Quarrying Africa MAGAZINE JANUARY/FEBRUARY 2022

PREMIER INFORMATION HUB FOR THE SUB-SAHARAN AFRICAN QUARRYING SECTOR

VOL. 1 ISSUE 1

UPPING LOADING EFFICIENCY

PREMIER INFORMATION HUB FOR THE SUB-SAHARAN AFRICAN QUARRYING SECTOR

JANUARY/FEBRUARY 2022

JANUARY/FEBRUARY 2022

FRONT COVER.indd 1

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A tale of two halves

14

The quest for Zero Harm

28

Getting the best out of your load & haul fleet

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IBC COVER.indd 1

3/4/2022 3:55:57 PM

COMMENT

DAWN OF A NEW ERA

MUNESU SHOKO Publishing Editor Email: munesu@quarryingafrica.com

LinkedIn: Munesu Shoko

Quarrying Africa

STARTING a business is hard work in any environment, but it’s even more challenging in a tough economy.

However, there is no stopping an idea that is finally ripe for its time! Having toyed with the idea for a while, I have launched Quarrying Africa, a new platform that I intend to position as the premier information hub for the quarrying sector in Africa.

Quarrying Africa is a must-read for the broader spectrum of the aggregates value chain, from quarry operators and aggregate retailers to cement producers, mining contractors and the supply chain at large. As you will see in this edition, the publication seeks to align the African quarrying sector with modern practices, while highlighting opportunities for business growth across the region.

Following the announcement of this venture, the principal question has always been: why quarrying? On a lighter note, quarrying is my greatest shot of adrenaline, and for the past 10 years, I have been an adrenaline junkie!

On a more serious note, despite the current slowdown, the quarrying sector is poised for massive growth in years to come. With Africa’s infrastructure investment gap standing between US$68-billion and US$110-billion per year, the continent’s need for adequate infrastructure is apparent, and the aggregates industry has a big role to play in the success of these projects.

For years, there has been a clarion call from key players in the infrastructure sector for enhanced partnerships between public and private sectors to develop Africa’s infrastructure to spur industrial growth and employment creation. In fact, leaders across the continent understand that infrastructure development is a key driver of the much-needed progress in Africa and a critical enabler for productivity and sustainable economic growth.

A major drawback, however, has always been the lack of implementation.

It is a widespread problem across the continent. In South Africa, for example, long-promised big infrastructure projects are not coming to market. There are concerns that the thin pipeline of new work is insufficient to resuscitate the economy.

At this year’s AfriSam Budget Breakdown Breakfast, Dr Azar Jammine, director & chief economist of Econometrix, noted that South Africa has a whopping R935-billion worth of investment projects in the pipeline, or 126% of the country’s total annual fixed investment, but this remains a pipedream given the government’s track record when it comes to implementation.

However, as you will see in this edition of Quarrying Africa, Andries van Heerden, CEO of Afrimat, is of the view that despite the slow pace of government’s infrastructure rollout, there is reason to be hopeful, with some exciting projects on the cards. Of the 62 projects announced at the Sustainable Infrastructure Development Symposium South Africa in 2020, about 33% of these are already in construction and some have already been completed, with another 20% at various stages of preparation and feasibility. On a further positive note, the third quarter of 2021 saw more tenders coming to market.

Away from South Africa, the Zimbabwean construction industry is defying political odds with a notable growth trajectory in the past three years.

An executive from a major cement company operating in Zimbabwe recently told me that the country has been experiencing a construction boom since 2019, driven by government-led infrastructure projects and individual home builders. As a result, cement demand rose 20% from 1-million to 1,2-million tonnes per annum in 2020. In the first half of 2021, demand was 30% higher than the same period in 2020.

Looking ahead, I believe that the continent should learn from its past mistakes and focus on the projects that it is going to implement in the next 10 years. Infrastructure development will contribute significantly to human development, poverty reduction and sustainable economic development.

To quote Rwandan president Paul Kagame’s report on the African Union reforms, “We have everything needed to succeed. To fail Africa again would be unforgivable.”

Enjoy the read! Your feedback is most welcome. b

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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CONTENTS 18

08

20 14

2

12

Reconnecting the quarrying industry

24

Early Rokbak endorsement

28

Getting the best out of your load & haul fleet

36

Looking beyond price

40

Optimising truck loading

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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04

LEAD STORY UPPING LOADING EFFICIENCY

Publishing Editor: Munesu Shoko Admin: Linda T. Chisi linda@quarryingafrica.com Design: Kudzo Mzire Maputire Web Manager: Thina Bhebhe

Quarrying Africa is a premier information hub for the subSaharan African quarrying sector. It is a valued reference tool positioned as a must-read for the broader spectrum of the aggregates value chain, from quarry operators and aggregate retailers, to concrete and cement producers, mining contractors, aggregate haulage companies and the supply chain at large.

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© Quarrying Africa Quarrying Africa, published by DueNorth Media Africa, makes constant effort to ensure that content is accurate before publication. The views expressed in the articles reflect the source(s) opinions and are not necessarily the views of the publisher and editor.

The opinions, beliefs and viewpoints expressed by the various thought leaders and contributors do not necessarily reflect the opinions, beliefs and viewpoints of the Quarrying Africa team.

Quarrying Africa prides itself on the educational content published via www.quarryingafrica.com and in Quarrying Africa magazine in print. We believe knowledge is power, which is why we strive to cover topics that affect the quarrying value chain at large.

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Scalping beyond expectations

46

Shift in attitude

52

The impact of stemming in blast outcomes

56

Ten tips to promote a safer working environment

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Corporate Partners

Printed by:

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

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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LEAD STORY

UPPING LOADING EFFICIENCY Having previously relied on old wheel loaders to stockpile material and load customer trucks at its crushing plant, Rustcrete Readymix Concrete, one of the oldest readymix concrete producers in the Rustenburg area, has opted to replace one of its old units with a Liebherr L 550 wheel loader, citing efficiency as a major driver of the buying decision, writes Munesu Shoko.

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| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

LEAD STORY

The Liebherr L 550 loading customer trucks at Rustcrete.

KEY POINTS Family-owned Rustenburg-based concrete producer, Rustcrete Readymix Concrete, has taken delivery of its new Liebherr L 550 wheel loader Having run some old machines for a long time, Rustcrete was looking for better loading efficiency and productivity, and the Liebherr L 550 ticked all the right boxes The innovative Liebherr driveline of the L 550 helps minimise fuel consumption, as well as brake and tyre wear The company operates two readymix plants – the Rustenburg Plant and the Boshoek Plant.

The Rustenburg Plant produces between 150 and 200 m³ a day, while the Boshoek Plant averages between 350 and 400 m³ a day

Hans Eiskonen | Unsplash

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t a recent handover ceremony attended by Quarrying Africa, family-owned Rustenburg-based concrete producer, Rustcrete Readymix Concrete, took delivery of its new Liebherr L 550 wheel loader from Liebherr-Africa’s Earthmoving division.

For Liebherr-Africa’s salesperson, Aurelia Chili, it was a reminder that persistence does pay, and customer care is the ultimate recipe for success.

The deal, she says, was four years in the making, and the customer only signed on the dotted line after countless meetings and amendments to quotations over the years.

Even JP Beumer, procurement manager at Rustcrete, admits that Chili’s efforts and commitment played a big role in the buying decision, and commends her for “going the extra mile” for Rustcrete.

Why Liebherr?

Commenting on the buying decision, JP says from the onset, the look and feel of the Liebherr L 550 was appealing. Having previously run some old competitor machines, Rustcrete was looking for better loading efficiency and productivity, and the Liebherr L 550 ticked all the right boxes.

“When we saw the machine for the first time, | January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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LEAD STORY 20 000 t

The crushing plant produces about 20 000 t of aggregate a month.

The new Liebherr L 550 feeding the plant.

we were impressed by the design.

After speaking to the Liebherr-Africa team, we were immediately aware of the potential benefits of going the Liebherr route. Although we haven’t run the machine for that long, we have already seen massive gains, both in terms of fuel efficiency and productivity,” says JP.

L 550 in detail

1989 Rustcrete started its crushing business in 1989, crushing waste material from mines and supplying aggregate to various industries, including mining and construction

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Tendayi Kudumba, GM – Earthmoving at Liebherr-Africa, says the innovative Liebherr driveline on the L 550 helps minimise fuel consumption, as well as brake and tyre wear. Its handling capacity also helps operators cut back on operating costs.

Equipped with a John Deere engine producing 146 kW (195 hp) of power, the 17,3 t machine’s bucket can discharge its 3,2 m³ capacity from a height of 2,88 m, which is above average in this size category.

Justin Bergh, national sales manager – Earthmoving at LiebherrAfrica, is excited to be associated with Rustcrete, a company he calls the yardstick of excellence in the readymix business in Rustenburg. He also believes that the two companies

– Liebherr and Rustcrete – share common values, given that they have both been family-owned entities since their establishment.

Strong foundations

Founded in 1962 by Henk Beumer as Beumer Transport, specialising in transport work for mines, the company is today run by his four sons. Although Henk is still involved in the business, the Beumer brothers – JP (cement and procurement of machines), Addy (aggregates supply), Henk Jnr (readymix concrete) and Martin (crushing plant) – are responsible for the day to day running of the several arms of the business.

Other family members active in the business include Henk Beumer’s daughter Judy Barnard (invoicing) and her husband Leon Barnard, who runs the engineering division, as well as JP Beumer’s wife Santi Beumer, the financial manager of the group.

The company started its crushing business in 1989, crushing waste material from mines and supplying aggregate to various industries, including construction and mining.

“From the onset, the crushing

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

LEAD STORY 195 hp

Equipped with a John Deere engine producing 146 kW (195 hp) of power, the 17,3 t machine’s bucket can discharge its 3,2 m³ capacity from a height of 2,88 m, which is above average in this size category.

The Beumer family taking delivery of the new wheel loader. From left: JP, Addy, Henk Snr, Martin and Henk Jnr.

business was established with a view to venture into readymix concrete, and in 1991, Rustcrete Readymix Concrete was formed. We are one of the pioneers of readymix concrete production in the Rustenburg area,” says JP. “In 2000, we also started a property development business, which is a key customer of the readymix business. However, most of our business comes from the mines in the area.”

Two readymix plants

The company operates two readymix plants – the Rustenburg Plant and the Boshoek Plant. The Rustenburg Plant produces between 150 and 200 m³ a day, largely supplying property developments and mines.

Situated close to Sun City, the Boshoek Plant averages between 350 and 400 m³ a day, largely catering for mines in the area.

The crushing plant produces about 20 000 t of aggregate a month. About 50% of the material is supplied to Rustcrete’s two readymix plants, while the rest goes to external aggregate clients in the area. The Liebherr L 550 has been

deployed to feed the crushing plant, load customer trucks and perform stockpiling duties on site, working about seven hours a day.

Given the difference it has made in a short space of time, JP is already thinking about replacing the remaining old wheel loader with another new Liebherr L 550. “We will start discussions for a possible second machine. We are looking at standardising our loading fleet with Liebherr machines,” he concludes. b

Liebherr-Africa and Rustcrete representatives during the official handover of the wheel loader.

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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FROM THE CEO’S DESK

80% Bulk commodities and industrial minerals continue to be lucrative for Afrimat, constituting 80% of the company’s profits

“

We are not expecting fireworks in a year or two.

However, we are hoping that government’s planned R96-billion infrastructure expenditure programme will materialise. Despite assurances of a revival of the construction industry, there has been an apparent lack of implementation.

KEY POINTS Having taken the brunt of the hard lockdown in early 2020, the aggregates sector enjoyed what Andries van Heerden calls a V-shaped recovery during the first half of 2021 There has been a general slowdown of the construction materials industry in the past six to seven months Despite the slow pace of government’s infrastructure rollout, there is reason to be hopeful, with some exciting projects on the cards KwaZulu-Natal seems to be enjoying a notable road project rollout, with Sanral’s R30-billion upgrade package for both the N2 and N3 highways in and around eThekwini forging ahead

Andries van Heerden, CEO of Afrimat.

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| January/February2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

FROM THE CEO’S DESK

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The South African government announced the rollout of 62 projects at the Sustainable Infrastructure Development Symposium South Africa in 2020.

