The 2025 Joburg Indaba, now in its 13th year, will take place on 8 & 9 October 2025 at the Inanda Club, Sandton, with the Gala Dinner taking place on the evening of 7 October.
Critical and constructive conversations are one of the stand-out features of the Joburg Indaba and we remain committed to serving the industry with robust discussions that get to the crux of the key issues. We once again bring together an outstanding panel of speakers, including CEOs and senior representatives from all major mining houses, local and international investors, government, parastatals, experts from legal and advisory firms and representatives from communities and organised labour. For
Follow us on our website for the latest speakers and programme developments www.joburgindaba.com
Sponsors of the 2025 Joburg Indaba include:
THE INANDA CLUB, FORREST ROAD, INANDA, JOHANNESBURG
“As they chase high revenue numbers, mining companies risk dropping the ball on compliance obligations like ESG reporting and health and safety regulations. This doesn’t always end well - it can result in costly breaches that egate anticipated gains.”
Contracting for Opencast Mining Projects
Editor’s Note
No Free Lunch — Africa, Get Your House in Order!
In the changing geopolitical landscape, President Donald Trump has revised the nature of the relationship between the USA and other countries: transactional deal-making is the name of the game. No free lunch. The days of lopsided arrangements, where other countries leeched off the USA, are long gone.
What comes to mind first when countries approach a bilateral relationship with the USA is: “What’s in it for us, and what can we offer?”
Of course, resource-rich African countries — especially those endowed with rare earths and critical minerals — have the leverage: something to bring to the table in engaging with Western countries.
One of those countries is the Democratic Republic of Congo (DRC), which, as this publication goes to press, is involved in negotiations with the USA. From what we have gathered, the deal involves the USA providing security guarantees in exchange for allowing US companies access to mineral resources. Other countries are set to follow suit. But having something to offer on the negotiating table is only half the story. The revenue windfall African countries get from such deals will count for nothing if they do not put their houses in order. Increased revenue is nothing to get excited about if the trajectory of events in the past sixty years of independence is anything to go by.
With the reduction of various forms of aid from Western countries, it is a wakeup call for resource-rich African nations to work on improving governance.
Nick Barnes editor@miningbusinessafrica.com
Editor
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On-Site Laboratory Construction
Wearable Technologies
Driver Bureau’s Operator Training
Modular Plant Solutions for African Mining Projects
Trusted, Independent, and Committed
Technical depth, execution capability, and regional understanding have made SGS Bateman a go-to company in the provision of modular mineral processing plants for various mineral commodities.
By Jimmy Swira
The nature of ore bodies in contemporary greenfield and brownfield mining projects in Africa necessitates mine planning with the short-term or medium-term in mind. The short life of mine (LOM) renders the use of conventional processing plants less feasible.
SGS Bateman’s Tailored Modular Plant Solutions
SGS Bateman meets this need through tailored modular processing plant solutions for both greenfield and brownfield mining operations. These solutions are particularly well-suited to addressing challenges such as short LOM in many modern projects, especially in the African context, where logistical, financial, and operational constraints can be significant.
A Vast Range of Options
Cognisant that every project has unique conditions, SGS Bateman has developed a vast range of options to suit the client’s specific needs. These standard Dense Media Separation (DMS) plants consist of 1, 5, 10, 20, 50, 70, 100, 150, and 200 tph modules, which can be incorporated into purpose-designed plants for large-capacity processing. Alternatively, they can be used as multiple modules in parallel to boost output and enable servicing while maintaining plant throughput.
A Broad Range of Applications
The broad range of applications for the modular plants includes:
• 1 tph plant suitable for prospecting
• 50 tph plant (one of the most popular)
• Modular plants in parallel for increased throughput
• Plants used for sampling campaigns with capacities from 10 tph to 60 tph of feed
• Ship and barge-mounted plants comprising floating modules to process material
pumped from beds under the sea and rivers. These include liberation modules for scrubbing, screening, and sizing, DMS modules, and diamond-recovery modules.
Necessity: The Mother of Innovation
The evolution of the modular plant has been phenomenal. Interestingly, from pioneering Dense Media Separation (DMS), modularisation has since been adopted in other areas of mineral processing. Initially, the modular plants were built out of necessity for remote sites requiring top performance. As the saying goes, “Necessity is the mother of innovation.” SGS Bateman has since applied the modular concept to other commodity applications, such as a 14 tph modularised gold CIL (Carbon In Leach) plant. To date, modular plants have been successfully deployed in diamonds, coal, graphite, copper, magnesite, andalusite, chromite, PGMs, iron ore, and lithium/spodumene.
Benefits of Modular Plants
By choosing SGS Bateman’s modular plants, African mining operations are assured of the following benefits:
• Pre-engineered, pre-fabricated, and pretested before packing and shipping
• Include mechanical, piping, electrical, instrumentation, and control elements, allowing for quick installation and commissioning
• Allow for future expansion or relocation, ideal for deposits with limited LOM or phased development strategies
• Logistically optimised for remote African sites, with minimal civil requirements and simplified construction
• Can be integrated into existing infrastructure with minimal disruption
• Compact footprint, minimised earthworks, lower water and power consumption, and potential for full plant redeployment
• Process design can include recovery improvement and energy efficiency enhancements
• Modular units allow for phased implementation of upgrades or capacity increases
• Pre-assembly and testing are done off-site before delivery, reducing on-site construction and commissioning time
• Construction risks on-site (weather, labour, etc.) are reduced as modules are largely built off-site
• Dedicated commissioning teams ensure quick ramp-up to nameplate capacity
Why SGS Bateman Stands Out
“When you need to be sure” coupled with “process plants that workTM” that are associated with SGS and SGS Bateman brands, is an assurance that clients can be satisfied that they will get the value that they expect. This is guaranteed from the decades of experience that a more than 100-year-old company will provide. The key to SGS Bateman’s success lies in the approach employed to create self-contained plants. Each plant is carefully constructed, and can be fully trial-erected and pre-commissioned in South Africa, before being stripped down and packed into containers for despatch to the designated project site. This approach ensures streamlined installation and swift operation, minimising time on site and maximising efficiency. Moreover, the modular plants’ compact nature means they can be incorporated easily into larger
processing plants. The modules are standalone, so they can be moved to new operations or sold to new owners.
Unique Offering
More importantly, SGS Bateman’s unique offering combines strong process expertise, vertically integrated services, and a track record of delivery in challenging environments. In partnering with the company, African mining companies can be assured of the following:
• SGS is the world’s leading testing, inspection, and certification company. It can leverage this to integrate metallurgical testing seamlessly and transition from lab test work into plant design. Being part of the SGS Natural Resources group gives SGS Bateman the ability to offer a full suite of services should the customer want to work with SGS throughout initial test work and all project phases.
• With extensive process design capability,
Innovative Engineering Solutions
SGS Bateman can offer innovation in flowsheets.
• Unlike some modular providers that only deliver engineering or fabrication, SGS Bateman is also a full-scope EPCM provider, which allows integration of the modular plant into existing operations and the addition of bespoke reagent service utility areas as required. It provides complete EPCM services in-house - from test work supervision and concept studies, feasibility and design to construction management and commissioning. Being strong in process plant design, SGS Bateman can engineer its plants from a process-driven foundation using metallurgical test work to optimise recovery and minimise surprises during operation. A selection of pre-engineered, proven process modules allows for rapid configuration and fast procurement.
• SGS Bateman prioritises robust designs that can be adapted to client requirements and comply with international safety and environmental standards.
• As a pioneer of modular plants since the 1960s, SGS Bateman has an extensive track record of successful modular plant installations around the world and in African countries like South Africa, Angola, Ghana, DRC, Zimbabwe, Namibia, and Mozambique.
SGS Bateman has been at the forefront of innovation, offering cutting-edge modular mineral processing plants that have revolutionized the industry.
Process plants that workTM
• Consulting
• Due diligence
• Testwork supervision
• Process development
• Feasibility studies
• Engineering & design
• Project management
• EPC & EPCM services
• Modular plants
za.bateman@sgs.com
T: +27 10 900 1990 sgs.co.za
Technical depth, execution capability, and regional understanding have made SGS Bateman a go-to company in the provision of modular mineral processing plants for various mineral commodities.
Data Drives Decisions
Accurate laboratory data drives decisions, earns investor trust, and secures regulatory compliance. Isn’t there a better way to guarantee its integrity, apart from using proficiency testing?
By Jimmy Swira
Quality laboratory services are essential in the contemporary African mining sector— more so now, as exploration and mining projects surge across the continent to meet rising demand for critical minerals and gold. Naturally, these projects require reliable data to support key decisions at various stages of the mining value chain.
More necessary than ever
Data from analysis informs decision-making. Hence, sampling errors can lead to poor decisions, which may cost investors significantly.
This explains why investors seem to be more tight-fisted or prudent, insisting on guarantees of project viability before committing funds. Their caution is particularly warranted because many current greenfield projects coming on stream have a short life of mine (LOM).
So, it’s understandable why investors may appear unnecessarily fussy - who would gamble with their hard-earned money on a short-term venture? Clearly, there is no margin for error.
Therefore, accurate data has become more vital than ever. It is a determining factor that can make or break a project. That is why minerals testing laboratories, where thorough sample analysis is carried out, must uphold high standards of competence, whatever the cost.
