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BULK HANDLING TODAY

August 2012

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August 2012

Contents

Featured on the cover: Flexco Tel: (011) 608-4180 www.flexco.com

CMA 5

FAQ’s

Training is Key

47 Frequently Asked Questions and Answers

Cover Story 9

Holistic Solutions

51 Market Forum

Project Management

Endorsing Bodies

13 Building a Mine

Mining

CMA (Conveyor Manufacturers Association) LEEASA (Lifting Equipment Engineering Association of South Africa)

19 From Mine to Market 25 Two Contracts Concluded

Crushers

29 Carpe Diem 35 A Case for Jaw Crushers

SAIMechE (SA Institute of Mechanical Engineering)

SAIMH (SA Institute of Materials Handling)

Trucking

also mailed to members of the RFA (Road Freight Association)

39 Driver of the Year 2012 43 Is Your Truck Tough Enough?

Copyright

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

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

The monthly circulation is 4 016

Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401, Fax: (011) 781-1403 E-mail: bulkhandling@promech.co.za www.promech.co.za Managing Editor: Susan Custers Editor: Kowie Hamman Advertising Sales: Surita Marx DTP: Zinobia Docrat and Donovan Vadivalu

Subscriptions: Please email us at accounts@promech.co.za if you wish to subscribe to “Bulk Handling Today” at R405,00 (excl postage and VAT) per year; R1 020,00 per year for Africa/Overseas. Printed by: Typo Colour Printing, Tel: (011) 402-3468 FSC (Forestry Stewardship Accreditation)

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CONVEYOR MANUFACTURERS ASSOCIATION

Training is Key

Simon Curry

Conveyor systems are potentially one of the most dangerous structures in mining operations if safety standards and mechanical specifications are not strictly followed. The lack of a well-trained and competent work force is thus of increasing concern. Recognising this, the CMA is concentrating its efforts on raising the level of competency in the materials handling industry by providing a number of practical, focused training programmes that aim to improve knowledge, skills and workmanship, optimise safety and ensure conformance to standards and specifications.

Our first major training investment was the six-day Diploma Course on the Design and Operation of Belt Conveyors,” says Simon Curry, chairman of the CMA. ‘This gives an across-the-board insight into the complexities of conveyor system design to engineers with little or no experience of conveyors, and includes a visit to a working conveyor site. Candidates who pass

the written examination at the conclusion of the course are able to solve common problems associated with conveyor design.’

Lack of suitably qualified skilled and semi-skilled workers

Following five years successful presentation of the Diploma Course, the CMA realised that the lack of basic skills in belt operation and belt splicing was growing to alarming proportions. To rectify this problem, three new certificated courses were designed and offered to the industry: the CMA Beltsman Certificate Course, the CMA Conveyor Certificate Course, and the Conveyor Belt Splicing Certificate Course.

Beltsman certificate course

The CMA Beltsman Certificate Course runs over one day and covers all procedures applicable to correct inspection, functioning, care and maintenance of conveyor belting. Tracking and training of the belt and belt spillage are major course components. Apart from mentioning methods used to join different belts, belt splicing and conveyor design are not included. The course is designed specifically for beltsmen, artisans and staff operating in a

Diploma Course participants on site visit

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CONVEYOR MANUFACTURERS ASSOCIATION

conveying environment. A written examination at the conclusion of the day assesses the knowledge gained by the participant.

Conveyor certificate course

The CMA Conveyor Certificate Course is a comprehensive three-day programme, familiarising participants with all aspects of conveyor operation, (excluding design), with a written examination Beltcon Conference 2011: An appreciative audience at the conclusion to assess the level of new learning acquired by the candidate. It is intended for artisans, those who may already have some experience in belt draughtsmen, junior engineers, apprentices and all technology and splicing, although anyone wanting technical personnel involved in operations where to learn belt splicing may do the course’ he adds. conveyors are used. ‘It is a detailed course for splicers to bring them up-to-date with new developments in belt splicing Conveyor belt splicing certificate course ‘Adherence to SANS manufacturing, belt splicing and and in particular, to familiarise themselves with safety standards is being increasingly scrutinised the most recent belt splicing standards.’ by end-users in the materials handling industry in These are: an attempt to increase the lifetime of belting and • SANS 484 Part 1 – Hot Multi-ply Splicing other components and to increase productivity,’ Procedures; points out Simon. ‘Under-qualified and unskilled technicians will find it difficult to operate under • SANS 484 Part 2 – Cold Multi-ply Splicing Procedures; these conditions.‘ ‘We developed a five-day course particularly for

• SANS 485 – Splicing of Steel Cord Reinforced

BRELKO

SPILLAGE CONTROL = COST CONTROL §Brelko design and manufacture conveyor belt cleaning equipment for a

CONVEYOR PRODUCTS

trouble-free flow of materials at transfer and load points. This is backed up by an installation and maintenance package including a 24 hour call out service.

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§We have over 25 years

experience as a supplier and advisor on spillage control to the bulk materials handling industry and offer proactive and ongoing maintenance for preventative spillage control and optimum belt cleaning. §We are accredited with ISO

9001:2008 and OHSAS 18001:2007 certification and are members of the Institute of Materials Handling and Conveyor Manufacturers Association.

PRODUCTS

§We supply and service our products

throughout the world, with branches in the United Kingdom and the United States, our master distributors, in Australia and Greece, and agents located in more than 23 countries. Tel

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August 2012

§Air Cannons

§Hi-Impact systems

§Belt Scrapers

§Impact Beds

§Belt Ploughs

§Belt Tracking Systems

§Chute Sealing Systems

§Belt Wash Systems.

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CONVEYOR MANUFACTURERS ASSOCIATION

Conveyor Belting; and • SANS 486 – Finger Splicing of Solid Woven Construction Conveyor Belting. (All these standards may be accessed and purchased on the SABS website). The course consists of one day of theory, followed by four days of practical work in a fully operating training venue with all equipment needed for candidates to obtain hands-on experience. This includes tools, samples of the different types of conveyor belting, cutting tables, vulcanising presses and splicing compounds. The course content covers splicing, lagging and lining; steel cord belt splicing; step splicing of fabric belts (hot and cold process); pulley lagging and rubber lining; vulcanising press set-up and operation. Training techniques include a variety of approaches and learning methodologies including classroom instruction; small group discussion; question and answer sessions; multimedia presentations; hands-on application; and exclusive training manuals. Since this course covers a great deal of information in a relatively short time, CMA also offers a five-day in-depth workshop (on request) for each speciality,

such as steel cord, fabric or finger splicing.

Intensive splicing course

Run under the auspices of the CMA, a comprehensive belt splicing course, including both theory and practical, is held over a period of five days. It provides formal education of a measurable standard to splicers which is recognised by industry, and is seen as the only route to becoming a qualified splicer by aspirant splicers. Conducted according to SABS specifications, splicing methods are standardised which will, as a result, resolve many of the splicing problems in the industry. It is geared towards qualified splicers and those splicers already working in the industry, as well as school leavers wanting to make splicing their career. Simon maintains that this course sets the splicing standard throughout the mining industry, and is turning out world-class belt splicers. Simon Curry believes that these training courses go a long way to redress the problems of inefficient conveyor operation, short belt life, downtime and accidents. ‘The CMA will continue,’ he states, ‘to be proactively engaged in raising the standard of professionalism and upgrading the knowledge and skills of personnel operating in the industry.’ Simon Curry, Chairman, www.cmasa.co.za

BULK HANDLING TODAY

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Delivering Engineering Solutions with World Class Technology Partners Since 1919

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COVER STORY

Holistic Solutions

For more than 100 years, Flexco has been providing belt conveyor operators around the world with efficient, safe products, services, and solutions for their systems. What started as a company manufacturing fasteners for leather transmission belts has grown into a global full-service manufacturer of solutions that maximise belt conveyor productivity.

