of 2 381kg, the machine has seen some major technological advancement over time such as the industry’s first true excavator style boom. Then there’s the industry exclusive 205 degree rotation bucket linkage while overall durability has been enhanced with improved hydraulic and electrical components.

The improved F series

First introduced in 2012, the F Series has continued this development tradition resulting in the latest range of machines – the F2’s. “We are seeing exceptional performance versatility and jobsite efficiency,” says Desigen. “They are also operating across sectors where due to their versatility they are proving their worth. One machine can do a lot on a site.” The F2 has an upgraded hydraulics system that provides improvements in oil flow for optimum delivery: the 422F2 from 125litres per minute to 132l/min; the 428F2 and 434F2 from 125l/min to 160l/min; and the 432F2 and 444F2 from 156l/ min to 163l/min. All machines feature Cat’s proprietary load-sensing hydraulics where the variable flow system senses the work demand and adjusts the flow and pressure to match. BULK HANDLING TODAY

February 2016

EARTHMOVING

“Essentially what this means is the achievement of high bucket dig forces whatever the engine speed, providing excellent control, while reducing fuel consumption,” explains Desigen. “Machines sold into Southern Africa also come equipped with new generation four-speed manual transmission in forward and reverse with the top speed at around 40km/h.”

of machines, is maintenance. “Planned maintenance is obviously far more cost effective as there is less downtime. Our VisionLink offering allows an owner to view machine vitals and machine hours online via a computer or even mobile phone allowing for preventative maintenance planning,” Desigen advises.

Three lives

Owners are catered for through a diverse range of products. “Whether it’s a major corporation or a small enterprise, we are geared to service the entire spectrum,” he adds. From buying a new machine, a Cat Certified Used or even just renting via the Cat Rental Store, Desigen maintains the company is opened to finding the right solution for each and every customer.

In line with customer requests for more safety features, the redesigned cab (except for the curved front window) now has flat glass doors and windows.

With the right parts, machines can easily be given second or even third lives Optional pilot controls provide low effort operation with the ability to switch between excavator and backhoe control patterns with the simple press of a button. “There have also been some changes to the aesthetic controls. The decibel level in the cab is improved significantly offering a much safer and quieter cab for operators. Another important focus for us is the aftersales component. Cat machines are designed with more than one life in mind. With the right parts, machines can easily be given second or even third lives.”

“We also offer a variety of financing package solutions and Cat work tool solutions are available for large or small companies with the focus on making it as affordable and versatile to own or rent our equipment. Ultimately – be it the design of the machine and its abilities, the purchase or renting process or the maintenance of the equipment – it’s all about making a less complicated environment for owners and operators,” Desigen concludes. Desigen Naicker,Barloworld Equipment, Tel: (011) 301-4000; Email: Marketing2@barloworld-equipment.com, www.barloworld-equipment.com

V14839

The motto nowadays to ensure optimum productivity

Customers first

Increase Your Productivity. Conveyor Drive Package Solutions Voith offers highly reliable fluid couplings and integrated conveyor drive package solutions including peripheral hardware as well as control and supervision electronics: • • • •

High availability of your belt conveyor Reliable operation under all conditions Optimised for each system Integrated design

BULK HANDLING TODAY

• •

Precise control of the system Power range 125 – 4 000 kW

Tel: +27 11 418 4000 info.vtza@voith.com www.voith.com

February 2016

WHISTLE BLOWERS

Get-rich-quick Scheme Whistle Blowers, South Africa’s largest independent whistle blowing service provider, is receiving a growing number of calls from companies seeking advice on the pro's and con's of offering rewards for information that leads to a fraud conviction.

Dale Horne

worried Dale Horne, who heads up the operation, believes this is because of publicity surrounding massive pay-outs running into hundreds of millions of dollars in America where it is encouraged.

