Quarrying Africa ISSUE 6 November/December 2022

e have come to the end of yet another tough year for the quarrying industry. Despite huge prospects of improved activity at the start of the year, the general sentiment is that construction remains sluggish. Considering the fact that the quarrying sector feeds off construction activity, 2022 has once again turned out to be a really tough year for the industry.

Owing to South Africa’s poor economic performance, we would all no doubt agree that the country’s construction industry has been under severe pressure over the past few years. Despite the urgent need for infrastructure investment, the rollout of government’s infrastructure projects has been undermined by maladministration and corruption, project delays, cost overruns and poor project management.

That corruption and irregular procurement have become endemic in the construction sector is no overstatement. In addition, construction mafia and extortion groups present a substantial threat to the industry. Shortages of building materials, compounded by soaring transport costs and inflation, are driving up construction costs and resulting in cost overruns.

For me, however, the lack of policy direction remains a big challenge for the industry. Earlier this year, I had the privilege of attending the IQSA Conference, where SANRAL executive, Louw Kannemeyer, openly admitted to some challenges bedevilling the roads authority. Firstly, he noted that the lack of clear road-funding policy in South is a major hindrance to service delivery.

The associated negative sentiment towards toll roads created by the non-resolution of the e-toll debacle in Gauteng, resulted in SANRAL not being able to proceed with over R150-billion of projects previously earmarked for toll financing.

Secondly, he said, regulatory uncertainties will continue to have a major impact on the project rollout programme. To provide context, the bickering around the Preferential Procurement Regulations of 2017 halted SANRAL tenders for 18 months, affecting over 70 projects.

The latest debacle concerns the recent awarding of construction tenders to foreign companies. Construction industry stakeholders have expressed concern over

SANRAL’s awarding of over R6,6-billion worth of tenders to Chinese-led joint ventures. Of the five tenders that were previously cancelled, four have now been awarded to Chinese contractors.

There are well documented concerns around the granting of infrastructure tenders to Chinese contractors. Of particular concern to many are China’s employment practices for large infrastructure projects on the continent. Among the issues are claims that Chinese firms often bring in Chinese workers and offer little training and skills development for African employees. In some cases, African workers complain of exploitation, claiming they receive low wages and are subject to poor working and living conditions.

In light of these concerns, the need to protect local construction companies cannot be reiterated enough, not from a competitive perspective, but rather from an employment perspective. This is because local construction companies employ local people – the industry does not want to see South Africa follow the lead of many other countries in Africa where investment from other countries comes with strings attached – especially when it comes to the investor country’s people delivering the projects.

Equally concerning are their procurement practices. These contractors have a track record of bringing everything they need, all the way from a small backhoe loader to a large crane on site, which limits the expected multiplier effect of government infrastructure programmes on the local economy.

Despite these challenges, it is, however, encouraging to see that the construction industry is somehow rebounding. If the latest Afrimat Construction Index (ACI) is anything to go by, the local construction industry is seemingly on an upward trajectory. The ACI for the third quarter of 2022 highlights the resilience of the economy and growth in construction sector activity.

The latest gross domestic product (GDP) data released by Statistics SA pointed to a real growth rate of 1,6% (quarter-onquarter) for the economy as a whole, with the construction sector recording real growth in value-added of virtually double this rate, namely 3,1%. The industry’s recovery mode is expected to trend well into 2023, thus injecting the much-needed confidence into a market that has been struggling for many years. a

Publishing Editor: Munesu Shoko

Sub Editor: Glynnis Koch

Admin: Linda T. Chisi

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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.

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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.

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

With a 24,3-t operating weight, a rated payload of 7 t and bucket capacity of 4,57 to 7 m3, the SW978K1 front-end loader is ideally suited for heavy-duty mining and quarrying operations. This is a radical upgrade of our existing 5-t SYL956H model, both in terms of the operating weight and features.

SW978K1

The new SW978K1 wheel loader has a special design focus on high productivity and lower cost per tonne of operation – key parameters of significance to every fleet owner

210 kW

Specifically tailored for SANY, the large-capacity 7-t fully automatic gearbox perfectly matches with the engine’s 210 kW @2 200 rpm rated power. Vehicle speed has been increased by 5%, while traction force has gone up to 205 kN, and the overall operating efficiency has increased by more than 10%

Key specs

Model SANY SW978K1

Operating weight 24 300 kg

Rated payload 7 000 kg

Bucket capacity 4,57 to 7 m³ Engine Weichai WP10

Rated power 210 kW @2 200 rpm

KEY POINTS

Having offered a single wheel loader model over the years, the 5-t SYL956H model, SANY is expanding its offering with the launch of the larger SW978K1

The SW978K1 is a radical upgrade of the existing 5-t SYL956H model, both in terms of operating weight and features

With efficiency in mind, the loader comes with a constant power loadsensitive variable flow system, which uses constant power control and pressure cut-off technology to maximise flow distribution on demand

To improve operator comfort and subsequently productivity, the SW978K1 comes with a newly upgraded cab

Having offered a single wheel loader model over the years, the 5-t SYL956H, SANY is expanding its offering with the launch of the larger SW978K1. The 7-t model, GM Samuel Zhang tells Quarrying Africa, allows SANY to compete at the larger end of the wheel loader scale. More importantly, the company can now

The 7-t model allows SANY to compete at the larger end of the wheel loader scale.

5%

Vehicle speed has been increased by 5%, while traction force has gone up to 205 kN

95%

In shovelling operations, the hydraulic system maintains high pressure and less flow, reducing power losses by 95%

10%

The machine’s overall operating efficiency has increased by more than 10%

LOADING LARGER TONNAGES

As part of its product expansion programme, SANY Southern Africa is introducing its new 7-t wheel loader, an upgrade to the existing 5-t model. With the larger model, SANY now has a wheel loader model to cater for highproduction operations in mining and quarrying, writes Munesu Shoko.

The SW978K1 also speaks to SANY’s recent strategy which has seen the company expanding its load and haul offering with larger models to cater for heavy duty mining operations.

offer a fitting solution for heavy-duty loadout and stockpiling operations.

“With a 24,3-t operating weight, a rated payload of 7 t and bucket capacity of 4,57 to 7 m³, the SW978K1 front-end loader is ideally suited for heavy-duty mining and quarrying operations,” says Zhang. “This is a radical upgrade of our existing 5-t SYL956H model, both in terms of the operating weight and features.”

The SW978K1 also speaks to SANY’s recent strategy which has seen the company expanding its load and haul offering with larger models to cater for heavy duty mining operations. As part of the strategy, the company has just brought in its largest mining excavators to date, the 100-t SY980H and the 125-t SY1250H. The new models come hard on the heels of the recent launch of the 70-t SKT105S wide-body dump truck, positioning SANY as a key player in the larger load and haul solutions market.

Efficiency to the fore

According to Zhang, the new SW978K1 wheel loader has a special design focus on high

productivity and lower cost per tonne of operation – key parameters of significance to every fleet owner.

At the heart of the loader is the proven Weichai WP10 engine, which comes with large displacement, power and driving force. With cost of operation in mind, the engine is efficient, is easy to maintain and comes with cost-effective accessories.

Specifically tailored for SANY, the largecapacity 7-t fully automatic gearbox perfectly matches with the engine’s 210 kW @2 200 rpm rated power. Vehicle speed has been increased by 5%, while traction force has gone up to 205 kN, and the overall operating efficiency has increased by more than 10%.

With efficiency in mind, the loader comes with a constant power load-sensitive variable flow system, which uses constant power control and pressure cut-off technology to maximise flow distribution on demand. With the variable piston pump, the machine constantly maintains sufficient power for the application at hand. In shovelling operations, the hydraulic system maintains high pressure and less flow, reducing power losses by 95%, while realising high efficiency- and energy-saving.

Reliability and durability

When designing the SW978K1, SANY also paid particular attention to reliability and durability –two parameters with great influence on machine uptime and longevity. The reinforced front axle, for example, allows for stronger bearing capacity, thus reducing maintenance costs.

“The wheel loader adopts a heavy-duty frame structure design, large articulation, double tapered roller bearings and a thickened steel plate with stronger load-bearing capacity. All these features speak directly to the greater focus on machine reliability and durability,” explains Zhang.

With safety in mind, the machine comes with a fully hydraulic wet brake system, which is sensitive, safe and reliable. The wet brakes run in oil, which keeps them cool, especially in heavy braking applications. Wet brakes generally last

longer, require less adjustment and maintenance over time. The multiple disc set-up also provides more stopping power and improves all around safety.

Operator in mind

To improve operator comfort and consequently productivity, the SW978K1 comes with a newly upgraded cab. The large space provides the operator with a comfortable and safe operating environment, thus ensuring that they remain at their productive best, even when working for long hours. The low noise level of up to 75 dB (A) effectively protects the operator and reduces fatigue.

“The large field view provided by the panoramic front window eliminates obstruction to important sight lines. The reverse monitor enhances the operator’s view of the back of the machine when reversing, thus reducing safety incidents on site,” says Zhang.

The electrical control shift offers smooth operation, while the pilot control offers more precise operation and takes less effort, thus reducing the motions required by the operator during a shift.

Available on rental

To allows customers to put the machine through its paces before they commit to outright purchasing, the new SW978K1 is available on rental through SANY Southern Africa’s rental facility.

“Rental gives customers the opportunity to evaluate the machine before they commit to a big-ticket purchase. Our rental fleet is serviced and maintained by the OEM, allowing fleet owners to eliminate the need to service their own equipment, keeping parts and employing a service team on site,” says Zhang.

In addition, customers will also benefit from SANY’s high inventory of machines. In an environment where customers have to wait for up to nine months for their machines, SANY offers the benefit of short lead times. In fact, customers can walk in and drive out with their machine. a

Customers will benefit from SANY’s high inventory of machines.

KEY POINTS

Zama

Sithole, founder and director of ZN Geo Services

2011

Zama Sithole began her career as a trainee geologist at leading construction materials provider, AfriSam, in November 2011

2017

Driven by her passion to help the industry up its environmental ‘ante’, she decided to establish ZN Geo Services in 2017, and has never looked back

PRESSING AHEAD WITH ENVIRONMENTAL COMPLIANCE

The environmental impact of quarrying activities and opencast mining operations at large cannot be underestimated. However, Zama Sithole, founder of KwaZulu-Natal-headquartered consultancy company, ZN Geo Services, is encouraged by the industry’s newly found focus on environmental compliance. In a one-on-one with Quarrying Africa, she hails the industry for putting the environment at the core of its activities, writes Munesu Shoko.

While quarrying is a vital industry which is critical to the economy of every country, it can be damaging to the environment.

Traditionally, the industry has sometimes been blamed for paying lip service to environmental

compliance. However, the focus on the environment and Environmental, Social and Governance (ESG) issues at large, has grown in recent years and it is now a priority for quarrying companies as they constantly grasp the impact to the long-term sustainability of companies.

This is the view of ZN Geo Services’ Sithole, who has seen a growing consciousness of the criticality of putting environmental management at the core of operations. “There is a growing focus on environmental compliance in the industry. In the past, this was not the case. In the olden days, environmental compliance was done as and when convenient or once the regulatory authorities had issued pre-compliance notices,” she says.