T

his transition didn’t happen overnight, and it wasn’t accomplished with several people sitting in a board room discussing the next big product advancement. It happened over years of engagement in the market while the Flexco team was out in the field, installing fasteners alongside our customers, asking them what would make their lives easier, safer, and more productive. The most common responses involved compatibility and serviceability. That’s why Flexco approaches every belt conveyor challenge with an emphasis on holistic solutions. Fasteners should be compatible with cleaners, cleaners should be compatible with belts, belts should be compatible with trainers, etc. Flexco goes beyond manufacturing fasteners, cleaners, and maintenance products to develop real solutions to belt challenges. This comprehensive and collaborative approach has moulded Flexco into a worldwide leader of belt conveyor products. As an industry leader, Flexco understands that

conveyors play a critical role in an operation’s productivity. When conveyors run efficiently, they make a real impact on an operation’s bottom line. Flexco views its role as more than a manufacturer of products, but rather a partner and provider of belt conveyor solutions for splicing, cleaning, tracking, and belt slippage. Flexco makes products that enhance belt conveyor productivity including mechanical belt fastener systems, belt cleaners and plows, pulley lagging, transfer-point systems, belt maintenance and installation tools, transfer chutes, and belt conveyor rollers. These products satisfy the needs of the belt conveyor system.

Solutions for every challenge

For systems that have loading challenges in transitions between conveyors, Flexco offers a variety of load-zone products like impact beds and slider beds, as well as soft-loading transfer chutes featuring Tasman Warajay Technology. These custom-designed chute systems not only improve throughput, but BULK HANDLING TODAY

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COVER STORY

loads, featuring lightweight construction, requiring less energy, and providing a longer service life than their steel counterparts. Mechanical belt fasteners offer splicing solutions for belt conveyor systems, quickly and easily creating a strong, durable splice using an on-site crew. The wide array of mechanical fastening systems can help maximise an operation’s uptime and keep output high. Slippage can occur when your pulley is not adequately gripping the belt, prompting the entire system to work harder, causing unnecessary wear. High-quality ceramic and rubber lagging from Flexco can increase friction between the pulley and belt, extending the life of both. also reduce excessive dust, spillage, plugging, downtime, belt wear, and combustion dangers. Thanks to nearly 30 years of experience and proprietary software, Tasman Warajay Technology can significantly boost an operation’s output by reducing spillage and delivering the maximum amount of material to the desired destination. This can lead to a reduction in the overall cost of owning and operating the system.

Maximum spillage control can also be achieved When it comes to keeping the belt running, Flexco offers trainers and positioners to handle the most stubborn tracking problems and ensure the belt stays away from the structure and the material stays on the belt. CoreTech engineered composite conveyor rollers from Flexco are durable enough to tackle a variety of environments and material

When materials on the belt create a carryback issue, serious problems can arise in the belt conveyor system, including mistracking, accelerated belt wear, and the seizing of return idlers. Flexco offers a range of belt cleaning systems that can efficiently remove even the toughest, stickiest material. With the concept of compatibility in mind, these systems are specially designed to minimise belt wear and interface seamlessly with mechanical fasteners. When used in conjunction with skirt clamp systems from Flexco, maximum spillage control can also be achieved.

Global experience and support

Flexco has developed a worldwide network of distribution partners who know Flexco products inside and out. The company ensures that its partners understand not just what the products do, but how to select the right solutions for each customer’s application and ensure they are installed and operating correctly. The Flexco team of field representatives and global distributors are always available. They evaluate a belt conveyor system’s performance, identify opportunities for improvement, and implement complete solutions. It’s all part of the Flexco commitment to being a valued partner on the job. Flexco serves customers in a variety of industries on six continents through a global network of subsidiary offices, sales representatives, and distributors. In addition to South Africa and the United States, the company operates subsidiaries in Australia, Chile, China, England, Germany, India, Mexico, and Singapore, marketing its broad line of products through a worldwide network of subsidiary offices, sales representatives, and distributors. Flexco SA, Tel: (011) 608-4180, www.flexco.com

BULK HANDLING TODAY

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BULK HANDLING TODAY

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PROJECT MANAGEMENT

Building a Mine Creating a mining operation from scratch is a long process involving the detailed planning of a multitude of engineering tasks which have to be executed in a specific sequence in order to create a highly-functional bulk handling operation and the resulting economically-saleable mineral product.

A

ll the engineering disciplines are involved from civil to mechanical, structural, electrical, rock engineering, conveyor specialists, pump experts, ventilation specialists and design engineers. Ultimately, however, it’s one single project with the single purpose of designing and building a mine to produce a mineral which goes to market cost-effectively. To hold together and co-ordinate this enormous task requires yet another specialist, the professional project manager.

It all starts with a concept study which emanates from the strategic plan where a mining company decides to build a mine and they contact us to help them The days when mining houses employed most of these engineering experts in-house are long gone, mainly for economic reasons. Thus, the engineering experts who do this kind of work are today found under the wing of engineering project houses that specialise in EPCM (Engineering, Procurement, and Construction Management) contracts. Some are even stepping in as mining operator once the mine is established.

Special expertise

For a glimpse into the complex world of project management on a large scale “Bulk Handling Today” speaks to Pieter Louw, project delivery officer at TWP Projects of the Basil Read Group of companies. “A Greenfield mine project typically is

Pieter Louw, project delivery officer at TWP Projects of the Basil Read Group

based on three main aspects, there’s the process side, the mining side and the infrastructure side,” he explains. “But it all starts with a concept study which emanates from the strategic plan where a mining company decides to build a mine and they contact us to help them.” No matter whether it’s a new mine or the expansion of an existing one, the project house usually follows a specific route to plan the series of operations which will achieve the mine’s objective most cost effectively. “We usually take such a project, whether it is open pit mining, incline mining or deep level

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PROJECT MANAGEMENT

mining, right from the concept through to the execution and finally the hand-over,” says Pieter. “However, we can also run the mine on behalf of the owner, a concept which is drawing more attention lately and for which we have created a specific section in the company.”

The plan

Regardless of the type of mine, or who will be operating it, the core of such a project operation lies in establishing the mining plant itself, designing the processing equipment, infrastructure above and below the ground, manufacturing the plant and installing it. “The design work will only start once we’ve carried out a pre-feasibility study to define the different options available for the specific project,” explains Pieter. “Once one of the options is chosen, we start with the implementation of the project. This includes shaft sinking, designing all the bulk handling conveying systems as well as the entire required infrastructure such as loading facilities

On-the-job training is complemented by the professional training provided so that potential juniors can gain the experience necessary to climb through the ranks when opportunities arise

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PROJECT MANAGEMENT

and equipment, water handling pump systems, and ventilation and cooling systems.”

Utilising skills

This undertaking not only requires experienced specialists in each of the different engineering disciplines, but also experts in all the different design software programmes, production planners and managers. “We have all the people to make up such a project team in-house,” says Pieter. “The only aspects we outsource are highly specialised studies like geo-hydrology or geo-technical analyses, but the rest, geologists, surveyors, mechanical, electrical and civil engineers are all drawn from our own staff. Very often the specialist engineers work on one or two projects simultaneously. For example, we have engineers who specialise in conveyor design, but when they’re not working on a conveyor design on any one of the projects running, they’re doing other engineering work.”

The team

Putting the team together is one of the first calls of business. “Depending on the size of the project,

Designing the processing equipment, infrastructure above and below the ground, manufacturing the plant and installing it

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PROJECT MANAGEMENT

we may require a dedicated team working on one single project, but very often the specialists only need to work on a project for a certain number of hours,” explains Pieter. “Therefore, to utilise a person’s potential to the full, we assign these experts to each project only for the time required for their input. It’s basically a juggling act to allocate your resources in terms of all the projects that are running at one time. However, big projects always have a dedicated team assigned only to that project.

The days when mining houses employed most of these engineering experts in-house are long gone, “At TWP Projects we have a definite procedure through which this team is established,” says Pieter. “A project comes in as a proposal and we appoint a proposals manager who draws in the experts needed from the different departments such as mechanical, electrical and civil in order to assemble our proposal for the client. According to this proposal, the different heads of departments will assign the number of engineers required according to the hours needed to complete each task.

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This proposal is then submitted to the client and when they accept, it becomes a contracted project.