Ultimately, the aim should be to create a culture of honesty within an organisation Bradley Birkenfeld, an ex-banker who reported his bosses at UBS for helping US clients to hide money in Swiss accounts received $104 million and Cheryl Eckard, a former employee of drugmaker Glaxo Smith Kline, who alleged that there were manufacturing faults at one of the company’s plants, collected $96 million. A group of employees at Pfizer netted $102 million in September 2009 for exposing the illegal promotion of the arthritis drug Bextra while Kyle Lagow

pocketed $14.5 million for providing information about alleged underwriting and mortgage fraud at a Bank of America subsidiary. But Dale says that local companies considering going this route, albeit on a far smaller scale, need to think carefully about the potential consequences for both themselves and their employees.

Wrongdoing

He explains that America’s much-debated Dodd-Frank Act, which targets corruption in the financial industry in particular, contains a whistle blowing clause that enables the Securities and Exchange Commission to pay out a reward equivalent to between 10% and 30% of the money recovered should it obtain a conviction with sanctions exceeding $1 million. Dale believes that whistleblowing is the best and most effective means of rooting out wrongdoing in the corporate domain – a fact underscored by the 2014 Report to the Nations on Occupational Fraud and Abuse carried out by the Association of Certified Fraud Examiners (ACFE). Based on 34 615 cases spread across America, Europe, Asia, Canada, Latin America, the Middle East and Africa (including South Africa) from October 2013 to December 2013, this report indicated that over 42 percent of all cases were the result of a tip. But fewer than 11 percent of companies provided rewards for whistle blowers. However, Dale doubts whether rewards contribute significantly towards these figures. The crux is that companies need to closely examine the motives of those reporting wrong-doing in exchange for cash. There is always the chance of a get-rich-quick scheme that could backfire, he warns.

Dishonesty

“The company intending to pay rewards must consider elements such as how the informer would communicate the information, who would the information be communicated to, how is protection guaranteed, how is the value of the reward

BULK HANDLING TODAY

February 2016

WHISTLE BLOWERS

determined, the grounds on which rewards will be paid out, how the rewards would be paid, for example, because it could take some years before a particular matter is finalised?

We believe that companies need to focus on protection of identities rather than on providing rewards Should a company satisfactorily answer these questions, then this should be operated separately from any official whistle-blowing facility. Dale says that Whistle Blowers does not pay for information. He warns that any investigations that include information for reward should be handled by a registered investigation body, totally independently of the whistle-blowing programme. The good news, according to Dale is that most people who do blow the whistle on corruption

don’t do so for a reward. The AFI study noted that at any company: 25 percent of employees are dishonest, 25 percent are honest, and the remaining 50 percent could go either way depending on the culture of the organisation. Therefore Whistle Blowers concentrates on the aspects of ethics and bringing the majority into the crime-fighting fold. “Our experience shows that people don’t come forward to give information for money generally but because it’s the right thing to do. Ultimately, the aim should be to create a culture of honesty within an organisation. We encourage an ethical solution to a problem where employees speak up in order to protect their employment and their companies,” Dale says.

Protection

Trust rather than money, he emphasises, is actually the chief determinant of whether an employee will blow the whistle. “We have systems in place to protect a whistle blower’s identity. Our primary focus is to provide absolute security so whistle blowers keep coming back and don’t fear reprisals. We believe that companies need to focus on protection of identities rather than on providing rewards.” Dale cautions that there is no formal legislation in South Africa that protects the identity of someone providing information for a reward. Instead, legislation such as the Protected Disclosures Act only provides for legal protection of whistle-blowers provided that a disclosure is made in good faith. If a whistle blower accepts a reward, he or she waives the right to protection with potentially serious consequences. Whistle Blowers (Pty) Ltd Dale Horne Tel: (031) 308-0500 Email: dale@whistleblowing.co.za

