Quarrying Africa ISSUE 5 2023 by quarryingafrica

PREMIER INFORMATION HUB FOR THE SUB-SAHARAN AFRICAN QUARRYING SECTOR

SEPTEMBER/OCTOBER 2023

PARTNERSHIP FOR SUCCESS 12

Up to the task

A decade of ‘ultimate dependability’

Putting a premium on conveyor maintenance

VOL. 2 ISSUE 5

COMMENT

THE BIGGER

PICTURE

MUNESU SHOKO Publishing Editor Email: munesu@quarryingafrica.com

LinkedIn: Munesu Shoko

Quarrying Africa

raditionally, the upfront price of an asset has largely been the principal driver of many procurement decisions. Understandably, in a difficult economy, capital is tight, and procurement decisions ought to be forcibly taken based on capital cost, without necessarily factoring the bigger picture – the ‘hidden’ lifecycle ownership costs. Ongoing costs after you have written the cheque for that piece of equipment are just as important, if not principal. In fact, there is a general consensus that the purchase price of a typical piece of equipment such as a quarrying excavator constitutes only 15-20% of the total cost of ownership. A total cost of ownership (TCO) analysis should therefore be conducted to uncover both the obvious costs and the hidden costs of ownership. TCO highlights the difference between purchase price and long-term costs. There is a general school of thought that owning the equipment could cost between five and eight times the purchase price, if not more. It is encouraging to see that TCO is an increasingly common purchasing approach among local capital equipment owners, particularly in the construction and quarrying space. This was the overarching message from my recent conversations with two leading truck manufacturers, who both noted that customers now consider not only purchase costs, but also all future costs that machine ownership entails. The cost of owning a machine includes so much more than the initial purchase price. Spare parts, maintenance and repair costs, tyres and wear parts, uptime, personnel, interest rates, depreciation, insurance, taxes and, of course, fuel consumption, all play an important role. In the quarrying environment, fuel is often the biggest cost when operating a piece of construction equipment or commercial vehicle. In an environment where fuel prices continue to soar, fuel can constitute up to 60% of the total cost of owning a typical mining vehicle. This makes lowering fuel consumption a quick win for dramatically reducing TCO.

As the TCO approach to procurement decisions continues to gain traction, fleet owners are finding value in telematics technology, which is why the majority of original equipment manufacturers (OEMs) now offer it as standard. The technology enables quarries and mines to migrate from traditional guesswork to putting actual numbers to every part of their operations. As you will see in this edition of Quarrying Africa, Daimler Truck Southern Africa (DTSA) has this year made its Fleetboard telematics offering standard on all of its construction and all-wheel drive vehicles. This is in response to the growing trend towards the consideration of TCO by customers in this market segment. In fact, DTSA is the biggest Fleetboard market outside of Europe, which speaks volumes about this mindset shift in the local market. UD Trucks Southern Africa is another OEM that has seen the growing demand for its Connected Services offering, as customers (especially those in the construction and mining environments) seek to keep an eye on their TCO. The system – which allows fleet owners to maximise efficiency through realtime vehicle tracking and geofencing – now comes standard across all UD models. Telematics technology plays an increasingly important role in the everchanging operating environment. It empowers fleet owners to streamline their operations, getting the most out of their investment while delivering added value. It provides visibility of the actual costs of operating a piece of equipment, data to develop strategic improvements and the opportunity to performance benchmark every part of their operations. Apart from telematics, quarry operators are also actively reducing their TCO across earthmoving equipment and trucks by using modern load weighing technologies to set benchmarks and measure productivity. By tracking the amount of material moved per hour to measure productivity and set benchmarks, operators can quickly detect underperformance and make appropriate adjustments to ensure all equipment is working at its optimum efficiency.

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CONTENTS 26

UP TO THE TASK

MAKING SENSE OF BLAST DATA

16 BRAUTESETH BREAKS NEW GROUND WITH SANDVIK PARTNERSHIP

A DECADE OF ‘ULTIMATE DEPENDABILITY’

22 INTO NEW SCREENING TERRITORY

PUTTING A PREMIUM ON CONVEYOR MAINTENANCE

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LEAD STORY PARTNERSHIP FOR SUCCESS

Publishing Editor: Munesu Shoko Sub Editor: Glynnis Koch Business Development Manager: Elmarie Stonell Admin: Linda T. Chisi Design: Kudzo Mzire Maputire Web Manager: Thina Bhebhe

Quarrying Africa is the information hub for the sub-Saharan African quarrying sector. It is a valued reference tool positioned as a must-read for the broader spectrum of the aggregates value chain, from quarry operators and aggregate retailers, to concrete and cement producers, mining contractors, aggregate haulage companies and the supply chain at large.

© Quarrying Africa Quarrying Africa, published by DueNorth Media Africa, makes constant effort to ensure that content is accurate before publication. The views expressed in the articles reflect the source(s) opinions and are not necessarily the views of the publisher and editor. The opinions, beliefs and viewpoints expressed by the various thought leaders and contributors do not necessarily reflect the opinions, beliefs and viewpoints of the Quarrying Africa team. Quarrying Africa prides itself on the educational content published via www.quarryingafrica.com and in Quarrying Africa magazine in print. We believe knowledge is power, which is why we strive to cover topics that affect the

INDUSTRY NEWS

ELIMINATING DUST IN CONVEYOR SYSTEMS

quarrying value chain at large.

46 50

UPWARD TRAJECTORY FOR SA’S CONSTRUCTION SECTOR

FACTORS TO CONSIDER WHEN BUYING A NEW EXCAVATOR

ACI SHOWS POSITIVE REAL GROWTH IN Q2 2023

Contact Information

ZENZELE CEMENTS PRECAST PRODUCTS WITH AFRISAM QUALITY

Email: munesu@quarryingafrica.com Cell: +27 (0)73 052 4335

KEEPING UP WITH AGGREGATES DEMAND FOR N3 PROJECT

DEWATERING: SOLUTIONS AS UNIQUE AS YOUR PROJECT

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INDUSTRY NEWS

ACI shows positive real growth in Q2 2023 Afrimat, the JSE-listed mid-tier mining and materials company providing construction materials, industrial minerals, bulk commodities and future materials and metals, has released the findings of the Afrimat Construction Index (ACI) for the second quarter of 2023. The ACI, a composite index of the level of activity within the building and construction sectors, is compiled for Afrimat by economist Dr Roelof Botha. According to Botha, the resilience of the economy during the second quarter of the year has been showcased by the construction sector, with eight of the nine constituent indicators of the ACI recording positive real growth rates compared to the first quarter of the year. “For the crucially important indicator of job creation, it is encouraging to note that construction took the honours on a quarter-on-quarter basis, adding more than 100 000 jobs and outperforming all other sectors of the economy, including those with much higher employment levels.” The ACI recorded a level of 115,4 in the second quarter compared to 109,1 in the previous quarter. “The quarter-onquarter increase of 5,8% is higher than the increase in the country’s GDP and is a welcome improvement on the decline recorded in the first quarter. Unfortunately, the year-on-year

The ACI recorded a level of 115.4 in the second quarter compared to 109.1 in the previous quarter.

increase was less than one percent, signalling the dire need for macro-economic policies aimed at encouraging the further expansion of construction activity in the country,” Botha adds. Over and above the sterling performance of new job creation in the construction sector, other highlights were the positive real growth in the category “Wholesale Sales Values of Construction Materials”, the rebound in the “Value of Building Plans Passed”, and the increase in “Volume Of Building Materials Produced”. a

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INDUSTRY NEWS

Zenzele cements precast products with AfriSam quality Zenzele Pavers and Cladding, a family-run Pretoria-based manufacturer, credits its unwavering commitment to quality and its lasting partnership with leading cement supplier AfriSam for its successful growth. Today, the business serves both local homeowners in Pretoria North, Ga Rankuwa, Soshanguve and broader regions, as well as large developers and construction contractors. Since its inception in 2007, Zenzele has specialised in precast products from concrete pavers and bricks to cladding, kerbs, blocks and tiles. “The backbone of our success is high-quality cement, ensuring consistency in results and colour,” says founder and owner Wendel Krook. “Our enduring relationship with AfriSam, who mirrors our dedication to quality, reliability and consistency, plays a significant role in our growth.” The company’s core principle of delivering a product that is ‘good enough for their own home’ has attracted a diverse clientele, ranging from local families to large commercial customers. Zenzele co-founder Hengelene Krook says, “Our loyal customer base is built upon quality, service and the trust that our products will pass the test of time.” This commitment to quality extends to Zenzele’s workforce, marked by low staff turnover and retention of skills

Scan QR Code for more on this story.

Very low staff turnover and many employees already having a decade of service ensures attention to detail in technical and other aspects.

and experience, ensuring attention to detail in all business aspects. GM Jacqueline O’Kelly, Zenzele’s first employee, applauds AfriSam’s support and reliability in meeting Zenzele’s highquality standards. Sales and marketing representative Tinus Redelinghuys emphasises AfriSam’s vital role in the success of phased construction projects. “With AfriSam’s quick service, we maintain a consistent supply of cement, facilitating efficient production and ex-stock deliveries,” says Redelinghuys. AfriSam’s consistent service and high-quality cement, including the 42.5R CEM II High Strength Cement, has notably benefitted Zenzele’s inventory

New CEO for PPC Leading South African cement maker, PPC, has announced the appointment of Matias Cardarelli as CEO of the company. He replaces Roland van Wijen, whose contract expired on 31 August 2023, but has been extended to 31 December 2023 to allow for a smooth handover and transition. Cardarelli brings a wealth of experience in the cement industry, having served across several emerging markets. Having spent the past five years in South Africa as CEO and chairman of Natal Portland Cement (NPC), he already has a good understanding of the local market. During his time at NPC, he successfully transformed the organisation by improving efficiencies, boosting margins and EBITDA, as well as increasing cash generation. “With his deep understanding of the local industry and his proven leadership skillset, Cardarelli will play a pivotal role in continuing to drive PPC’s growth, improve profitability and enhance returns,” says the company. a

management and delivery efficiency. Wendel Krook comments, “AfriSam’s cement consistency and quality allow us to accurately predict our paver supply and promptly deliver to our customers.” Praising the partnership, Hengeline Krook says, “AfriSam genuinely values our relationship, a sentiment we greatly appreciate as a smaller business.” Adele Wentzel, AfriSam’s sales manager manufacturing for Gauteng, further emphasises the importance of their collaboration. “We provide technical support, share information and interact regularly to strengthen our partnership. We are proud to be associated with such a caring and wellrespected company.” a

Albert Sigei to take the reins at PPC Zimbabwe Pretoria Portland Cement (PPC) Zimbabwe Limited has announced the appointment of Albert Sigei as the company’s MD, effective January 1, 2024. Sigei will take over from Kelibone Masiyane, who will step down from his position at the end of December after serving as MD for seven years. In 1994, Masiyane began working for the organisation as a trainee electrical engineer at the Colleen Bawn Plant. In 2016, he was named the MD of PPC Zimbabwe Limited. In 2009, he was promoted to general manager of the Bulawayo Factory and Colleen Bawn Plant before being appointed PPC Zimbabwe MD. “After 29 years of service at PPC Zimbabwe Limited, seven years of which were spent at the helm of the company, Masiyane informed the board of the company of his intention to step down as MD of the company,” PPC said in a statement. a

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Keeping up with aggregates demand for N3 project To meet high aggregates demand for the ongoing N3 national road upgrade, AfriSam has successfully transformed its small KwaZulu Natal-based Umlaas Road Quarry into a ‘big operation’ using existing resources. Despite having a lean team on site, the operation has successfully doubled its volumes. Part of government’s 62 Strategic Integrated Projects gazetted as part of the Infrastructure Investment Plan approved by Cabinet in 2020, the N3 national road upgrade – which focuses on an 80 km section from Durban to Pietermaritzburg – continues apace. Located right at the doorstep of the very first package of the project – the 6 km stretch between the Dardanellas Interchange and the Lynnfield Park Interchange – Umlaas Road Quarry is playing a key role in keeping this vital national project ticking. The magnitude of the project has placed severe pressure on local construction material suppliers in the area. To provide context, the project required 300 000 tonnes of fill material per month for the past two years. However, the past few months have seen the demand scale tilting in favour of the ‘blue’ material, confirms Theolan Govender, regional manager overseeing the AfriSam Umlaas Quarry. From the onset, the team at AfriSam’s Umlaas Quarry has always focused its efforts on the ‘blue’ material, with AfriSam’s Pietermaritzburg Quarry, located some 30 km away, providing the necessary backup with the supply of sub-base material, including G2, G4 and G6. “Due to the sheer scale of the project, we had to more than double our pre-Covid volumes in 2021, maintaining the same feat in 2022,” says Govender. “A key talking point is our ability to push these massive volumes using the existing resources, thus transforming this small quarry into a big operation using a very lean team.” a

AfriSam’s Umlaas Road Quarry has doubled its volumes using existing resources.