R30-billion

Sanral’s R30-billion upgrade package for both the N2 and N3 highways in and around eThekwini is forging ahead.

A TALE OF TWO HALVES The South African aggregates sector was a tale of two halves in 2021, with the first half of the year experiencing a V-shaped recovery and the second a gradual slowdown in volumes. This is the view of Andries van Heerden, CEO of Afrimat, who tells Quarrying Africa that while government’s Recovery and Reconstruction Plan has been slow out of the starting blocks, there are however some exciting projects on the horizon. By Munesu Shoko.

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aving taken the brunt of the hard lockdown in early 2020, the aggregates sector enjoyed what Van Heerden calls a V-shaped recovery during the first half of 2021. “Last year was a tale of two halves. After the 2020 slowdown, we saw a strong recovery during the first half of 2021, with volumes even surpassing the pre-COVID levels at some point. It was a welcome relief for an industry that had been on a downward trajectory since 2017,” he says.

Unfortunately, adds Van Heerden, the industry started experiencing a gradual slowdown in demand in the second half of 2021. Despite

Afrimat’s Lyttelton operation in Centurion, Gauteng.

talk of government’s economic recovery plans announced in 2020 being centred on infrastructure development for job creation, Van Heerden says not much has happened on the ground. With no meaningful infrastructure projects coming to market, there has been a slow recovery of the country’s construction sector, with significant knock-on effects on the quarrying industry and the economy at large.

“There has been a general slowdown of the construction materials industry in the past six to seven months. While it has not necessarily come to a grinding halt, the market is nowhere near the envisaged volume levels. We expected a lot better, given government’s announcements in 2020 that infrastructure development would be central to resuscitating the economy. Given the circumstances, the industry is making a good living out of the current market conditions,” says Van Heerden.

Exciting projects on the horizon

Despite the slow pace of government’s infrastructure rollout, Van Heerden says there is reason to be hopeful, with some exciting projects on the cards. According to the South African Institution of Civil Engineering (SAICE), the South African government announced the rollout of 62 projects at the Sustainable Infrastructure Development Symposium South Africa in 2020. About 33% of these projects are in construction and some have already been completed, with another 20% at various stages of preparation and feasibility.

On a further positive note, the third quarter of 2021 saw more tenders coming to market.

While the net effect of these tenders will only be felt in six to 12 months’ time, quarries in areas where the projects will take place may need | January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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FROM THE CEO’S DESK to start preparing for increased business activity. after years of delay due to legal wrangles between Van Heerden has noted a meaningful rollout Sanral and the City of Cape Town. of road projects across the country, but more 2021 outlook significantly in three provinces – KwaZulu-Natal, Having travelled extensively around the country in Mpumalanga and the Western Cape. “As Afrimat, recent months, Van Heerden notes that the state we have seen good volumes in KwaZulu-Natal and of the country’s roads is deteriorating at an alarmMpumalanga,” he says. ing rate and Sanral needs to commit meaningful He makes special mention of the N3 upgrade, investment in maintenance projects this year. a major highway that links the economic hubs of While this will be enough to keep quarry operaJohannesburg and eThekwini. The R18,4-billion tors ticking for now, Van Heerden does not believe project for the N3 upgrade in KwaZulu-Natal forms that maintenance projects will drive high levels of part of the national government’s key Strategic aggregate demand.

Integrated Projects. It focuses on an 80 km section “We are not expecting fireworks in a year or from Durban to Pietermaritzburg. two. However, we are hoping that government’s In fact, KwaZulu-Natal seems to be enjoying a planned R96-billion infrastructure expenditure pronotable road project rollout, with Sanral’s R30gramme will materialise. Despite assurances of a billion upgrade package for both the N2 and revival of the construction industry, there has been N3 highways in and around eThekwini is forging an apparent lack of implementation,” he says. ahead. Initial work entails the upgrade of the N3 Looking ahead, Van Heerden believes that the between the Dardanelles interchange and the timing is right for “some strategic interventions” in Lynnfield Park interchange situated between Cato the aggregates industry. “There are some interRidge and Pietermaritzburg. esting opportunities in the construction materials Here, the existing four-lane dual carriageway industry, but there is need for consolidaroad is being upgraded to an eight-lane tion and restructuring of the industry to dual carriageway by widening to the make the most of the opportunities. median and outer shoulders. The The old model has served its purpose existing Dardanelles interchange and Afrimat will probably take the will also be upgraded to improve 40% lead in ushering in what we believe traffic flow. The project has seen are strategic interventions to take a R1,48-billion investment in this Construction materials remains an important part of Afrimat’s the industry forward.” section of the highway, creating business, constituting 40% of the company’s revenue and 20% of profits Van Heerden adds: “We can sit ample aggregate demand for and complain about things that are quarry operators in the vicinity. going wrong, but if we actually open Elsewhere, Van Heerden believes our eyes, we will realise that there are that Mbombela, Mpumalanga is far more opportunities than what we have another road infrastructure development capacity for, not only in construction materials, but hotspot. The area is benefitting from the N4 Toll in open pit mining at large.”

Route upgrade project, which will see R1,5-billion While aggregates remain an important part of in major upgrades over the next few years, including lane-widening and new interchanges.

Afrimat’s business, Van Heerden says the company One of the notable projects where Afrimat will further diversify its portfolio. “Construction recently supplied is the Karino N4 Intersection Materials remains an important division of our bridge. Valued at R390-million, the Sanral project business. To provide context, in the results we commenced in 2019 and was completed in published recently, it constituted 40% of our November 2021. This section of the N4 Toll Route, revenue and 20% of our profits. Bulk Commodities which serves as the most important link between and Industrial Minerals continue to be more Mbombela and KaNyamazane, was experiencing profitable for us, constituting 80% of our profits,” excessive peak-hour traffic delays as residential he says. areas such as KaNyamazane and Karino continue Consequently, Van Heerden sees Afrimat further to grow. The interchange improves traffic flow positioning itself as a mid-tier miner through onto and off the N4 and provides a direct link from strategic acquisitions. “I see Afrimat further the R514 to the N4. expanding its mineral basket as part of our While the Western Cape has been another diversification strategy, which has served us well project hotspot in recent years, Van Heerden says over the years. There are already 10 minerals in our most of the projects in the province have been portfolio, including aggregates, lime, dolomite, completed. He is however encouraged by the silica, iron ore, anthracite and we will soon add prospect of the controversial Winelands Toll Road manganese, phosphate and rare earths. We are Project – entailing the upgrade of the N1 and N2 also excited about our venture into critical minerals, national routes spanning 170 km in the Western phosphate and rare earths,” concludes Van Cape – being reconsidered for implementation Heerden. a

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| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

IQSA CONFERENCE PREVIEW

RECONNECTING THE QUARRYING INDUSTRY The IQSA Conference, a staple on the local quarrying sector’s calendar, returns this year after a two-year COVID-19 influenced disruption. Held under the ‘IQSA Reconnect’ theme, this year’s event will tackle a range of critical issues affecting the industry – from legislation to technology and training, among other matters of importance. By Munesu Shoko.

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he Institute of Quarrying Southern ageing workforce is a matter of concern across Africa (IQSA) Conference returns industries, and quarrying is no different. this year following the cancelation “Not much has changed over the past few of the event in 2020 and 2021 due years, but we are constantly looking for ways to to the COVID-19 pandemic. This attract young professionals to our industry. It is year’s event will be held at the Kopanong Hotel an illustrious career path with several opportunities, given the diverse nature of skills required & Conference Centre in Benoni, Gauteng, on in our industry,” says Hunter-Smith. “It is, howMarch 16 – 17, confirms IQSA president Jeremy ever, encouraging to see many great young Hunter-Smith, who began his two-year tenure people coming through the pipeline. With the on June 1, 2021. right mentors, they will be able to develop and The 2022 conference is held under the take the industry to the next level.”

‘IQSA Reconnect’ theme and is truly To attract young people into the a platform for reconnection after quarrying industry, the Institute the industry last congregated in of Quarrying Southern Africa 2019. “This year’s conference has for the past six years run has been branded ‘IQSA a Young Members Network, Reconnect’ for obvious March 16 – 17 aimed at creating awareness reasons; the past two of the global network beyears have really pulled This year’s event will be held at tween the Institute of associations apart, limiting the Kopanong Hotel & Conference Quarrying member countries. members’ ability to Centre in Benoni, Gauteng, on March 16 – 17 Two student papers at this network and connect with year’s conference will give exhibitors. We therefore young professionals a chance believe that 2022 is the year for to present a case study to the reconnection,” says Hunter-Smith. industry, with the winner set to get Delegates can look forward to a a prize. The winner of the 2017 student full two days’ programme filled with paper had the privilege of joining the Austragreat papers. While the keynote speaker is lian Young Members’ international tour to New always a drawcard, an economist will also shed Zealand in June 2018. “Our goal is to continue some light on what is happening and what to offering these incentives for our young profesexpect during the year. Other key papers, adds sionals to gain international experience and Hunter-Smith, will touch on the Mining Charter, be part of the global IQ network,” says Huntdigitalisation of quarry operations and issues er-Smith. affecting small-scale mining, among others.

Attracting young skills

One of the key issues of discussion at the conference will be the ageing workforce and the industry’s urgent need to attract skilled young people. Hunter-Smith acknowledges that the

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Skills development

Skills development is another area of critical significance, stresses Hunter-Smith, thus both IQUK and IQSA will use this year’s conference to launch the IQ Academy Select

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

IQSA CONFERENCE PREVIEW

2022

2019

The 2022 conference will be held under the ‘IQSA Reconnect’ theme.

This year’s event is a platform for reconnection after the industry last congregated in 2019.

“ for online courses. “This programme is our way of championing skills development for our members,” he says. “The programme will allow young professionals to gain CDP points along their journey to their required professional field.”

Hunter-Smith acknowledges that the current brain drain is a major challenge, not only for the quarrying industry, but across the economy at large. This is particularly hostile to business growth. He, however, believes that this can also create wonderful opportunity for individuals to “grab the stick and run with it”. With the right attitude and willingness to learn, Hunter-Smith believes that young professionals can drive the industry forward.

Outlook

Commenting on the industry outlook, HunterSmith says there is a notable rebound, and the aggregates market is bouncing back from the low levels experienced during the hardlockdown period.

“For a growing economy such as South Africa, aggregates and building materials are essential. We have an economist scheduled to paint the picture for us at the conference, but I am positive that the market is turning, which is positive for an industry that has endured such a lengthy downturn due to COVID-19. On a personal level, I am looking forward to the next year and a half; the aim is to make a difference to our members and add value to the industry at large in my capacity as president of IQSA,” concludes Hunter-Smith. a

Not much has changed over the past few years, but we are constantly looking for ways to attract young professionals to our industry. It is an illustrious career path with several opportunities, given the diverse nature of skills required in our industry.

Jeremy Hunter-Smith, IQSA president

KEY POINTS The IQSA Conference returns this year following the cancelation of the event in 2020 and 2021 due to the COVID-19 pandemic The 2022 conference will be held under the ‘IQSA Reconnect’ theme and is a platform for reconnection after the industry last congregated in 2019 One of the key issues of discussion at the conference will be the ageing workforce and the industry’s urgent need to attract skilled young people Skills development is another area of critical significance, thus both IQUK and IQSA will use this year’s conference to launch the IQ Academy Select for online courses

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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HEALTH & SAFETY Afrimat’s Qwa Qwa Quarry was the Top Performer in the 2021 ISHE Audit.

Key highlights of the 2021 ISHE Audit Showplace Status (95% +):

9 operations

5 Shield Status (90 – 95%):

33 operations

4 Shield Status (80 – 90%):

19 operations

3 Shield Status (70 – 80%):

8 operations

No operation scored below 70%

KEY POINTS A total of 69 operations participated in the 2021 ISHE Audit, compared with 48 the previous year The average score of the 2021 ISHE Audit was 89,19%, with the highest being 97,63% and the lowest 70,4% Although the average score for the year was 0,25% lower than the previous year, some encouraging improvements were recorded in the face of tough operating conditions No operation scored below 70%, which shows the high-level nature of compliance among ASPASA member operations

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| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

HEALTH & SAFETY 89,19%

97,63%

Average score for the 2021 ISHE Audit

The highest score achieved in the 2021 ISHE Audit

THE QUEST FOR ZERO HARM

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Despite the documented operational challenges brought about by the COVID-19 pandemic, ASPASA members have once again exhibited high levels of health & safety compliance. Members audited in the association’s 2021 ISHE Audit demonstrated total commitment to the industry’s quest for Zero Harm in the face of difficult operating conditions, writes Munesu Shoko.

hat the past two years will be remembered as the most difficult in managing health & safety at operations is no overstatement.

