Bulk Handling Today August 2018

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH

T O D A Y

August 2018

SECURE RAIL-GUIDED CLIMBING LARGE AFRICAN POWER POOL

C16092

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BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH

T O D A Y

August 2018

BULK

HANDLING August 2018

T O D A Y

SECURE RAIL-GUIDED CLIMBING LARGE AFRICAN POWER POOL

On the cover: Demag Tel: (011) 898-3500 john.macdonald@konecranes.com

Contents CMA News SAIMH LEEASA News Cover Story

Lifting

4 10 22 6

28 Rail Climbing System

Earthmoving

31 Refocusing on the Local Market

Mobile Workshop in the Middle of Nowhere

Forklifts 9

An Impressive Plant Indeed

Conveying

Beltcon 19

33 Applying Dynamic and Fatigue Analysis on Bulk Materials

Market Forum Endorsing Bodies 42

14 All Weather and Ambient Conditions

•

CMA (Conveyor Manufacturers Association)

•

LEEASA (Lifting Equipment Engineering Association of South Africa)

Safe Operation

•

SAIMechE (SA Institution of Mechanical Engineering)

Port Handling

•

Commercial Transport

•

SAIMH (SA Institute of Materials Handling) also mailed to members of the RFA (Road Freight Association)

Earthmoving

16 New Wheel Dozer

Thought Leadership

19 Cryptocurrency Transactions 20 Checking All the Boxes 23 Milestone Agreement 26 Nitrogen Tyre Inflation

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.bulkhandlingtoday.co.za

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BULK HANDLING TODAY

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From The Chairman’s Desk

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his month I would like to describe some interesting history on our National Idler Standards, and for this we have been delving back into the records from the earliest days of the CMA. I hope it will be interesting reading for many of our newer members! A

Jay Pillay

sub-committee was set up as early as 1972 to study the need for Idler dimensional standards, the scope of which was for conveyor idlers manufactured in South Africa, covering leading dimensions, conversions from inches to millimeters and allowable tolerances, quality of materials, and load carrying capacity.

A first draft of an Idler dimensional standard was drawn up by CMA members using their own manufacturing specifications, ISO and British Standards, and Eskom and Anglo American tendering specifications and standards.

Private standard

The draft was registered with SABS in December 1973 as a private standard with the intention that it would later become a National Standard.

Minor technical changes were made to the CMA document by the technical committee in April 1975 and in July 1975 SABS agreed to set up a committee to start the process for publishing the National Standard.

Moving forward to October 1976, the CMA drafted an Idler Standards Brochure that members could send to end users outlining the provisions of the CMA Idler standard.

Wing roll about to fail

At the end of March 1977, SABS held a technical committee meeting to record changes to the technical document but major hurdles still had to be overcome on SABS proposal to standardise individual idler rolls, which manufacturers thought impractical, and some of the limitations of ISO should thus be adopted instead.

Comment and voting

In March 1978 the CMA Uniform Dimensions for Idlers was published. During the period August 1978 to November 1979 a SABS document originally developed without the assistance of the CMA was reviewed and changed by our technical committee, until finally SABS had a document that could be sent to countries around the world for comment and voting prior to publication, a process that was expected to take six months.

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CONVEYOR MANUFACTURERS ASSOCIATION

Damage due to seized roll

Subsequently, in 1980 the National Standard which we know as SANS 1313-1 was published.

Over the years since, Parts 2 and 3 were added and improvements to the original document continued to be made with the close co-operation of SABS and the CMA. The current version of SANS 1313 was published in 2012, but regrettably several errors appear to have crept in during the re-drafting process. The CMA has identified the errors and requested that the Standards be amended by SABS, but these things take time as can be seen from the history described herein.

To limit potential manufacturing errors, a list of these potential errors is being made available to the industry in the interim period before the standards are amended Intellectual property rights

Solely as a service to industry, and in the interests of safety and to limit potential manufacturing errors, a list of these potential errors is being made available to the industry in the interim period before the standards are amended. Anyone interested, but especially users of SANS 1313 of 2012, may download the list from the website www.cmasa. co.za.

This list is made available subject to the intellectual property rights of SANS 1313:2012 remaining with the SABS and is used and applied solely at the discretion of the user. We hope you find it useful.

Jay Pillay, Chairman

BULK HANDLING TODAY

August 2018

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COVER STORY

Mobile Workshop in the Middle of Nowhere One of the most innovative products to come from Konecranes recently is the CXT Explorer. It is a combination of a 6.3T mobile overhead crane, travelling on a gantry, supported by two sturdy containers which make for fully equipped workshop that can literally be set up in the middle of nowhere.

I

t is ideally suited to conditions in Africa and is expected to do very well here.

The CXT Explorer comes as a predesigned package in one of the 20 ft standard ISO shipping containers, with a carefully-selected range of standard functions and optional extras. These include a full CXT electric overhead crane of approx. 1250 kg, supported by the two containers, and an electric or manual hoist.

You have a full-blown mobile maintenance workshop ready to go

able it can be plugged into the grid, or otherwise a generator.

And voilà, you have factory-level lifting a few hours after arriving on site. To relocate the crane, it is packed

The shipping containers double as storage for the crane components, service tools, equipment, and spare parts.

Factory-level lifting

The CXT Explorer is easily transported together with another ISO shipping container. The containers are put onto the ground; the supporting steel structure is built on top, secured with twist locks. If avail-

ALL BRANCHES EQUIPPED WITH WATER BAGS Load testing of cranes is a vitally important part of Konecranes’ service and maintenance programme, especially where older cranes are concerned. In order to speed up the load testing and avoid downtime, all Konecranes branches are now equipped with their own water bags.

Konecranes South Africa has also designed and manufactured a mobile test crane for load testing on site. The customer no longer has to wait for his or her lifting equipment to be returned to site, as all the units are tested on the customers' premises, in their presence. This service is unique as it can print the Load Test Certificate on the spot.

All safety aspects

Lifting equipment is certified proof load tested in accordance with all safety aspects and regulations. This rig can test from

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chain blocks (manual and air driven) to lever hoists, coffin hoists etc.

The mobile test rig can handle a 30t capacity and it has a heavy duty battery back-up where electricity is not available.

The advantage of testing in this manner has proven far better and much quicker, improving Konecranes' service.

“Our investments in fully equipping our branches with mobile test rigs and our own static weights and branded water bags has already proved to have tremendous benefits and advantages,” says John MacDonald, Service, Sales and Marketing Director of Konecranes.

“It has most certainly raised the bar in our industry and set new and higher standards in service delivery," he concludes.

back into the container and it’s ready to go.

It can be used in construction, mining, vehicle maintenance, agriculture, natural gas compressor stations, in the military, oil exploration, onshore and offshore drilling. In the CXT Explorer, you have a fullblown mobile maintenance workshop ready to go.

Konecranes is a world-leading group of Lifting Businesses, established in Finland over 100 years ago, serving a broad range of customers, including manufacturing and process industries, shipyards, ports and terminals. Konecranes provides productivity-enhancing lifting solutions as well as servicing for cranes and hoists of all makes. The Group has 12 100 employees, at 626 locations in 54 countries, including ten branches in South Africa (Johannesburg, Port Elizabeth, Durban, Cape Town, Witbank, Klerksdorp and Ngodwana, Uitenhage, Maputo and Richards Bay).

John MacDonald, Tel: (011) 898-3500, john.macdonald@konecranes.com

Konecranes is listed on NASDAQ OMX Helsinki (symbol: KCR1V).

BULK HANDLING TODAY

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FORKLIFTS

An Impressive Plant Indeed It’s not often we are invited on an overseas junket but “Supply Chain Today” happily climbed on board for the official opening of Combilift’s new manufacturing facility in Monaghan, just outside Dublin, Ireland.

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he initial travel arrangements were seamless but nothing compared with what we soon realised was the scale of this ‘operation.’ The opening took place over a full week with over 300 media and guests flown in from all over the world.

In fact, Combilift had their own stall set up at Dublin airport to chivvy arriving guests to the nearby Radisson hotel, from where we were transported for 90 minutes, using a series of mini-vans, to Monaghan.

Having settled into our various hotels, the next day certainly didn’t disappoint. A threehour guided tour of the plant at a steady pace just about covered it, to give an idea of the size of the facility. The building has been deliberately designed in an L-shape with admin and engineering in the middle of the ‘L’, so that all the functions of the business are centrally connected.

Two carriers can also work in tandem with in-built features ensuring that safety is taken care of as two operators move in the same direction and at a coordinated speed The two partners of Combilift, Martin McVicar and Robert Moffett, started planning their new premises three years ago on 100 acres of industrial land. One of the guests told us on the tour that their new building is like chalk and cheese, compared with their old one.

Differentiator

Having started out twenty years ago, Combilift was initially focused on handling long and over-sized goods as a differentiator considering that there are over 200 producers of fork trucks worldwide. After the 2008/09 downturn, the company felt it was too exposed to the construction sector and entered the manufacturing and warehousing space.