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LEAD STORY

The HD100 will be offered in two different versions – General Purpose and Multi-Purpose.

PARTNERSHIP FOR SUCCESS With the addition of BULL backhoe loaders and skid steers to its stable, Babcock has plugged a crucial gap in its product line-up. The range provides Babcock customers in the mining and quarrying value chain with a proven utility tool for housekeeping and

other small-scale support functions on site. By Munesu Shoko. o offer a comprehensive ‘yellow metal’ equipment solution to its customers, Babcock has partnered with BULL to supply BULL backhoe and skid steer loaders in southern Africa. Announced in July this year, the partnership gives Babcock exclusive distributorship rights of the range in South Africa, Zimbabwe, Namibia and Botswana. David Vaughan, MD of Babcock’s Equipment business, is thrilled to be adding the BULL backhoe loaders and skid steers to the company’s stable. Having previously supplied and supported several backhoe and skid steer brands in the local market, Vaughan is aware of the importance of this market segment in southern Africa. Despite the competitive nature of

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1 600-1 700

Available industry figures show that the local backhoe loader market ranges between 1 600 and 1 700 units per annum

Top 3

Within a span of a decade, BULL is now among the top three backhoe loader manufacturers in India

4 800

BULL currently has the capacity to manufacture 4 800 backhoe loaders per annum, catering for more than 62 countries in the world

15%

Powered by a naturally aspirated Kiloskar engine delivering 56,7 kW of power at 2 200 rpm, the HD76 is said to offer 15% more bucket breakout force than some of the closest competitors in its class size

KEY TAKEAWAYS Babcock has partnered with BULL to supply BULL backhoe and skid steer loaders in southern Africa Announced in July this year, the partnership gives Babcock exclusive distributorship rights of the range in South Africa, Zimbabwe, Namibia and Botswana The addition of BULL machines not only gives Babcock a proven tool to compete in this important segment of the market, but, more importantly, complements its existing offering to become a true one-stop shop for its customers’ equipment needs Babcock will initially offer a single BULL skid steer model, the AV490.

Babcock will bring in three backhoe loader models in five different variants, as well as one skid steer model in two configurations

the market, with more than 24 brands competing for market share, backhoe and skid steer loaders remain the ‘picks and shovels’ of the yellow metal equipment market in the region. To provide context, available industry figures show that the backhoe loader market ranges between 1 600 and 1 700 units per annum, with skid steer loaders in the region of 300-350 units per year, based on CONMESA figures for the past 12 months. “The addition of BULL machines not only gives us a proven tool to compete in this important segment of the market, but, more importantly, complements our existing, extensive offering to become a true onestop shop for our customers’ equipment needs,” says Vaughan. “We are now better equipped to offer a comprehensive solution across applications, including construction, plant hire, agriculture and waste management, among others.” While backhoes and skid steers are the ultimate

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LEAD STORY

“

the BULL brand, I have been impressed

“

with the continuous improvement of

crucial jobs on mine and quarry sites, such

the products in a very short space of

as housekeeping, small-scale trenching,

time. The company’s proactive approach

cleaning around processing plants and

to customer and dealer feedback

under space-constrained areas such as

and the commitment to research and

conveyors.

From the time of my first association with

While these are not production machines, they are an important utility tool for

development are key attributes driving the growth of the brand.

Mark Senyard Product Manager – Bull Equipment & SDLG Babcock

tools of choice for construction and plant hire markets, Vaughan says the BULL range will also find application in quarrying and mining environments. “While these are not production machines, they are an important utility tool for crucial jobs on mine and quarry sites, such as housekeeping, small-scale trenching, cleaning around processing plants and under space-constrained areas such as conveyors,” he explains.

Why BULL?

Commenting on the reasons behind choosing BULL, Vaughan says from the very first meeting with Guminder Singh Malik, President – International Business and Strategy at BULL, it was clear that the principles and ethos of the two businesses were very much aligned. Both Babcock and BULL also share the same growth appetite. As a norm, Babcock has always distributed products at the top end of their market segment, which is one of the reasons BULL fits the bill for the company. “Having first entered the backhoe market with the launch of what is said to be the world’s first 60 hp Hydrodynamic backhoe loader in November 2011, BULL is the youngest and fastest growing backhoe

David Vaughan MD – Equipment Babcock

loader manufacturer in the global market,” says Malik. “Within a span of a decade, BULL is now among the top three backhoe loader manufacturers in India. During the first four months of 2023, we clinched second position in our domestic market, ahead of some of the established global OEMs competing in this market segment,” adds Malik. Owned by the longstanding AV Group, BULL currently has the capacity to manufacture 4 800 backhoe loaders per annum, catering for more than 62 countries in the world. The company, confirms Malik, is expanding its facilities, with plans to increase capacity to 6 000 backhoe loaders per annum by mid-2024. Locally, the brand has been well received since its introduction into the South African market in 2017. Under the stewardship of Babcock, it is expected to gain more traction, leveraging Babcock’s widespread support infrastructure across the region, as well as an existing customer base in new markets such as quarrying and mining. To maintain continuity and a seamless transition of the brand from its previous dealer into the Babcock fold, both Babcock and BULL have agreed to bring Mark Senyard on board as the product manager. Senyard, who brings a wealth of experience in the construction and mining equipment market, has been

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The AV490 skid steer comes in two variants – a typical canopy version and a fully enclosed cab with air conditioner.

associated with the BULL brand since 2021. “From the time of my first association with the BULL brand, I have been impressed with the continuous improvement of the products in a very short space of time. The company’s proactive approach to customer and dealer feedback and the commitment to research and development are key attributes driving the growth of the brand. Looking ahead, I anticipate an upward trajectory for the brand in southern Africa under the stewardship of Babcock,” says Senyard.

The range

Babcock will bring in three backhoe loader models – the HD76, the HD 96 and the larger HD100 – in five different variants. The HD76 will be offered in a General Purpose (GP) configuration only. The HD96 and HD100, confirms Senyard, will be offered in two different versions – GP and Multi-Purpose (MP). The MP configuration will see the machine coming with a clamshell bucket, fold-over forks and an extended dipper. Powered by a naturally aspirated Kiloskar engine delivering 56,7 kW of power at 2 200 rpm, the HD76 is said to offer 15% more bucket breakout force and 4% more backhoe bucket capacity than some of the closest competitors in its class size. The HD96 is powered by a turbo-charged Kiloskar engine delivering 70,6 kW power at 2 200 rpm, while the larger HD100 is driven by a 74,5 kW Perkins engine. A key competitive edge of the range is represented by well-known components such as the Kiloskar

and Perkins engines, as well as the Italian-made Carraro transmission and Casappa pumps. These are complemented by the reputable Danfoss braking system and AKG radiators. In addition, the machines come with standard hammer piping and airconditioning, as well as ROPS and FOPS as standard – key requirements for the quarrying and mining industry. In addition, Babcock will initially offer a single skid steer model, the AV490, in two variants – a typical canopy version and one with a fully enclosed cab and air conditioner.

Support matters

Under Babcock, existing BULL customers will experience new levels of aftermarket support. Babcock is the exclusive regional distributor for other leading international brands and construction equipment including Volvo and SDLG construction equipment, Sennebogen cranes, and Winget concrete handling machinery. Working closely with its customers, the company has a proud history of sales and servicing of construction equipment that spans more than six decades. Over the years Babcock has built its business on the back of its aftermarket offering, including parts as well as service and maintenance contracts. “A benefit of our service contracts is that they are flexible and tailored to meet individual customer needs. We will extend the same offering to our BULL customers,” concludes Vaughan. a

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MOBILE SCREENING

Ian Brink (contracts manager), Casper Booyse (Astec South Africa product sales manager) and Lizarox director Michael Crackett.

UP TO THE TASK The first Astec GT205 mobile tracked unit supplied in South Africa, a threedeck mobile screen, has been successfully commissioned by Astec Industries for long-standing KwaZulu-Natal based customer, Lizarox, where it has proven to be up to the task.

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600 tph

Installed at a leading quarry in Ladysmith, KwaZulu-Natal, the Astec Global Track machine boasts a 600 tph capacity

5 x 20

The three-deck mobile unit is fitted with a 5” x 20” screen and a Caterpillar C4.4 129 HP Tier III diesel engine

KEY TAKEAWAYS The first Astec GT205 mobile tracked unit supplied in South Africa, a three-deck mobile screen, has been successfully commissioned for Lizarox in KwaZuluNatal The Astec GT205 has proven itself to be more than up to the task since it was delivered

Lizarox chose the Astec GT205 because the screen is robust, and its operation is straightforward Lizarox also favoured the GT205’s large screen box which enables the production of high volumes of material when producing straightforward products such as G5

7 & 10 mm The three-deck four-product conveyor setup allows Lizarox to maximise high-quality low-yield products such as 7 mm and 10 mm surfacing stone

6 years The screen is operating in line with the Osborn mobile jaw and cone crusher that were supplied to Lizarox six years ago

nstalled at a leading quarry in Ladysmith, KwaZulu-Natal, the Astec Global Track machine boasts a 600 tonnes per hour (tph) capacity. It has proven itself to be more than up to the task since it was delivered, says Lizarox director Michael Crackett, who describes the unit as “a beast”. The screen is operating in line with the Osborn mobile jaw and cone crusher that were supplied to Lizarox six years ago. The three-deck mobile unit is fitted with a 5” x 20” screen and a Caterpillar C4.4 129 HP Tier III diesel engine.

Why Astec GT205?

Crackett says that Lizarox chose the Astec GT205 because the screen is robust, and its operation is straightforward. “Certain competitor products

are unnecessarily complicated. The maintenance of some equipment is difficult as a result of the logistics challenges experienced globally since the Covid-19 crisis. With the Astec GT205, we felt that we had a degree of independence if we needed to run repairs amid any supply challenges, because we are familiar with the major components used to drive the machine,” says Lizarox. He explains that the screen complements the existing plant mix and will be used in a two-stage and multi-stage crushing and screening application for the production of base materials such as G5 and G2, as well as single-size aggregates for use in concrete and asphalt. Lizarox also favoured the GT205’s large screen box. “This enables the production of high volumes of material when producing straightforward products

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MOBILE SCREENING

The Astec GT205 mobile screening plant on site in KwaZulu-Natal.

more Astec products,” adds Crackett. Commenting on the partnership, Astec Industries regional sales manager, Casper Booyse, says: “We are delighted to add this latest successful undertaking to our long partnership with Lizarox, a solutionsoriented company with a wealth of knowledge. We look forward to continuing to partner with them, and helping them to attain Longstanding profitable production goals, relationship valued benefits and deliver a Astec Industries’ longThe screen complements the existing plant mix and will be used in a two-stage competitive advantage to their standing relationship and multi-stage crushing and screening clients through our innovative, with Lizarox is founded on application for the production of base materials such as G5 and G2 world-class equipment.” consistently reliable products Astec mobile incline screen plants and service, he says. “Astec’s have an array of features for maximum backup on our existing equipment screening efficiency and production. has always been excellent. When “These plants combine heavy-duty screens faced with challenges in the past, they with industry-leading conveyor heights for have always stepped up to the plate. This remains maximum stockpile capacity. A large range of media the case today and provides us with a sense of provides flexibility for a variety of applications. Pair comfort that we are in good hands when it comes that with the flexibility and mobility of the track unit to product reliability and backup service. We are and producers can quickly and easily produce the excited about Astec Industries’ range of products material they need,” concludes Booyse. a and hope to expand our current plant mix with such as G5. However, with the three-deck fourproduct conveyor setup, there is also an element of finesse available when coupled with the height and angle-adjustable screen box. This functionality allows us to maximise high-quality low-yield products such as 7 mm and 10 mm surfacing stone,” Crackett states.

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DRILLING

The recent high-water mark of this relationship was Brauteseth Blasting’s purchase of units from every one of Sandvik’s boom drill ranges – within a single year.