To enhance the credibility of sampling and analytical results, laboratories must engage in third-party proficiency testing. Proficiency testing is a requirement for ISO 17025 accreditation in laboratories, which verifies the accuracy and reliability of analytical methods used. This is the only reliable way to validate results.
Specific benefits
The previous editions of Mining Business Africa (May/June 2023 and October/November 2024) featured two interviews with specialists from Qotho Minerals, one of the leading providers of proficiency testing services to mineral laboratories and a producer of certified reference materials. The two specialists were Dr Hannelie de Beer, the Managing Director, and Takudzwa Tsapayi, Qotho Minerals’ Operations Manager.
De Beer cited two critical purposes that proficiency testing (PT) serves in analytical laboratory QAQC operations: enhancing the credibility of results and identifying areas of improvement.
i. Enhancing the credibility of results
PT programs ensure laboratory results are accurate and reliable, which is essential for making informed decisions in mining operations. There is little or no margin for error — even minor inaccuracies in results can have major consequences for resource estimation, mine planning, and mineral processing.
On how PT enhances credibility, Takudzwa Tsapayi, Qotho Minerals Operations Manager, demonstrated: “The worst thing for any geologist, metallurgist or the marketing department is to doubt the credibility of the results they receive from their laboratory. For this reason, participation in regular, accredited and independently operated PT programmes is key to developing and ensuring a trusting relationship between the laboratory and the end-users.”
ii. Identifying areas of improvement
Proficiency testing enables laboratories to excel in analytical sampling. Identifying areas where processes or procedures need improvement promotes continuous enhancement.
By participating in proficiency testing schemes, laboratories can benchmark their performance against industry standards and identify where they may fall short. Ultimately, this helps detect potential losses or biases, improve data quality, meet regulatory requirements, and demonstrate laboratory competency.
Undoubtedly, the importance of using proven proficiency testing programs for laboratories in today’s mining environment cannot be overstated.
Key steps in PT
Given their critical role in ensuring data accuracy,
proficiency testing schemes require careful execution. These include:
1. Designing sample concentration ranges
Samples used in a PT program must be fit for purpose and meet industry requirements for the commodity in question.
2. Enhancing quality control measures
In quality assurance during PT delivery, both the client and the laboratory play a role in ensuring the analytical outcomes meet expected standards. Evaluation of a laboratory’s performance in a PT programme typically drives procedural improvement and quality control. de Beer explained: “Tracking their performance over time highlights trends and flags biases and systematic errors within the laboratory. Random fluctuations in performance, beyond the acceptance criteria, also alert a laboratory to the presence of gross random errors within their facility.”
Adhering
to international quality
standards
Tsapayi elaborated on the need for consistency: “Key to a successful PT sample and program is material homogeneity. As a PT provider, it is critical to ensure that each test item (within a batch) is deemed practically identical. Therefore, appropriate blending and sub-division methodologies are critical to ensure that we can ultimately demonstrate that the batch of samples is homogeneous.”
The stability of the material throughout the PT round must also be guaranteed. Tsapayi added: “Where the material characteristics can change, clear instructions must be provided to participants on how to handle the samples before analysis— for example, drying to ensure no moisture has been gained in transit.”
Non-negotiable
Overall, if there is a list of non-negotiables in mining projects, topping it is the accuracy of laboratory data. In an atmosphere that is increasingly competitive and risk-averse, safeguarding the integrity of analytical results allows PT to achieve three objectives in one fell swoop: building investor confidence, facilitating sound decision-making, and, the cherry on top, ensuring regulatory compliance.
Site Refurbishment and OnSite Laboratory Construction Laboratories for
Steenkampskraal Monazite Mine has initiated Site Refurbishment and On-Site Laboratory Construction. The facility will enable Steenkampskraal to fine-tune the MGS process, which is essential for producing high-quality monazite concentrate
In South Africa, Steenkampskraal Monazite Mine (SMM), a key player in the rare earth sector and one of the world’s highest-grade rare earths and thorium mines, has launched a significant phase of its development that marks the construction of a new on-site laboratory and a comprehensive refurbishment and reclamation programme.
“The laboratory, one of the cornerstones of the initiative, is set to enhance the mine’s ability to refine its innovative concentration processes, ensuring operational efficiency and supporting long-term sustainability goals,” explains Graham Soden, CEO of SMM.
“The project underscores Steenkampskraal’s commitment to advancing rare earth production responsibly, with a focus on optimising the extraction of monazite concentrates through a process called Multi Gravity Separation (MGS) and a subsequent hydrometallurgical cracking process to produce mixed rare earth carbonate (MREC), thorium and Radium-228.”
He says the on-site laboratory will serve as a
critical hub for testing and improving the mine’s processing techniques. Focusing on conventional gravity and flotation concentration methods. The facility will enable Steenkampskraal to finetune the MGS process, which is essential for producing high-quality monazite concentrate.
“In addition, having the laboratory on-site offers several practical advantages: it allows for immediate analysis and adjustments during the concentration process, minimising downtime and reducing the need for off-site testing. This close proximity also facilitates real-time data collection, enabling the mine’s technical team to make informed decisions quickly, which is vital for optimising resource use and reducing operational costs.”
“Furthermore, the laboratory will support Steenkampskraal’s broader sustainability objectives by helping to streamline processes, thereby reducing waste and improving the efficiency of rare earth extraction. This is a critical factor in meeting global demand for these materials, essential for technologies ranging from
renewable energy systems to advanced defense electronics,” he adds.
Enock Mathebula, Executive Chairman of Steenkampskraal Monazite Mine, notes, “The on-site laboratory will be instrumental in refining our processing techniques, ensuring we meet our operational targets efficiently. Combined with the safety infrastructure we’ve put in place, we’re creating a secure and productive environment for this project.”
Steenkampskraal has appointed Vetus Schola as the full-time safety and security service provider, ensuring 24/7 protection for personnel and assets. To bolster emergency preparedness, a 4x4 vehicle equipped with a fire-fighting skidunit has been deployed on-site.
Health and safety measures have also been enhanced with ER24 stationing a fully equipped 4x4 ambulance at the site, supported by a first-responder emergency room and a team of qualified paramedics available during working hours to provide immediate medical assistance if needed.
A Smarter, Faster Alternative to Traditional Fire Assay Methods
Baltic Scientific Instruments (BSI) Limited, headquartered in Riga, Latvia in the EU, but globally focused, is introducing its world-acclaimed Gamma Activation Analysis instruments to the African market. In regions where exploration and mining activities are ongoing or planned, the company hopes to replicate the success it has had in other regions on the continent.
Keeping an eagle’s eye on trends in global mining and pinpointing emerging needs to be met is BSI’s tried-and-tested approach to serving end-users of its Gamma Activation Analysis (GAA) analytical instruments. True to form, the company has identified a niche for Gamma Activation Analysis (GAA) equipment customised for gold-bearing ores in the African gold mining sector. Rising global demand has sparked increased exploration and new mining projects across the region.
The Suitability of GAA Instruments
Dr Vladimir Gostilo, the president and CEO of BSI, states that, typically, gold ore requires high detection sensitivity at the parts-per-million level which GAA instruments provide similarly to the fire assay method. To underline the advantages of GAA, he first highlights the shortcomings of the fire assay method.
Shortcomings of the Fire Assay Method
Typically, the fire assay method involves processes like preparation (grinding and
mixing), collection (lead fusion), and separation (cupellation). Conduct of fire assay analysis requires specially prepared laboratories, their equipage with precision analytical equipment, and the presence of trained and highly qualified personnel. All this calls for a lot of material costs, as well as time, since the process is time-consuming and slow. Thereby, the productivity of fire assay is very low, same as the representativeness of the results – since the weight of analyzed ore sample is small. In addition, for fire assay, chemical reagents are needed, which as a result of the analysis turn into chemical waste and their disposal is required.
The Effectiveness of GAA
Dr Gostilo highlights the most effective aspect about GAA: “Gamma Activation Analysis is a nondestructive control method. The same sample can be retested an infinite number of times. The high penetrability of gamma radiation allows to analyze large enough ore particles (1-3 mm). This eliminates the need for thorough crushing and grinding of ore, which provides advantages over conventional methods of selection and
preparation of samples.”
Further, he mentions the following attributes of GAA:
1. High penetrating ability of gamma radiation provides good representativity of samples due to using probes of 500-700 g weight;
2. Due to the short half-life of excited gold nuclei, the duration of the analysis does not exceed 20-30 s;
3. The method provides the necessary sensitivity and accuracy of analysis;
4. The analysis results practically do not depend on the chemical composition of the sample;
5. The method allows multi-element analysis over the course of a single cycle of the study and measurements;
6. The method can be fully automated. Extensive Applications
Unsurprisingly, due to these attributes, GAA is widely used in the analysis of samples for gold, other precious metals, and complementary elements. Generally, the method has proved very effective for application in mining and metallurgy.
Tailor-Made Turnkey Solution
BSI delivers its analytical equipment to clients in the mining sector in the form of tailor-made, turnkey solutions. In line with the requirements of customers, the company installs and then hands over the equipment, trains personnel on-site, and provides ongoing technical support. Moreover, as a firm believer in ‘local content’, wherever possible, the company always involves local technical companies in its business.