The project manager

“At this stage we appoint one of our 72, PMI registered PMP professionals as project manager who, more often than not, happens to be the proposals manager who initially compiled the proposal for the client,” adds Pieter. “These project managers hail from different engineering backgrounds but have mostly come through the ranks of mining operations and mineral processing. Obviously, the project manager has a huge responsibility in that he’s fully in charge of delivering all aspects of the project within budget and within the time allocated.” Apart from special personality attributes like being a team player with the ability to communicate well with others, we asked Pieter what other traits a typical engineering project manager should have? “The ideal project manager should have a good knowledge of the technical aspects, he should have experience of project work and he should have the necessary qualifications. We have a system whereby we bring in project managers at different levels such as junior project managers, project managers up to senior project managers, so they learn as they go along” says Pieter in conclusion. “This on-the-job


PROJECT MANAGEMENT

Project managers hail from different engineering backgrounds but have mostly come through the ranks of mining operations and mineral processing training is complemented by the professional training we provide so that potential juniors can gain the experience necessary to climb through the ranks when opportunities arise.� Pieter Louw, TWP Projects, Tel: (011) 218-3000, Email: plouw@twp.co.za

To hold together and co-ordinate the enormous task of building a mine requires a specialist, the BMG-MAT16012012.ps professional project manager

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MINING

From Mine to Market

Surprisingly, even within one country, the requirements at different border posts can be vastly diverse

Shipping cargo is ex tremely paperintensive and requires infinite attention to detail,” says Bridge Shipping Group’s Chief Executive Officer, Colin Emanuel. He points out that cross-border operations have always functioned independently, therefore it is important for a logistics company to ensure that they are up to speed on the requirements for each country through which the cargo enters or exits.

Colin Emanuel, CEO of the Bridge Shipping Group

It is therefore critical to ensure that the operational procedures we have in place are capable of tracking every shipped item to the nth degree, at every point of its journey,” Colin adds. He points out that a collection document is acquired as the first point of contact with the cargo, together with the relevant customer-specific documentation. The cargo is then received at the relevant Bridge Shipping Group depot and a document is produced for its receipt. When the cargo leaves the depot a further document is produced, accompanied by security transit documents and border documentation. When the cargo crosses the border, the relevant paperwork is completed and an entry document is

issued by the border post officials. Finally, documentation is required when the shipment reaches the Bridge Shipping Group depot and again when it leaves the depot and arrives at either an exit port or its final destination. The Bridge Shipping Group utilises its own operating system – Bridge Operating System (BOS) – but we also need to be aware of and work closely with the specific operating systems intrinsic to each country’s border post.

EDI and ‘BOS’

“The South African border control authorities have spent the past few years implementing and finetuning their operating system to a stage where it is much easier for cargo to readily cross the border when all the correct documentation is in place.

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MINING

The system, known as EDI (Electronic Data Integration), allows for a virtually paperless environment. This is useful from both the perspective of companies that have already adopted this philosophy, and from its reduction of carbon footprint. However, it will be some years before other countries achieve this same level of automation,” Colin comments. The BOS provides the company’s operations with commonality of documentation. “This consistency results in an increased logistics flow, since all documentation produced will be identical, no matter in which country Bridge Shipping employees are accessing it. This is also important in terms of simplifying each individual country’s legal and statutory requirements,” Colin explains.

Understanding in-country culture and operations

Colin believes that having an operational knowledge of each geographical area in which a logistics company operates, greatly assists in addressing the relevant physical infrastructure challenges. “The Bridge Shipping Group is already extremely entrenched in five of its operational areas. Senior management of the company is required to spend up to two years cross-border, in order to familiarise themselves with the particular regulations and business culture of this country. Surprisingly, even within one country, the requirements at different border posts can be vastly diverse, which makes it even more difficult to understand a country’s

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MINING

requirements when operating systems from a physical distance.”

Zero tolerance of corruption

The subject of corruption often rears its head in cross-border operations. “We have adopted a policy, from the outset, that under no circumstances will we negotiate with corrupt officials. We stand by our principles of producing the relevant documents, the relevant entry and exit fees, but we will not pay bribes. We have a strict code of conduct in place and our adherence to ethical practice forms a large part of our accountability to our stakeholders,” Colin affirms. In spite of the limitations placed on each corridor, the Bridge Shipping Group is under obligation to guarantee that a specific route to market will be provided for its customers, by dominating that corridor. “This entails prior planning and implementation of a sustainable plan of action.-

Depot network strengthens presence

“One of our strengths in the market is the presence of depots within each country of operation. These depots allow us to pre-assemble and dismantle cargo, store cargo, use both rail and road transport and to develop import cargo for our customer base. We have built our reputation on the premise that

customers are provided with the entire supply chain from ‘mine to market’. We are able to leverage our import and export experience to maintain and grow these corridors,” says Colin. He adds that all their depots are served by a rail link. “This obviously provides us with a great advantage, since we can predetermine the most expeditious route for a customer’s cargo, based on the volume of cargo, its final destination and the fastest route.

In spite of the limitations placed on each corridor Great relationships

“We are fortunate that we have developed strong and synergistic relationships with Transnet, National Railways of Zimbabwe, Rail Systems of Zambia and other counterparts which allow us to maximise our utilisation of rail transport. In addition, we have built up an extensive database of preferred road transportation suppliers. By being able to offer our customers preferential service, based on our capacity, capabilities, systems expertise and local, in-country knowledge, we can guarantee a seamless and qualified logistics service,” Colin concludes. Colin Emanuel, Bridge Shipping Group Tel (011) 625-3000, Email: colinem@bridgeshipping.co.za www.bridgeshipping.co.za

BULK HANDLING TODAY

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MINING

Two Contracts Concluded Concor Roads & Earthworks and Concor Civils, two operating entities in Murray and Roberts Construction, undertook two separate contracts aimed at extending the loadout facilities and increasing the rail loading capacity from 12 to 16M tons of iron ore per year at Assmang’s Parsons plant near Kathu in the Northern Cape. Assmang is a joint venture between Assore Pty (Ltd) and African Rainbow Minerals Pty (Ltd). The overall objective is to increase the volume of iron ore being produced at Khumani mine.

T

he work resulted in the expansion of the stockpiling storage capacities for different ore grades and included the addition of new stackers for the lumpy and fines stockpiles, the addition of a new reclaimer for the fines stockpile and an extension to the existing medium-size stockpile. All work was carried out in the loadout area while the open cast mine continues operating day and night.

Increasing volumes

A primary portion of the contract awarded to Concor Roads & Earthworks comprised the construction of 3 metre high terraces for the new stackers and reclaimers in order to increase the volume of the stockpiles. The elevated terrace for the new stacker for the lumpy stockpile is 1.34 km long and 15.5 metres wide while the elevated terraces for the new stacker and new reclaimer for the fines stockpile are 1.34 km long and 30 metres wide. Deon Douglas, project manager at Concor Roads & Earthworks, says a total of 450 000 m³ of en-

gineering fill and 80 000 m³ of material for two engineered layers were required for the terraces.

Deadlines achieved

Apart from clear and grub (60 ha) and stripping of 80 000 m³ of topsoil, the contract also included the building of roads around the terraces, relocation of existing services for fire water, potable water, storm water drainage and electrical feeder concrete pipes, the latter positioned in concrete 8 metres below ground level for safety purposes, and backfilling between concrete slabs on the terraces after the completion of civils work. Deon remarks that since the start of the contract in January last year all deadlines have been achieved to provide access for civils work in tranches despite the fact that timelines were exacting.

Cast sections

Concor Civils was contracted to construct about 9.5 km of reinforced concrete rail support beams, hundreds of precast conveyor sleepers, supply and installation of 65 000 holding down bolts and cast-in items on 3 metre terraces for the new

An aerial view of the work being undertaken by Concor Roads & Earthworks and Concor Civils to extend the loadout yard at Assmang’s Parsons plant near Kathu

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MINING

Pouring concrete using a boom on the new fines stacker line that comprises part of the extension to the loadout facilities

stackers for the lumpy and fines stockpiles, the new reclaimer for the fines stockpile and the extension to the existing medium-size stockpile.

A new stacker conveyor operates between the two rail slabs Additional work comprised the construction of cast sections to support a new 0.57 km discard transfer conveyor, 20 metre long tail end/drive in situ cast sections to allow the extension by 160 metres each of two existing loadout conveyors, casting in situ of two transfer chute bases for a 100 metre long transfer conveyor, transfer base for a new chute under an operational conveyor, reinforced concrete foundations, sumps, plinths and bund walls for three mini sub stations; and reinforced concrete foundations, plinths and hold down bolts for 16 light mast bases.

Civil work

The civil work for the stacker operating on the new lumpy stockpile required the construction of two 1.33 km stacker rail slabs 7 metres apart. Each rail slab is 2.1 metre wide and consists of 600 mm thick reinforced concrete. Rail slabs were constructed on a 50 mm thick blinding layer of 10 MPa concrete and each slab had groups of 4 x 20 M hold down bolts located at 600 mm centres along the length of both slabs. A new stacker conveyor, which is about 1.38 km long and comprises a 30 metre long tail end and 30 metre long head end/drive in situ cast section, operates between the two rail slabs. The civil work included the fixing between the head and tail ends

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MINING

of 450 mm x 450 mm x 2100 mm concrete precast sleepers at 3 metre centres.