BRAUTESETH BREAKS NEW GROUND WITH SANDVIK PARTNERSHIP Partnerships, it is often said, are the secrets to success – and this truism has been more than borne out in the life of KwaZulu-Natal-based Brauteseth Blasting, whose long

collaboration with Sandvik Mining and Rock Solutions has just reached new heights. equipment acquisitions from Sandvik Mining ounded in 1983, Brauteseth Blasting and Rock Solutions, in a strong collaboration that today has an active footprint in the dates back to 2005, says Sandvik Mining and Rock civils, quarrying and opencast mining Solutions account manager Andre Blom. sectors, having seen especially exciting growth in the last few years. According to company MD Clive Brauteseth, who has headed Across the range up the business since 1989, its work was “The recent high-water mark of this relationship traditionally in KwaZulu-Natal and the was Brauteseth Blasting’s purchase of units Eastern Cape, but this has changed from every one of Sandvik’s boom drill to a national footprint as well as ranges – within a single year,” says across-border footprint. Blom. “This included the Leopard “Demand for our services has DI550 and Leopard DI650 down-theseen our operations expand hole drill rigs from our Leopard range, By implementing correct preventative maintenance exponentially in recent years and the Pantera DP1500i and the Ranger programmes in place, Brauteseth we are working on contracts in DX800 and Ranger DX900i surface Blasting has since improved its business model by reliably running the Northern Cape, Limpopo and top hammer drill rigs.” its drills for up to as much as Mpumalanga,” says Brauteseth. The application of Sandvik’s boom 12 000 hours “We have also just started work on drills spans a wide spectrum, he points a copper mining project in Zambia, out, reflecting on how the scope of which is very exciting for us.” Brauteseth Blasting’s work has broadened. With Underpinning this growth have been regular its steady expansion, the company also ramped up

12 000

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The latest orders have brought the number of Sandvik drill rigs acquired by Brauteseth Blasting to almost 50, with that landmark sure to be exceeded by the end of 2023

6 500

In the early days, the company was aggressive with its replacement policy, moving machines on at around 6 500 hours

KEY TAKEAWAYS Founded in 1983, Brauteseth Blasting today has an active footprint in the civils, quarrying and opencast mining sectors, having seen especially exciting growth in the last few years Underpinning this growth have been regular equipment acquisitions from Sandvik Mining and Rock Solutions, in a strong collaboration that dates back to 2005 The recent high-water mark of this relationship was Brauteseth Blasting’s purchase of units from every one of Sandvik’s boom drill ranges – within a single year This included the Leopard DI550 and Leopard DI650 down-the-hole drill rigs from the Leopard range, the Pantera DP1500i and the Ranger DX800 and Ranger DX900i surface top hammer drill rigs

“

Demand for our services has seen our operations expand exponentially in recent years and we are working on contracts in the Northern Cape, Limpopo and Mpumalanga. We have also just started work on a copper mining project in Zambia, which is very exciting for us.

Clive Brauteseth, MD of Brauteseth Blasting

its capital investments in 2021 and into 2022. “We first entered the opencast mine drill and blast space in 2010 on one of the biggest anthracite projects in the country situated in KwaZulu-Natal. This was followed by a drill and blast project in phosphates in the Limpopo province in 2020,” says Brauteseth. These projects led to the acquisition of Leopard DI550 and Leopard DI650 drill rigs – designed for demanding high-capacity production drilling in medium-sized to large opencast mining operations. Those orders brought the number of Sandvik drill rigs acquired by the company over the years to almost 50, with that landmark sure to be exceeded by the end of 2023, he explains. While the Ranger DX800 and Ranger DX900i surface top hammer drill rigs serve mainly the construction and small mining sectors, the Pantera DP1500i surface top-hammer drill rig is a ‘cross over’ for applications in quarries and into the smaller opencast mines. “We have found that the Ranger DX900i and the Pantera DP1500i are versatile machines that we can deploy across more than one space,” says Brauteseth. “We can therefore use them in our construction projects as well as in quarrying, and even in some mining operations.”

Recipe for success

With a background in opencast mining, Brauteseth was able to successfully leverage the company’s

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DRILLING

The Pantera DP1500i surface top-hammer drill rig is a ‘cross over’ for applications in quarries and into the smaller opencast mines.

Brauteseth Blasting’s operating model is underpinned by the experience and skills of a stable and committed staff complement.

initial focus on civil engineering work over the years. He sees an important ingredient for success in ‘sticking to its knitting’ in the field of drilling and blasting. “What we prioritise is good people who are fairly rewarded, and good equipment,” he says. “The result is that we have a team that has been with us since day one, and more than a few have between 25 to 30 years of service.” Brauteseth Blasting trains and upskills staff continuously to develop its skills base and capabilities, while spending as much time as possible with customers to identify and satisfy their precise needs. This approach also includes firm links with suppliers, Brauteseth points out. “In the beginning, we had a variety of drill rigs but have built a strong relationship with Sandvik over almost 20 years,” he says. “We have some of the best equipment in the market, and keep it well maintained and up-to-date. This means continual investment in replacing plant regularly.” This operating model gives the company the performance, reliability

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The ongoing upskilling also ensures the latest technology investments are put to the most productive use in the field.

and uptime that its projects demand, backed up by the experience and skills of a stable and committed staff complement. The ongoing upskilling also ensures the latest technology investments are put to the most productive use in the field – to deliver the bottom-line results that keep customers loyal.

Step ahead

“When there is new equipment in the market, we are always interested in what it can do for our fleet capability and our customers,” says Brauteseth. “We embrace new technology and this ensures we stay a step ahead in our market.” He believes that, from his almost two decades of running Sandvik drills, that Sandvik Mining and Rock Solutions have always had the edge in this space. The first of these units that he purchased, for instance, were the only ones available with a turntable that could slew. “This was a great innovation at the time that helped us considerably in our construction sector work, getting into tight spaces and being able to safely spread the weight of the

machine,” he explains. “The Sandvik Ranger DX900i brought even further improvements in slew angles.” Continuous improvement within model ranges is also a significant benefit, such as the evolution of the Pantera DP1500 to the intelligent Pantera DP1500i model. He appreciates the reliability levels and how the CAN Bus system allows easier troubleshooting, for example. Similarly, he highlights the innovation in the Leopard DI550 and Leopard DI650i where less fuel is used through decoupling the compressor when the machines idle. “The fuel saving resulting from this development is significant, and can be passed on to our customers,” he says. “Now we are moving into the field of intelligent machines which can drill without an operator, and a few of our machines are in principle ready to do this with the necessary upgrades. We really value Sandvik’s continuous innovation, and the way they listen to customers when pursuing those developments.”

Safety

He also highlights the dust control features on Sandvik drill rigs, as

this is critical for health and safety compliance on mining sites. Whether this is through water injection or dust plants, he argues that Sandvik’s dust control is among the best he has encountered. For night work, the machines’ own lighting equipment allows safe work without the need for a separate lighting plant. “Our operators appreciate the quiet cabs on the drills, which make the working conditions more comfortable and supports their productivity,” adds Brauteseth. There are currently almost 30 boom drills operating in the Brauteseth Blasting fleet, weighted towards the Leopard DI550 and Leopard DI650i range. “In the early days, we were very aggressive in our replacement policy, moving machines on at around 6 500 hours,” he says. “We have since improved our business model by reliably running these for up to as much as 12 000 hours, with the correct preventative maintenance programmes in place.” In the case where component replacement is necessary, the company has well equipped workshops to conduct this work in-house. Brauteseth emphasises that a strong maintenance and support team – many of them trained by Sandvik Mining and Rock Solutions – is vital for any business in this field. Understanding the need to ensure continuity here, the company has been training its own apprentices for the past decade. Drifter servicing is also done in-house. If warranty conditions call for Sandvik technicians, attendance for this is then arranged. “This is one of the aspects that makes the Brauteseth-Sandvik partnership so unique,” says Blom. “Even with Brauteseth being so selfsufficient – both operationally and technically – we can support the company as the OEM in whichever way is required.” As Brauteseth Blasting continues its growth path, Brauteseth expects even more drill rig acquisitions in 2023 – signalling a bright future for the business and its close collaboration with Sandvik Mining and Rock Solutions. a

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MOBILE SCREENS

The Anaconda SR520 is now available in southern Africa through Vermeer Equipment Suppliers.

INTO NEW SCREENING TERRITORY

Vermeer Equipment Suppliers is introducing the Anaconda SR520 screen to the southern African market. Ideal for fine screening, the machine marks the company’s first foray into the finishing screening market. By Munesu Shoko. aving signed the exclusive distributorship deal for the full Anaconda Equipment range of crushing, screening, feeding, washing and conveying equipment in southern Africa in 2021, Vermeer Equipment Suppliers has initially brought two scalping screening models (DF514 and DF518) and a jaw crusher (J12). The latest product to join the growing Anaconda offering in the local market is the Anaconda SR520 finishing

incline screen. “We are delighted to add the SR520 screen to our growing Anaconda range locally,” says Shaun O’Toole, sales manager – Mining, Crushing & Screening at Vermeer Equipment Suppliers. “The SR520 not only gives us the much-needed footprint into the finishing screen market, but also allows us to offer a full range of crushing and screening solutions to our local customers.”

Machine in detail

The Anaconda SR520 is a high-production screen that can stockpile up to four different

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450 tph

The Anaconda SR520 is a high-production screen that can stockpile up to four different products at an output of up to 450 tph, depending on screen size and product moisture content

33 000 kg

Vermeer Equipment Suppliers is bringing in the two-deck version, which weighs in at 33 000 kg

KEY TAKEAWAYS Vermeer Equipment Suppliers is launching the Anaconda SR520 finishing incline screen in southern Africa

The Anaconda SR520 is a high-production screen that can stockpile up to four different products

The screen is said to be extremely easy to commission and can be up and running within 20 minutes of arrival on site

Vermeer Equipment Suppliers stocks a full range of spare parts as a statement of its commitment to provide a dedicated and responsive service to its customers in the region

Vermeer Equipment Suppliers has launched the twodeck version of the machine.

products at an output of up to 450 tonnes per hour (tph) depending on screen size and product moisture content. Complete with a 6 m x 1,52 m screen box, the machine has an option of either two or three decks. However, confirms O’Toole, Vermeer Equipment

Suppliers has brought the first unit in a two-deck configuration, which weighs in at 33 000 kg. With a maximum hopper capacity of 6 m³, the machine comes with a main conveyor and either three or four hydraulically folding stockpiling conveyors. The screen is said to be extremely easy to commission and

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MOBILE SCREENS

The arrival of the SR520 marks Vermeer Equipment Suppliers’ first foray into the finishing screen market.

solution that ticks all the right boxes for the can be up and running within 20 minutes of arrival crushing and screening fraternity – from on site. Commissioning is aided by the hydraulic versatility to productivity and efficiency. controls to position and guide all the conveyors, In addition, the Anaconda product benefits screen box and landing legs into place. from Vermeer Equipment Suppliers’ proven Since its global launch, the SR520 is said to have aftermarket support regime in southern established itself as a leading player in the global Africa. The company stocks a market. This recognition particularly stems full range of spare parts as a from the machine’s ability to suit fine statement of its commitment screening operations such as sand and to provide a dedicated and other fine material. This screener can responsive service to its also be fitted with a rinsing screen customers in the region. This, to allow users to introduce primary says O’Toole, is particularly washing to their operation. The Anaconda SR520 is easy to commission and can be up and important for the contracting “One of the key talking points is running within 20 minutes of fraternity where machine that the SR520 takes into account all arrival on site downtime is out of the aspects of screening with a tipping question. grid to scalp away the bulky overs, the “Our reputation in the market screen box for separation of up to four when it comes to the provision different sizes of end product and also builtof parts and services speaks for itself. in conveyors that allow for constant stockpiling of Vermeer Equipment Suppliers has established product as the screen is fed,” says O’Toole. a track record of dependability over the past 22 years, which has been key to building Support matters long-lasting relationships with our customers,” The SR520 comes in at a competitive price concludes O’Toole. a point, confirms O’Toole, yet it is a premium

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BLASTING TECHNOLOGY

The new version of Xplolog continues to raise the bar in leveraging digital technology.

MAKING SENSE OF BLAST DATA Mining solutions specialist BME has released a new version of its popular Xplolog system for capturing and analysing data on blast holes and decks.