Through an integrated approach, customers benefit significantly from BSI’s technology. The company’s gamma activation analysers are precisely engineered for analysing ore samples for gold, other precious metals, and complementary elements. “Our equipment is originally developed for each of the specified applications. Besides, we always take into account the technological wishes of our customers. Last but not least, we use our vast experience to constantly improve the equipment,” says Dr Gostilo.
BSI delivers its analytical equipment to clients in the mining sector in the form of tailor-made, turnkey solutions.
Well-Equipped and Up to the Task
BSI is aware that there is an increasing number of manufacturers of mineral sample analytical instrument technologies aiming to get a slice of the African mining market. However, Dr Gostilo assures African mining companies that BSI is well-equipped and up to the task of meeting their respective needs. He particularly mentions the following:
1. Proficiency of the BSI Team
There is no better proof of the proficiency of BSI than the rich know-how and experience of its employees. For the record, leading specialists of the company have been involved in work on GAA of gold ores for more than forty-five years, since the first laboratories of GAA were established in the former Soviet Union. They participated in the organisation and technical support of GAA laboratories which has allowed to accumulate a huge methodological and metrological experience in carrying out the analysis.
2. Edge Over Competitors
BSI is aware that there are a number of providers of various analytical technologies targeting the African mining sector. However, in the field of
gamma-activation analysis equipment, there is only one competitor on the market that entered the GAA space in 2015-2016. BSI believes that competition is good for business and especially beneficial for the end user. However, the company believes that it has an advantage in the provision of gamma-activation analysis technologies:
• Extensive practical experience in GAA of gold-bearing ores;
• Flexibility to customise GAA systems in accordance with customer requirements;
• Development and manufacturing of a wide range of all components for GAA (linear electron accelerators, spectrometers and HPGe-based gamma radiation detectors, highly reliable systems for moving containers with samples, etc.) are handled in-house.
Africa: A Lucrative Market
It is small wonder that BSI has built quite a reputation in other parts of the world as an esteemed provider of GAA and XRF instruments for various products. The company regards Africa as a lucrative market, with huge growth potential for its GAA instruments.
Dr Gostilo reminds readers that BSI already delivers its online conveyor XRF analysers for determining the concentration of elements in minerals directly on the conveyor at mining enterprises.
Now, it is interested in promoting equipment for gamma activation analysis of gold-bearing ores to the market. “We are excited to bring a smarter, faster alternative to traditional fire assay methods,” enthuses Dr Gostilo.
Growing Global Success Portfolio
Along presence in other mining projects demonstrates the longevity of the technology and, most importantly, clients’ confidence in BSI’s technology. For instance, two sets of Gamma Activation Analysis facilities at the largest Muruntau Gold Mine in Uzbekistan have been running since 1977. Recently upgraded, they now churn out 1,600,000 samples annually. The same productive equipment for GAA is also installed at Pavlik Gold Mine in Russia.
Accuracy, Precision, and Speed
This couldn’t have happened at a better time! Coincidentally, as more mineral exploration projects come on stream across Africa, Spectrem Air is offering fast, precise, and high-impact AEM surveys.
In the mining industry, extracting valuable insights from high-resolution survey data is becoming increasingly sophisticated. Handily, enhanced visualisation tools and expert data interpretation add significant value to the process.
Fixed-wing Airborne Electromagnetic (AEM) Surveys
There are exciting advancements, particularly in airborne geophysics and mineral exploration technology. Fixed-wing Airborne Electromagnetic (AEM) surveys are revolutionising the exploration process by rapidly surveying regional areas early on in a project. This is shortening the exploration cycle and focusing expenditure on the most prospective geological terrains.
Rapid Decision-Making
The data collected from AEM surveys permits rapid decision-making early on in a project. This shortens the exploration cycle and significantly reduces costs. While subsequent electromagnetic surveys — ground, helicopter, or drone — are often carried out for additional
detail, primary targets or target areas are in many instances generated at the regional stage.
Spectrem Air at the Forefront
Spectrem Air is at the forefront of AEM technology. The company’s AEM systems are well-suited for exploring and mapping geology under cover, typical of most African environments. The multiple sensor data acquired — including magnetics, radiometric, and gravity data — provide clients with multidimensional coverage. Spectrem Air’s General Manager, Louis Polome, is elated at seeing AEM systems help meet clients’ project objectives.
“Ongoing investment in technology continues to deliver exceptional results. Advanced capabilities enable mapping mineral potential deep below the surface, helping clients sterilise the ground and pinpoint exact areas for exploration mining efforts.”
Africa-Focused
As a South African-based and Africa-focused company, Spectrem Air takes pride in its extensive experience across Africa to provide
relevant solutions to clients. It has completed successful projects in southern African countries and across the continent.
Opportunity for Innovation
While content with seeing the benefits of its AEM technology in African mining, Spectrem Air is focusing on the long term. It has been keenly observing developments in green energy.
The demand for critical minerals and metals for the global energy transition is driving the need for more extensive geological mapping and exploration. This will boost interest in effective techniques that help exploration teams meet their goals — and Spectrem Air sees this as an opportunity for innovation and would welcome enquiries for discussion.
R&D Investment in AEM Technologies
Thus, to effectively meet the need for innovative AEM for critical minerals projects, Spectrem Air is heavily investing in ongoing Research and Development (R&D) in AEM technologies. Its core focus is on the following areas:
Spectrem Air is at the forefront of AEM technology
a. Enhanced resolution for exploring deeper areas
Exploring deeper areas under cover with enhanced resolution, focusing on improving system bandwidth, lowering base frequencies, and achieving a better signal-to-noise ratio on both fixed-wing and helicopter-borne AEM systems.
b. Optimising and automating processing procedures
Optimising and automating processing procedures through better hardware and software improvements to enhance inversion and other interpretation techniques in AEM surveys. Notably, there is significant attention on utilising as much available data as possible, employing joint inversion of different geophysical and geological data sets, and applying Artificial Intelligence (AI) and machine learning techniques.
c. Better groundwater imaging
Besides probing deeper, there is a growing need to understand and image the near surface better for accurate groundwater location and better management of groundwater, as well as engineering and other environmental applications.
d. Non-invasive tests
The mining industry is shifting towards greener, less invasive practices. Hence, service providers
Fixed-wing Airborne Electromagnetic (AEM) surveys are revolutionising the exploration process by rapidly surveying regional areas early on in a project.
are increasingly recognising that state-of-the-art AEM technology meets the non-invasive criteria by generating high-resolution mapping and targeting solutions. In this way, they can mitigate the need for invasive tests or drilling in unsuitable areas.
Generally, as the world transitions to a more carbon-lean future, AEM is finding its place more and more in groundwater, natural hydrogen, and safe waste management site exploration, among other applications.
SPECTREM AIR: PIONEERING GEOLOGICAL EXPLORATION
We help you uncover what lies beneath with cutting-edge technology.
Comprehensive 3D Solutions – Integrated and interpreted data for Geological Mapping, Mineral Exploration, Geo-hydrology, and Geo-engineering.
Unmatched Precision – Accurate positions and orientations of both the aircraft and the towed bird result in superior resolution and data accuracy.
Enhanced Mapping – From shallow surface features to deep geological structures, we deliver higher quality insights.
Proven Expertise – Over 2.5 million-line kilometres of data processed across five continents.
How can we improve your geological explorations?
www.spectrem.co.za | info@spectrem.co.za
Committed
Looking ahead, Spectrem Air remains committed to investing in cutting-edge technology and equipping its team with the expertise to leverage it, says Polome.
“The goal is to solidify our position as a leader in airborne electromagnetic exploration globally and the partner of choice for companies entering new territories,” he explains, emphasising that the company is proud to bring accuracy, precision, and speed in AEM surveys accross Africa.
Malan Scholes
No Need to Fix What’s Not Broken
In the South African context, currently existing laws suffice to compel sound ESG reporting compliance. Effectively, this rules out the need for further measures, which could potentially increase the regulatory burdens for mining operations
By Jimmy Swira
You can safely bet on Environmental, Social and Governance (ESG) compliance being mentioned at highprofile mining conferences or related events in South Africa, just as it has been observed in other countries on the continent. In some cases, if one pays close attention, the impression is that there is a gap in the form of a universal yardstick to measure compliance. Implicitly or seemingly, this line of thinking excuses non-compliance or the evasion of compliance obligations.
However, in legal terms, non-compliance is no valid defence. So, could this perspective hold water?
Demystifying ESG Compliance
Prominent South African law firm Malan Scholes Incorporated has been passionately raising awareness, where necessary, about ESG in recent years. As expected, while fielding questions from Mining Business Africa, the firm’s Director, Hulme Scholes, demystifies ESG compliance.
“ESG compliance in South Africa is simply a new collective noun for obligations which already exist,” Scholes clarifies, referencing sections of existing legislation that mandate compliance.
Existing Regulations
In the South African mining context, ESG compliance takes the form of complying with environmental laws, the Social and Labour Plan applicable to mining rights, and governance over environmental and social obligations. Shedding more light on this, Scholes states:
“Mining companies in South Africa must comply with the National Environmental Management Act 107 of 1998 (‘NEMA’), the Social and Labour Plan, which is approved and issued by the Department of Mineral
and Petroleum Resources (‘DMPR’), and the Mining Charter, which gives guidance to the transformation imperatives under South African mining law (Mineral and Petroleum Resources Development Act 28 of 2002).”