Nonetheless, ASPASA members have managed to maintain high standards on their sites. Testimony to this is the 89,19% average score achieved in the 2021 ISHE Audit.

The enforcement of strict COVID-19 protocols and the non-stop development and implementation of health & safety management systems, says ASPASA ISHE auditor Marius van Deventer, is testimony to the industry’s commitment to mitigating what is believed to be the biggest health and safety challenge in modern history.

Speaking at a recent ASPASA event, Van Deventer noted that there was a notable increase in the number of operations audited in 2021 than in 2020. A total of 69 operations participated in the audit, compared with 48 the previous year.

Audit findings

The ISHE Audit, explains Van Deventer, covers all operations on the mine that fall under the legal requirements of the Mine Health and Safety Act and applicable regulations.

In 2021, audits were also done for members who run operations that are governed by the Occupational Health and Safety Act. Both audit protocols are frequently revised and updated in line with new legal requirements and industry standards.

The audit process is designed to provide guidance and to add momentum to the industry’s quest for Zero Harm. Knowledge and experience are shared between operations, thus uplifting best practice and compliance standards at industry level.

A total of 69 operations were audited during 2021, with some members opting out of the audit due to COVID-19 restrictions at their operations.

Although the average score for the year was 0,25% lower than the previous year, some encouraging improvements were recorded in the face of tough operating conditions.

“The average score of the 2021 ISHE Audit was 89,19%, with the highest being 97,63% and the lowest 70,4%. Some 60% of the audited members scored more than 90%, which is an excellent achievement. Special recognition is given to those quarries that achieve Showplace Status, but to be honest, it’s no easy feat to score more than 90% in this audit,” says Van Deventer.

A total of nine operations achieved Showplace Status (95%+), while 33 operations achieved 5 Shield Status (90 – 95%). Some 19 operations attained 4 Shield Status (80 – 90%), with eight managing 3 Shield Status (70 – 80%). Not a single operation scored below 70%, which shows the high-level nature of compliance among ASPASA members.

Afrimat's Free State-based Qwa Qwa Quarry was the Top Performer in the 2021 ISHE Audit, with a score of 97,63%. This was a significant

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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HEALTH & SAFETY protocols remains high, with wearing of face masks, sanitising and social distancing taking centre stage across operations.

Areas of attention

Having taken top spot in the 2020 audit, Midmar Crushers achieved second place in the 2021 audit with a 96,32% score.

69 A total of 69 operations participated in the audit, compared with 48 the previous year

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improvement for the operation, having placed 27th in the 2020 audit with a 90,75% score. Qwa Qwa Quarry has over the years won numerous ASPASA Showplace awards and produces some of the highest specification road and asphalt stone in the country. It is a benchmark of how any quarry operation should be run.

Positive observations

According to Van Deventer, the sharing of information continues to be a crucial aspect of the audit process, with quarry managers eager to learn from their peers to improve their own health and safety performances.

“Overall, high health and safety standards were maintained throughout the industry under difficult conditions. We have also noted a significant improvement in the compliance to machine guarding requirements. Some operations have also made expensive modifications and improvements to their crushing and screening plants to further improve their health and safety standards,” he says.

During the audit period, no serious incidents were recorded because of mine failure or blasting. No mining fatalities were recorded, although a few noise-induced hearing loss (NIHL) incidents were logged.

Van Deventer adds that employees are better informed about the requirements of a safe work environment. Compliance to COVID-19

While the 2021 audit has once again demonstrated ASPASA members’ commitment to health and safety of their employees and all other parties affected by their operations, Van Deventer however notes that several “silly” accidents, which he believes could have been prevented, were recorded during the year.

“Of concern were the many lost time injuries, disabling injuries and reportable injuries recorded during the audit period. We also discovered that there was poor identification of risks and/or non-compliances in some instances. This was exacerbated by poor inspections and deviations. This is either due to incompetence of the people doing the inspections, or the inspection itself has become a box-ticking exercise,” says Van Deventer.

Most managers have identified the psychological effect of COVID-19 as the root cause of most of these accidents. Although COVID-19 is wreaking havoc on sites, Van Deventer is concerned about the general lack of proper investigations to establish the real cause of some of the recorded accidents. Proper investigations, he says, are crucial in the implementation of control measures to prevent same incidents from happening in the future.

Commenting on Traffic Management Plans, Van Deventer notes that several operations did their risk assessments a few years ago, in accordance with legal requirements, which saw subsequent plans being put together to segregate vehicle-to-vehicle and vehicleto-person interaction. However, implementation of such traffic management plans has come to a grinding halt during the past two years as no further developments were identified at most quarries.

Additionally, failure to comply with trackless mobile machinery (TMM) pre-start checklist hazard classification has been noted as an area

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

HEALTH & SAFETY ISHE Audit results for 2021 No

OPERATION

Awards '21

1

Afrimat Qwa Qwa

97.63

2

Midmar Crushers

96.32

3

Lafarge Qala Quarry

96.24

4

Afrisam Rheebok

96.08

5

Afrisam Peninsula

95.29

6

Afrimat Kliprug

95.21

7

Afrimat Dundee

95.04

8

SPH Kundalila Pilanesburg

95.03

9

PPC Laezonia

95.00

10

Afrisam Verulam

94.93

11

Raumix Rosslyn Quarry

94.92

12

SPH Kundalila Aggeneys

94.82

13

Raumix Crushco

94.81

14

Afrimat Marble Hall

94.61

15

South Coast Crushers (Pty) Ltd - Margate

94.57

16

Afrisam Coedmore

94.49

17

Afrisam Umlaas Rd

94.44

18

Raumix Alfa Sand

94.37

19

Eskay Crushers

94.26

20

Afrimat Lyttelton Dolomite Mine

94.24

21

Afrimat Umfolozi

94.23

22

Afrimat Rietfontein

94.14

23

Afrimat Maritzburg

94.05

24

Afrisam Jukskei

93.99

25

Afrimat De Kop

93.89

26

Afrimat Dingwell Nelspruit

93.77

27

Afrisam Rooikraal

93.67

28

Sterkspruit Aggregates (Pty) Ltd

93.44

29

Afrimat Vryheid

93.24

30

Afrimat Palmiet

93.22

31

Afrisam Eikenhof

92.89

32

Afrimat Bethlehem

92.60

33

Afrimat Brewelskloof

92.34

34

Afrimat Hluhluwe

92.31

35

Afrimat Glen Douglas Mine

91.96

36

Afrimat Scottburgh Quaries

91.30

37

Raumix Aggregates Donkerhoek

91.25

38

Afrimat Denver Quarry

90.71

39

Drift Laezonia

90.67

40

Idwala Ottosdal

90.45

41

Drift Super Sand

90.37

42

Afrisam Pietermaritzburg

90.16

43

Blurock Quarry (Pty) Ltd

89.96

44

PPC Mooiplaas

89.10

45

Raumix Rossway Quarry

88.59

46

Raumix Aggregates Willows Quarry

88.44

47

Taylors Halt - Midmar Group

87.59

48

Silica Quartz (PTY) Ltd

86.78

49

Afrisam Zeekoewater

86.74

50

Raumix Aliwal Dolerite Quarry

86.74

51

Raumix Aggregates Kimberley

86.26

52

Tshwane Aggregates

85.71

53

Raumix Petra Quarry

85.28

54

Labucon Resources - Krokodil Sand

85.06

55

SPH Kundalila Aroams Quarry

84.65

56

O M V (Pty) Ltd Stilfontein

84.61

57

Marlin Granite Minaco Quarry

84.23

58

West End Clay Brick

83.91

59

Vergenoeg Mining Co (Pty)Ltd

83.76

60

CBS Manufacturing Gran Sasso Quarry

80.66

61

Rietspruit Crushers

80.54

62

Supacrush Bigwill Quarry

78.87

63

Argent Industrial Megamix Quarries

76.16

64

Marlin Granite Springbok Quarry

75.63

65

Marlin Granite Bloemhoek Quarry

73.85

66

Raumix/Transkei Quarries Mthatha

73.08

67

Raumix/Transkei Quarries Butterworth

71.72

68

Procon Precast

70.43

69

Roodepoort Crushers Janniek Mining

70.40

that needs immediate attention.

Poor housekeeping on plants is also contributing to dust exposure. This is compounded by poor compliance to isolation and lockout requirements.

Recommendations

In conclusion, Van Deventer says as the COVID-19 pandemic continues unabated, operations need to find new ways of driving their health and safety programmes to ensure legal compliance. The COVID-19 protocols, he says, are well established by now and known by all, and there is need to refocus and continue with the health and safety campaigns.

Van Deventer adds that employees need to understand why health & safety programmes are developed; why checklists should be correctly completed every day; why isolation records and permits need to be signed off before a plant or machine can be started after maintenance work; the benefits of planned task observations and near miss reporting and the correct way of doing accident and incident investigations to get to the root cause by not focusing on an individual but rather on the problem. These are all human factors that must be addressed to change the safety culture, he says.

“Every operation needs to find a way to set up proactive programmes in line with the core values of the organisation, to promote a health and safety culture for the benefit of all employees and stakeholders,” concludes Van Deventer. a

AfriSam’s Peninsula Quarry placed fifth overall with a 95,29% score.

95%+ Nine operations achieved Showplace status (95%+)

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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READYMIX CONCRETE

Afrimat has established a readymix plant in Bushbuckridge to take advantage of public and commercial projects in the area.

RIDING ON THE CONSTRUCTION WAVE Afrimat’s newly established readymix plant is riding on the wave of public construction activity in the Bushbuckridge area of Mpumalanga, South Africa, writes Munesu Shoko.

T

o take advantage of to establish a strong footprint some of the projects in the region. Together with underway in the Nelspruit and Hazyview 3 Bushbuckridge, readymix operations, the Afrimat new Bushbuckridge plant established a readymix gives Afrimat a good coverThree contractors – Clear Choice Builders (Afrimat’s client), Steffanuti Stocks and Barzane – age of the Lowveld region. plant in the area in are working on the Mapulaneng Hospital project.

Afrimat also operates September 2021. The plant its Bushbuckridge Quarry, is strategically located to which is located some 10 km service both public and away from the readymix plant. private commercial projects in “The 19 mm concrete stone we use the area. is sourced from our own Bushbuckridge The anchor project, however, is the Quarry. The quarry also produces 13 mm Mapulaneng Hospital, where Afrimat is concrete stone, crusher dust and G5 materisupplying concrete to one of the three al for projects in the area,” he says. contractors working on the project.

“We have been supplying to the project State-of-the-art hospital since the establishment of the plant. All Following the completion of phase 1 and indications are that we will be supplying 2 (fencing and palisades), phase 3 of the concrete to this project for the next two Mapulaneng Hospital project commenced years,” explains Martin Kruger, RSC at Afrimat Contracting International. in 2020. Three contractors – Clear Choice The project, he adds, has enabled Afrimat Builders (Afrimat’s client), Steffanuti

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| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

READYMIX CONCRETE R2,5-billion

2020

Afrimat has established a readymix plant to supply the R2,5-billion Mapulaneng Hospital in Bushbuckridge, Mpumalanga.

Following the completion of phase 1 and 2 (fencing and palisades), phase 3 of the Mapulaneng Hospital project commenced in 2020.

An aerial view of Afrimat’s newly established plant in Bushbuckridge.

KEY POINTS To take advantage of some of the projects underway in Bushbuckridge, Afrimat established a readymix plant in the area in September 2021 The plant is strategically located to service both public and private commercial projects in the area The anchor project, however, is the Mapulaneng Hospital, where Afrimat is supplying concrete to one of the three contractors on the project Together with the Nelspruit and Hazyview readymix operations, the new Bushbuckridge plant gives Afrimat a good coverage of the Lowveld region

Stocks and Barzane – are working on the project, which is due for completion in the next six years.

