Quarrying Africa ISSUE 4 2025

CHASING EFFICIENCIES

By their very nature, quarries produce high-volume, low-cost material. To run profitable operations in such a generally challenging business environment, it is critical for quarry owners to find ways to drive efficiencies in every aspect of their operations. In the past few months, I have had the privilege of visiting several quarry operations, and in my view, the industry is heeding the call for innovation to improve efficiencies.

It is encouraging to see operations chasing efficiencies through the integration of technology, optimisation of key processes such as drilling and blasting, streamlining of the value chain and leveraging data for informed decision-making to reduce costs and increase profitability. This holistic approach focuses on everything from accurate drill patterns and efficient load and haul operations to precise material flow in crushers, ultimately minimising waste and maximising value from resources.

The general takeaway from some of the operations that I visited recently is that the industry cannot afford to ignore the benefits of using the latest technologies to drive efficiencies. The increased economic and operational pressures demand that today’s quarries stay ahead of the technological wave to remain competitive.

are not only looking at investing in new comminution solutions but also at streamlining the value chain, particularly by addressing bottlenecks in their crushing and screening operations in order to maintain an efficient flow of material.

Bottlenecks lead to plants running below capacity, wasted energy, increased wear and tear, compromised product quality and higher operational costs. By identifying and resolving bottlenecks, quarries can ensure smooth material flow, maximise equipment utilisation, improve end-product consistency and ultimately achieve their production targets more efficiently and profitably.

In a competitive and low-margin industry such as quarrying, efficiency and costeffectiveness are crucial for survival. Regularly identifying and solving bottlenecks is essential to stay ahead. Addressing bottlenecks ensures that all equipment, especially the most expensive crushers, is utilised effectively.

It is also encouraging to see a greater focus on data-driven decision-making – using realtime data and comprehensive metrics to track operational efficiency and identify areas for improvement. Local quarries are leveraging data analytics to make swift, informed decisions that enhance productivity and reduce operational expenses.

MUNESU SHOKO

Publishing Editor

Email: munesu@quarryingafrica.com

LinkedIn: Munesu Shoko

Quarrying Africa

One area where this is particularly crucial is in blasting – a critical function that greatly influences operational efficiency, costs and the success of all the other downstream processes, such as load and haul, as well as crushing and screening. With the use of electronic blasting systems, for example, it is now possible for quarries not only to meet higher safety levels and environmental impact control, but also to gain more blast control and improve fragmentation, thus delivering more downstream value to the whole operation.

Another area that I found to be of great focus in the quest to pinch more efficiencies is crushing and screening. Several operations

Over the years, developments in digitalisation and connectivity have created the ‘perfect storm’ for big data in quarrying and mining at large. One area where operations are seeing the benefits of applying data and analytics is maintenance, with predictive and prescriptive asset-management strategies becoming prevalent. By harnessing the power of data, quarry operators can drive significant improvements in their operations.

By reducing operating costs and adding value to resources, efficiency directly contributes to higher profit margins. It is therefore important to investigate areas of continuous improvement to remain competitive and achieve long-term success in a generally tough industry.

CREATING A CULTURE OF EFFICIENCY

FITTING THE HAULING BILL

BOOSTING CAPACITY TO MEET RISING DEMAND

TRENDS IN CONCRETE BATCHING TECHNOLOGY

POWERED UP FOR SUCCESS

OPTIMISING LOADING CYCLES

Publishing Editor: Munesu Shoko

Sub Editor: Glynnis Koch

Admin: Linda T. Chisi

Design: Kudzo Mzire Maputire

Web Manager: Thina Bhebhe

GAINING

FACILITATING

Quarrying Africa is the information hub for the sub-Saharan 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, 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.

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PLUGGING THE SCALPING GAP

In an environment where scalping screens are gaining preference due to their versatility, Wirtgen South Africa is adding the new Kleemann MOBISCREEN MSS 502(i) EVO mobile scalping screen to its offering. With its 350 tonnes per hour (tph) capacity, the compact screen closes a crucial gap in the company’s portfolio. By Munesu Shoko.

In recent years, one of the notable trends in the mobile screening market has been the growing uptake of mobile scalping screens in the quarrying and mining landscape. According to Waylon Kukard, sales manager at Wirtgen South Africa, scalping screens have become more popular than their classifying counterparts largely due to their versatility and ability to handle larger feed sizes.

The versatility of scalping screens, he says, comes from their ability to be deployed in different tasks – particularly in both heavy duty scalping and fine screening applications. This adaptability streamlines operations, reduces redundancy and enhances overall efficiency across different environments. On the back of this growing popularity, Wirtgen South Africa introduced its first scalper in 2023, the Kleemann MSS 802 EVO.

90%

The scalping screen market is generally dominated by two product sizes – the 350 and 500 tph offerings – which, together constitute 90% of the market

KEY TAKEAWAYS

Wirtgen South Africa is launching the new Kleemann MOBISCREEN MSS 502(i) EVO mobile scalping screen in southern Africa

The arrival of the Kleemann MOBISCREEN MSS 502(i) EVO closes an important gap in the company’s scalping screen offering

One of the major talking points on this machine is efficiency, which largely stems from the incorporation of a John Deere engine

As a diesel-electric unit, this machine can also be operated all-electrically, scoring high in efficiency and sustainability

350 tph

With its 350 tph capacity, the compact MOBISCREEN MSS 502(i) EVO scalping screen closes a crucial gap in the Wirtgen South Africa portfolio

The arrival of the Kleemann MOBISCREEN MSS 502(i) EVO, says Kukard, closes an important gap in the company’s scalping screen offering. The scalping screen market, he continues, is generally dominated by two product sizes – the 350 and 500 tph offerings – which together constitute 90% of the market.

“The launch of the Kleemann MSS 802 EVO back in 2023 gave us the much needed footprint into the 500 tph market, but to be truly competitive, we needed a 350 tph machine as well. The arrival of the MOBISCREEN MSS 502(i) EVO therefore gives us a foothold into the 350 tph market segment, plugging a crucial gap in our offering,” says Kukard.

Since the launch of the larger Kleemann MSS 802 EVO in 2023, Kukard has observed an increased appetite for mobile screens in the local market, with several of these units already operational across applications. He believes that the launch of the compact MOBISCREEN MSS

The MOBISCREEN MSS 502(i) EVO comes with a generously dimensioned feed hopper, a screening surface of 5,4 m² and a wide main discharge conveyor, guaranteeing sound material guidance.

Ergonomic access to all screen decks and maintenance-relevant components increases work safety and reduces downtime.

502(i) EVO allows Wirtgen South Africa to be in a position to challenge for more market share in this segment, with the first units expected to arrive in South Africa in early 2026.

Major talking point

One of the major talking points on this machine is efficiency, which largely stems from the incorporation of a John Deere engine. As is the case with other Kleemann machines, the MOBISCREEN MSS 502(i) EVO benefits from the efficiency of the John Deere engine technology. This follows John Deere’s 2017 purchase of the Wirtgen Group.

According to Kukard, John Deere engines in Kleemann machines are not simply off-the-shelf components. They are specifically tailored and mapped for the crushing and screening applications, ensuring optimal power delivery and performance.

The efficient design and mapping of the engines contribute to lower fuel consumption. The combination of optimised performance and reduced fuel consumption directly translates into lower overall operating costs for Kleemann machine users.

As a diesel-electric unit, this machine can also be operated allelectrically, scoring high in efficiency and sustainability. The diesel-electric configuration contributes to more sustainable operations through both reduced emissions and fuel consumption.

“Sustainability plays a crucial role at Kleemann, even in the development and design phase of these machines. This is demonstrated by the new MOBISCREEN MSS 502(i) EVO where the option of an electro-hydraulic dual power drive allows on-site carbon (CO2) emission-free work because the machine can be operated allelectrically,” explains Kukard.

Key features

The MOBISCREEN MSS 502(i) EVO comes with a generously dimensioned feed hopper, a screening surface of 5,4 m² and a wide main discharge conveyor, guaranteeing sound material guidance. For high flexibility, the speed of all conveyor belts is easily adjustable and a simple conversion from two to three final grain sizes is possible. The wide setting range of the screen casing angle (15,4-20°) makes for a high screening capacity combined with high product quality.

The large selection of screening media also contributes to increased flexibility. Whether finger decks for

As is the case with other Kleemann machines, the MOBISCREEN MSS 502(i) EVO benefits from the efficiency of the John Deere engine technology.

clayey excavated earth or square mesh for classifying decorative grit – the screen decks of the MOBISCREEN MSS 502(i) EVO can be designed to match the application at hand. Mixed covering of the screen decks is also possible. Overall, the new machine offers comprehensive configuration diversity to impress as a stand-alone or, in conjunction with further Kleemann machines, to precisely meet the customer’s needs.

The user-friendly operating concept of the MOBISCREEN MSS 802(i) EVO is also replicated in the MSS 502(i) EVO. Automatic mode for simple and fast production start is a core element, as well as the telematics solution for improved planning and analysis of the machine.

The SPECTIVE CONNECT digital application from Kleemann provides the operator with all relevant data such as speed, consumption values and fill levels directly on their smartphone. Stockpile monitoring can be used to display the current status of material stockpiles. When a certain predefined value is reached, the operator is notified that the stockpile should be cleared promptly. This makes work easier and increases productivity.

“SPECTIVE CONNECT is the logical extension of the SPECTIVE operating concept. All important information is transmitted to the operator’s smartphone. Irrespective of whether the operator is in an excavator or wheel loader or somewhere else nearby, they always have all relevant information on the status of the machine at their disposal,” says Kukard.

Apart from relevant data such as fuel consumption, current production output, and diesel- and urea-filling levels, fault messages are also displayed. Work does not need to be interrupted to view the status. The option

for preparing clearly arranged reports creates additional transparency for the operating company.

Minimising downtime

A good view of transfer points and material flow is always possible thanks to LED lighting. Ergonomic access to all screen decks and maintenance-relevant components increases work safety and reduces downtime.

With its compact transport dimensions and easy drive control, the scalping screen simplifies transport from one site to the next. On site, the interplay between the mobile operating device and the assembly-free folding out of the discharge belts pays off. Thanks to the joystick control, the operator has a perfect view of the belt to be folded and can move it into position with great precision. This saves unnecessary walking distances and, above all, time.