In other words, this rules out the need for enacting an additional yardstick by which compliance should be measured. Already, mining companies must annually report the extent of their compliance with the Environmental Authorisation issued to them under NEMA and the Social and Labour Plan.
No Excuse for Non-Compliance
In view of this, there is no excuse for noncompliance. Failure to meet environmental and social obligations — whether deliberate or inadvertent — can lead to the withdrawal or cancellation of mining rights and environmental permission by the DMPR, as well as the laying of criminal charges against directors of non-compliant mining companies. Moreover, DMPR inspectors are mandated with sweeping powers to access mining areas and investigate alleged noncompliance.
Otherwise, Potential Unintended Consequences...
On the whole, Scholes asserts that, thus far, changes to current prescripts to enhance compliance are not necessary. Moreover, further changes could have the unintended consequence of increasing regulatory burdens and raising operational costs — a concern repeatedly voiced by mining operators. The question is: If it’s not broken, why fix it?
Malan Scholes Incorporated is a highly regarded law firm, active across several African countries, with mining companies among its most prominent clientele.
Driver
Collision Avoidance Sensors
Wearable Technologies Surveillance for Safety
In life, there is always a trade-off — contemporary safety in mining being no exception. To ensure they are safe and focused on their tasks, mine workers are using sensor-equipped wearable technologies such as vests, smartwatches, and helmets, among others. Their whereabouts and state of health are continuously monitored. However, this hasn’t escaped the attention of human rights bodies, who raise concerns about the infringement of individuals’ rights, with personal data potentially falling into the hands of bad actors.
By Jimmy Swira
There is more at stake in contemporary mining. Pertinent issues (not in order of importance) include:
• The health and safety hazards employees face have escalated
• Increased activity means more pollution (emissions)
• Mines are dealing with increased operating costs
• At the same time, they are obligated to increase the bottom line
If that is not enough, compounding matters, regulators or related bodies are introducing new regulations to enhance compliance, enabling mining operations to mitigate safety and environmental risks. Is there a more compelling
business case for the adoption of suitable technologies to cope with these myriad issues?
Wearable Technologies
Accordingly, mines and other industries are exploring means to help them manage these challenges. Wearable technologies (wearables), which are integrated with sensors and the IoT (Internet of Things), have emerged as one of the effective options they can utilise. The real-time data gathered is relayed to control centres, where the appropriate course of action is determined.
Based on information Mining Business Africa has sourced from leading suppliers and the Wearable Devices Market Insights, a global market report on wearables, three key aspects emerge: the increasing scope of wearables, the needs they are addressing, and the benefits
they bring (results from industries adopting them increasingly prove their relevance).
Scope of Wearables
Devices that are used widely in mining operations include smart helmets, smart vests, smartwatches, wearable sensors, smart glasses, and helmet-mounted glasses and sensors. With breakthroughs in research and development, more are certain to be added to the list.
Using sensors, wearables can perform tasks in rugged environments that were previously thought to be the stuff of science fiction. It is worth appreciating what some of them — smart helmets, smart glasses, and smart vests — can do.
Smart helmets detect hazardous gases like methane or carbon monoxide. They alert
Industrial workers with wearables
workers to the dangers these gases pose in their environments.
Their communication systems enable realtime coordination, and they can monitor vital signs, such as heart rate, to manage fatigue and track environmental risks.
Incorporating RFID tags, smart vests can be used for real-time location tracking during emergencies, providing supervisors with precise information about workers’ locations. In addition, the sensors in the vests monitor dust, noise exposure, or temperature. In this way, they reduce health risks like silicosis with respect to dust exposure.
Smartwatches monitor workers for signs of danger, onset of fatigue, or injury during a task, allowing appropriate instant interventions. In the event of fatigue, the intervention could be rest breaks.
Smart glasses offer augmented reality (AR) for hands-free access to equipment schematics or maintenance instructions.
Benefits
The list of capabilities of each set of wearables is long, but vitally, by adopting them, mining operations benefit mainly in the following ways:
1. Enhanced safety
By facilitating communication between workers and supervisors, wearables can improve safety and coordination. For instance, when hazards are identified, necessary and timely interventions — enabled by track-and-trace features — can take workers out of harm’s way, such as removing them from a fire or a caving site before the situation worsens.
2. Prioritising worker health
By monitoring fatigue, body temperature, and potential carcinogenic exposure to dust or fumes, among other factors, wearables can help make workers’ health a top priority.
3. Improved productivity
Tracking worker whereabouts and behaviour can ensure that workers stay focused on their tasks, enabling them to meet their targets. Improved
communication can provide access to actionable real-time data for making critical decisions, improving efficiency, and resulting in increased productivity. This, together with productivity gains from other areas, can increase revenue.
4. Compliance with regulations
With reliable, accurate data allowing for informed decisions in environmental management (like reducing emissions), and health and safety, a mining operation can comply with regulations.
‘Big Brother is Watching’ Fears Immersed in excitement over the incredible potential of wearables, it is easy to overlook their impact on employees and individuals’ rights. This issue was raised and discussed at length during a Human Rights Dialogue hosted by the Minerals Council South Africa, in conjunction with Anglo American and the Global Compact Network South Africa. It was facilitated by Synergy Global Consulting in 2022, which Mining Business Africa attended. And it is as relevant as ever, if not more so.
Coincidentally, the issue of individual surveillance resonates with fears depicted in George Orwell’s widely referenced dystopian novel, 1984. How much of their privacy can people give away for the convenience of wearables?
During the discussion, Anglo American’s International Government and Sustainability Relations Group Head, Froydis CameronJohansson, raised the alarm about the serious
implications of the growing use of surveillance technologies, drones, and wearables on employees’ and individuals’ rights to privacy. She particularly referenced the role of track-and-trace wearables to monitor employee behaviour and record health-related data. She lamented that civil society and the private sector seemed to be oblivious to the issue. And, it must be added, they still are.
“Everybody has a phone. You’re going onto an app; it asks you for all this personal information that you probably wouldn’t ever give a stranger, except you’re just sending it into the Metaverse, so to speak.”
“Where does the buck stop?” a charged member of the audience asked. What if the information is exploited by bad actors with little regard for human rights?
Human rights bodies have echoed this concern, drawing attention to the blurring of lines between privacy and unfettered access to information and monitoring of employee whereabouts.
Legal Safeguards and Responsible Data Use
Hopefully, sanity will prevail, and legal safeguards will be put in place by regulators in respective countries, including in Africa, to ensure that workers’ data is used responsibly. Without question, while legal grey areas linger, the benefits that wearables bring to industries like mining are worth highlighting.
Another reality is that, for all the convenience they may offer, these devices suffer damage in harsh conditions — like every other product used in mining. Hopefully, relevant OEMs will address this and improve the robustness of their products.
Here to Stay
Whatever surveillance fears persist, wearables are here to stay and will only evolve. The global IoT wearables market, including South Africa, is expected to grow at a compound annual growth rate (CAGR) of 20.8% from 2025 to 2030 (Grand View Research).
Which is better: no surveillance and a high risk of accidents, or surveillance with a low risk of accidents?
Fleet Management for Mining Operations
Driving Interoperability in Mixed Fleets
Andrey Komov, Volvo Construction Equipment’s Head of Productivity for Region International, illustrates how the company is simplifying fleet management across equipment brands globally through the integration of vetted third-party dashboards. In the pipeline is the unveiling of brand-agnostic productivity services. This will surely benefit clients in the African market, which the company regards as a strategic growth area.
By Jimmy Swira
Across Africa, customers in mining and other heavy industries need more from OEMs beyond just supplying and servicing mobile equipment. They require easy access to real-time machine data to boost fleet efficiency, reduce emissions, cut fuel costs, limit unscheduled downtime, and promote both operator safety and responsible machine usage.
However, a major challenge mining operations face is the use of equipment from different OEMs. This complicates fleet management, as system integration becomes an obstacle.
This arises in situations where some OEMs’ fleet management systems are noninteroperable. This means they cannot be integrated with systems from competitors’ brands. Isn’t it ironic that the very tools designed to streamline operations can end up becoming a hindrance?
Even more intriguing is an observation from Andrey Komov, Volvo Construction Equipment’s Head of Productivity for Region International. He explains that the non-interoperability issue is not limited to machines from different OEMs. Would you believe it also exists within fleets containing older and newer machines from the same brand?
“This shouldn’t be the case,” states Komov. Drawing on Volvo’s experience as a globally respected OEM, he explains: “Customers view solutions from each OEM as only part of the overall answer. They seek interoperability because they operate mixed fleets, and managing systems from different OEMs adds complexity.”
Volvo’s CareTrack Fills the Gap
Playing its part to fill the gap, Volvo is actively working to offer interoperability and is already rolling out the necessary components. The company has devised integrated systems designed to work seamlessly with Volvo
equipment, and critical technical support is available to customers as and when needed.