When completed, the R2,5-billion project will be a state-of-the-art district hospital that will serve Bushbuckridge and the surrounding areas. It will also be one of the regional health facilities in the Mpumalanga Province.

“We are proud to be part of a project of this magnitude as it enables us to showcase our versatility and ability to deliver products that meet high specifications for such high-profile projects,” says Kruger.

Opportunity abounds

While the Mapulaneng Hospital remains the anchor

Afrimat has been supplying the Mapulaneng Hospital project since September 2021.

project at the moment, Kruger tells Quarrying Africa that the plant is also servicing other public and commercial building projects in the area.

“We have also seen some demand from the commercial building market, but on a small scale.

There is opportunity to further grow the market for readymix concrete in the area, especially in the residential housing market where people still mix their own concrete on site, which in many instances lacks the consistency and quality required to ensure the integrity of structures,” says Kruger.

Commenting on the significance of Afrimat’s readymix plant, Kruger says: “Through our involvement in the project, we are contributing to the local economy. For example, we rent property from a local businessperson, who also supplies us with sand. Together with our existing quarry, we have employed people from local communities, thus contributing to the local economy in a positive way.” a

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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LOAD & HAUL A 76 t SY750H excavator loading a 100 t SRT95D rigid dump truck in the pit.

COST-EFFECTIVE YELLOW METAL RENTAL FOR MINING CONTRACTORS Amid the current uncertainty, influenced by the COVID-19 pandemic and various other factors outside the control of the industry, SANY Southern Africa has established a rental division, offering flexible and costeffective yellow metal equipment solutions to help opencast mining contractors navigate the tough operating conditions, writes Munesu Shoko.

20

I

n an environment where mining contracts are few and far between, and that those that come to market have become shorter, SANY Southern Africa’s equipment rental facility provides contract miners with a comprehensive range of yellow metal solutions that speak to their needs.

Established in 2021, amid the COVID-19 pandemic, the rental arm of SANY Southern Africa’s business is aimed at helping customers deal with increased uncertainty, explains Samuel Zhang, GM of Southern Africa.

SANY Rental is focused on open-pit mining, largely targeting mining contractors. On the loading front, SANY Rental offers the SY365H (36 t), SY500H (50 t), SY750H (76 t) excavators and the SYL956H (5 t) wheel loader.

This is complemented by the SRT55D (60 t) and SRT95D (100 t) rigid dump trucks, as well as a range of rollers and graders to keep haul roads in top condition. The rental fleet is set for expansion this year with the introduction of the 100 t SY980H

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

LOAD & HAUL 2021

100 t

The Rental division was established in 2021.

SANY will this year introduce the 100 t SY980H excavator to its rental fleet.

KEY POINTS Established in 2021 amid the COVID-19 pandemic, SANY Rental is aimed at helping customers deal with increased uncertainty On the loading front, SANY Rental offers the SY365H (36 t), SY500H (50 t), SY750H (76 t) excavators and the SYL956H (5 t) wheel loader This is complemented by the SRT55D (60 t) and SRT95D (100 t) rigid dump trucks, as well as a range of rollers and graders

All SANY machines in the rental fleet are brand new, so customers can have peace of mind knowing that they are guaranteed high machine uptime and efficient production.

smooth and precise control of movement. Since the introduction of the division late last year, our rental fleet has already clocked more than 6 000 hours, offering non-stop production to customers,” says Zhang.

SANY will this year expand its rental fleet with the new 100 t SY980H excavator, as well as a range of articulated haulers and wide body trucks

Why rental?

6 000 hours

SANY Rental machines have clocked more than 6 000 hours since last year

excavator, articulated dump trucks and wide body dump trucks, Zhang tells Quarrying Africa.

The SANY Rental fleet is currently deployed across commodities, including coal, granite and chrome. The machines have thus far proven their mettle. Their efficient operation in unforgiving applications such as chrome mining are testimony to their ability to match up to taxing operating conditions.

“Our rental machines enable customers hassle-free operation, thanks to their great stability, productivity and a strong backup regime. We have received positive feedback thus far, with operators enjoying working with SANY machines because of their power, high efficiency, comfort,

Commenting on why contract miners should consider the rental route, Zhang says, firstly, it gives them the opportunity to test the quality and service of the machines to avoid bad procurement choices when it’s buying time.

At a time when the market is enduring a seemingly tough cycle, especially in the aggregates sector, buying equipment for some cash-strapped contractors might be out of the question. However, when the market turns, companies may probably consider revving up their procurement engines again. Running a piece of equipment on rental gives the company a good testing platform, thus informing sound procurement choices when it’s buying time.

Given the tough financial situation, rental helps contract miners minimise their capital outlay and reduce the risk of an uncertain market. Traditionally, contractors working in the aggregates sector have generally preferred outright purchase and ownership of their equipment, which is still largely the case today. Owning equipment may be part of a company’s culture or simply a financial preference.

Additionally, some contract miners opt to own their equipment because it provides physical assets and a sense of control over the assets.

However, in recent years the status quo has changed significantly as varying underlying forces – including the size and duration of projects and the general tough economic

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

21

LOAD & HAUL

A 76 t SY750H rental excavator destined for a mining site.

SANY rental machines enable customers hassle-free operation, thanks to their great stability, productivity and a strong backup regime.

conditions – have had far-reaching effects on mining contractors’ businesses. This has cultivated a growing rental culture as companies continue to investigate smart ways of executing their mining contracts.

While there is no right or wrong in either buying or renting, Zhang says rental gives contract miners access to the equipment they need with minimal upfront costs and credit constraints associated with outright purchasing. Renting also reduces the need for a down payment and allows mining contractors to redirect the little cash they have to other areas of the business, especially when times are this tough.

Zhang adds that rental also makes sense for most emerging mining contractors. Buying new equipment comes at a huge upfront cost, which most start-ups can’t afford. Given the growing local procurement strategy in mining, where local mining contractors are given preference as part of mining and quarrying companies’ enterprise development efforts, rental also makes sense for these young companies.

100 t SANY will this year introduce its 100 t SY980H excavator to the rental fleet

22

More gains

Given that SANY’s rental fleet is serviced and maintained by the OEM, contract miners can avoid challenges associated with servicing own equipment, keeping parts and employing a dedicated service team on site. Full-service rental from SANY, says Zhang, is of great benefit to mining contractors who don’t have their own mechanics and workshops.

“Our OEM service teams are professional and know the product very well. Customers can, therefore, focus on their core business, which is to mine, and leave the servicing and maintaining of equipment to us,” says Zhang.

Efficient production is the goal for every company. All SANY rental machines are relatively new, thus maximising efficiency, productivity and equipment availability. “All our machines in the rental fleet are brand new, so customers can have peace of mind knowing that they are guaranteed high machine uptime and efficient production. Operators are also at their productive best as they enjoy working with new models,” concludes Zhang. a

RENTAL Rental makes sense for emerging mining contractors

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

2021 SANY's Rental division was established in 2021

LOAD & HAUL Rokbak represents the continuation of the company’s strong hauling heritage with a future-focused vision.

EARLY ROKBAK ENDORSEMENT Following the 'exciting' rebrand late last year, the response to the Rokbak brand has been extremely positive, with the company reporting a strong order book this year. Speaking to Quarrying Africa, sales director Guy Wilson says Africa holds enormous potential for Rokbak and plans are underway to expand the brand’s footprint on the continent, writes Munesu Shoko.

I

n late 2021, articulated hauler specialist Terex Trucks rebranded as Rokbak. At the time of the launch, the company revealed that the Rokbak name represented an exciting new future and reflected the significant advances the organisation has made in recent years as well as its new strategic priorities.

A few months later, the response to the Rokbak launch has been extremely positive thus far. “It was the culmination of several years’ hard work and what makes it so significant is that Rokbak is the first new

24

brand ever to be launched by Volvo Group,” says Guy Wilson, sales director, Rokbak.

“Anecdotally, customers have said they like the name and the look of the machines.

They feel the branding is simple, powerful and perfectly embodies what we do, which is producing rock-solid haulers and always having our customers’ backs,” he adds.

And crucially, he says, the company has a very strong order book for this year, which signifies customers’ belief in the Rokbak team and products.

“Customers choose Rokbak because our

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

LOAD & HAUL 2021

Following the rebrand in 2021, the response to the Rokbak brand has been extremely positive.

2040

As part of the plan to reach net zero at its factory in Scotland by 2040, Rokbak has already switched to renewable energy sources.

KEY POINTS Following the rebrand late last year, the response to the Rokbak launch has been extremely positive thus far The company has a very strong order book for this year, which signifies customers’ belief in the Rokbak team and products Africa holds enormous potential for Rokbak, with its haulers ideally suited to the many mining and quarrying projects on the continent Rokbak is currently expanding its dealer network and is in the process of signing with some new dealer partners in Africa

people are equally as reliable as our machines.

We are an approachable and dedicated partner that cares about our customers’ businesses. They can rely on us to have their back no matter what – from product availability to finance solutions, servicing and parts. Through our trusted network of dealers, customers can count on high-quality, responsive service and reliable parts availability wherever they are in the world,” stresses Wilson.

African plans

Commenting on the strategy for Africa, Wilson says the continent holds enormous potential for

“

Customers choose Rokbak because our people are equally as reliable as our machines.

We are an approachable and dedicated partner that cares about our customers’ businesses. They can rely on us to have their back no matter what – from product availability to finance solutions, servicing and parts. Through our trusted network of dealers, customers can count on high-quality, responsive service and reliable parts availability wherever they are in the world.

Guy Wilson, sales director, Rokbak.

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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LOAD & HAUL simplify fleet management, as well as automation through operational functions that enhance productivity, while ensuring high levels of machine protection.

Built around the customer

The 38-tonne payload RA40 from Rokbak.

RA30 The RA30's 8-speed transmission offers extended fluid maintenance intervals and reduced fuel consumption

Haul Track As many customers demand higher levels of connectivity and automated functionalities, Rokbak has introduced a telematics system, Haul Track, to simplify fleet management

26

Rokbak. “Our haulers are ideally suited to the many mining and quarrying projects in Africa, where they can contribute to high tonne per hour production and a low cost per tonne.

We are currently expanding our dealer network and are in the process of signing with some new dealer partners, so watch this space,” he says.

With the first Rokbak units now being shipped internationally, Wilson could not however be drawn to comment specifically on when the first units will arrive in Africa. “I am really looking forward to seeing them on some African projects where they can make a big difference to customers’ productivity, uptime and total cost of ownership,” he says.

Major improvements

Since becoming part of the Volvo Group, the company has made significant investments in its people, processes and products. On the product front, the company has introduced several new technologies with the aim of delivering new benchmarks in power, performance and reliability.

These include the driveline and hydraulic control systems that extend oil maintenance intervals, a transmission retardation system, as well as exhaust brakes and oilcooled multi-disc brakes to support operator safety and wellbeing.

As many customers demand higher levels of connectivity and further automated functionalities, says Wilson, Rokbak has introduced a telematics system, Haul Track, to

Given the importance of the ‘voice of the customer’ in today’s innovations, Wilson says the new Rokbak brand has been built around its customers.

In preparation for the launch, the company spent a lot of time talking to customers to find out what they needed, wanted and expected from the brand and products, both now and in the future so it could deliver on those needs.

“Rokbak customers are shrewd, business-focused people who run the toughest worksites around the world and their profitability depends on us,” he says. “Hence, they want durable, easy to operate and easy to maintain machines where every feature contributes to an overall low total cost of ownership and operation – all backed by reliable aftermarket support. Going forward, customers can expect Rokbak to continue listening, learning and improving to deliver the industry’s most robust and reliable haulers with high uptime and high productivity.”

Additionally, the company is placing greater emphasis on environmental care, given its importance to the world and its customers too. “As a member of Volvo Group, we are on a collective mission to create efficient and sustainable transport solutions so our world and society can prosper.

Individually, as Rokbak, we are taking our own steps to reduce the environmental impact of our products and operations,” he says.