The renewed focus on environmental issues is pleasing to note, she says, adding that even smaller quarrying companies are engaging the services of environmental consultants to make sure that their environmental ‘ducks’ are in a row.

“I am pleased to see that quarrying companies, apart from focusing on occupational health and safety, are becoming increasingly aware of the need for strong environmental management regimes,” she says.

Consulting services

Improving environmental performance requires an appropriate level of understanding and skills which are needed

The focus on the environment has grown in recent years as quarrying companies constantly grasp the impact to the longterm sustainability of companies.

My career began and blossomed in the quarrying sector. I was so fortunate to be afforded an opportunity to work my way up from a trainee to a professional geologist within AfriSam, which had more than 15 aggregate quarries nationally at the time.

to ensure that companies understand their obligations. To help quarrying companies be at the top of their environmental game, Sithole founded ZN Geo Services, and the company has grown its footprint over the years, with projects and clients throughout southern Africa.

A geologist (BSc Honours – UKZN) and environmentalist (MSc – University of Free State), Sithole began her career in the industry as a trainee geologist at leading construction materials provider, AfriSam, in November 2011, before moving to Idwala Carbonates as an environmental officer in 2015. Driven by her passion to help the industry up its environmental ‘ante’, she decided to establish ZN Geo Services in 2017, and has never looked back.

ZN Geo Services offers both geology- and environmental-related services. On the geology front, the company helps companies with mineral exploration, mine planning, compilation of mineral resource statements and general geological consulting.

The environmental portfolio is extensive and includes Environmental Impact Assessments (EIAs), prospecting right applications, mining permit applications, mining right applications, Mineral and Petroleum Resources Development Act (MPRDA) Section 11 transfers, MPRDA Section 102 applications, environmental control officer functions, water use licence applications, auditing, compilation of rehabilitation plans and facilitation of public consultations.

Why quarrying?

The majority of the company’s projects are currently in the quarrying fraternity. “My career began and blossomed in the quarrying sector. I was so fortunate to be afforded an opportunity to work my way up from a trainee to a professional geologist within AfriSam, which had more than 15 aggregate quarries nationally at the time,” she says. “In this role, I largely performed mine planning functions for various quarries.”

The exposure to the quarrying industry during the early days of her career planted her love for the

industry. “My first mine manager, Mpho Dibakoane, imparted extensive knowledge and guidance in mineral processing, plant- and screen-setting, among other functions, which at the time did not seem to be part of my scope, but has since made me an overall miner with a deep understanding of all the processes, from drilling and blasting to load and haul and processing.”

Her time at the Idwala Group, which owns multiple industrial mineral operations, further exposed her to other minerals such as pyrophyllite, thus broadening her knowledge base.

Commenting on some flagship projects she has undertaken thus far, Sithole says one which stands out entailed the imparting of rehabilitation awareness to unskilled and semi-skilled farm workers in northern KwaZulu-Natal.

“This was quite fulfilling,” she says. “In fact, any project that involves any type of teaching or creating awareness warms my heart. If I was not a geologist/environmentalist, I would probably be a teacher. My passion for teaching is probably why I particularly enjoy community engagements and the public consultation scope of EIAs or auditing.”

Women in mining

While greater strides have been made in the industry to promote a more diverse, collaborative mining sector, there is still so much more to be done to afford women the same opportunities as their male counterparts. Sithole believes that there is need to unlearn several employment biases that have hindered the progress or created a glass ceiling for women in the mining sector.

“Revisiting company policies is a great start, but there is a greater need to ‘walk the talk’ in order for change to take place. This needs committed people who can champion the cause, otherwise progressing women in mining will become a ‘pie in the sky’ idea for generations to come. This does not discount the fact that some notable strides have been made, but there is still a long way to go,” concludes Sithole. a

Zama Sithole is the founder and sole director of KwaZulu-Natalheadquartered consultancy company, ZN Geo Services.

BLAST OPTIMISATION PAYS OFF

Due to the complex nature of its geology – characterised by extremely hard andersite rock containing joint planes which damage easily, creating voids on the back and side walls of each blast – AfriSam’s Eikonhof Quarry has traditionally struggled with both big boulders and limited fines in its blasts. In order to overcome the problems, the quarry has implemented a blast optimisation programme with great success. Munesu Shoko was recently on site and filed this report.

Given its impact on all quarry activities, blasting should be given the full attention it deserves in the process development of any quarry. Drilling and blasting influences nearly every aspect of the downstream operations, from load and haul though to crushing and screening. Poor drill and blast,

therefore, leads to poor mine results and expensive operations. This was the overreaching takeaway from Quarrying Africa’s recent visit to Gauteng-based Eikenhof Quarry, where a blast optimisation programme has changed the fortunes of an operation that has traditionally battled to get optimal blast results due to the challenging geological conditions on site.

A blast improvement programme has paid dividends for AfriSam Eikenhof Quarry.

500 MPa

The andersite found at AfriSam’s Eikenhof Quarry is known to be one of the hardest and most abrasive rocks in the world. It is extremely hard, with a UCS of more than 500 MPa and Young’s Modulus of about 100

2,5 m

One of the interventions was to reduce the burden from 2,8 m to 2,5 m between the two back lines of holes when drilling 102 mm holes

KEY POINTS

Eikonhof Quarry has traditionally struggled with both big boulders and limited fines in its blasts

While the andersite at Eikenhof is unusually strong, with a high UCS and high elastic modulus, it also contains joint planes that damage easily, creating voids on the back and side walls of the blast faces, creating large boulders and limited fines in each blast

The objective of the blast optimisation programme, which was implemented in May 2021, was to reduce the proportion of boulders in each blast and to find ways to increase the percentage of fines in the fragmented rock

Following the implementation of the new blast parameters, the proportion of fines in each blast has almost doubled, helping to reduce the bottlenecks related to sand production on site

Blasting at AfriSam’s Eikenhof quarry is outsourced to B&E International

Problem statement

The andersite found at AfriSam’s Eikenhof Quarry is known to be one of the hardest and most abrasive rocks in the world. It is extremely hard, with a uniaxial compressive strength (UCS) of more than 500 MPa and Young’s Modulus of

“The rock structure at Eikenhof

challenging when it comes to blasting. The proportion of big boulders was always between 18% and 22% in each blast, which called for either secondary blasting or mechanical breaking using a hammer

The blast improvement programme has resulted in a significant increase in production.

has always been

Yedwa Christopher Mgxekwa, works manager

about 100, making it very difficult to blast and process. Its density is between 2,85 and 2,92. It therefore requires more explosive energy than granite, for example, to create fresh cracks in the intact rock between joint planes.

Works manager Yedwa Christopher Mgxekwa tells Quarrying Africa that although the andersite at Eikenhof is unusually strong, with a high UCS and high elastic modulus, it also contains joint planes that get damaged easily by creating voids on the back and side walls of the blast faces, creating large boulders and limited fines in each blast.

on the higher benches of the western end of the pit, poor fragmentation has always been experienced in relatively blocky ground, whereas there have been fewer boulders on the lower benches on the south edge of the pit.

50%

The impact of the rock structure is exacerbated by extensive back damage caused by blasting. The damage causes joint planes to open, thus generating a loose matrix of boulders on the free face of each blast, with very little fines.

Due to good fragmentation, Eikenhof has seen a massive 50% reduction in its wear costs

During blasts, the rock breaks preferentially along joints and planes and, therefore, joints would have a greater influence on fragmentation because of the huge difference between the joint strength and the rock strength. Consequently, the energy needed during blasting along joint planes is much lower than the energy required to create fresh cracks in the rock mass.

The rock structure at Eikenhof is quite variable across the pit, with some areas being moderately jointed and others being blockier to massive. In some places, shallow dipping joint planes exist. This complexity in structure led to inconsistent blast results. For example,

“The rock structure at Eikenhof has always been challenging when it comes to blasting. The proportion of big boulders was always between 18% and 22% in each blast, which called for either secondary blasting or mechanical breaking using a hammer,” explains Mgxekwa.

Secondary blasting, he adds, is the most expensive type of blasting. To provide context, it is believed that mechanical breaking of oversize material is four times the cost of the original blast. Secondary blasting also creates excessive noise, and given the quarry’s proximity to communities, with Southfork just about 1 600 m and Eagles Nest just under 1 100 m away, this created unwanted community issues.

“The issue of boulders not only created a cost issue, but also presented safety challenges and

An aerial view of Eikenhof Quarry.

downtime issues at our primary crusher. Having oversized rock in our run of quarry material resulted in incessant blockages at the primary plant. This resulted in safety issues related to the unblocking of the crusher. In addition, the process of unblocking the primary crusher would always cost us between two to three hours of production, depending on the type of blockage,” says Mgxekwa.

Blast optimisation

To get the better of these issues, the AfriSam Eikenhof team embarked on a blast optimisation programme in May 2021, which was led by well-known blasting consultant, Tony Rorke. During a site visit, Rorke got a better understanding of the rock properties and made several recommendations based on his findings.

pressure exerted on the back wall of each blast. Several measures were taken for blasts on the western end of the pit.

With a good proportion of fines in its blasts, the quarry has now doubled its jaw liner life to six months

Firstly, the blasting team had to double delay time between the two back rows. “We also had to reduce the burden from 2,8 m to 2,5 m between the two back lines of holes when drilling 102 mm holes. This provided faster burden response and thus limited confinement and the associated damage,” explains Mgxekwa. “We also had to cut the ends of each blast to an open angle to limit sheering and associated damage at the front corners of the next blast.”

“The objective of the blast optimisation programme was to reduce the proportion of boulders in each blast and to find ways to increase the percentage of fines in the fragmented rock,” explains Mgxekwa. “In order to achieve this, we implemented a range of changes to our blast parameters.”

The main aim was to limit the extent of damage on the back walls, which created a lot of boulders. To achieve this, confinement on the back line of holes was reduced to lower the

To increase the proportion of fines in each blast, one of the recommendations by the blasting consultant was to increase hole diameter from 102 mm to 115 mm. This would increase the velocity of detonation (VOD) and subsequently the shock component during detonation. In turn, this would help to increase the annulus of crushing around each hole and optimise fracture creation in the hard andersite rock.

At the time of writing, however, this recommendation had still to be implemented. The blasting team was awaiting a drill rig that could drill 115 mm holes. “With the current 102 mm holes, we have seen massive improvements to our blast

The rock structure at Eikenhof has always been challenging when it comes to blasting. The proportion of big boulders was always between 18% and 22% in each blast.

Image from a bench face on the northwestern end of the pit showing shallow dipping structures (apparently joint planes) that are pervasive.

results. We are anxious to see what sort of further improvements we will experience once we start drilling 115 mm holes,” says Mgxekwa.

The amount of energy lost through the collars by blow-outs also needed to be contained within each blast. As a result, a 1,5 m stemming length was deemed too short to contain the energy. The blasting consultant therefore recommended an increase in stemming height to 2 m for 102 mm holes.

Massive results

As a result of these interventions, the issue of boulders in blasts is now a thing of the past. The proportion of boulders in each blast has been reduced from the previous 18-22% to less than 1%. “Consequently, we haven’t had a hammer on site for a long time, which significantly reduces the cost of blasting and our fuel burn on site,” says Mgxekwa.