A critical solution is CareTrack telematics, specially developed for customers operating both older and newer Volvo machines, as well as third-party systems. Komov highlights its ease of use: “The hardware for CareTrack has been standard for many years now. And because CareTrack enables services such as ActiveCare (our 24/7 proactive machine monitoring service), it’s just a case of switching it on.”
Worth mentioning, Volvo Co-Pilot hardware (that enables the Load Assist, Haul Assist or Dig Assist apps) is factory-installed, but can also be retrofitted to existing machines. “Because the hardware is made by Volvo and installed by Volvo engineers, it is securely mounted and covered by the Volvo warranty,” Komov adds.
A haul track from Volvo Construction Equipment
Third-Party Dashboard Integration
Mining companies often operate fleets with multiple brands, each with a different portal. It is hard to imagine the complexity of managing several portals at once.
Hence, to address this, Volvo enables CareTrack data to be integrated into vetted thirdparty dashboards, offering a unified machine overview. This is facilitated via the industrystandard API from the Association of Equipment Management Professionals (AEMP). “To support integration, we provide developers with all the resources they need to set up and test the API via the Volvo Developers’ Portal,” Komov explains.
Thus far, customer reaction to the value the system offers has exceeded expectations. “Initially, customers only wanted API data. But after we demonstrated our solution, they chose to adopt it instead of developing their own,” Komov says, refering to reliable Volvo’s on-site connectivity is as key to enabling these capabilities.
Integration of third-party systems
For customers interesting to add third-party solutions to Volvo machines, their local dealer can assist. In South Africa, for instance, Volvo offers a proximity detection system (PDS) interface kit, which enables seamless integration of Level 8 PDS solutions from any third-party
supplier on wheel loaders and articulated haulers.
Brand-Agnostic Solutions in the Pipeline
While it is contented to its solutions bringing significant changes, Volvo Construction Equipment is always in continuous pursuit of enhancing the operational experience for fleet owners in the mining sector. In the pipeline is the launch of brand-agnostic Productivity Services to drive interoperability. These solutions will integrate with any connected asset and offer performance and safety insights across mixed fleets.
Maximising Machine Value
Generally, Volvo Construction Equipment’s solutions help customers maximise the value of their machines. They enable them to achieve productivity, profitability, and decarbonisation through accurate, real-time data on performance, health, location, productivity, and cost efficiency.
Volvo CE remains a global leader in construction equipment solutions. Always forward-looking, it is committed to offering premium products and services that combine power, performance, and sustainability.
Volvo is actively working to offer interoperability and is already rolling out the necessary components.
A Proactive Way of Reducing Operator Error
Driver Bureau can be used to pass data via API to telematics companies who may want to enhance their reporting ability, or deliver the Visual performance journey directly to a mine. The program is not meant as an employment screening tool; it is a tool to manage psychomotor ability, which declines with time.
By Andrew Crickmay
Background
A study done in 2018 in an underground mechanical operation in the South African coal mining industry showed that 45% of all accidents were related to judgment error.
Judgment error relates to operators’ failure to see, recognize and react to hazards, particularly during risk assessments (SLAM) and machinery operation. For the purpose of this article, we will refer to this as psychomotor or visual motor ability.
Despite efforts to remove the reliance on human judgment through what we would call a mechanistic approach, using such interventions as the fitting of governors, proximity monitors, telematics and the tightening of operating procedures, judgment error stubbornly remains a significant problem.
While incredibly useful the drawback of the mechanistic approach has been that it is reactive (action taken after a recorded event has happened) and often punitive in nature. In other words, pressure is put on the operator for bad results without understanding what is causing them.
Because Psychomotor ability starts to decline sharply in an operator’s early 30’s, understanding the level of skills is extremely helpful. We will use telematics data of underground LDV’s to demonstrate what we are talking about.
Improved understanding
By graphing Driver Bureau’s annual psychomotor assessment scores against the machine telematic data in 5 mines, a much clearer picture emerges of what is causing the results.
Note that each dot represents a driver or operator
A few insights emerge from the graph below:
• O perators with poor eye-brain-motor scores can still operate safely, provided they are aware they have a problem and are extra careful.
• We can often easily and quickly move operators from quadrant 1 to 3 with targeted AI-driven feedback to individuals, using the annual assessment and our feedback module.
• We can improve eye-brain-motor skills, moving operators into quadrant 4, using daily EyeGym training amounting to nine sessions of 10-minutes a year ( on tablets or PC’s)
Driver Bureau’s operator training in session
Fig 1: Note that each dot represents a driver or operator
What does our Visual Performance Journey do?
We have two levels:
Level 1 Base line and feedback. This involves an annual Psychomotor assessment on PC or tablet and feedback using AI in some cases to target areas needing attention.
Level 2: EyeGym Training on tablets or PC.
This involves Eye-Brain-Hand exercises in approximately 9 sessions of 10-minutes each.
Does it actually work?
To answer this question a series of studies were done using telematics data to measure if the products were making a difference on the machines.
Typically, improved telematics results particularly harsh operating means less fuel consumption and less accidents, resulting in higher machine availability.
In conclusion
The program is not meant as an employment screening tool; it is a tool to manage psychomotor ability, which declines with time. Driver Bureau can be used to pass data via API to telematics companies who may want to enhance their reporting ability, or deliver the Visual performance journey directly to a mine.
Mine’s using a 12-hour shift with training days and access to PCs or tablets once a month are ideally suited to the product. The system comes with an optional rewards system (airtime) to encourage operator EyeGym training.
As our product does use AI it is an opportunity to demonstrate Ai’s usefulness. You can either read this article or click on the link below to listen to an AI panel discuss the contents of the article! https://rb.gy/yxbbvp
For a demo, please contact support@ driverib.com
https://www.driverib.com/
Andrew Crickmay is the owner and founder of several businesses, all of which use seemingly unrelated datasets to create massive, unexpected value. Drivers Bureau is one such business.
Managed Data Solutions for Industry
Virtualscape Solutions is an Industrial Technology company focused on scalable solutions in mining, logistics and industrialised sectors of the African economy, with footprint across the continent.
Sens Mining is the proprietary smart mining platform that concentrates on the open-cast mining sector. The holistic solution comprises hardware, firmware and software intellectual property developed exclusively by Virtualscape. This solution is proudly associated with Kudumane Manganese Resources (KMR) and other leading mining houses across Africa.
Chief Executive – Ravi Naidoo says that in keeping with the company’s dogma of delivering Managed Data Solutions for Industry, Sens
Mining seeks to leverage data into insights for management at all levels of the production value-chain. The ubiquitous management principles of Measure Manage Decide have been augmented and elevated into the Sens Mining proprietary proposition of Measure – Manage – Decide – Trust. This mantra within the culture of the business clearly identifies what is to be measured, how that is to be managed, what decisions need to be cultivated and how that infrastructure, process and people can be trusted on a repetitive and consistent basis to deliver success for stakeholders. Naidoo identifies this as the key differentiator of the business approach to solving industrial and mining pains adding that in commercial operations, particularly at
scale, Trust equals Speed. This can make all the difference in an operational environment has a nexus between time and money.
This level of engineering, commercial and people complexities does not just require a smart but rather SMARTT approach to executing at the highest levels of excellence. Naidoo unpacks the Virtualscape trademarked acronym as being the very fibre that the business culture is based on from every aspect and facet of engagement –internally and externally.
The business further prides itself in being a wholly South African owned, led, managed and constituted business. It is proud of the teams that drive site operations, technical support, technology development and engineering. The business has an exciting feature-functionality roadmap and invests in an active R & D lab. This is a tribute to South African excellence in operation in the highly advanced, complex and competitive environment of connected architecture solutioning – often referred to as Internet of Things (IoT). Naidoo confidently claims to be the most comprehensive and advanced smart mining solution developed in Africa. This he attributes to having some of the best seasoned technology solution architecture minds in the sector headed by Chief Technology Officer Johan Pietersen. Virtualscape strives to put its people at the centre of its growth
and invests in a continuous skills development through its Centre of Excellence (CoE) initiative – in the business and in client forums creating SMARTT people.
A further innovation – apart from technology and solution per se is in the business model adopted by Virtualscape in commercialising its offerings. This has resulted in all solutions being packaged as a Managed Service with a tailored Service Level Agreement (SLA). This removes the friction that often clouds digitisation or technology advancement investments in an enterprise, by delivering defined outcomes and value for a fee as opposed to purchasing a product. This requires highly skilled and experienced Business Improvement Specialists
(BIS) to assist, guide, partner and collaborate with client vision and destinations.
This approach affords Virtualscape clients a win-win, value-only experience that do not require infrastructure or people commitment as the solutions become autonomous once driven by our teams. This allows management and leadership of these businesses to focus on making those SMARTT decisions and concentrate on core business variables and not managing people or technology initiatives. This drives value and builds trust, which Naidoo emphasises is the best indicator of progress in a commercial relationship.
The success of the Virtualscape and its Sens Mining solution lies in its ability to play well with others as it is a hardware and software agnostic platform that leverages existing ecosystems to deliver augmented value and insights. Naidoo quips that there has always been power in knowledge, but now there is money in knowledge at the right time – this is what we do.
Block C, Little Fourways Office Park, Fourways, 2067
+27 (0) 11 465 5169 info@vsv.co.za www.vsv.co.za
Preventing Theft, Protecting Profits
Xscann Technologies’ turnkey X-ray body scanning solutions empower mining operations to safeguard every gram of precious metal - effortlessly, efficiently, and with precision.