The result is that they are now the largest global manufacturer of multi-directional forklifts. Side loaders, articulated forklifts, pedestrian stackers and trucks for the poultry and agricultural sectors complete the lineup as do straddle carriers. The company

The South African Institute of Materials Handling

Sample

The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions.

The SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who volunteer their time to execute the SAIMH’s objective. The main aim is thus to promote the advancement of the art, science, theory and practice of the Bulk Materials Handling principles and techniques.

Company Affliates as at May 2017 Afripp Projects cc Brelko Conveyor Products (Pty) Ltd Bulkcon CPM Engineering CT Systems cc Conveyor Watch (Pty) Ltd David Brown Gear lndustries (Pty) Ltd ELB Engineering Services (Pty) Ltd Engicon Systems (Pty) Ltd Facet Engineering cc Flexco (SA) (Pty) Ltd

Hagglunds Drives SA (Pty) Ltd Hansen Transmissions SA (Pty) Ltd Hatch Goba (Pty) Ltd lllustech J & A Engineering Services Kimrae Engineering Prolects Loadtech Load Cells (Pty) Ltd MacsteelVRN Martin Engineering Melco Conveyor Equipment Morris Material Handling SA (Pty) Ltd

Osborn Engineered Products (Pty)Ltd PD Engineering Services cc PH Projects Holdings (Pty) Ltd Rio Carb (Pty) Ltd Sandvik Materials Handling Africa Screw Conveyors & Material Handling Senet SEW Eurodrive Spar Western Cape SSAB South Africa (Pty) Ltd Tenova Zest Electric Motors (Pty) Ltd

Tel: (011) 867-0902  Fax: (011) 867-0036  Email: saimh@global.co.za  www.saimh.co.za

is particularly proud of their counterweight truck which is the smallest in the world to move in all four directions.

Also up there among their achievements is the fact that water-based paint is used to coat their products, and the facility is testament to other green initiatives such as lighting, space heating etc.

The staff talks about space, safety, speed, service and solution. Getting a six-metre aisle down to two, advising a client in Brazil to change their cold storage facility from north to south-facing – these are some of Combilift’s recommendations as they work with clients to achieve the best results.

Good farming stock

Heavy duty

And results are top of mind for Combilift management. Martin McVicar advises that he and Robert started the business twenty years ago with two staff members and now employ over 500 people.

They’ve made a point of employing people from the neighbouring area with 60 percent of the workforce being ex-farmers.

Able to lift items at the centre of gravity and straight up, two carriers can also work in tandem with inbuilt features ensuring that safety is taken care of as two operators move in the same direction and at a co-ordinated speed.

These men and women are excellent at finding a solution to a problem coming as they do from an agricultural background where they learn to be hands-on from an early age

The second arm of the Combilift business is their straddle carriers. These are not off-the-shelf items but are mostly customised for clients and form around 30 percent of the company’s business.

This equipment continues to find use when moving large, heavy objects.

Logistics

The third arm for Combilift is its move into providing solutions rather than just product. The company will help its clients to re-design and reconfigure their warehouse space. This focus on logistics is less about sales and more about partnering with their customers to get the very most out of their facilities.

Says Martin, “These men and women are excellent at finding a solution to a problem coming as they do from an agricultural background where they learn to be hands-on from an early age. In fact, many of our staff still go home to feed the livestock at the end of a hard day. Pretty much nothing defeats them.”

BULK HANDLING TODAY

August 2018

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FORKLIFTS This can-do attitude is reflected in the company doubling its turnover in the last five years to €250 million and an expectation to double again in the next five. In fact, we are told that €1 billion is the aim through organic growth rather than acquisitions.

Not having saturated the Irish market, there is still plenty of scope on home ground and much business to be done internationally.

Combilift exports to 85 countries worldwide and is watching the outcome of Brexit with interest.

South African presence

“Supply Chain Today” asked Martin about their presence in South Africa. He says, “Although currency fluctuations are hard on South African clients, your country has a strong manufacturing bias which is good for us. Of the BRICS countries, you are the most open to importing from Ireland.

“Also as money is tight, assets are sweated which is a good advertisement for us particularly as our products go the distance.

For example, one of our first units sold was to Columbus Stainless which after 30 000 hours is still going strong. A nice order has also come in for a brewery in South Africa who are particularly interested in the green credentials of our trucks.”

No article on one of Ireland’s top five manufacturing plants would be complete without

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FORKLIFTS

a short note on the press lunch, scrumptious food, awe-inspiring Irish dancers and rousing traditional music. An over-riding final impression, apart from the size and scope of the plant is the warmth, openness and professionalism of the entire Combilift staff. www.combilift.com

BULK HANDLING TODAY

August 2018

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CONVEYING

All Weather and Ambient Conditions The Bulkscan LMS511 uses time-of-flight laser technology to provide non-contact volume flow measurements on conveyor belts. Regardless of the bulk material type and weather or visibility conditions, the multi-echo technology in the Bulkscan sensor allows it to generate reliable volume flow signals using the laser’s time of flight and the conveyor belt speed. This calculates total quantities of mass and flow.

T

his Sick Automation sensor monitors conveyor belt operation without making belt contact and provides prompt warning of any belt slippage. An integrated bulk materials centre-of-gravity calculator detects uneven loading, preventing excessive belt wear, and an integrated heater ensures safe operation at low ambient temperatures. These, and other benefits, make this scanner ideal for most bulk material types, including uncommon types as is demonstrated in the following case study.

Case study

The Inorganic Pigments Business Unit at Lanxess manufacturers over 100 colour shades to dye concrete materials. Concrete is dyed with synthetic

Ultra-fast sampling technology which enables high precision laser measurement in virtually all weather and ambient conditions

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BULK HANDLING TODAY

iron oxide and chromium oxide pigments which allows for colour in projects like hotel facades or waterside paving stones, for example.

At its production site in Krefeld-Uerdingen, Germany, Lanxess uses five Sick Bulkscan LMS511 laser volume flowmeters to optimise the processes used for transporting high-quality iron chips. Using an oxidation and chemical precipitation process, colour pigments are obtained from the chips over a period, which are transported to the individual processing stations on conveyor belts while the transformation process occurs.

A solution to guarantee the quantity and volume of material transported, as well as provide sensible control of the metering flow over a work day, was needed.

These requirements amounted to a non-contact measuring principle,

Measurement of conveyor belts at speeds of up to 30 metres per second

August 2018

CONVEYING

traditionally a challenge for optical devices in the environments in which Lanxess operates. Detecting dark iron chip masses on dark conveyor belts under difficult lighting conditions is one of them.

Sick proposed the Bulkscan LMS511 with ultra-fast sampling technology which enables high precision laser measurement in virtually all weather and ambient conditions. Called 5-echo technology, it is suitable for applications needing reliable detection of dynamic objects in changing or unfavourable conditions. This includes applications with poor visibility such as in tunnels or in mines. In addition to maintaining excellent visibility in unfavourable conditions, 5-echo technology ensures maximum accuracy.

Control loop

“We have a classic control loop at two locations,” explains Achim Eumes of Lanxess Deutschland GmbH. “Bulkscan supplies us with the current actual value for the quantity being transported on the conveyor belt and set point values are used for control at certain points. The measurement supplies the actual value and the controller then adapts the desired quantity by means of the speed of the first screw conveyor. This results in a constant transport flow.”

The laser scanners are mounted at five locations above the conveyor belt and continuously measure the height profile of the iron scrap passing

beneath using laser pulsing. “A notable aspect of this design is the reliable detection of the height profile, even with external interference factors such as dust or bulk material suspended in the air. “This is possible due to new signal analysis technologies, which reliably filter out the correct height profile signal from a large number of echoes. The software algorithm determines the correct signal from the various reflected laser pulses and, at the same time, suppresses any haze that might interfere with measurement.”

30m per second

Fast scanning frequencies, up to 75 Hz, and fast response times are used to achieve maximum resolution for the height profile (and thus high measurement accuracy). They also enable the measurement of conveyor belts at speeds of up to 30 metres per second.

The Bulkscan system offers six individually assignable switching outputs for additional signal processing, such as a warning or impulse output or as continuous outputs for measured value transmission over TCP/IP (Ethernet). Processing and measured value preparation take place directly in the sensor, which also has two inputs. No additional data acquisition system is required.

Sick Automation, Robert de Scánde, Tel: (011) 472-3733 Email: Robert.deScande@sickautomation.co.za www.sick.com/za/en/

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BULK HANDLING TODAY

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NEW WHEEL DOZER The Cat 814K wheel dozer features a new, sound-suppressed cab, efficient power unit and transmission drive, and centralised service station configuration to drive machine uptime and operator productivity to new levels.