BULK HANDLING TODAY

February 2016

MARKET FORUM

Super Heavy-Duty Belt Cleaners A family of primary conveyor belt cleaners has been engineered for the world’s fastest, most heavily-loaded belts, with industrial-strength construction that delivers effective cleaning, minimal maintenance and long service life, even under punishing conditions. Martin SHD cleaners have been proven on belts up to 305cm wide, with speeds as high as 10m/sec, carrying loads up to 300 000 tons per day. Designed with patented “Carp” technology to achieve constant angle geometry to match pulley diameter accurately across all stages of service life, the massive urethane blades deliver up to 271 sq cm of wear surface, more than seven times the wearable surface of standard cleaner designs. With a broad range of colour-coded, highperformance blade choices available, the cleaners can be specified to suit a wide variety of materials and performance requirements. The SHD Series was developed for super heavy-duty applications, with structural

Engineered for the world’s fastest, most heavily-loaded belts.

steel components to prevent bending of the main frame. The extremely durable construction helps eliminate carryback, reduce emergency outages and minimise unscheduled downtime. In some applications, it has been shown to be the only design that can withstand the severe operating conditions.

“This design allows conveyor operators to improve maintenance planning and reduce expenses,” observes product engineer, Daniel Marshall. “With lower maintenance requirements, it saves money through fewer repairs and blade replacements, as well as faster service procedures. The reduced carryback means improved working conditions and plant safety, maximised equipment life and reduced cleanup.” “The SHD Series was originally designed for a severe-duty mining application, built to handle the overburden at one of the largest pit mines in the world,” Daniel continues. “Every cleaner they tried was getting destroyed by the harsh conditions. There just wasn’t anything on the market that could withstand the speed and abrasive forces, so we completely reengineered the conventional belt cleaner design, from the I-beam frame to the huge blade segments. In fact, these cleaners are so large that we had to invent a way to properly tension them,” he concludes.

The SHD Series was developed for super heavy-duty applications, with structural steel components to prevent bending of the main frame.

Martin Engineering, Rick Felde Tel: (541) 306-4815 www.martin-eng.com

Total Solution Vishay’s Model 178 extensometer is a load sensor designed for force measurement on any load-bearing structure. This extensometer provides the total solution for weighing, level control, stress and fatigue monitoring. The design also allows multiple sensors to be permanently mounted for more complex stress profiling and analysis. The unit provides the solution for non-

intrusive level measurements for materials that are subject to uneven buildup, bridging, or sidewall collection. Also, liquids or wetted materials that are not suited for direct contact level measurement are an ideal application. The design of the Model 178 makes it an excellent solution for retrofitting existing structures without compromise of the integrity of the vessel or structure.

The 178 has application in tank weighing or level systems, agricultural equipment, rolling mill sensing, moment sensing, structural loading measurements and bridge structures. Instrotech, Tel: (010) 595-1831, Email: sales@instrotech.co.za www.instrotech.co.za

BULK HANDLING TODAY

February 2016

cantly, the global benchmark for transfer points is the Weba Chute System. Weba Chute Systems pioneered the engineered transfer point and extensive research and development by the company identified the root causes of numerous problems related to materials handling and transfer points. These include lack of material control resulting in excessive impact and poor belt loading, disproportionate wear, excessive dust emissions and spillage.

Benchmark for Transfer Points Transfer points are finally being recognised as key elements in plants, and Mark Baller, managing director of Weba Chute Systems, says this has seen other players enter the market as they too begin to recognise transfer points as critical to the operational success of plants.

“As the market leader with more than 4 000 Weba Chute Systems successfully operating globally, we welcome legitimate competition as it keeps companies motivated and customers are assured of continual improvement in both product and service delivery,” he says. Signifi-

Netshield, a WestconGroup Southern Africa business, provides special development for local businesses, giving them the tools and skills required to transform an idea into a tangible, innovative and working business solution. Drawing from its pool of highly-skilled and qualified engineers from myriad backgrounds, the Netshield team works with customers to develop bespoke solutions based on a customer’s express business challenge. The team transforms ideas by assisting with the development, design, and architecture of each.

have a great idea that they want to put into action, but cookie cutter systems and application don’t allow them the flexibility they need in order to innovate,” says Inus Dreckmeyr, CEO at Netshield SA. “It is with this in mind that we created the Netshield South Africa Special Development division. While yes, companies do want to standardise on processes, they still need flexibility in execution.