By Jimmy Swira
Rudzani Ramovha, the Director of Xscann Technologies Pty. Ltd., has been on the block long enough and needs no convincing that the rise in precious metal production comes with a simultaneous increase in the risk of theft by mineworkers. And with the current record rally in global gold prices, he fears the risk is surely going to escalate further, especially in gold mining operations.
Rudzani wonders: “As they target high revenue, mining operations are increasing production. But will their hard-earned asset –gold – be secure?”
Conventional theft prevention inefficient
Unfortunately, it is always unbeknown to management, as the theft takes place under the radar, and in most cases, it could be an elaborate syndicate, sometimes with the collusion of trusted security personnel and employees. Worse still, just when management believe they have tightened the guardrails and are one step ahead, the criminal syndicates are already two steps ahead. This renders conventional methods of theft prevention like body searches and CCTV cameras inefficient or inadequate.
Investing in reliable technology
In view of this, as he has done in the past few years, Ramovha is unwaveringly consistent
in his advice to mining companies to invest in reliable technology to safeguard their precious metals. This time, he doubles down on the message. “The importance of investing in reliable technology cannot be underestimated,” he stresses, introducing Xscann X-ray turnkey full-body scanning solutions to new clients in the mining sectors.
Turnkey Body Scanning
Xscann Technologies’ Turnkey Full-Body Scanning solution offers massive value to mining operations. The following are key benefits:
• High-precision body scanning technology
• Real-time detection of precious metals or contraband
• Seamless integration with existing security protocols such as access control systems
• Rapid scanning capabilities without disrupting the workflow
• Regulatory compliance
New Technologies or Upgrades
In addition, Xscann continuously adapts new technologies or upgrades existing ones to enhance security at mining operations or places where precious metals are stored. Recent additions have resulted in improved scanning resolution and accuracy, minimal human intervention with more remote monitoring capabilities, and web browser interface developments.
Theft busting milestones
There is no better proof of the efficiency of Xscann Technologies than success stories at mine sites. Since the first installation at a mine site more than ten years ago, Xscann’s body scanning technology has deterred theft of precious metals, preventing potential losses amounting to millions in revenue. A recent milestone was the bust of a precious metals theft syndicate involving 18 individuals, operating at a gold mine in the Free State, South Africa, in October 2024.
Successful Partnerships
By deterring precious metal theft, Xscann body scanning technology prevents theft, protecting profits. In a nutshell, Ramovha mentions the following reasons why companies should choose to partner with Xscann Technologies:
• Demonstrate proven effectiveness in theft prevention of precious metals
• Deliver a rapid return on investment through reduced theft losses of precious metals
• Offer customised solutions tailored to specific mining environments
• Provide ongoing technical support and system upgrades
Ramovha pronounces: “For mining operations seeking cutting-edge theft prevention, Xscann Technologies represents a strategic partner committed to security, innovation, and operational integrity.”
Xscann Technologies Pty. Ltd. is based in Edenvale, Johannesburg, from where it serves clients in different sectors in the whole of Southern Africa.
Xscann Technologies, a South African company, has demonstrated the signi cance of mining companies to invest in e ective methods of safeguarding the invaluable minerals they produce. The company helps producers to address theft problem.
Unaccounted for, the potential loss of precious metals through employee theft should worry producers. Cumulatively, it could represent considerable loss of revenue. Xscann Technologies o ers sure re way for producers to mitigate this risk by employing its X-ray Full-Body scanning solution, which has excelled in di erent mining sites.
Operational Health and Safety Risks in Mining Operations
From tickbox exercise to safety culture
As they chase high revenue numbers, mining companies risk dropping the ball on compliance obligations like ESG reporting and health and safety regulations. This doesn’t always end well - it can result in costly breaches that negate anticipated gains.
On the subject of occupational health and safety operational risks and Mine Health and Safety Act, we spoke to Sian Thurtell, Chief Operating Officer at KBC Health & Safety, about common problem areas and how to mitigate them.
By Jimmy Swira
Tyres are important elements of a vehicle, representing a significant investment in both purchase and maintenance costs. Like all items subject to wear, tyres have operating limits and a service life. However, many are disposed of before reaching their full service life.
The Need for Monitoring Tyres MBA: As mining companies ramp up production, what are common occupational health and safety operational risks likely to emerge?
ST: In a high-pressure environment where production is the primary focus, operational risks often emerge. These risks are typically driven by increased pace, stretched
resources, and a shift in focus from safety to productivity. Common risks include:
• Fatigue from longer shifts, overtime, or insufficient rest, reducing attention and increasing the likelihood of incidents or accidents.
• Skills gaps due to rapid onboarding of contract workers without adequate training, resulting in rushed, unprepared teams being sent to site.
• Increased machinery use, leading to higher chances of mechanical failure.
• Safety shortcuts taken under production pressure, exposing workers to hazardous conditions.
• Lack of verification of competence (VOC) before work begins.
MBA: What gaps have you identified in how mining companies approach the mitigation of operational risks?
ST: In my experience, many mining companies struggle with the practical implementation of operational risk mitigation. While they often have all the right protocols, underpinned by legislation, executing these protocols on the ground remains a challenge.
One major gap is the non-integrated approach to onboarding contractors. We frequently see inconsistent onboarding processes, duplication of effort, and unnecessary downtime. Often, no system is in place to properly track and monitor compliance or training records for workers on site. This creates significant risk exposures, as there may be no real or accurate verification of qualifications or training documentation for site workers.
Safety is often viewed as a compliance checkbox, not a strategic priority. If safety were treated as a primary operational goal, mining houses would take a more proactive stance.
Sian Thurtell, Chief Operating Officer at KBC Health & Safety
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Operational Health and Safety Risks in Mining Operations
Incident data is collected daily, weekly, and monthly, but rarely analysed for trends or early warning signs. These signs, if spotted, could allow for swift preventative action.
MBA: What specific steps must be undertaken as part of a root cause analysis to better inform the mitigation approach?
ST: At KBC, our approach to Root Cause Analysis goes beyond identifying what went wrong. We focus on understanding why it happened, to ensure it doesn’t happen again.
1. Define the incident and detail the problem.
2. Gather and verify data - interviews, documents, photos, and system logs
3. Reconstruct the timeline of events.
4. Evaluate contributing factors, including human behaviour, equipment, processes, procedures, environmental conditions, and organisational systems.
5. Determine the root cause, which is often due to:
• Inadequate risk assessments
• Training gaps or competence failures
• Weak supervision or unclear procedures
• Poor communication or handovers
• Lack of safety culture
6. Develop a corrective action roadmap.
7. Implement ongoing monitoring and review mechanisms.
MBA: Mining operations are complex, and so are their safety risks. What critical strategies can be adopted as part of an integrated approach?
ST: At KBC, we work closely with clients to implement a fully integrated onboarding solution, which is especially crucial when dealing with contractors. We collaborate with executive teams to align the entire organisation with its operational risk management objectives.
Safety must be embedded as a core organisational value — it should be a way of life, not just a compliance exercise.
An integrated onboarding model ensures that both contractors and permanent staff undergo consistent, standardised training programmes and follow the same safety protocols. The implementation of practical, high-impact training across all levels strengthens knowledge retention and fosters a safety-first culture.
MBA: What opportunities has AI opened — if any — that can support implementation and review of this integrated approach?
ST: AI has opened up several possibilities to customise the learning experience. We are currently exploring tools that enhance our client solutions.
One exciting area is how AI can deliver personalised training based on a worker’s role, performance history, knowledge gaps, and risk exposure. There are also adaptive e-learning tools that adjust content and difficulty in real time, boosting engagement and knowledge retention.
We are also exploring the use of AI in culture surveys, helping us deliver faster insights and recommendations. AI can analyse responses, feedback, and communication data to assess safety sentiment, leadership effectiveness, and engagement levels. It can then help generate a comprehensive action plan based on the results.
KBC Health & Safety is a health and safety consultancy that provides solutions across industries in South Africa. Some of its prominent clients are in the mining sector mining.
AI & Machine Learning in Remote Equipment Monitoring
Proactive Maintenance, Powered by AI
Just when we thought remote equipment monitoring on its own was the pinnacle of innovation in predictive machinery maintenance, a layer of machine learning is added to it. Ramjack’s Katrina Wertheim touts machine learning to have a profound impact in simplifying complicated machinery maintenance tasks in African industries — of course, if embraced and applied properly (industries can be a conservative lot at times when it comes to adopting technologies). She notes that machine learning has elevated predictive maintenance for end-users already, based on feedback from interactions with organisations with ‘mission-critical’ equipment. With optimism, she foresees machine learning becoming a handy tool for mining operations — as they increase production, cases of equipment failure are a sure bet to rise, simultaneously.
By Jimmy Swira
Remote monitoring systems have transformed equipment maintenance in unimaginable ways — minimising errors and bringing efficiency, ultimately increasing availability. What the emergence of AI and machine learning on the scene has done is fundamentally shift how remote monitoring systems function by adding a layer of intelligent decision-making to data collection. Historically, remote monitoring systems have been just passively logging sensor inputs — identifying patterns and enabling maintenance teams to react to them. However, instead, taking the game further, AI-enabled remote systems can perform three functions — identifying patterns, detecting anomalies, and even predicting failures before they occur.
