ELB Equipment proudly represents Powerscreen, one of the most trusted names in the global crushing and screening industry across Southern Africa. Recently, the company added Powerscreen Premiertrak and Maxtrak models to the range, offering more value to customers in the mining sector.
TEAM
Editor
Nick Barnes
editor@miningbusinessafrica.co.za
+27 10 055 3356
Web/Sub-Editors
Jimmy Swira
Jimmy@miningbusinessafrica.co.za
+ 27 10 055 3356
Anita Anyango anyangoanita18@gmail.com
Contributing Writers
Chantelle C.
chantellec@miningbusinessafrica.co.za
+ 27 10 055 3356
Susan M.
susanm@miningbusinessafrica.co.za
Sales and Marketing
Winnie Sentabire
winnie@miningbusinessafrica.co.za
+27 83 530 6832 | +27 10 055 3356
Angeline Ntobeng
angien@miningbusinessafrica.co.za
+ 27 078 322 5938
+ 27 010 055 3356
Accounts
Precious Chirunga
accounts@miningbusinessafrica.co.za
+ 27 10 055 3356
Editor’s Note
The Costly Trade-Off
Doing things in desperation is never advisable, not least when you are running an economy that doesn’t have many sources of revenue. You get far less than you deserve after selling yourself short, which shouldn’t be the case.
Sadly, this is the position some African countries find themselves in: desperate to curry favour with certain western countries that are only interested in gaining access to critical and rare earth minerals for next to nothing.
Instead of using the mineral resources they are endowed with as leverage, they are being coerced, or some would say bullied, into lopsided deals that are tantamount to mortgaging their assets to the lowest bidder.
The attitude of some of the parties involved is nothing short of condescending: “We are only doing you a favour; you could have got nothing anyway.” It is a costly trade-off.
In hindsight: If only resource-rich African countries could value their resources as Gulf countries do, they could address some of their economic problems without begging from western countries. It is about good governance, of which there is a paucity.
Nick Barnes editor@miningbusinessafrica.com
Art Director/Layout
Augustine Ombwa
Arobia Creative Consultancy
austin@arobia.co.ke
+254 772 187 334
Circulation/Sales
info@miningbusinessafrica.co.za
+ 27 10 055 3356
Published By Media Icon (Pty) Ltd
Smarter Compliance
Tailored REMA TIP TOP Tyre Repair
Caldas’ Turnkey Crusher Wear Parts Solution
The Trailblazer
Innovations in Mine Health & Safety Smarter Compliance
Mining operations are becoming more complex, and regulations more stringent. To manage this, companies are adopting smart innovations, ranging from autonomous systems to real-time monitoring and predictive analytics. These technologies are helping them enhance safety, minimise risk, and, more importantly, ensure alignment with regulations.
Innovations that can enable mining companies to achieve compliance with mine health and safety regulations - once viewed as a luxury they could do without - are now increasingly regarded as a necessity. These innovations, referred to as smart technologies in some circles, are radically transforming compliance.
Necessity: The Driver of Decisions
There is an old expression: “Necessity is the mother of innovation”. This fits perfectly within the context of growth in the uptake of smart technologies in mine health and safety.
The pressing need to maintain compliant operations has driven mining companies to embrace innovations in this space. Several factors are behind this shift.
In the past, due to loopholes in regulations, organisations could escape with minimal or no consequences for breaches. However, recent amendments to legislation have highlighted how serious regulators are about enforcement.
South African Case Study
In South Africa, for instance, there have been amendments to both the Occupational Health and Safety Act (OHSA) and the Mine Health and Safety Act (MHSA). Most recently, in October 2024, the Minister of Mineral and Petroleum Resources published an explanatory summary of the draft Mine Health and Safety Amendment Bill (“the Bill”). The Bill is scheduled to be introduced in the National Assembly.
According to a review from Webber Wentzel Attorneys (Draft Mine Health and Safety
Amendment Bill, 2024: Key considerations for employers): “The intention, as set out in the Bill, is to, among other things, streamline administrative processes and strengthen managerial responsibility and accountability.”
Clearly, the changes are a clarion call for mining companies to raise the bar in their efforts to ensure compliance.
The Department of Mineral and Petroleum Resources (DMPR)’s directive that led to the suspension of activity at Impala Platinum in 2024 following an accident is a strong indication of zero tolerance for breaches. The widely covered event resulted in fatalities.
While in some cases the financial penalties may seem like a mere reprimand, the real cost lies in production downtime: potential revenue losses that can run into millions must be factored in. This is certainly not something shareholders would take lightly.
In addition, reputational damage from negative publicity can be severe. As harsh as it may sound, one incident can tarnish the public image of a well-established brand that has taken years to build. This is not worth the gamble.
Complexity of Contemporary Mining
Beyond the obligation of complying with health and safety regulations, mines are under pressure from multiple fronts: shareholders and investors seeking returns, expectations regarding environmental best practices, and the need to maintain sound relations with stakeholders. Compounding matters are rising operating costs, particularly energy. Energy accounts for no less
than 30 percent. This figure could even be a conservative estimate, considering ongoing price hikes.
Moreover, underground mining for precious metals and PGMs is moving into deep and ultradeep levels in search of viable ore, and this pursuit does not come any cheap. It demands investment in robust equipment capable of operating in rugged conditions.
Surface mining is not in a better position either. It faces unique challenges, chief among them the need to extract more from increasingly depleted ore-bearing rock: essentially, producing more with less.
This new environment presents significant challenges: increased health and safety risks, stricter environmental compliance demands, and the need to maintain sound stakeholder relations.
Given the mounting pressures, ensuring compliance with mine health and safety regulations is becoming increasingly difficult. While well-intentioned, conventional approaches such as deploying human inspectors, using analogue equipment to analyse conditions, and relying on employees to make rational decisions independently may fall short. This widens the existing gap in compliance capacity within mining operations.
Perfect Proliferation
Thus, the rapid proliferation of innovations in mine health and safety could not have come at a better time. It presents mining operations with a wide choice of solutions to meet critical safety and compliance objectives.
New Technologies
Based on the latest industry reports and developments, several categories of innovations are being added to the toolbox. Specificaly, in the context of modern mining, the following stand out:
1. Automation and Robotics
There has been an increase in the use of autonomous vehicles, robotic drilling systems, and remotely operated equipment. Deploying these in high-risk zones significantly reduces the need for humans to work in hazardous environments.
Sensor-equipped drones have transformed the inspection of shafts, pit faces, equipment, and air quality. These drones can access areas that are inaccessible to humans. These tasks that would otherwise pose serious risks.
For underground mapping, ground-based robots are now used to generate 3D images using LiDAR and IMU to identify hazards in advance.
2. Advanced Monitoring Systems
Real-time AI and IoT platforms analyse sensor data — such as dust, gas, vibration, and micro-seismic activity — to forecast hazards like rockfalls, gas build-ups, or equipment failures. These systems also track worker location and trigger alerts for immediate intervention.
Another area of advanced monitoring is micro-seismic monitoring and roof failure alerts.
In underground coal mines, the fall of ground (goafing) is a serious issue. To address this, South Africa’s CSIR, in partnership with Guduza Technologies, has developed GoafWar, a realtime micro-seismic monitoring platform that provides early warnings of roof collapses and goaf failures.
3. Wearable Technology (Wearables)
The integration of smart sensors into personal protective equipment (PPE) and wearable devices is another groundbreaking development. These wearables monitor worker location, vital signs, and exposure to hazardous conditions, enabling timely alerts and interventions.
Smart helmets and badges, for example, monitor heart rate, oxygen saturation, fatigue, gas exposure (such as methane and carbon dioxide), dust levels, and location. If danger levels are detected, they issue real-time alerts to both workers and supervisors.
Another recent development is the integration of wearables into geofencing and proximity detection systems, designed to prevent workers from entering restricted or unsafe zones.
4. Immersive AR and VR Training
Another area gaining traction is the use of Virtual Reality (VR) and Augmented Reality (AR) to simulate emergency situations during training. Traditionally, virtual models of underground environments were shown in lecture rooms
via PowerPoint presentations. If that could be considered modern, even more outdated is the instructor standing in front of employees with a whiteboard and marker in hand.
Instead, operations are now using VR simulations to create immersive and realistic training scenarios of emergencies such as fires and explosions. This approach improves preparedness and knowledge retention, allowing workers to plan and rehearse hazard responses before entering actual operational zones.