A new transfer base was cast for a new chute constructed under the operational conveyor The civils work was replicated for a stacker for the new fines stockpile and a new fines reclaimer but with the addition of the casting of two transfer bases for new chutes. Concor Civils was contracted to cast plinths with bases for a conveyor and transfer base for an extension 113 metres long of an existing conveyor which feeds iron ore to a stacker for the new lumpy stockpile.

Transfer base

Civils work on the extension to the existing medium size stockpile comprised the relocation of an existing vehicle cross-over culvert 100 metres to the south and the construction of two 0.48 km stacker rail slabs. A new transfer base was constructed under an operational conveyor to accommodate a new chute. In order to relocate an existing discard transfer conveyor to create space for the new fines stockpile, cast sections were required for a new 0.57 km discard transfer conveyor prior to the decommissioning of the existing conveyor. A new transfer base was cast for a new chute constructed under the operational conveyor. Sue Upton, Murray & Roberts Construction, Tel: (011) 495-2222, Email: info@murrob.com, www.murrob.com

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ThyssenKrupp PDNA Engineering

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CRUSHERS

Carpe Diem

This technology is now also used in a dedicated crusher feeder design

While most people moan and groan about the skills shortages, the lack of qualified maintenance personnel and ever rising energy costs, others see it as an opportunity. Based on this philosophy Vipro, specialists in the design and manufacture of vibrating and screening equipment, have come up with new designs in vibrating screens and feeders which use less energy, require minimum maintenance and are quick and easy to manufacture.

Zeüs Venter, managing director of Vipro

Bulk Handling Today” speaks to managing director of Vipro, Zeüs Venter, at the company’s headquarters in Menlyn near Pretoria. “In view of the challenges industry faces in terms of skills

BULK HANDLING TODAY

(Continued on page 32)

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Demag Cranes & Components, the complete solution provider, was founded in South Africa in 1958, and is a wholly owned subsidiary of Demag Cranes AG in Germany. The head office, as well as the manufacturing facility, are located in Boksburg on a site of 77 000 sq m, of which the office area totals 3 000sq m and the production facility 40 000 sq m. Demag has a network of branches, satellite stations and agents throughout South Africa, as well as in Namibia and Zimbabwe. Demag Cranes & Components (Pty) Ltd is a market leader in the design and manufacture of cranes and a supplier of materials handling components and equipment. Demag is a fully integrated part of an international operation, which has full product ownership of all essential components in material handling.

150t Heavy Crane

The company’s culture is to ensure that every project is successful, with continuous advancement of our knowledge base and quality of our products, which ultimately guarantees customer loyalty. Our cranes are built to the highest and unmatched quality in the world. The superior quality of our equipment ensures reliability, ease of maintenance and ultimately adds to the profitability of our clients.

Industrial Crane

Explosion Proof Equipment 30 BULK HANDLING TODAY August

2012

Demag’s product range: ■ Demag heavy cranes ■ Demag industrial cranes ■ Demag crane construction kits - KBK System ■ Demag slewing jibs ■ Demag chain hoists ■ Demag rope hoists ■ Demag drives ■ Specialized ancillary products for material handling solutions ■ Explosion proof equipment


Services ■ Erection and commissioning ■ Safety checks ■ Maintenance and inspection ■ Fault elimination and repairs ■ Refurbishment ■ Laser measuring systems ■ Crane and crane runway surveys ■ Factory repairs ■ Spare part supplies

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Demag Cranes & Components (Pty) Ltd 60 Atlas Road, Boksburg North P O Box 311, Benoni, 1500 Telephone +27 (0)11 898 3500 Telefax +27 (0)11 898 3533 E-mail demag@demagcranes.co.za Internet www.demagcranes.co.za

The Demag network: Boksburg Cape Town Durban Kuruman Nelspruit Newcastle North West, Free State Namibia Zimbabwe

Pietermaritzburg Polokwane Port Elizabeth Pretoria Richards Bay Rustenburg

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CRUSHERS

Vibrating screen system

and maintenance, we decided to develop equipment which requires the minimum human intervention in order to function efficiently,” he says. “In addition we’re constantly revising production methods so that we can manufacture more effectively without increasing the costs of our products.”

This means that when a feeder is operating at full capacity, for example at 2 000 tonnes per hour, the out-put can be adjusted as low as 200 tons per hour New design

This approach paid off when an American company, FMC Technologies, recognised the merits of a Vipro design for vibrating feeders which reduces the consumption of these energy guzzlers by 50 percent. “We’ve had a long-standing relationship with FMC, one of the biggest suppliers of vibrating equipment in the world,” says Zeüs. “Until recently we only imported small vibrating feeders from them, but since we participated with them in developing a new range using totally new technology, we’re now manufacturing some of the large machines locally under licence. “One of the reasons they partnered with us to manufacture locally for the world market is because South Africa still has a lower manufacturing cost factor than the USA or Europe and our delivery times are far quicker than China,” says Zeüs. “What’s more, our manufacturing is robust and on a par with world standards in terms of quality.”

Changes

In essence, the main difference in the new design is that the feeders are no longer driven by a gearbox, pulleys and belts and in the place of coil springs, the system uses rubber mountings. “Tests over the past two years of development have shown that the vibrating motor we use now is much more effective than the transmission system which was the norm in the past,” Zeüs explains. “Where we required 18 KW power on an old type system, for example, we can now drive the new design with 5 KW for the same capacity machine. The feed rate has also

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CRUSHERS

improved significantly. To handle 2 000 tonne of coal we’d normally need four 11 KW drives, but with the new design we’re now doing the same with one motor of 11 KW.”

The technology

The newly-designed, FMC Syntron vibrating feeders, are sub-resonant tuned, two mass, spring-connected systems. “These features enable the feeders to work consistently under material damping and other varying head load conditions with negligible changes in trough stroke,” explains Zeüs. “Sub-resonant tuning maintains stroke consistency and speed stability to deliver higher capacities at controlled feed rates. “The sub resonate tuning and two mass design permits a full 10:1 turn down ratio for the output of any feeder,” he adds. “This means that when a feeder is operating at full capacity, for example at 2 000 tonnes per hour, the output can be adjusted as low as 200 tons per hour without interruption to the flow consistency and reliability of the feeder output. Precise, sub-resonant tuning is a key characteristic of these vibrating feeders. The electromechanical models are tuned by adjusting the operating speed to obtain the exact tuning ratio.

Electrical control

“Also new is the control system for these feeders, yet

Feed rates are easily adjusted and the response is instantaneous

South Africa still has a lower manufacturing cost factor than the USA or Europe and our delivery times are far quicker than China another factor which contributes to energy saving,” says Zeüs. Dependable, flexible solid-state control sets the heavy duty feeder range apart from other

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CRUSHERS

feeding and conveying machinery. Feed rates are easily adjusted and the response is instantaneous. Control devices can be supplied for integration in systems using external signals from automatic sensing devices in instruments.

This technology is now also used in a dedicated crusher feeder design

We’re constantly revising production methods so that we can manufacture more effectively without increasing the costs of our products

Exports

This technology is now also used in a dedicated crusher feeder design. “Our new crusher loading feeder is a traditional mechanical style vibratory feeder with a peripheral discharge,” says Zeüs. This feeder retains the high reliability and robust design of the mechanical feeder where the peripheral discharge enables equal distribution of fine and coarse product. The trough is fully lined to account for wear, and it is suspended by the same method as traditional vibratory feeders. The suspension framework is mounted on a trolley that can simply be moved out of the way for crusher maintenance. “Interest in this new technology has been overwhelming,” Zeüs says in conclusion. “We’re now in the process of manufacturing 36 of these feeders for export to Brazil. Apart from the energy saving aspects, the fact that we can now increase the capacity of a feeder system in an upgrade to the new technology within the same footprint as an old system, has created particular interest from one and all.” Zeüs Venter, Vipro, Tel: (012) 365-3131, Email: zeus@vipro.co.za

Promech Publishing has a BBE rating of 168.75%

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A Case for Jaw Crushers Twin primary jaw crushers is a cost efficient mining industry new technology alternative to conventional gyratory primary crushing stations for high volume processing of ore or hard rock. Gyratory crushers have been the traditional, high capacity choice for primary crushing stations. Can today’s massive, new jaw crushers offer a viable alternative?