Eliminating boulders in each blast has also translated into no blockages at the primary crusher, thus eliminating previous safety issues related to the unblocking of the jaw crusher, as well as increasing plant uptime and subsequently productivity. In fact, he says, production at the secondary plant section has almost doubled due to better fragmentation.

Due to the abrasive nature of the andersite rock, which makes it a nightmare for every piece of equipment that handles it, the quarry has always struggled with a high wear rate of liners in its primary crusher. Velapi Vilakazi, maintenance superintendent at Eikenhof, notes that following the implementation of the blast optimisation programme, liner usage life has increased significantly.

“Previously, we would change our liners every

three months. With a good proportion of fines in our blasts, we have now doubled our liner life to six months. We have also seen a massive 50% reduction in our wear costs. The increased liner change intervals have also translated into less maintenance time, thus allowing the team to focus on other pressing matters on site,” explains Vilakazi. Good fragmentation has also allowed the team to squeeze more life out of the jaw crusher. In fact, the current primary jaw crusher flywheels were due for replacement in 2022.

“Because of good fragmentation, the jaw is no longer working as hard as before, allowing us to defer the replacement to 2024. We have therefore managed to squeeze more life out of this big-ticket equipment item,” says Mgxekwa.

Due to the lack of optimal blasts, the Eikenhof team has traditionally struggled to produce 22 mm road stone, 7,1 mm concrete stone, and sand. As a result of several improvement efforts in the plant, the constraints around the production of 22 mm and 7,1 mm stone have been sorted out over the past two years. However, the production of sand, which currently constitutes almost 45% of the quarry’s sales, has always constituted a significant constraint.

Following the implementation of the new blast parameters, the proportion of fines in each blast has almost doubled, helping to reduce the bottlenecks related to sand production on site. “Apart from blast improvements, we have also started using poly ripple wire from Multotec on our screens. This has helped us improve the production of 22 mm and 7,1 mm products. The new screen media has helped us double the production of these products,” concludes Mgxekwa. a

To drive efficiencies, the company invested in a new, state-of-the-art static plant in 2017.

AT THE QUARRYING EDGE

To operate profitably in a lowmargin aggregates market, Danoher Group is championing operational efficiencies at its Bloemfonteinbased Bloemspruit Quarry. Adoption of new technologies has helped to improve quality of the product, increase productivity, reduce overheads and, more importantly, improve efficiencies. Munesu Shoko recently visited the quarry and filed this report for Quarrying Africa.

By their very nature, quarries produce high-volume, lowcost material. To run profitable operations, it is critical for quarry owners to find ways to drive efficiencies in every aspect of their operations. Based on that understanding, Danoher

KEY POINTS

Adoption of new technologies has helped to improve quality of the product, increase productivity, reduce overheads and, more importantly, improve efficiencies at Danoher’s Bloemspruit Quarry

In November 2017, the company commissioned a brand new 250 tonnes per hour plant, which has offered several advantages to date

To meet the high demand for washed sand and washed super sand (a high-end fine sand) used by several construction product manufacturers, Danoher invested in a leading-edge 80 tph EvoWash 102 wet processing plant from CDE, becoming the first and only company in the Bloemfontein area to run this type of technology

To further drive efficiencies, Bloemspruit Quarry makes use of Loadrite belt scale technology from Loadtech. This has proved its worth in maximising equipment value by having it employed in the most efficient manner

30%

2017

“We have seen a high demand for our sand, particularly from brickmakers. They prefer it because of its high strength and quality. It is made from virgin blue rock, which is also good for the strength of the bricks.

has heeded the call for innovation to drive productivity and improve efficiencies.

Situated on the outskirts of Bloemfontein, Bloemspruit Quarry is endowed with a highquality, sought-after dolorite rock. Acquired by Danoher in January 2017, the operation produces all aggregate sizes, including crusher dust, washed super sand, 7 mm, 10 mm, 14 mm and 20 mm road and concrete stone, base and subbase materials, as well as specialised products.

Massive investment

During the initial days of Danoher’s ownership, the quarry operated mobile crushing and screening equipment. By November 2017, the

The CDE EvoWash plant has helped increase sand production by 30%, while water usage has gone down by 15%

Acquired by Danoher in January 2017, the quarry produces all aggregate sizes

An aerial view of the pit at Bloemspruit Quarry.

Johann van Niekerk, business manager: Bloemspruit Quarry

The CDE plant produces two grades of sand, compared to only the one grade of sand previously produced by the bucket wheel system.

company had invested in a new, state-of-theart static plant. “From the onset, we understood that for us to run a profitable business, we needed to invest in a new, efficient and flexible 250 tonnes per hour (tph) plant, capable of reacting to fluctuating market demand and supporting bespoke customer requirements,” explains Johann van Niekerk, business manager: Bloemspruit Quarry.

Bearing in mind the constant pounding these machines take, it is good to see how these new crushers and screens, being subjected to a stringent maintenance programme, have proven reliable and less prone to breakdowns, thus bringing about maximum plant availability and productivity. In addition, the new equipment, such as the two Metso HP300 cone crushers, contains the most advanced safety features, thus reducing workplace injuries.

“The investment in a contemporary plant was essential for us to drive productivity, plant uptime, efficiency and ultimately run a profitable business,” says Van Niekerk. “We have seen high levels of efficiency, which makes us competitive in such a cut-throat market.”

High-tech wet processing

To meet the high demand for washed sand and washed super sand (a high-end fine sand) used as input material by construction product manufacturers, Danoher invested in a leadingedge 80 tph EvoWash 102 wet processing plant from CDE, becoming the first and only company in the Bloemfontein area to run this type of technology.

Before investing in the CDE plant in 2020, Danoher previously deployed a bucket wheel system. Traditionally, bucket wheel technology was deemed the mainstay for sand production in South Africa. It was cheap to buy, however, a

major downside was that a substantial proportion of valuable fine sand would be lost to waste dams. In addition, high and variable moisture content and inaccurate material classification were some of the downsides of the bucket wheel that have been addressed by CDE’s cyclone technology. Unlike the bucket wheel, which relies on gravity as the means of separation, CDE’s cyclone technology entails the use of centrifugal force to classify materials.

“We were aware of the quality variability and sand losses we incurred through the old generation washing plant we had. We therefore had to seek ways to maximise our productivity and efficiency in difficult market conditions. With the investment in the CDE plant, we have seen massive benefits in terms of production, efficiency and reliable quality of the product,” says Van Niekerk.

The CDE cyclone technology has been an important technological advancement for the quarry. Firstly, Danoher is now producing two grades of sand – fine (0 - 1,5 mm) and coarse (0-5 mm) – compared to only the one grade of sand previously produced by the bucket wheel system.

More importantly, says Van Niekerk, production is up by 30%, while water usage has gone down by 15%. In addition, the quality of the product has improved significantly, thus setting Bloemspruit Quarry apart from competition.

“We have seen a high demand for our sand, particularly from brickmakers. They prefer it because of its high strength and quality. It is made from virgin blue rock, which is also good for the strength of the bricks,” he says.

[Subhead] More efficiencies

To further drive efficiencies, Bloemspruit Quarry makes use of Loadrite belt scale technology from Loadtech. This has proved its worth in maximising equipment value by having it employed in the

most efficient manner.

The Loadrite belt scales give plant operators and the management team a range of powerful tools to measure the actual production from screens and crushers, analyse plant and machine downtime.

Apart from these technologies, Van Niekerk and his team also pay special attention to their haul roads. Haul roads maintenance, he says, requires a dedicated focus and is addressed on a continual basis as part of the operational cycle, since good roads improve production, extend tyre life and reduce overall operating costs.

500 m

“We haul around 500 m one-way distances from the pit to the processing plant. To optimise our cycle times and our trucks’ fuel-efficiency, and to reduce tyre wear, we have tried to keep our haul roads as straight and free of inclines as possible,” he says.

For its load and haul equipment, Danoher has always preferred Volvo equipment. Two Volvo A30 articulated dump trucks (ADTs) are deployed to haul material from the pit to the processing plant. These are loaded by a Volvo 480 excavator in the pit. Two Volvo wheel loaders, L150 and L190 models, are deployed for stockpiling duties, as well as for loading customer trucks.

“As the Danoher Group, we have always standardised our yellow metal equipment with Volvo. We get a good life out of the machines, while they have over the years proven to be fuel-efficient. Fuel is one of the biggest cost drivers in a load and haul operation, and it is therefore important to pick the best equipment to reduce your fuel bill. After standardising our equipment, spare parts,

For its yellow metal equipment, Danoher has always preferred Volvo.

repair procedures, equipment and repair training have become much less onerous,” says Van Niekerk. “We also get good service from Babcock, which is key to maximising our equipment uptime, productivity and efficiency.”

A strong focus on keeping every part of the business in-house, all the way from drill and blast to load and haul, helps improve efficiencies and reduces the cost of the material for customers. Additionally, this also helps with quality control.

State of the market

Despite the generally depressed market conditions in the South African construction industry, Danoher has grown the Bloemspruit Quarry’s market share which has enjoyed a good market run in the past few months, buoyed by its wide client base and a few road projects in the area. The company’s existing customer base includes aggregate resellers, brickmakers, asphalt plants, readymix plants and property developers, amongst others.

When we visited the site in October, production and sales had reached record production levels.

“The three months between July and September were our best ever. We broke our production record three times in a row. September was our best month, with total sales of nearly 50 000 t, which was quite good for us. We have been fortunate to have the capacity to ramp up and supply a few road projects in the area, without letting our base volume customers down. We are supplying three projects on the N1 South, the R30 and a new project on the R48,” concludes Van Niekerk. a

The production team hauls 500-m one-way distances from the pit to the processing plant

REAPING QUALITY AND EFFICIENCY GAINS

Taking advantage of the vast and homogeneous dolomitic reserve that allows it to spread its wings across several industries, complemented by several efficiency improvement initiatives, PPC’s Mooiplaas Dolomite Quarry is one of a few South African quarries currently producing in excess of a million tonnes a year. By Munesu Shoko.

2,5%

Anything with a silica content of below 2,5% is classified as metallurgical dolomite, and anything above that is considered aggregate material

24/7

To meet the high demand of its products, PPC runs a 24/7 operation at Mooiplaas

Since 2017, the South African construction sector has seen a steady decline in volumes, with the Covid-19 outbreak in 2020 providing a fatal blow to an already ailing industry. That many quarries in the country are in dire straits is no overstatement. In the face of it all, business is still firing on all cylinders at PPC’s Mooiplaas Dolomite Quarry, despite a dip in overall volumes, especially on the aggregates side of things.

The quarry’s key competitive edge is its homogeneous dolomitic reserve, one of the three of its nature in the Gauteng province. Apart from the traditional aggregates market, the dolomitic nature of the rock allows the quarry to supply

three other industries, namely the steel industry (metallurgical dolomite), the chemical industry (metallurgical dolomite powder to fertiliser manufacturers) and agricultural sector (agricultural lime).

“Most of the products we manufacture add real value to our customers’ businesses. For example, due to the cementitious properties of dolomite, many readymix concrete producers prefer our super sand because it helps them reduce both cement and water content in their mixes,” explains Arthur Ndindani, General Manager PPC Aggregate Quarries.

Apart from super sand, Mooiplaas also produces a unique -2mm product, a very fine type of sand mostly used for finishing in the production of paving bricks.