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ith its rugged structure designed to achieve multiple lifecycles under the toughest operating conditions, the 814K delivers high production operation in applications such as utility work at mines, heavy civil construction backfilling and grading work, and ground preparation and subbase work on airport and commercial projects.

Offering four forward and reverse speeds to match application demands, the wheel dozer boasts the best-in-class planetary powershift transmission, designed specifically for the most demanding mining applications

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Operator’s office

The wheel dozer’s upgraded cab design makes the operator’s workspace more comfortable and provides for more efficient machine operation. Isolation cab mounting plus seat air-suspension safeguard against machine vibration feedback to the operator. The quiet cabin reduces operating noise levels to just 71 dB, compared with 78 dB of its predecessor, with a sound-suppression package option to lower sound levels to 70 dB. Cab entry/exit is greatly facilitated through integration of the new fold-up STIC (Steering and Transmission Integrated Control System) armrest. STIC delivers maximum machine responsiveness and control plus smoother, faster cycles, while minimising operator movement to reduce fatigue. Simple side-to-side

EARTHMOVING movements turn the machine to the left or right, and gear selection control is operated through a finger-controlled rocker switch.

under load. Apecs results in no loss of momentum on slopes during gear shifts, so the dozer climbs grades more efficiently and with less fuel burn.

Removal of the steering wheel console vastly increases operator space and improves forward visibility of the work area.

Two Cat blade design options offer rugged durability and excellent dozing and rolling characteristics.

The 2.84-m3 straight blade delivers high production dozing on stockpile material and general earthmoving projects. Alternatively, the 10.5 m3 (13.8 yd3) coal blade provides precise and productive dozing, while helping to retain load control with increased capacity for lighter materials.

A newly-upgraded touch screen information display is included for intuitive machine control. The new panel displays critical machine operating data such as system temperatures, fuel use and machine hours. The dozer’s new Vital Information Management System (VIMS) allows technicians to connect directly to the machine to access a wide range of sensor information and expanded machine data. This allows managers to create productivity reports, identify operator training opportunities, see data logging of machine parameters and diagnostic codes, and monitor machine health.

Cat Product Link offers remote access of machine operating data through the easy-to-use VisionLink interface to facilitate fleet management.

Efficiency advancements

The new 814K is powered by the Cat C7.1 Acert engine meeting US EPA Tier 4 Final and EU Stage IV emission standards, or Brazil Mar-1 emission standards equivalent to Tier 3 and Stage IIIA to meet global emissions standards. Featuring engine idle shutdown and auto idle kickdown to avoid unnecessary idling, the new field-proven engine boasts lower fuel consumption than previous models. Load sense control hydraulics provide on-demand hydraulic flow required by the implement and steering system to further improve fuel efficiency and deliver increased rimpull.

Offering four forward and reverse speeds to match application demands, the wheel dozer boasts the best-in-class planetary powershift transmission, designed specifically for the most demanding mining applications. Through the Advanced Productivity Electronic Control Strategy (Apecs), the 814K delivers consistent and smooth shifting, even when

Reducing service time

The dozer includes a host of features that reduce service time to maximise machine uptime. The machine’s new central ground-level service area provides quick access to the master disconnect switch with integrated lock-out/tag-out, DEF purge lamp for Tier 4 Final/Stage IV engines, circuit breakers, emergency fuel shutoff switch and jump start receptacle. Grouping of grease points for steering, hitch and rear axle trunnions, along with easily visible fluid sight gauges reduce time spent on daily maintenance requirements.

Notifications alert operators and technicians of machine issues, so they can be quickly addressed before experiencing a significant downtime event By providing the operator with real-time operating data, VIMS system notifications alert operators and technicians of machine issues, so they can be quickly addressed before experiencing a significant downtime event. The machine’s new high efficiency hydraulic filtration results in cleaner hydraulic oil to increase component life and extends the oil inspection requirement by 50 percent, from 2 000 to 4 000 hours.

Railings, ladders and non-slip surfaces for platform level access points help to enhance technician safety when working on the engine and cooling system. www.cat.com

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Piecing together your success.

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THOUGHT LEADERSHIP

Cryptocurrency Transactions In South Africa, as with most other countries around the world, there is no guidance and regulation regarding cryptocurrencies such as Bitcoin.

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Chetan Vanmali, Partner and Kagiso Nonyane, Associate, Webber Wentzel

iven the uncertainty as to the nature of cryptocurrency, it is imperative that National Treasury and SARS issue clear and concise rules regarding the tax treatment of cryptocurrencies in South Africa.

VAT purposes? “Goods” are defined in the VAT Act as corporeal movable things, fixed property and any real right in any such thing or fixed property.

Given that cryptocurrencies are incorporeal, they would not constitute “goods”.

While National Treasury has not yet revealed which route it will be taking regarding the taxation of cryptocurrencies in South Africa, it is likely it will adopt an approach that would allow them to collect additional revenue and contribute to reducing the budget deficit.

However, it is apparent that they do constitute “services”, as defined, in that they can be said to constitute a right, facility or advantage as contemplated in the definition of “services”. To the extent that the trade (supply) in cryptocurrencies is considered to be a supply of services, it would most certainly trigger VAT consequences if it is bought or sold in the carrying on of an enterprise.

The Budget Review 2018 (Budget) proposes that the income tax and value-added tax (VAT) legislation be amended to deal with cryptocurrencies, which pose a risk to the South African tax system.

Current situation

The imposition of taxes on cryptocurrencies would assist the South African Revenue Service (SARS) with increasing its revenue collection going forward Given the current Budget deficit, the imposition of taxes on cryptocurrencies would assist the South African Revenue Service (SARS) with increasing its revenue collection going forward.

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From a VAT perspective, it is important to determine whether cryptocurrencies would be considered as the supply of money (and therefore fall outside the VAT net), or whether it could be considered to constitute the supply of goods or services that are subject to VAT. “Money”, as defined in the VAT Act, includes South African coins and any paper currency that is legal tender under the South African Reserve Bank Act 90 of 1989. In this regard, the South African Reserve Bank (SARB) has already stated that cryptocurrencies do not have legal-tender status.

Consequently, cryptocurrencies do not constitute “money” for VAT purposes.

The next question is whether trading in cryptocurrencies can be regarded as the supply of goods for

Definitions around the world

Authorities in other jurisdictions around the world, such as Germany, do not regard cryptocurrencies as “e-money” within the meaning of the Payment Services Oversight Act (Zahlungsdiensteaufsichtsgesetz, ZAG) and the European Union Electronic Money Directive and are of the view that it should be classified as a financial instrument.

The UK has classified cryptocurrencies as “taxable vouchers” and therefore VAT would have to be levied on the sale thereof. On the other hand, the Chinese Central Bank has completely prohibited banks and payment processers from being involved with cryptocurrency-related transactions and the Russian Central Bank has indicated that virtual currency is illegal in terms of Article 27 of the Federal Law. Canada appears to be the leading jurisdiction when it comes to regulating cryptocurrencies. It has two separate rules and the application thereof depends on whether cryptocurrency is used to buy goods or services or whether it is merely bought and sold for speculative purposes. In circumstances where cryptocurrency is purchased for speculative purposes, it is taxed just like any other investment.

Webber Wentzel www.webberwentzel.com

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SAFE OPERATION

Checking ALL the Boxes While design developments in vehicle ergonomics continue to mitigate human error, there remains the need to ensure the safe operation of all construction, earthmoving and mining machinery.

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lectronic safety equipment supplier, Booyco Electronics has leveraged technology to provide an effective option that eliminates the need for the physical clipboard prestart checklist that is still used by so many operators. And more significant than taking away the paper and pen procedure, the software system allows for the inclusion of no-go and go parameters that will determine whether the driver may operate the vehicle.

The checklist itself is randomised to ensure that the operator completes it in its entirety This specially developed software system is easily integrated into vehicles to facilitate confirmation that all the requisite prestart checks have been carried out by the operator. This is essential not only from a safety perspective, but also to ensure that the vehicle is in sound running order.

An important first step is that the system is able to identify whether the operator attempting to access the vehicle has the authority and capability to do so. Once the vehicle ignition is switched on, initial checks will validate the operator according to vehicle type and the operator’s current licence. This ensures that only The specially developed Booyco Electronic Checklist system is easily integrated into vehicles to facilitate confirmation that all the requisite prestart checks have been done by the operator

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licensed persons can operate a specific vehicle or range of vehicles.

Preset parameters

Once the operator has been verified, the Booyco Electronic Checklist will start running through a wide range of preset parameters that can be configured according to individual operation requirements.

The easy-to-read display shows both text and images, making it operator friendly, and each item being checked requires a simple ‘yes’ or ‘no’. The checklist itself is randomised to ensure that the operator completes it in its entirety.

The checklist is divided into critical and non-critical items, ensuring that preventative maintenance is carried out on equipment. As an example, should a low oil level be detected, the vehicle will be inhibited from moving until this is rectified. However, should a low fuel level be detected, the vehicle will be allowed to start and drive to the nearest fuel bowser.