The high cost of gyratory primary crushing

A gyratory’s high productivity and reduction ratio, as it applies to coarse crushing of various ores and rock, comes with a high capital investment and associated operating costs. While the gyratory crusher is effective, it is also accompanied with a number of disadvantages. Initial capital investment is very high and the machine, foundation and supporting structure’s design, manufacture and installation is correspondingly very ambitious. The entire procurement and installation-to-operation process can take up to two years or more. Considerable project costs include delivery of the unit as well as installation costs.

T

raditionally, large mining operations have relied on gyratory crushers for use as their primary crushing stations. Gyratory crushers effectively reduce coarse feed material to the optimal size for downstream secondary and tertiary crushing stages of a mineral processing or large quarry operation. Materials such as iron ore, copper ore and limestone, produce a wide range of fragmentations when drilled and blasted. Until recently, high capacity gyratory crushers were the only suitable primary machines to handle feed tonnages above 1000 tph. Generally, gyratory crushers can crush ore with a top feed size of 54 inches at rates up to 5000 tph.

This complex structure results in a crusher design of substantial height and inherently difficult to access and maintain, thus making repair or replacement of sophisticated components difficult and costly The gyratory machine requires design and installation of a complex structure consisting of a tall cone within a shell, a main shaft and mantle, as well as a countershaft all engineered to provide an eccentric, continuous crushing action. This complex structure results in a crusher design of substantial height and inherently difficult to access and maintain, thus making repair or replacement of sophisticated components difficult and costly.

Alternatives

In summation, for all the high productivity gyratory machines bring to large mine and quarry operations,

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CRUSHERS

Once capacity and throughput are achieved, simplicity, lower initial capital investment, lower installation costs, and ease of operation and maintenance trump convention there exist legitimate reasons to explore, based on application, other alternatives for a primary crushing station. Today’s higher capacity jaw crushers often offer a better alternative. Today, very large model, high capacity, heavy duty jaw crushers are being considered, selected and installed in lieu of the gyratory option. These jaw crushers are in fact the optimal choice for certain primary crushing parameters. Jaw crushers are far less complex machines, have lower height requirements and simpler supporting structure and foundation requirements. They offer reliable, repeatable performance and are very easy to maintain.

The jaw crusher’s open side or “throat” is comprised of two opposing non-parallel plate assemblies. One plate is held stationary while the second, opposing plate, moves as an integral part of the swing jaw assembly whose movement is defined by an eccentric shaft. This elliptical plate action applies the crushing force to the devoured rock by trapping it in a tapered configuration, where fractured rock is progressively broken into smaller pieces until it falls through the closed side or “gap” at the bottom of the opposed jaw plates. The plate assemblies are often lined with reversible and easily replaceable high alloy liners to reduce wear. A hinged jaw’s crushing action is considered to be cyclic and progressive, rather than continuous.

the right

ingredients

for the perfect mix

Multotec, a leading mineral process solutions provider to the mining and mineral beneficiation industries, partners with customers for perfect equilibrium between the life of equipment and process effectiveness in every individual customer application. Our value-added products and extensive application knowledge have established our global reputation for providing optimum technical solutions and the highest levels of support through consulting services and field service teams.

Indulge yourself in the Multotec experience 10 - 14 September 2012 • Hall 6 • Stand A18 Tel: +27 (11) 923-6285 • marketing@multotec.co.za www.multotec.com

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Changing conventional rules

Today, Lippmann, a leading jaw crusher manufacturer located in the US, has introduced a new, massively constructed 5062 model heavy-duty jaw crusher. The high capacity Lippmann primary crushing station employs two 5062 jaws running in a side by side or “parallel” configuration. This parallel installation of Lippmann 5062 jaw crushers has challenged the limits of high productivity and high throughput previously thought possible from any prior-designed primary jaw crushing station. Because the robust twin jaws can be installed for the cost of one single gyratory installation, Lippmann offers material processing operations a serious, previously unavailable alternative with high capacity, high throughput, highly productive and cost efficient crushing alternative. Of significant consideration is that this concept assures a mining or aggregate processing operation 100% uptime with and due to redundancy. When considering proper equipment selection, twin jaws may not be the right solution for every application, but this option may change the equation for many. Once capacity and throughput are achieved, simplicity, lower initial capital investment, lower installation costs, and ease of operation and maintenance trump convention.

Shortened lead time to take delivery

The twin 5062 crushers can be manufactured in a fraction of


CRUSHERS

the time it takes to manufacture a gyratory, thus jaws are more promptly delivered and installed. The more advantageous installation of the 5062 includes less costly civil engineering, a reduced installation requirement set and improved ease of operational support. Training and operation are also simplified. Working together, the twin units can achieve gyratory-comparable material throughput and provide a better ratio of reduction, while virtually eliminating any risk of total production stoppage from the primary station. For many operations today, installation and operation of the twin jaw alternative presents a reasonable, highly cost efficient and highly reliable option to the conventional primary gyratory crushing station.

Proper equipment selection

Each mining and aggregate operation has unique considerations that factor into proper equipment selection. Matching a plant’s specific throughput requirements, maximum feed size requirements, crushability and strength of feed material, distribution, and discharge settings for optimum utilization of downstream crushers, as well as other considerations must be carefully factored to achieve maximum crushing efficiency and minimum cost per ton of material processed. The Lippmann twin 5062 Jaw

Primary Crushing Station is a suitable option worth consideration that has proven to exceed expectations for an increasing number of leading, large mining and aggregate installations. Lippmann Engineering, Lippmann-Milwaukee, www.lippmann-milwaukee.com or www.lippmannrockcrushers.com

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Fit For Hard Work.

Scania construction trucks are created from generations of hard work in the toughest conditions. Rugged, robust trucks that get the job done. We are committed to your profitability. That’s why we focus on uptime. You need trucks that just keep going, no matter what. With Scania you are always fit for hard work.

For more information contact your nearest Dealer. Details available on www.scania.co.za

38 BULK/HANDLING August 2012 / Scania Finance & Insurance / Services Trucks BusesTODAY / Engines


TRUCKING

Winners of the truck drivers competition: (1st) Ryno Niewoudt, (2nd) Steven Stroebel, (3rd) Ebrahim Mathobela, (4th) Martin Barnard and (5th) Charles Leibrand

Driver of the Year 2012 The 28th UICR (Union Internationale Des Chauffeurs Rouiters) World Drivers’ Championship, hosted for the very first time on African soil, came to an end at Sun City, North West Province on August 11th with Team South Africa walking off with 10 medals and country named as the overall winner of the competition. The World Championship, which was hosted by the Road Traffic Management Corporation (RTMC) in conjunction with the Department of Transport and the North West Department Human Settlements, Safety and Liaison, saw participants from fifteen countries compete for the top honours in five categories: light delivery vehicle, rigid trucks over 12 tons, bus, semi truck and trailer and articulated truck. Ashref Ismail on 071 680 3448 or Ashrefi@rtmc.co.za

Collins Letsoalo, Acting CEO, RTMC

Pick n Pay, Sabelo Mngomezulu

Gideon de Swartd, Scania

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* With the choice between two uncompromisingly powerful engine makes, the New Generation Freightliner Argosy offers enhanced fuel economy, supreme engine response and the brute strength of a real champion. You wouldn’t expect anything less from the hero of long haul.

WWW.FREIGHTLINER.CO.Z A

OUR VALUE CHAIN PARTNERS

August 2012

BULK HANDLING TODAY

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TRUCKING

From Left: Miss Road Safety SA, Pabi Notoane, Most improved: Truck driver, Abraham Steenkamp and a representative from Avis

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Is Your Truck Tough Enough? The romantic vision of truckers gliding across America’s skyline in their shiny chrome-intensive cabs is dispelled after taking one look at the sort of landscapes being tackled by our large commercial vehicles, particularly across sectors such as the mining, abnormal load, recovery/towing and speciality industries. Our road infrastructure is generally inhospitable and unsafe for a great number of abnormal load trucks on the road. On the mines, extremely steep gradients have to be navigated by heavy-load vehicles throwing up safety and braking considerations.

D

aimler Trucks North America, the parent company of Western Star, based in the United States, has taken a close look at South African conditions, and examined the requirements put forward not only by their local distributor but also from potential customer

enquiries. It’s a market they view as having growth potential so, with about 250 units in the field, they offer a tough, safe and economic core-rig suitable for local conditions, through improved driver safety technology, and improved braking and gear mechanisms.