An aerial view of Mooiplaas Quarry after several improvements to the pit.

Even the general aggregate products from Mooiplaas, such as 19 mm, 13 mm, 9,5 mm, 6,7 mm and washed crusher sand are well sought after because of the cementitious values of the rock. This is further complemented by the fact that the quarry washes all its products to improve quality.

Aggregate by its nature is a high-volume, low-margin material and cannot, from a cost perspective, be transported over 80 km. However, because of the high-quality nature of the product, Mooiplaas supplies its aggregates to areas as far as Polokwane, Limpopo (about 300 km) and Nelspruit, Mpumalanga (about 350 km), according to Shadrack Molawa, works manager at Mooiplaas. The metallurgical lime produced here is of very high quality and is supplied to areas as far as Eastern Cape, over 600 km away.

The quarry’s footprint in the agricultural sector also worked to its advantage during the Covid19-influenced hard lockdown in 2020. When all other operations had to close shop, Mooiplaas

KEY POINTS

PPC’s Mooiplaas Dolomite Quarry is one of a few South African quarries currently producing in excess of a million tonnes a year

The quarry’s key competitive edge is its homogeneous dolomitic reserve, one of the three of its nature in the Gauteng province

During the Covid-19 lockdown, the management team had to rethink the business, resulting in a number of efficiency improvements which have had a vast impact on the overall business to date

To further grow its market reach, PPC has broadened its footprint by catering for the informal market

As part of the mine redesign, the mining direction was changed to allow the team to tap into the northward deposit.

was considered an ‘essential service’ operation because it had to continue supplying agricultural lime to the farming community. This placed the business in good stead to survive the pandemic better than traditional aggregates quarries.

Rethinking the business

It was during the Covid-19 lockdown that the management team at this operation also had to rethink its business, resulting in a number of efficiency improvements that have had a vast impact on the overall business to date.

the quarry to shorten the hauling distances.

1-million t

“The year 2020 was undoubtedly one of the most difficult in recent memory. However, it compelled us to find new ways of improving our business in an uncertain environment. In order to tackle this reality, we all agreed that our post-lockdown success lied in efficiency,” explains Ndindani. “We identified some problem areas in our processes and the mining area was our first point of focus. We also realised that improvements in the pit would have a big ripple effect in downstream processes.”

“As part of this process, we also redesigned our haul roads. The hauling distances from the face to the primary tipping point have become shorter, thus improving our cycle times significantly. Previously, we were achieving between seven-and-a-half and eight-minute cycles times, but we have now cut that down to about five minutes. Consequently, our tonnes per hour have jumped from around 550 to 620 tph. We also saw a huge decline in our fuel burn, which reduces our costs significantly, given the soaring prices of diesel,” explains Molawa.

Despite the downward trend in the local aggregates market, PPC’s Mooiplaas Dolomite Quarry is one of a few South African quarries currently producing in excess of a million tonnes a year

As part of the mine redesign (with the help from the group’s mining team) the mining direction was changed. Traditionally, the team had always mined towards the western side. Because of inherent safety issues, the previous mining team put less focus on the north bound section.

Firstly, the team looked at all the factors that affected the tonnes per hour (tph). One of the problem areas identified was the long cycle times, largely due to the long hauling distances from the quarry face to the primary crusher. Consequently, a decision was taken to redesign

“We had to redesign the mine. After the redesign we actually realised that the deposit is outcropping as you move to the north, reducing the amount of overburden we had to strip. By changing the mine design, we have managed to reduce our stripping ratio from the previous 25% to 16%,” explains Ndindani.

Evaluation of blast efficiency

Evaluation of blast efficiency in quarrying, stresses Ndindani, is one of the most important

decisions that should be made by quarry operators for productivity assessment. Based on this understanding, the Mooiplaas team reviewed its blasting practices to improve fragmentation. This has also improved other downstream operations such as load and haul as well as crushing and screening.

As part of the new blasting regime, Mooiplaas adopted electronic blasting, moving away from traditional shock tube technology. The quarry was one of the first operations to adopt BME’s latest generation AXXIS Titanium electronic detonation system. Having been involved in the testing phase of this product well before its commercial rollout last year, the Mooiplaas team experienced first-hand the efficiency benefits of electronic blasting, which outweighed the initial higher capital outlay.

“With electronic detonation, we have managed to improve our blast outcomes, mining efficiencies, environmental impact control and safety. Because of better fragmentation capabilities of this technology, we have managed to increase our burden and spacing, which reduces our powder factor and total metres drilled, thus cutting costs related to drilling and blasting,” says Molawa.

Although Mooiplaas is blessed with a soft rock, the geology traditionally dictated for close burden and spacing using the previous shock tube technology. This is because within the

dolomite itself, there are pockets of soil fissures. If not managed properly, the blasts end up with big boulders which require secondary blasting or further mechanical breaking.

Secondary blasting or breaking of oversize material costs money, and a lot of it. Industry statistics show that it could be as much as four times the cost of the initial blast. With electronic blasting, the soil pockets are easily intercepted without the need to close the burden and spacing, which reduces the overall cost of blasting.

Close cooperation

Working closely with suppliers has been another success factor for Mooiplaas. A significant portion of the processes at Mooiplaas are outsourced to contractors.

Drilling is outsourced to Bustque, which has been on site for many years, while load and haul is done by Alpha Plant Hire. Outsourcing these processes is aimed at a combination of downsizing the company’s fixed costs and reducing capital investments.

“We work closely with our contractors, and they have been part of our optimisation process. They understand what we are trying to achieve. Consultation was a big process of our efficiency improvement programme. For example, we had to demonstrate to the drilling contractor that reducing burden and spacing didn’t necessarily translate into reduced metres drilled. The more efficient we are in all our processes, the more we

Mining contractor, Alpha Plant Hire, has a big focus on efficiency, which speaks to what PPC is trying to achieve at Mooiplaas.

Mining contractor, Alpha Plant Hire, has a big focus on efficiency, which speaks to what PPC is trying to achieve at Mooiplaas.

deplete our run of quarry material on the ground, which increases our drill and blast frequency, thus translating into more business for the drilling contractor,” explains Ndindani.

“On the load and haul side of things, we have brought in a new contractor, Alpha Plant Hire. They have a big focus on efficiency, which speaks to what we are trying to achieve at Mooiplaas. We also involved them in the optimisation process from the start, and they fully understand our goals,” adds Ndindani. “A close working relationship with blasting technology supplier, BME, has also translated into massive efficiency gains. The guidance received from BME has helped us realise the massive gains associated with electronic blasting.”

Market reach

25% to 16%

To further grow its market reach, PPC has broadened its footprint by catering for the informal market. “During the hard lockdown in 2020, one of our resolutions was to approach the informal market. With all the developments happening in the townships, we targeted township brickmakers. The majority of them were not aware that they could buy material directly from us. Because of the cementitious properties in our sand, they have seen massive cost reductions in their brickmaking processes,” explains Ndindani.

After the redesign of the quarry, the team realised that the deposit is outcropping towards the north, reducing the amount of overburden to be stripped. By changing the mine design, PPc has managed to reduce its stripping ratio from the previous 25% to 16%

Blasts are kept large to meet the high demand of material from the various markets. The quarry blasts about 150 000 t of material on the ground every month, with 100 000 t destined for the aggregate market and the remaining 50 000 t to the dolomite market. A chemical analysis is conducted on the material inside the company’s laboratories. Anything with a silica content of below 2,5% is classified as metallurgical dolomite, and anything above that is considered aggregate material.

PPC’s strategy also entails ‘keeping everything at home’. There are two divisions within the company, namely PPC Cement and PPC Materials Division, which consists of PPC Ash, PPC Readymix and PPC Aggregates. The Readymix business is a major volume driver for the other three divisions – Cement, Ash and Aggregates.

While the quarry supplies to various other external customers, PPC Readymix is the largest customer in terms of aggregates. PPC is one of the largest readymix suppliers in the country, with a national footprint of 32 sites. To meet the high demand of its products, PPC runs a 24/7 operation at Mooiplaas. a

GAINING EARLY TRACTION

Following its official local launch in June this year, which marked Liebherr-Africa’s debut in the highly contested ADT market, the award-winning Liebherr TA 230 Litronic articulated dump truck (ADT) has gained early traction in the regional market. By Munesu Shoko.

As part of Quarrying Africa’s Top Launches 2022 series, we have selected the Liebherr TA 230 Litronic as one of the key new arrivals of the year. Featured in our May-June edition of 2022, the 30-tonne (t) class articulated hauler fits the bill for quarrying, coal mining and large infrastructure projects.

Tendayi Kudumba, GM: Earthmoving, at Liebherr-Africa, tells Quarrying Africa that local customers have shown immense interest in the new ADT, with pre-orders dating as far back as last year soon after its global launch.

The Liebherr TA 230 Litronic made headlines after winning the coveted Red Dot Award: Product Design 2021 for its high design quality just a few months after the machine was first unveiled to the public. The award is widely considered to be one of the most important international accolades in the field of design.

The 30-tonne class articulated hauler fits the bill for quarrying, coal mining and large infrastructure projects.

30-t

The new 30-tonne class articulated hauler fits the bill for quarrying, coal mining and large infrastructure projects

Quarrying Africa’s View

Apart from its good looks, the Liebherr TA230 scores with a range of innovative features, which is why it makes the cut as one of our top launches of the year. We are particularly thrilled by the new machine concept, which has been developed especially for challenging off-road applications.

The newly designed articulated swivel joint creates sound off-road capability; it allows independent movement of the front and rear ends, thus ensuring maximum manoeuvrability. The positive-locking swivel joint with tapered roller bearing is perfect for the shear stresses associated with tough underfoot conditions, while it also withstands maximum loads and provides optimal force distribution.

Quarrying Africa

Watch: Liebherr - The new TA 230 Litronic articulated dump truck

Key specifications

Empty vehicle weight 24 600 kg Payload 28 000 kg

Max. trough capacity with tailgate 18,1 m³

Engine power 265 kW / 360 hp

Max. driving speed 57 km/h (forward) / 16 km/h (reverse)

KEY POINTS

For the very first time, Liebherr-Africa will offer an articulated dump truck to its local customers following the official launch of the Liebherr TA 230 Litronic on 24 June 2021

A major talking point is the new machine concept, which has been developed especially for challenging off-road applications

The newly designed articulated swivel joint creates sound off-road capability; it allows independent movement of the front and rear ends, thus ensuring maximum manoeuvrability

The front of the trough – designed for the effective transport of a 28-tonne payload – is straight and the sills are low so that loading with a wheel loader, for example, is easily possible across the entire length

“A combination of balanced weight distribution, permanent 6 x 6 all-wheel drive, solid, flexible mounting and large bank angle as well as the machine’s high ground clearance, enable the TA 230 Litronic to deliver unparalleled performance on uneven terrain.

Tendayi Kudumba, GM: Earthmoving, at Liebherr-Africa

Talking points

Through a range of innovative features, the Liebherr TA 230 ushers in a new era in this market segment. A major talking point is the new machine concept, which has been developed especially for challenging off-road applications. Modern designs in the front-end area, says Kudumba, create maximum ground clearance for greater off-road performance.