Apart from the operating concept and material flow, ease of maintenance determines the economic operation of screening machines to a considerable extent. A wellthought-out hydraulic concept on the new MOBISCREEN MSS 502(i) EVO guarantees high-power transmission and lowers operating costs.

Easy access to all maintenance components, flexible refuelling from both sides and simple, and therefore fast, cleaning of the hopper discharge conveyor undersize through the use of a retractable chute, all ensure that downtime is kept to a bare minimum.

“Water spraying at the discharge conveyors, in turn, reduces the dust emissions significantly during machine operation and therefore ensures better working conditions for plant operators and higher levels of acceptance by local communities,” concludes Kukard. a

CREATING A CULTURE OF EFFICIENCY

In a cutthroat trading environment, Afrimat’s Cape Lime Vredendal places a culture of efficiency at the heart of its operations in order to reduce operating costs, increase profitability, ensure sustainable operations and maintain market competitiveness.

Fostering a mindset of continuous efficiency improvement, the management team recently reconceptualised its load and haul regime, and central to that strategy was the migration from traditional construction-type tipper trucks to Scania mining tippers. The move has ushered in a new era in both efficiency and productivity. Munesu Shoko was recently on site and filed this report for Quarrying Africa.

Over the years, Afrimat’s growth strategy has been buoyed by strategic acquisitions of businesses in dire straits and turning them into formidable operations. As part of that strategy, in 2016, the company took control of Cape Lime’s two operations located at Vredendal and

Robertson (Langvlei), in the Western Cape province of South Africa.

In a deal that became the company’s largest acquisition at the time (worth R276-million), this acquisition, which diversified the business with exposure to high-quality limestone and dolomite products, fortified Afrimat’s Industrial Minerals Division,

7 km

One of the main challenges at Afrimat Vredendal are the long 7-km haul distances, which impact overall efficiencies through longer cycle times and generally higher fuel consumption

20%

One of the immediate benefits of deploying the Scania mining tipper fleet has been the marked 20% increase in productivity which to date comprises Vredendal, Langvlei and Marble Hall operations.

The success of these operations has over the years hinged on Afrimat’s continuous improvement efforts. In line with that approach, the management team at Afrimat Vredendal is leaving no stone unturned in its quest to drive efficiencies. According to Andrew Wray, MD of Afrimat Industrial Minerals, the Vredendal team – under the capable leadership of mine manager Ruan Smit and quarry manager Robert Hurn – places a strong emphasis on ongoing and systematic enhancement of processes through a sustained effort to identify areas of improvement, implement changes and monitor results.

One function that has recently received greater attention is load and haul. Hauling run of mine material represents a significant component of the total operating costs of any quarry or surface mine. Consequently, the incentive to increase efficiency and reduce costs in this area is very high, especially for Afrimat Vredendal, where haul distances from the high-quality calcite pit to the primary plant are a whopping 7 km.

Because of these unusually long haul distances, Afrimat Vredendal is one of the only two sites within the Afrimat Group that has always deployed conventional tipper trucks for its load and haul operations, while the rest of the operations run articulated dump trucks (ADTs), confirms Wray.

Upgrading hauling tools

KEY TAKEAWAYS

As part of its continuous improvement efforts, Afrimat Vredendal is leaving no stone unturned in its quest to drive efficiencies

The operation places a strong emphasis on ongoing and systematic enhancement of processes through a sustained effort to identify areas of improvement, implement changes and monitor results

In the quest to improve hauling efficiencies, the management team recognised a need to change its hauling tools, swopping the existing four conventional 6x4 tipper trucks to three Scania mining tippers

In addition to increased payload, the Scania tippers are significantly more fuel efficient than the previous units the operation had on site

In the quest to improve hauling efficiencies in the face of these long hauling distances, last year the management team recognised a need to change its hauling tools – in this case the four conventional 6x4 tipper trucks from one of the premium original equipment manufacturers. Having run these four trucks for nearly 15 years, Smit says the trucks, due to their age, had become uneconomical to run – both from an availability and maintenance perspective – especially in such a taxing load and haul application.

“In the early part of their life, these conventional tipper trucks were efficient to run in this application. As they became older, it was an ongoing challenge to maintain efficiencies. These particular ones had been on site for about 15 years, and had clocked between 340 000 and 360 000 km which, for a mining truck, is unheard of. We looked at replacing them with new equivalent units, but we realised that the capital outlay was going to be out of reach for the operation,” explains Wray.

After careful consideration, a decision was taken to go the Scania mining tipper route, which saw the operation deploying three Scania G460 XT mining tipper units. The first two arrived in April 2024, before the third unit joined the fleet in November of the same year. These, however,

were not new acquisitions, but existing assets redeployed from Afrimat’s Tygerberg Quarry.

“The Scania mining tippers came in at a conservative ticket price for the Vredendal operation. The good news is that we sat with these three machines at Tygerberg Quarry, which became part of Afrimat as part of the Lafarge deal. In fact, these trucks were not ideal for the Tygerberg operation and were swopped out for ADTs, allowing us to redeploy them at Vredendal, where they have proven to be perfect for the operating conditions here,” says Wray.

Immediate gains

As previously highlighted, one of the main challenges at Afrimat Vredendal are the long 7-km haul distances, which impact overall efficiencies through longer cycle times and generally higher fuel consumption.

“It is generally difficult to be efficient when loading and tipping activities are that far from each other. We therefore needed to pull every lever available to get our load and haul efficiencies right. The arrival of the Scania mining tippers has addressed this challenge. Firstly, we run these trucks at 60 km/hour speeds, on average, getting to a top speed of 70 km/hour on a straight stretch, which we could not achieve with the previous hauling tools. This has significantly improved our cycle times,” says Smit.

For this to be achievable, however, Smit reiterates the need to keep haul roads as smooth and debris-free as possible. This not only allows the trucks to achieve their top speeds, but also avoids possible costly tyre cuts, which are generally a big challenge when running this type of truck in a mining environment.

One of the immediate benefits of deploying the Scania mining tipper fleet has been the marked 20% increase in productivity. This has largely been through the trucks’ higher payload of 34 tonnes (t), which translates into a 10-t payload increase compared with the previous tipper range. Consequently, the increased payload on the Scania mining tippers has allowed the operation to replace the existing four trucks with three units.

“Given that our hauls at Vredendal are longer, switching to a larger truck means more material is being carried along that longer distance – and the costs come down, thus increasing efficiencies,” explains Smit. “In addition to increased payload, the Scania tippers are significantly more fuel efficient than the previous units we had on site.”

“With fewer trucks in the system comes another added benefit – bringing down our shift count, which means fewer heads on the haul side of the operation. Going the Scania mining tipper route was therefore a single change with vast improvements – we saw it immediately through our efficiencies,” adds Wray.

Removing bottlenecks

The removal of the fourth truck from the hauling system has also translated into reduced traffic and standing time at both the loading tool and the tipping point, which previously caused significant cycle time and efficiency hurdles. In fact, one of the previous

challenges that the team had to contend with was that the primary jaw crusher would often run empty due to these hauling bottlenecks, resulting in increased power consumption and wear.

The arrival of Scania trucks has since addressed the challenge of having the primary crusher running empty. In fact, due to the Scania mining tippers’ quick speed and increased payload, the bottleneck has shifted from feeding the primary plant to the crusher itself being too small for the available run-of-mine material capacity. This, confirms Wray, has informed the need to replace the existing jaw crusher with a larger unit.

“What Ruan and team are doing here is creating a culture of efficiency. A big focus of the mine manager’s efforts is to create a culture of continuous improvement by always seeking to do things better, challenging the status quo, consistently measuring and analysing processes to identify areas for enhancement, as well as implementing data-driven changes,” says Wray.

Speaking of data-driven operations, to further improve its hauling efficiencies, Afrimat Vredendal has adopted the AVA Load & Haul monitoring system. The GPS-based system gives the management team instant access to real-time reporting tools, from daily production reports to live alerts and trend insights, allowing them to manage the operation smarter and faster.

“We have embraced AVA across all of our Afrimat sites. AVA’s Load & Haul system transforms GPS data from any device into a detailed, second-by-second performance model, categorising all activity to show exactly where time is lost. It breaks down every component of fleet performance to pinpoint exactly where improvements are possible, thus allowing for data-driven decision making,” concludes Smit. a

of

FITTING THE HAULING BILL

In a landmark deal, M Civils became the first recipient of the New Generation Volvo articulated dump trucks (ADTs) in southern Africa in early June this year, taking delivery of 12 new A40 units from Babcock to execute a newly-awarded surface mining contract in Rustenburg. Deployed on a taxing chrome mining project, the machines have already lived up to their billing, prompting the company to place an order for 12 more A40 units. Munesu Shoko was recently on site and filed this report for Quarrying Africa.

Founded by managing director Mike de Kock in 1997, M Civils has its roots in construction, with a particular focus, during its early days, on road building and civil infrastructure development in general. However, from the onset, the mining sector formed a large part of its client base. Over the years, the company has executed some flagship greenfields mine development projects for most of the major mining houses, mostly within its Rustenburg domain.

Given its proximity and exposure to mining houses, establishing a contract mining arm of the business was only a natural step in its growth trajectory. Leveraging this foothold in the mining sector, the company secured a materials handling project from one of the major mining houses some five years ago, where it has proven its mettle with good quality service.

Based on this favourable track record, three months ago M Civils was awarded a major opencast mining contract by the same mining house at a

10-14 l

Fuel consumption to date ranges between 10 l per hour, when running with overburden, and 14 l per hour, when loading chrome

KEY TAKEAWAYS

M Civils became the first recipient of the New Generation Volvo articulated dump trucks (ADTs) in southern Africa in early June this year, taking delivery of 12 new A40 units from Babcock

The 12 A40 units have been deployed to haul both waste and ROM material from the newly-opened pit to the designated waste rock dumps and ROM pads

One of the factors behind the decision to opt for the 39-t A40 ADTs from Volvo was the availability of an interface kit for the integration of Level 9 PDS/CAS technology

Another feature of great interest to M Civils was the Haul Assist with On-Board Weighing, a Volvo CE system that provides real-time payload data

greenfields chrome mining project in Rustenburg. With a 13-year life of mine, the project will see M Civils producing 90 000 tonnes (t) of run-of-mine (ROM) chrome per month, initially for the next five years. When M Civils went into the market for the hauling gear to execute this contract, special consideration was given to ADTs. Site manager Mpho Ramalepe explains that articulated haulers fit the bill for the mining

600-700

The haulers – which work 12-hour shifts – have already clocked between 600 and 700 uninterrupted hours, delivering the goods as per the client’s expectations

conditions, where seams are dipping at 10-12 degrees on average.