One of the safest rigs of its kind in the country

The Western Star ‘red monster of a truck‘ was handed over to Mincon and Booysen Bore Drilling in June 2012 at the handover was Jaco Scott, Managing Director of Mincon, Mr Hennie Booysen of Booysen Bore Drilling and Duncan Prince of Mercedes Benz SA

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TRUCKING

truck but for it to be the best truck for tough and difficult tasks – and that is our way forward locally. The Western Star 4900SA model that we recently supplied to Mincon in South Africa is one of the safest rigs of its kind in the country.”

Specialised

The truck’s transmission has a hydraulic retarder which doubles the margin of safety offered by the Jacobs Engine brake, which is fitted to the Detroit Diesel Series 60 engine. This allows a dual auxiliary braking system to become operational increasing truck safety when the rig is descending steep inclines, for example into open cast mine pits. Duncan comments, “The T685WS is the drilling contractor’s rig of choice for mineral exploration, shallow oil and deep water applications because of the improved mechanisms installed. It also has a pullback force of around 40 metric tonnes making it capable of handling a string of drill pipes of more than 1km in depth. “We are known for our efforts to move forward with green initiatives on our commercial vehicles, but due to the individual building specs of all the Western Star trucks, it does make it hard to ensure that all green options can be incorporated. However, the vehicle is fitted with emission controlled engines making them locally emission compliant wherever they are based”.

35 tonnes handed over

Mincon took delivery of the Western Star in June, it is a 8 x 6 rigid truck fitted with a Schramm T685 drill rig truck destined for their client, the Booysen Bore Drilling Company in Kuruman in the Northern Cape. The drill rig will be used for mine de-watering operations at iron ore facilities in the region. The complete unit weighs some 35 tonnes, cost nearly R15 million and took nearly 9 months to build in order to meet the high specifications required by the mining industry who are the main benefactor of Booysen Bore Drilling equipment. Mincon chose the Western Star because it can build right-hand drive cabs from scratch, making it compliant with South African heavy-duty vehicle legislation. Very abnormal load is the 35 tonne Western Star truck carrying the T685 Schramm drill rig

Biggest plus being the availability of local technical back-up and support Speaking to “Bulk Handling Today”, Duncan Prince Product Manager, Freightliner Mitsubishi Fuso Division says, “The Western Star is not a mass market product, but a vehicle built for specialist and extreme duty applications. The truck sells well in the US, Canada and Australia, but the success of the vehicle is not measured by sales volume alone, the objective is not to make it the highest selling

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“The rig was specifically customised to the hauling needs of Mincon and their Schramm T685. Being a heavy and large piece of drilling machinery needing to be transported to Kuruman, in the Northern Cape – not exactly next door – the rig needed efficient power and gear shifts to ensure this journey was not only successfully completed but that safety, particularly braking safety along certain sections of the journey were in place and functioning. In addition, the vehicle is intended to be as easy to drive as possible,” says Brian Coetzee, Divisional Manager at Mincon.

Biggest plus

The relationship between Mincon and Western Star started over three years ago when a smaller unit was commissioned, with Mincon Managing


TRUCKING

Director Jaco Scott commenting, “We have looked at other vehicles, tested them out, but the conclusion we came to is that the Western Star is in fact a far superior truck to other truck offerings. It gives us a far better return on investment through performance, with the biggest plus being the availability of local technical back-up and support. The bonus is that it has many components that are common to both the Western Star and the Freightliner fleets currently operating in South Africa”.

Biggest plus being the availability of local technical back-up Duncan adds, “The Mincon order required a custom-made truck comprising three of the four axles being The Western Star showing the complexities of the Schramm T685 drill atop the Star’s chassis driven axles, which provides good traction when the truck is operating in difficult terrain The Western Star is a brand of Daimler Trucks such as that experienced in the mining industry. North America and is distributed and maintained The unit also has a specified Allison RDS4500 throughout South Africa by Mercedes Benz South six speed automatic transmission, making the 35 Africa. tonne mass of the vehicle easy to handle for driv- Duncan Prince, Mercedes Benz SA, Tel: (012) 677-1589, ers with limited experience, even when running Email: Duncan.prince@daimler.com on steep inclines”.

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? FAQ’S

Frequently Asked Questions and Answers

Viv Nel (Pr Tech Eng) of LEEASA (Lifting Engineering Equipment of SA) answers some FAQ’s

OHSAct

Occupational Health & Safety Act

DMR 18 Driven Machinery Regulation 18, which covers lifting equipment User requirements

ECSA

The Engineering Council of South Africa

April 2006. This amendment granted exemption from the original date of 28th April 2006. (See also Government notice R.158 on 18 February 2005).

LEEASA Lifting Equipment Engineering Association of South Africa

LMI

Lifting Machinery Inspector (an individual person who is registered with ECSA as an LMI).

B. The Government Gazette No 30829 No. R. 257 of 7 Match 2008 grants exemption to individuals that submitted their applications to the Engineering Council of South Africa before 30 September 2006 until 27 June 2008.

LME

LTI

Lifting Tackle Inspector, qualified by knowledge, experience and training.

The Department of Labour (DOL)

Lifting Machinery Entity (Companies, Close Corporations, & / or one man businesses conducting inspections and tests)

Note: Some Government notices also use LME to denote LMI’s.

What are the Department of Labour requirements for lifting machinery inspectors.

A. Lifting Machinery Inspectors (LMI) are individuals, who were required by law to apply for registration with The Engineering Council of South Africa (ECSA) by the 29th September 2006, as per the amendment to the act as gazetted in the Government Gazette No 28755 No R 396 of 28th

(Previous Notice was Gazette 29730 No R260 of 30 March 2007 which granted exemption to individuals that submitted their application forms to the Engineering Council of South Africa (ECSA) before 30 September 2006 until 31 October 2007). C. This means LMI’s who have not yet applied to ECSA may not legally practice their work.

D. LMI’s who have not applied to ECSA yet, must apply to ECSA for registration immediately. You are advised to keep a copy of your application and use registered mail to prove your application and date.

If I am not registered as an LMI with ECSA may I sign load test certificates?

If you are not a registered LMI you may not sign certificates, as you would be breaking the law. A registered LMI may witness and/or supervise an inspection by an unregistered person (as in training and gaining experience). This must be

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co-locating in hall 9

Tr a n s p o r t f o r t h e M i n i n g I n d u s t r y

SKETCH4619/12

VISIT

G IN DE A IN R A RIC M T AF L T ES IC A RN G a G TR HE I ric C T B Af E E LE O U H h S T D ut IN So AN W , b ily O J h da SH c,

em

be

12 0 r2

stated on any certificate issued and while both signatures are required and the LMI's registration number, the LMI will be the only one held legally responsible.

May an LMI do repairs and make modifications to the equipment being tested?

No. Another engineering person must carry out the repairs and/or modifications. The repairer and tester cannot be the same entity or person. Any modifications and or repairs have to be recorded in the equipments logbook for future reference and inspection purposes.

ptsre m e S , N a 5p

4 e - 1Centr9am

10Expo

PRE-REGISTER AND BE PART OF THE IN-CROWD INTERNATIONAL MINING, INDUSTRIAL, CONSTRUCTION AND POWER GENERATION EXHIBITION SHOWCASES NEW INNOVATIONS, PRODUCTS, SERVICES AND TECHNOLOGIES Pre-registration is now open for Electra Mining Africa, the ultimate market place for all stakeholders involved in the mining, construction, industrial and power generation industries. Visitors can expect to see leading local and international industry players in the packed halls and outside precincts. It’s the ideal place to view the latest in technology and equipment, innovative products and new supplies and services. Experts will be on hand to give advice, live demonstrations will be happening daily and co-located conferences and workshops will add even greater value. Electra Mining Africa is recognized as the second largest mining show in the world and the biggest trade exhibition in southern Africa with global recognition for its broad reach across mining, construction, industrial and power generation industries. Electra Mining Africa and co-located Elenex Africa, Machine Tools Africa and Transport Expo runs from 10-14 September 2012 at the Expo Centre, Nasrec, Johannesburg, South Africa.

PRE-REGISTER FOR FREE ENTRY It’s simple – just complete the registration form at www.electramining.co.za R15 per vehicle, per day for secure parking

Contact the Marketing Director at Specialised Exhibitions Leatitia van Straten leatitiavs@specialised.com +27 (0) 11 835 1565 www.electramining.co.za

MINING • INDUSTRIAL • CONSTRUCTION • POWER

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Does a person who only examines lifting tackle have to register with ECSA?