Should some TMM component be operating outside of preset functionality or be completely out of order, the checklist can be configured to inhibit the vehicle. An example where this would be particularly relevant would be if the vehicle brakes are faulty.

SAFE OPERATION

Biometric identification

The information recorded on individual units is easily downloadable using WiFi allowing easy accessibility to the data. This provides accurate reporting on vehicle condition and usage.

Operators using a specific vehicle need to access the checklist only once per shift, thereby avoiding production losses. Should the vehicle be switched off during that particular shift, the operator need

only provide biometric identification to continue using the vehicle.

The checklist is available as a standalone system or can be incorporated in the full Booyco PDS solution.

Booyco Electronics Anton Lourens Tel: 0861 Booyco (266926) Email: anton@booyco-electronics.co.za www.booyco-electronics.co.za

Should the vehicle be switched off during that particular shift, the operator need only provide biometric identification to continue using the vehicle

VISIT US! 10 – 14 September 2018 | Expo Centre, Nasrec, Johannesburg, South Africa BRINGING YOU THE FUTURE OF MINING, MANUFACTURING, ELECTRICAL AND POWER SINCE 1972

IT’S A SHOW THAT BELONGS TO YOU. Source 100’s of cutting-edge solutions Compare products and brands Get advice from technical experts Watch live demo’s For more information contact Leigh Miller: Acquire knowledge seminars Tel:at + free-to-attend 27 (0) 10 003 3060 Email: leighm@specialised.com

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BULK HANDLING TODAY

August 2018

21

ENDORSER OF “BULK HANDLING TODAY”

LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SA

• A recognised ECSA Voluntary Association (VA) •

LEEASA is a fully-fledged association devoted to the lifting industry across Southern Africa. Members hale from the crane, forklift, mobile elevated work platform, aerial and suspended access platform, chain hoists, rigging and lifting tackle arenas, etc. Primarily devoted to the LMI’s (Lifting Machinery Inspectors), and LME’s (Lifting Machinery Entities), the association considers safety paramount. As such it serves in an advisory capacity to the SABS, the Department of Labour, various training bodies and the industry at large. LEEASA is recognised by ECSA as a voluntary association.

What’s in it for you:

As an Individual member who is registered as a Lifting Machinery Inspector (LMI), you may qualify for any concessionary fee granted by ECSA (this could save you over R1 000 a year).

and other training courses accredited by the association attract ECSA CPD points.

ECSA registered LEEASA members are awarded one Continuing Professional Development (CPD) credit each year. CPD is an ECSA requirement to retain registration.

Members benefit from the collective power of a recognised and established association and collective co-ordination in dealing with authorities in policy making and matters concerning the industry.

Members obtain a discount on LEEASA seminars. Both these

LEEASA has some 650 members (Individuals and Companies).

• • •

LEEASA Occupational Health & Safety Act and Regulations LEEASA Mine Health & Safety Act and Regulations LEEASA Lifting Equipment Inspection & Legal Compliance Register

Available for purchase online at www.leeasa.co.za

1

LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SOUTH AFRICA Head Office: 8 Boris Road, Bordeaux, Randburg, Johannesburg Tel: 074 900 8378 • www.leeasa.co.za Secretary: Arni Sommer • email: arni@leeasa.co.za

BULK HANDLING TODAY

February 2012

RESEARCH PORT HANDLING FORKLIFTS

Milestone Agreement In a first for the South African ports and container handling industry Kwane Capital signed a distribution and localisation agreement with Italy’s CVS Ferrari S.p.A, one of the world’s leading suppliers of port container handling equipment.

K

wane Capital is a wholly owned subsidiary of Ritam Holdings (Pty) Ltd.

Signed in Johannesburg in early 2018, it is estimated that the distribution and localisation agreement’s capex investment in Operation Phakisa will exceed R1 billion - with an initial market offtake of R3 billion in the first year – which will also lead to significant job creation and skills investment in the ports and handling industry.

“Our agreement with CVS Ferrari represents an important milestone not only in the ports and handling industry but in our own business operations,” says Mcebisi Mlonzi, Chairman and CEO of Ritam Holdings

A show of faith

handlers and reach stackers. The company’s “Partnering with a global reach stackers for example can lift equipment brand such as CVS Ferrari exceeding 45 tons while its forklift range shows tremendous faith has a lifting capacity of 48 tons. Kwane in our ability to provide Capital will provide sales and afterPartnering with a global superior services to immarket support to CVS Ferrari’s South portant customers such brand such as CVS Ferrari show African customer base. as Transnet as well our tremendous faith in our ability to commitment to growing Importantly, the agreement proprovide superior services to important this crucial industry vides for the transfer of intellectual customers such as Transnet through job creation property and designs from Italy to and skills investment. We South Africa enabling significant look forward to a mutually product localisation. This will include beneficial and fruitful relathe assembly of partially assembled tionship with CVS Ferrari,” or pre-fabricated parts as well as the Mcebisi continues. local manufacture of specific equipment such as the container straddle carrier through Colin Clegg, Regional Manager – CVS the TFM Group in which Kwane Capital holds Ferrari adds, “CVS Ferrari will, through a 63.7% stake. our agreement with Kwane Capital, support the localisation of our product range in South Africa which also means we will be supplying specialist skills and training to support the programme.

“Also, with a dedicated distribution in South Africa we can significantly improve our after-sales support and services to our current and future customers.”

Premier range of forklifts

The agreement will see Kwane Capital distribute CVS Ferrari’s premier range of forklifts, empty container

The TFM Group specialises in the manufacturing, supply and support and import of specialist truck bodies.

CVS Ferrari has been a supplier of port handling equipment for over 20 years in South Africa, with an unblemished record of quality, reliability and service. The company currently has port handling equipment actively operating in 250 ports worldwide.

Kwane Capital, www.ritamholdings.com

BULK HANDLING TODAY

August 2018

23

TRACE Inte is a globa anti-br or leading pr party risk

TRACE due diligence solutions are based on internationally accepted best practices and our experience and familiarity with the compliance needs of multinational companies. Services range from a denied parties screening to enhanced due diligence, including TRACE Certified Due Diligence.

International, Inc. globally recognized ti-bribery business organization and g provider of third risk management solutions.

COMMERCIAL TRANSPORT

Nitrogen Tyre Inflation Over the years nitrogen tyre inflation has become well-known, and is no longer the sole preserve of specialist tyre users, such as the international motorsport or commercial aviation sectors. In fact, today it is conveniently available on the forecourts of many petrol stations in South Africa.

L

ess widely known is the significant cost-savings that commercial transport fleet owners can enjoy when they run their vehicle tyres on nitrogen inflation.

Small and large fleets

“The benefits of inflating your fleet tyres with nitrogen are really significant if you are a major commercial transportation company with dozens of vehicles on the road,” says NitraLife’s sales director, Tom Sowry.

Local nitrogen generator supplier, NitraLife launched its business in 1996, and was very much a pioneer in the field of nitrogen tyre inflation locally; as well as being the first supplier of generators for nitrogen tyre inflation to the commercial transportation sector.

The benefits of inflating your fleet tyres with nitrogen are really significant if you are a major commercial transportation company with dozens of vehicles on the road Since then, the company has also successfully expanded into supplying generators for nitrogen inflation of tyres to the passenger vehicle market and the mining industry.

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BULK HANDLING TODAY

August 2018

Tyre inflation

“The longer the distances travelled and the heavier the loads, the greater the benefits,” Tom explains.

“If you enter ‘savings with nitrogen tyre inflation’ into an Internet search engine, there are pages of evidence on the cents-per-kilometre savings which

COMMERCIAL TRANSPORT

Tom Sowry, Sales Director of NitraLife, which has pioneered the use of nitrogen inflation in heavy transportation and latterly passenger vehicle tyres

Tom cites the example of one of his customers – a major tanker operator – which previously had to scrap some 20 tyre casings a month. Once they started to fill their tyres with nitrogen, this number decreased to some 13 casings a month.

Nitrogen escapes through tyre walls four times more slowly than oxygen and water vapour escapes 117 times more quickly than nitrogen. Nitrogen tyre inflation ensures that correctly inflated tyres will not overheat. Heat build-up – as underinflated tyres flex beyond their specified limits – is a major cause of premature tyre failure.

Long distances

“Maintaining correct tyre pressure with nitrogen is even more important if your vehicles are travelling very long distances, particularly if they are going beyond South Africa’s borders to areas where tyre maintenance facilities are more rudimentary or not available at all,” he explains. nitrogen tyre inflation can bring about. These savings are not confirmed to large fleets.

“Even if your company is not a commercial transporter, and you are simply using a couple of delivery vehicles to get your goods to market, our experience has shown that savings of between 5 – 30% - depending on fleet and load size, and distances travelled, are eminently possible.”

In the early days of NitraLife, its highly efficient membrane nitrogen generators were manufactured in a limited ‘litres-per-minute’ size, which was more suited to the larger commercial transporter.