Weba Chute Systems, Mark Baller, Tel: (011) 827-9372, www.webachutes.com

seamlessly into your existing solutions if the need arises. “Key markets where we have seen a lot of success include the mining and government sectors – both of which are environments that need specific solutions for specific needs. The beauty of special development is that it pushes the boundaries of what we think is available off the shelf, what we would like to see in our environment, and it lays a path for us to be able to create solutions to problems that may seem overwhelming,” concludes Inus. Netshield, Marien Dreckmeyr, Tel: (012) 841-0320, Email: sales@netshieldsa.com

Complete Festoon

“One technology solution simply cannot meet the requirements of every customer. To this end, there are also customers that

“Working with your team, Netshield can identify the functionality and specifications you require from a product, and is able to turn this into an industry specific solution that caters for the market you operate in, your specific business processes and needs, and one that melds

Today the Weba Chute System is a custom engineered transfer point solution designed to address the numerous issues plants face with material movement. Each chute system is engineered for the specific application and this is what accounts for the success that these transfer points have achieved worldwide.

BULK HANDLING TODAY

February 2016

MARKET FORUM

Long Haul Cover The transport and logistics business demands unique insurance cover that addresses every aspect of freight and transport risk. MiWay cover is designed to give peace of mind to both short and long haul transport operators across multiple risk areas. Mornè Stoltz, MiWay Head of Business Insurance, explains that MiWay offers standard and perils based cover, but

always recommends full comprehensive cover to ensure all possible risks are covered. He notes that it is essential to cover the transport company’s assets, loss or damage to third parties’ goods, and have sufficient liability limits. “Many vehicles spend a large part of the day travelling, increasing the risk of an incident happening. By keeping to dedicated routes on a fixed time-

table, it makes vehicles prime targets. Vehicle claims are the most frequent, while goods in transit claims can be the most expensive. Often vehicles are found abandoned following a theft or hijacking with the items the vehicle was carrying having been stolen. Our business vehicle product is supported by a goods in transit policy to address these risks,” he says. Mornè notes that liability insurance should not be overlooked either. “This covers the insured for injuries and/or loss to third parties where the insured can be held legally liable in the case of negligence.” MiWay, Tel: (011) 990-0296, www.miway.co.za

Hybrid Rail Vehicles The Changchun Railway Vehicles Company Ltd. (CRC) of China is planning to build 30 hybrid rail vehicles featuring RailPack 400DE drive systems from Voith Turbo. Each three-part vehicle will have two of these systems, both with a 375 kW diesel engine and a 345 kW generator. The first three RailPack 400DEs have undergone comprehensive testing at CRC’s own test ring in Changchun and at Beijing Jiaotong University. The rail vehicle itself is expected to be tested and approved by the China Railway Corporation, the country’s national railway operator, in 2017.

System Solution

The hybrid vehicles can reach a top speed

Open cast and underground mining operations, stockyards, ports and other bulk handling facilities rely on powerful electric machines to do the heavy work. Maximum uptime, and high production levels, require reliable, easy to maintain materials handling machines. “It is therefore essential to install high quality specialised festoon systems to ensure uninterrupted and reliable feeding of energy, data, etc. to these machines even in extremely harsh and arduous environments,” states Powermite marketing director, Donovan Marks. The Powermite/Conductix range comprises light, medium and heavy duty festooning for straight runs, bends

drive system can handle extreme temperatures of minus 40°C. of 120 km/h with the diesel-electric drive, The RailPack 400DEs also feature a quick-switch system from electric to diesel-electric drive. In addition, the Voith

or circular configurations. The design and correct alignment of the cable significantly influences the performance of energy and data transmission. The I-Beam cable carrier is suited for heavy duty applications including bulk container handling by cranes typically found at ports. With a load capacity of up to 125kg and maximum system length of 150m, the C-Rail cable carrier is an ideal energy supply system for light to medium duty applications. Suitable for indoor and outdoor use, the C-Rail is available in zinc-coated and stainless steel and the company can supply a special version for explosion-proof areas, although these are fully imported systems. “We also