The newly designed articulated swivel joint creates sound off-road capability; it allows independent movement of the front and rear ends, thus ensuring maximum manoeuvrability. The positive-locking swivel joint with tapered roller bearing is perfect for the shear stresses associated with tough underfoot conditions, while it also withstands maximum loads and provides optimal force distribution.

The front and rear axles of the machine are secured using sturdy A-rods at the articulated

2021 The Liebherr TA 230 Litronic won the coveted Red Dot Award: Product Design 2021 for its high design quality just a few months after the machine was first unveiled to the public

The front of the trough –designed for the effective transport of a 28-t payload – is straight and the sills are low so that loading with a wheel loader, for example, is easily possible across the entire length.

swivel joint and at the rear end. On front, the truck uses hydro-pneumatic suspension for maximum comfort, which is key to the smooth driving. The shock absorbers at the articulated swivel joint and the position of the separate and oscillating A-rods of the rear axles at the rear end, provide maximum ground clearance.

When developing the new ADT, Liebherr also paid particular attention to the performance of the machine.

12-l

Productivity

As quarrying and mining companies work to rebuild profitability, improving productivity is high on the agenda. With that in mind, Liebherr focused its efforts on maximum productivity when designing the TA 230 Litronic.

Powered by a 6-cylinder Liebherr engine with a 12-l displacement, producing 265 kW of power, the TA 230 Litronic is driven by an automatic 8-speed powershift transmission which ensures optimal force distribution.

The new Liebherr dump truck impresses with great driving performance and massive pulling force, even in the most difficult ground conditions and on challenging gradients. “A combination of balanced weight distribution, permanent 6 x 6 all-wheel drive, solid, flexible mounting and large bank angle as well as the machine’s high ground clearance, enable the TA 230 Litronic to deliver unparalleled performance on uneven terrain,” says Kudumba.

The actively controlled inter-axle differential locks mean that the Liebherr TA 230 has automatic traction control. As soon as one axle experiences wheelspin, it is decelerated, and the traction is intelligently redistributed to the other axles. In addition to maximum forward drive, this reduces the power requirement and therefore translates into lower fuel consumption.

Efficiency is further enhanced by the smart gear selection, which enables the machine to adjust automatically to its current speed and load to ensure optimum torque and fuel consumption at all times. The machine therefore automatically reduces its fuel consumption per tonne of transported material.

The optimised trough ensures that more material can be moved in a short time. The front of the trough – designed for the effective transport of a 28-t payload – is straight and the sills are low so that loading with a wheel loader, for example, is easily possible across the entire length.

A standard Liebherr weighing system shows the current payload during loading on the display in the operator’s cab, helping eliminate guesswork in loadout processes. An optional loading light on both sides at the back of the operator’s cab shows the loading level outdoors.

In order to accelerate the release of the material during unloading, the inner edges of the new trough are tapered. The two tipping cylinders at the side give the TA 230 Litronic high tipping pressure. The load can be tipped against the slope easily and quickly.

“During transportation, the long chute at the end of the trough ensures minimal material loss. The trough volume can be increased with the optional tailgate,” explains Kudumba. “Thanks to the large opening width, tipping of large and bulky transported material is easily possible. Even with the tailgate the overall width of the TA 230 Litronic is still below three metres, which allows the machine to be easily and quickly transported on a lowbed truck.”

In a world where data is king, the TA 230 comes with LIDAT, Liebherr’s data transfer and location system, allowing fleet operators to manage, monitor and control their fleets efficiently. All the main machine parameters can be viewed at any time using a preferred web browser. a

www.quarryingafrica.com

The machine is powered by a 6-cylinder Liebherr engine with a 12-litre displacement, producing 265 kW of power

The 42-t class ADT made its debut on 26 July 2022 at a launch event held at AfriSam’s Jukskei quarry in South Africa.

USHERING IN A NEW ERA IN HAULING

Launched in July 2022 as part of John Deere Africa Middle East’s (AME) rollout of production class equipment in Africa, the new 460E-II articulated dump truck (ADT) fits the bill for quarrying and high-production mid-tier mining operations. The machine pushes the boundaries with a distinctive design focus on increased productivity, economy, performance and lower total cost of ownership. By Munesu Shoko .

For its range of innovative features, the 460E-II makes the cut as one of Quarrying Africa’s top launches of 2022. The 42-tonne (t) class ADT made its debut on 26 July 2022 at a launch event held at AfriSam’s Jukskei quarry in South Africa. Griffiths Magkate, sales manager Construction

and Forestry AME, tells Quarrying Africa that the 460E-II ADT is the culmination of a thorough research and development (R&D) regime, informed by customer needs.

“Given the importance of the ‘voice of the customer’ in today’s equipment designs, the development of the 460E-II ADT was informed by customer feedback.

7%

In a comparison between the E Series truck and the new E Series II, it is apparent that customers can enjoy up to 7% fuel efficiency gains in Normal Mode

12%

Eco Mode, which conserves fuel by managing engine power delivery and enhancing transmission response for applicable conditions, further improves fuel consumption by up to 12%

John Deere spent considerable time talking to customers to find out what they needed, wanted and expected from the product. We believe that the 460E-II ADT is everything that the market wants from an ADT today, ticking all the right boxes, from increased productivity and uptime to efficiency and lower total cost of ownership,” says Magkate.

Efficiency to the fore

One of the enhancements that will be of great interest to mines and quarries is the ADT’s fuel efficiency, especially considering the high fuel prices in South Africa and the region at large. At the centre of the truck’s fuel economy are the three different drive modes – Normal, Economy and Traction – which help optimise the drivetrain, reduce input from the operator and enable easy customisation.

In a comparison between the E Series truck and the new E Series II, it is apparent that customers can enjoy up to 7% fuel efficiency gains in Normal Mode. Its Eco Mode, which conserves fuel by managing engine power delivery and enhancing transmission response for applicable conditions, further improves fuel consumption by up to 12%. Eco Mode is ideal for instances where the ADT does not always have to travel at full throttle moving at top speed. This is often the case when there are many trucks in a normal haul cycle.

KEY POINTS

Key to increased productivity is the redesigned dump body, which is wider and has a lowered and levelled rail height to improve material retention and allow it to be easily loaded

Key to increased productivity is the redesigned dump body, which is wider and has a lowered and levelled rail height to improve material retention and allow it to be easily loaded

All service points are reachable from ground level. At the front of the truck are side doors, a front panel and a bonnet, which provide access to all major service points.

In Traction Mode, the truck locks up four differential locks – one in each axle and one in transmission, thus allowing a fully loaded ADT to travel as smoothly and efficiently as possible, even in tough underfoot conditions. The new wheel-speed sensors also provide a more accurate reading than the ground-speed radar to confirm that the traction-boosting auto-differential lock engages when needed.

“The 460E-II is powered by the 13,5-litre John Deere PowerTech 6135 engine which is also fitted in other large John Deere construction machines, agricultural tractors and combined harvesters for greater parts’ commonality. The transmission is a ZF 8 EP 420 designed specifically for ADT applications and thrives in long, hard and fast hauling. The top gear sets are countershaft type, more suited for high RPM, low torque from the engine. The lower gear sets are planetary type and are suited to

The 42-tonne (t) class ADT made its debut on 26 July 2022 at a launch event held at AfriSam’s Jukskei quarry in South Africa

Watch: John Deere Africa Middle East | 460E Series II ADT

Key to increased productivity is the redesigned dump body, which is wider and has a lowered and levelled rail height to improve material retention and allow it to be easily loaded.

lower RPM and high torque generated by the transmission,” explains Marshall.

Productivity

The 460E-II also has a special design focus on productivity. The machine, says Marshall, has the largest bin capacity and payload of all ADTs in this size class. With a payload of 41 820 kg, the truck has 800 kg more payload than the nearest competitor offering in this size range.

Based on John Deere’s understanding that a comfortable operator is a productive one, the 460E-II casts the spotlight on operator comfort. The cab, says Marshall, is the most important part of the truck for operator comfort.

41 820 kg

“Key to increased productivity is the redesigned dump body, which is wider and has a lowered and levelled rail height to improve material retention and allow it to be easily loaded. Additionally, the bin rail features an angled top, helping to reduce material spillage while travelling,” explains Marshall.

With a payload of 41 820 kg, the truck has 800 kg more payload than the nearest competitor

“Operators are in their cab all day long – spending anything between 10-12 hours in it. It is therefore important that their working environment be comfortable, which is also key to productivity on site. With that in mind, the 460E-II’s updated operator station includes features that promote increased productivity and all-round comfort. One of the notable features is the single switch model, which reduces the number of switches by 25% compared with previous models,” explains Marshall.

The 460E-II model is also available with a new ejector body solution, which allows operators to spread a load over a given area and which can be used in areas with overhead power line concerns or where the risk of rollover is high due to steep grade unloading.

The quiet, pressurised cab also features a new, easy-to-read monitor and rear camera display, along with options such as the premium heated/ventilated seat and automatic control (ATC) system.

In addition, subscription to John Deere’s

offering in this size range

JDLink™ telematics system is available free of charge to users. JDLink allows owners and managers to connect to their machinery remotely, to help monitor and track operations and productivity.

Ease of service

With uptime in mind, John Deere paid particular attention to ease of service during the design of the new ADT. All service points are reachable from ground level. At the front of the truck are side doors, a front panel and a bonnet, which provide access to all major service points.

Quarrying Africa’s View

The 460E-II also has a special design focus on productivity.

To further improve service access, the front suspension travel can be decreased at the push of a button to bring service points closer to the ground. As part of the enhancements to the new range, John Deere has also reduced over 10% of the hose connections and electrical routings, making the 460E-II one of the most serviceable trucks on the market.

An optional factory-installed auto lube system with ground refill is electrically powered and integrated with machine diagnostics in order to help verify that daily maintenance is being performed. In addition, diesel exhaust fluid (DEF) refills are also easily accessible at ground level. a

As quarries seek to improve their businesses, the 460E-II’s distinctive design focus on increased productivity, economy, performance and lower total cost of ownership is a big appealing factor for the industry.

At a time when the industry seeks to optimise efficiency at every opportunity, we are particularly impressed by up to 7% fuel efficiency gains in Normal Mode. Bear in mind that in Eco Mode, customers can expect up to 12% fuel savings. With a payload of 41 820 kg, the 460E-II is said to have 800 kg more payload than the nearest competitor offering in this size range, thus increasing productivity.

Quarrying Africa

SCREENING ACROSS APPLICATIONS

Amid increasing demand for scalping screens across all tiers of the crushing and screening market, Pilot Crushtec International launched Metso Outotec’s Lokotrack ST2.3 in southern Africa

earlier this year. A key talking point is the machine’s ability to process various feed materials across both primary scalping and fine screening applications. By Munesu Shoko.

In June this year, Pilot Crushtec debuted the ST2.3 scalping screen in southern Africa. Due to a number of innovative features, the screen makes the cut as one of our top launches of the year.

While scalping screens have long been a prominent fixture in aggregate processing plants, they have always been located early in the flowsheet for ‘scalping’ oversized material for further processing, explains Francois Marais,

sales and marketing director at Pilot Crushtec.