“Today we can customise generators, for example manufacturing a smaller 120 litre-a-minute machine, which is a size better suited to the needs, and budget, of the smaller fleet operator,” continues Tom. He explains that even if a fleet operator can save 3-5% on tyre costs, this will most often pay for the rental or purchase of a NitraLife generator.

However, there are many more reasons why commercial transporters should consider nitrogen tyre inflation. For example, oxygen and water vapour are constituents of air. Once air is pumped into a tyre, water vapour is concentrated inside the casing and, along with the action of oxygen, degrades the rubber and causes the steel within the tyre to corrode. This reduces the tyre’s ability to hold pressure and also leads to early casing failures.

Obvious savings

Tom points out that a number of South Africa’s major commercial transportation companies have been using their generators for the past two decades to do their tyre inflation. Clients have found that the tyre casing is able to be re-treaded several times more than its air-filled counterpart.

“With the cost of a heavy transport vehicle tyre, if the operator can get two or three more ‘lives’ out of a casing, the savings are obvious.”

Maintaining correct tyre pressure with nitrogen is particularly important if your vehicles are travelling very long distances “If a vehicle is on the road and away from its home base for two or three weeks, knowing that the tyres are not losing pressure gives fleet operators real peace of mind.

“As any fleet operator knows, commercial transportation is a highly competitive sector. Customers want their goods delivered quickly and reliably. Tyre failures mean lost time and late deliveries. Furthermore, a vehicle stranded next to the road with a valuable cargo on board, known as an ‘on-the-road’ failure, is a tempting target for criminals and poses a real security threat,” he adds.

All tyres flex during normal operation which leads to the build up of rubber particles inside the tyre.

Rubber is composed primarily of carbon and therefore, when these very small particles are exposed to high heat levels caused by binding brakes or a wheel bearing failure, they can – when mixed with air – combust or even explode with potentially calamitous consequences.

With high purity nitrogen filling a tyre, this cannot happen and the safety of driver, vehicle and valuable cargo is ensured.

Proud record

For the fleet owner, NitraLife has rental or purchase options available; both of which feature the added attraction of having almost no additional maintenance requirements. This is because the generators have no moving parts and a conventional air compressor supplies the compressed air used to feed them.

NitraLife Tel: (011) 706-7884 www.nitralife.co.za

BULK HANDLING TODAY

August 2018

27

LIFTING

Rail Climbing System

The complex core geometry at the Katherine Towers project in Sandton saw Peri South Africa deploy its RCS-CL (rail climbing system carriage light) to reduce crane time and maximise platform sizes for the complex core geometry.

T

he project was designed by architecture and interior architecture group Paragon, with Trencon Construction as the main contractor, and Sotiralis Consulting as the consulting engineer. The complex multi-cell core structure boasts an architectural scenic shaft opening up in the centre of the building.

The RCS-CL has been developed specifically for cores in medium-height buildings with limited crane capacities and hook times Here Peri Vario GT24 wall formwork was used to achieve the necessary quality of the concrete surface finish.

PERI South Africa Susan Barker Marketing Manager Phone: (011) 729 2318 Fax: (021) 880 0948 Cell: 079 501 8830 Email: susan.barker@peri.co.za Web: www.peri.co.za

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BULK HANDLING TODAY

August 2018

Located at 46 Katherine Street in Wierda Valley, Sandton, the 21 000 m2 project is being developed by Alchemy as the new Bidvest head office, and is a key element of the new Katherine Street mixed-use precinct. The premium-grade development is within walking distance of both Sandton City and the Sandton Gautrain Station.

The Peri South Africa team on the project includes technical representatives Stephen Sprong and Sebastian Burwitz.

Peri Skydeck and Multiflex slab systems were selected due to the faster slab cycles achievable, a critical

factor in this fast-track project. The balcony slab construction required complex back-propping, including the support of 6.5-m-high feature concrete walls.

These were realised using specialised Quickshore shoring tower up to 10m high, as well as a combination of GT24 Girders and SRZ walers.

Peri Trio and Domino were deployed for the various retaining walls and upstand beams, which are repeated as a main feature throughout the building.

Fast and safe

The climbing systems used, in conjunction with the Vario GT24 wall formwork, consisted of specialised SRU, CB 240, and BR platforms, and an additional RCS-CL. “The RCS-CL has been developed specifically for cores in medium-height buildings with limited crane capacities and hook times,” Stephen points out.

Rail-guided climbing ensures that the climbing unit is connected securely to the building at all

times, which makes the climbing procedure fast and safe, even in windy conditions. The units are moved by crane, or by means of mobile climbing hydraulics.

Rail-guided climbing ensures that the climbing unit is connected securely to the building at all times “The main benefit of the RCS-CL system is that there are reduced crane requirements for the core, a particular advantage on a highly-constrained site, which also frees up time for related construction activities,” he comments.

“Our main challenges on this project have been limited cranes, site space, and laydown areas.

In addition, there was a specific requirement for concrete work with a high degree of accuracy, with an ultra-smooth finish on all vertical structural elements,” Stephen concludes.

Peri South Africa www.peri.co.za

BULK HANDLING TODAY

August 2018

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The Local Manufacturing Expo Aims to:

21 – 23 MAY 2019

Promote local manufacturing

EXPO CENTRE, NASREC,

Demonstrate Southern Africa’s export potential

JOHANNESBURG, SOUTH AFRICA

Provide access to global markets

A Showcase of Southern Africa’s Manufacturing Capabilities Who Will Exhibit?

Networking opportunities Develop public / private partnerships Public / private sector collaborations Identify industry challenges and opportunities for growth

Manufacturers across a variety of sectors, including:

Agriprocessing

Automotive

Business Process Outsourcing

Capital Equipment

Chemicals

Construction

Engineering

Food and Beverage

Furniture

ICT and Electronics

Metals

Mining

Plastics

Textiles/ Clothing/ Footwear

Transport

www.localmanufacturingexpo.co.za In association with:

30

Endorsed by:

BULK HANDLING TODAY

August 2018

Implemented by:

Brought to you by:

s

tor

owth

EARTHMOVING

Refocusing on the local market An exciting range of equipment including skidsteers, articulated loaders and BHL’s from one of the world’s leading compact equipment manufacturers, has been relaunched by ELB Equipment.

A

merican-made Gehl machines are a wellknown brand across the globe known for compact machines that deliver powerful performance in a rugged and reliable package that is versatile enough to be used across almost all industries.

“The relaunch of Gehl represents one of the most anticipated re-entries of a premium brand into the local earthmoving construction and agriculture markets in many years.”

ELB’s business development manager, Danie Gerber, says the range complements the distributor’s best-of-breed philosophy for products which have track records to prove their quality and with high levels of service and aftermarket support.

Gehl skidsteers, tracked skidsteer loaders, articulated loaders and TLBs are available in South Africa through ELB Equipment

ELB Equipment’s Ernest Moremedi, Dean Logan, Rhett O’neill and Keon Kardolus at the launch of the new Gehl compact equipment brand at Nampo Harvest Day

Global acquisition “The product range arises from the procurement internationally of the Terex Construction brand by the manufacturer’s parent company. The Gehl range is a large and well-known one throughout the world and will be in safe hands here in South Africa with ELB Equipment.

“We have been distributing Mustang Skid steers for 10 years now and will convert to the manufacturer’s Gehl brand which is the same product manufactured under a different brand name. This means that we will continue to support and provide backup for the Mustang population in the market”.

He adds that the Gehl display at the Nampo show earlier this year has already paid dividends with a number of would-be customers interested in machines. Not surprising, considering that the country’s newest premium-brand machines are competitively priced and have an additional reputation for having among the lowest costs-of-ownership in the international industry.

Local market “The relaunch of Gehl represents one of the most anticipated re-entries of a premium brand into the local earthmoving construction and agriculture markets in many years. Supported by a foremost equipment supplier, it is sure to gain the attention of fleet owners across the southern African region,” Danie concludes.

ELB Equipment Danie Gerber Tel: (011) 306 0700, Email: danieg@elbquip.co.za www.elbequipment.co.za

BULK HANDLING TODAY

August 2018

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BOOk yOur space nOw Transport Evolution presents

2 - 3 October 2018 | Durban International Convention Centre, South Africa

engage with over 15 african ports and rail authorities secure one-on-one meetings with African port and rail authorities and government officials.

showcase and launch your latest products, technologies and services.

raise your brand awareness by positioning yourself in front of your key buyers and partners.

Generate qualified leads by networking with key stakeholders who attend the event.

There are only a few stands available. Book now!

Daniel Bloch:

Host city

Host Ministry

danielbloch@dmgevents.com or

In partnership with

www.transportevolution.com

Platinum sponsor

+27 21 700 5504

Official mobility partner

Co-located event

BELTCON 19

Applying Dynamic and Fatigue Analysis on Bulk Materials Handling Equipment, Structures and Components Bulk material handling structures and equipment are subject to variable and dynamic loads. But when is the design governed by them? When is fatigue a relevant factor and when is it not? This is a subject normally neglected and poorly understood.