After a rigorous due diligence, the company looked no further than Volvo Construction Equipment (Volvo CE), placing an order for 12 new generation A40 units, which were delivered in early June this year, just ahead of the official launch of the range in southern Africa.

While M Civils was not necessarily the first company to sign on the dotted line for the new generation ADTs, Rob Baker, sales representative at Babcock, the Volvo CE dealer in southern Africa, confirms that the company marked a significant milestone by becoming the first recipient of the new range in the region.

Delivering the goods

When Quarrying Africa visited the site in early August, the 12 A40 units were hard at work, deployed to haul both waste and ROM material from the newly-opened pit to the designated waste rock dumps and ROM pads, over 1,7-2 km distances. At the time of writing, the haulers – which work 12-hour shifts – had already clocked between 600 and 700 uninterrupted hours, delivering the goods as per the client’s expectations.

“Despite the fact that we are still in the early stages of mining and that the surfaces are still very much flat, we have already been impressed by how quick these haulers are, even over challenging terrain, which affords us faster cycle times and ultimately greater productivity,” says Ramalepe.

Vincent de Kock, contracts manager at M Civils, has been particularly impressed by the fuel efficiency. “Fuel consumption to date ranges between 10 l per hour, when running with overburden, and 14 l per hour, when loading chrome, which by its nature is heavy due to its specific gravity, typically between 4,5 and 4,8,” he explains, adding that these figures might change in future as mining conditions become tougher.

When designing the new generation ADT range, says Baker, Volvo CE cast a special focus on fuel efficiency, and the first units in the region are already demonstrating exactly that. The new generation range marks a significant technological leap forward thanks to innovations such as the new electronic system and an in-house developed transmission, delivering fuel efficiency improvements of up to 15%, depending on model and industrial application.

Feedback from the operators has been positive. According to Ramalepe, operators have praised the enhanced comfort through redesigned cabs with better ergonomics, visibility and noise reduction, as well as features such as heated/cooled storage and improved controls. They also benefit from features such as advanced traction control and smoother hydraulic

At the time of writing, the haulers – which work 12-hour shifts – had already clocked between 600 and 700 uninterrupted hours, delivering the goods as per the client’s expectations.

operations for increased efficiency and productivity.

“Our operators have previously driven other ADT brands in their careers, but there is a general consensus among them that Volvo is the gold standard in ADTs. The comfort levels are unmatched,” says Ramalepe.

Why Volvo?

Having previously run other ADT brands, this transaction represents the first time that M Civils has bought Volvo ADTs. The decision to go the Volvo route, says Reino de Kock, COO at M Civils, was motivated by several factors. “There are a few aspects that we look at when making such a big-ticket purchasing decision. Firstly, the product must be costcompetitive and, secondly, it must have a strong aftersales regime behind it,” he says.

While Volvo is a premium product that commands a premium capital price, Reino says focus is not necessarily on the upfront price only, but the total cost of ownership (TCO). Understanding the TCO of equipment, he expands, is fundamental in making strategic buying decisions. Based on this approach, M Civils did not only consider the initial purchase price of equipment, but also all costs associated with operation, maintenance and eventual disposal over the entire lifecycle, which justified the Volvo decision.

In Babcock, the Volvo CE product is supported by a reputable dealer in southern Africa. Strong aftermarket support is crucial for the success of our operations – it minimises costly downtime, extends equipment lifespan, reduces TCO and improves operational productivity through expert technical support, timely parts delivery and a proactive maintenance regime.”

Other factors

From a product point of view, one of the factors behind the decision to opt for the 39-t A40 ADTs from Volvo was the availability of an interface kit from the original equipment manufacturer (OEM), which facilitates the integration of Level 9 Proximity Detection Systems (PDS)/Collison Avoidance Systems (CAS) from any third-party supplier.

Based on the performance of the ADTs to date, as well as an array of features of interest, M Civils has placed an order for 12 more A40 units

The Department of Mineral and Petroleum Resources (DMPR) made the Level 9 CAS compulsory through a gazette published on December 21, 2022, making it law in South Africa. This legislation requires trackless mobile machinery (TMM) in mines to automatically detect pedestrians, warn operators and pedestrians of each other, and, if necessary, automatically apply the brakes to prevent collisions.

“Once a product has been identified, the second factor is the aftermarket support behind it,” says Reino. “Every good product is only as good as its support.

“The biggest benefit of dealing with an OEM with its in-house Level 9 interface is seamless integration. Volvo CE has its own OEM interface, which reduces compatibility challenges, a common issue when using third-party interfaces,” says Reino.

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The 12 A40 units have been deployed to haul both waste and ROM material from the newly-opened pit to the designated waste rock dumps and ROM pads.

According to Baker, the cutting-edge interface kit from Volvo CE offers customers greater flexibility in choosing their preferred PDS solution.

“With this innovation, Volvo CE has reaffirmed its commitment to driving advancements in safety technology while prioritising customer needs and satisfaction,” says Baker.

Another feature of great interest to M Civils was the Haul Assist with On-Board Weighing, a Volvo CE system that provides real-time payload data, aiming to increase productivity, efficiency and reduce wear and fuel consumption by preventing underloading and overloading. Powered by the Volvo Co-Pilot display, this integrated system measures the hauler’s load in the body, offering features such as work order management, precision loading and detailed production reporting.

“The importance of payload management in our operations cannot be reiterated enough, which is why the On-Board Weighing system from Volvo was a major consideration for us. The system provides us with real-time payload information which can help to eliminate carry-back and overloading; the result is peak productivity, reduced fuel consumption and less machine wear. External lights provide a visual guide to assist the operator of the loading unit in achieving the nominal load,” says Vincent.

Based on the performance of the ADTs to date, as well as an array of features of interest, M Civils has placed an order for 12 more A40 units. At the time of writing, the new fleet of machines was due for delivery by midAugust. “As we ramp up production, we are looking forward to receiving another 12 A40 units, which we will deploy on the same project,” concludes Reino. a

BOOSTING CAPACITY

TO MEET RISING DEMAND

Amid rising aggregates demand, Cape Town-based Gran Sasso Quarry, owned and operated by Ciolli Bros, is investing in a major plant upgrade to boost capacity. Having already set the upgrade in motion with the 2022 investment in a primary jaw crusher from Astec, the company is set to expand the large installed base of Astec equipment with another major capital investment. Munesu Shoko was recently on site and filed this report for Quarrying Africa

O-6 mm

For Gran Sasso Quarry, one of the major demand drivers to date is manufactured sand (-6 mm)

35%

Current production patterns show that manufactured sand constitutes about 35% of total product sales

2

Gran Sasso Quarry runs a large fleet of Astec comminution equipment within its two plants

n the back of a hive of construction activity within its vicinity, Durbanville Hills, Cape Town-based Gran Sasso Quarry has in recent years experienced high demand for aggregates. A combination of road projects, property development projects and blockyards, have been central to increased demand for aggregates in the area, confirms mine manager Andre Wilson.

In fact, the Western Cape province has been one of the major construction hotspots in South Africa in recent years. To provide context, in 2022, the province accounted for a third of all building plans passed and 40% of all buildings completed in South Africa. In March 2025, the Western Cape, along with KwaZulu-Natal, championed a 23% rise in South Africa’s construction project

awards, according to Industry Insight’s Construction Monitor.

The sustained construction activity has translated into a favourable business environment for quarries operating in the province. For Gran Sasso Quarry, which processes a Malmesbury slate (Hornfels) rock, demand drivers to date are largely manufactured sand (-6 mm), 19 mm concrete stone and G5 subbase material. In fact, current production patterns show that manufactured sand constitutes about 35% of total product sales, confirms quarry manager Tshilidzi Ngobeni.

Another product driving demand is what the quarry terms block mix – a blend of the right amount of dust and aggregate used by block makers in the area. This product, says Wilson, is highly sought after, and some customers send trucks from as far as Gordons Bay and

Strand. Other demand drivers are the 9 mm and 6 mm stone, particularly used in asphalt production for road projects.

Need to boost production

On the back of high aggregate demand, Ciolli Bros is investing in a major plant upgrade to boost production capacity for Gran Sasso Quarry.

In fact, the plant upgrade was set in motion with the 2022 upgrade of the primary section of the main plant. This saw the quarry investing in a 3648 jaw crusher with a Gbex vibrating grizzly feeder from Astec Industries. With its 750 tph capacity, the 3648 jaw crusher was a major upgrade to the existing 3042 which, to date, still forms part of the two primary sections of the main plant.

“The 3648 was installed to increase production capacity to meet rising demand. However, the increase in capacity at the primary jaw crusher only means that we have created bottlenecks down the line. We are currently running the jaw at 40% of its capacity due to the constraints downstream the plant. Due to the 3648’s ability to put such a huge quantity into the system,

KEY POINTS

On the back of a hive of construction activity within its vicinity, Durbanville Hills, Cape Town-based Gran Sasso Quarry has in recent years experienced high demand for aggregates

To meet increasing aggregate demand, Ciolli Bros is investing in a major plant upgrade to boost production capacity for Gran Sasso Quarry

In fact, the plant upgrade was set in motion with the 2022 upgrade of the primary section of the main plant

For this upgrade, Astec Industries is the preferred supplier. Ciolli Bros has traditionally been a firm proponent of the Astec brand, way back from the Osborn days

we therefore need to upgrade the rest of the plant to maximise its capacity,” says Wilson.

For this upgrade, Astec Industries is the preferred supplier. In fact, Ciolli Bros has traditionally been a firm proponent of the Astec brand, way back from the Osborn days. Gran Sasso Quarry runs a large fleet of Astec comminution equipment within its two plants.

In addition to the new jaw crusher, says plant manager Renier van Rooyen, the old 3042 jaw crusher with its 42x16 vibrating grizzly feeder have been kept as a standby primary section. The plant also constitutes a total of seven Astec screens, namely a 6x16 triple deck Vibroking screen, two 5x14 triple deck screens, two 5x14 double deck screens, a 5x12 double deck screen and a 4x10 triple deck screen. The subbase plant runs with a 2536 jaw crusher and a 36 cone crusher.