ME – part of Omnia’s mining segment – developed Xplolog as a powerful tool for mines to monitor their block progress in real time, providing the necessary data to track trends and continuously improve the quality of blasts. The focus in developing this nextgeneration Xplolog has been the detailed guidance by users, according to Christiaan Liebenberg, BME product manager Software Solutions. This has proved to make the system more user friendly, scalable and streamlined with other BME digital solutions – while also benefitting from improved data security.

“We engaged our Xplolog users in a highly systematic way to inform us at every step of our upgrade process,” explains Liebenberg. “After our first structured interviews with users, for instance, we developed mock-ups and wireframes that we could take back to the user group for further testing. This approach was even taken into the design and prototype stages, ensuring that the system was in many ways actually built by the users.”

Key upgrades

With the design and application code built from the ground up, and with a new and upgraded database using Google’s Cloud Services, the performance of

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Hours

The capacity of the system can also be rapidly increased, allowing better scalability; customers can have a site set up within a matter of hours

KEY TAKEAWAYS

3rd party

Xplolog is well integrated with other BME offerings such as its blast planning software, Blastmap, and is also in line with third-party blast software

“

Users will appreciate how everything is

BME developed Xplolog as a powerful tool for mines to monitor their block progress in real time, providing the necessary data to track trends and continuously improve the quality of blasts With the design and application code built from the ground up, and with a new and upgraded database using Google’s Cloud Services, the performance of the Xplolog has been enhanced Security has been improved through a more robust log-in and registration process Customised reports can be created and saved, allowing users to return to that recurring daily, weekly or monthly report each week or month as required

Xplolog has been enhanced. The capacity of the system can also be rapidly increased, allowing better scalability; customers can have a site set up within a matter of hours. “Security has been improved through a more robust log-in and registration process,” he says. There are different user access levels in the new version, giving customers more control over who

centralised in this version of Xplolog, and how we have improved the workflow for third party blast design uploads in the system.

Christiaan Liebenberg, BME product manager Software Solutions.

can access information related to their role in the organisation. “Users will appreciate how everything is centralised in this version of Xplolog, and how we have improved the workflow for third party blast design uploads in the system,” he notes. The look and feel of Xplolog has been revised in line with the progressive standardising of design across BME’s Blast Alliance digital solutions. This makes users feel familiar with the BME offering, through increased brand identification and continuity of the customer experience with Blast Alliance, says Liebenberg. “Another important aspect of our upgrade is

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BLASTING TECHNOLOGY

Xplolog provides the necessary data to track trends and continuously improve the quality of blasts.

that users can easily customise their dashboards, creating a personalised view of block information important to the user,” he says. Customised reports can be created and saved, allowing users to return to that recurring daily, weekly or monthly report each week or month as required. A summary view of block data is visible to track progress at a quick glance for the user. “We have also given users the ability to better visually track block progress, with the creative use of colours and iconography,” says Liebenberg. The process of inputting data has been optimised by rationalising the number of steps or actions wherever possible. Importantly, he points out that Xplolog’s integration with BME’s mobile manufacturing units (MMUs) has taken account of different regional preferences and conditions around the globe. “The system also provides mines with a digital audit trail, so that they can track operator performance during the drilling and charging phases, as well as provide hole loading information per truck,” he says.

Integration

Xplolog is well integrated with other BME offerings such as its blast planning software, Blastmap, and is also in line with third-party blast software. Integrated with BME’s MMUs, Xplolog allows the MMU operator to charge and top-up holes accurately from the source application, which will have the latest blast design updates loaded. The actual charged and top-up values from the MMU’s digital panel will automatically be sent back to Xplolog, which will make the data available on the cloud platform for review and analysis. “Our new version of Xplolog continues to raise the bar in leveraging digital technology,” he says. “Our Software Engineering team continues to add new features and implement continuous improvements as we receive feedback from users of the system in the field – to help mines operate more efficiently, cost-effectively and safely. These updates are released to all existing customers of Xplolog every quarter at no additional cost.” a

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TIPPER TRUCKS

The Quester has enjoyed remarkable success in the local construction and quarrying markets.

A DECADE OF ‘ULTIMATE DEPENDABILITY’ UD Trucks’ Quester range celebrates 10 years of its international launch this year. Having made its local debut in 2015, the model has enjoyed remarkable success across applications, principally in the construction and quarrying markets. Rory Schulz, sales director at UD Trucks Southern Africa, details the evolution of the truck and local successes during the past decade. By Munesu Shoko.

fter its international introduction in 2013, the UD Quester was launched in Southern Africa in March 2015. At the time, UD Trucks Southern Africa stated that the extra heavy truck range was specifically aimed at growing the Japanese manufacturer’s market share in developing markets – a feat well achieved to date.

In fact, the company noted that the Quester range was the first in a new generation of UD Trucks specifically developed for growth markets across the world, including the “unique African market”. To date, the Quester range is available in about 20 variants in Southern Africa, including truck tractors, rigids, freight carriers, compactors and specific construction focused derivatives such

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2015

After its international introduction in 2013, the UD Quester was launched in Southern Africa in March 2015

To date, the Quester range is available in about 20 variants in Southern Africa, including truck tractors, rigids, freight carriers, compactors and specific construction focused derivatives such as tippers and mixers

KEY TAKEAWAYS After its international introduction in 2013, the UD Quester was launched in Southern Africa in March 2015 Since its launch, the Quester model has done well across several market segments, principally in construction and quarrying With the Euro 5 offering on the Quester, UD Trucks has improved the truck’s fuel efficiency through the higher power and torque without increasing the size of the engine The truck has also amassed significant market share in the construction segment.

To help customers further optimise their TCO, UD Trucks Southern Africa has established a Used Trucks division, which helps fleet owners get a good residual value for their assets at the end of their preferred operating cycles

as tippers and mixers. The arrival of the range also allowed UD Trucks Southern Africa to offer 8x4 model options for the first time.

Performance

Since its launch, the Quester model has done well across the two product groups that it caters for. The first, says Schulz, is the regional and longhaul segment, which basically entails the highhorsepower truck tractors and freight carriers. “Initially, we had a slow start in terms of our performance in the regional and long-haul segment with the Quester,” says Schulz. “This was mainly because we only had a manual transmission for the segment. We subsequently introduced the automated transmission (AMT) option, which allowed us to compete strongly in the truck tractor market. That correction in our product offering ushered in a new era in the success of the Quester in this market segment.” The second segment, which Schulz divides into two sub-segments, includes public utilities and construction/quarrying. In the public utilities space, he says, the Quester is one of the strongest performers in the compactor market, supporting public utilities such as municipalities and government operations. From the onset, UD Trucks Southern Africa offered a fully automatic Alisson transmission, which is ideal for the stop/start nature of the compactor application. The truck has also amassed significant market share in the construction segment. “Once again, we

“

The launch of the Euro 5 marked one of the significant milestones in the evolution of the Quester. While it has not been a dominant volume driver for us yet, predominantly due to the lack of legislation, we see great interest in the product as local customers, particularly blue-chip companies, seek to drive their sustainability agendas.

Rory Schulz, sales director at UD Trucks Southern Africa

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TIPPER TRUCKS

Over the past decade, the Quester has benefitted from several major upgrades.

to the local market. The truck has been upgraded with all the necessary heavy-duty componentry, allowing it to operate at close to 60-tonne (t) payload in off-road conditions, a significant increase to the standard 45-t payload.

Key upgrades

were among the first to introduce a fully automatic transmission in that application,” he says. “An extra edge is the fact that, from the outset, we were able to introduce 8x4 model options into this market segment, which are utilised as tippers, concrete mixers and concrete pumps.” The range has done exceptionally well at the light end of the construction market – in the typical 6x4, 330 hp, 10 m³ tipper market.

Into new terrain

One of the growing trends in the quarrying/mining value chain is the move towards construction type tippers, better known as mining tippers, for arduous in-pit applications, allowing cost-conscious operators to switch from traditional yellow metal haulers where possible. Traditionally, tipper trucks have been excluded from so-called arduous applications such as hauling run-of-mine material from the quarry face to the processing plants, where yellow metal haulers, mostly articulated dump trucks (ADTs) and rigid dump trucks (RDTs), have always been preferred. However, passing through immense innovative technological modifications, tipper trucks are now offering cost-effective haulage solutions to mining and quarrying markets. The new models of tipper trucks have been reengineered completely to their core. They come with better ground clearance, allowing them to operate well on uneven work sites. In line with this trend, UD Trucks Southern Africa recently completed a testing programme for its Quester-based mining tipper. “In recent years we have had a couple of requests for an alternative to yellow metal haulers. We have therefore successfully developed and tested a mining tipper in a limestone operation in the Lichtenburg area,” he says. Based on the successful results from the testing programme, the mining tipper – an upgraded Quester 8x4, 440 hp C-Model – is now commercially available

Over the past decade, the Quester has benefitted from what Schulz refers to as two major upgrades. The first phase, he says, was the introduction of the AMT transmission for the regional and long-haul applications. The introduction of the ESCOT transmission on the Quester took away the drivers’ need to shift an average of 1 000-1 500 times a day by automatically selecting the right gear at any given time. This leads to less stress and improved safety by allowing the driver to focus more on the road. Combined with lighter tare weight and optimised driveline, the ESCOT transmission offered up to 10% improvement in fuel economy compared with the manual Quester model. The second phase, he adds, was the introduction of the Euro 5 option in 2019. “The launch of the Euro 5 marked one of the significant milestones in the evolution of the Quester. While it has not been a dominant volume driver for us yet, predominantly due to the lack of legislation, we see great interest in the product as local customers, particularly blue-chip companies, seek to drive their sustainability agendas,” says Schulz. The Euro 5 launch bolstered UD Trucks’ Better Life purpose – to be better for the planet, people and growth. Better Life drives the integration of sustainability across all of the company’s operations and processes to realise lower environmental impact, higher customer satisfaction, higher profitability, and a better place for people to work and live. As one of the first truck manufacturers to introduce Selective Catalytic Reduction (SCR) technology in 2004, UD Trucks’ new Euro 5 range features SCR technology to significantly boost environmental protection and fuel economy. With these benefits, SCR technology is proven to be more reliable when compared to other emission control technologies for reducing NOx emissions.

Focus on TCO

The construction/quarrying market is generally regarded as a cost-conscious market, and operators in these segments often base their vehicle selection on parameters such as fuel economy and total cost of ownership (TCO) at large. The TCO drive, says Schulz, has been one of the catalysts to UD Trucks’ strategy change from only selling trucks to providing total transport solutions. Reducing fuel consumption, which constitutes the

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ensuring the customer more uptime. In addition, UD Trucks Southern The Quester range is available in about 20 variants in Southern Africa, Africa now offers UD Trucks Connected including concrete mixers. Services as standard across all models, including the Quester. The system allows fleet owners to maximise efficiency with real-time vehicle tracking and geofencing. The service is free for one year from date of purchase, whereby fleet owners have the option to renew the contract. “Connected Services plays an increasingly important role in the everchanging transport environment,” states Schulz. “It empowers fleet owners to streamline their operations, getting the most out of their investment while delivering added value, including enhanced turnaround times, to their customers.” UD Trucks’ Connected Services system basically monitors the heartbeat of the truck as it provides real-time positioning, information on preventative maintenance largest operating expense, representing about 60% and manages the breakdown assistance. This also of total operating costs of a vehicle, remains a top provides fleet owners and UD Trucks dealers with priority in the quest for reduced TCO. With the Euro 5 all the information they need to do the required offering on the Quester, for example, UD Trucks has preventative maintenance on time, and to schedule improved the truck’s fuel efficiency through the higher standard services more efficiently. power and torque without increasing the size of the To help customers further optimise their TCO, engine – this is made possible by the optimised UD Trucks Southern Africa has established combustion. a Used Trucks division, which helps fleet Apart from a Euro 5 system with SCR owners get a good residual value technology, the upgraded Quester also for their assets at the end of their features a new instrument cluster preferred operating cycles. with real-time fuel coaching. This enhancement provides drivers with immediate and specific feedback Trends The introduction of the Euro 5 on driving techniques that are more Commenting on new trends in option in 2019 marked one of fuel-efficient. the market, Schulz points out the significant milestones in the evolution of the Quester “Quester’s built-in fuel coaching the accelerated pace at which system constantly monitors the automation, connectivity and performance of the drivers in real time. electromobility (ACE) are gaining This system keeps drivers informed of the momentum. True to UD Trucks’ vision to truck’s fuel consumption and whether they are ‘provide the trucks the world needs today’, the driving at the optimum speed and gear which ensure Japanese truck maker’s innovation roadmap takes a the best economy. Fuel Coach is also able to advise step-by-step approach together with customers to the driver which corrective action to take to get back offer commercialised solutions for select automation into the so-called ‘sweet spot’ of performance,” he and electromobility applications from 2020, with a says. view toward full-fledged commercialisation by 2030. The second important parameter in lowering TCO, “From an automation point of view, the fixed he says, is maintenance. The lower maintenance operating environments such as construction, requirements on Euro 5 engines, for example, quarrying and agriculture lend themselves to full reduce operational costs. In addition, UD Trucks automation because of the repetitive nature of the Southern Africa now offers service agreements work and ease of control than in a typical road setup. (maintenance contracts), affording customers best In Japan, UD Trucks is already running an autonomous practice maintenance of assets in order to ensure prototype truck, alternating between a mining/ optimal performance throughout their lifecycle. quarrying type of application and an agricultural Service agreements also ensure reduced capital environment. Should we bring a prototype locally, we outlay of critical components and consumables will also target construction and mining/quarrying as well as reduced repair and breakdown costs environments for testing,” concludes Schulz. a

2019

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CONVEYORS

The Walk the Belt Programme from Martin Engineering provides regularly scheduled reviews of belts, cleaners, tracking, chutes, dust control and other components from experienced specialists.