Voith Turbo, Terry-Lynn McIntosh, Tel: (011) 418 4000, Email: Terry.Mcintosh@voith.com, www.voith.com

offer festoons that run on diamond track or square rail which has been specially engineered to reduce dust accumulation by preventing dirt buildup,” explains Donovan. Powermite supports a complete range of cable and festoon hardware and accessories including cable guiding and anchoring devices, damping devices, junction boxes, cable connectors, organisers and clamps, connection boxes, towing clamps, reels, cable, rope and webbing plugs and end clamps, etc. Powermite (a division of Hudaco Trading), Tel: (011) 271-0000, www.powermite.co.za

BULK HANDLING TODAY

February 2016

MARKET FORUM

Critical Support Service

“HPE Africa has recognised a need from industry for greater assistance with onsite repairs and support. For this reason, the company has increased its field services fleet and extended its support service throughout South Africa and into neighbouring countries,” says Alex Ackron, managing director, HPE Africa. “The company now has well-equipped workshops in Gauteng, Durban, Cape Town and East London, which are supported by dealers in Limpopo, Upington, Kimberly, Douglas and Lesotho.”

Repairs and services include minor and major component replacement, as well as re-building and refurbishment of units. The company has established specialist divisions for engine repairs, hydraulics and boiler making, encompassing a bucket rebuild facility. HPE Africa, Capital Equipment Group (CEG), Invicta Holdings Limited Charene Butterfield, Tel: (011) 397 4670 Email : charene,butterfield@hpeafrica.co.za www.hpeafrica.com

Full steam ahead Advisian, the advisory business line of WorleyParsons, is rapidly becoming a leading provider of rail advisory and engineering services in Africa, offering independent management and strategic advisory services for the railway sector. Advisian’s rail practice deals primarily in resource-based rail, focusing on freight and bulk transport. The company is currently involved in a number of rail projects in sub-Saharan Africa that are in various front-end planning stages. Advisian’s Sub Sahara Africa Managing Principal for Transport Consulting, John Marshall, says that rail transport is increasingly becoming the option of choice in many African countries, where poor infrastructure and road systems hinder the capacity of contractors to deliver goods and services. “The challenge in sub-Saharan Africa is that there is simply insufficient infrastructure, and this is why rail is more frequently being considered as a feasible means of transport,” says John. “Although road transport may be cheaper in the short term, in many cases rail is the more viable option over the long run.” Advisian is able to provide an integrated service capability for the rail sector including feasibility studies, project management, engineering support and EPCM for new rail corridors, renewal of colonial railways, complex urban rail and integrated rail systems, as well as related services. WorleyParsons, John Marshall Email: john.j.marshall@advisian.com

Global improvement in 2016 Global sales of construction equipment are forecast to grow 3.9 percent in unit terms in 2016, to 760 508 machines, according to specialist economic forecasting and market research consultant, Off-Highway Research. The expected improvement follows a weak performance in 2015, when global unit sales fell more than 10 percent from the total of nearly 818 000 machines sold in 2014. In 2016, growth is expected in the European, North American and Indian equipment markets. “There can be no doubt that 2015 was a tough year for the global equipment industry, due to slowing world economic growth and weak commodity prices,” says Off-Highway Research managing

BULK HANDLING TODAY

director David Phillips. “Unit sales fell to their lowest since the crisis years and the drop in the Chinese market was particularly brutal. However, there were improvements in several developed countries which helped offset some of these losses.” David adds, “The company’s forecast is for the start of a gradual return to health in the global construction equipment market in 2016. However, as has been the case since the crisis years of 2008 and 2009, business confidence remains fragile, and the uncertain geopolitical outlook around the world could have a negative impact on the sector.” Off-Highway Research Email: mail@offhighway.co.uk www.offhighway.co.uk