Keeping Employees from Harm’s Way
When used effectively, these innovations can help mining operations improve compliance with health and safety regulations by:
• Keeping employees out of dangerous environments,
• Predicting and preventing incidents, and
• Promoting a proactive safety culture and improving worker well-being.
The benefits extend beyond health and safety compliance. These innovations also contribute to improved productivity and reduced emissions.
The Nutshell
The adoption of smart safety technologies is no longer a luxury but a necessity in contemporary mining. Certainly, the adoption of smarter technologies improves compliance.
Vodacom Business and Sasol partner to deliver MPN Solution
Johannesburg, South Africa – Vodacom Business has deployed a Mobile Private Network (MPN) at Sasol’s synthetic fuel facility in Secunda, Mpumalanga. This collaboration marks a significant milestone in leveraging advanced technology to enhance operational efficiency and connectivity in the industrial sector.
“As part of Sasol’s digitalisation journey, there is a focus on utilising technology to improve processes that impact safety and efficiency across our facilities,” says Victor Bester, Sasol Executive Vice President of Operations and Projects. “This initiative allows us to accelerate these efforts through improved connectivity and control of the mobile network deployed at our Secunda production facility. Our collaboration with Vodacom Business creates opportunities for us to do things differently and grow our digital maturity. We look forward to the positive impact this advanced connectivity solution will have on
our operations.”
Peter Malebye, Managing Executive at Vodacom Business says Vodacom’s MPN offers future proof, secure and robust connectivity so that businesses can address key safety, efficiency, and visibility concerns. By leveraging a single network to create a connected environment, be it a mine or a giant petrochemical facility, organisations can better understand key performance drivers, reduce operational outages and extend asset life.
“Our MPN solution provides a dedicated, secure, and high-performance mobile network tailored to meet the specific needs of Sasol’s operations. It delivers the scalability and reliability required to ensure continuity for its mission-and business-critical applications,” says Malebye. He adds that the partnership with Sasol represents Vodacom’s commitment to innovating with our clients, “helping them stay connected today and supporting their digitalisation into the future.”
“When all of this comes together, an organisation can ultimately bring in other innovations, such as digital twins or enable remote and autonomous operations to improve planning,” adds Malebye.
If Sasol wanted to connect everyone working across its massive operation (around 3 000 people) using Wi-Fi, for example, they would have had to roll out a huge amount of infrastructure across the site, which is not only time-consuming and extremely costly but it’s also highly inefficient. The MPN integrates Vodacom’s robust network infrastructure with Sasol’s systems, enhancing connectivity to employees, equipment and assets. In addition, the solution enables real-time and remote monitoring, improves safety and compliance, streamlines asset management, boosts collaboration and optimises overall operational efficiency.
With an MPN solution, it’s possible to deliver optimal connectivity in regions where public networks may be unreliable or unavailable. An MPN solution differs from a public mobile network in that it provides exclusive access to a particular facility or business, which ensures that the network is optimised for their specific use case. Other key advantages of an MPN solution include greater control, customisability, increased security and reduced latency.
Additionally, the MPN architecture ensures that data never leaves the site, providing low latency and high uptime and making it easier to build redundancy. With a facility like Sasol’s, it’s always mission-critical, which is why having an on-site local network that offers secure and reliable connectivity and enables seamless communication is important.
“While MPNs are becoming increasingly relevant in a South African context, they are not yet as widespread as traditional public mobile networks,” adds Malebye. “Vodacom Business has been a pioneer in developing tailored MPN offerings for our clients in the southern African region. When Sasol turned to us to embark on this digital journey, it was a privilege for us to walk alongside them and provide them with solutions they needed to transform their operations while making a positive impact on our country’s industrial sector.”
DRIVING EXCELLENCE IN UNDERGROUND INFRASTRUCTURE ACROSS THE
MENA
16–17
SEPTEMBER 2025
SCAN TO KNOW MORE
RITZ CARLTON, DUBAI INTERNATIONAL FINANCIAL CENTRE (DIFC) DUBAI, UAE
Smart, Safe and Sustainable Tyre Management
Michelin’s end-to-end OTR tyre management solutions help mines reduce costs, improve safety, and boost sustainability through smart design, real-time monitoring, and data-driven insights.
By Jimmy Swira
Mining operations are under intense pressure to adopt practical ways to achieve the following objectives: sustainability (reducing their environmental footprint), increasing productivity, enhancing safety, and, most importantly, ensuring compliance with relevant legislation within their respective jurisdictions. This is critical throughout the life of the mine.
Unfortunately, the reality is that focusing on these simultaneously – let alone achieving them – can be an intricate task from pit to port.
The End-to-End Tyre Approach
Conveniently, one of the readily available avenues that can enable mines to achieve this is the end-to-end approach to OTR tyre management. If adopted, this can ensure that every critical area is covered.
This is what Michelin’s OTR tyre management specialists propose to mining companies, referencing the company’s endto-end solutions. Hein Venter is the SSA B2B
Off Sales Director, and Ashutosh Jha, the AIM (Africa, India, & Middle East) Marketing Director for B2B Off.
Comprehensive Tyre Solutions
Michelin recognises that tyre management starts from the moment an order for a tyre is made, continues through its usage, and ends at the end of its life. Thus, it offers a comprehensive solution through Michelin Better Mining. This is a portfolio of innovative products, services, solutions and support customised to help mines operate safer, smarter and more sustainably.
“We help mines lower operating costs, improve safety, and minimise environmental impact through specialised tyre designs, tyre monitoring systems, tyre management services, haul road condition monitoring, and tyre recycle and recover solutions,” says Jha.
i. Specialised Tyre Designs
With a wide variety of features, Michelin’s repairable tyres are specially designed with the demanding conditions of both surface and underground mines in mind. For instance, robust tyres for underground conditions can withstand
rockslides, floods, and heavy loads.
The tyre selection process is meticulous. The Michelin team provides on-site analysis and expert advice, to ensure that a mine selects the right tyres and manages them effectively.
As any fleet manager would attest, while robust design ensures durability, effective tyre usage and cost efficiency depend heavily on how well tyres are managed during operation and maintained.
To address this, Venter explains that Michelin uses its flagship Tyre Pressure Management Systems (TPMS), which provide real-time data on vital aspects of tyre condition.
iii. Michelin’s Flagship TPMS
Michelin offers Tyre Pressure Monitoring Systems for fleet owners in two alternatives: the MEMS 4 and MEMS LITE.
MEMS 4 is suitable for rigid dumper trucks over 150 tonnes. On the other hand, MEMS LITE is suitable for rigid dumper trucks <150 T.
Utilising tyre-embedded sensors, data analysis, and connected technologies, the TPMS performs a wide range of functions. These
include – but are not limited to – monitoring tyre pressure and temperature, vehicle location and usage, tyre wear, and related incidents.
Real-time insights from TPMS help mines make timely interventions regarding tyre maintenance, replacement, and fleet operations. Alerts are accessible via laptops, tablets, and smartphones.
One of the main challenges experienced with monitoring systems is non-interoperability. However, highlighting the interoperability of TPMS, Jha explains: “By integrating with existing fleet management platforms, our systems enable a holistic view of fleet operations. This helps mines in proactive management of incidents. There isn’t better convenience if you ask me.”
Haul Road Monitoring
While tyre monitoring provides valuable insights into tyre condition, Michelin recognises that poor haul road conditions are often the primary cause of excessive tyre wear and damage.
In view of this, Venter says Michelin has extended the application of data beyond tyre performance management to haul road monitoring. Accordingly, the company has developed a tool called Better Haul Road to address this.“By monitoring haul road conditions, the tool provides data that enables mines to mitigate risk to their tyres. Ultimately, improving road conditions enhances productivity and safety,” Venter explains.
Tyre Management Services
To ensure a seamless, tyre management experience, Michelin offers tyre management services which comprise the following:
• Site Safety & Productivity Seminars
• Audits, Studies and Analyses
• Productivity Improvements
• Actionable Studies
Tyre Recycling and Recovery
Last but not least, Michelin also supports sustainable tyre management through recycling and recovery. As and when needed, it can help mines set up systems for tyre collection and disposal.
Integrated Benefits
When combined, Michelin’s product design, digital tools, and consulting services create a comprehensive framework that supports mines on all fronts.
Benefits i. Sustainability
Through recycling and recovery, Michelin helps mines reduce the environmental impact of tyre waste. “Once tyre life is extended, it means fewer used tyres are sent for disposal. What is more, less fuel consumption translates into lower emissions. This minimises environmental impact,” Jha explains.
ii.