PUTTING A PREMIUM ON CONVEYOR MAINTENANCE Routine maintenance of a conveyor system is often overlooked, yet it is a sure-fire way of extending component life. Fran van der Berg, GM at Martin Engineering Africa, tells Quarrying Africa that regular maintenance is not only critical to productivity and safety, but also vital to cost control and overall profitability, amongst other operational parameters. By Munesu Shoko.

hatever type of material is being processed, a production plant’s conveyor belt network forms part of the critical artery that moves material through the system from run-of-quarry to saleable end product. According to Van der Berg, it is no overstatement to say that regular conveyor maintenance is absolutely crucial to productivity and profitability. A proactive approach to conveyor maintenance, she adds, also

plays a vital role in safety, the longevity of the plant and its components, cost control and energy efficiency. “Keeping belts running efficiently demands that they are well maintained to ensure they remain free from carry-back, spillage and build-up, which would otherwise cause excess wear and unscheduled downtime. Regular inspection and maintenance are proven to ensure that everything is running as it should, and that components such as belt cleaners are performing at their

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Martin Engineering’s N2 Remote Monitoring System allows for predictive maintenance by ensuring belt scrapers are monitored on a real-time basis and visible to customers on their mobile devices or desktop computers

50%

Despite the clear downsides of reactive maintenance, it is estimated that over half of all conveyor maintenance programmes still follow this approach

Regular inspection and maintenance are proven to ensure that everything is running as it should, and that components are performing at their optimum.

KEY TAKEAWAYS A production plant’s conveyor belt network forms part of the critical artery that moves material through the system from run-of-quarry to saleable end product

It is no overstatement to say that regular conveyor maintenance is absolutely crucial to productivity and profitability

“

Keeping belts running efficiently demands that they are well maintained to ensure they remain free from carry-back, spillage

A proactive approach to conveyor maintenance also plays a vital role in safety, the longevity of the plant and its components, cost control and energy efficiency

and build-up, which would otherwise cause excess wear and unscheduled downtime. Regular inspection and maintenance are proven to ensure that everything is running

Martin Engineering has long been a pioneer of technologies that help producers assist with conveyor maintenance, reducing the need for manual intervention, minimising the interaction of people and machinery while maximising plant uptime

as it should, and that components such as belt cleaners are performing at their optimum. Fran van der Berg, GM at Martin Engineering Africa

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CONVEYORS

Every production plant needs a comprehensive maintenance plan, not just to address the basics but with goals to minimise unscheduled downtime, improve health and safety and reduce costs.

optimum,” she says. regular basis include material carryback and Van der Berg points out that the benefits of spillage, structure damage due to belt mistracking regular conveyor maintenance extend far beyond or causing mistracking, belts and pulleys engulfed plant productivity, especially as far as the health in spillage, seized rollers, missing belt scrapers and safety of workers is concerned. Conveyors are and other components, belt sag or damage to the one of the places where the most accidents occur, conveyor in the loading zones due to inefficient and, having conveyor components such as belt support, airborne dust, flow obstructions in chutes scrapers well maintained, does lower health and and hoppers, as well as component wear, damage safety risks. or failure. In Van der Berg’s experience, “These are sometimes caused by poorly however, the benefits of well designed systems and mismatched maintained belts and belt components, but usually result scrapers are rarely understood from a lack of regular inspection or prioritised by busy plant and maintenance that can help maintenance teams, unless to keep on top of these kinds they have a specially trained of issues,” she says. “In terms resident expert in conveyors. of the frequency and interval CleanScrape provides unparalleled “That is where a scheme of maintenance, that really cleaning at the lowest operating cost, such as Martin Engineering’s depends on the capacity, design with the greatest ROI over the life of the cleaner, while significantly reducing the Walk the Belt programme and condition of the plant, the frequency of maintenance comes in,” she says. “During components being maintained, inspections, our highly trained and the types of materials being technicians will see things that processed, amongst other things.” are often overlooked by in-house The downside, she adds, is that many teams. Our team gets to the root causes companies still rely on reactive maintenance and provides a detailed report with solutions and on their conveyors – they simply fix when it recommendations on the entire conveyor system.” breaks. This approach means that components Apart from improving productivity, Martin’s are left to run until they fail, and the resulting unique Foundations learning programme is a great downtime is unscheduled, disruptive and almost way to develop workers so they can understand the always expensive. Among the contributors to the benefits of regular maintenance and identify the costs of this approach are unplanned stoppages, most common problems. ancillary damage (when a broken component damages something else), personnel overtime and emergency service fees. Common problems “Worse still, technicians tend to take more risks Commenting on some of the common conveyor and make more mistakes when under pressure maintenance issues to look out for, Van der Berg to restore operations in the shortest possible says some of the challenges encountered on a

ROI

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CONVEYORS

Poorly maintained transfer points can create numerous problems that can be costly to rectify.

times. Despite the clear downsides of reactive maintenance, we estimate that over half of all conveyor maintenance programmes still follow this approach,” states Van der Berg.

Basics of conveyor maintenance

Fundamentally, says Van der Berg, every production plant needs a comprehensive maintenance plan, not just to address the basics but with goals to minimise unscheduled downtime, improve health and safety, increase efficiency and reduce costs to achieve a better overall return on investment (ROI). “This naturally leads to regular inspection and servicing schedule as an integral part of a preventive maintenance regime. The idea of preventive maintenance – performing regular maintenance to reduce the chances of failure – is nothing new but it is still not commonplace despite the obvious advantages,” she says. Bulk handling equipment endures continual punishment while transporting millions of tonnes of raw materials, and preventive maintenance prolongs component life, increases productivity, improves efficiency and reduces maintenance costs. Some firms, she says, take this responsibility in-house, but others find that specialist service providers deliver a better return on their maintenance investment, bringing in external experts for specific inspection or maintenance tasks so employees can focus on core activities. “A preventive maintenance approach to conveyor maintenance assumes that each component has a typical functional life span. Using observation and experience, preventive maintenance determines when relevant parts should be retired, replaced or refurbished, before the expected failure point. The result is generally greater safety, higher system

efficiency, reduced spillage and better overall system control,” says Van der Berg.

Maintenance solutions

Martin Engineering has long been a pioneer of technologies that help producers with conveyor maintenance, reducing the need for manual intervention, minimising the interaction of people and machinery while maximising plant uptime. The most notable examples include the company’s N2 Remote Monitoring System, which allows for predictive maintenance by ensuring belt scrapers are monitored on a real-time basis and visible to customers on their mobile devices or desktop computers. Before N2, the only way for maintenance teams to identify what service was needed on belt scrapers was to physically go to each head pulley, taking all the necessary steps to address the hazards involved in the inspection. However, with N2, technicians only need to visit conveyors when their system shows that a belt scraper needs attention. It is the ideal solution, especially for large-scale plants which have numerous difficult-to-access belt conveyors distributed over a large area. “In addition, our revolutionary CleanScrape belt scraper provides unmatched cleaning performance and is guaranteed to last longer than any conventional cleaners. Featuring a series of hardwearing tungsten carbide tips tensioned at an angle across the discharge pulley, CleanScrape provides unparalleled cleaning at the lowest operating cost, with the greatest ROI over the life of the cleaner, while significantly reducing the frequency of maintenance. We have proven success, especially on critical conveyors with the CleanScrape belt scraper,” concludes Van der Berg. a

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CONVEYORS

The contact-free AirScrape conveyor belt skirting system is a highly effective side seal that is installed just above the belt surface and the stainless steel blades create a venturi effect which sucks fugitive dust material back onto the material flow on the belt.

ELIMINATING DUST IN CONVEYOR SYSTEMS In a one-one-one with Quarrying Africa, Ken Mouritzen, MD of BLT WORLD, the distributor for ScrapeTec in Africa and the Indian Ocean Islands, stresses the importance of investing in a low-maintenance, long-lasting system to reduce

excessive dust and material spillage at tail and transfer chutes. By Munesu Shoko. he importance of eliminating dust at special sections of conveyor belt systems and at transfer points cannot be reiterated enough. All measures taken for this purpose serve to protect workers and surrounding communities, to keep the production environment clean and often to provide explosion protection. “Without an efficient dust control system, there is a greater risk of explosions, while spillage on the floor is wasteful

and dangerous. A dust control system also improves visibility and enhances a safe working environment. In addition, it eliminates the need for a costly extraction system and because there is no spillage, there is no need for extensive cleaning operations,” he says.

Common issues

According to Mouritzen, mine and quarry managers are therefore constantly seeking solutions to deal with dust and spillage

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Studies have shown that even five years after installation and with continuous use in harsh conditions, the AirScrape system hardly shows any signs of wear

At a recent installation, BLT WORLD solved many production problems for a customer who was losing almost 5% of material on conveyor belts, as a result of dust and material spill

KEY TAKEAWAYS The importance of eliminating dust at special sections of conveyor belt systems and at transfer points cannot be reiterated enough Without an efficient dust control system, there is a greater risk of explosions, while spillage on the floor is wasteful and dangerous Apart from the cost-saving benefit, DustScrape and AirScrape dust control systems are said to be highly effective in minimising exposure of workers to environmental pollution, which is a major problem in dry bulk handling, caused by fugitive dust Correct installation of suitable dust control equipment ensures cost efficiency, optimum performance and safety, reduced risk of breakdown and extended service life of the conveyor system

problems at the transfer points of conveyor systems. The risk of explosions caused by dust emissions on conveyor belts is an ongoing issue. Although conventional dust prevention side-seals do reduce conveyor problems in the short term, these components quickly deteriorate as a result of friction and can also damage the belt of the conveyor system during extended periods of use. “Conventional skirting is pressed against a conveyor belt to keep dust and material in the middle of the belt, but after a certain period, wear of the skirting and belt can be so severe that material and dust escapes,” says Mouritzen. “Material spillage at transfer points needs to be removed and regular maintenance of belt skirting and transfer points is essential.” For optimum performance of a conveyor system, he adds, it is critical that the belt always runs straight on the conveyor, without sideways movement. Scrapetec’s new PrimeTracker belt tracker has been designed to automatically guide a conveyor belt back into the correct straight-line position to prevent costly downtime and component replacement.

The solution

ScrapeTec and BLT WORLD experts have developed a new dust control system that is proving to be highly effective – not only for preventing dust formation and material spill, but also for minimising the risk of explosion at critical sections along the conveyor route and transfer points, and for more efficient beltcleaning. Apart from the cost-saving benefit, DustScrape and AirScrape dust control systems are said to be

“

Without an efficient dust control system, there is a greater risk of explosions, while spillage on the floor is wasteful and dangerous. A dust control system also improves visibility and enhances a safe working environment. It also eliminates the need for a costly extraction system and because there is no spillage, there is no need for extensive cleaning operations.