Through Astec’s simulation technology, both Ciolli Bros and Astec will be able to determine the type of upgrade required for the plant to meet the targeted 450 tph capacity. Simulation is an engineering tool for virtually exploring and testing new possibilities. By investigating capacity needs virtually, Astec engineers can more swiftly identify the equipment needed for the upgrade, says Robert Shead, regional aftersales manager – Western and Eastern Cape at Astec.

Why Astec?

Commenting on why Astec is the preferred comminution equipment supplier, Wilson says the original equipment manufacturer (OEM) has proven that it makes quality equipment which lasts longer. “The longevity of Astec equipment, especially jaw crushers, is unmatched in this industry. For example, our 3042 has been running for more than 30 years, while the 2536 has been here for just over 15 years. The longevity of their equipment bodes well for quarries, especially in an environment where capital investments are hard to come by,” says Wilson.

To be successful in today’s quarrying environment, says Van Rooyen, quarries need to consider working with OEMs that supply competitiveness, not just equipment.

“Leveraging over 100 years in this game, Astec understands the technical requirements of its customers, allowing them to tailor solutions to each customer’s unique operational needs. For example, when we bought the 750-tph 3648 jaw crusher, we needed to scale it down to match the capacity of the rest of the plant, and Astec engineers were quick to design a special liner for us to be able to do that,” says Van Rooyen.

Another big factor in choosing Astec, says Wilson, is the company’s proven aftermarket support capabilities, from OEM parts supply to technical support.

Local production matters

Given that Astec manufactures locally, says Van Rooyen, the resultant quick lead times, both from a capital equipment and parts perspective, bode well for Ciolli Bros’ operational requirements. “We are also impressed by Astec’s focus on technology. For example, back in the day, it was just a mission to adjust the closed side setting (CSS) on a crusher. As someone who is in charge of the mechanical side of the business, one of the key features that I like most is the hydraulic dual wedge CSS adjust, which eliminates manual shims and provides quick adjustment and enhanced safety. The ability to adjust on the fly increases production every time an adjustment is needed,” says Van Rooyen.

Astec’s Shead, who looks after Ciolli Bros, is impressed by how the company places value on OEM support. “Ciolli Bros is a company that is OEM-orientated –they request for OEM parts and technical support because they understand how crucial it is for them to keep machines running all the time. Buying an aftermarket part is a big risk factor because downtime is out of the question, especially given the busy nature of their operations. Based on the alignment of our values, we have therefore built a closelyknit relationship with them over the years, and we intend to keep it that way for the long haul,” concludes Shead. a

From Rock to Road

Astec Africa Middle East

The Lintec UCP120 is capable of producing up to 120 m³ of concrete per hour, ensuring smooth execution of large-scale projects.

TRENDS IN CONCRETE BATCHING TECHNOLOGY

Like many other sectors of the capital equipment market, concrete batching technology is evolving to meet changing market needs. As one of the leading manufacturers of concrete batching technology, Lintec & Linhoff notes that four global trends are defining the future of concrete batching – automation and digitalisation, modular compact designs, higher-capacity systems, and a strong emphasis on sustainability. By

Munesu Shoko.

KEY TAKEAWAYS

Digitalisation is increasingly built into customer expectations. Concrete batching plants equipped with Lintec & Linnhoff’s Windows-based ECS control system, offering PLC automation and remote access, are now a standard solution

Modularity has also gained prominence. The Lintec ECP Eco Concrete Batching Plant and the Lintec CC & CCE Containerised Concrete Batching Plants are prefabricated and mobile, allowing quick installation without foundations, reducing civil works and commissioning time

For high-volume infrastructure work, demand is growing for higher-capacity plants. Lintec’s UCP Ultra Concrete Batching Plants offer outputs of up to 250 m³/hour, using twin-shaft mixers and large-capacity bins to deliver performance without compromising quality

Sustainability is becoming a global standard. Enclosed, cladded plants reduce noise and dust, and meet the strict environmental regulations increasingly enforced in urban zones

In a fast-paced construction industry, characterised by increasing demand for faster project execution and superior quality, the role of technologically advanced batching systems is becoming more vital than ever. Today’s concrete batching plants are not just about mixing aggregates and cement; they are about precision, data and control to enable the production of consistent, high-quality concrete efficiently and cost-effectively.

Speaking to Quarrying Africa, Tee Peow Aik, Group

Chief Operating Officer at Lintec & Linnhoff, says automation and digitalisation, modular compact designs, higher-capacity systems, and a strong emphasis on sustainability, are some of the major trends shaping the future of concrete batching technology.

“Digitalisation is increasingly built into customer expectations. Plants equipped with Lintec & Linnhoff’s Windows-based ECS control system, offering PLC automation and remote access, are now a standard solution. This system supports full control of the plant’s functions, ensuring consistent production and enabling off-site troubleshooting,” says Peow Aik.

Modularity, he adds, has also gained prominence. The Lintec ECP Eco Concrete Batching Plant and the Lintec CC & CCE Containerised Concrete Batching Plants are prefabricated and mobile, allowing quick installation without foundations, reducing civil works and commissioning time. These attributes are in high demand across markets that require fast deployment and flexibility.

For high-volume infrastructure work, demand is growing for higher-capacity plants. Lintec’s UCP Ultra Concret e Batching Plants offer outputs of up to 250 m³/hour, using twin-shaft mixers and large-capacity bins to deliver performance without compromising quality.

Sustainability is becoming a global standard.

Enclosed, cladded plants reduce noise and dust, and meet the strict environmental regulations increasingly enforced in urban zones.

Meeting evolving jobsite needs

In response to these emerging trends, Lintec & Linnhoff’s approach to innovation is grounded in close collaboration with its global customer base. Rather than just following trends, says Peow Aik, the company listens to evolving jobsite needs and channel that feedback directly into its product development, service enhancements and training programmes.

“One key example is our investment in engineering hubs across Asia and Europe, where customer insights

250 m³

Lintec’s UCP Ultra Concrete Batching Plants offer outputs of up to 250 m³/hour, using twin-shaft mixers and large-capacity bins to deliver performance without compromising quality

5%

from across the globe are used to shape new features,” he says “The launch of the Lintec UCP Ultra Concrete Batching Plants, which offer high hourly output and advanced control logic, reflects growing market demand for faster, more efficient concrete production that can adapt to a wide range of operating environments.”

Lintec & Linnhoff also prioritises long-term support, recognising that access to skilled service personnel and spare parts can be a challenge in some regions. That is why the company has expanded its training programmes and now offers technical onboarding sessions and plant commissioning support, both in-person and virtually. This ensures local teams are empowered to operate and maintain their plants efficiently, maximising uptime and

The African construction market is expanding steadily, valued at around US$58,4-billion in 2024, with a CAGR of approximately 5% expected through 2029

ECP60

Lintec & Linnhoff has already had the opportunity to support major projects across the continent, including in Madagascar, where a Lintec ECP60 worked on a major port redevelopment

return on investment (ROI).

“In response to growing digitalisation, we have built remote diagnostic tools and real-time monitoring into our ECS control platform. This is not just about convenience; it directly reduces travel emissions and downtime, especially in isolated project sites,” explains Peow Aik.

Additionally, Lintec & Linnhoff is testing new technologies to support energy-efficient operations, including lower-power conveyor motors and energy pods. These initiatives reflect its broader commitment to not just respond to industry change, but to lead it through thoughtful, customer-centric innovation.

African market dynamics

Commenting on some specific trends that are unique to the African market, Peow Aik says Africa has unique market dynamics that shape technology requirements in important ways.

“A top priority in many African markets is mobility. Infrastructure projects are often located in remote or rural areas, so customers need plants that can be relocated efficiently. The Lintec ECP Eco Concrete Batching Plants, along with the Lintec PCP Portable Concrete Batching Plants, are in high demand because they offer high performance in a highly mobile format,” he says.

Another key trend is infrastructure-driven growth.

The African construction market is expanding steadily, valued at around US$58,4-billion in 2024, with a CAGR of approximately 5% expected through 2029. This growth is creating strong demand for reliable concrete batching plants to support roads, housing, ports and energy infrastructure.

“We have already had the opportunity to support major projects across the continent, including in Madagascar, where a Lintec ECP60 worked on a major port redevelopment, and in Mali, where a Lintec ECP90 helped in supporting a nationwide push to increase public housing,” says Peow Aik. “These deployments underscore how we are responding to Africa’s need for mobile, efficient and durable concrete batching plants.”

Africa, stresses Peow Aik, remains a key strategic market for Lintec & Linnhoff. The company continues to

The Lintec PCP is a portable concrete batching plant designed for flexibility and efficiency, particularly in projects requiring mobility and quick setup.

grow its presence across the continent with trusted local distributors and service partners.

“We believe our success is built not just on our technology, but also on our close partnerships with customers, working side by side to understand project needs and deliver long-term value. From worldclass automation and modular engineering to robust sustainability features, our concrete batching plants are helping to build the future of infrastructure across Africa and beyond,” he says.

To the future

Looking ahead, Peow Aik believes that several exciting innovations are on the horizon as the market continues to evolve:

AI and IoT integration: Lintec &Linhoff anticipates the growing use of artificial intelligence (AI) in batching control, optimising mix designs in real time based on environmental conditions or material variability. Internet of Things (IoT) sensors will provide predictive maintenance data, reducing unplanned downtime.

Full plant connectivity: Concrete plants will become smarter, networked systems. Centralised dashboards will allow companies to monitor multiple plants across regions from a single interface.

Greater modularity: Plants will become more reconfigurable, allowing customers to scale production, add or remove bins, or switch mix formulas easily, adapting to changing project demands.

Increased electrification: Lintec & Linhoff expects more systems to run on electricity, including solar-augmented controls, reducing fossil fuel dependence and making batching operations cleaner and quieter.

Circular economy principles: More plants will be designed to use recycled aggregates, waste concrete and industrial by-products, helping contractors meet environmental regulations while reducing raw material demand.

“Lintec & Linnhoff is actively developing solutions in each of these areas, ensuring our plants are future-ready and aligned with global construction trends,” concludes Peow Aik. a

Linnhoff NVX NovaMax Asphalt Mixing Plant Efficiency meets Sustainability

The Linnhoff NVX NovaMax Asphalt Mixing Plant features enclosed modules for pollution and noise control, a compact footprint with stacked modules, and fast setup and dismantling for efficient installation. It supports up to 60% recycled material with the Hot Recycling system, while accurate and precise batch mixing ensures consistent asphalt quality. Designed with an Environment-Friendly pollution control unit that recycles fine dust and offers optional fume control, the NVX NovaMax combines efficiency, accuracy, and sustainability for modern paving needs.