Cost Reduction
Repairable tyres reduce the expense of frequent replacements (depending on the extent of damage). In addition, good tyre condition reduces tonne-per-kilometre costs and lowers fuel consumption.
iii. Optimising Tyre Usage
“By specialising in all aspects related to tyres and their application on site, Michelin helps mines optimise tyre usage,” Venter emphasises.
iv. Increasing Productivity
Fewer unscheduled maintenance stops increase truck availability and overall productivity.
v.
Enhanced Safety
By minimising risks associated with tyre failures, Michelin’s management system improves safety for people, tyres, and equipment.
Well-Equipped for the Future
The Michelin team is eager to address complex OTR tyre management issues. “We are wellequipped to provide end-to-end comprehensive solutions to clients in the mining sector as they embark on critical mineral projects in Africa. We hope to help operations improve productivity and safety, make operations environmentally sound, and, above all, ensure legal compliance,” Venter affirms.
Greater Recovery Better Grade
Your Roughing, Cleaning & Scavenging with Eriez Magnetic Elements & Tanks
• Hybrid Rare Earth-Ceramic elements produce greater recovery in cobbing and roughing stages
• Cleaning and finishing magnetic elements improve selective separation
Tailored REMA TIP TOP Tyre Repair
South African-based and African-focused, REMA TIP TOP offers a full OTR tyre maintenance programme for mining clients throughout the continent from a single point. All REMA TIP TOP’s solutions are locally available via its Africa-wide footprint of 12 service outlets with deep logistics capability.
There are a number of OTR (Off-the-Road) tyre management solution providers on the market targeting African mining. However, what makes REMA TIP TOP’s services stand out is its ability to devise practical solutions to specific challenges that a typical mining operation faces.
The Common Challenges
Through constant client engagement, REMA TIP TOP has identified the following common challenges in mining operations:
• Frequent, costly tyre damage: In abrasive conditions, OTR tyres suffer sidewall damage and tread cuts from sharp rocks or debris. This leads to unexpected downtime.
• Rising replacement costs and delivery delays: New OTR tyres can cost tens of thousands of dollars each, with long lead times disrupting mine schedules and planned haulage.
• Environmental and safety pressures: Mines need sustainable choices and safer work practices, which extend beyond simple tyre replacement.
The Practical Solutions
Accordingly, REMA TIP TOP has devised a specific scope of practical solutions to address these challenges. These include:
• Permanent hot-vulcanisation repairs: Using industry-leading tyre repair patches and advanced vulcanisation curing equipment, REMA TIP TOP offers solutions that restore tyres of all sizes, fully integrated to fit all applications. The curing equipment includes the Thermopress EM series and REMAVULC.
• Complete product offering: This ranges from tyre mounting and demounting equipment and tooling, valves and accessories, compounds and patches (of all sizes and applications), to cements, adhesives, and sealers. This offering ensures full in-house repair capability.
• On-site training and certification: Delivered through REMA TIP TOP Academy or on-site, ensuring technicians are fully qualified for safe, professional repair work.
More solutions are added in response to shifting customer requirements, as and when needed, to improve tyre reliability.
Latest Additions
True to form, REMA TIP TOP recently introduced new additions to the company’s solutions, including:
• Enhanced repair patches and chemicals: Formulations now offer stronger bonding, environmental compliance, a reduced carbon footprint, and up to 80% cost saving over full tyre replacement.
• Expanded vulcaniser range: EMI, EM II and EM III or the REMAVULC systems suit various tyre sizes and thicknesses, improving repair speed and quality.
Full OTR Maintenance Programme
REMA TIP TOP is cognisant that mining operations do not just need separate services, but one-stop convenience. To cater for this, REMA TIP TOP offers turnkey solutions, which bundle repair products, vulcanising machines, tools, training, and ongoing field support.
All these solutions are locally available via its Africa-wide footprint of 12 service outlets with deep logistics capability. This approach enables mining operations to implement a full OTR maintenance programme from a single provider.
Flexibility – Modular and Configurable
Worth mentioning about the full OTR maintenance programme is REMA TIP TOP‘s flexibility. The system is modular and configurable in the following ways: clients can purchase full start-up service solutions, key individual components, or specific service-based materials and tooling for all tyre sizes, tyre constructions (radial or cross-ply), damage frequencies, and in-house repair capabilities. What’s more, the company’s African group operations create bespoke solutions jointly with mining customers.
Committed to Serve Africa
The REMA TIP TOP team is committed to serving the respective needs of every client in the African mining sector. The team is eyeing opportunities that are opening up as new projects are being unveiled, pledging to offer tailored REMA TIP TOP tyre repair solutions.
REMA TIP TOP offers solutions that restore tyres of all sizes, fully integrated to fit all applications
REMA TIP TOP African Group
Your Specialist in OTR Tyre Repair Across Africa
Our comprehensive solution includes:
Premium OTR repair products –trusted by leading tyre manufacturers
Heavy-duty vulcanising machines –built for mine-site demands
On-site technical training –delivered by certified professionals
Specialised repair and handling tools – from bead breakers to hot cutters
Chemical safety products & accessories – for a safer, smoother operation
Whether it’s radial or diagonal tyre damage, REMA TIP TOP African Group’s proven system delivers durability, performance, and peace of mind –wherever your mine operates.
Put quality, safety, and reliability on repeat.
In mining, every minute counts and every tyre matters. at’s why REMA TIP TOP African Group offers a certified OTR Repair System designed to permanently restore value to your damaged off-the-road (OTR) tyres — maximising uptime and reducing replacement costs.
TyrFil™ Flatproofing’s Impact on Underground Mining Operations
Complexities within the African mining industry continue to evolve, as climate change, global geopolitical tensions, and an increasingly strict regulatory environment reshape the sector. Mining site managers must remain vigilant, adopting the best strategies, technologies, and protocols to maximize revenue opportunities while prioritising safety and compliance. As future investments in mining materials and equipment face uncertainty—due to potential tariff impositions and supply chain challenges—savvy mining leaders recognise that worker safety and hazard reduction will remain non-negotiable priorities.
Meanwhile, the push for environmental, social, and governance (ESG) compliance drives increased attention to carbon footprint reduction, waste minimization, land rehabilitation, and renewable energy integration. At the same time, new technology—from artificial intelligence (AI) and drone surveillance to automated equipment and advanced data analysis—is transforming how mines operate and measure efficiency. At the heart of this operational evolution lies a critical but sometimes overlooked factor: tyre technology.
Off-the-Road (OTR) vehicles and heavy equipment are only as dependable as the tyres they rely on, especially in harsh underground environments where downtime can be catastrophic. Unexpected flats in mining settings can halt entire operations for hours, putting workers at risk and draining productivity and profitability. A single loader or shuttle car breakdown in a narrow tunnel, for example, can block all movement behind it, effectively freezing production and causing cascading delays.
This is where polyurethane tyre fill solutions—
such as industry-leading TyrFil flatproofing technology—offer a transformative advantage. Unlike traditional air-filled pneumatic tyres, which remain vulnerable to punctures and blowouts, TyrFil flatproofing eliminates flats completely, even under the harshest mining conditions. TyrFil is pumped into pneumatic tyres through the valve stem, replacing all air and curing into a solid, durable elastomer core within 24–36 hours. Once filled, tyres become completely flat-free and can safely operate over the sharp rocks, nails, metal fragments, and debris that characterise mining sites. This superior reliability ensures that critical mining equipment remains operational, keeps underground tunnels clear, and supports continuous productivity while protecting workers.
TyrFil flatproofing also offers mining operators the ability to customise the “durometer,” or tire hardness, to match specific job site conditions and operational needs. Choosing the right durometer helps optimise ride comfort for
operators by reducing vibration on rough, rocky surfaces and ensures more even load distribution across heavy equipment. This customisation can help improve traction, reduce excessive tyre wear, and enhance overall equipment performance, especially in demanding underground environments.
Additionally, tyre fill use reduces the severe bumping and jarring driving impact from cross-axle G-force vibrations, which can cause muscular/skeletal fatigue for workers who spend countless hours behind the wheel—a condition referred to as Whole Body Vibration or “WBV. Polyurethane tyre fill is engineered to absorb this shock and therefore reduces this jolting drive—lowering discomfort for workers and helping to prevent liability claims for mine site management. In terms of structural protection for mining vehicles, flatproofing technology can also reduce the wear-and-tear on equipment chassis that cause premature damage—making it a win from both a safety reduction and costefficiency perspective. And as budget scrutiny— surrounding rising equipment expenditures due to potential tariff fall out or other continent-wide economic factors—grows, this technology choice provides additional cost protection for underground mining site managers.