Ken Mouritzen, MD of BLT WORLD

highly effective in minimising exposure of workers to environmental pollution, which is a major problem in dry bulk handling, caused by fugitive dust. The success of the combination of the DustScrape and contact-free AirScrape conveyor belt skirting systems is an effective energy-free dust control system. This compact and easy-to-install skirting adheres with most new dust-prevention guides to prevent health and safety issues on site. Studies have shown that even five years after installation and with continuous use in harsh

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CONVEYORS

The success of the combination of the DustScrape and contactfree AirScrape conveyor belt skirting systems is an effective energy-free dust control system.

arms to hold the system above the belt and a rubber curtain to eliminate further dust development – all sized to specific requirements. This system is easy to install and can be retrofitted to existing conveyors for continuous operation and for extended periods. The contact-free AirScrape conveyor belt skirting system is a highly effective side seal that is installed just above the belt surface and the stainless steel blades create a venturi effect which sucks fugitive dust and material back onto the material flow on the belt. Because the system hovers freely above the conveyor belt, skirt friction and belt damage are eliminated and service life of every component of the conveyor is Solutions in detail extended. DustScrape consists of a durable The durable system consists of filtering cloth that is installed above non-flammable and anti-static the conveyor belt to retain dust polyurethane materials and particles created by conveyed The SpeedScrape secondary belt cleaner design is based blades made from stainless steel. materials, while remaining on the inclined and staggered FDA-approved materials are also permeable to circulating air. positioning of Tungsten blades, available for specific conveyor The long-lasting filter cloth, which increases the scraping surface to as much as 150% of the handling applications. with cleaning and dust-releasing conveyor belt width The recently launched properties, is available in different SureSupport system works in qualities, including anti-static features, conjunction with DustScrape and for specific applications – for example, in AirScrape to deliver support and stability to sugar processing or underground mining. The the belt at transfer points. Other advantages of this dust retaining filter cloth, which is manufactured in system include quick and simple installation, as well rolls, can be extended to any required length and is as reduced maintenance time and costs. suitable for any conveyor belt width. The TailScrape system enhances performance of The DustScrape dust emission prevention system the AirScrape, by sealing the transfer tail in the rear comprises a filter cloth, support arches and skirts, conditions, the AirScrape system shows hardly any signs of wear. “This advanced system minimises product loss by effectively preventing material from escaping into the surrounding environment. As a result, users benefit from substantial energy savings, housekeeping and maintenance costs, without the need for collection of material spills,” says Mouritzen. “At a recent installation, BLT WORLD solved many production problems for a customer who was losing almost 5% of material on conveyor belts, as a result of dust and material spill.”

150%

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CONVEYORS

Scrapetec’s new PrimeTracker belt tracker has been designed to automatically guide a conveyor belt back into the correct straight-line position to prevent costly downtime and component replacement.

area and also works according to the Venturi concept, to prevent dust generation and material spills. The intelligent blade structure on the underside of the system creates negative pressure in the conveying area, preventing the escape of materials. Dust is kept in the material flow by air intake. The SpeedScrape secondary belt cleaner design is based on the inclined and staggered positioning of Tungsten blades, which increases the scraping surface to as much as 150% of the conveyor belt width. This high-performance system allows scraped material to be easily discharged. “In the range of ScrapeTec conveyor components is also the PrimeTracker belt tracker, which eliminates other problems associated with conveyor belt systems, including misalignment, abrasion and belt damage,” says Mouritzen. “The PrimeTracker ensures the belt is constantly in the correct position during operation, thus eliminating problems with belt mistracking, while the Airscrape efficiently controls dust, prevents material spill and minimises explosion risks.” An advantage of this device is that it operates in the idling position at all times, unless there is sideways movement of the belt. The system corrects misalignment immediately, by guiding the belt back into the correct position, with no damage or abrasion to the belt or tracker. This is unlike conventional belt trackers that slide over the belt surface causing possible abrasion and belt damage. Conventional belt trackers, with tapered edges, never idle and are

always in a braking mode. “Of note is the cylindrical shape and pivot bush that allow this belt tracker to swing and tilt during operation and to always be in full contact with the belt. Added to this, the Scrapetec PrimeTracker has the same peripheral speed over the entire surface of the belt, where traditional crowned rollers have different speeds at the centre and edges of the system,” explains Mouritzen. Other advantages include easy installation, low maintenance requirements and protection of belt edges and structure of the conveyor belt. A strong corrugated EPDM (ethylene propylene diene terpolymer) rubber hose protects the system from dust and sand, while the rubber pivot offers soft suspension of the tracker shaft, ensuring extended service life of the system. The system can be installed in front of every return pulley, above and below the belt.

Correct installation

Correct installation of suitable dust suppression equipment ensures cost efficiency, optimum performance and safety, reduced risk of breakdown and extended service life of the conveyor system. “In close co-operation with ScrapeTec experts, BLT WORLD provides an assessment and solutions service to customers, for planning and implementing projects. A technical advisory and support service enhances performance of every ScrapeTec system,” concludes Mouritzen. a

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CONSTRUCTION VEHICLES

The FUSO FJ26-280C is one of the top performing construction vehicles in the DTSA stable.

UPWARD TRAJECTORY FOR SA’S CONSTRUCTION SECTOR An apparent momentum in the construction and mining space is driving an upward trajectory in the sales of construction type commercial vehicles. In an exclusive interview with Quarrying Africa, Maretha Gerber, vice president of Sales & Marketing at Daimler Truck Southern Africa (DTSA), discusses the state of affairs and the emerging trends in this market segment. By Munesu Shoko. here is a general school of thought that the supply chain is always a good measure of the state of the construction industry, or even sectors such as quarrying and mining at large. If sales of construction type commercial vehicles are anything to go by, construction activity is therefore on an upward trajectory in South

Africa. This was the overarching message from a recent one-on-one with Gerber, who says there is definitely an apparent positive momentum in the construction space, which has translated in an uptick in concrete mixer and tipper truck sales. While the growth in construction activity is not at the levels experienced during the so-called boom days in the run up to the 2010 Soccer World Cup, Gerber is encouraged by the recent government tender activity in the country and the regional investment in infrastructure

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R59-billion

SANRAL has awarded a whopping 323 tenders to the value of R59-billion in the past financial year

Euro 5

In response to new trends, DTSA, together with several stakeholders, is driving the transition to Euro 5 engines

KEY TAKEAWAYS If sales of construction type commercial vehicles are anything to go by, construction activity is therefore on an upward trajectory in South Africa Top performing construction vehicles in the DTSA stable are the FUSO FJ26-280C and the FJ26-280C HYP as well as the Mercedes-Benz Arocs 3236B/51 To further boost its offering in the construction/ quarrying value chain, DTSA has introduced the new Mercedes-Benz Arocs 4152K/51 tipper chassis which, to date, has performed well in the market A trend in the construction/quarrying space is the ‘sweating of assets’, especially following the Covid-19 pandemic and the resultant slump in construction activity

development in some of the country’s provinces. “It is interesting to see the amount of government tender activity this year and the resultant sales of construction vehicles going into that space, which gives us an indication that government is somehow starting to invest in infrastructure again,” she says. To provide context, the roads authority alone, the South African National Roads Agency Limited (SANRAL), has awarded a whopping 323 tenders to the value of R59-billion in the past financial year. This is nearly triple the R22-billion tender value awarded in the previous financial year. “In general, it is my view that the construction industry is not dormant anymore, although the pace of growth is not at the levels we hope for. We have also seen a steady rise in demand for our vehicles in the mining space, particularly in the rest of Southern Africa,” says Gerber.

Top sellers

Top performing construction vehicles in the DTSA stable are the FUSO FJ26-280C and the FJ26-280C HYP. “From a product point of view, these two products are our top performers at the moment and we cannot keep up with orders in

“

In general, it is my view that the construction industry is not dormant anymore, although the pace of growth is not at the levels we hope for. We have also seen a steady rise in demand for our vehicles in the mining space, particularly in the rest of Southern Africa.

Maretha Gerber, vice president of Sales & Marketing at Daimler Truck Southern Africa

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CONSTRUCTION VEHICLES

DTSA has seen an uptick in the sales of its Mercedes-Benz Arocs range in the construction market.

aerodynamic FUSO FJ cab which reduces tractive some instances. The two vehicles are designed and resistance and increases fuel efficiency. engineered to fulfil customer business needs in the On the Mercedes-Benz side of things, the Arocs construction segment,” says Gerber. 3236B/51 is the shining star which, according to A key selling point of the FJ range, she says, is the Gerber, is the benchmark in the 8 m³ concrete mixer bodybuilder-friendliness of the vehicles. The FJ26market. The application-specific mounting elements 280C HYP, for example, is available with both the provide for a bodybuilder-friendly and fast-mounting engine Power Take Off (PTO) and a transmission PTO, process. The mixer chassis comes standard with the allowing customers the flexibility to either fit a mixer mixer mounting brackets, together with the modular or tipper body when taking delivery of the vehicle. bolted frame and the 50 mm chassis hole pattern. “The proven versatility of the FJ range makes it easy to interchange between a concrete mixer and a tipper body, giving customers the flexibility to change, with New arrival no complexity, to whatever the market requires at the To further boost its offering in the construction/ time,” she says. quarrying value chain, DTSA has introduced the new Efficiency, a major parameter in construction Mercedes-Benz Arocs 4152K/51 tipper chassis which, customers’ buying decisions, is another key competitive to date, has performed well in the market, largely edge of the FUSO FJ offering. The FJ26-280C HYP, for due to its focus on reduced maintenance costs. example, is specifically fitted with hypoid rear axles “This model comes with a high-performance engine (single reduction axles), contributing extensively to brake, which effectively reduces brake wear in typical low fuel consumption, and reducing the tare weight tipper applications in construction and quarrying. This of the vehicle. This is to ensure that the vehicle can speaks directly to the increased focus on lower accommodate a 6 m³ concrete mixer and still total cost of ownership (TCO) in this market comply with the permissible axle loads. segment,” she says. The FJ26-280C HYP is powered by the 6S20 6.4-litre direct-injection Emerging trends engine producing 205 kW of power Commenting on some emerging at 2 200 rpm delivering high torque trends, Gerber says electrification (1 100 Nm between 1 200 rpm to is one topic on everyone’s On the Mercedes-Benz side of 1500 rpm) over a wide range of engine mind. Electric trucks, she says, things, DTSA’s shining star is the speeds and is paired with the G131 will definitely have their space Arocs 3236B/51, which is the benchmark in the 8 m³ concrete nine-speed transmission with crawler in the market in future, but she mixer market gear. This vehicle has oil-lubricated fuel believes that ultimately sustainable injection pumps which inject the precise transportation will be achieved quantity of required fuel at high pressure, through a combination of carbon neutral resulting in improved combustion of fuel, delivering technologies. unmatched fuel efficiency. “We are bringing in electric solutions to the local The engine also features an e-viscous electric fan, market as quickly as possible. However, in my view, and its intermittent operation improves fuel economy electrification is the bridge to our end goal to provide by disengaging the fan when the engine is operating hydrogen solutions to this market. While infrastructure below a pre-set temperature. The model features an and the current costs of ‘green’ hydrogen are still

8 m³

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The FUSO FJ26-280C is designed and engineered to fulfil customer business needs in the construction segment.

major constraints, we believe this remains the right solution for Africa in the long term,” says Gerber. On the other hand, she says, electrification seems ideal for the mining environment, especially from a charging infrastructure point of view. Given that vehicles in a quarrying or mining setup work on a fixed site, it is easier to set up charging infrastructure than in a long-haul environment. Another major trend in the construction/quarrying space, says Gerber, is the “sweating of assets”, especially following the Covid-19 pandemic and the resultant slump in construction activity. “Because of the challenging market conditions, customers were forced to delay their replacement cycles. However, as these older vehicles have started to work again in the past two years, the replacement cycles that were postponed as a result of the slump are starting to trigger themselves, hence the increased enquiries,” she says. From a market expansion point of view, DTSA has taken a deliberate approach to expand its supply scope into government sectors. Traditionally, the company has never been as aggressive in government tenders, but now it is part of its strategy to look after several government departments. In addition, Gerber sees significant growth in DTSA’s export markets, in countries such as Zimbabwe, Zambia, particularly driven by investments in mining and infrastructure development.