POWERED UP FOR SUCCESS

Athos Crushing & Screening, a sister company to Pilot Crushtec International, is introducing a new range of fully electric mobile crushers and screens called PowerTrack from SRHeavy (SRH). The introduction of this reputable mid-tier brand to the local market, aligns with the vision to become a true ‘home of crushing and screening’, allowing the two companies to cater for all tiers of the market, from entry level to premium. By Munesu

Shoko

Some five years ago, Pilot Crushtec International, one of the leading names in the crushing and screening game in southern Africa, broadened its reach with the establishment of a sister company, Athos Crushing & Screening. While Pilot Crushtec focuses on the premium end of the crushing and screening market, particularly Metso and the in-house Pilot offering, Athos Crushing & Screening provides both mobile and static solutions from approved providers, focusing on

entry-level and mid-tier segments of the market.

One of the latest additions to the Athos Crushing & Screening stable is Powertrack from SRH, a Chinese original equipment manufacturer (OEM) that specialises in electric mobile crushing and screening solutions (fully electric and dualpowered), together with their static counterparts.

Following an extensive testing regime, Athos Crushing & Screening is officially launching the fully electric range to the local market. Dubbed the e-Power, Powertrack, the range comprises a

The Powertrack PT Pro J-11E is equipped with an SJC108 jaw crusher with a 1 060 x 700 mm feed opening.

mobile jaw crusher, a mobile cone crusher, a mobile triple-deck screen and a mobile scalping screen, explains sales and marketing director Francois Marais.

“For the past five years, Athos has been testing the waters with different products to gauge the reliability and gain confidence in the products before rolling them out at full scale. During that time, we have put some 15 SRH units into the market, and some of them have been running for more than four years across applications, including mining and construction. Based on the performance of these units to date, we are now confident to commercially roll them out, initially through the fully electric Powertrack range,” says Marais.

Target customers include contractors, quarries and

150-500 tph

Equipped with an SJC108 jaw crusher with a 1 060 x 700 mm feed opening, the Powertrack PT Pro J-11E has the capacity to process between 150 and 500 tonnes per hour (tph), application dependent

KEY TAKEAWAYS

Athos Crushing & Screening, a sister company to Pilot Crushtec International, is introducing a new range of fully electric mobile crushers and screens called PowerTrack from SRHeavy

Dubbed the e-Power, Powertrack, the range comprises a mobile jaw crusher, a mobile cone crusher, a mobile triple-deck screen and a mobile scalping screen

Target customers include contractors, quarries and certain mining applications, particularly where there is access to grid power

The range comes at a time when the industry seeks to simultaneously drive efficiencies and reduce its carbon footprint

certain mining applications, particularly where there is access to grid power. At the time of writing, the first three machines, a mobile jaw crusher, a mobile cone crusher and a mobile triple-deck screen, had touched down in South Africa, with two of the machines, the jaw and screen, heading to a customer operating outside South Africa.

Why electric?

While the e-Power Powertrack range comprises both fully electric and dual-powered options, Marais tells Quarrying Africa that Athos is initially introducing the fully electric range only, marking a truly new era in the local crushing and screening scene. Why electric?

One of the major factors behind that decision, says Marais, is the fact that these machines come in at an extremely competitive price point. Central to their cost-competitiveness is the fact that they come out of China, inarguably the global leader in electromobility. The economies of scale in China, especially for electric components such as electric drives, provides for a notable cost advantage, making the e-Power Powertrack range an attractive crushing and screening solution for the local market, especially for cost sensitive entry-level contractors.

According to Marais, the range also comes at a time when the industry seeks to simultaneously drive efficiencies and reduce its carbon footprint. “The fully electric approach is probably unique to the local market, where focus has previously been on dual-powered solutions. Going fully electric offers a significant capital

250 tph

Equipped with four product conveyors, the Powertrack PT Pro ST-08E triple-deck screen can be deployed in 250 tph capacity requirements

150-250 tph

Ideal for secondary and tertiary crushing, the Powertrack PT Pro C-20E cone crusher has the capacity to produce between 150 and 250 tph, depending on application

Following an extensive testing regime, Athos Crushing & Screening is officially launching the fully electric Powertrack range of mobile crushers and screens in southern Africa.

Featuring the SCH2000 cone crusher, the Powertrack PT Pro C-20E is ideal for secondary and tertiary crushing.

cost advantage because of the absence of an expensive diesel engine that normally drives the price of these machines up,” says Marais.

Another remarkable aspect with fully electric crushing and screening solutions is the lower cost of operation. These machines are primarily intended to be plugged into grid electricity. Electric drive systems are cost-effective and more efficient than their conventional diesel hydraulic counterparts. To provide context, in a recent study, Athos found that a fully electric machine plugged into the grid (based on current costs of electricity versus diesel in South Africa), offers power cost savings of up to 50%, which is good news for operators seeking to boost their bottom lines in a tough economy.

In the absence of an electric plug-in, end-users can power the machine/s with a genset which, unlike in a dual-power setup, is completely separate from the mobile machine. This, says Marais, is a

completely new concept in the mobile crushing and screening market. One of the major benefits of keeping the generator away from where crushing takes place, is the elimination or reduction of dust ingression into the engine, which tends to be a major challenge for machines that come with an on-board genset.

“Anyone who runs a mobile machine will know that servicing an on-board diesel engine can be a challenge. Space is generally constrained and because of the dusty conditions, the diesel engine becomes a service-intensive component. Being able to power the machine or the full train using a separate genset therefore alleviates some of these challenges. In addition, fully electric machines require less servicing and maintenance, leading to lower repair and downtime costs,” says Marais.

Range in detail

Ideal for aggregates, mining and recycling, the Powertrack PT Pro J-11E is equipped with an SJC108 jaw crusher with a 1 060 x 700 mm feed opening. The machine, explains Marais, can handle lump sizes up to 600 mm and typically runs with a closed side setting of about 70 mm. The machine has the capacity to process between 150 and 500 tonnes per hour (tph), application dependent.

“The machine is equipped with all the latest features that one would expect from a primary mobile jaw crusher,” says

Marais. “The grizzly feeder’s pre-scalping system and variable frequency feeder enable even and continuous feeding. The pre-scalped material can be discharged through a side conveyor, which can also be folded for easy transportation.”

The hydraulically driven tracks are designed for flexible movement on site, while the compact dimensions – 15 450 mm (length) x 3 150 mm (width) x 3 600 mm (height) – enable ease of transport between sites.

Of note is that the SJC108 jaw crusher is also available in a static option. In fact, Athos Crushing & Screening has recently sold one static jaw crusher. The static SJC108 jaw crusher will also form part of the Athos modular range.

can be deployed in 250 tph production capacity requirements. The flexible adjustment of the screening angle ensures optimal screening capabilities across applications. The electrically driven screening unit reduces operational costs significantly.

500 tph

for pre-screening,

Another model in the new range is the Powertrack PT Pro C-20E, which features the SCH2000 cone crusher. Ideal for secondary and tertiary crushing, the machine has the capacity to produce between 150 and 250 tph, depending on application. The machine’s feeder conveyor and crusher are interlocked to ensure even and continuous feeding by controlling feed material. In future, Athos will bring the C-20ES, which features a hanging screen and recirculating belt.

On the screening front, Athos is launching the Powertrack PT Pro ST-08E, a mobile triple-deck screen with a 5,4 m x 1 ,5 m screen box and a large 8,4 m² screening area. With its four product conveyors, it

Lastly, Athos is launching the Powertrack PT Pro SP-08E scalping screen, which comes with a 4,8 m x 1,5 m screen box. Ideal for prescreening of feed with excessive fines such as topsoil, recycled waste and gravel, amongst others, the machine can easily handle capacities of up to 500 tph. The machine features a standard apron feeder which ensures consistent feeding of coarse material.

Aftermarket support

Customers opting for this range can have peace of mind knowing that the product is backed by a strong aftermarket regime. All the parts and technical support for anything purchased via Athos will be provided under Pilot Crushtec, which is known for its extensive parts stockholding and proven technical support capabilities in the crushing and screening market.

“With Athos Crushing & Screening now offering the SRH range, while Pilot Crushtec continues to focus on the Metso range and our own Pilot offering, the idea is to develop a true home of crushing and screening, catering for all tiers of the market, from entry level all the way up premium contractors,” concludes Marais. a

OPTIMISING LOADING CYCLES

By ensuring each piece of equipment is loaded correctly, quarries can optimise haulage efficiency, leading to better resource utilisation, increased output and more sustainable practices. Based on this understanding, two leading quarries in South Africa have deployed the VEI load weighing systems from Dynamic Weigh Systems (DWS) with great results. By Munesu Shoko.

Payload management in quarries is crucial for improving productivity, reducing operational costs and enhancing equipment longevity by preventing overloads and underloads. In light of this, KwaZulu-Natal-based Blurock Quarries and Midmar Crushers place value on payload management technology, which saw them purchase the VEI systems from DWS.

Midmar Crushers first installed a HelperX in 2014 on a Volvo L120 wheel loader, before taking delivery of a Millennium 5 for a Komatsu WA480 wheel loader in 2017. Blurock Quarries also took delivery of Millennium 5 units for its Bell wheel loaders, initially in 2014 and later in 2020, before installing a HelperM on a backhoe loader operating at its block

and precast operation in 2024.

Commenting on what makes these units tick, Ivan van Heerden, MD of DWS, the local supplier of the VEI systems in Africa, says the units have a variety of functions, not least the ability to be able to seamlessly switch from split trailer targetweighing for side tippers and then to incrementalweighing for single trailers.

“The units also do not require input from the operator in order to totalise the load. Product loading and customer selection are very easy. An additional feature is that if the specific gravity of the product is known, one can get both the cubic volume and the tonnes of the loaded product,” explains Van Heerden.