From reactive to proactive real-time monitoring
In essence, what value does machine learning add to predictive maintenance for industry?
In practical terms, for instance in mining, the integration of machine learning means real-time monitoring becomes proactive rather than reactive, Ramjack’s Katrina Wertheim elaborates. “Key areas where we recently are seeing AI making an impact include analysis for predictive maintenance, fuel efficiency, operator performance, and productivity monitoring. Machine learning algorithms constantly refine themselves, learning from both historical and live data to provide increasingly accurate insights over time. This ultimately turns vast data sets from equipment and operational environments into actionable intelligence when properly integrated across your mine site.”
Safety and equipment availability
The addition of machine learning to remote monitoring is very significant from safety and
equipment availability perspectives. The ability to predict potential failures before they happen has a direct and measurable impact on both safety and uptime, Wertheim says, highlighting two points, as identified consistently in their rROC (Ramjack’s Remote Operations Center).
From a safety perspective, AI-driven alerts can identify dangerous trends — like overheating brakes or unstable ground conditions — long before they reach critical levels. As a result, operators and managers can intervene early, reducing the risk of equipment failure-related incidents.
From an availability standpoint, AI helps minimise unplanned downtime by ensuring maintenance is conducted only when necessary, rather than on fixed schedules. This keeps highvalue equipment running efficiently for longer stretches and maximises asset utilisation without compromising safety.
Integrating AI and machine learning into existing remote monitoring
For a practical industry application, Wertheim references how Ramjack is utilising AI and machine learning opportunities to help clients achieve optimal equipment safety and efficiency. “At Ramjack, we work closely with our technology partners and our mining customers to integrate AI and machine learning into their existing remote monitoring solutions through our rAIL program (Ramjack’s Artificial Intelligence Lab).
For example, our real-time data integration platforms allow us to marry equipment telemetry with contextual data — such as environmental conditions or operator behaviour — so machinelearning models can deliver hyper-relevant insights,” she demonstrates.
Ramjack leverages predictive analytics for critical assets like mobile equipment. This enables mines to forecast component failures, reduce maintenance costs, and avoid unnecessary shutdowns. “Our approach isn’t
just about deploying AI. In particular, it’s about integrating the right AI for the specific challenges faced by our customers, always with a focus on practical outcomes and measurable ROI,” Wertheim expounds.
Facilitating ESG compliance
Another area where the marriage of AI and machine learning is having a marked impact is in facilitating ESG reporting compliance. In jurisdictions worldwide, ESG requirements are becoming more stringent and data-heavy. In this environment, AI is proving essential in helping mines stay compliant and transparent, Wertheim states, citing two examples. “AI can aggregate and analyse data from multiple systems — ventilation, energy usage, water management, and more — to provide realtime ESG insights. Machine learning models can also identify deviations from compliance baselines and automatically flag them for review or corrective action. For example, if emissions suddenly spike beyond acceptable thresholds, an AI system can alert relevant stakeholders and even trace the issue back to a specific piece of equipment or operational condition. This level of data granularity and automation makes it far easier for mining companies to meet ESG reporting obligations with accuracy, consistency, and confidence.”
If African mining operations and related industries embrace the marriage of machine learning and remote monitoring, Ramjack believes they will achieve more through improved safety, equipment availability, and improved compliance.
Ramjack is the provider of remote equipment monitoring solutions and technology integration services to various industries worldwide. The company considers Africa as one of its biggest markets.
WearCheck’s Key to Transformer Reliability
Oil-contaminated related transformer failure remains a challenge in mining operations with huge implications on production and safety. MINING BUSINESS AFRICA asks Pierre le Roux, WearCheck’s laboratories manager: transformer oil and fuel testing, about fundamental practices in transformer condition monitoring as part of predictive maintenance.
MBA: From your engagements with the industry, what are the common fluid-related issues that accelerate transformer performance degradation?
PIR: At WearCheck, our transformer oil testing division has been operating for more than 20 years. Over this time, we have noticed that transformer performance degradation is often accelerated by insulating-fluid-related issues such as oxidation, contamination, and water infiltration. Oxidation occurs when transformer oil reacts with oxygen, forming acidic by-products and sludge that reduce its insulating and cooling properties. Contamination from particles, such as dust or metal fragments, can degrade the oil further, leading to a decrease in dielectric insulating properties. Furthermore, water infiltration - be it from leaks, condensation or a b-yproduct of cellulose degradation - significantly lowers the dielectric strength of the oil, making it more prone to electrical breakdowns. These factors collectively compromise the oil’s ability to insulate and cool the transformer, ultimately reducing its efficiency and lifespan.
MBA: What key parameters should be considered in oil sampling (fluid analysis) as part of predictive transformer condition monitoring?
PlR to get the best results from a transformer oil condition monitoring programme, it is necessary to follow these guidelines:
• Samples should be taken only by welltrained, competent personnel,
• Samples must represent the bulk of the transformer’s oil content,
• Always use a clean process to sample the oil,
• Ideally, sample an area after the cooling system, where there is a constant flow of oil,
• Samples, once taken, should be sealed, so that the integrity of the oil is not lost, in other words, a gas-tight seal should be used. We also recommend that samples should be transported as soon as possible to a laboratory to minimise degradation of the sample through exposure to environmental elements.
MBA: Are there any measures to ensure the accuracy of results? Are other tests recommended?
PlR: All the laboratory equipment in WearCheck’s transformer oil testing laboratories undergo regular calibration assessment to ensure that the test results are in line with the recommended guidelines stipulated by the various international standards, such as the IEC (International Electrotechnical Commission), SANS (SysAdmin, Audit, Network, and
Security), and ASTM. (ASTM testing refers to the evaluation of materials, products, systems, or services according to standards set by the American Society for Testing and Materials).
The transformer oil testing laboratories at WearCheck participate at regular intervals in round-robin testing, which is hosted by either international bodies such as SGS (Société Générale de Surveillance) and ASTM, or by local laboratories. The outcome of these tests is used as a tool to evaluate accuracy of test results.
WearCheck’s Johannesburg transformer oil testing laboratory has achieved ISO / IEC 17025 accreditation, which is the standard for which labs must hold accreditation in order to be deemed technically competent. In many cases, suppliers and regulatory authorities do not accept test or calibration results from a non-accredited lab. At WearCheck, we use the ISO/IEC 17025 standard to guide our quality system, to ensure that we produce accurate, valid results consistently.
In addition, all our transformer oil testing technicians have undergone the required training to perform the various tests. If any new testing techniques or instruments are incorporated into our transformer oil analysis regime, then all staff are trained accordingly.
In terms of recommending other tests, based on the outcome of the oil test results, further testing might be recommended to verify the initial diagnosis. For example, the degradation of cellulose can be visible through three different tests: dissolved water content, carbon monoxide / dioxide content, and furan content. Conducting all three tests on the sample is a sure way to verify the condition of the cellulose.
Normally, international standards are followed to select the testing needed for specific transformers and specific oils. In other words, certain transformers need particular tests, and certain oils need additional tests.
Apart from transformers, we also test the insulating oil in electrical switchgear. Electrical switchgear has different requirements to which the oil must comply, than transformer requirements.
The more tests that are conducted, the more holistic the view of the transformer’s health, which enables diagnosticians to pinpoint problems with greater accuracy.
WearCheck’s transformer laboratory in Johannesburg
MBA: What common indicators suggest there are anomalies with transformers?
PlR: Common indicators of anomalies in transformers include unusual temperature spikes, which may signal overheating or insulation failure, and abnormal noise levels, such as humming or buzzing, suggesting issues with the core or windings.
Changes in electrical parameters, like sudden variations in voltage or current, could point to internal faults. Deterioration in oil properties, revealed through fluid analysis, often hints at insulation or cooling problems. Additionally, signs of physical damage, oil leaks, or corrosion are clear warnings of potential malfunctions. We recommend regular monitoring and early identification of these indicators – this is essential to prevent major failures and ensure transformer reliability. It is also useful in order to establish a trend in the transformer’s performance.
MBA: What critical assessments are conducted to inform decisions about interventions?
PlR: A transformer’s condition is assessed on a physical inspection - visual inspection can reveal signs of rust, oil leaks, excessive humming and other problems. Furthermore, the test results from the insulating oil sample are used to assess
the electrical and thermal properties of the transformer and its oil.
In addition, an electrical assessment of the transformer should be conducted through various electrical tests. The majority of these tests are done when the transformer is in offline condition.
A further consideration is the comparison of the transformer’s behaviour with the behaviour of sister transformers, or those of the same family of transformers, and in similar designs.
MBA: What practical interventions can be incorporated to improve transformer condition?
PlR: In our experience, we find that improving transformer condition involves implementing practical interventions such as regular maintenance schedules, comprehensive fluid analysis, and enhanced cooling systems.
Routine maintenance, including inspection of bushings, windings, and insulation, helps identify early signs of premature failure of the transformer or its components. Fluid analysis detects contaminants, water (dissolved and free water), and dissolved gases, allowing timely action to rectify possible faults. Only after repairs have been conducted, should oil treatment or replacement be done to maintain optimal insulation and cooling properties.