As part of the plan to reach net zero at its factory in Scotland by 2040, Rokbak has already switched to renewable energy sources, is replacing dieselpowered forklift trucks to electric ones and is converting its gas heating and cooling to electric systems. The site is now practically landfill free and the company is actively working with suppliers to reduce the amount of materials consumed in the first place. a

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

LOAD & HAUL A Kobelco SK850XDLC-10 excavator loading a Bell B50E articulated dump truck.

GETTING THE BEST OUT OF YOUR LOAD & HAUL FLEET Equipment selection problems in surface mining involve choosing a fleet of trucks and loading tools that have the capacity to move the material specified within a stipulated period. In a one-on-one with Quarrying Africa, Nick Kyriacos, GM: Central Region for Bell Equipment Sales South Africa, unpacks some of the key factors that affect the selection of a load & haul fleet. By Munesu Shoko.

T

he productivity of any surface mine hinges on the efficiency of its load and haul system.

Yet, this function represents a significant component of the total operating cost. Consequently, the incentive to reduce cost in this area remains high.

The truck and excavator combination remains the most common materials handling solution in surface mining operations such as quarries in southern Africa. Commenting on the importance of truck per shovel match factor, Kyriacos says the starting point is to always look at the production required per day or per month, and then determine the production required per hour to meet the

28

daily or monthly target. From this, fleet managers can ensure that they have an excavator with the right capacity to load the truck at a rate that allows them to deliver on their targeted production rates.

Typically, he says, excavators are slightly more efficient than wheel loaders, and four to six passes per truck remains the industry benchmark, although it is still acceptable to load a truck with up to seven passes.

“The loading cycle can be divided into two key areas. The first is the time that it takes for the truck to get into position to be loaded together with the time taken by the excavator to fill the bin. The second consideration is the amount of time that it takes for the truck to leave

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

LOAD & HAUL 6x6

The Bell B25E 6x6 and B30E 6x6 ADTs matched with either the 40 t Kobelco SK380XDLC-10 or 50 t SK520XDLC excavators are Bell’s most common combinations in the quarrying sector due to their overall productivity and value proposition.

4x4

The B30E 4x4 is gaining popularity in quarries where underfoot conditions permit. Key benefits are the tight turning circle and reduced scuffing for increased tyre life and reduced haul road maintenance.

KEY POINTS The truck and excavator combination remains the most common materials handling solution in surface mining operations such as quarries The industry benchmark is five passes per truck, although seven passes ate still acceptable The loading cycle can be divided into two key areas. The first is the time that it takes for the truck to get into position to be loaded together with the time taken by the excavator to fill the bin The second consideration is the amount of time that it takes for the truck to leave the loading area, travel to the dump site, dump its load and return to the loading tool

“

two-and-a-half minutes for a truck to get into position and be loaded, and then 10 minutes more to complete the haulage cycle and be back and ready to be loaded, it means there is opportunity to load four more trucks in that period. Five trucks in a cycle would be the most efficient for that operation to achieve the required productivity.”

Kyriacos says it is therefore important to make sure that the loading tool can achieve the loading rate required. Additionally, depending on the time it takes for the truck to complete its cycle, production managers would want to ensure that the loading tool is being used continuously, to ensure that run of mine material is moved at the required rate.

The loading cycle can be divided into two key areas.

The first is the time that it takes for the truck to get into position to be loaded together with the time taken by the excavator to fill the bin. The second consideration is the amount of time that it takes for the truck to leave the loading area, travel to the dump site, dump its load and return to the loading tool.

Choosing the fleet

Nick Kyriacos, GM: Central Region for Bell Equipment Sales South Africa

the loading area, travel to the dump site, dump its load and return to the loading tool,” explains Kyriacos.

“The truck’s cycle time presents opportunity to load other trucks. For example, if it takes

Commenting on the key factors to be considered when choosing a load and haul fleet, Kyriacos says the key is always cost per tonne. “You need to get a fleet that gives you the lowest cost per tonne. The main contributors to this are product durability, service and maintenance costs, fuel economy and productivity. Productivity needs to be factored in because it doesn’t help to have machines that run cheaper per hour rates, but don’t necessarily translate into a cheaper per tonne operation. In the same vein as durability and quality should be a good residual value of the product at the end of the day, which is an

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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LOAD & HAUL bucket and bin capacities based on the material’s specific gravity or density and choosing the right ground engaging tools – bucket tips, bin liners and wear packages.

“On the Kobelco side, Bell Equipment offers heavy-duty general-purpose buckets and heavy-duty rock buckets suited to a wide variety of materials. This allows us to cater for various needs on different sites,” he says.

Efficiency in focus

important consideration when making purchasing decisions,” he says.

Service costs, he adds, are a black and white comparison between A 50 t Kobelco products and it is a consistent cost SK520XDLC that is always there. Fleet owners excavator loading a Bell must service their machines – that B50E articulated cannot be reiterated enough. hauler.

Durability talks to reduced repair and maintenance costs, because the more durable the machine is, the less money fleet owners will spend on repairs and maintenance.

Another factor critical to durability is the cost of downtime, adds Kyriacos, because a primary loading tool can cost you all your production – when it breaks down your hauling tools also have to stand. Even with just one truck standing, an operation still loses a substantial portion of its production. The cost of downtime can be damaging; thus, operations managers need to make sure they have durable load and haul kit on site.

“Fuel economy is application specific, but it is probably the biggest cost in terms of cost per tonne.

5% Both Bell and Kobelco have huge fuel effiBell Equipment’s three-point ciency focus without weighing system provides bestin-class accuracy of within 5% compromising on productivity,” he says.

Other specific application factors that affect the overall efficiency of the excavator and truck combination include correct

30

Having a mismatched excavator can lead to bottlenecks at the loading and/or discharge points, thus negatively impacting efficiency.

Matching the load capacity of the machines to the material they are handling also adds to efficiency.

“If loading a light material, make sure you have a large bin and a large bucket to maximise capacity. Being able to access and use all areas of the bin when loading is another consideration. It’s also important to bear in mind that using a half bucket load to reach a truck’s full capacity uses almost the same fuel as a full bucket load,” explains Kyriacos.

To ensure maximum fill factor, Bell ADTs are fitted with loading lights that help the excavator operator to always reach maximum bin capacity given that underloading is inefficient for an operation and overloading can be detrimental to the truck.

The lights shine amber to indicate that loading has started and switch to a green flashing light once 75% capacity has been reached. A solid green light indicates 100% bin capacity, and a red light shows overloading. The ADT operator can also monitor the loading operation from the central display unit on the truck’s dashboard. Moreover, the Bell threepoint weighing system provides best-in-class accuracy of within 5%.

In addition, the design of the loading area, how the trucks need to position themselves, the space that they have and how long it takes them to get into position, all affect the efficiency of the operation. Trucks that need to reverse some distance to reach the loading area are far less efficient than trucks that can drive in

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

LOAD & HAUL

The B30E 4x4 is gaining popularity in quarring applications.

parallel to the loading area.

“Operations managers would, as far as possible, want to ensure that the truck arrives just in time to be loaded. It is important to avoid standing time throughout the cycle because standing translates into unnecessary fuel burn. This is one area where we see a big advantage of autonomous control in the future because autonomy can pick up where the bottlenecks are and allow the truck – based on the programmed knowledge of the haul profile – to take advantage of downhills and optimal gear selection going uphill to get to the tipping site as the other truck departs and avoid any congestion,” says Kyriacos.

Wide range

According to Kyriacos, Bell Equipment offers the widest range of ADTs on the market, with a 6x6 offering ranging from 18 t to 50 t, complemented by a niche range of 4x4 articulated trucks in the 30 t, 45 t and 60 t classes. A key factor to consider when choosing trucks is whether a 6x6 ADT is necessary or if an articulated 4x4 truck would be suitable for the underfoot conditions on site. In some operations, the 4x4 trucks outperform the 6x6 trucks in terms of tyre wear due to the significantly reduced scuffing while offering the same productivity.

All Bell Equipment ADTs are fitted standard with the company’s proprietary satellite fleet management software, Fleetm@tic®

which allows operations managers to track productivity in detail per operator, per cycle, per shift. It also gives a quick glimpse of bottlenecks by highlighting all unladen and laden idling times.

“If laden idle times are more than 5%, this points to either congestion at the tipping area or mismatched equipment. It could also mean that there is congestion at the loading area – either there are too many trucks in the cycle, or the excavator is too small,” says Kyriacos.

Prominent combination

Commenting on Bell Equipment’s most popular excavator/truck combination in the quarrying sector, Kyriacos says the Bell B25E 6x6 and B30E 6x6 ADTs matched with either the Kobelco SK380XDLC-10 or SK520XDLC excavators are the company’s most common combinations due to their overall productivity and value proposition.

The Kobelco SK380XDLC-10 is a 40 t machine with rated power of 191 kW and a 2,1 m³ bucket, while the Kobelco is a SK520XDLC is a 50 t excavator with rated power of 257 kW and a 3,4 m³ bucket.

“The B30E 4x4 is gaining popularity in quarries where underfoot conditions permit. Some of the key benefits of this model are the tighter turning circle and reduced scuffing for increased tyre life and reduced haul road maintenance,” concludes Kyriacos. a

5% If laden idle times are more than 5%, this points to either congestion at the tipping area or mismatched equipment

75% Bell ADTs' loading lights shine amber to indicate that loading has started and switch to a green flashing light once 75% capacity has been reached

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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LOAD & HAUL With the new Volvo EC550E, Tier 3 markets can brace themselves for up to 35% more productivity and 22% more fuel efficiency.

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

F

ollowing the expansion of the distribution of the Volvo EC550E crawler excavator internationally, quarry operators and surface miners in Tier 3 markets can brace themselves for up to 35% more productivity and 22% more fuel efficiency, combined with enhanced operator comfort and uptime.

Now available for Africa and the Middle East from January 31, 2022, the first units of the Volvo EC550E crawler are expected to ship internationally in April this year. Olle Watz, product manager – Excavators, Volvo Construction Equipment Region International, is optimistic about a positive response from African customers.

The EC550E, he says, is well suited to the mining and quarrying projects in Africa, delivering on customers’ priorities for high reliability, high production and high efficiency for both cost and environmental reasons.

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| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

LOAD & HAUL

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

KEY POINTS

Punching above its weight

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

Traditionally, the excavator’s production has a direct link to its operating weight. With the EC550E, Watz tells Quarrying Africa, Volvo CE managed to break the norm by introducing the Independent Metering Valve Technology (IMVT) hydraulic setup, in conjunction with a totally new engine trim on the D13 engine block and electrohydraulic command for the joysticks. As a result, the machine punches well above its weight, offering production more in line with a bigger class machine, despite the decals stating 550.

“We were able to accommodate a larger bucket (2,4 – 4,2 m³ capacity) by increasing the size and

Armed with high levels of power and productivity, the EC550E is suited for mining, mass excavation and large infrastructure projects The machine breaks the industry norm of production having a direct link to operating weight With the ability to fill a 35 - 40 tonne hauler or highway truck in just 4 to 6 buckets, the result is optimum pass-matching and high-levels of production at a low cost per tonne

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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LOAD & HAUL matched to the capabilities of the engine. So, you can also get high flow/fast cycle times at the same time as when operating at a high torque,” explains Watz.

35% more productivity

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

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

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weight of the undercarriage, which gives greater stability. The more stability you have, the bigger the bucket you can put on – it is the law of physics. By load distribution surface/ footprint of the undercarriage, the EC550EL has almost an identical size to some competitor 70-t machines,” says Watz.

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

The 2 071 Nm (320 kW) engine, with rated power @1 600 rpm, is also well in line with certain competitor 70 t machines. This, coupled with the large displacement pumps (832 ℓ per minute), results in faster cycle times.

For most competitor offerings in the bigger class, says Watz, one needs to rev the engine at 1 800 rpm to reach the maximum power. Low revs are generally good, so the EC550E has the upper hand here.

“Experienced people tend to be relatively more interested in torque than power when it comes to large excavators. Torque is more about force, and power is more about speed – and typically excavator force can be more of a priority than speed, subject to application. However, you cannot see torque in isolation. The EC550 is fitted with large displacement pumps,

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

The EC550E can fill a Volvo A35G or A40G articulated hauler with four to six buckets, which is considered a well-balanced match in the industry.