Moreover, as climate compliance and environmental stewardship become increasingly critical for global and regional underground mining operations, TyrFil’s innovative recycling pumping technology offers meaningful sustainability advantages. Used cured polyurethane tyre fill can be removed, then ground up using TyrFil Recycling Technology, and blended with virgin fill. This reduces raw material usage, lowers carbon footprint, and saves money by using up to 65% reclaimed fill and reducing petrochemical (including oil) consumption—all without compromising tyre performance. By enabling the reuse and recycling of materials in line with circular economy principles, TyrFil flatproofing helps mining operations achieve sustainability goals while maintaining the highest standards of tyre performance and reliability underground.
Established in 1971, Carlisle TyrFil has pioneered the tyre fill industry for nearly six decades, leading the way for greater performance, efficiency and environmental responsibility around the globe and across southern Africa. For more information on how your mining business can benefit from incorporation of flat-free tyre technology, visit www.CarlisleTyrFil.com.
When you o er TyrFil™ Flatproo ng to your customers, you are o ering the Gold Standard in the industry.
Dedicated and empowered Customer Service
Proven pumping equipment technology
Global on-site technical support
Complimentary training
TyrFil® is a polyurethane material that is pumped into OTR mining vehicle tyres, replacing all the air. It cures into a exible, durable lling that acts as a shock absorber and completely eliminates at tyres. Compared to other No Flat products such as solid tyres, cores and liners, TyrFil is the most cost-e ective solution and provides the best overall performance.
Eliminates 100% of at tyres
Lowers G-force impact to operator and equipment
Maintains constant internal pressure
Extends tyre life
Reduces downtime
Prevents catastrophic blowouts
Redefining Crushing & Screening Powerscreen Gets More Edge
ELB Equipment proudly represents Powerscreen, one of the most trusted names in the global crushing and screening industry across Southern Africa. Recently, the company added Powerscreen Premiertrak and Maxtrak models to the range, offering more value to customers in the mining sector.
By Jimmy Swira
As long as it identifies a gap in any niche market, ELB Equipment does not hesitate to provide a relevant solution. That is how the multibrand crushing and screening solutions provider has stayed abreast of customer expectations, and even exceeded them, across Southern Africa.
The recent additions to the iconic Powerscreen range are a case in point: Powerscreen Premiertrak 450 and Maxtrak 1150 models. Louisa Ngwenya, Marketing Lead at ELB Equipment, is excited about the value these are going to add to screening tasks in mining.
More versatility
The Powerscreen Premiertrak and Maxtrak models add more versatility to the current Powerscreen inventory.
Typically, Powerscreen is designed specifically with Southern African mining operations in mind. It features high-performance mobile jaw crushers, cone crushers, impact crushers, and a versatile range of mobile screens. These machines are engineered for durability in tough conditions and deliver excellent throughput.
Now, raising the bar, the Powerscreen Premiertrak and Maxtrak models offer advanced features like hybrid drive options, telematics for fleet tracking, and improved fuel efficiency. These features address the evolving demands of modern mining.
Multi-franchise dealer
Furthermore, the introduction of the Powerscreen models demonstrates the flexibility of ELB Equipment. As a multi-franchise dealer, the company is able to source and provide solutions as and when needed, to the client’s convenience, across Southern Africa.
“Through a multi-franchise approach, we are able to offer unbiased, needs-based solutions. The longstanding partnership with Powerscreen epitomises this,” Ngwenya explains.
“Whether clients need primary crushing, secondary screening, or a fully integrated solution, ELB Equipment matches the best technologies to each operation,” she adds.
Solutions-based supply model
Always keeping abreast of market trends, ELB Equipment has noticed the shift toward solutionbased supply. And so, accordingly, the company delivers end-to-end Powerscreen turnkey solutions. These include equipment selection, design consultation, plant layout, commissioning, training, and lifecycle support.
Noteworthy, ELB Equipment offers customised turnkey solutions for clients that require mobility, flexibility, and productivity. “We supply complete Powerscreen mobile systems configured to meet exact output and specification requirements. We have also recently added digital monitoring tools via Powerscreen Pulse, which allows mines to track performance and maintenance schedules in real time, improving operational decisions.”
After-sales service
While it offers a tailored turnkey solution, ELB Equipment notes that after-sales service remains a big concern for mine operators, particularly access to critical spare parts. For this reason, it takes after-sales service seriously when supplying Powerscreen equipment to clients. “Our long-standing distribution of Powerscreen equipment in Southern Africa has been supported by a wide network of service centres and parts warehouses. Critical spares for Powerscreen machines are held locally, and our regional service teams are equipped to perform everything from routine maintenance to major
overhauls on-site,” assures Ngwenya.
More to the point, ELB Equipment’s service agreements and planned maintenance programs help reduce unplanned downtime. For mine operators, this means less waiting, more operating, and dependable support when and where it is needed most.
Increased uptime and reduced total cost of ownership
Generally, ELB Equipment has robust support infrastructure across Southern Africa. This, combined with readily available Powerscreen parts and OEM-certified technicians, ensures uptime and reduced total cost of ownership for mining clients operating under pressure.
Custom Leasing and Rental Packages
ELB Equipment understands the capital constraints and project-based nature of many South African mining operations. Consequently, the company extends its flexibility to offering the option of leasing crushing and screening equipment in addition to outright purchase.
ELB Equipment offers custom leasing and rental packages for Powerscreen crushing and screening equipment. These packages are flexible and designed to meet both short- and long-term needs.
The packages include operator training, technical support, full-service maintenance, and contractual service agreements. These give clients access to industry-leading Powerscreen technology without the upfront cost.
Due to the convenience it offers, this model has been especially popular among contract miners and operations looking to scale up quickly with minimal risk.
Caldas’ Turnkey Crusher Wear Parts Solution
Caldas’ approach reduced Wear and Downtime in a High-Impact application at a gold minining operation in Southern Africa. The company supplied a redesigned set of swing and fixed jaws in a high-impact resistant 20Mn2Cr composition with a deeper profile and additional tooth support.
At Caldas Engineering, our turnkey wear parts solution goes beyond supply. We partner with clients to extend the lifecycle of their crushing equipment by offering:
From this, we determined the existing liners were underperforming due to an unsuitable manganese composition and profile for the highimpact quartzite feed.
1. Precision-engineered wear components tailored to site-specific applications
2. Metallurgical consulting to match manganese grades with material feed
3. Wear pattern analysis and reporting
4. Supply chain and inventory planning to eliminate downtime
5. Technical support for our parts.
Case Study: Reducing Wear and Downtime in a High-Impact Application
Client Challenge:
A gold mining operation in Southern Africa was experiencing excessive wear on their primary jaw crusher swing and fixed jaws – requiring change-outs every 6–8 weeks. This frequent maintenance was disrupting throughput and causing unplanned production halts.
Caldas’ Approach:
Our engineering and field service teams conducted a full wear audit, including:
1. 3D scanning of worn components
2. Feed material and throughput analysis
3. Review of crusher stroke, nip angle, and choke feed consistency
Solution & Installation:
We supplied a redesigned set of swing and fixed jaws in a high-impact resistant 20Mn2Cr composition with a deeper profile and additional tooth support. Installation was coordinated with the client’s maintenance shutdown, with our technicians on-site to supervise and optimise fitment.
Results:
4. Wear life extended from 6 - 8 weeks to over 8 - 10 weeks
5. Crusher availability improved by 22% over the quarter
“You don’t need to live with unplanned downtime. With the right partner, wear parts become a performance asset – not just a cost line.”
We look forward to reviewing the draft prior to publication and would be happy to provide supporting images or technical diagrams if required.
Expansion to Support Nexgen Polyurethane Innovation
FLS has significantly upgraded its Delmas polyurethane manufacturing facility to serve as a global hub for its high performance NexGen screen media, supporting growing demand across Africa, the Middle East and Europe.
FLS has completed a significant upgrade to its polyurethane manufacturing facility in Delmas, Mpumalanga, positioning the site as a key global hub for the production of its advanced NexGen wear -resistant material. This development forms part of a wider modernisation programme by FLS, aimed at strengthening supply chains, increasing manufacturing efficiency and enhancing sustainability across its global footprint.