In addition, DWS also offers a three-year warranty

2014

Midmar Crushers first installed a HelperX in 2014 on a Volvo L120 wheel loader, before taking delivery of a Millennium 5 for a Komatsu WA480 wheel loader in 2017

2020 Blurock Quarries took delivery of Millennium 5 units for its Bell equipment wheel loaders, initially in 2014 and later in 2020

KEY TAKEAWAYS

Payload management in quarries is crucial for improving productivity, reducing operational costs and enhancing equipment longevity by preventing overloads and underloads

In light of this, KwaZulu-Natal-based Blurock Quarries and Midmar Crushers place value on payload management technology, which saw them purchase the VEI systems from DWS

The units have a variety of functions, not least the ability to be able to seamlessly switch from split trailer target-weighing for side tippers and then to incremental-weighing for single trailers

A key feature is that all the VEI head units can be upgraded via a simple software upgrade

on all systems. A key feature is that all the VEI head units can be upgraded via a simple software upgrade. For example, a customer can start with the costeffective HelperM unit on a small wheel loader. In the event that they upgrade their wheel loader, DWS can upgrade the system to a Millennium 5 or HelperX for the price difference of the units. “If the customer has a Millennium 5 and they need more data handling, they can move to the HelperX without having to change the system,” says Van Heerden.

Accurate loading

Derryn Fourie, director at Midmar Crushers, was first introduced to VEI systems when the quarry purchased a new Volvo L120 wheel loader and needed it to be equipped with a load weighing system. At the time, Midmar Crushers had been using competitor products on existing machines and Fourie and his team wanted to compare the units

with the VEI system in terms of performance and ease of use. Of particular importance to Midmar was also the backup service that would come with the solution.

“Fast forward to 2025, and several VEI systems later, I am happy to report that not only is the original system still operating without a single component failure, but the newer unit, installed in 2017, is as good as, if not better, than the first one,” says Fourie.

In terms of service, he adds, the three-year warranty that comes with these units has never been needed and when there is a problem, it has been rapidly resolved over the phone. The few times that DWS has been needed on site have been mostly for training.

“DWS also shows us how to maintain the accuracy of the systems so we can check and tweak calibrations as needed without having to wait for an expensive service call out,” says Fourie, adding that the operation and performance of the VEI system is “something to write home about”. The zero-point calibration, he adds, is a simple, quick push of a button. The unit also totalises the product automatically, with minimal operator intervention required. The tip-off functionality is rapid and accurate.

Ridding losses

Jeremy Hunter-Smith, CEO of Blurock Quarries, says in quarrying operations, having loaded trucks return to the stockpile from a weighbridge due to overloading or underloading is a traditional loss factor through wasted

time and fuel. With that in mind, Blurock Quarries has always placed value on payload management systems.

“We were previously using a different onboard weighing product for several years, but when we had a recommendation for the VEI system, we decided to give DWS, the local supplier, a chance to showcase the capabilities of its products,” says Hunter-Smith.

“The whole process, from quotation to installation, was seamless and professional. Once the installation was complete, the unit appeared like OEM equipment, rather than an aftermarket product. Our operator was super keen to give the new scale a try,” he says, adding that calibration was a simple five-minute process and “the training provided was top notch as DWS believes that its product is only as good as the training the client receives”.

Once the training was done, DWS provided a reallife demonstration of why quarries cannot just rely on their weighbridges. The company had just used the weighbridge to calibrate the wheel loader. However, there were still discrepancies between the loader weights and those of the weighbridge. DWS returned immediately to check the calibration. Again, all appeared to be in order until the first truck was loaded.

“DWS then suggested we weigh the loader at three different points of the deck. We discovered a 300 kg difference between the two ends of the deck. It is important to note that the weighbridge itself had just been calibrated, but due to poor maintenance and cleaning under the weighbridge, it gave false readings across different points of the deck. The error would have amounted to many tonnes of un-invoiced product over the course of a year,” says Hunter-Smith.

Being trained on how to keep the unit at peak efficiency is also a major plus for Blurock Quarries as the quarry cannot risk either the potential loss of revenue or the downtime related to waiting for a technician to arrive, with subsequent call-out costs. The three-year warranty on all parts is also extremely valuable for Blurock Quarries, although Hunter-Smith confirms that there has never been a need for it.

“We have subsequently put the smaller VEI HelperM on a backhoe loader operating at our Precast Products yard with huge success,” says Hunter-Smith. “I always joke with DWS that their products should be less robust, so that we can buy more of them!”

Proven capabilities

According to Van Heerden, VEI pioneered hydraulicbased onboard weighing in 1985. Its products to date can be found across industries, including mining, recycling and agricultural applications, to name a few.

“A total of 94 countries and over 55 000 units operating in the field give VEI an unmatched global footprint, coupled with the research and development that this exposure enables,” says Van Heerden.

According to Fourie, fast, accurate loading of trucks is paramount for quarries, where time and margins are tight. “The VEI systems supplied by DWS have paid for themselves many times over and we look forward to a continued relationship with them,” concludes Fourie. a

Bell Equipment has expanded its OEM product range with the official launch of its own motor graders

INTO NEW TERRAIN

Following years of development and a rigorous testing regime, Bell Equipment has officially unveiled its motor grader range. Comprising three base models – G140, G160 and G200 –the range represents a major step forward in the company’s strategy to expand its original equipment manufacturer (OEM) products for the global construction and mining industries. Munesu Shoko recently attended the Gauteng launch and filed this report for Quarrying Africa

To meet the emerging needs of the evolving global earthmoving industry, Bell Equipment has expanded its OEM product range with the official launch of its own motor graders.

In an exclusive interview with Quarrying Africa last year, Ashley Bell, CEO of Bell Equipment, noted that the Bell motor grader development inarguably represented the largest research and development (R&D) project in recent years. Following a nearly three-year rigorous testing

regime, which initially entailed prototype units and ultimately pre-production units, across various applications in all major grader markets such as southern Africa, North America and Australia, the range is now available for a staged commercial rollout, initially in Stage 3 markets such as Africa, Australia and South East Asia.

Why motor graders?

The ongoing development and enhancement of OEM products is a major growth strategy for Bell

For enhanced manoeuvrability, the front wheels can lean left or right, enhancing traction and stability on slopes or tough surfaces.

Equipment. This is currently anchored by the Bell motor grader range which, according to Stephen McNeill, Head of Group Marketing at Bell Equipment, is expected to roll off the Richards Bay production line during August 2025.

Why motor graders? The decision to venture into the design and manufacture of motor graders, explains McNeill, was largely informed by market fundamentals – the size and potential of the global motor grader market. The Richards Bay-headquartered OEM is strategically positioning motor graders as a core earthmoving product to complement its staple articulated dump truck (ADT) offering, especially given the fact that the global motor grader market is comparable in size to the ADT market, making it a crucial area for growth and diversification for Bell.

70%

The new Bell motor grader range consists of 70% local content

Following years of development and a rigorous testing regime, Bell Equipment has officially unveiled its motor grader range

Bell Equipment is initially introducing three base models – the G140, G160 and G200 – each with the option of a four- or six-wheel drive configuration

The Bell motor grader range offers advanced design features that give operators maximum control and flexibility to tackle a variety of tasks with precision

The sealed slew bearing delivers consistent mouldboard accuracy due to minimal wear and requires less maintenance compared to open gear designs

“Based on our market research, we have found most major ADT markets in the world to be key motor grader markets as well. Developing our own motor grader range was therefore a natural step in our quest to provide a comprehensive OEM product offering to both our dealers and customers operating in these major markets,” explains McNeill.

Engineering prowess and proven expertise in supporting motor graders were also key factors behind the decision to venture into this market, stresses McNeill. A motor grader, he adds, is a highly complex machine from an engineering

500

With the sealed slew bearing, there are no brass inserts required –just greasing at 500-hour intervals

21-t

The G140 – a 21-t machine powered by a 6,7-litre Cummins QSB6.7 engine delivering 179 kW of power – is well suited to all maintenance and light to medium construction tasks

Following a nearly three-year rigorous testing regime, the range is now available for a staged commercial rollout, initially in Stage 3 markets such as Africa, Australia and South East Asia.

perspective, largely due to its unique design features and the precision required for operation. Additionally, the advanced hydraulic systems – with up to 15 hydraulic functions needed – add to the manufacturing complexity.

“Our ADT is to date one of the most innovative machines in the global market. Leveraging that skill set behind such a globally renowned product – enabled by over 70 topclass engineers at our Richards Bay factory – we realised that we had the necessary engineering capability and resources to build our own motor grader,” says McNeill, adding that all the 3 000 employees and over 1 000 suppliers at the Richards Bay factory can be proud of this locally manufactured Bell motor grader range, which consists of 70% local content.

With over 20 years of experience in distributing, maintaining and repairing motor graders, along with insights from local and international experts, McNeill says Bell also has a clear understanding of what is important to make this product work optimally.

Range in detail

Bell Equipment is initially introducing three base models – each with the option of a four- or six-wheel drive configuration. The G140 – a 21-tonne (t) machine powered by a 6,7-litre Cummins QSB6.7 engine delivering 179 kW of power (both in 6x4 and 6x6 configurations) – is well suited to all maintenance and light to medium construction tasks.

Powered by a 9-litre Cummins QSL9 delivering 209 kW in a 6x4 configuration and 229 kW in a 6x6 configuration,

the G160 packs sufficient power and performance to handle heavy construction applications. Designed for bulk earthworks and the mining industry, the G200 is powered by a 9-litre Cummins QSL9 engine delivering 231 kW (6x4) and 245 kW (6x6) of power to undertake arduous grading operations.

The range is driven by ZF transmissions. According to Jeremiah Mokhomo, product manager at Bell Equipment, the G140 uses the Ergopower transmission, which is well respected in the grading application for entry level units. The larger G160 and G200 use the cPower hydromechanical transmission, which offers significant benefits in terms of fuel efficiency, driving comfort and productivity. It achieves this through continuously variable speed control, hydrostatic-mechanical power splitting and the ability to operate at lower engine speeds while maintaining high efficiency.

Durability in focus

One of the special design focus areas for the Bell motor grader range is durability – giving the machines the ability to withstand the toughest operating conditions, while maximising productivity and uptime. Several features speak directly to this, with Mokhomo making special mention of the sealed slew bearing, which comes as standard across the range to maintain precision.

The sealed slew bearing delivers consistent mouldboard accuracy due to minimal wear and requires less maintenance compared to open gear designs.

Smooth operators

Choose from – the G140 Eco, G140, G160 and G200 – there’s a Bell Grader built for your site and application.

Each model delivers the power, precision, and comfort you expect from a premium grader, with local Bell support you can count on:

• G140 Eco: For government and general maintenance applications

• G140: For maintenance and light to medium construction tasks.

• G160: Increased power and performance for heavy construction.

• G200: For bulk earthworks and mining applications. The three larger models are available in 4WD or 6WD. Contact your nearest Bell Dealer to find out more.