Response

In response to the emerging trends, DTSA has over the years adopted a constant re-evaluation strategy which allows it to meet the everchanging customer needs. “For us, it is important to constantly re-evaluate ourselves and our product offering. For example, we see a growing interest in a certain solution in our trucks, instead of having it as an option, we take a standard approach to it,” says Gerber. For instance, DTSA has this year made its Fleetboard telematics offering standard on all its construction and

all-wheel drive vehicles. This, she says, is in response to the growing trend towards the consideration of TCO by customers in this market segment. Traditionally, the construction and quarry truck owner has never taken a TCO approach to buying decisions. While many still largely consider the capital cost of the product, Gerber says several industry players are starting to develop a better understanding of the TCO factor, showing interest in not only the purchase price, but also in the costs related to keeping the truck running. Testimony to this TCO approach, says Gerber, is the high adoption rate of telematics. “The South African truck owner has become sophisticated, and telematics has become a gold standard. To give context, DTSA is the biggest Fleetboard market outside of Europe. This demonstrates the type of customer that we are dealing with – they understand that it is not just about the metal; it is about the whole package, including driver and truck performance as well as a proactive approach to maintenance. Fleetboard gives them that opportunity to keep an eye on these important parameters,” she says. Another major response to new trends by DTSA is the transition to Euro 5 engines. The company is actively engaging various stakeholders, including government, The National Association of Automobile Manufacturers of South Africa (NAAMSA) and The Road Freight Association to help with the transformation. The quicker the market transforms to Euro 5, the more product and new technology will DTSA have available for local customers. The company will initially have Euro 5 products available in parallel to Euro 3 but will eventually migrate to Euro 5 completely in the future. In conclusion, Gerber says, “I am very excited to see the momentum in the construction and mining space. This shows that there is willingness to continue a positive trajectory to drive economic recovery. Despite all the challenges, the activity in these segments shows some much-needed confidence is brewing.” a

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DEWATERING

Envirotech Spiroglide multistage dewatering pump set to be installed at a platinum mine.

DEWATERING: SOLUTIONS AS UNIQUE AS YOUR PROJECT Often considered an afterthought, pit dewatering is fundamental to the viability of quarries and mines. Given that each site’s dewatering requirements vary and present unique challenges, Marnus Koorts, GM – Pump Products at Weir Minerals Africa, notes that the optimal approach to dewatering is to work with an experienced dewatering systems original equipment manufacturer (OEM) to ensure a bespoke solution that is site-specific, cost-effective and manageable. By

Munesu Shoko. n quarrying and surface mining in general, the assessment of dewatering needs is important for every operation. In most cases, says Koorts, this is considered a postscript, yet it should be ‘front and centre’ as early as the design phase of the operation. Every mine or quarry site needs to account for dewatering at some point in time. However, it is important to determine the exact nature of potential disruptions. Ahead of potential torrential rains in the region, most operations are susceptible to flooding – some more so than others, depending on geographical location. “It is always important to first define potential

water hazards before installing a dewatering solution. In a mining environment, water comes from several sources, rain being just the most obvious one. However, there are also other sources such as natural seepage in the bedrock as the pit gets deeper, as well as aquifers which can yield a significant amount of ground water,” explains Koorts. All these types of runoffs can lead to catastrophic flooding that shuts down operations with costly consequences. A comprehensive, reliable and flexible dewatering plan is therefore essential to remove excess water from working areas in order to allow operations to continue while safeguarding

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1 or 2

It is important to factor the changing conditions in the pit. For example, a solution might be fit for the prevailing conditions, but in a year or two, the pit might be considerably deeper

Real time

With Weir Minerals’ Synertrex intelligent platform, customers have a tool that lets them know in real time, when something is wrong, preventing problems from developing into costly breakdowns

KEY TAKEAWAYS In quarrying and surface mining in general, the assessment of dewatering needs is important for every operation For every dewatering project, it is important that the OEM understands the environment before developing a solution There is an industry perception that dewatering is just about the pump itself. The truth of the matter is that a pump is only one portion of a series of components Weir Minerals has a large portfolio of in-house components that allow it to provide flexible dewatering solutions from one stable

operators and maintaining productivity. “Mining activities require different dewatering solutions, yet operations do not take this into consideration during designs. Of course, there is planned water reticulation, which is generally engineered into the plant to ensure there is a steady supply of process water throughout the site. However, in most cases mines do not account for water seepage or rain, which often results in unplanned water agglomeration,” says Koorts.

Factors to consider

There are numerous factors to consider when determining the type of dewatering solution required. One of the key factors is the voltage of the pumps needed to pump the water from the pit, which is much higher than that required for above-ground applications. “Normal motors do not work in the pit without using transformers. For electrical pumps, the knowledge of

“

Each site’s dewatering requirements vary and present unique challenges. That is why we believe that dewatering solutions should not be standardised; they must be custom solutions designed and built in line with the available site conditions.

Marnus Koorts, GM – Pump Products at Weir Minerals Africa

the required pump, the drivetrain and the electrical interfacing is crucial. If the operation decides to go the diesel pump route, which obviously comes with higher running costs, there is a need to be able to interface the pump with the diesel engine manufacturer. These are some of the crucial matters that are not considered from the onset. In most cases, there is no infrastructure in the pit to cater for these requirements,” says Koorts. In addition, the characteristics of water being moved can have a notable impact on the equipment and materials used. The pH range, temperature, corrosive and abrasive content all play a critical role in selecting the equipment to transport water effectively. The presence of solids in the water, the specific gravity, size distribution and content percentage will determine the type of pumps required. Equally, the pipework and valves are also subject to corrosion and abrasion from the products handled and must be designed accordingly. “It is important

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DEWATERING assess the different scenarios that determine an optimal solution for the operation.” In addition, it is also important to factor the changing conditions in the pit. For example, a solution might be fit for the prevailing conditions, but in a year or two, the pit might be considerably deeper. Weir Minerals can therefore design a solution with the evolution of the mine in mind.

Weir Minerals offers a large portfolio of products to offer customers an integrated dewatering solution.

Integration

For every dewatering project, it is important that the OEM understands the environment before developing a solution. The pitfalls of over- or undersized equipment include excessive energy use, high-cost capital outlay and maintenance, as well as risk to equipment and personnel, and also lost production, in the case of insufficient capacity. “There is an industry perception that dewatering is just about the pump itself. The truth of the matter is that a pump is only one portion of a series of components. The OEM should therefore be The Synertrex intelligent platform monitors able to interface and integrate asset health and analyses data in real time. the various components – some internal and some from external suppliers. At Weir Minerals we have a large portfolio of in-house components that allow us to provide flexible solutions from to determine what is in the water. In most cases the one stable. These include hoses, pump combinations, water has traces of solids, which calls for a dirty-water valves, slurry pumps and hydrocyclone separators, pump. Copper ores, for example, contain sulphides amongst others,” he says. which create acidic properties, which in turn However, there is also need for call for a stainless steel pump option,” integration with various external explains Koorts. components that make up dewatering Another critical factor is the head solutions. These include skids, hoists, pressure required to pump the water diesel engines, electric motors, out of the pit. Many of the pits are motor control centres, transformers very deep, which means additional Operations should always consider an OEM that has a and electrical interfaces. booster pumps are needed to broad knowledge of industry “Operations should always overcome the large vertical lift. These componentry outside of the hydraulic pumping sphere consider an OEM that has a broad are positioned at multiple levels to knowledge of industry componentry help raise the water from the bottom outside of the hydraulic pumping of the pit. sphere, which I believe is one of our key “Each site’s dewatering requirements vary strengths at Weir Minerals Africa,” says Koorts. and present unique challenges,” says Koorts. “That is why we believe that dewatering solutions should not be standardised; they must be custom Wide range solutions designed and built in line with the available One of the key considerations when choosing a site conditions. At Weir Minerals, we do not supply a dewatering solutions provider is its ability to offer dewatering solution without first going to the site to a range of pump products from one stable. For

OEM

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Weir Minerals engineered a pontoon and walkway solution that prevents crocodiles from climbing onto the equipment.

example, Weir Minerals has a range of solutions that allows it to use several types of pumping equipment, from self-primed diesel driven, submersibles, vertical turbine and multistage, to high-wall pump designs for sites that have limited access due to high-sided mine pits. The company also develops sophisticated pontoon and barge designs which allow its equipment to float out over water bodies for easier access. They can also be fixed to banks with access walkways or set up as standalone installations. In addition, they can be constructed from a variety of materials, from heavy-duty steel to low-density polyethylene with steel frames, for lighter applications. All designs are rigorously tested and include safety features to help prevent risk to operators.

Additional capabilities

Apart from a wide range of pump solutions, Weir Minerals also boasts additional knowledge and capabilities that are crucial for successful mine dewatering solutions. One of the key strengths of the company is its strong engineering capabilities. “We have an experienced engineering team that specialises in designs, interfacing and buoyancy calculations, amongst other functions,” he says. “Over the years, a lot of lessons have been learned from the different complex projects that we have undertaken. We are also particularly good with control philosophies, having developed systems that start and stop automatically to seamlessly operate when required,” he says. With Weir Minerals’ Synertrex intelligent platform, customers have a tool that lets them know in real time, when something is wrong, preventing

problems from developing into costly breakdowns. As a plug and play system, Synertrex technology measures asset health, gathers and analyses data subsequently, converting that data and insights into recommendations. Another important parameter that often does not receive the necessary attention it deserves, is the sealing arrangement for dewatering solutions, comments Koorts, for which Weir Minerals has “a couple of solutions in its envelope”. For instance, the company can use the expellor, which creates a positive pressure on the one side and a negative pressure on the other. Not all pump suppliers can offer this sealing arrangement – it is a sensitive piece of equipment that needs to be selected for the right application. The OEM can also do a mechanical seal interface, which is also specialised. Not a lot of suppliers in the market, says Koorts, can interface with mechanical seals. “An OEM needs to have all these facets to be able to operate in the dewatering sphere. A complex customised solution is required – no two solutions are the same. To provide context, we have installed crocodile-proof pontoons in Madagascar because the mine has to contend with crocodiles coming into the pit whenever it rains. We have also developed pontoon solutions in Europe with water heaters because the water in the pit freezes due to extremely cold temperatures. These are clear instances of custom-made solutions for unique operational changes,” says Koorts. In conclusion, Koorts says customers in Africa can benefit from Weir Minerals Africa’s local, countryspecific infrastructure to support them in this critical field. a

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EXCAVATORS

A Kobelco SK850LC excavator deployed to load a dump truck in the pit.

50 t Any machine under 50 t should have a ROPS FOPS-certified cab and machines over 50 t should have a FOPS-certified cab guarding to protect the operator against rock falls

FACTORS TO CONSIDER WHEN BUYING A NEW EXCAVATOR Deciding on the right excavator for your quarrying operation requires careful consideration of several important factors. Here are some of the top tips to help quarry owners/managers make informed decisions when it is procurement time. By Munesu Shoko.

xcavators are some of the most critical heavy equipment used in quarries. Given that they come in different shapes and sizes, with a wide range of options available, picking the right machine for the project requirements at hand can be a daunting task. It is therefore important for quarry managers to understand the factors that should inform their decision-making process.

Safety, efficiency, bucket size, machine size and weight, reach and digging depth, total cost of ownership (TCO), resale value, warranty and financing options are some of the key factors to consider when making that buying decision.

Match factor

Keon Kardolus, divisional manager for Earthmoving and Construction at ELB Equipment, the official distributor of

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100%

With face loading, there is a need to establish the tonnage that represents the output of the crusher at 100% efficiency, assuming in this case there is only one crusher

2 m³

A 50-t excavator with a 2 m³ bucket will provide the same output as a 30-t excavator but with higher running costs, impacting the cost per tonne and therefore profit margins

“

When selecting an excavator, it is not just about the machine weight and size but also about the machine configuration. For pure production loading, the same machine will have a shorter boom, a slightly shorter stick, with a much bigger bucket.

Gary Martin, senior market professional for heavy construction and quarry industries, Caterpillar

KEY TAKEAWAYS Matching the right excavator to the specific quarrying tasks can significantly enhance efficiency and productivity

One of the key factors that affects the overall efficiency of the excavator is ensuring the correct bucket is fitted to the excavator

“

Fuel economy is application-specific, but it is probably the largest cost in terms of

When selecting an excavator, it is not just about the machine weight and size but also about the machine configuration

cost per tonne. Kobelco has a huge fuel efficiency focus without losing focus on productivity. There is no compromise when it comes to productivity.

Consider the maximum reach and digging depth of the excavator to ensure it can access the areas you need to work in your quarry

Stephen McNeill, head of Marketing and Sales Support at Bell Equipment

SEPT/OCT 2023 | Vol. 2 ISSUE 5 | www.quarryingafrica.com |

EXCAVATORS

Sumitomo excavators deployed to work in a granite application.