Brad Shepherd, Director Service LineScreen and Feeder Consumables at FLS, says the investment at Delmas aligns with the company’s global strategy to standardise and optimise production processes.
“This is a milestone for us,” says Shepherd. “We are integrating cutting edge technology and modern manufacturing methodologies across all our polyurethane plants, and Delmas is leading the way. The upgrade enables us to respond more quickly and reliably to customer needs
across Africa, the Middle East and Europe.”
The centrepiece of the upgrade is the introduction of purpose-built infrastructure to produce NexGen screen media - a polyurethane material developed by FLS to deliver extended wear life, reduced maintenance and improved operational efficiency. In on-site trials, screen panels made from NexGen have demonstrated up to three times the wear life of conventional rubber and polyurethane products, making it a gamechanger for industries that rely on high performance screening solutions.
Warren Walker, Head of Global Manufacturing - Polyurethane Operations at FLS, explains that Delmas is the first of the company’s five global polyurethane plants to complete this transition. “We have installed new, latest generation polyurethane machines, precision tooling and dedicated preheating ovens for inserts,” he says. “This allows us to significantly increase our output while ensuring
consistent quality.”
The facility now includes two trommel screen media stations and three screen media stations, each tailored to produce NexGen products. One of the standout technologies introduced is a programmable auto-calibrating polyurethane machine capable of adjusting material hardness to suit specific applications.
“The flexibility to produce varying hardness levels is critical,” Walker notes. “It means we can tailor our screen media precisely to the customer’s application, ensuring optimum performance and longevity.”
To complement this, a high capacity polyurethane machine capable of pouring up to 42 kg per minute is in operation at the facility. This system is particularly suited to applications requiring large volume pours, such as flotation spare parts and vertical mill components.
The Delmas facility already benefited from a significant upgrade in 2019, when a state-of-
FLS manufactures NexGen media, trommel and screen panels with expert precision to ensure consistent quality and high performance.
the-art six-axis machining centre was introduced for tooling precision, along with robotic welding systems for manufacturing screen media panel inserts and a CNC controlled spiral welding machine to produce wedge wire products. The latest round of investments builds on this foundation and brings the facility to the forefront of global polyurethane production capability.
Energy efficiency was a key consideration in the new layout and equipment design. “We have incorporated smart energy saving features like individual temperature control on each casting table station,” Walker says. “This avoids the need to heat large surface areas unnecessarily and contributes to our carbon reduction goals.”
Further supporting these goals is the installation of 300 kW of solar generation capacity at the Delmas site, completed in 2024. Plans are already in place to expand this by another 500 kW in 2026, along with the integration of a battery energy storage system (BESS), enabling greater energy independence and resilience.
FLS’s offering from Delmas extends beyond screen media manufacturing. The facility is equipped to handle the complete fabrication of vibrating screens, from raw material processing and in-house machining to assembly and factory acceptance testing. This vertical integration allows the company to deliver customised solutions with tighter control over quality and lead times.
Shepherd emphasises that FLS operates both as an original equipment manufacturer (OEM) and a screen media specialist, supplying screen panels for all types and brands of vibrating screens, feeders and trommel screens.
“We don’t just supply products,” he says. “We work closely with our customers through our network of on-the-ground specialists to assess site conditions and select the best screening media for their specific needs.”
He notes that many older processing plants are treating materials that differ from their original design specifications. In these cases, screen efficiency can often only be improved by optimising the screen media. “This is where NexGen makes a real difference,” Shepherd
says. “Combined with the correct aperture design, it allows customers to get more life and better performance from their screens.”
Unlike injection-moulded polyurethane, which can compromise the structural integrity of screen panels, FLS’s proprietary process retains superior mechanical properties, resulting in a tougher more durable product. “We have never used injection moulding because it reduces the quality of the end product,” Shepherd explains. “Our process delivers a product that stands up to the toughest operating conditions and offers lasting value.”
Walker adds that the expansion at Delmas not only supports FLS’s global operations but also contributes meaningfully to the South African economy. “Our commitment to local manufacturing is evident in the scale of our investment and the jobs we have created,” he says. “We have expanded our workforce, prioritised local recruitment and significantly grown our apprenticeship programme.”
A strong focus has also been placed on developing female artisans. In 2024, six women from the local community were recruited into a three year trade apprenticeship programme, receiving training in welding, fitting and boilermaking.
“Our investment during a period of economic uncertainty underlines FLS’s long term commitment to South Africa and to our customers in the broader EMEA region,” says Walker. “We are not just building products – we are building skills, opportunities and partnerships that will power sustainable growth for years to come.”
: NexGen polyurethane screen media from FLS is durable, reliable and engineered to deliver efficient high performance screening even in the toughest operating conditions.
Brad Shepherd, Director Service Line – Screen and Feeder Consumables at FLS.
Turning ESG Data into a Business Advantage
Artisanal miners in the Democratic Republic of Congo. Human rights bodies have highlighted abuse of workers’ and children’s rights in these activities
Assured ESG data can strengthen compliance, build investor trust, and give African mining companies a competitive edge.
ESG has become central to business operations in African mining. Increasingly, based on information shared with the public, many organisations claim to embrace it. However, finicky stakeholders are not easily swayed by data presented at face value. They are now demanding more — nothing short of complete and accurate sustainability reporting.
Stakeholders need more
Key stakeholders such as investors, regulators, and consumers are asking questions: “Of course, you have ESG data, but what about its accuracy? What if it is all fabricated?”
This scepticism is understandable, reflects Jameel Essop. “ESG data carries more weight. It informs critical decisions. So, you can understand the insistence on accuracy,” he states, highlighting evolving global regulations and increasing emphasis on investor-grade reporting.
1. Regulatory perspective
Globally, standards are evolving rapidly, and industries must catch up — and quickly. In the
US, the Securities and Exchange Commission (SEC) sets disclosure requirements. The Financial Conduct Authority (FCA) in the UK and the International Sustainability Standards Board (ISSB) are also key regulatory bodies. In the European Union, the Corporate Sustainability Reporting Directive applies. Other countries are making changes as well.
2. Investor-grade reporting
From an investor’s perspective, there has been increasing pressure on companies to share reliable information, also called investor-grade reporting. Companies aiming to lead in this space will need a strong reputation built on assured ESG reporting.
In-house measures
In this context, Essop advises organisations to view ESG compliance reporting requirements as an opportunity to transform a risk into a business advantage through verified data. For example, he emphasises the need for a comprehensive review of ESG data quality and the establishment of internal controls to support the ESG reporting
process before seeking independent assurance. “There is a need for a clear strategy to validate sustainability data with strong processes and controls from source to disclosure. This means consistent methodologies, timely data, and accuracy throughout the value chain.”
Enhancing ESG measures in-house
Concerns about data validity often arise in environmental compliance and ethical sourcing:
1. Environmental compliance
One key challenge in environmental compliance is data quality. When data collection methods are questionable, the credibility of the data is compromised, inevitably leading to accusations of greenwashing. Therefore, credible data collection methods are essential in critical areas like water usage.
Highlighting the drawbacks of manual data collection, such as sending personnel to record meter readings, Essop explains: “Manual collection is prone to human error. It is ineffective.”
He suggests that the most cost-effective solution is investing in technologies that enable real-time or near real-time monitoring. “It is important to consider the issue from a costbenefit perspective. Investment in an IT system can be worthwhile.”
2. Ethical sourcing
Another major concern is ethical sourcing, particularly when ore is procured from artisanal miners involved in child labour, working under deplorable conditions, or in conflict-ridden areas. Companies often do this to access raw materials cheaply.
Unfortunately, such practices can damage an organisation’s reputation. To meet ethical sourcing requirements, mining companies must tackle the issue in two ways — internally and through engagement with certification bodies.
In-house, mining operations must develop and rigorously implement sourcing mechanisms for their supply chains, Essop suggests. “It is vital that organisations conduct thorough due diligence when onboarding new suppliers and perform ongoing self-assessment.”
Additionally, to enhance ethical sourcing, mines can apply for membership in certification bodies relevant to their commodities. For example, the Platinum Council serves platinum mining companies, and the World Gold Council represents gold mining companies. These bodies conduct thorough assessments and screenings to ensure responsible sourcing.