Furthermore, adjustable mouldboard inserts can be adjusted in five minutes and are designed to maximise the life of the wear inserts.

“Open gear designs found on some competitor offerings come with brass inserts, which tend to be expensive because they wear quite quickly due to the blade’s movement. To provide context, the brass inserts found on some competitor offerings are generally replaced at every 400 hours, costing clients up to R15 000 per each replacement. With the sealed slew bearing, there are no brass inserts required – just greasing at 500-hour intervals, thus reducing both maintenance and costs,” says Mokhomo.

One of the features that is directly related to durability is the main frame’s single piece construction approach, which is designed to eliminate fatigue on fabricated joints. “The single plate gooseneck, from the front to the rear, does away with welded joints. The absence of fabricated joints eliminates potential weak points and reduces the risk of failure,” continues Mokhomo.

The parallelogram design of the two-cylinder, cantilevered ripper maintains an efficient ripping angle regardless of depth. The consistent tooth angle ensures optimal performance throughout the working range. The tilting ripper beam provides a better departure angle when retracted, and the high lift design improves transport clearance.

The optional blade impact absorption accumulator (standard on the G200) acts like a shock absorber, minimising the impact on the blade during accidental contact with curbs, rocks, or other obstacles. The Bellmade tandem axle is designed with long distance operation in mind. This is supported by enhanced trunnion bearing life and integrated axle cooling for extended brake life.

Maximum control and flexibility

The Bell motor grader range offers advanced design features that give operators maximum control and flexibility to tackle a variety of tasks with precision. Whether it is adjusting blade positioning for fine grading, enhancing manoeuvrability in tight spaces, or maintaining alignment on uneven surfaces, the grader’s adaptable functionality ensures performance is tailored to each task’s needs.

The two-position drawbar, with two mounting positions, allows operators to adjust the drawbar height depending on the tyre size. This ensures the drawbar remains level,

preventing the mouldboard corners from digging or lifting as one rotates the circle during grading.

For enhanced manoeuvrability, the front wheels can lean left or right, enhancing traction and stability on slopes or tough surfaces. This feature reduces side pull, ensuring precise and efficient grading. The crab walk feature allows the grader’s front and rear wheels to steer in the same direction, allowing diagonal movement without changing orientation. This is especially useful when working around windrows, ensuring continuous grading without disturbing material placement.

Easy operation

Given that the motor grader is often considered one of the most challenging pieces of heavy equipment to operate due to the complexity of its controls and the precision required for many tasks, the Bell motor grader range places a special design focus on ergonomically engineered controls and exceptional visibility, allowing operators to work with ease and confidence. Equally, the range is designed with ultimate operator comfort in mind, ensuring reduced fatigue and thus increased productivity.

“Control is always crucial on motor graders and the Bell range has intuitive controls with a 30-button sealed switch module (SSM), and a sealed 6WD selection controller for applicable models. The 7” colour display is multifunctional for monitoring machine operation, including diagnostics and easily navigated using the automotive mouse (B-drive),” explains Mokhomo.

The advanced speed control allows precise control for optimal grading performance. An analogue highdefinition (AHD) camera system affords enhanced situational awareness, ensuring clear visibility through the 7” monitor.

The Bell motor grader range offers operators the flexibility to select their preferred control configuration, with the option of traditional antler controls or advanced joystick controls. This allows for alignment with operator familiarity and comfort, whether favouring antler controls or joystick controls, ultimately enhancing productivity on the job.

“When it comes to grade control technology, we have adopted a technology-agnostic approach. Customers are able to incorporate Leica, Topcon and Trimble grade control technology, depending on their preference. The technology-agnostic approach offers numerous benefits, including increased flexibility, allowing organisations to choose the best tools for the job,” concludes Mokhomo. a

Helping miners move less rock, use less energy, use water wisely and create less waste.

Weir is a global leader in mining technology. We recognise that our planet’s future depends on the transition to renewable energy, and that transition can only happen with the metals and minerals our mining customers deliver.

With signature brands including ESCO®, WARMAN®, ENDURON®, GEHO®, CAVEX®, LINATEX®, and MOTION METRICSTM, we combine our deep customer insights, world class engineering, materials science expertise and intelligent automation to deliver innovative end-toend mining technology solutions that help our customers move less rock, use less energy, use water wisely and create less waste — accelerating the path to smart, e cient and sustainable mining.

global.weir

EMERGING

TRENDS IN VIBRATING SCREENS

As the extractive industry continues to evolve, vibrating screen designs have adapted accordingly to meet new requirements. Corné Kleyn, Global Product Manager: Vibrating Screens at Weir, highlights some of the emerging trends in the vibrating screening market and how Weir is responding to them. By Munesu Shoko.

Vibrating screens play an integral role in mining and quarrying. The machines are essential for sorting, classifying and separating materials based on particle size, making them crucial across commodities.

As the quarrying and surface mining industries continue to evolve, so has been the design of vibrating screens to meet the increased need for more advanced screening solutions to handle the changing requirements.

According to Kleyn, several key trends are currently shaping the vibrating screen market in Africa. These include the need for high-capacity machines for brownfield expansions; demand for screens with a wide operating window to meet changing material conditions; and the growing focus on screen designs that minimise energy consumption and reduce wear and tear to ensure sustainable operations.

Additionally, there is a drive for the integration of digital

solutions in modern vibrating screens to help optimise the screening process by detecting material variations and adjusting operational parameters accordingly.

To respond to these emerging trends, Weir has recently brought to market its new ENDURON® Orbital and ENDURON® Elite vibrating screen ranges. Customer feedback, says Kleyn, was crucial in informing some of the most important design elements of these new vibrating screens, incorporating direct insights into user needs and preferences.

High throughput needs

The African mining sector, says Kleyn, has in recent years witnessed a growing appetite for brownfield expansions, especially as opencast mines seek to ramp up production and increase throughput to meet rising demand for certain commodities.

Brownfield expansions, which entail the extension of operations at existing mine sites, are becoming

50 t

The ENDURON Elite double-deck banana screens weigh up to 50 tonnes

400-500 tph

The ENDURON Orbital is ideal for smaller tonnage mining, aggregate and sand segments, with typical production rates up to 400 to 500 tph

Weir’s vibrating screens can be equipped with digital sensors and control systems to optimise the screening process.

“KEY TAKEAWAYS

As the quarrying and surface mining industries continue to evolve, so has been the design of vibrating screens to meet the increased need for more advanced screening solutions to handle the changing requirements

On the back of brownfield expansions in the mining sector, Weir has seen a rising demand for large, high-capacity vibrating screens to enable highthroughput operations

Weir notes the growing trend towards more sustainable practices in mining processes, which has led to innovations in screen design to minimise energy consumption and reduce wear and tear

One of the emerging needs in the mining and quarrying markets is the integration of digitalisation. As a result, modern vibrating screens are now equipped with sensors and control systems that help optimise the screening process

increasingly common due to their lower risk and cost compared to developing new greenfield projects. These expansions leverage existing infrastructure, geological data and operational expertise to unlock new resources and extend the life of mines.

“On the back of this trend, we have seen a rising

As mines get deeper, they start accessing areas of the pit that often contain different material from what they originally processed when they commenced operations. These variations in feed can disrupt the optimal operating parameters of processing plants, leading to overstretching of machines in some instances, and ultimately resulting in decreased recovery rates, increased operating costs and reduced overall profitability.

demand for large, high-capacity vibrating screens to enable high-throughput operations,” Kleyn expands. “Weir has responded to this trend with the 2024 launch of the ENDURON Elite vibrating screen range, offering some of the largest banana screens in the world. To provide context, the ENDURON Elite double-deck banana screens weigh up to 50 tonnes. Some of the first units operating in an iron ore application in West Africa measure 4,3 m wide by 9,7 m long, highlighting the massive nature of these screens to meet high throughput needs.”

One of the major design features of these screens are the large exciters. Weir’s ETX exciters, capable of driving a vibrating screen with a deck that spans 4,27 m, are said to

have the largest capacity of any exciter currently available on the market. Their large size allows large vibratory screens to be driven with two exciters, reducing exciter drive complexity and maintenance costs. This provides high performance and long service life. In addition, fewer exciters to maintain on site translate into reduced downtime, routine inspections and inventory management.

Changing feed conditions

As mines get older and deeper, changing feed conditions, such as variations in ore grade, particle size and mineral composition, can significantly impact the efficiency and cost-effectiveness of mineral processing operations. Understanding and managing these changes is crucial for optimising mining operations.

profitability,” says Kleyn. When feed conditions change, he adds, screens are subject to harmonic resonance, which can lead to structural failure. To mitigate against this, Weir has designed both its ENDURON Orbital and ENDURON Elite vibrating screen ranges with a wider operating window, giving operators greater flexibility to adapt operating parameters as feed conditions change.

4,27 m

Weir’s ETX exciters, capable of driving a vibrating screen with a deck that spans 4,27 m, are said to have the largest capacity of any exciter currently available on the market

“As mines get deeper, they start accessing areas of the pit that often contain different material from what they originally processed when they commenced operations. These variations in feed can disrupt the optimal operating parameters of processing plants, leading to overstretching of machines in some instances, and ultimately resulting in decreased recovery rates, increased operating costs and reduced overall

The ENDURON Orbital – ideal for smaller tonnage mining, aggregate and sand segments, with typical production rates of up to about 400 to 500 tonnes per hour, allows for throw-angle, speed and stroke adjustments without compromising the equipment’s structural integrity. As the application or feed conditions change, these screens can be easily adjusted without risk of structural failure related to harmonic resonance.

Sustainable screening

Additionally, Kleyn notes the growing trend towards more sustainable practices in mining processes, which has led to innovations in screen design to minimise energy consumption and reduce wear and tear. The shift towards sustainable solutions has significantly informed

The ENDURON Orbital range is lighter, allowing for the use of smaller exciters, increasing efficiency and reducing environmental impact.

the design and manufacturing of the new Weir vibrating screens.

For example, the ENDURON Elite banana screens form part of Weir’s transformational flowsheet solution.

“With the mining industry increasingly focused on sustainability, Weir is committed to helping its customers reduce their energy consumption in the grinding circuit. We have therefore developed our transformational flowsheet solution, which replaces traditional tumbling mills with HPGRs and vertical stirred mills,” he says. “Our transformational flowsheet features a closed circuit with the ENDURON HPGR in combination with ENDURON Elite banana screens. This powerful duo works together to deliver efficiency and cost-effectiveness for miners.”