The Government Notices No R 257 of 7 March 2008 states, "This registration does not apply to persons who examine lifting tackle in terms of regulation 18 (10)(e) of the Driven Machinery Regulation”.

What are the Department of Labour requirements for Lifting Machine Entities?

Companies, or service providers who perform statutory inspections, repair or perform annual load testing on their own, or customer’s lifting machines, must apply to the DoL to be registered as an LME. The DoL will issue a certificate to the LME as proof of the LME’s registration.

Are company staff required to be registered with DoL?

No. Company staff do not have to be registered with the DoL regarding the amendments published which reference to lifting machinery and equipment. However, other DoL registrations, which the DoL may require must not be confused with the requirements for lifting machinery.

Do staff millwrights and other crane inspectors who inspect cranes regularly have to be registered with DOL?

No But any practitioner performing statutory inspections and annual load tests, as defined in the OHS act regarding Driven Machinery (DMR18), is compelled to register with ECSA by the deadline date which was originally 31st of March 2006 as an LMI but is 29 September 2006.


?

Do staff (and non staff) persons who do 3, 6, and 12 monthly inspections on lifting tackle and cranes have to register with DOL?

No. Different types of equipment have specific requirements regarding the frequency and type of inspection required as set out in the regulations. Users are encouraged to familiarise themselves with the relevant clauses which affect them.

Do persons who carry out load testing (LMI) have to register with DOL and by when?

No, the LMI only has to be registered with ECSA. The companies (entities) that are carrying out the testing must register with the DoL as Lifting Machinery Entities (LME). The cut-off date has expired, but the DoL are still entertaining applications for new entries into the market.

Do persons who carry out repair work on cranes have to register with DOL?

No. Repairers of equipment do not have to register with the DoL specifically for this purpose, however a proposal to the amendment of the act clearly identifies that a repairer cannot be the inspector of their own work, and visa versa.

If a company carries out its own tests on its own cranes is it required to register with DOL?

Yes. A company doing this has to register with the DoL as an LME. However the actual inspection must be carried out by a LMI who is registered with ECSA.

If a company contracts out to a load test provider is it required for the company still to be registered with DOL?

No. The company is not required to register, but the load test provider must be registered with the DoL as a LME and the load test provider's people doing the testing must be registered as LMI’s with ECSA.

FAQ’S

Do Companies and/or individuals have to be members of LEEASA as well as registering with DOL?

No. It is not necessary for either companies or individuals to be members of LEEASA, which is a voluntary engineering association, not for gain. However, it is advisable for them to become members to have a unified voice in influencing the decisions regarding legislation and informing authorities and other interested parties of the industries viewpoint. Members are regularly updated on information about issues that are relevant. Members are recognised as credible participants as they have to abide by a Code of Conduct.

What forms etc are required and what is the contact detail and postal address of DOL regarding any registration of persons and companies as an LME? The contact details for companies wanting to register with the DoL are listed below; (Ask them for their latest forms, as they seem to change from time to time. Keep copies of your submitted forms and use registered mail so you can prove your application and date of application). Department of Labour, Private Bag X117, Tshwane, 0001 Fax 012 309 4151, or Laboria House, 215 Schoeman Street Pretoria E Mail mohlakola@labour.gov.za

Disclaimer

While every attempt is made to ensure that the information provided in this article is correct, we do not accept any liability this article contains any errors or is not up to date. This article is published in the interests of providing information only and does not purport to be an all-encompassing piece or to be a legal opinion on any matters. The user must and shall check on any information provided in this article. Any use of this article is solely at the users risk. LEEASA, www.leeasa.mirrorz.com

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MARKET FORUM

Aggressive Growth Plan Hino has aggressive plans to grow its global sales volumes from the 113 000 units sold in financial year 2010/2011 to 196 000 units in financial year 2014/2015 – a 73% increase. The global market for trucks with a GVM of 3,5-tons and over, which stood at 6,73-m in the boom year of 2007 surpassed this total last year, with sales of 7,1-m units, and this total is expected to grow to 8,5-m units in 2015. This was revealed by the president of Hino Motors Ltd., Yoshio Shirai, in a presentation when the company announced its 2011/12 financial results. China and Russia are seen as major growth areas for Hino, while plans are being put in place to grow markets in the Middle East, Africa and Latin America. In terms of development this will involve more use of modularisation in the design of new models, together with product adaptations to suit specific markets. Production will also incorporate modularisation for fabrication and assembly, together with a reduction in lead times with the introduction of new products. Sales changes will focus on ensuring products have the appropriate specifi-

Hino President Yoshio Shirai at the 2011 Johannesburg Truck and Bus Show at Expo Centre

cations for the markets where they are being sold and the applications for which they will be used. Enhancing the Hino support systems for all parties involved is also high on the priority list, with particular focus on providing lower cost replacement and service parts. Besides from plans to grow sales and production capacity is a powerful drive to develop new technologies, especially in terms of those that are environmental friendly. Here Hino is working on a wide variety of solutions from diesel/electric hybrids to pure electric vehicles and

those powered by fuel cells. In addition progress continues to be made in using alternative fuels such as gas and biofuel. Hino Motors had a comparatively conservative approach to growing sales outside Japan in the past and relatively few, selected export markets it had served for years. Now the increased sales planned for the next few years is changing all that and a major growth and revitalisation programme is underway. Ignatius Muthien, Hino Division, Tel: (011) 809-2064/2255, Email: imuthien@hino.co.za

Crushers in West Africa An end user in West Africa recently experienced leakage problems on their crushers which, upon investigation, turned out to be damage to the all radial shaft seal arrangement caused by severe operational conditions. The customer contacted the company and although SKF West Africa could supply ten off split seals with dimensions 1180 x 1230 x 20, the lead time of twelve weeks was unacceptable to the customer who required a speedy solution due to costly lubrication losses and environmental pollution. SKF South Africa offered a SKF machined seal option which could be delivered to the customer at a third of the initial lead time quoted. “Although the size of the seals was too big for the locally-operated NG60 (600mm OD), we opted for the Austrian manufactured solution where SKF has the capability to machine endless seals up to 4000mm OD,” explains Andrè

Weyers - Platform Manager SKF Southern Africa. The seals are manufactured from G-Ecopur which is a cast hydrolysis-resistant polyurethane elastomer known for its chemical stability. In addition to prompt manufacture, G-Ecopur material has higher temperature and wear resistance capability than standard NBR seal materials and also requires no costly tooling to produce. With a manufactured lead time of three weeks and shipping to South Africa of one week, eight off SKF large diameter machined seals type: R01-G Special, were supplied to the customer. Samantha Joubert, SKF South Africa, Tel: (011) 821-3500, Email:samantha.joubert@skf.com, www.skf.co.za

André Weyers - SKF large diameter machined seal solution - manufactured from technologically advanced G-Ecopur material

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Richards Bay Ship Unloader Port operator Transnet Port Terminals (TPT) has earmarked the biggest slice of its R33 billion budget over the next seven years for new equipment acquisition projects at Richards Bay, the country’s largest bulk export facility. The last week of July saw the arrival of one of the terminal’s largest assets, a custom-built pneumatic ship unloader produced by Swiss shipping manufacturer, Rio Tinto Alcan (RTA) Alesa Engineering Ltd. This machine will be able to unload alumina and petcoke from vessels and will facilitate a homogeneous and dust reduced material flow. It has the capacity to unload 1 000 tons per hour by design, making it a valuable acquisition in improving the terminal’s operational efficiency. TPT client BHP Billiton Aluminium SA expressed its commitment to working with its long-standing partner TPT to

Richards Bay’s newest asset, the Rio Tinto Alcan Alesa unloader, marks the start of its multi-billion rand equipment replacement programme

ensure the success of the newly-acquired pneumatic unloader. Says TPT’s Richards Bay Terminal Head, Victor Mkhize, “A number of tasks will be executed when the new unloader arrives. This includes assembling, operator training, endurance testing, hot and

cold commissioning and handover. This is an historic moment for TPT and an important milestone we can be proud of,” he concludes. Sne Makhanya, Transnet Port Terminals, Tel: (035) 905-3693, Cell: 071 882-5933, Email: sne.makhanya@transnet.net, www.transnetportterminals.net

Heavy Trucks for Africa This has resulted in much success. 2011 saw a 400% increase in heavy truck sales, which created the need to support and maintain these high investment vehicles to world class standards. This has been achieved locally in South Africa with the appointment of dedicated specialist heavy truck technicians regionally based and equipped with made-forpurpose trailers, stocked with service, first line support parts and specialized tooling to guarantee uptime availability of up to 98%.