E

xamples taken from the actual operating life of equipment are discussed where these factors are relevant.

Both successes and failures are used as examples.

Conveyor belts, pulleys, conveyor support structures, boom stackers and bridge reclaimers are included.

The words 'fatigue' and 'dynamics' are often used in the bulk materials handling industry, but are not widely understood.

Fatigue refers to the effects of variable forces or stresses in the life of a component, while dynamics refers to the effect of transient forces, both instantaneously and over time as a result of fatigue.

Whether considering conveyor belting, idlers and pulleys, their supporting structures, or mobile material handling machines such as stackers and reclaimers, transient dynamic forces are present. These forces are normally generated by starting and stopping or external phenomena such as earthquakes or collisions.

Fatigue is produced by stress fluctuations over time, sometimes related to repeated transient forces, other times to cyclical stress variations. Many times, the failure of an old structure or component is attributed to fatigue, while collapse is produced by corrosion, wear and tear or a one-off event such as a storm or a large impact, or operating the equipment outside its design parameters.

Figure 1: Dynamic magnification factor

Sergio Zamorano

Belt conveyors

Conveyor dynamics Transient forces generated during starting and stopping of conveyor belts are well documented and their calculation is incorporated in commercial software available in the market.

However, it is still far from being as widely understood as water hammer phenomena in hydraulics or transient behaviour in electrical grids, even though the mathematical principles are quite similar. Also similar are the dangers of catastrophic failure in large or complex systems.

In a nutshell, the cause of dynamic problems in belt conveyors is the application of forces in a period similar or smaller than the system's natural period, as it causes a dynamic magnification effect as shown in Figure 1. This could be the start-up of a long belt or the stopping of a high incline system. A simple rule of thumb from Dr Funke, one of the pioneers in the field who started his work in the 60s, is to count one second per kilometre of length as an estimate of the half-period of the system and apply any change in force or speed in periods five times greater. In his work, he called it 'stress wave traveling time', as he was an electrical engineer and used grid dynamics nomenclature. This corresponds roughly with the behaviour of a steel cord system, while fabric belts have much longer natural periods and are therefore more prone to dynamic problems, even in relatively short conveyors.

Non-transient problems are normally related to resonance of the supporting structures due to the operation of the belt. The most frequent culprit is the rotation of the idlers. Rolls with high eccentricity or presenting material build-up will produce a dynamic force in the rotation frequency of the rolls. If the natural frequency of the belt in the transversal direction is close to the exciting frequency, significant vibrations might appear, sometimes strong enough to cause bearing or structural fatigue failure, but in any case, quite detrimental to the roll life.

Transient and non-transient dynamic effects can be calculated using published formulae or even commercial belt conveyor calculation software.

As a basic principle, a large capacity, long and/or fast conveyor should be subject to a preliminary evaluation regarding dynamic analysis to avoid potential problems.

Belt splices Belt rating is traditionally selected based on a static safety factor above the maximum operating tension. Usually 10 for fabric belts and 6.7 for steel cord belts. Experience shows that when BULK HANDLING TODAY

August 2018

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An Initiative by TIKZN Think Global: KZN the African Trade Hub

1-5 October 2018 | Inkosi Albert Luthuli ICC, Durban A FULL WEEK OF ACTIVITIES DEDICATED TO GROWING KWAZULU-NATAL’S EXPORT BUSINESSES AND INDUSTRIES

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NETWORKING AND RECEPTIONS

Make sure you join us at the 2018 KZN Export Week - the annual programme of Trade Invest KZN developed to recognise, promote and assist with growing KwaZuluNatal’s export businesses and industries!

BUSINESS SHOWCASE / EXPO

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TIKZ Nw offe ill be ri plac ng 100 F es to REE em expo rters erging ! To out find if yo uq cont ualify danie act l.claa sse n@e

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30 Top speakers: Hear some of the top business minds share their tips and stories on how to build a global business.

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50 Leading service providers: Learn about the latest technologies and services on offer from leading service providers participating in the expo showcase.

• Network and build new relationships with fellow attendees from across the continent

15 Countries:

• Hear some of the top business minds share their tips and stories on how to build a global business

Meet with global trade partners and associations from: Africa: Botswana / Ethiopia / Ghana / Kenya / Lesotho / Mauritius / Mozambique / Swaziland / Tanzania / Zambia / Zimbabwe China / India / Turkey / UK / USA

CONTACT US Daniel Bloch:

Presented by:

danielbloch@exportweek.co.za or

Strategic partner:

Supported by:

www.tikzn.co.za/exportweek

+27 21 700 5504

Co-located with:

week .c

o.za

BELTCON 19 a belt fails it does so in the splice, and research over the last 30 years or so has shown that apart from edge tension, mechanical damage or workmanship problems, most splice failures are caused by fatigue.

Figure 2: Steel cord splice diagram

Figure 3: Overland conveyor structure

Figure 4: Weld endurance resistance vs type of weld

Figure 5: Weld endurance resistance vs weld quality (example)

In actual fact, steel cords and fabric plies are not themselves subject to fatigue, but rather the rubber that holds them together. Figure 2 shows a typical steel cord splice layout.

Cords are cut and laid next to each other in a staggered pattern. Bonding rubber is placed in the gap between the cords, rubber sheets are placed to complete the covers and the joint vulcanised. After this, forces are transmitted from one side of the splice to the other by the bonding rubber acting in shear. Something similar happens between the layers of a fabric belt splice.

As far back as 15 years, DIN revised their well-known 22101 standard to include transient forces and splice fatigue in the election of belt rating. However, the change has had little impact in the way belts are designed to date. For large installations, accounting for dynamic and fatigue behaviour can lead to lower capital and operational costs and at the same time increase the reliability of the system. High tension belts present lower splice fatigue resistance due to the limited space between cords to transmit the forces as the cords are bigger. Pulley selection and layout also has a large influence on splice fatigue life. The bottom line is that a lower rating belt, with the right pulley layout and splice design might be more reliable than a stronger belt. Splice strength is not always directly proportional to fatigue resistance.

Conveyor stringers With the use of faster and longer conveyors, the need to optimise the stringer design has become more and more important. High speeds and capacities lead to a point where the dominating factor in the selection of a stringer section is the dynamic response and not the static design criteria.

Static calculation is based on allowable stress and deformation while dynamic calculation requires the avoidance of resonance between the rotating idlers and the stringer. As a rule of thumb, the natural frequency required for the structure is at least double the rotating frequency of the idlers.

The saving obtained by using smaller diameter idlers could be lost by the need for a heavier structure in a fast conveyor.

Failure to identify the relationship between transversal belt vibrations, idler rotations and supporting structures is a common mistake made by unqualified designers that lead to problems in the field.

Conveyor pulleys Conveyor pulleys, subjected to thousands of load cycles per hour, usually fail due to fatigue. Even so, the design requirements of fatigue design are not widely understood beyond the shaft design, and that is well documented.

Old Excel spreadsheets are still used for pulley calculation, using some formulas derived before the advent of finite element analysis. Examples of these spreadsheets can be found in engineering offices all over the world.

These programmemes derive results regarding end disc and shell thickness that seem to have little relation to actual requirements and are not related to the real problem in pulley construction: welds!

It is not only the position of a weld that is relevant, also the type of weld, as described in many design standards.

BULK HANDLING TODAY

August 2018

35

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BELTCON 19 Although the joint is in a stress concentration area, in lightly loaded pulleys the stresses are below the endurance resistance of the assembly.

Figure 6 shows a heavy pulley with a shaft above 300mm with such design, where the weld was applied with manual arc. Not surprisingly this pulley failed shortly after a year of operation. 'Savings' in time and cost using a welded hub are irrelevant compared to the loss of reliability and losses due to downtime.

Figure 6: Welded end disc and hub

Static design wisdom calls for reinforcements to increase the strength of a design, however, when facing fatigue loadings, every weld is a new opportunity for failure and every

Figure 7: Pulley failed at disc/shell interface

Figure 4 shows the effect of the type of weld on endurance resistance for the same material. A full penetration weld can have several times the resistance of a fillet weld.

increase in stiffness creates more stress concentrations. A flexible design with thinner walls is quite often more reliable regarding fatigue than a rigid one.

Besides the type, the quality of the welding is also important.

Figure 5 shows the difference in endurance between sound and defective welds.

Figure 7 shows an example of reinforcements that made the problem worse. This relatively light-duty pulley presented cracks in the disc/hub weld. The client decided to install a radial reinforcement as shown on the left side. The result was a crack that grew around the pulley in the interface between the disc and the shell. For the technically orientated, the pictures are quite beautiful, as the crack follows the 3-lobe sinusoidal pattern of the pulley deflection under load, like a lotus flower, that can be seen on a finite element simulation.