Generally, for organisations to effect meaningful changes in environmental compliance and ethical sourcing, leadership must come from the top. This requires assembling a multidisciplinary team with diverse skill sets and certifications across sustainability, finance, accounting, and supply chain.
Independent assurance
While internal improvements to ESG reporting may be well-intentioned, ultimately, stakeholder confidence depends on the publication of complete and accurate sustainability data. This is where qualified auditors providing independent assurance of end-to-end consistency play an essential role, offering either limited or reasonable assurance.
Engaging an auditing firm for independent assurance can help elevate sustainability reporting to investor-grade standards. This goes beyond demonstrating a company’s commitment to addressing climate change and related issues.
Who is doing your assurance?
Given the complexity of ESG assurance processes, it is important to engage a firm with a proven track record, says Essop. “The choice of auditing firm can significantly impact the quality of reporting and assurance. For instance, large multidisciplinary firms and boutique
firms differ in diversity, depth of resources, and competencies.”
Typically, auditing is conducted in accordance with ISAE 3000 (International Standard on Assurance Engagements 3000), which sets out how sustainability assurance should be performed and who is qualified to conduct it.
Therefore, companies should seek advice from experienced entities with credible sustainability and audit expertise. An organisation with broad expertise and certifications across sustainability, finance, accounting, supply chain, and more - and a verifiable ESG track record - would be ideal.
Finally, Essop advises mining companies to develop a sustainability roadmap. “A roadmap ensures a business is future-fit - with a competitive advantage that goes beyond product pricing.“
Jameel Essop is a chartered accountant by profession with over 15 years’ experience. He specialises in end-to-end sustainability and is a Partner at PricewaterhouseCoopers South Africa (PwC SA). His diverse project portfolio includes consulting for blue-chip mining companies such as Gold Fields, Impala Platinum, and Harmony Gold, with experience spanning gold, copper, and downstream industries like refineries.
Women Empowerment in mining - The South African Context
Develop, Unite, and Empower
Ankia Roux of Pinpoint Stewards, a prominent women-owned company in South Africa, fields questions on the forthcoming 4th Annual Women & Leadership in Mining Conference and its relevance to the empowerment of women in mining.
2024 Conference - In the midst of the hectic event, the women leaders had time to pose for photo.
MBA: What is the theme of the Annual Women & Leadership in Mining Conference?
AR: The theme of this year’s conference is DUE, which stands for Develop, Unite and Empower women by focusing on planning for the next five years.
MBA: We have seen many events themed around the role of women in mining. What makes the Annual Women & Leadership in Mining Conference unique?
AR: Pinpoint Stewards, a women-owned company, aims to display South Africa’s leadership across all levels, from junior to executive positions within industry.
Each year, a new panel of speakers is selected to broaden the scope of women who are profiled in the sector and to gain a wellrounded understanding of leadership, rather than highlighting only well-known and established leaders.
We believe that profiling different leaders annually not only gives them the opportunity to be noticed but also allows them to influence the lives and career paths of others hoping to follow
in their footsteps.
We have a passion for young professionals, and since the inception of our annual conference four years ago, we have included between 10 and 20 postgraduate students yearly who attend and are actively introduced on the day to a potential mentor or job shadowing opportunity.
The format of our conferences encourages networking. This is done through round table seating, sit-down lunches, networking functions, and open forum discussions.
A percentage of profits is given to selected beneficiaries each year. This is based on our Christian values as an organisation to tithe.
Our delegates are also showered with a Women’s Month gift to remind them that they are celebrated within mining and should stand their ground to build equity.
MBA: We noticed your speaker list includes male leadership. Isn’t this a misnomer in a women’s conference?
AR: You cannot effect change if all parties are not included, and last year women emphasised the importance of men participating to effect
change as co-workers and co-leaders. The conference is therefore aptly titled Women and Leadership in Mining.
To ensure mining becomes more inclusive for women, every effort must be made to eradicate gender bias. This can only be achieved by having men present to exchange solutions and ideas, and to gain introspection on what is shared from the podium.
MBA: Why include men? Why is it important for men to be part of the conversation?
AR: The specific topic addressed by Dr Moagi, Executive of Group Health Services from Implats, will be an overview of health and safety for women at the mine, addressing some of the biggest challenges including harassment, bullying, and victimisation.
Women and men need to co-exist in mining, and a male perspective can ensure the two worlds meet. A notable aspect is that while the conference unearths a host of strategies for the successful inclusion of more women in mining, leadership in mining is a universal topic applied by both women and men.
MBA: The conference is organised in collaboration with women empowerment partners. What specific role do they play in the conference?
AR: As defined in the dictionary, empowerment means authority or power given to someone to do something. Through empowerment partners at the conference, companies show that they do not just go alone but go as a team, investing in their women-capital. Personnel at all levels of the mine are handpicked to attend and are afforded the opportunity to share empowering talks to lead and foster growth.
MBA: What do you regard as the conference’s key milestones since its inception?
AR: Key milestones over the past four years have been using this platform to enable more women to be recognised within the sector. Media partners have stood with us since the beginning in making this happen.
I was part of hosting the first Women in Mining conferences in the year 2000. At that time, it was almost impossible to find women in the sector, maybe only in HR or finance.
Now the options are limitless. Women are found at all levels of the mine, which is encouraging to see.
A personal milestone for us is when women walk away from the two days saying it was a “life-changing” experience. We do not do it for the applause but to be part of growing womencapital and the visibility of leaders.
MBA: You have described women-capital as “the most untapped investment in the world”. In the context of the mining sector, are South African companies making the most of this untapped capital?
AR: To a degree, mining companies are including more women in their employment, which has positively impacted statistics. That
being said, we need to see an acceleration in the appointment of more women at senior and executive levels.
Women have a lot to contribute, so skill them and include them to drive your overall output. It is proven that diverse teams perform better, so why not tap into that at a faster pace?
MBA: If not entirely, where could they do better? In which roles would you like to see more women participating?
AR: While the employment of women is increasing yearly, the dialogue needs to move towards the appointment of more women in C-suite positions. The lack of women at the top is concerning, and there are only a handful of women in CEO roles.
MBA: Last but not least, talk about the importance of benchmarking progress of women in mining.
AR: Women attending sometimes feel they
are “alone” in facing various challenges in a male-dominated sector. But being part of the magnitude of this event, they realise they are making inroads to close the gap on gender inequality.
Benchmarking their progress and best practices against what other mines are implementing enables them to use these tools to further progress and promote inclusivity and sustainable development. Tracking key metrics helps companies assess how well they attract, retain, and promote women, and highlights areas needing improvement. This not only fosters a diverse workplace but also strengthens industry performance and its reputation for change.
Note: The 4th Annual Women & Leadership in Mining conference will take place on 27 and 28 August 2025 at Indaba Hotel Fourways, Johannesburg.
A conference in session: Tackling pertinent issues head-on
Mining is part of our DNA, and we are committed to fostering sustainable growth and innovation across Africa’s mining sector. For over a century, Webber Wentzel has supported clients with forward-thinking legal solutions throughout Sub-Saharan Africa’s mineral-rich jurisdictions.
As the mining industry continues to evolve, women are playing a pivotal role in driving this transformation. Whether in legal, technical, operational, or leadership positions, their impact is shaping a more inclusive and responsible future for the sector.
We are proud to acknowledge and support the women who are breaking new ground, leading with insight, driving progress, and contributing meaningfully to the future of mining in Africa.
Home to some of the foremost legal minds in mining, Webber Wentzel is especially proud to highlight the women who play a crucial role in guiding our clients through this complex and dynamic landscape.
As the continent increasingly power purchase resilient energy
We are proud in advancing these professionals applying their fresh perspectives, a more inclusive,
Recognising Women Powering Africa’s Energy Transformation
Wentzel provides strategic legal support across the energy value chain, from renewable energy and solutions to petroleum and gas regulation, enabling clients to deliver complex projects and navigate regulatory landscapes throughout Sub-Saharan Africa.
continent progresses towards a just energy transition, legal reform and sustainable procurement are increasingly vital. Women are playing a central role in this evolution, leading in areas such as grid integration, purchase agreements, ESG compliance, and energy pricing, driving a more inclusive and energy sector.
CELEBRATING WOMEN
proud to recognise the women whose leadership, legal expertise, and technical insight are instrumental advancing a sustainable energy future and creating meaningful impact across Africa. In our Energy Sector, professionals play a key role in developing the legal frameworks that support innovation and sustainability, their knowledge and leadership to drive positive, lasting change in the sector. They bring deep expertise, perspectives, and bold leadership to every challenge, enriching our legal services and contributing to inclusive, forward-thinking industry.