However, due to their continued evolution in recent years, scalping screens are gaining prominence in both heavy duty scalping and fine screening applications. Their adaptability speaks in particular directly to contractors who are increasingly on the lookout for versatile solutions that can be deployed across various processes and applications.

Contractors know that every jobsite is different. However, they are also aware

The new Lokotrack ST2.3 mobile scalping screen is the most compact mobile screener with wide screen and aggressive stroke.

Watch: Lokotrack® ST2.3™ mobile screenerin action

Weighing in at 17 t, the machine comes with a 3 m long x 1,5 m wide screen box

4,6 m²

Despite its compact build, the Lokotrack ST2.3 punches above its weight with a 4,6 m² screening area, said to be the widest in this size class

KEY POINTS

The Lokotrack ST2.3 sets new standards in versatility with its ability to process various feed materials across primary scalping and fine screening applications

It can be used as a standalone unit or as part of a multi-stage crushing and screening process

The machine is designed to process a range of materials, from topsoil and recycled concrete waste, to road base material and fine aggregates. It can also be deployed in commodities such as diamonds

Its versatility is enhanced by the various screen media options, including grizzly, punch plate, finger grizzly, piano wire and wire mesh

that they don’t have the luxury of purchasing specific pieces of equipment to match the needs of every project. With a growing requirement to do more with less, they can take advantage of the Lokotrack ST2.3 scalping screen’s versatility, which allows it to be adapted, and to deliver the desired results on a broad range of applications.

“Traditionally, aggregate producers and mines have always used finishing screens to size their final product. In the past five years, we have seen the trend shifting to using scalping screens to perform this function,” says Marais. “The major difference between a traditional screen and a scalping screen

is that the latter can take a much bigger feed size than the conventional screen. Where a traditional screen accepts a 100 mm feed size, for example, a scalping screen can take up to 400 mm size material.”

A key benefit of scalping screens, adds Marais, is their versatility. They can be used as initial sizers to remove oversize pieces of material from the feed, or they can do fine screening. The Lokotrack ST2.3 scalping screen is a multi-use scalping screen perfectly suited to heavy duty scalping, fine screening and recycling. The machine is designed to process a range of materials, from topsoil and recycled concrete waste, to road base material and fine aggregates. It can also be deployed in commodities such as diamonds.

“The machine is versatile in terms of who can use it, where they can use it and in what applications they can use it. For that reason, we believe that it’s going to be a popular product in the market, especially for entry level and midrange contractors, as well as junior miners doing exploration work, for example,” says Marais.

It can be used as a standalone unit or as part of a multi-stage crushing and screening process. Its versatility is enhanced by the various screen media options, including grizzly, punch plate, finger grizzly, piano wire and wire mesh.

“Pilot Crushtec supports all these various media types. We also have some innovative ones such as heavy-duty fingers or forged tynes,” adds Marais.

This mobile screener can be used as a standalone unit or as part of multi-stage crushing and screening process.

The ST2.3 can be easily transported in one piece between sites. The set-up is quick and easy with hydraulic functions and visual indicators.

Key specs

Weighing in at 17 tonnes (t), the machine comes with a 3 m long x 1,5 m wide screen box. Despite its compact build, the Lokotrack ST2.3 punches above its weight with a 4,6 m² screening area, said to be the widest in this size class. This is complemented by an aggressive stroke up to 13 mm with 5G acceleration, resulting in a high screening performance.

“There is also a variable inclination on the screen box, so depending on application, operators can change the angle of screening from 13 to 25 degrees,” says Marais.

conveyor, which is pretty common in largesized scalpers, making the Lokotrack ST2.3 more attractive, especially in applications with large-sized material.

13 mm

The Lokotrack ST2.3 is equipped with a 1,2 m-wide belt feeder and a hopper capacity of 5 m³, which is considered to be ground-breaking for a machine of its size. The machine also comes with a 1,2 m wide oversize

Quarrying Africa’s View

“Another key feature of this machine is the impact bed located at the discharge point of the screen, which is not common for most screens. This results in a longer lifespan for the conveyor. The fines and mid-size belts are both 650 mm wide, with adjustable heights and speeds to suit different applications,” says Marais. Amid record high fuel prices, fleet owners will also benefit from the machine’s fuel efficiency. Powered by a CAT C3.6 diesel engine producing 55 kW of power, the machine consumes as few as eight litres of fuel per hour, translating into lower total cost of operation. a

Brought in to plug a product gap in the entry-level contractor market, you could think of the ST2.3 as the ‘Swiss Army Knife’ of screening, given its ability to process various feed materials across both primary scalping and fine screening applications.

In addition, contract crushing is a nomadic venture by its nature, which often calls for moving of machines from one site to the other. With that in mind, Metso Outotec paid particular attention to ease of transportation during the development of the Lokotrack ST2.3 scalping screen.

With its compact dimensions (11 m long x 2,8 m high x 2,2 m wide) and optimised weight (17 000 kg), the machine can be moved from one site to another using a standard trailer, with no need for abnormal load permits, thus helping contractors cut back on transportation costs.

Quarrying Africa

An

The increased undercarriage dimensions (for stability) allows the machine to work with a larger bucket (2,4-4,2 m³ capacity).

For any mining or quarrying project, machine reliability, high production and high efficiency for both cost and environmental reasons, are non-negotiables. While delivering on all these parameters, the new Volvo EC550E crawler excavator, now available with a Tier 3 engine for Africa and the Middle East, also breaks the industry norm of production having a direct link to operating weight.

Breaking the norm

Traditionally, the excavator’s production has a direct link to its operating weight. With the EC550E, Volvo CE managed to break the norm by introducing the Independent Metering Valve Technology (IMVT) hydraulic setup, in conjunction with a totally new engine trim on the D13 engine block and electrohydraulic command for the joysticks. As a result, the machine punches well

By Munesu Shoko.

Watch: The Volvo EC550E crawler excavator

35%

The 35% greater production is made possible by the larger bucket (+25%) and the faster cycle times (+10%)

22%

The main control valve uses IMVT, which provides significantly more precise control compared to a conventional system and contributes towards up to a 22% improvement in fuel efficiency

above its weight, offering production more in line with a bigger class machine, despite the decals stating 55 t.

“We were able to accommodate a larger bucket (2,4-4,2 m³ capacity) by increasing the size and weight of the undercarriage, which gives greater stability. The more stability you have, the bigger buckets you can put on – it is the law of physics. By load distribution surface/ footprint of the undercarriage, the EC550EL has almost an identical size to some competitor 70 t machines,” says Olle Watz, product manager – Excavators, Volvo Construction Equipment Region International.

“The EC550E is well in line with heavier operating weight machines,” adds Watz. “In mass excavation (ME) configuration, it can even challenge bigger class competitors. For a typical ME machine, at 6 m reach, 1,5 m elevation – in other words where stability really counts – you have a lift value of 17 910 kg across tracks. This is, by kilos, comparable to certain 70 t competitor offerings,” he says.

The three-point right-hand access ensures the upper structure can be accessed with confidence when needed.

The 2071 Nm (320 kW) engine, with rated power @1 600 rpm, is also well in line with certain competitor 70 t machines. This, coupled with the large displacement pumps (832 litres per minute), results in faster cycle times. For most competitor offerings in the bigger class, says Watz, one needs to rev the engine at 1 800 rpm to reach the maximum power. Low revs are generally good, so

KEY POINTS

Volvo Construction Equipment has expanded the distribution of its EC550E crawler excavator to Tier 3 markets of Africa and the Middle East

Armed with high levels of power and productivity, the EC550E is suited for mining, mass excavation and large infrastructure projects

The machine breaks the industry norm of production having a direct link to operating weight

With the ability to fill a 35-40 t hauler or highway truck in just four to six buckets, the result is optimum pass-matching and high-levels of production at a low cost per tonne

the EC550E has the upper hand here.

“Experienced people tend to be relatively more interested in torque than power when it comes to large excavators. Torque is more about force, and power is more about speed – and typically excavator force can be more a priority than speed, subject to application. However, you cannot see torque in isolation. The EC550 is fitted with large displacement pumps, matched to the capabilities of the engine. So, you can also get high flow/fast cycle times at the same time as when operating at a high torque,” explains Watz.

High productivity

Ideal for mining/quarrying, mass excavation and large infrastructure projects, the EC550 can fill a 35-40 t hauler or highway truck with just four to six buckets. The result is optimum passmatching and high production at a low cost per tonne.

The EC550E can fill a Volvo A35G or A40G articulated hauler with four to six buckets, which is considered a well-balanced match in the industry. It also means that Volvo now offers two perfect match excavators for A35G or A40G haulers in Africa – the EC750D and the EC550E.

While Volvo’s existing EC480D model is aimed at customers looking for an efficient and reliable 50 t class excavator, the EC550E offers 35% greater production than the EC480D in typical dig and dump applications, meaning it is closer to the EC750D and so challenges the 60-65 t excavator class.

“As quarry and opencast mine operators seek to increase their tonne per hour and lower their cost per tonne, while reducing their environmental impact, pass-matching is especially important. Matching the size and capacity of the loading machine to the hauler shortens cycle times and minimises idling for greater productivity, lower fuel consumption and lower emissions. Essentially, it avoids unnecessary waste of time, fuel and money,” says Watz.

Away from the machine, the EC550E is available with a range of optimum-sized heavy-duty rock buckets designed for use in abrasive conditions,

with the Volvo Tooth System making light work of teeth replacements thanks to its place, push and click functionality.

Efficiency

Customers can take fuel efficiency to a new level thanks to the next generation electrohydraulic system with IMVT and engine/pump optimisation, which lowers engine rpm while optimising power. The main control valve uses IMVT, the latest pioneering innovation from Volvo, said to be the most high-performing hydraulic system in the industry. It provides significantly more precise control compared to a conventional system and contributes towards up to a 22% improvement in fuel efficiency.

“The IMVT is probably the biggest news as it is an industry first in this excavator size class. It involves a new concept main control valve (MCV). Instead of a conventional spool-type MCV, we have built an MCV with dedicated valves – one each for feed and return for each actuator. This means that the pumps pump exactly according to demand at any given time, subject to the precise and exact requirement of oil for any specific actuator,” says Watz.

This, he adds, eliminates hydraulic losses, delivers increased fuel efficiency and unparalleled level of command of the machine. The system does not only cut fuel consumption for mining contractors, but it also reduces carbon (CO2) emissions significantly. Operators can achieve production that is close to the 70 t mark but without the fuel consumption that comes with a 70 t class machine.

To support the fuel-efficient performance of the machine, Volvo offers a range of services to help customers reduce the fuel expenditure and carbon emissions of their operations even further, including Fuel Efficiency Reports and operator training initiatives. Using Volvo Site Simulation, Volvo dealers can also help customers to optimise site productivity and lower their total cost of ownership, by providing recommendations on the best fleet configuration and site set-up to maximise profitability. a

Quarrying Africa’s View

Following its global debut at the start of this year, Babcock has recently announced that the much-awaited Volvo EC550E crawler excavator is now available in southern Africa. A major talking point for us is the new 55 t class machine’s ability to deliver up to 35% more productivity and a 22% improvement in fuel efficiency, which is good news to every fleet owner.

We also commend Volvo CE for breaking the weight-productivity norm. As a result, the machine punches well above its weight, offering production more in line with bigger class machines in the 60-65 t range, despite the decals stating 55 t.