It also means that Volvo now offers two perfect match excavators for A35G or A40G haulers in Africa – the EC750D and the EC550E. While Volvo’s existing EC480D model is aimed at customers looking for an efficient and reliable 50 t class excavator, the EC550E offers 35% greater production than the EC480D in typical dig and dump applications, meaning it is closer to the EC750D and so challenges the 60 – 65 t excavator class.

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

The EC550E is available with a range of optimum-sized heavy-duty rock buckets designed for use in abrasive conditions, with the Volvo Tooth System making light work of teeth replacements thanks to its place, push and click functionality.

Customers can further take control of their productivity with OnBoard Weighing, helping to ensure the optimum amount of material is loaded. The optional system provides real-time information to eliminate under and overloading of trucks and records total tonnage for complete production management.

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

LOAD & HAUL Efficiency to the fore

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

“The IMVT is probably the biggest news as it is an industry first in this excavator size class. It involves a new concept main control valve (MCV).

Instead of a conventional spooltype MCV, we have built an MCV with dedicated valves – one each for feed and return for each actuator.

This means that the pumps pump exactly according to demand at any given time, subject to the precise and exact requirement of oil for any specific actuator,” says Watz.

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

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

Boosting uptime

With a host of uptime-boosting machine features combined with the support of the Volvo dealer,

customers can count on the EC550E to deliver maximum machine availability. With the optional delayed engine shutdown customers can keep their turbocharger working in top condition for longer.

To avoid overheating, the intelligent function turns the machine off when the turbo charger has cooled down to the appropriate temperature. The EC550E can also be fitted with a high-performance fuel filtration system which delivers 99,7% water separation efficiency consistently over the full service life of the filter.

CareTrack, the Volvo telematics system, also helps customers to maximise machine uptime and reduce repair costs. Customers can choose to keep track of their machines themselves, or let Volvo take care of it with ActiveCare. The Volvo Uptime Centre provides 24/7 machine monitoring, supplying weekly reports and notifying customers should preventive maintenance action be required.

When it is maintenance time, grouped filters accessible from the ground level make servicing quick and easy, while the three-point right-hand access ensures the upper structure can be accessed with confidence when needed. Industry renowned features such as bolted anti-slip plates, high visibility guardrails and handrails, as well as large walkways further ensure the highest levels of convenience when servicing the machine. a

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

24/7 The Volvo Uptime Centre provides 24/7 machine monitoring, supplying weekly reports and notifying customers should preventive maintenance action be required.

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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CONTRACT CRUSHING Pilot modular equipment requires no civils, is easily configurable and easy to install.

LOOKING BEYOND PRICE When it comes to procurement of their mission-critical equipment, crushing contractors should always look at the bigger picture. While the spotlight is largely cast on the upfront capital cost, Francois Marais, sales & marketing director at Pilot Crushtec, tells Quarrying Africa that procurement decisions should look beyond the price and consider a range of other critical issues such as aftermarket support and uptime. By Munesu Shoko.

I

n many instances, price remains a key factor in many procurement decisions.

For crushing contractors, whose success hinges on uptime, there is a need to take a comprehensive approach to buying decisions than just focusing on the capital cost. This is the view of Francois Marais, sales & marketing director at Pilot Crushtec, who believes that ‘cheaper’ offerings often turn out to be costly down the line, proving to be detrimental to contractors’ success.

Marais believes that there is often no cohesion in procurement decisions. For example, the decision criterion followed by the head of procurement is often different to that of a site manager. “The head of procurement is more concerned about reducing capital

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expenditure – it’s their job function. A site manager, however, is more driven by uptime, aftermarket support, spares availability and delivering on contractual obligations,” he says.

Marais says that in a tough economy, the final decision often favours the financial criteria, without necessarily taking a long-term view of the impact of the procurement decision on production and the actual results on site. He says while capital is always a question, crushing contractors should always have their eyes on the overall cost of production, rather than the upfront cost of equipment.

One of the key considerations, he says, should be equipment reliability. “If the equipment is going to break all the time, the contractor is probably not going to be able to deliver on

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

CONTRACT CRUSHING 50%

Given its significance in ensuring that contractors execute their jobs timeously at a lower cost of ownership, reliable aftermarket support should constitute about 50% of the decision criteria.

12 000 m²

Pilot Crushtec owns a 12 000 m² parts facility at its Jet Park head office, where critical spares and wear parts take most of the space.

“

The reality is that crushing equipment is exposed to tough operating conditions. There is bound to be challenges to keep the equipment running optimally all the time. If aftermarket from the supplier is not up to scratch, then there are going to be incessant downtime issues.

Francois Marais, sales & marketing director at Pilot Crushtec

Aftermarket

KEY POINTS In many instances, price remains a key factor in many procurement decisions Given that their success hinges on uptime, crushing contractors must take a comprehensive approach to buying decisions rather than just focusing on the capital cost Given its significance in ensuring that contractors execute their jobs timeously at a lower cost of ownership, reliable aftermarket support should constitute about 50% of the decision criteria To be able to execute a proper aftermarket strategy, a fundamental pre-requisite is to have the infrastructure that allows the supplier to respond to any service needs timeously

their contract. It also impacts on their reputation, which makes it difficult to be considered for future jobs,” says Marais, adding that crushing African rock is no easy feat and crushing contractors should therefore consider proven and tough gear to get the job done.

The importance of aftermarket in purchasing decisions of capital equipment cannot be stressed enough, says Marais. Given its significance in ensuring that contractors execute their jobs timeously at a lower cost of ownership, Marais believes that reliable aftermarket support should constitute about 50% of the decision criteria.

“The reality is that crushing equipment is exposed to tough operating conditions. There is bound to be challenges to keep the equipment running optimally all the time. If aftermarket from the supplier is not up to scratch, then there are going to be incessant downtime issues,” he says.

“While our premium Metso Outotec brand is no stranger to the market and has proven itself, we believe that every piece of equipment is as good as its support. That is why we are not only concerned about delivering a piece of capital equipment, but supporting it well beyond the 20 000-hour mark in the field,” he says.

To be able to execute a proper aftermarket strategy, a fundamental pre-requisite is to have the infrastructure that allows the supplier to respond to any service needs timeously. “One of our key strengths is the high volume of critical spares at our Jet Park facility, where we carry in excess of R230-million worth of critical spares

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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CONTRACT CRUSHING

The Lokotrack LT120E is a hybrid mobile jaw crusher for primary crushing.

Pilot Crushtec SupportLink division provides equipped, qualified and experienced personnel to professionally service and repair all products.

R230million Pilot Crushtec carries more than R230-million worth of critical spares and wear parts at any given time

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and wear parts at any given time.”

Pilot Crushtec owns a 12 000 m² parts facility at its Jet Park head office, where critical spares and wear parts take most of the space. “We believe we are probably the biggest spare parts holding distributor for Metso Outotec around the world.

Although many of these critical and wear parts do not necessarily turn quickly, we still believe that carrying them is in the best interests of our customers.”

Product warranty

Contrary to the belief that warranties are “not worth the paper they are written on”, Marais believes that a warranty is a valuable component to any capital equipment purchase, especially mission-critical and big-ticket purchases such as crushing equipment.

While different crushing products from different manufacturers may have different price tags, the length of warranties has traditionally been the same for years, pegged at 1-year/2 000 hours. Based on Supplier reputation the understanding that The reputation of the the longer and more supplier should also be a comprehensive the critical factor in making warranty is, the that buying decision. lower the overall 5 years/ Marais says crushing cost of ownership 10 000 hours contractors should for customers, be able to rely Pilot Crushtec Pilot Crushtec and Metso rolled on the supplier and Metso rolled out an industry-first, to ensure their out an industrystandard 5-year/10 000 hours warranty on all Metso own business first, standard crushers and screens success. “Uptime 5-year/10 000 in 2019 is the difference hours warranty on between success and all Metso crushers failure for contractors, so and screens in 2019. it’s important to buy from a “It is now well-documented that we carry a reputable supplier,” he says.

5-year/10 000 hours Extended The 2017 and 2019 Metso awards, Protection Services warranty. adds Marais, are testimony to Pilot This is in the best interests of the Crushtec’s ability to look after its customers. At Metso’s Distributor Days customer – a longer warranty in 2017, Pilot Crushtec was named gives customers extra coverage the Best New Services Distributor, for their equipment, along with a barely 16 months after taking over as little more peace of mind. It also the Metso dealer in southern Africa. says a lot about our confidence in The 2017 accolade was followed by our offering. As a supplier it also the Best Sales Award in 2019, ranking means that we want to be there for Pilot Crushtec among Metso’s global our customers for the long haul,” top four distributors. concludes Marais. a | January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

LOAD WEIGHING SYSTEMS

OPTIMISING TRUCK LOADING Optimising truck loading helps to minimise fuel, maintenance and labour costs per tonne of material moved. It also reduces the impact on the environment. A quarry loading 1 600 road trucks per week, Glen Webster, sales director at Loadtech tells Quarrying Africa, could save 800 hours of staff time, 800 hours of equipment time and 7 800 ℓ of diesel each year by using weighing systems onboard its wheel loaders.

O

nboard weighing systems are often used to help wheel loader operators load road trucks to their rated capacity first time. This improves efficiency by allowing operations managers to reduce the number of trucks that must tip off excess material or be topped up; reduce the average time a truck spends on-site; reduce queues at the outgoing weighbridge; reduce the number of trucks that leave the site underweight, thus minimising the number of truck trips needed to move a certain amount of product; and reduce overload fines.

“Informal estimates suggest that when a wheel loader operator loads trucks by eye, roughly 10% of all trucks will be significantly overor under-loaded and need to be adjusted.

This compares to less than 2% of all trucks in a case study of a quarry using Loadrite weighing

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Annual savings achieved by using a Loadrite weighing system to load road trucks.

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

On-board weighing systems are designed to help operators load trucks to their rated capacity the first time.

LOAD WEIGHING SYSTEMS

KEY POINTS Onboard weighing systems are often used to help wheel loader operators load road trucks to their rated capacity first time

This improves efficiency by allowing operations to reduce the number of trucks that must tip off excess material or be topped up

Trucks that are overloaded typically tip off excess material in waste piles near the weighbridge

Trucks that are under-loaded are typically topped up near the weighbridge by a wheel loader that drives down from one of the main stockpiles

10%

1 600

Informal estimates suggest that when a wheel loader operator loads trucks by eye, about 10% of all trucks will be significantly over-or under-loaded and need to be adjusted.

A quarry loading 1 600 road trucks per week could save 800 hours of staff time, 800 hours of equipment time and 7 800 ℓ of diesel each year by using weighing systems onboard its wheel loaders.

systems onboard its Caterpillar 980-G and 980-H wheel loaders,” explains Webster.

typically topped up near the weighbridge by a wheel loader that drives down from one of the main stockpiles. For simplicity, the calculations do not include a return trip for the wheel loaders as they sometimes move onto other tasks near the weighbridge.

Huge gains

This site typically runs four wheel loaders at any one time and loads an average of 1 600 trucks per week. Without weighing systems on its wheel loaders, an estimated 8 320 trucks would need to be adjusted. This compares with 1 560 truck adjustments when Loadrite weighing systems are used.

By reducing the number of trucks that must be adjusted by 6 760, the quarry saves over 800 hours of staff time, 800 hours of equipment time and 7 800 ℓ of diesel each year. For each litre of diesel saved, the quarry also reduces its carbon emissions by 2,68 kg, leading to an annual reduction of 21 t of CO2.

Trucks that are overloaded typically tip off excess material in waste piles near the weighbridge. Trucks that are under-loaded are

The calculations

The calculations also assume that no unnecessary truck trips are made from quarry to job site. In practice, however, it is likely that wheel loader operators will try to under-load trucks slightly when loading by eye. This is because an overloaded truck can be fined, whereas an under-loaded truck cannot.

“As such, the results are likely to underestimate fuel and time savings. Take a fleet of trucks that can each carry 26 t as an example. If each truck was under-loaded by an average of 1 t, it would take 26 trips to move the same amount of material that could be moved in 25 trips if the trucks were correctly loaded,” concludes Webster. a

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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CRUSHING & SCREENING The McCloskey R155 scalper working at one of CrushIt Green’s sites in Gauteng.