Women in Mining
The Trailblazer
Thelma Horsfield leads the way in water quality and condition monitoring. She is the General Manager of WearCheck Water, a division of WearCheck.
In the male-dominated world of mining, women are increasingly stepping into key leadership roles, bringing a wealth of expertise, fresh perspectives, and unmatched resilience. One such trailblazer is Thelma Horsfield, general manager of WearCheck Water, a division of WearCheck, renowned for its expertise in fluid analysis and condition monitoring.
In the male-dominated world of mining, women are increasingly stepping into key leadership roles, bringing a wealth of expertise, fresh perspectives, and unmatched resilience. One such trailblazer is Thelma Horsfield, general manager of WearCheck Water, a division of WearCheck, renowned for its expertise in fluid analysis and condition monitoring.
With a career spanning nearly three decades in the mining and analytical chemistry sector, Thelma’s journey is a testament to grit, adaptability, and a commitment to excellence. Initially drawn to the medical field, she accepted a bursary from ArcelorMittal (then Iscor) to study Analytical Chemistry - an opportunity that set her on a path to play a vital role in the mining industry. ‘It was more important to make a sensible decision that worked for myself and my family,’ she reflects. ‘I’ve never regretted it.’
Today, Thelma leads a team - 95% of whom are women - in the specialised field of water analysis for the mining sector as well as for other industrial sectors, ensuring regulatory compliance and safe operational conditions. Her work is critical to maintaining high standards in water quality monitoring, a cornerstone of sustainable mining and environmental stewardship.
But the road was not always smooth - as a young woman and shift leader in a plant at Anglo Platinum, Horsfield faced the daunting challenge of managing an all-male team. ‘I was 27 years
old, shy, and soft spoken,’ she recalls. ‘I had to dig deep to find my confidence and ensure my voice was heard and respected.’
Her story reflects broader shifts in the mining sector. ‘When I started, men were often paid more simply because they were seen as breadwinners. That’s slowly changing. Abilities and responsibilities - not gender -must define a person’s value,’ she says. She’s encouraged by the growing number of women in supervisory and management roles, but acknowledges that there is still progress to be made in areas such as pay equity and workplace flexibility.
Through structured training, mentorship, and a strong emphasis on equity and inclusion, WearCheck Water actively supports women’s advancement. Thelma also points to external support networks like Women in Mining South Africa (WiMSA) as invaluable to career development.
For women entering the sector, Thelma offers this advice: ‘Build a strong network, keep your technical skills up to date, and invest in your soft skills and confidence. There’s always something new to learn - especially in analytical fields where accuracy, critical thinking, and attention to detail are vital.’
In her experience, women bring unique strengths to the mining sector, especially in analytical roles. ‘Women often excel at multitasking, planning, and managing complex systems with precision. These skills are critical in condition monitoring, where accurate data and timely interpretation directly impact equipment performance and safety.’
As Thelma continues to lead with vision and compassion, she remains a shining example of how women are not just participating in miningthey are transforming it.
Who is Thelma?
Thelma Horsfield is in charge of WearCheck Water – the water analysis division of condition monitoring specialist company, WearCheck.
Thelma entered the mining sector in 1995, joining WearCheck Water via WearCheck’s sister company, previously SetPoint, in 2004 as a spectroscopist in the ICP-OES department, and worked her way up to the position of general manager in 2018.
Thelma is based in the WearCheck Water’s Cape Town laboratory and is also in charge of the Johannesburg laboratory. WearCheck Water analyses and processes over 700 water samples per month for clients in multiple industries, including mining, agriculture, medical and others.
In her time as General Manager, the WearCheck Water team managed to get over 90% of their methods accredited under the ISO 17025 standard.
In 2019 she assisted in starting up the Cape Town water laboratory and accredited most of this laboratory’s methods nine months later. Currently, WearCheck Water has 33 ISO-accredited methods and will add more methods in the company’s next surveillance audit.
Recently, WearCheck gained accreditation for AdBlue analysis - a new and exciting extension of the company’s scope of analysis. Additionally, WearCheck Water’s Johannesburg laboratory was recently awarded ISO/IEC17025 accreditation for Total Coliforms and E.coli Testing, reinforcing the company’s commitment to adhere to national and international work-quality standards.
Safe, Efficient, and Compliant Weighing
It is not just a matter of weighing rail cargo, it is about how it is done and the technology employed. Intelligent weighing technologies fill the gap for safety, efficiency, and compliance in this area for contemporary African mining operations in ports, freight yards, and cross-border routes.
During the 2025 Investing in African Mining Indaba, the underlying message from stakeholder presentations was the need to explore potential avenues to improve efficiency, contain costs, meet sustainability goals, and enhance safety from pit to port. Currently, mining companies are exploring viable options to achieve this.
Among other options, rail transportation could present a viable path, but only if utilised effectively.
Opportunity in Rail Transportation
In rail transportation, cargo weight measurement presents immense opportunity. This is essential as it ensures safety, compliance with regulations, and efficient operations.
Unfortunately, many African mining operations may be missing out, as they still rely on traditional weighing methods or outdated technologies. This issue was raised during a panel discussion at the Rail Africa Exhibition 2025, held at the Sandton Convention Centre, Johannesburg, South Africa. It came up in a presentation by South African governmentowned rail operator, Transnet.
Pitfalls of Traditional Weighing
Traditional weighing methods typically include:
• Static weighbridges
• Portable wheel/axle scales
• In-motion weighing (dynamic weighing)
• Mechanical lever scales
While these methods serve a purpose, each has pitfalls, often costly ones.
i.
Wrong measurements
Data from scale measurements must be as accurate as possible. However, as is the case with in-motion weighing, accuracy declines at higher speeds or under poor track conditions compared with static weighbridges.
Portable wheel/axle scales are also less accurate, more labour-intensive, and unsuitable for high-volume weighing. Similar challenges apply to the other methods.
As a result, common and serious problems arise:
1. Overloading
Wagons that are too heavy or unevenly loaded present two major risks:
• Infrastructure damage: Overloading strains tracks, points, and bridges.
The Refinery: An East African Affair
With Uganda’s refinery development entering a pivotal phase, UIOGS 2025 will spotlight the project’s transformative potential - not just for Uganda, but for the wider East African region
From industrial growth and regional trade to local capacity building and energy security, the summit will explore how the refinery will drive long-term, shared prosperity.
Join us this September for the 10th Uganda International Oil & Gas Summit (UIOGS 2025).
Intelligent Rail Cargo Weighing
• Accidents: Overloading increases accident risks. This is a frequent issue in many African countries. In the DRC, for instance, overloaded wagons carrying cargo and passengers have tipped over, sometimes with fatalities and extensive damage. Similar incidents occur elsewhere on the continent.
Further, where outdated sensors are used, inconsistencies in recorded data increase transportation and operational risks. At Rail Africa, a German company highlighted their client’s experience in Kazakhstan. A rail operator servicing mines had been using an outdated system, which increased the normal operational cycle by 20% to 40%.
3. Time-consuming
Static weighbridges require trains to stop. This slows operations. Similarly, mechanical lever scales require manual operation.
4. Regular maintenance
In addition to track infrastructure requirements, static weighbridges and in-motion systems require significant investment in maintenance.
A Compelling Business Case for Alternatives
Clearly, traditional weighing methods fall short of meeting the requirements of modern mining. This creates a strong business case for adopting alternative weighing methods, particularly solutions that are flexible, adaptable, highly accurate, cost-efficient, and easy to use.
Intelligent Weighing Fills the Gap
At Rail Africa 2025, manufacturers and vendors showcased advanced rail weighing systems designed to meet these needs. A key feature across most solutions was the integration of intelligence in weighing. Handily, rail operators serving mines now have a wide range of options. It is a matter of making informed choices of products that offer features that meet their needs in intelligent rail weighing.
Features of Modern Systems
Automated in-motion rail cargo weighing systems (intelligent rail weighing) with AI and sensor integration share several features:
a. High-Precision Sensors
Advanced systems use high-sensitivity sensors such as quartz crystal load cells, strain gauges, and accelerometers embedded in rail tracks.
One exhibitor explained:
“These sensors measure axle or car weight with precision, achieving accuracy within ±0.2–0.5%, even at speeds up to 40 km/h.”