Modern engineered class pulleys use turbine or T/bottoms for the end discs and automated control atmosphere welding.

Older designs used a plate end disc welded to the hub and manual arc welds.

This system is still used successfully on light applications.

Boom stackers

This type of machine is probably the most common in storage yards. An analysis of the operation would show that except for the rotating parts, the main structural components are not subject to large load variations and failures are normally experienced due to corrosion or wear and tear. However, many engineers use the term material fatigue when analysing potential or actual failures.

As an example, Figure 8 shows the finite element model of the mast of a large stacker that was subjected to a design audit by a consultant. The audit report highlighted the stress concentration in the changes of angle of the main columns as a possible cause of fatigue failure in the future.

This finding has two problems. In the first place, the columns are not subject to significant load variations that could cause fatigue.

Figure 8: Boom stacker mast FEA model

In the second place, the stress concentration is caused by the geometrical singularity in the model. An inexperienced engineer would reduce the mesh size to analyse the problem, but in the presence of a change of direction, with no radius, BULK HANDLING TODAY

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37

BELTCON 19 the smaller the mesh, the larger the stress at the edge. The real solution would be to simulate the weld and the radiuses involved if it were necessary, which it is not.

This is a 'not so rare' example of lack of understanding by inexperienced designers of the physical phenomena behind a computer simulation. Or as the saying goes: “garbage in, garbage out�.

A dynamic problem that is relevant to these large and tall machines are seismic loads, especially in countries like Chile and Peru.

Seismic design codes determine the forces in the form of acceleration to be used per location, usage and soil conditions.

Figure 9: Seismic design factor vs natural period (example)

Figure 10: Boom stacker, first natural vibration mode

Another important factor to be considered is the flexibility of the structure that is associated with the fundamental period.

The more flexible the system, the lower the forces to be considered. Figure 9 shows a typical design response spectrum table that has a factor for structures with natural periods below 0.5 seconds (or a natural frequency above 2 Hertz) and is reduced as the natural period increases.

The first natural vibration mode of a stacker with a long boom with a natural frequency of 0.33 Hz is shown in Figure 10. If this value is considered, seismic forces applied could be reduced by about 90% as compared with a rigid structure. A more in-depth analysis can be done using known seismic spectra from the site in question, using modal type analysis and an appropriate number of natural modes, or a fully-fledged dynamic analysis of the structure. The normal result is that the deeper the analysis, the lower the resultant forces. The seismic codes apply higher safety (or ignorance) factors to simplified design methods.

The common wisdom about seismic design is that it should increase the weight of the structure. This is true if a static approach and an acceleration force without any reduction factor is used. As it is already well known by civil engineers, in seismic design, stiffer is not the same as more resistant.

Most modern buildings use flexibility to withstand large seismic loads that include innovative solutions like mounting an entire building on rubber bearings.

Bridge type reclaimers

Most bridge type reclaimers use scrapers, but for large volumes, sticky and/or abrasive materials, other soutions such as drum reclaimers as shown in Figure 11 are used.

Figure 11: Drum reclaimer

The drum rotates and has buckets distributed along the shell that take the material from the face of the pile. When each bucket reaches the top, the material falls by gravity onto a belt that runs inside the drum and transfers the material to a yard conveyor.

Figure 12: Bucket wheel bridge reclaimer

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As it rotates, the drum is subject to alternating stresses while the buckets and the associated openings in the shell present multiple stress concentration points. Old designs from the 60s and 70s had a double skin with even more welds and potential crack problems; the same pattern as some old conveyor pulley designs. Double shells have been replaced today by single skin drums. Even so, cracks appear often and drums have to be replaced periodically, with no comprehensive solution having been found for large capacity

BELTCON 19 oped parametric formulae to calculate the dynamic forces caused by operation of the bucket wheels moving across the bridge. For illustration purposes, part of the torsional model is shown in Figure 14. The mathematical model allows quick evaluation of the dynamic behaviour of the machine. The evaluation can be conducted during basic engineering or even during the bid period and later confirmed in detailed engineering by finite element analysis, although the correlation of the results obtained by analitycal method and FEA is quite good.

Conclusions

Figure 13: Bucket wheel bridge reclaimer with single bridge

The examples discussed show that dynamic phenomena do not correlate with the methods and standard practices used for static analysis.

It is necessary to use the proper tools and do away with the preconceived idea that stronger and heavier is more reliable.

The higher speeds, larger capacities and longer spans more frequently required by more and more demanding clients require analysis to identify potential problems before they arise. This can only be achieved by stepping out of the comfort zone provided by proven, but often limited solutions and examining any conceivable problem areas from a different perspective.

Figure 14: Bucket wheel bridge reclaimer parametric model

systems to date. A conceptual analysis shows that having a large, thin shell drum, with lots of openings that create stress concentrations in a high cycle reverse stress regime is not the best technical solution. Needless to say, this type of machine has lost popularity over the years.

Another design for similar applications, far more popular in modern times, is the bucket wheel bridge reclaimer shown in Figure 12. The bucket wheels feed the collecting conveyor while rotating and moving along the bridge to cover the full width of the pile.

A mining company bought one such machine which developed severe vibration and cracking problems. A consultant recommended remedial action based on static analysis and recommended modifications despite the fact that the problems were most probably of dynamic nature. The machine collapsed shortly thereafter.

The machine was replaced by a new machine, the design of which was based on a succesful lower capacity reclaimer.

The new machine presented serious vibration problems and was unable to work at full capacity. A visual assesment of the significant vibrations experienced when the machine crossed the 50% capacity threshold led to the conclusion that one or more of the fundamental frequencies of the structure were being excited. The lack of a dynamic analysis was most probebly the root cause of the problem.

Equally dangerous is the use of static design methods to analyse dynamic problems and the use of computer simulations without proper understanding of the physical problems.

Catastrophic failure is a likely result.

The purpose of this paper is to convey the concept that identifying potential dynamic problems is paramount when non-standard designs are used, even in relatively low-tech applications such as materials handling. Using adequate analytical tools requires both theoretical and practical skills that are not widespread and are predominantly concentrated in the realm of specialised consultants.

This paper was first presented at the Beltcon Conference in 2017.

Copyright is vested with IMHC. www.beltcon.org.za Sergio Zamorano Email: szamorano@zingeirl.com

The dynamic behaviour of this type of machine was studied

by Mr Lucas Assis as part of his master’s degree dissertation.

He analysed a more modern design supplied by the company he works for with a single bridge with the reclaiming conveyor inside the main girder as shown in Figure 13.

Mr Assis analysed the operation of the machine and develBULK HANDLING TODAY

August 2018

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“THE LINK FOR AFRICAN TRADING”

TRANSNET FREIGHT RAIL

www.transnetfreightrail-tfr.net

MARKET FORUM

Conveyor belting

An IP rated, stainless steel miniature enclosure is used for one-to-one data communication connections. Typically the sensor head and encoder mounted on the conveyor structure are wired initially into the junction box and from the junction box to the main rEscan enclosure.

BMG has strengthened its 20 year relationship with Fenner, by enhancing the Fenner power transmission portfolio, with the addition of Fenner conveyor belting products.

belting. Fenner products are manufactured at the Isando plant, according to stringent international quality standards.

“Through a long-term agreement with Fenner Conveyor Belting, BMG is the exclusive distributor of Fenner conveyor belting products locally and in sub-Saharan Africa,” says Donovan Scott, business unit manager, bulk materials handling, BMG.

BMG, with a technically competent team and a well established network of over 130 branches, is well positioned to develop sales opportunities and provide support for Fenner conveyor belting.

“As part of this arrangement, BMG has also acquired Fenner’s Engineered Conveyor Solutions (ECS) service operations and related assets in South Africa.

This highly effective tool is designed for preventive maintenance, ensuring reduced downtime on steel cord conveyors.

“This means BMG now supplies a wide range of Fenner conveyor belting, which includes steel cord and solid woven conveyor

SKF Explorer tapered roller bearings

Fit the right part at the right time, every time Getting a replacement tapered roller bearing can sometimes be a challenge, especially if it’s needed in a remote location. Machines can be out of action.

Productivity can slow and costs quickly escalate.

With SKF you’ll get the right support and the best tapered roller bearing solution for your needs, wherever the application. With 17 000 distribution locations in over 130 countries around the globe and a continually extending range of standard metric and imperial sizes, we’ll get the part to you, no matter what.

SKF South Africa (Pty) Limited Tel: +27 11 821 3591, Fax: +27 86 677 7876 Email: sales.za@skf.com, Web: www.skf.co.za ® SKF is a registered trademark of the SKF Group. | © SKF Group 2018

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“Fenner’s field services teams have been integrated into the BMG Engineering Hub and we know that shared skills, equipment and experience will benefit our extended customer base,” Donovan adds.