“

Investing in the right equipment from the outset can lead to substantial cost savings in the long run. A machine that is optimised for the application will likely have lower operating costs, reduced maintenance requirements and a longer lifespan.

Keon Kardolus, divisional manager for Earthmoving and Construction at ELB Equipment

Sumitomo excavators in South Africa, says it is incredibly important for quarry owners to ensure they are buying a machine that is best matched to the application at hand. Matching the right excavator to the specific quarrying tasks can significantly enhance efficiency and productivity. Quarry owners, says Kardolus, need equipment that can handle the demands of their operations effectively, whether it is digging, loading, hauling or crushing. The wrong machine may struggle or underperform, leading to costly delays and decreased output. “Investing in the right equipment from the outset can lead to substantial cost savings in the long run. A machine that is optimised for the application will likely have lower operating costs, reduced maintenance requirements and a longer lifespan. This translates into better return on investment (ROI) for quarry owners,” says Kardolus. Stephen McNeill, head of Marketing and Sales Support at Bell Equipment, the approved distributor of Kobelco and JCB excavators, says one of the key factors that affects the overall efficiency of the excavator is ensuring the correct bucket is fitted to the excavator. A bucket that is not correctly matched to the material density and the lifting capacity of the machine will slow cycle times and decrease machine stability. The excavator size needs to match the requirement of the application, whether its loading trucks or a hopper. For example, if an excavator is deployed to load a dump truck, the bucket needs to have the capacity to load the dump truck in five to seven passes in order to optimise the efficiency of the equipment. Gary Martin, senior market professional for heavy construction and quarry industries, Caterpillar, says to operate at the lowest cost per tonne, it is essential that quarry managers do their homework to select the correctly sized machine.

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A Cat 395 large excavator loading a Cat 777G rigid dump truck.

“Let’s start with face loading – there is a need to establish the tonnage that represents the output of the crusher at 100% efficiency, assuming in this case there is only one crusher. Then, select the trucks to match the crusher maximum production output. As first indicators to match production, look at the excavator weight and bucket size,” says Martin. It is all about the calculation, stresses Martin. Take for example, a crusher with a feed rate of 500 tonnes per hour (tph) serviced by two Cat 770G trucks with a payload of 38 t each. The 770G trucks carry the material from the face to the crusher before returning for another payload. To complete one cycle of load-haul-dumpreturn takes a truck some eight minutes or 285 tph (2 x Cat 770G trucks = 570 tph). “Now that the required production rate is known, the excavator can be sized for performance and optimum efficiency. The industry benchmark is to load the truck in six to seven buckets. Taking the maximum 38-t truck capacity, then dividing it by six or seven buckets, means that the excavator should hold five to six tonnes per bucket. Divide the tonnes by the material density and you have the bucket volume,” he says. For example, 5,5 t divided by material density of 1,6 is equal to a bucket with a volume size of 3,45 m³, which indicates that the Cat 352 excavator is the right match. Another easy rule of thumb to calculate the correct size Cat excavator to match the production is by using the last two digits of the model number – in the case of the Cat 352, 52 x 10 represents the approximate tonnage that can be safely loaded per hour. This works for the Cat excavators, from the Cat 320 to the 395.

Correct choice

Kardolus adds that the choice of the right excavator for the right application plays a crucial role in ensuring a safe working environment – a concern

which is paramount in any industrial setting. Using an excavator that is appropriately sized and equipped for the task can help minimise accidents and injuries, safeguarding both the workers and the investment. “Providing operators with the right equipment not only enhances their comfort but also their productivity. A machine that is well-matched to the job reduces operator fatigue and allows for more precise and efficient work, ultimately leading to higher output,” says Kardolus. Given that quarrying needs can change over time, having the flexibility to adapt to evolving requirements is essential. Purchasing a machine that can be easily configured or equipped with attachments to handle various tasks ensures long-term utility and versatility. Reputation and customer satisfaction are also outcomes of good purchasing practices. Successful quarry operations, says Kardolus, often rely on their reputation and customer satisfaction. Using the right equipment ensures that jobs are completed efficiently and on time, which can lead to satisfied customers and positive word-of-mouth referrals. “In summary, for quarry owners in South Africa or anywhere else, selecting the right equipment that matches the specific quarrying application is of great importance. It directly impacts efficiency, safety, costs, and overall operational success. As the official distributor for Sumitomo excavators in South Africa, we play a vital role in helping quarry owners make informed choices to achieve these benefits and drive the success of their businesses,” says Kardolus.

Factors to consider

Commenting on some key factors to consider when choosing an excavator for a quarry operation, Caterpillar’s Martin says the configuration of an excavator plays a major part in its production output.

SEPT/OCT 2023 | Vol. 2 ISSUE 5 | www.quarryingafrica.com |

EXCAVATORS

Sumitomo excavators are supplied by ELB Equipment in South Africa.

There are two different offerings from Caterpillar and other suppliers configured for different environments. The reach excavator version comes with a longer boom, a longer stick and a smaller bucket which is designed to give more reach in applications. It also normally comes with a slightly different undercarriage with wider triple grouser track pads to improve flotation in moderate applications. “When selecting an excavator, it is not just about the machine weight and size but also about the machine configuration. For pure production loading, the same machine will have a shorter boom, a slightly shorter stick, with a much bigger bucket,” explains Martin. “For harsh and demanding quarry and mine environments, a heavy-duty undercarriage with double grouser track pads is recommended. It is not all about the size and horsepower. For example, a 50-t excavator with a 2 m³ bucket will provide the same output as a 30-t excavator but with higher running costs, impacting the cost per tonne and therefore profit margins.” Cat dealers, he adds, have considerable experience and expertise and can advise quarry managers on the right equipment to achieve their production targets within their unique operating conditions.

More considerations

For McNeill, one of the key considerations should be choosing an excavator design that has a proven reputation in the market for being able to handle the application/s that it is intended for. It should also provide quarry operators with low overall running costs – from fuel through to maintenance costs – that are within the quarry’s operational budget. “Fuel economy is application-specific, but it is probably the largest cost in terms of cost per tonne. Kobelco has a huge fuel efficiency focus without losing focus on productivity. There is no compromise when it comes to productivity,” says McNeill.

Support from the local dealer, he adds, is another crucial consideration because every machine, especially those working in harsh applications, will require some technical backup at some point and it is important that a service provider is quick to respond and has the necessary expertise and parts availability to avoid costly downtime. In this respect, says McNeill, Bell Equipment South Africa has a large footprint of customer service centres, each with trained technicians and a wellstocked parts department. “The excavator should also have the ability to provide you with the telematics data that you require to be able to track machine hours, fault codes and productivity for the relevant application. The Kobelco range of excavators, sold and supported by Bell Equipment South Africa, can be integrated with the Bell Fleetm@ tic fleet monitoring system to enable fleet owners to monitor their whole fleet with one, user-friendly telematics system,” adds McNeill. Additional factors to consider are operator comfort and safety. Any machine under 50 t should have a ROPS FOPS-certified cab and machines over 50 t should have a FOPS-certified cab guarding to protect the operator against rock falls. In terms of comfort, operator comfort reduces operator fatigue, which positively influences productivity. “The key to operator comfort is operator-friendly controls, and the Kobelco range has a comfortable and spacious cab with excellent visibility, a powerful automatic air-conditioner, easy-to-understand displays, and smooth controls. The travel pedal is also larger for greater operator comfort. The wide access cab allows for smooth entry and exit. A quieter working environment is achieved through strategic component positioning and the superior sealing of the cab, while the rigid cab construction and liquid-filled viscous cab-mounts minimise cab vibration for fatigue-free operation,” explains McNeill.

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A Kobelco SK850LC excavator loading a Bell B60E dump truck.

Attachments have also become key to enhancing an excavator’s versatility. According to McNeill, most hydraulic-operated attachments can now be fitted to Kobelco excavators without any need for modifications to the machines as they are factory-fitted with two-way piping which has foot-operated controls. Hydraulic flow can also be adjusted from inside the cab at the flick of a button. This alleviates the need for flow gauges and making mechanical adjustments on the pump itself. This is now a standard on all Kobelco machines up to and including the 50-t SK520. Kobelco machines also allow for the switching between single and bi-directional hydraulic flow within the cab. Electronics significantly affect the versatility of the machine in terms of switching between different functions and from a diagnostics point of view. The Kobelco range uses an Intelligent Total Control System (ITCS) – an electronic system that responds quickly to sudden changes in hydraulic load to ensure that the engine runs as efficiently as possible with the minimum of wasted output.

Essential factors

For Kardolus, when buying an excavator for quarrying purposes, several key factors should be carefully considered to ensure one makes the right choice. Here are some of the essential factors to keep in mind, with a focus on Sumitomo excavators: Excavator size and capacity: Consider the size of the excavator needed based on the scale of your quarry operations and the types of materials you will be handling. Smaller excavators are suitable for lighter tasks, while larger ones are needed for heavy-duty operations. Bucket size and attachments: Ensure that the excavator can accommodate the appropriate bucket size and attachments for the specific tasks in your quarry. Different buckets and attachments are designed for various tasks like digging, grading or lifting.

Engine power and fuel efficiency: Evaluate the engine power to ensure it provides sufficient horsepower for your quarrying needs. Also, check for fuel efficiency to reduce operating costs over time. Hydraulic system: Assess the excavator’s hydraulic system for its speed, precision and durability. A welldesigned hydraulic system can significantly impact the machine’s performance and efficiency. Reach and digging depth: Consider the maximum reach and digging depth of the excavator to ensure it can access the areas you need to work in your quarry. Operating weight and stability: Ensure that the excavator’s weight and stability are suitable for your quarry’s terrain and conditions. Stability is crucial for safe and efficient operation. Cab comfort and operator features: A comfortable and well-equipped operator’s cabin can improve productivity and reduce operator fatigue. Look for features such as ergonomic controls, air conditioning, and visibility. Maintenance and serviceability: Check the ease of maintenance and access to key components. Easy maintenance can minimise downtime and reduce operating costs. Brand reputation and dealer support: Consider the reputation of the manufacturer and the availability of dealer support and spare parts in your region. A reliable support network can be crucial for ongoing maintenance and repairs. Warranty and financing options: Review the warranty offered by the manufacturer and explore financing options to fit your budget. A good warranty can provide peace of mind and potentially save on repair costs. Environmental compliance: Ensure the excavator meets environmental regulations and emissions standards applicable in your area. Compliance can be essential for legal and environmental reasons. Safety features: Look for safety features such as backup cameras, proximity sensors and rollover protection systems (ROPS) to enhance the safety of your quarrying operations. Resale value: Consider the potential resale value of the excavator, as this can impact your long-term investment. TCO: Calculate the total cost of ownership, which includes initial purchase price, maintenance costs, fuel consumption and resale value. This will help you make a more informed decision. Operator training: Ensure that your operators are trained and certified to operate the specific excavator model safely and efficiently. Demonstration and evaluation: Whenever feasible, schedule a demonstration of the excavator to gauge its real-world performance in quarry conditions. According to Kardolus, this is just one of the additional advantages one can expect when partnering with ELB Equipment to fulfil their equipment requirements. “By carefully evaluating these factors and their relevance to their quarrying operations, quarry owners can make informed decisions when purchasing a Sumitomo excavator or any other brand that suits their needs,” concludes Kardolus. a

SEPT/OCT 2023 | Vol. 2 ISSUE 5 | www.quarryingafrica.com |

CORPORATE PARTNERS

AfriSam AfriSam is a leading construction materials group in southern Africa. Since establishing its first cement plant in 1934, the company has grown into a formidable construction materials group with operations in South Africa, Lesotho and Eswatini.

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IPR IPR is recognised across the SADC region as the pump, heavy duty slurry handling and dredging specialist operating in underground and surface mining, quarrying, construction, wastewater, petrochemical and oil and gas sectors.

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Loadtech LOADTECH Load cells Onboard Weighing are specialists in onboard weighing providing complete solutions onboard your heavy goods vehicle, primarily in the application of load cell and transducer systems for payload protection and accuracy in the commercial vehicle sector.

Weir Minerals Weir Minerals Africa offers a wide range of equipment solutions including pumps, hydrocyclones, valves, dewatering equipment, wear-resistant linings, rubber products, screens and crushers – backed throughout the product lifecycle by high levels of aftermarket support.

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| SEPT/OCT 2023 | Vol. 2 ISSUE 5 | www.quarryingafrica.com