SCALPING BEYOND EXPECTATIONS When Crush-It Green (CIG) went into the market for a scalper early last year, its preferred supplier had just sold the last two scalping screens it had in stock at the time. Waiting for new stock was not an option as current supply chain disruptions meant that there was going to be a long lead time. Instead, partner Clint Rodwell tells Quarrying Africa, CIG ‘took a chance’ on a Kemach Equipment-supplied McCloskey R155 scalper, which to date has lived up to its billing, writes Munesu Shoko.

F

ounded in 2019 when the two partners took over an existing recycling and production facility that had been in operation since 2016, Crush-It Green has grown significantly in a short space of time. With environmental stewardship becoming an increasingly popular topic globally, recycling construction materials has become more important than ever, as the industry seeks to reduce its carbon footprint.

With its origins firmly rooted in recycling, CIG is one of the few South African companies that holds a Global GreenTag Certification, one of the world’s most trusted and widely recognised ecolabels. Although it is

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still involved in some notable concrete and rubble recycling projects, the company has in recent years ventured into crushing and screening of virgin material, given the slow nature of the recycling business in South Africa, due to the lack of legislation and incentives for companies to recycle.

CIG is currently working on a few sites in Gauteng, including Nigel, Soweto and Germiston, where it is screening gold-bearing dumps for a client and then crush the rock to make aggregate for the construction and building industry. Here, the company produces a range of product sizes, but G5, builder’s mix and crusher sand are the market drivers.

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

CRUSHING & SCREENING

March 2021

Crush-It Green took delivery of its first ever McCloskey machine, the R155 scalper, in March 2021.

The reason behind CIG’s decision to buy the McCloskey scalper was due to its versatility.

2 years/3 000 hours

The McCloskey machine comes with a standard 2 years/ 3 000 hours warranty.

KEY POINTS A year ago, Crush-It Green took delivery of its first ever McCloskey machine, the R155 scalper

With an expanding project portfolio, the CIG is currently working on a few sites company went into the market for a new scalper in Gauteng, including Nigel, Soweto and early last year to bolster its existing fleet of five Germiston, where it is screening gold-bearing dumps for a client and then crush the rock machines – two cone crushers, a jaw, a scalper to make aggregate for the construction and and a screen. Having traditionally been loyal to building industry a certain premium brand for its crushing and screening equipment needs, CIG took delivery of CIG opted for the McCloskey scalper because its first ever McCloskey machine, the R155 scalper, of its versatility in March 2021.

“We have always run a certain brand, but our usual supplier didn’t have stock at the time, and Another crucial factor in CIG’s decision was the fact that McCloskey runs common components we wanted a scalper quite urgently. We were not such as engines and hydraulics keen on a second-hand unit and could not afford the long lead time due to the current supply es, we decided to take a chance and chain disruptions brought about the bought the McCloskey scalper. From COVID-19 pandemic,” says Rodwell. the onset, we were impressed by the At the time, Bradley Karolus, sales commitment from Kemach. We are specialist at Kemach Equipment, 4 years/ happy with the decision we made. whom Rodwell had dealt with 6 000 hours Previously we would not look at before at a different company, An extended warranty option any other brand, but in future we had just joined Kemach to drive of up to 4 years/ 6 000 hours is available. will also consider McCloskey for our sales for McCloskey following the crushing and screening equipment company’s appointment as the needs,” says Rodwell.

South African dealer in October 2020.

Versatility to the fore “Bradley assured us that the McCloskey R155 scalper was equally good, The reason behind CIG’s decision to buy a production-wise, and this has turned out to be scalper was due to its versatility. “We went into true. In fact, Kemach offered to trial the machine the market for a scalper because it’s a multi-purpose machine; it can be used as a scalper and a at our site for two weeks with no obligation for final screen,” explains Rodwell. us to buy. At the end of the day, we did not take According to Karolus, the McCloskey range is them up on the offer. With Bradley’s assuranc| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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CRUSHING & SCREENING points with ease. This ensures that the wheel loader, which burns the most fuel on site, is not riding too far to feed the machine.”

Parts and support

CIG took delivery of its first ever McCloskey machine, the R155 scalper, in March 2021.

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one of the most versatile offerings in this market. For example, the feeding arrangement of the machines can swing between an apron and a belt feeder, whereas most other OEM offerings offer either of the two.

“We have both options – apron and belt feeder – to suit different customer needs. We understand that customers require different feeder arrangements for different applications. We have taken a deliberate decision to offer unparalleled flexibility in many areas of our offering,” says Karolus.

The other feature which appealed to CIG is the interchangeable top deck of the scalper. “The machine’s top deck is much more versatile; it can be configured with grizzly, mesh or punch plate. McCloskey is one of the very few manufacturers in the market offering such a versatile scalper,” says Rodwell. CIG initially ordered its McCloskey R155 scalper in a grizzly configuration, but later opted for a punch plate, which was more suited to the application.

The ability to change the machine’s conveyors to either side of the machine is another key feature that speaks to the machine’s versatility. “This is an important feature,” says Rodwell. “Being able to configure the fines and mid-size conveyors in either direction means that one can change their discharge

Another crucial factor in CIG’s decision was the fact that McCloskey runs common components such as engines and hydraulics. “One of the important things for us was the fact that the machine runs a Cat engine, which is a common motor in the market. If for whatever reason the dealer is not able to help with idlers or pumps, for example, we can easily access those parts elsewhere,” says Rodwell.

Karolus also makes special mention of parts commonality among the company’s different models as a key competitive edge for the McCloskey offering. For example, the McCloskey I44R's discharge pulley is interchangeable with the McCloskey R155 scalper’s feeder belt.

Every machine is as good as its service. A year after taking delivery of the machine, Rodwell says the service from Kemach has been good.

To better support the McCloskey brand, Kemach has put in place dedicated support structures. Parts availability, especially critical and fastmoving parts, has been a key factor in ensuring uptime for customers.

Additionally, the company’s strong branch footprint across all key regions of South Africa has ensured quick growth for the McCloskey brand under Kemach’s distributorship. Sales, support and service are delivered through Kemach’s extensive southern African footprint, including its national office based in Gauteng, and branches situated in 11 locations throughout South Africa.

The McCloskey machine comes with a standard 2 years/3 000 hours warranty. An extended warranty option of up 4 years/ 6 000 hours is available. Of importance to CIG, concludes Rodwell, was the fact that the McCloskey warranty is transferable to another owner on resale, something several other manufacturers do not offer. a

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

PROXIMITY DETECTION SYSTEMS

SHIFT IN ATTITUDE That proximity detection systems have traditionally been deemed a ‘grudge buy’ in the surface mining industry is no overstatement. However, Anton Lourens, CEO of leading PDS and CPS provider Booyco Electronics, tells Quarrying Africa that there is an apparent change in attitude, with surface miners working hard to comply well ahead of the compliance deadline. By Munesu Shoko.

Putting a PDS or CPS solution in place in a mining operation requires a proper risk assessment to be done.

W

ith legislation set to compel surface mining operations to install proximity detection systems (PDS) and collision prevention systems (CPS), Booyco Electronics believes that the industry has already gone down the PDS route well ahead of the regulator’s compliance deadline, which is expected to be announced soon on the back of increased fatalities at South African mines.

Having recorded 51 deaths in 2019, the lowest number of mine fatalities in the history of the South African mining industry, the sector witnessed a regression of 18% and 23% in 2020 and 2021, respectively, according to figures provided by the Department of Minerals and Energy (DMRE). Consequently, the regulator is expected to compel the mandatory use of PDS and CPS at surface mines as a matter of urgency.

“The Minerals Council South Africa has over the years been working closely with the industry, PDS suppliers and original equipment manufacturers (OEMs) to review the technology and make the

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necessary recommendations to the regulator. The industry should be commended for the apparent mindset shift towards PDS technology. Traditionally, it was viewed as a ‘grudge buy’, but that is no longer the case. Surface mining companies are busy making strides to comply, well ahead of the enforcement date of the legislation,” he says.

When Booyco Electronics was founded some 16 years ago, recalls Lourens, installation of PDS solutions was largely driven by corporate social responsibility – it was just the ‘right’ thing to do.

The industry eventually developed to a point where installations were all about complying with the legislation.

“Despite the lack of certainty around the enforcement of the legislation, there is a growing acceptance in the surface mining industry that the legislation is coming. As a result, lots of work is happening in the background to make sure that mining operations comply with the legislation well before the compliance deadline. I believe that there has been a change in attitude; the grudge purchase stance has been replaced by

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

PROXIMITY DETECTION SYSTEMS

For PDS and CPS systems to effectively reduce risk as they are designed to do, everyone must buy into the project.

“

KEY POINTS Booyco Electronics believes that the industry has already gone down the PDS route well ahead of the regulator’s compliance deadline Despite the lack of certainty around the enforcement of the legislation, there is a growing acceptance in the surface mining industry that the legislation is coming Surface miners have largely implemented Level 7 and 8 systems, with further tests being conducted on Level 9 systems To further optimise technology value for mines, Booyco Electronics has in recent years collaborated with various strategic technology partners

an understanding of the value proposition of this technology and overall solution,” says Lourens.

Significant headway

The industry has over the years made significant headway with regards to the testing of the technology. The Minerals Council, says Lourens, has worked closely with PDS suppliers to review the functional requirements of PDS specifica-

Despite the lack of certainty around the enforcement of the legislation, there is a growing acceptance in the surface mining industry that the legislation is coming.

As a result, lots of work is happening in the background to make sure that mining operations comply with the legislation well before the compliance deadline.

Anton Lourens, CEO of Booyco Electronics

tions. Several operations have done their risk assessments and, where significant risk exists, deployed the technology in mitigation of those significant risks.

Lourens has seen increased testing and implementation in the surface environment than ever before. Traditionally, he says, the underground environment has had a much higher compliance rate than surface mining.

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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PROXIMITY DETECTION SYSTEMS

A PDS or CPS solution is a potentially game-changing safety device that will improve workers’ wellbeing in their daily working environment.

ISO 21815-2 (2021) From an integration point of view, one of the recent key achievements was the industry’s adoption of the ISO 21815-2 (2021) standard, which deals specifically with how a PDS solution should integrate with OEM offerings

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“Surface miners have largely implemented Level 7 and 8 systems, with further tests being conducted on Level 9 systems. Of note is that the industry is accelerating its risk assessments, which are crucial in informing the level of risk on each site. In some surface mining environments, there are low risk vehicles that do not require fitments of PDS units. Therefore, it is crucial that every operation performs its own risk evaluation to identify its specific PDS needs,” he says.

In the quarrying industry, for example, risk evaluation done at industry level has identified that vehicles posing most risk are typically articulated dump trucks, front-end loaders and light-duty vehicles (bakkies). This has enabled the industry to approach PDS unit suppliers for quotes on units that can warn of possible collisions (level 7), identify and advise on corrective actions (level 8), or implement a ‘slow-down and stop’, a level 9 engineering control intervention.

Out of the enquiries that Booyco Electronics is getting, Lourens notes that there is limited assumed risk on people detection. “We see a big focus on vehicle-to-vehicle risk, with limited interest in the people protection aspect of PDS installations. We are not sure if the approach is informed by internal risk assessments or the fact that mines have put in place measures to separate people from machines.”

As part of their risk assessments, several operations have implement-

ed pedestrian walkways as a means of separating people from moving machinery. While Lourens acknowledges that PDS technology is no silver bullet to the quest for Zero Harm, he believes that as an engineering control, the technology has proven its mettle in mitigating risk at mines.

Although initial focus has been on Level 7 and 8, Lourens notes that there is significant uptake of Level 9 interventions at surface operations.

According to a survey conducted by the Minerals Council, he says, there are over 300 machines running Level 9 units in surface operations across South Africa.

“There are some sites that have implemented Level 9 successfully, while some are still conducting tests, with a view to adopting,” says Lourens.

Testing

Some three years ago, PDS suppliers had to undergo simulation testing at the University of Pretoria, as well as a trial run in a mining environment to demonstrate the capabilities of their solutions before submitting their technical files to the DMRE. The Minerals Council managed this process.