Quarrying Africa

MEETING BIG CRUSHING REQUIREMENTS

400 mm

The jaw takes a maximum feed size of 400 mm

162 kW

Powered by a Volvo diesel engine producing 162 kW of power, the machine is tipped to be a hit with customers in the local market due to its lower fuel consumption. The patent ECO setting brings fuel burn to below 10 litres per hour, depending on application

Earlier this year, Kemach Equipment introduced the new McCloskey J35R to the local market. The compact jaw crusher impresses with its ability to meet big crushing requirements at sites where space is at a premium. It fits the bill for small-scale recycling contractors seeking a solution for crushing both abrasive and non-abrasive materials, writes Munesu Shoko.

Suited particularly to construction, demolition recycling, asphalt recycling and aggregates, the J35R compact jaw crusher is the perfect solution for projects with small footprints but big requirements, states Bradley Karolus, sales specialist at Kemach Equipment. Speaking to Quarrying Africa, Karolus says the J35R addresses a special need in the market, especially in the recycling industry

where impact crushers have traditionally been the only available solution for small-scale projects. The downside is that impact crushers are better suited to non-abrasive material, which makes it difficult for contractors to deploy the same machines to crush abrasive material.

“With impactors, contractors are limited to less-wearing material, such as coal and rubble. It becomes difficult when they win contracts to crush high-wearing material such as blue rock and

26,5 t

Weighing in at 26,5 t, the J35R is said to be one of the first jaw crushers of its weight and size in the market with a large opening of 900 × 600 mm

2,5 m

Less than 2,5 m wide, the crusher can be transported easily from site to site

KEY POINTS

Suited particularly to construction, demolition recycling, asphalt recycling and aggregates, the J35R compact jaw crusher is the perfect solution for projects with small footprints but big requirements

The J35R offers the best of both worlds – it allows contractors to move between abrasive and non-abrasive jobs using one machine

The machine is said to be the only jaw of this size to have the recirculating option

Powered by a Volvo diesel engine producing 162 kW of power, the machine is tipped to be a hit with customers in the local market due to its lower fuel consumption

Key specs

Model

The J35R compact jaw crusher is the perfect solution for projects with small footprints but big requirements

chrome slag. These materials are high-wearing because of their abrasive nature and are therefore suited to a jaw crusher. From a cost perspective, deploying an impact crusher in abrasive applications is not a good idea, because your cost per tonne will increase,” explains Karolus.

The J35R offers the best of both worlds – it allows contractors to move between abrasive and nonabrasive jobs using one machine.

Features and benefits

Weighing in at 26,5 t and less than 2,5 m wide, the J35R is said to be one of the first jaw crushers of its weight and size in the market with a large opening of 900 × 600 mm. The jaw takes a maximum feed size of 400 mm, with a minimum closed side setting (CSS) of 40 mm. It has a production capacity of between

McCloskey J35R

Production capacity 250-300 tph

Maximum feed size 400 mm

Weight 26 500 kg Transport Width 2,4 m

Engine Volvo (162 kW)

250 and 300 tph.

The J35R can easily crush and move at the same time, ensuring maximum mobility and productivity on project sites. A two-speed system is selectable at the control panel which enables a smooth start/stop.

The machine is said to be the only jaw of this size to have the recirculating option. The recirculation conveyor allows operators to produce a crushed and screened final product using only the one machine.

“Combining the productivity of the J35R with the versatility of a full screening and recirculating system allows operators to produce a crushed and screened final product with just one machine,” he says. “This design approach makes the process cost-effective by removing the need for two separate machines.”

Another key talking point is the post screen, which offers a number of benefits. With a 55 mm mesh, for example, the post screen allows contractors to produce G5 material without having to close the CSS beyond its design limits.

“Traditionally, contractors have had to close the jaw’s CSS beyond its tolerance levels to enable them to produce G5 material, which has proved detrimental to the life of the machine,” he says.

In addition, because of the post screen, contractors can now

Powered by a Volvo diesel engine producing 162 kW of power, the machine is tipped to be a hit with customers in the local market due to its lower fuel consumption.

feed a vertical shaft impact (VSI) crusher directly from a jaw. Previously, this was not achievable as the topsize from a jaw is too big to report directly to a VSI before further reduction. The post screen allows operators to control the size of the product that goes into the VSI. This reduces the number of machines required in the train, translating into lower wear and running costs.

Powered by a Volvo diesel engine producing 162 kW of power, the machine is tipped to be a

hit with customers in the local market due to its lower fuel consumption. The patent ECO setting brings fuel burn to below 10 litres per hour, depending on application.

Less than 2,5 m wide, the crusher can be transported easily from site to site. Because it weighs less than 30 t, no special permits are required to transport it between jobsites. This is particularly beneficial for contractors who have to move from one job to the other. a

Kemach Equipment has brought in the first J35 unit in the country.

CHANGING THE FACE OF BLASTING

At the beginning of 2022, blasting and explosives solutions provider BME launched its flagship AXXIS Titanium™ detonation system, which is set to change the face of blasting. Not only has the system pushed the boundaries of safety within blasting, but it has shown to positively improve mines’ operational efficiencies.

The Omnia-group company has already achieved significant milestones since introducing the system to the mining industry, confirms Tinus Brits, BME global product manager – AXXIS. These include the initiation of record blasts, the exciting testing of the system’s capabilities and taking this innovative system into new markets.

“Since introducing the AXXIS Titanium – as well as the smaller AXXIS Silver, which caters

for the quarrying and construction market – BME has been conducting trial blasts across South Africa,” says Brits. “Many mining companies have already made the switch to our latest electronic detonation system, considered to be one of the safest systems available.”

Big blasts

The switch to electronic detonators has also allowed for more controlled blasting in sensitive settings. BME’s AXXIS support

BME designs its electronic detonators so that key blast impacts are both measurable and predictable.

5 or 6 holes

Electronic detonation systems allow detonators to be accurately initiated within milliseconds of each other, staggering the energy release rather than having five or six holes detonating at the same time

50°C

The detonators were tested at -50°C at an accredited testing facility in the United States

5 209

To date, the company’s biggest blast was achieved at a chrome mine in South Africa’s North West Province, when a blast of 5 209 detonators was conducted

KEY POINTS

Since introducing the AXXIS Titanium – as well as the smaller AXXIS Silver, which caters for the quarrying and construction market – BME has been conducting trial blasts across South Africa

Several mining and quarrying companies have already made the switch to BME’s latest electronic detonation system, considered to be one of the safest systems available

The switch to electronic detonators has also allowed for more controlled blasting in sensitive settings

To meet the demands of growing business opportunities in colder climates, AXXIS has now also been certified for cold weather applications in the United States

“

The market appreciates the speed at which you can now fire a blast. After the detonators have been programmed, you can start up the controller from the view site and blast within two minutes.

Several mining and quarrying companies have already made the switch to our latest electronic detonation system, considered to be one of the safest systems available.

“

Tinus Brits, BME global product manager – AXXIS

Hennie du Preez, BME’s AXXIS support manager

manager Hennie du Preez highlights that the company recently undertook a blast in an industrial area in Gauteng for a construction project, with no damage to surrounding buildings.

As mining becomes more difficult or edges closer to communities, mines need to control their blasting better. Brits explains that electronic detonation systems play an important role in achieving safe blasting.

“They allow detonators to be accurately initiated within milliseconds of each other, staggering the energy release rather than having five or six holes detonating at the same time,” he notes. “By reducing the charge mass per delay, electronic systems can reduce the resulting vibration.”

He explains that BME designs its electronic detonators so that key blast impacts are both measurable and predictable.

“With our integrated blast planning software, mines can simulate each blast before it is implemented,” says Brits. “This means that they can predict aspects such as ground vibration to ensure it will be within the required parameters.”

He adds that this allows users to establish how fast they would be able to fire a blast, with the logged data from the detonators stored into the memory of the blasting box.

“As this data is now available to miners and managers, they are able to download important

information directly after a blast,” he says. “The data informs them of the number of detonators that have been fired and how many – if any –detonators have been damaged.”

Du Preez concurs, noting that the blast preparation functions being built into the logger can now do the programming, scanning and testing.

“The market appreciates the speed at which you can now fire a blast,” he says. “After the detonators have been programmed, you can start up the controller from the view site and blast within two minutes.”

To date, the company’s biggest blast was achieved at a chrome mine in South Africa’s North West Province, when a blast of 5 209 detonators was conducted.

Testing versatility

To meet the demands of growing business opportunities in colder climates, AXXIS has now also been certified for cold weather applications in the United States.

“A client requested that we blast in challenging conditions, including -40 °C temperatures,” says Brits. “We then tested the detonators at -50°C at an accredited testing facility in the United States.”

He explains that the testing required the AXXIS detonation system, loggers and detonators to be frozen in the testing facility, and then used in a blast.

The AXXIS Silver is a cost-effective solution for operations with less demanding blasting needs.

“Our blasting boxes and loggers were frozen around five or six times during testing, but remained in perfect condition, with technicians carrying out normal blasts without hassle,” he adds.

BME will continue to undertake further cold weather field condition trials with their detonation systems.

Reaching new heights

Following its recent success in initiating an AXXIS Silver blast in Lesotho – its first outside of South Africa – Brits notes that the company

Quarrying Africa’s view

The logger is a hand-held device for logging and testing of the detonators.

is enjoying a growing interest in its products in the Australian and Indonesian regions.

“BME introduced the AXXIS Silver detonation system to the Australian market about a month ago and has already seen some significant blasts,” he says. During one of the blasts, the detonators were submerged under water and mud for four days due to heavy rains with no errors or leakage experienced on the day of the blast.

The company will continue its growth strategy into new and emerging markets in 2023, including the Northern Cape and Western Cape provinces, Namibia and Zambia. a

As quarries further embrace modern technology, there is an apparent increased uptake of electronic blast detonation systems. QA is particularly impressed with the new AXXIS Silver digital initiation system from BME, which we believe is a step-change in efficient and safe blasting for quarries and small-scale mining operations.

While the AXXIS Titanium allows for large blasts of up to 20 000 detonators, the AXXIS Silver is designed for up to 1 600 detonators – 800 per blast box, which is more than enough for the quarrying industry’s blasting requirements.

The accuracy of detonation delays has been enhanced, reaching 0,0067% firing accuracy for consistent quality blasting that results in optimal rock fragmentation and consistency. The programmability of 15 seconds with 1-millisecond intervals allows for blast designs to be precision-designed, resulting in better fragmentation. Based on these outstanding capabilities, BME’s AXXIS is definitely one of our top launches of the year.

Quarrying Africa

NEW PAYLOAD BENCHMARK

Thanks to its ground-breaking 38-tonne (t) bogie which allows for a gross combination weight of up to 150 t, the new Volvo FMX – launched locally by Volvo Trucks South Africa – sets a new payload benchmark in the mining tipper market. By Munesu Shoko.

In the quest for increased cost-efficiency and productivity, there is a deliberate migration from traditional dump trucks to construction-type mining trucks at some of the local quarrying and surface mining operations.