February 2016

MARKET FORUM

4Site is a new project management service introduced by Terex Washing Systems (TWS) to specifically aid customers and distributors with the installation of TWS equipment. 4Site comprehensive management service provides enhanced reliable and efficient levels of support every step of the TWS installation. Each of the project management packages include 4 key steps and are supported by TWS at an international level through regional partners from its headquarters in Northern Ireland. Sean Loughran, director TWS says, “The response to the introduction of 4Site from our global distributor network has been incredible and distributors are excited about offering the service to their customers. TWS is the premier

W orkshop P ortal F rame A characteristic of Verlinde´s VGPA workshop portal frame is that it is entirely made of Eurosystem Alu type aluminium hollow sections. It is designed for handling loads of from 125 to 2000kg. Eurosystem Alu sets itself apart by the lightness of its aluminium hollow sections with a rolling coefficient enabling effortless travelling trolley positioning. The lightness of the sections enable the VGPA portal frame to be installed and handled by one person. Its weight is now half that of equivalent conventional steel structures. The lightness of the rails also offers the user easy, relatively effortless manipulation even with heavy, unwieldy loads. With its fully modular design, VGPA portal frames are fitted with folding legs and their height can be adjusted from 1550 to 4000mm. They are mounted on white polyamide hinged wheels for inside use. The portal frame is fully mobile under load. Verlinde, Tel: 0861 837 546, www.verlindecranes.co.za

provider of advanced plant solutions and the introduction of 4Site project management service greatly enhances our position in the marketplace to better serve our customers.” TWS offers three tailored service management packages, Silver, Gold and Platinum, with a common theme centered

on effective and efficient communication throughout the process. The silver package is complementary with all TWS machines and ensures simplification of the installation and commissioning of TWS washplants globally. Terex Washing Systems, www.terex.com/washing

World-class Facilities Sandvik’s new support facilities in Zambia are enabling faster and more efficient turnaround times for the maintenance and repair of mining fleets throughout the central African region. In a year since moving into the new facility from their old premises and opening its doors in Kitwe, the operation has significantly improved throughput of repairs and rebuilds and has slashed delivery lead times for parts to ensure maximum uptime of Sandvik fleets in the region.

equally modern facilities as elsewhere in the world. Mines in the region now have access to the same services that are available globally and can optimise their fleets accordingly without concerns over technical support. Sandvik Mining Zambia, Mutale Chilufya, Email: mutale.chilufya@sandvik.com, www.mining.sandvik.com

Sandvik invested in state-of-the-art support offices that include administrative offices, workshops, parts distribution and logistics centres. Up-to-date equipment and tooling, along with globally accepted management systems, are also in place to ensure services and support that is comparable to other Sandvik centres across the globe. Steve Chambers, Sandvik technical and workshop manager for central Africa, says burgeoning fleets in the area require

Technicians rebuilding an LH514 for a customer

BULK HANDLING TODAY

February 2016

MARKET FORUM

Maximised Uptime Several key issues can affect the life cycle and productivity of a screen and have an impact on the bottom line at minerals processing operations. These include the shortage of skills within the industry, which often results in sub-standard maintenance being performed. In addition, maintenance is often undertaken on a reactive rather than a proactive basis, which can lead to further costly issues. “Significantly, Joest Kwatani engineers aim for maximised tonnage of the screen during its lifetime. However, since screens are such critical elements in the process it is important to undertake regimented maintenance to ensure ongoing efficient operation and improved yield,” says Theresa Walton, general manager, service at Joest Kwatani. These issues are best addressed by the implementation of a service level agreement that is customised for individual mine requirements. The first step is to

It is important to undertake regimented maintenance to ensure ongoing efficient operation and improved yield

undertake a full audit covering the operating performance and the condition of the screen. “We also consider the upstream processes to ensure that the feed is within the original specifications for which the screen was engineered,” says Theresa.

intervals to measure improvements in performance as well as the condition of the screen. Remedial action is often recommended and could entail the proactive identification of vibrating machines which require extensive repair work or refurbishment as a result of their age.