Additionally, employing cutting-edge
monitoring technologies like thermal imaging and online condition monitoring systems ensures real-time detection of anomalies, enabling prompt corrective action to enhance reliability and performance.
MBA: In brief, what is your advice to industries on best practices for maintaining optimal transformer condition?
PlR: WearCheck’s transformer maintenance programme is aimed at maintaining optimal transformer condition, and includes several points of action. We advise our transformer clients to prioritise regular maintenance and monitoring. Key practices include scheduling routine inspections to detect early signs of wear, and performing fluid analysis to monitor water, dissolved gases, and contamination, as well as prevention of overheating.
Employing advanced diagnostic tools, such as thermal imaging and online monitoring systems, allows real-time tracking of performance and anomalies. Proactive interventions such as timely oil management, insulation checks, and maintaining cooling mechanisms can extend the lifespan of transformers, reduce downtime, and ensure reliable operations. A commitment to these best practices fosters efficiency and longterm cost savings.
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!
Powering Performance in Extreme Environments
How Sanden’s Compressor Technology is Shaping the Future of Heavy-Duty Air Conditioning
With over 80 years of engineering excellence, Sanden has earned a global reputation for delivering robust, highperformance air conditioning solutions tailored to the demanding needs of heavy-duty vehicles and mining operations. From blazing desert mines to sub-zero construction sites, Sanden’s compressor technology is trusted by the world’s leading equipment manufacturers to deliver reliable climate control in the harshest conditions on earth.
A Legacy of Innovation and Leadership
Founded in 1943, Sanden’s journey began in Japan with a commitment to manufacturing quality components for the automotive sector. Over the decades, Sanden has evolved into a global leader in thermal systems, with a legacy built on innovation, precision, and durability. In the heavy-duty and off-highway vehicle sector, Sanden’s heritage translates into deep expertise. The company has consistently led the way in developing compact, efficient, and rugged compressors that meet the unique demands of mining, construction, agriculture, and other highimpact industries.
Engineered for Extreme Mining Conditions
Mining environments present some of the most extreme operating challenges for vehicle components. High dust levels, constant vibration, heavy shock loads, and temperature extremes to name a few. Sanden’s sealed heavy-duty compressors and clutches are engineered to thrive in these conditions, ensuring maximum uptime and operator comfort. Sanden’s heavy-duty clutches feature reinforced sealing, protecting internal mechanisms from contamination and wear. This translates into longer service intervals and lower total cost of ownership for operators.
Powered by Partnerships
Sanden’s reputation for reliability has made it the supplier of choice for many of the world’s top OEMs, including Caterpillar, JCB, Volvo, and Liebherr. These partnerships are more than just business relationships; they’re collaborative platforms for innovation.
Leading the Shift Toward Electrification
As the mining and industrial sectors begin their transition toward electrified equipment, Sanden is already leading the charge with a range of next-generation electric compressors. These units are designed for high-voltage electric and hybrid platforms, delivering efficient cooling performance without relying on engine-driven belts or pulleys. Looking ahead, Sanden is actively investing in R&D to develop smart compressor systems with integrated diagnostics and predictive maintenance capabilities— features that will be critical in autonomous and remote mining operations.
Building a Sustainable Future
Sustainability is not a trend at Sanden; it’s a strategic imperative. The company has implemented eco-conscious practices across its global manufacturing footprint, including energy-efficient production lines, and increased use of recyclable materials. In product design, Sanden is advancing low-GWP (Global Warming Potential) refrigerant compatibility and compressor efficiency. These efforts contribute to reducing the environmental footprint of mining and industrial fleets without compromising cooling performance.
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Air Conditioning for the TOUGHEST CONDITIONS
SANDEN have been at the forefront of mobile air conditioning compressors for 80 years. We are a principle Tier 1 supplier to the OEM and are the compressor of choice for machine producers of heavy duty vehicles to be used in the toughest conditions.
SANDEN supply Caterpillar, JCB, Volvo, Liebherr among others. Quality and endurance are unrivaled and our compressors work with traditional R134a gas and the new R1234yf gas starting to be seen in the heavy truck and off highway machine industry.
Mechanical Compressors | Hydraulic Compressors | Electric Compressors
Contracting for Opencast Mining Projects
Digging Deep for Excellence and Innovation
Zizwe Opencast Mining Pty Ltd is intentional about meeting clients’ needs, and the results speak for themselves: achieving milestone upon milestone. The company is now eyeing growth beyond South Africa, in the region - starting with Namibia.
By Jimmy Swira
It is not easy to stand out in South Africa’s volatile and fiercely competitive open-cast mining sector. Generally, the same applies elsewhere.
So, how has ‘Zizwe Opencast Mining Pty Ltd prevailed and distinguished itself - particularly in client retention and in the ability to add new business to its project portfolio?
Kobie Pruis, the company’s CEO, tells Mining Business Africa that it’s not the stuff of rocket science, but rather the richly deserved dividends of focusing on five core areas and strategic approaches.
The solid foundation: core values and strategic approaches
The solid foundation that has enabled Zizwe to remain a go-to mining contractor lies in several core values and strategic approaches. Pruis outlines them:
i. Safety, Operational Efficiency, and Environmental Stewardship
First, placing a strong emphasis on safety and
operational efficiency has ensured that Zizwe’s projects meet - and often exceed -production targets. The company implements rigorous safety protocols, including comprehensive assessments and certifications for all operators, to ensure a secure working environment.
Moreover, Zizwe is dedicated to environmental stewardship. It adopts alternative excavation methods - such as the use of hydraulic ripper attachments - to reduce environmental impact, particularly in ecologically sensitive areas. Going further, Zizwe prioritises concurrent rehabilitation, restoring land alongside active mining activities to ensure prompt environmental recovery.
ii. Fostering Robust Relationships
Second, actively fostering robust relationships with clients has led to repeat business and the acquisition of new contracts.
iii. Strong Relationships with Local Communities
Third, strong relationships with local communities have been central to the company’s success. Tri-party agreements involving clients and
Zizwe places a strong emphasis on safety
Kobie Pruis handing over an award to a longserving employee
community stakeholders ensure mutual benefit and foster goodwill that promotes shared development and addresses mutual concerns.
iv. Teamwork
Fourth, teamwork at Zizwe is a cornerstone of its success. It fosters cross-functional collaboration, shared expertise, and a unified commitment to safety, innovation, and operational excellence.
v. Investment in Workforce
Last but not least - perhaps most importantlyZizwe’s most invaluable asset is its workforce. The company has invested heavily in employee welfare by fostering a safe, supportive work environment, investing in skills development, and promoting well-being through structured shifts, rigorous training, and a culture of mutual respect.
This approach has raised the proficiency of the workforce, giving Zizwe an edge in project implementation. The employees’ combined 150 years of extensive industry experience bring a high level of expertise to complex mining operations. This enables the company to navigate challenging projects with efficiency and precision.
“Our depth of knowledge supports a positive work environment where safety, clear communication, and opportunities for professional growth are prioritised. The leadership’s commitment to innovation and adaptability ensures that the company remains responsive to evolving industry demands and technological advancements,” Pruis explains.
Furthermore, Zizwe’s reliability and consistent performance have fostered strong, trust-based relationships with clients - grounded in the
Key Project Milestones
Zizwe’s commitment to operational excellence has paid off immensely, as several key milestones demonstrate. Notably, one major advancement is the initiation of operations at a new site that includes underground mining services - expanding the company’s capabilities.
In addition, Zizwe significantly upgraded its operational capacity by expanding its fleet with the introduction of Caterpillar’s 777-series trucks and 992-series loaders - equipment not previously used by the company.
To further boost efficiency and minimise downtime, Zizwe also implemented dedicated onsite tyre servicing teams. This effectively eliminated reliance on external providers, improving equipment uptime.
These developments, along with the company’s strong performance and reputation for reliability, have contributed to Zizwe securing new contracts - further strengthening its position in the industry.
So After the Milestones, What’s Next?
Long-Term Vision
Pruis says the company has identified several strategic growth opportunities in line with its
long-term vision for sustainable expansion.“We are actively exploring geographical growth by pursuing mining opportunities in neighbouring countries, with a particular focus on Namibia and Botswana.”
In addition to regional expansion, Zizwe is placing strong emphasis on building and strengthening partnerships with local communities - fostering trust and collaboration that support the successful launch and longevity of new projects.
Embracing technological innovation is another key area of focus. The company is continually adopting new methods and equipment to enhance operational efficiency while minimising environmental impact. It is committed to digging deep for excellence and innovation in open-cast mining to meet customer needs.
Optimal Capital Equipment Capacity
Another contributor to Zizwe’s success is the optimal use of critical capital equipment. The company has achieved capital equipment adequacy through the following measures:
a. Strategic Investments: Investing in high-capacity machinery to enhance operational efficiency.
b. In-House Maintenance: Establishing dedicated onsite maintenance teams to reduce reliance on external service providers and minimise downtime.
c. Fleet Expansion: Continuously expanding and updating its fleet to meet diverse project requirements.
Zizwe has Optimal Capital Equipment Capacity to handle any project
delivery of high-quality, tailored services that meet the specific needs of each project.
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