Additional sensors, e.g., temperature or vibration detectors, further ensure reliable measurements under diverse conditions.
b. AI-Driven Data Processing
AI algorithms process real-time data to correct for dynamic factors such as train speed, track irregularities, or load shifts. They detect anomalies like overloading or uneven distribution, and also identify wheel wear or track degradation.
c. IoT and Cloud Connectivity
IoT integration allows real-time data transmission to cloud-based platforms, enabling remote monitoring and seamless integration with logistics or regulatory systems.
Edge AI devices further reduce delays by processing data locally. This is critical for hightraffic rail networks.
d. Multi-Sensor Combination
These systems combine load cells, laser scanners, RFID readers, and cameras to deliver comprehensive data on weight, cargo condition, and train health. This enhances load verification, tracks individual wagons, and correlates weight with cargo manifests. In this way, it reduces manual inspections.
e. Automated Compliance and Alerts
Real-time analytics automatically flag weightlimit violations, load imbalances, or equipment issues, sending alerts directly to operators.
Tangible Benefits
If properly deployed, modern automated inmotion rail cargo weighing systems with these features offer significant benefits in ports, freight yards, and cross-border routes:
• Enhanced Data Accuracy
AI corrects for dynamic variables, delivering near-static precision and minimising errors.
Real-time detection of overloading and imbalances reduces derailment risks.
• Predictive Maintenance
AI forecasts equipment or track issues, enabling timely interventions and preventing costly downtime.
• Compliance
Automated alerts ensure adherence to regional standards across African countries.
• Seamless Integration
Through IoT and cloud connectivity, teams can access real-time data across devices and functions.
Informed Decisions
From the foregoing, as African mining companies are in pursuit of greater efficiency, safety, and sustainability, there is a compelling case for intelligent weighing technologies as a viable solution across the logistics chain. Why stick with outdated systems that cost time, money, and at times lives?
One thing is clear: the mining in Africa runs on smarter weighing. Thus, mines have to make informed decisions on solutions they utilise.
Low-Emission Plug Valves
AZ Sealing System Solutions for a cleaner and safer environment
According to ISO 15848, TA-Luft and API 641 (German standard) Local for local - Local manufacturer since 1985
ARMATUREN
free of cavities & maintenance
Product range
Plug Valves with PTFE-sleeve two-way and multi-way valves
HIGH PERFORMANCE valves for processes with demanding requirements
Valves with PFA / FEP lining full safety for operator and environment
Sampling systems safe, representative, reliable
Control plug valves precise equal percentage or linear control
Piping accessories
metallic or with PFA / FEP lining, lined strainers, lined ball check valves, lined sightglasses
Actuation aligned, verified and tested components
Special solutions customized plug valves made of cast and forged special materials
AZ-Armaturen South Africa (Pty) Ltd 28 Derick Coetzee Street, Jet Park Ext. 20, Boksburg, 1459
www.az-armaturen.co.za
SILVERPOINT DYNAMIC RAILWAY SCALE
SilverPoint is a modern automatic dynamic railway weighing system for weighing of train set and wagons and for monitoring of their other load parameters. The system is available both in a technology version and in a commercial-use version (type-approved measuring device for commercial purposes).
ADVANTAGES
dynamic weighing system for measuring the weight of a train and wagons and for checking the lateral and longitudinal overloading of individual wagon in motion
scale suitable also for checking errors caused during wagon loading
excellent accuracy, type-approved measuring device very easy to install, no disruption to the transport operations
suitable for both commercial and technological weighing
possibility of connection to Tamtron OCR system for recognition of wagons and containers
SPECIFICATIONS OF SILVERPOINT
RAILWAY SCALE
SilverPoint dynamic scale for commercial use measures individual wagons weights and the total weight of the train set in commercial quality according to OIML R106. In addition, the system is also capable of detecting incorrectly-loaded wagons, both longitudinally and laterally, as is the case with the technology version of the SilverPoint scale.
SilverPoint dynamic scale for technological purposes is capable of monitoring and measuring wagon weight parameters such as axle and bogie loads, and of measuring its total weight. The system also provides the total weight of the train set being weighed and the speed at which the weighing was carried out. In addition, the system compares the weights of the wagon bogie to detect incorrectly loaded wagons, both longitudinally and laterally.
FULLY AUTOMATIC WEIGHING SYSTEM
SilverPoint dynamic scale can operate in a fully automatic mode without the need for scale operator intervention, or as a classic operator-controlled railway dynamic scale.
In the automatic mode, the weighing data is transferred from the scale to the user’s superordinate system which further processes it according to the user’s need and purpose.
In the case of a standard weighing performed by the operator from their PC, the scale is equipped with the data-processing and operator user software ScalexPC - railway scale with all standard functions such as databases of customers, wagons, materials or products, etc. The system enables the printing of not only weight tickets, but also various reports defined by the user.
SCALE INSTALLATION
SilverPoint scale can be installed quickly and easily without the need for any civil works modifications or interference to railway gravel bed. Load sensors are installed directly into the rails of all standard types without the need to cut the rails. The track into which the scale is installed should meet the manufacturer’s slope and flatness requirements. The scale’s measuring electronics, including an industrial computer with analysis software, are located either in a separate outdoor cabinet next to the tracks, or in a cabinet inside any nearby building, depending on the customer’s requirements.
The installation is carried out without the need to interrupt the operation on the railway track; no track closure is required. Typically, the total installation time is three days. The installation of the scale itself, including the electronic parts and static calibration, takes two days. On the third day, dynamic calibration is performed with reference train set.
TECHNICAL SPECIFICATION
WEIGHBRIDGE: sensors installed into a rail.
WEIGHING CAPACITY: 40 t / axle.
DIVISION: e = d = 100 kg.
WEIGHING RANGE: 1 t - 40 t for a single axle.
MAX. WEIGHING SPEED: 40 km/h.
MIN. WEIGHING SPEED: 1 km/h.
CROSSING SPEED: unlimited.
WAGON TYPES: all standard wagons.
WEIGHING ACCURACY*): maximum permissible error of 2%(1%) for an individual wagons and of 1%(0,5%) for the entire train (total weight of the train set) depending on the quality of the track in front and behind the scale.
TYPE APPROVAL: EC-Type Examination Approval number
TCM 128/15 - 5310.
RAIL TYPE: all standard railway rails such as S49, R60, R65, etc.
*) The scale in the commercial weighing version can only be used for weighing solid cargo, not liquid cargo
Tamtron is an advanced product manufacturer and weighing information management service provider in the weighing industry that is committed to high-quality and responsible service. The company’s success is based on the ability to produce some of the most innovative and competitive weighing solutions in the industry. The weighing solutions provided by Tamtron make customers’ everyday operations easier and more efficient not only in the construction and mining industry, but in industries such as manufacturing, harbours, forestry and timber, transport and logistics as well as recycling and waste management. The company’s ISO 9001:2015 quality certified know-how ensures high-quality deliveries.
The internationally operating company has a turnover of EUR 55 million, and the group employs 300 professionals. The company’s main office is in Finland, and it has subsidiaries in Czech Republic, Denmark, Germany, Norway, Poland, Slovakia and Sweden. In addition to strong domestic trade, Tamtron exports its products globally to more than 60 countries. Tamtron is a reliable partner for demanding weighing solutions with more than 50 years of experience.
WearCheck, Africa's leading condi�on monitoring company, is commi�ed to serving the mining industry with its range of sophis�cated analy�cal techniques.
Our specialist oil, coolant and fuel tes�ng programmes allow customers to reduce maintenance costs, avoid unexpected mechanical failures and ul�mately reduce unscheduled down�me.
Unlock Machine Reliability!
Mining Business Africa (MBA) is Pan-African bi-monthly publication that focuses on latest developments in mining and allied industries in Africa. The publication covers the scope of critical activities from pit to port – mineral exploration (prospecting), mine planning and development, extraction, mineral processing, storage transportation, as well as beneficiation.
Mining Business Africa provides the desired mileage for companies looking to promote their products and services to a specific niche clientele in the African Mining Sector. Subscribers are located or at least involved in projects in South Africa, Botswana, Zimbabwe, Zambia, Kenya, Democratic Republic of Congo, Kenya, Tanzania, Ghana and Nigeria.
MBA is published by Media Icon, a company manned by personnel with a combined experience of 30 years in the publishing space. TO ADVERTISE | CALL: + 27 10 055 3356 | Email: info@miningbusinessafrica.co.za