Dedicated Heavy Truck Service Technicians next to fully fitted Heavy Truck Trailer

Linde Heavy Truck Division (LHTD) has been producing a range of trucks up to 52 tons capacity in South Wales for over 40 years serving many industry types throughout the world. Africa being one of the current most important developing areas in the world has become a key target market for Linde

and in particular for LHTD. Recently Craig Golden has been appointed to focus exclusively on heavy truck business development throughout Sub Saharan Africa. He is based in South Africa and commutes to Linde distributors, subsidiary companies and new and existing heavy truck users in the region.

Country distributors are receiving specialized training to support all heavy trucks, in particular container handling reach stackers on site and in Linde factories as the population of units continue to grow. Craig Golden, Linde Heavy Trucks, Tel: (011) 723-7000, Email: craig.golden@linde-htd.com, www.linde-mh.co.za

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Conveying to the World Managing director Gavin Hall points out that Melco’s commitment to product and service excellence has resulted in the company expanding the reach of its product range into more than 75 countries worldwide. “Melco specialises in the design, manufacture and supply of conveyor idlers, rollers, motorised pulleys and supporting structures. The company has set the highest standards in manufacturing, which has resulted in our being recognised as one of the largest and most highly-respected manufacturers in the world today.” Melco products are designed for use in applications which range from mining and quarrying, to power generation and sugar milling. The company boasts a state-of-the-art manufacturing facility and a workforce of more than 400 employees, which ensures that

REDEFINING

the company has the capacity and ability to meet the most demanding customer deliveries.

TECHNOLOGY

Melco has been a proud member of the Rulmeca Group of Companies since 2006. “Almost all of Rulmeca and Melco’s activity involves the design, manufacture and sale of idlers, rollers and motorised pulleys for bulk materials handling applications,” notes Gavin. “As a group, we have chosen to specifically focus on this core business, to ensure that we remain experts and leaders internationally, without being distracted by non-core activities.” Melco, Gavin Hall, Tel: 087 806-3160, Email: gavinh@melco.co.za Craig Warmback, Tel: (011) 255-1600, Email: craigw@melco.co.za, www.melcoconveyors.com

Haver Eccentric Screens process high capacities of up to 5,000 tph. The completely balanced drive generates constant G-force to classify even difficult or sticky materials without introducing dynamic forces into your structure, minimizing investment into your building. For extreme applications, Haver Linear Screens process up to 15,000 tph. The exciter drive operates up to 50,000 hours without repair and has been designed to ease maintenance. The Linear Screens provide maximum screen surface to classify your materials while setting a new benchmark for reliability in your process. Haver Eccentric and Linear Screens redefine your choice in high-capacity screening.

On the Move Jacques Carelse has been appointed managing director at UD Trucks Southern Africa.

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MARKET FORUM

Peak-performing Belts

Advanced rubber technology and effective teeth designs mean the Falcon HTC transfers more power for greater efficiencies

Goodyear Engineered Products has developed a revolutionary rubber compound for its Falcon HTC synchronous belts that offers low-speed, but high-torque drives a new level of performance – transferring up to 30% more power. Extensive research and a series of tests have shown that the Falcon HTC features ground-breaking tensile strength, comparable to that of a steel chain. “This means our customers can enjoy longer-lasting belts, lower belt maintenance, and up to 6dB of quieter operation,” says Paul van Zyl, marketing manager, Goodyear Engineered Products. “The Falcon HTC is further exceptionally apt for today’s modern and efficiency-driven drives with a power transfer of up to 98%.” Advanced rubber compounds used in the Falcon HTC accommodate for backside idler applications, and feature improved resistance to chemical and oil breakdown. Unlike conventional polyurethane synchronous belts, it also features static conductivity for increased peace of mind, as well as an improved resistance to both flex and fatigue, and also high operating temperatures. Falcon HTC, Tel: (011) 248-9400, Paul van Zyl, Goodyear Engineered Products, Tel: (011) 248-9337, Email: paul_vanzyl@veyance.co.za, www.goodyearep.co.za

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Lifting equipment Crushers, screens, chutes and liners Trucking Bulk Storage

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MARKET FORUM

Intelligent Screening “Haver & Tyler Southern Africa is a turnkey solutions provider,” says Joachim Hoppe, Operations Manager, Haver Southern Africa. “Our complete monitoring and process control systems increase plant cost-effectiveness and productivity across the globe wherever freeflowing bulk materials have to be screened or packed quickly, cleanly and precisely”. Niagara screening systems have been synonymous with functional, solid and efficient screening technology since 1930 and the Haver Niagara 4-bearing screening machine with eccentric shaft drive can be used for classifying or as a scalping machine. “The screening machine offers numerous advantages for classifying applications as in primary crushing, widely varying or irregular input material feed rates,

varying particle sizes from fine to very course material, as well as difficult to screen material such as moist, sticky and/or very dirty materials”, explains Hoppe and adds that the machines are ideal for limestone and hard rock processing, gravel screening and building rubble recycling. Discussing the advantages of scalping screens, Joachim says that the instal-

lation of a scalping screen will increase the capacity of existing primary crushing plants. “A scalping screen provides increased capacity and ensures minimum down time. It reduces workloads for subsequent crushers by screening away the smaller particles in advance. By using the scalping screen as a double check machine, screening of separable elements such as clay or other impurities from the input material is possible.” Joachim Hoppe, Haver Southern Africa, Tel: (011) 476-4181/(011) 678-2279, Email: j.hoppe@haverboecker.co.za, www.haverscreeninggroup.com

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MARKET FORUM

Upswing in Orders MBE Minerals, formerly Humboldt Wedag South Africa, reports an upswing in orders for vibrating screes in recent months. MBE Minerals, which manufactures screens for the entire international group, is also preparing two replacement USLE horizontal screens for Anglo Coal’s Goedehoop mine to replace screens originally supplied by the company in 1998 and which have now reached the end of their lifecycle. The new screens, ordered in January 2012 and delivered in May, feature modifications to the side plate mounted drive. In February Botswana-based Debswana placed an order for a VSLE horizontal motor driven screen for its Orapa mine, also as a replacement for a screen supplied by MBE in 1995 that has reached the end of its ecoA USL-D double deck screen for coal sizing and washing nomic life. MBE Mineral’s Graham Standers, sales manager:vibrating equipment, says the company’s screens have been operating in the African mining industry for the past 40 years, primarily in the coal, diamond and iron ore sectors. With

products for sizing, scalping, dewatering and media recovery, MBE Minerals screens feature an innovative side plate mounted drive, making them lighter than those utilising vibrator motors. The company also supplies screens with

vibrator motors where required, while its resonance screens offer the benefit of low power consumption. Johannes Kottmann, MBE Minerals SA, Tel: (011) 397-4660, www.mcnallybharat.com

Index to Advertisers AJM Engineering 50 Akhanani 29 AMD Rotolok 34 Bateman 4 BMG 17 Bonfiglioli 18 Brelko 6 Conveyor Industrial Supplies Inside Front Cover Clyde Bergemann Africa Inside Back Cover Demag 30, 31 Dunlop/Rema 32, Outside Back Cover Dymot 49 ELB 8 Electra Mining 48 FB Cranes 32

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Fenner 7 Flexco Outside Front Cover FLSmidth 14 Freightliner 40 Hägglunds 46 Haver Screen Group 55 Horne 58 Intermodal Africa 42 Iptron 19 Joy Global Africa 16 Konecranes 27 Linde 47 Martin Engineering 34 MBE Minerals 15 Megaroller 56 Melco 13 Metso 57

August 2012

M&J Engineering 23 Multotec 36 Nepean 21 Osborn 45 Rula 37 Sandvik 10 Scania 38 Scaw Metals 22 SEW 12 Tegnon 35 ThyssenKrupp 28 Tru-Trac 52 Veyance 26 Wearcon 54 Weir Minerals 24 WH Lifting 33


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2012/08 - Bulk Handling Today  

Bulk Handling Today" is endorsed by the SA Institute of Materials Handling, the Conveyor Manufacturers Association, the Lifting Equipment En...

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