Under the terms of the service level agreement, Joest Kwatani undertakes continuous audits at predetermined

Joest Kwatani, Kim Schoepflin, Tel: (011) 923-9000, www.joest-kwatani.co.za

Easy and Reliable ifm electronics’ new rotational speed evaluation systems DD0203 and DD0296 supply the basic functions of rotational speed monitoring and standstill detection by means of external pulse pick-up. All settings are intuitive via four potentiometers: The rotational speed is set using a logarithmic scale, multiplier x

1 / x 100 and output function, start-up delay and hysteresis. Featuring one semiconductor output and one relay output which function can be set in case of under speed or over speed. Four LEDs indicate the switching and operating states. The integrated wide-range power sup-

ply, which can be supplied with direct or alternating voltage, guarantees high flexibility. The monitor’s supply 24 V DC output power to the connected sensors. Small in design with plug-in screw terminals simplify installation. ifm electronic ZA, Tel: (012) 450 0400 Email: info.za@ifm.com, www.ifm.com

Used Plant Equipment Dura Equipment Sales invests hundreds of millions of rands each year in the procurement and refurbishment of quality used plant machines to enter a second term of life in mining, construction, plant hire and other applications. With a more affordable price tag, these machines offer small and medium size operations the opportunity to expand their fleet with highly productive machines at a fraction of the cost of new equipment.

restore them to near factory condition ready for resale.” The company also has the expertise to import and export machines across the border making the setting up of operations in any African country a seamless operation no matter where machines come from or are going to.

Ernest Human, Dura Equipment Sales marketing manager says, “Machines on offer range from small TLB-type machines for agricultural applications and general construction, to road resurfacing machines, loaders, dumpers, excavators, graders and large production machines for mining applications. These are serviced within our fully equipped workshop facility and, where refurbishment is required, we

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February 2016

“With more than 110 machines available in Johannesburg and many more throughout our branches, there is sure to be a machine to match almost any requirement,” concludes Ernest. Dura Equipment Sales, Ernest Human, Tel: (011) 918-4760, www.durasales.co.za Email: ernest@durasales.co.za

MARKET FORUM

Patriot Cone Crusher Superior Industries debuts their Patriot cone crusher, marking a major milestone for the company’s new crushing and screening division. The high-performance cone is the manufacturer’s first entry into crushing technologies for bulk processing applications.

backed by the industry’s first two-year standard warranty and is manufactured in the United States at our new Pekin, Illinois-based factory.” Engineers designed high throw and high-pivot point crushing performance to achieve strong production rates at a low cost per ton. Mobile applications will appreciate a readily mounted design for transportation on a cone/screen chassis.

“In the month’s leading up to the launch of our first crusher, we have worked hard to arm ourselves with a group of bright, experienced crusher service and parts professionals to provide our customers with world-class support,” says John Garrison, Superior director of crushing and screening. “In addition, each Patriot Cone Crusher will be

Models include units for 200 to 500 horsepower operating conditions and production rates up to 805 tons per hour (730 mtph). Superior Industries, Corey Poppe, Email: corey.poppe@superior-ind.com www.superior-ind.com

‘smartPORTS’ All eight commercial ports across South Africa’s coastline are now using Transnet National Ports Authority’s new R79-million web-based Integrated Port Management System (IPMS), following the rollout of the system to the Port of Richards Bay in November 2015. The MS Insignia passenger vessel was the first to be brought into the port by using the new ‘smartPORT’ technology. IPMS has been rolled out to the Ports

of Durban, Cape Town, Saldanha, Port Elizabeth, Ngqura, East London, Mossel Bay and Richards Bay.

key port operations to be managed online and in real time across TNPA’s eight commercial ports.