In quarrying and mining, articulated dump trucks (ADTs) have always been the go-to solution for arduous in-pit duties such as hauling run of mine (ROM) material from the quarry/mine face to the processing plants. Understandably, the ADT’s prowess in such tough underfoot conditions is unparalleled. While tipper trucks are a common sight on quarries, they have traditionally been relegated to light duty applications such as re-handling of ore and hauling of crushed material from the crushing plants to stockpiles, for example.

As cost pressures bite, quarries and mines continue to embrace new ideas. As part of this mindset shift, there is a growing acceptance

of construction-type mining trucks, which are proven to be cheaper than dumpers – both to buy and to operate.

As this shift towards mining tippers gathers pace, Volvo Trucks South Africa has brought in what it believes to be a game-changer. The all-new Volvo FMX – which made its local debut late last year – sets a new benchmark with the heaviest axle in its class, which results in increased payload.

New payloads

Eric Parry, senior manager: Sustainability at Volvo Group Southern Africa, says there has been a huge interest in the new truck since its launch last year. A couple of units are already in operation in South Africa, with several more on the way.

A key differentiator, explains Parry, is the brand-new heavy-duty axle designed in conjunction with sister company, Volvo

The Volvo FMX being put through its paces at a hematite and fluorite ore operation in Limpopo, South Africa.

20 t

With increased front axle loads of up to 20 t and a 38-t rear bogie, the new Volvo FMX makes light work of heavy quarrying and mining assignments

38-t bogie

The 38-t bogie is a major improvement on the predecessor range’s 32-t rear-axle capacity

58-t GVM

58 t

Watch: Learn more about the new Volvo FMX

During testing at a haematite and fluorite ore operation in Limpopo recently, the Volvo FMX ticked all the right boxes in what is known to be an unforgiving application.

Construction Equipment. With increased front axle loads of up to 20 t and a 38-t rear bogie, the new Volvo FMX makes light work of heavy quarrying and mining assignments. The 38-t bogie is a major improvement on the predecessor range’s 32-t rear-axle capacity.

“The front suspension has been updated, allowing for front axle loads of up to 10 t, and 20 t for double front axle units,” explains Parry. “On the 8x4 variant, for example, the two 10-t front axles with four full springs, combined with the 38-t rear bogie with huge parabolic springs, provide a gross vehicle mass (GVM) of 58 t.”

Depending on the type of the body and the specific gravity (SG) of the loaded material, the truck can achieve anything between 38 t and 41 t of payload. “Some customers choose the extra-wide body (3 m), because it lowers the centre of gravity of the vehicle, while offering good stability and payload. This, however, is not road-legal,” explains Parry. “Others prefer narrow and high bodies because they allow them to run the truck on certain sections of the national roads when empty.”

During testing at a haematite and fluorite ore operation in Limpopo recently, the Volvo FMX ticked all the right boxes in what is known to

KEY POINTS

As cost pressures bite, quarries and mines continue to embrace new ideas. As part of this mindset shift, there is a growing acceptance of construction-type mining trucks, which have proven to be cheaper than dumpers – both to buy and to operate

As this shift towards mining tippers gathers pace, Volvo Trucks South Africa has brought in what it believes to be a game-changer, the allnew Volvo FMX

A key differentiator is the brand-new heavyduty axle designed in conjunction with sister company, Volvo Construction Equipment

A couple of units are already in operation in South Africa, with several more on the way

On the 8x4 variant, the two 10-t front axles with four full springs, combined with the 38-t rear bogie with huge parabolic springs, provide a gross vehicles’ mass of

be an unforgiving application. Equipped with a standard width body, the truck carried 50% more payload than existing site ADTs, taking about nine scoops per load, compared with six for the articulated hauler.

“The client was sceptical about the truck’s ability to negotiate the steep gradients with a full load, especially given that the ADTs were already struggling with the sharp inclines from the pit to the processing plants. The truck outperformed the ADTs in every aspect – it pulled out of the pit faster, with greater payload,” he says.

Safe operation

Visibility is of paramount significance in mining applications. For this reason, the FMX offers 10% better visibility than its predecessor, thanks to a lowered door line and new rear-view mirrors. This is enhanced by a standard camera that is installed on the passenger side, thus providing a complementary view of the side of the truck.

“With its ability to carry more payload and manoeuvre more easily in difficult conditions, while keeping the driver safe and comfortable, the Volvo FMX ushers in a new era of productivity and safety at quarries and mines,” says Parry.

Quarrying Africa’s View

Benefits abound

One of the major advantages of the FMX over traditional ADTs is the lower total cost of ownership (TCO). Both investment and running costs are a lot lower than those of a comparable ADT. The light body results in lower fuel consumption and increased payload. Although the truck runs on specialised tyres (325/95R24 sizes), these are much cheaper than those of an ADT, thus further lowering total cost of ownership( TCO).

The versatility of the truck is yet another major benefit. While the FMX is designed to challenge traditional yellow metal dumpers in off-road applications, it can also be deployed on public roads when empty, provided it is equipped with a road-legal body. Consequently, there is no need to hire costly lowbed trucks to transport the vehicle between sites.

However, Parry agrees that not all mining sites are ideal for the construction-type trucks. “There are some mining environments where the ADT is a better option, especially where tough underfoot conditions exist. However, in most quarrying applications where you have fairly smooth, well-maintained roads, the FMX will be the preferred choice. Quarry operators can therefore take advantage of the truck’s unmatched value proposition to ensure more profitable operations,” concludes Parry. a

As this shift towards mining tippers gathers pace in the quarrying and surface mining environment at large, Volvo Trucks South Africa has brought in what we believe is a game-changer. The all-new Volvo FMX sets a new benchmark with the heaviest axle in its class, which results in increased payload.

A key differentiator is the brand-new heavy-duty axle designed in conjunction with sister company, Volvo Construction Equipment. With increased front axle loads of up to 20 t and a 38-t rear bogie, the new Volvo FMX makes light work of heavy quarrying and mining assignments. The 38-t bogie is a major improvement on the predecessor range’s 32-t rearaxle capacity.

Quarrying Africa

Leveraging Volvo Trucks’ I-Shift with crawler gears technology, the truck could also pull off with a full load from a standstill position at the steepest of gradients with no difficulty.

ARE REMANUFACTURED PARTS RIGHT FOR YOUR BUSINESS?

Truck operators have to consider a multitude of fixed and variable factors that have an impact on their cost of operation, and subsequently, their business’ bottom line. These include fuel costs, financing, labour, insurance, maintenance and repair.

When a vital component breaks down the question that inevitably arises is how you should replace it. Repair, buy new or go for a remanufactured part?

To make the right decision for your business it’s vital to consider all your options to essentially solve the same problem.

“Buying a new part could be your first instinct when something breaks down; after all you want something that works, has a warranty, and is guaranteed to fit your truck. A new part will also come with the latest technology, have the longest life expectation and work efficiently. But it will also mean a higher price tag and you will have to evaluate how this will impact your operating costs and total cost of ownership of your truck,” says Eric Parry, sustainable solutions manager at Volvo Trucks South Africa.

When you repair a part, the malfunctioning or worn component gets replaced while the rest stays the same. While repairing can save you money it’s good to be aware repairing also almost always comes with certain downtime as the truck will have to be in the workshop for a while.

Understanding remanufacturing

Before considering whether remanufactured parts are the right option for your business, it’s important to distinguish remanufacturing from rebuilding a piece of equipment.

Remanufacturing is a standardised industrial process in which worn-out parts are returned to a condition that is as good as new in technical specifications and performance. It is usually a good idea to replace heavier components with remanufactured parts as these tend to be more expensive. Engine, chassis parts, transmission brakes and steering are just a few of such components. When it comes to electronics, starter motor, control units and alternator can be replaced using remanufactured parts as well.

“When we remanufacture parts at Volvo Trucks this process includes dismantling, cleaning, remachining, assembling and testing the equipment.

The process is much like the original manufacturing process, except that some of the components have had a previous life,” said Olga Naert, remanufacturing business development manager at Volvo Trucks.

Quality, safety and environment

There are a few reasons why a remanufactured part might be the right investment if you are facing the breakdown of a critical component.

“The most obvious is of course the lower cost compared to a new part. When you buy a reman unit, all parts will be updated with the latest technology,” explained Naert. “Quality is another plus as remanufactured parts meet OEM standards for performance and always comes with a warranty.”

Last but not least, a remanufactured part also has much lower impact on the environment as a lot less raw material, energy and water is used in the production process.

A concern about the environment and diminishing resources is a great reason to choose remanufacturing. A newly produced part is made using 100% new raw material whereas a remanufactured part only uses 15% since most of the material comes from the core (the faulty part).

“Using remanufactured parts also saves energy, reduces landfill waste and it means that dangerous residuals inside worn components are taken care of,” said Parry. “The process of remanufacturing, which is labor intensive, can also be seen as sustainable from a societal perspective as it creates demand for high-skilled jobs.”

In addition to quality and lower cost, remanufactured parts can also be a quick fix compared to repairing thanks to their growing popularity and availability. In fact choosing a remanufactured part could put you back on the road just as quickly as purchasing a new product.

“At the end of the day whatever purchase strategy you decide on will depend on the specific needs of your business,” explained Parry. “Remanufacturing can be a great option if you are cost sensitive but also want a high-quality product. The cost of a remanufactured part can be up to 50% cheaper than a new one, depending on the type of part.” a

ASPASA URGES MEMBERS TO REUSE AND RECYCLE WASTE

Surface mining industry association Aspasa continues to encourage its members to handle waste responsibly and to turn excess mining waste into a positive contribution to the environment.

ccording to the latest available statistics, South Africans generate roughly 122-million tonnes of waste per year. Of this waste, a maximum of only 10% is recycled or recovered for other uses, while at least 90% is landfilled or dumped illegally. Similar figures apply to the mining industry where more can be done to reuse and recycle.

Leading by example is Labucon which has found a novel way of reusing tyres that are no longer serviceable to build retaining walls. After seeing how successful the projects were, the mine went on to build a demarcation barrier along the internal roadways. “Labucon was established in 1993 and has a large fleet of trucks. With tyres piling up we decided to find a new use for the old tyres to try and make a difference,” says Martie Joubert from Labucon Resources.

As reported by the ‘Tyre Industry Project for the World Business Council for Sustainable Development’, 1-billion end of life tyres are generated every year and there are currently 4-billion such tyres in landfills and stockpiles worldwide.

Innovative recycling and reusing ideas contribute to the reduction of waste to the landfills, guiding the positive impact of reusing disposable waste. “Not only did they reduce the cost of disposal, they also contributed to a cleaner and more sustainable environment,” adds Anthony Bowen, environmental auditor of Aspasa.

Publicise

Bowen adds that Aspasa is calling upon all member companies to publicise their examples of good practices “no matter how big or small, utilising waste material better has an impact on the environment and leads the way to innovative methods for the mining industry.”

Because tyre chips are almost three times lighter than gravel with the reduction of frost penetration in cold climates it’s possible to use tyre chips to minimise vibration and noise. Examples of such applications can be seen underneath railway and roads.

Other outstanding reuse and recycling projects of ASPASA members include Lafarge Ninians Quarry in Empangeni where manager, Patrick Ndlwana, was personally involved in donating their waste office paper to a special needs home. This brilliant project enabled the home to equip a bakery where they are baking their own bread and selling the excess. a

AfriSam Jukskei Quarry recycles its concrete waste on site.