Lourens says the Minerals Council contracted the Vehicles Dynamic Group (VDG), part of the University of Pretoria, to develop a simulation model on how to evaluate PDS functionality. The simulation – developed at a lab scale level – was made for both surface and underground mining scenarios.

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

PROXIMITY DETECTION SYSTEMS

Level 7, 8 & 9 Surface miners have largely implemented Level 7 and 8 systems, with further tests being conducted on Level 9 systems

3 Some three years ago, PDS suppliers had to undergo simulation testing at the University of Pretoria, as well as a trial run in a mining environment to demonstrate the capabilities of their solutions before submitting their technical files to the DMRE

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to the ecosystem.

The first partnership was with Australian-based automation systems provider, Remote Control Technologies (RCT), which brings to the table a third-party interface that enables Booyco PDS and CPS systems to speak to OEM machines.

RCT has successfully integrated with multiple OEMs across the globe with Integration its remote and automation offerings.

From an integration point of view, Booyco Electronics has also partnered with technology systems inteone of the recent key achievements, says Lourens, was the grator, Ramjack Technology Solutions. industry’s adoption of the ISO Technological specialisation, says Lourens, now demands expertise, skill sets 21815-2 (2021) standard, which and hardware that extend far beyond deals specifically with how a PDS what single multinational companies solution should integrate with OEM can provide. This invariably leads to offerings. It allows for a common silos of expertise developing on mines interface between all PDS suppliers that require bridging. Booyco Elecand the different OEMs. tronics therefore works with Ramjack “The adoption of the interface Technology Solutions to help standard was a major coup mines to integrate their for the industry. One of CPS and PDS solutions the important things with other technolwe had to do before ogies effectively, we even got to the 300 in the interests of single machine greater safety and testing stage was According to a survey productivity. to make sure that conducted by the Minerals Council, there are over 300 Booyco we complied to machines running Level 9 Electronics has the standard, units in surface operations across South Africa also collaborated which allows our with another solution to interface systems integrator, with all the OEMs. It’s TecWise. TecWise’s encouraging to have in-depth knowledge of the standard adopted and underground and open pit approved to make sure that all mining allows the two companies industry players can work on a single to deliver cost-effective, relevant, as interface,” he adds. well as technologically advanced and Technology partnerships robust solutions in a safe manner.

From an internal technology The newest collaboration is with development perspective, Wenco International Mining Systems, Booyco Electronics is committed which is traditionally a fleet management systems provider. to continuous improvement.

“Wenco develops an integrated “While we have made some good suite of solutions to support the improvements, we are currently not digital transformation of the mining 100% where we want to be from industry. Fleet management, asset a functional perspective. There health, data analytics and other is, therefore, some dependency technologies join together in the spirit on third-party information for of open interoperability to raise mine us to perform the outstanding productivity and efficiency, lower functionalities,” says Lourens. routine costs and establish a safe and To further optimise technology smooth mining operation. We saw value for mines, Booyco Electronics it valuable to incorporate Wenco’s has in recent years collaborated with fleet management solutions with our various strategic technology partners.

PDS solutions to give the customer a Each of the partners brings a different level of expertise and experience turnkey solution,” concludes Lourens. a

“We ran multiple tests while continuously improving on performance until we got to a point where we were progressing to single and multiple machine tests on site. These single and multiple machine tests are ongoing at a couple of surface mines, and we have been pleased by the results thus far,” he says.

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

BLASTING Varistem plug before being installed.

THE IMPACT OF STEMMING IN BLAST OUTCOMES Blasting is an important part of the quarrying process. To achieve the best blast result, good stemming practices are necessary. During blasting, explains Eugene Preis, MD of ERG Industrial, stemming plays a key role in confining the explosives and making effective utilisation of blasting energy. By Munesu Shoko.

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here are various parameters that affect the performance of a blast, such as burden, spacing, type of explosive and stemming. Commenting on the significance of stemming, Preis tells Quarrying Africa that in blasting, energy follows the path of least resistance, and in most cases, that’s right up the blast hole. Good stemming thus creates more resistance at the top of the blast hole and directs the energy to where it’s needed – the rock mass.

“The knock-on effect of better energy containment is significant. On the health and safety side, there is a reduction in flyrock, noise and airblast.

From a productivity point of view, there is an improvement in fragmentation.

Good stemming is thus a small principle of creating better resistance in the blast hole which leads to a range of benefits,” explains Preis.

Stemming material

There are different types of stemming materials used in blasting, including crushed aggregate, drill chippings and clay, among others.

Because they produce aggregate, quarries have traditionally used crushed aggregate as stemming material. However, for most mines, it’s not economically feasible to use crushed aggregate, thus operations tend to use drill chippings or cuttings.

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| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

BLASTING 2018

In line with the requirements of Regulation 4.16(2) of the Mining Health and Safety Act’s Explosives Regulations of 2018, quarries need to acquire a licence to blast within 500 m of structures.

KEY POINTS During blasting, stemming plays a key role in confining the explosives and making effective utilisation of blasting energy A stemming plug is an optimisation tool that allows better confinement of energy for effective blast outcomes Using stemming plugs reduces the likelihood of stemming ejection and flyrock Due to their better energy containment properties, stemming plugs help improve fragmentation and reduce oversize material in blasts

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With mines and quarries fast realising the massive benefits offered by stemming plugs, ERG Industrial reports that the rate of adoption for its Varistem technology has increased tenfold in the past two years.

According to Preis, operations that use aggregate for stemming are leaders of the pack.

“Crushed aggregate has great interlocking properties because of the sizing of the stone. If you apply pressure to a column of aggregate, you get interlocking and that in turn creates a counter force against the pressure being exerted,” he says.

However, he adds, the downside of using aggregate alone is that because of the particle size, there is room for contamination of the upper part of the explosives. The weight and size of the aggregate can sink into a portion of the explosives, which reduces the effectiveness of the bang. This in most cases results in oversize in the upper layer of the block or the capping layer.

“Additionally, because there are so many spaces and voids between the rock particles,

SCAN QR CODE TO WATCH EUGENE PREIS DISCUSSING THE IMPACT OF STEMMING IN BLAST OUTCOMES

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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BLASTING the stemming material and the sides of the hole. As a result, there is better retention of the shockwave gases within the rock mass,” explains Preis.

Key benefits

there is no effective containment of explosive gases and shockwave.

However, it should be noted that operations that are already using aggregate are counted among those ahead of the pack in terms of their stemming practices,” says Preis.

Eugene Preis, MD of ERG Industrial (left), with Riaan Gilfillan, GM at Enviro Blasting Services.

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Enter stemming plugs

Typically, the loss of explosive energy through stemming ejection reduces the performance of the blast. The core principle behind stemming plugs is to improve the effectiveness of stemming material in the blasthole. As a result, this helps better contain the explosives energy within the rock mass and yield a more controlled and efficient blast.

“A stemming plug is not a standalone solution; it works in conjunction with stemming material, whether aggregate or drill chippings, to help contain energy for much longer,” says Preis. “As soon as the force is exerted onto the stemming plug, it engages with stemming material and compacts it, forcing itself into any voids between

Commenting on some of the key benefits of stemming plugs, Preis says there are several knock-on effects of better energy containment. For quarries, one of the biggest challenges is their proximity to communities and infrastructure. In line with the requirements of Regulation 4.16(2) of the Mining Health and Safety Act’s Explosives Regulations of 2018, quarries need to acquire a licence to blast within 500 m of structures.

“Because quarries are by their nature located close to communities and existing infrastructure, they need to find ways to control flyrock and keep their noise and airblast down. Using stemming plugs reduces the likelihood of stemming ejection and flyrock. As a result, most of our clients in the quarrying space use our Varistem stemming plugs for that reason,” says Preis.

On the productivity side of things, due to their better energy containment properties, stemming plugs help improve fragmentation and reduce oversize material in blasts. The benefits of good fragmentation are well documented, says Preis.

“Firstly, good fragmentation eliminates the need for costly secondary blasting or mechanical breaking of oversize material.

Secondly, there is a positive impact on downstream processes such as load and haul. Crusher throughput also increases due to improved overall particle size distribution,” he says.

A key trend in the quarrying sector, says Preis, is that there is almost a trade-off between productivity and health & safety, and in most cases the later wins. Quarries are overly cautious when it comes to stemming heights in their blast designs. They therefore design their blasts to produce no flyrock, but in the end they get oversize in the top stemming layer.

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

BLASTING

ERG Industrial team on site.

“By incorporating a stemming plug such as Varistem in their blast designs, quarries can reduce their stemming heights, for example, by leaving an air deck. By using this solution, they can keep flyrock down, while at the same time dealing with the oversize problem.

The system therefore offers great value on both fronts – productivity and health & safety,” he says.

Changing perception

Of the various products that have come to market to improve blast performance, flyrock control and downstream productivity, stemming plugs have been looked upon with some scepticism.

However, ERG Industrial has seen renewed interest in the technology following its 2019 introduction of the Varistem range from United States company, MOCAP. “To say that the perception towards stemming plugs was negative when we started in 2019 is an understatement,” says Preis. “The core reason is that in the past there were some suppliers who were not able to deliver on their promises.

The only way to quell this perception was to prove that our product works.

We started doing field testing at customer operations, using drones and monitors to collect data to scientifically show that the product added real value.”

With mines and quarries fast

realising the massive benefits offered by this technology, Preis tells Quarrying Africa that the rate of adoption has increased tenfold in the past two years. Central to that perception change is ERG Industrial’s ability to prove the capabilities of the technology through scientific evidence.

The future

Based on the current shift in attitude towards stemming plugs, Preis foresees a rapid increase in adoption in future. “We have had more mining and quarrying companies coming on board in the past six months than we have seen in the past two years,” he says.

Preis says there is a better understanding that drill and blast, as the very first process in the quarrying and mining value chain, has a significant bearing on the performance of all other downstream processes. By making a small change in outcomes at the beginning of the value chain, operations can see exponential gains downstream.

“From a macro perspective, if all mining and quarrying operations were able to improve their blast outcomes by 5%, for instance, there would be an incredible knockon effect on their bottom line, and effectively on the industry’s contribution to the economy at large,” concludes Preis. a

5% From a macro perspective, if all mining and quarrying operations were able to improve their blast outcomes by 5%, for instance, there would be an incredible knock-on effect on their bottom line, and effectively on the industry’s contribution to the economy at large

| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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WORD FROM NICO

TEN TIPS TO PROMOTE A SAFER WORKING ENVIRONMENT

No matter how much we talk about health and safety in the surface mining industry, it is our actions that ultimately decide whether our plans are successful or not. By Nico Pienaar, director of ASPASA.

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Nico Pienaar, director of ASPASA.

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legal requirements.

Create a culture of safety by sharing information and acting fairly and appropriately when transgressions occur. Highlight the need to work together to identify health and safety risks and encourage two-way communication at all levels.

Report accidents on time and in accordance with requirements of the company, as well as those of the Department of Mineral Resources and Energy (DMRE). This will ensure that information exists to put preventative measures in place within the organisation and industry-wide if required.

Correct behaviours that may be repeating over and again. It is often said that “it’s the way we have always done it” but that doesn’t mean it’s the right way. Train, train, and train again and be alert to risky behaviours no matter how familiar they are. a

CORPORATE PARTNERS

he following 10 basic steps can help make a significant difference to a mine’s safety record. As part of a larger health and safety framework, these tips are easy to remember and serve as a foundation to start from.

• Conduct a comprehensive and professional risk management assessment to identify the potentials for health and safety concerns.

• Adopt a health and safety management plan, such as ASPASA’s ISHE requirements, and implement it methodically throughout your organisation.

• Communicate and consult with all levels of employees, including sub-contractors, about their safety requirements and concerns. Note these and include them in your safety management strategy.

• Document all findings and incorporate them into your health and safety file. Remember these may be needed in the event of evidence being required.

• Inductions need to be conducted for all new workers and visitors to the mine who will have access to the mining site. This should include evacuation, first aid and fire drills.

• Comprehensive and ongoing training should be given to employees. Training must be appropriate to their work and seniority and should be updated as the person progresses or changes roles within the mine.

• Undertake at least one annual audit/check, such as offered by ASPASA, to establish whether you ticked every block to ensure compliance with

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| January/February 2022 | Vol. 1 Issue 1 | www.quarryingafrica.com

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