The technology was developed by Navayuga Infotech, a company based in India, in collaboration with their South African partner, Nambiti Technologies. The system replaces manual processes that were previously used for monitoring marine operations, vessel traffic services and terminal performance and enables

Since IPMS was first introduced in July last year, more than 300 vessel agents have registered onto the system and more than 1 600 vessel arrival notifications have been submitted across all eight ports. Transnet National Ports Authority, Tel: (035) 905-3118, www.transnet.net

Test Laboratory Flexicon has completed construction of an all-new test laboratory for Flexi-Disc tubular cable conveyors and integrated bulk handling equipment. The laboratory is centred around separate 10 and 15 cm diameter tubular cable conveyor circuits with drive systems and tensioners which can be demonstrated as stand-alone systems. Both circuits are also configured with metered and non-metered inlet adapters, and valved and full-flow discharges that allow for rapid connection to a variety of full size upstream and downstream bulk handling equipment also produced by the company. Using customer supplied bulk materials, engineers and laboratory technicians verify system performance prior to final equipment design and fabrication, and demonstrate newly constructed equipment for visiting customers prior to shipment. In addition, Flexicon engi-

neers utilise the laboratory to study the performance of new designs. Flexicon Africa, Tel: (041) 453 1871, sales@flexicon.co.za, www.flexicon.co.za

10 and 15 cm diameter Flexi-Disc tubular cable conveyors shown with Tubular Discharge Valves for selective discharging of material into downstream equipment

BULK HANDLING TODAY

February 2016

MARKET FORUM

Expanding upward According to the United Nations, by 2030, almost 5 billion people, or 60 percent of the world’s population will live in cities. In the context of mega-cities, expansion is no longer outward, it’s upward. Brett Fleming, CEO of Eazi Group, Africa’s market leader in work-at-height solutions comments, “This industrial growth underpins the need for a shift in the trend of work-at-height solutions, where safety, efficiency and cost are key.” Recently, Eazi Access Rental landed southern Africa’s first JLG 1850 telescopic boom lift that reaches 58.5 metres in height, in layman’s terms that equates to 17 storeys. This colossus is the shape of things to come and reflects the rising volume of projects and tasks being performed at height. Eazi Access Rental has seen the need for smaller nimbler cranes, like the Maeda Mini Crane. With the expansion trend being upwards, space becomes increasingly constricted, which is where this mini crane has no equal.

New Appointment

Another major trend is the demand for increasingly environmentally friendly machines that reduce the risk for hydraulic spills and run on electric supply or low-emission diesel engines. “While traditional work-at-height solutions still remain relevant in many industries,

powered access machines and mobile elevated work platforms should be considered as the modern alternative, being more than just a trend, they offer the latest technology with safety, flexibility and efficiency in mind,” Brett concludes. Eazi Access Rental, www.eazi.co.za

Tyrexpo Africa The Tyrexpo Africa 2016 will be held at the Sandton Convention Centre in Johannesburg between 8 to 10 March 2016.

MAN Truck & Bus AG has appointed Markus Geyer as Managing Director (MD) of the German commercial vehicle manufacturer in South Africa and the Sub Equatorial Region.

All registered visitors to the show are entitled to win a Nikon Coolpix digital camera on each of the three days of the event, once they have completed their meetings with the exhibitors. Registered visitors, who use the online Tyrexpo Business Matching Service, will stand double chances of winning at the draw. Tyrexpo Africa 2016 www.tyrexposeries.com/africa

Index to Advertisers Afzelia 18

Melco 21

Bibby Turboflex

SKF 25

BMG

24 Outside Front Cover, Outside Back Cover

CIS 26 Condra Cranes

Inside Front Cover

HPE Africa

Tega Industries Torre Lifting Solutions

Inside Back Cover 11

Veyance 10

ifm 30

Voith 28

ILS 12

Worley Parsons

BULK HANDLING TODAY

February 2016