Through this new agreement, BMG supplies the recently launched Fenner rEscan system, which is a belt diagnostic device – available as a purchase or rental option.

The rental option includes monthly reports and technical back-up.

BMG Donovan Scott Tel: (011) 620-1778 Email: donovans@bmgworld.net www.bmgworld.net

MARKET FORUM

LIF TING SOLUTIONS An in-depth understanding of lifting solutions, and in particular tower cranes, has seen Crane & Hoist Equipment SA secure an order from WBHO for three used Potain tower cranes.

Louw Smit, sales director of Crane & Hoist Equipment SA, says that when a company is adding to its tower crane fleet, it is critical that the configuration of the units already in the fleet is considered. “By doing this, it is possible to allow optimum usage of the new cranes as well as the existing equipment by ensuring that the majority of sections and chassis are interchangeable.”

Louw says it is also always advisable when making the decision to purchase second-hand tower cranes, that the supplier selected has a sound understanding of the market, the application of this equipment and most importantly has access to quality used equipment.

“We sourced two of the tower cranes via our network in Europe and the third one locally. The tower cranes will be thoroughly inspected to ensure the

lifting performance of the equipment prior to handing over to the customer,” Louw adds.

The tower cranes which will bolster the WBHO fleet are a Potain MD238A, a Potain MD 208A and a Potain MTD218.

The Potain MDT 218 has a 65 metre jib length with a 10t maximum capacity and is installed using fixing angles making it suitable for erection in tight areas.

Crane & Hoist Equipment SA was

established late last year to offer a range of tower crane sourcing, refurbishment, sales and site management services. The company has strong supply networks locally and abroad to source used cranes, and also has close links with original equipment suppliers allowing it to provide an above average service to the market.

Crane & Hoist Equipment SA Louw Smit, Tel: 083 413-7524 Email: Louw@Che-Sa.co.za www.che-Sa.co.za

ABSOLUTE MATERIAL FLOW CONTROL

CHUTE SYSTEMS & SOLUTIONS • Optimum material flow • Up to 80% decrease in material degradation

• Reduced dust and noise levels • Virtually maintenance free

• Greatly reduced spillage • Significant reduction in belt damage

Tel: +27 (0) 11 827-9372 email: info@webachutes.com

www.webachutes.com

BULK HANDLING TODAY

August 2018

43

Your boutique business destination Surrounded by lush gardens in the hub of Johannesburg’s northern suburbs, The Peartree in Craighall Park caters for groups of two through to 100 guests in nine well-appointed and equipped business suites.

Breakfast meetings, working lunches, indoor or outdoor dining, half-day and full-day packages including all welcome refreshments, teas and lunches are offered in Standard, Gold and Platinum packages.

Secure parking, business centre, fibre optic broadband AV, lockable space, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.

www.thepeartree.co.za e-mail: info@thepeartree.co.za Tel: 011 781 1401 41 St. Albans Ave, Craighall Park

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MARKET FORUM

A perfect gem The 21t Sany SY210C-9 excavator from Goscor Earth Moving (GEM), offers the highest level of efficiency and productivity demanded by arduous applications such as mining.

It features a six-cylinder in-line watercooled Cummins 6BT5.9-C140 engine, with a rated engine power of 140hp at 2 000rpm, and a maximum torque of 571Nm at 1 300rpm. The engine is matched perfectly to the hydraulic system, thanks to the proprietary Dynamic Optimisation Matching Control System (DOMCS) developed by Sany.

This advanced control system not only boosts operating efficiency by 6%, but furthermore slashes fuel consumption by 10%, which also goes a long way in reducing the total cost of ownership, Andre Steenkamp, General Manager of the Sany range under GEM, points out.

The matched auto-idle speed function is designed for increasing fuel efficiency

even further, while ensuring maximum stability during idling for smooth operation. Variable working modes include heavy-duty, standard, light-duty, and break, which enhances the versatility of the excavator in different working environments.

undercarriage has a unique X-shape structure in terms of its lateral beams for extra strength and rigidity, excellent torsion, and bending-resistant performance.

Additional ‘smart’ features include an advanced GPRS monitoring system and machine alerts to allow for proactive monitoring of engine hours, fuel usage, and location history. The upgraded

Goscor Debby Marx Tel: (011) 230-2600 Email: dmarx@goscor.co.za www.goscor.co.za

DEMAG V-GIRDER CRANES – NOW AVAILABLE UP TO 50 TON LIFTING CAPACITY.

Visit us at Electra Mining Africa 2018 10-14 September 2018 Hall 5, Stand E28

+27 11 898 3500 www.demagcranes.co.za

BULK HANDLING TODAY

August 2018

45

MARKET FORUM

Safety anchors

An 80% improvement Weba Chute Systems should not be compared with conventional chute systems as these locally- manufactured systems adopt a completely different approach to the control and handling of bulk materials.

Skyriders Access Specialists recently installed working-atheight safety anchors to allow telecoms technicians safe access to install and maintain equipment for Maredi Telecoms in Polokwane.

A two-person specialist team completed the project successfully over a two-day period. “It was a relatively straightforward scope of work, utilising our rope-access skill set in assisting our client to reduce its maintenance costs and downtime, while ensuring the health and safety of its technicians at all times, especially when working at height,” Marketing Manager Mike Zinn explains.

Another recent project that showcased Skyriders’ diversification into different niche markets was a maintenance project for the 237-m-tall Sentech Tower in Johannesburg, known originally as the Brixton Tower.

In addition to traditional rope access, Skyriders continues to innovate, such as its recent acquisition of an Elios collision-tolerant drone from Flyability of Switzerland. “This is one of the latest inspection technologies available for indoor and confined spaces.

It offers a particular synergy with rope access that we hope to exploit increasingly in future, allowing us to offer our customers a total solution for all of their maintenance requirements,” Mike concludes.

Mike Zinn, Skyriders Marketing Manager Tel: (011) 312-1418 Email: mike@ropeaccess.co.za www.ropeaccess.co.za

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Mark Baller, managing director of Weba Chute Systems, says these transfer points are an improved alternative to traditional chute systems.

The Weba Chute System is based on the lined ‘super tube’ or cascade system, whereby much of the material runs on material at all times. The bottom layer of particles in the product stream moves in a tumbling motion and subsequently does not slide down the chute. This not only reduces the wear significantly, but in many cases the lip remains completely covered by material and never needs replacement.

Weba Chute Systems takes this means of controlling material movement a step further by designing the internal angle of the transfer chute to match the product discharge velocity with the belt speed, which eliminates or greatly reduces spillage.

Extensive experience and technical expertise, coupled with applications knowledge, has positioned Weba Chute Systems as the leader in its field, Mark notes.

Each system is custom designed for a specific application, considering factors such as belt width, belt speed, material size and shape, as well as throughput. When applied to a Greenfield project, this locally designed transfer system achieves the optimum design configuration for a specific application.

Mark Baller Weba Chute Systems Tel: (011) 827-9372 www.webachutes.com

Bulk Material Handling Solutions ELB Equipment, the Sub-Sahara Africa distributor of a complete range of Telestack Tracked and Radial Telescopic Conveyors is dedicated to offering the most cost-efficient and effective way of stockpiling material on the market.

In today’s competitive environment, you need high quality equipment accompanied by an outstanding support network.

Telestack TS 542

BUILT TO LAST Telestack TC 421 R Our sales and aftermarket teams are trained to provide customers with outstanding stockpiling solutions accompanied by product warranty, 24/7 technical support and parts service.

ELB EQUIPMENT - HEAD OFFICE: 14 Atlas Road, Anderbolt, Boksburg • Tel: +27 (0)11 306 0700• Fax: +27(0)918 7208 • e-mail: Elb@elbquip.co.za • Website: www.elbequipment.com BRANCHES & DEALERS – SOUTH AFRICA: • BRITS: +27 (0)12 250 1565 • CAPE TOWN: +27 (0)21 933 2383 • DURBAN: +27 (0)31 464 6522 • EAST LONDON: +27 (0)31 464 6522 • GEORGE: +27 (0)21 933 2383• KIMBERLEY : +27 (0)53 841 0040 • MIDDELBURG: +27 (0)13 246 2312 • POLOKWANE: +27 (0)81 826 4493 SUBSIDIARY: ELB EAST AFRICA: • NAIROBI, KENYA: +254 (0)20 807 0728 DEALERS – SOUTHERN AFRICA: • BOTSWANA: +267 (0)390 9972 • LESOTHO: +266 (0)28 313 926 • MOZAMBIQUE: +268 (0)76 022 8488 • NAMIBIA: +26 (0)46 123 4052 • SWAZILAND: +268 (0)518 5348 / 518 5602 • ZAMBIA: +26 (0)21 221 0642 • ZIMBABWE: +263 (0)77 236 2596 Distribution and Product Support by:

CXT EXPLORER

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The Konecranes CXT Explorer is an affordable, strong and portable solution for all kinds of lifting needs.

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