Compared with traditional screen offerings such as triple shaft horizontal and incline machines, Weir’s ENDURON Orbital range is lighter, which allows for the use of smaller exciters than comparable offerings. The lighter nature of the screen often allows for use of a motor one size smaller than similar size screens, thus increasing efficiency and reducing the screen’s environmental impact.

In addition, the ENDURON Orbital range features an allbolted construction that improves reliability by eliminating welding in high stress areas, allowing the screens to deliver greater performance and service life. The machines’ long service life is crucial for sustainability because it reduces the need for frequent replacements, thereby minimising resource consumption and waste generation.

Individual components can be easily replaced thanks to the modular screen construction, while common interchangeable screen parts reduce inventory overflow. Exciters are bolt-on/bolt-off, meaning they can be easily changed on site and refurbished in a mechanical workshop. Both E-series and C-series exciters feature the same bearings, shafts and seals, further reducing customer spares inventory.

Driving digitalisation

One of the emerging needs in the mining and quarrying markets, explains Kleyn, is the integration of digitalisation. As a result, modern vibrating screens are now equipped with sensors and control systems that help optimise the screening process by detecting material variations and adjusting operational parameters accordingly.

To meet this growing trend, Weir has recently added NEXT Intelligent Solutions to its extensive digital solutions offering. The new technology extends and expands its existing digital capabilities and transforms its process optimisation services into real-time digital solutions.

“NEXT utilises sensors and data analytics to provide real-time insights into screen health and performance, enabling predictive maintenance and process optimisation. This allows for increased uptime, improved efficiency and enhanced sustainability for mining operations,” concludes Kleyn. a

Through Haver & Boecker Niagara’s refurbishment programme, restoring machines to near-new condition is often just over half the cost of a new screen.

SIDESTEPPING

SCREENING CHALLENGES

In aggregate production, screening equipment plays a crucial role in ensuring the quality, efficiency and profitability of operations. Yet, in southern Africa, poor procurement decisions and challenges such as skills shortage and the unpredictable cost of importing equipment, remain. Fabian Stuart, head of mineral processing and mining for Haver & Boecker Niagara’s southern Africa operation, explains how the company is helping customers sidestep these challenges. By Munesu Shoko

Commenting on some of the notable trends in the screening market in southern Africa, Stuart tells Quarrying Africa that one of the most significant challenges in the regional screening market is the high and unpredictable cost of importing equipment. Shipping fluctuations, he says, can delay delivery timelines and increase project costs. To help customers overcome this, Haver & Boecker Niagara is focusing on local solutions that reduce reliance on imports.

“A key initiative is our screen refurbishment programme. Instead of replacing ageing equipment, we assess whether a rebuild is possible. What many

operations do not realise is, often restoring machines to near-new condition is just over half the cost of a new screen. This approach not only saves money but also extends the life of existing assets, offering a practical and sustainable alternative for operations across Africa,” explains Stuart.

Despite the critical role of screening in the overall success of operations, Stuart notes that poor procurement decisions in the region, often driven by price, are made, with less emphasis on long-term performance. This, he says, can lead to short-term savings but higher costs over time due to frequent replacements or failures.

“At Haver & Boecker Niagara, we help customers

90%

With screen refurbishment, Haver & Boecker Niagara assesses and rebuilds its out-of-service screens, restoring them to 90% new condition

make informed decisions by comparing solutions side-byside – stripping away pricing to focus on quality, durability and performance. For example, one of our screens operated for 15 years at a limestone mine, compared to just five years for a competitor’s vibrating screen at the same site. That kind of longevity translates directly into operational savings and reliability,” says Stuart.

Key solutions

To respond to evolving market needs, Haver & Boecker Niagara has introduced several solutions tailored to the African market. For example, with screen refurbishment, the company assesses and rebuilds out-of-service Haver & Boecker Niagara screens, restoring them to 90% new condition. This is a cost-effective alternative to full replacement and helps customers extend the life of their assets.

“In addition, we maintain a warehouse of critical original equipment manufacturer (OEM) parts in South Africa and work closely with clients to ensure they stock sitespecific spares. This minimises downtime, thus increasing productivity and profits, while ensuring the equipment is repaired with components that meet original specifications,” continues Stuart.

A strong aftermarket support regime is another key initiative. Because of its global footprint, Haver & Boecker Niagara’s team of experts in Canada, Brazil and Germany can remotely analyse the data and provide actionable insights around the clock. This, paired with 24/7 monitoring tools such as Pulse Condition

KEY TAKEAWAYS

One of the most significant challenges in the regional screening market is the high and unpredictable cost of importing equipment. Shipping fluctuations can delay delivery timelines and increase project costs

To help customers overcome this, Haver & Boecker Niagara is focusing on local solutions that reduce reliance on imports. A key initiative is its screen refurbishment programme. Instead of replacing ageing equipment, it assesses whether a rebuild is possible

Despite the critical role of screening in the overall success of operations, Haver & Boecker Niagara notes that poor procurement decisions in the region, often driven by price, are made, with less emphasis on long-term performance

Haver & Boecker Niagara helps customers make informed decisions by comparing solutions sideby-side – stripping away pricing to focus on quality, durability and performance

24/7

To help bridge the skills gap, Haver & Boecker Niagara developed Pulse Condition Monitoring – a smart, 24/7 monitoring system that uses AI to track the health and performance of vibrating screens

“What many operations do not realise is, often restoring machines to nearnew condition is just over half the cost of a new screen. This approach not only saves money but also extends the life of existing assets, offering a practical and sustainable alternative for operations across Africa.

Monitoring, allows operations to be more proactive with maintenance, even in regions where experienced labour is becoming harder to retain.

In addition, the company has conducted side-by-side tests of its screen media against competitors’ products in real-world applications. In every case, says Stuart, Haver & Boecker Niagara’s media has outlasted the alternatives –sometimes by more than double the lifespan.

“What truly sets Haver & Boecker Niagara apart is our ability to serve as a full solutions provider – a one-stop shop for screening technology, service and support. We do not just sell equipment; we partner with our customers throughout the lifecycle of their machines. From OEM parts and rebuilds to diagnostics and aftermarket service,

we provide everything needed to keep operations running efficiently,” he says.

A key part of that value, he adds, is the quality of the company’s vibrating screens and screen media. In regions where lower-cost imports are common, Haver & Boecker Niagara’s equipment is said to stand out for its durability and performance.

The future

Commenting on some of the major developments that we are likely to see in the near future when it comes to screening, Stuart says minimising downtime remains a top priority for aggregate operations and expects manufacturers to continue focusing on technologies that support faster maintenance and more reliable performance.

“One of the most impactful developments is the integration of vibration analysis software into screening equipment. In Africa, many skilled labourers are leaving for opportunities abroad, which makes it more difficult for operations to retain experienced personnel. To help

bridge that gap, we developed Pulse Condition Monitoring – a smart, 24/7 monitoring system that uses artificial intelligence to track the health and performance of vibrating screens,” he explains.

“If a screen begins to underperform or shows signs of failure, Pulse Condition Monitoring alerts operators directly on their mobile devices. We like to say it gives operators a ‘Superman’s eye’, allowing them to see issues that are not visible to the naked eye. It is a powerful tool for staying ahead of maintenance needs and avoiding costly downtime,” adds Stuart.

Haver & Boecker Niagara has also made significant improvements to its screen media. For its vibrating screens used in aggregates, the company has transitioned from traditional woven wire mesh to polyurethane panels. These panels offer greater durability, longer wear life and better performance in wet or corrosive environments.

Another innovation Stuart is excited about is the new Ty-Deck Twist system for screen media panels. Traditionally, removing and installing screen media panels required hammers or mallets, which could be time-consuming and physically demanding. In some cases, screens would be offline for up to three days during resurfacing. Haver & Boecker Niagara’s Twist technology replaces the hammer-driven pins with a screw-like mechanism, allowing operators to quickly and easily secure or remove panels. This simple change can reduce maintenance time from three days to just one, significantly improving uptime and efficiency.

“At Haver & Boecker Niagara, we are more than an equipment supplier – we are a long-term partner. Our goal is to be a one-stop resource for customers. We believe in building trust through transparency, quality and responsiveness. As skilled labour becomes harder to find in some regions, our tools and services help bridge the gap, ensuring that even with fewer hands on site, operations can run smoothly and efficiently,” concludes Stuart. a

ust and spillage from insufficient transfer sealing can jeopardize worker health, impair equipment performance, and negatively impact your bottom line. Martin Engineering delivers comprehensive solutions to control fugitive material and maintain a clean and efficient operation.

Martin's easy-to-install Modular Transfer Point Kits — with several loading, settling, and stilling zone configurations — combined with our ApronSeal™ dual-seal skirting, wear liners, and impact cradles, effectively arrest fugitive material while maximizing material flow. When transfer locations are properly designed and maintained, operations run cleaner, safer, and more efficiently.

Multotec’s side tension polyurethane (PU) mats have been designed specifically for the quarrying industry.

KEY TRENDS IN SCREEN MEDIA

Like many other segments of the quarrying and mining value chain, the screen media market is undergoing a notable transformation, with a shift towards more intelligent, efficient and sustainable solutions, ultimately contributing to improved productivity and profitability.

Speaking to Quarrying Africa, experts from Multotec and MAJOR discuss some of the emerging trends in this market. By Munesu Shoko.

In recent years, the screening and screen media market in Africa has witnessed significant transformation driven by the demand for increased efficiency and durability in challenging mining and quarrying environments. That is the view of John Pelser, territory manager, Africa at MAJOR, who notes a marked shift towards the adoption of high-performance screen media, which offers longer wear life and reduced maintenance in most applications, compared to traditional wire or synthetic media, such as rubber and polyurethane.

The same view is shared by Pieter Uys, business development manager at Multotec, who says there is

a definite shift, perhaps not a trend in the traditional sense yet, towards alternative screening media solutions in applications where conventional options such as woven wire mesh no longer adequately address operational challenges. This growing shift, says Uys, is seeing quarry operators explore more advanced and efficient screening media tailored to their specific operational requirements.

Drivers and response

Commenting on the major driver behind the marked shift towards the adoption of highperformance screen media, Pelser says there is a continuous pursuit for operational efficiency, with

MAJOR’s FLEX-MAT modular design, manufactured in most of the existing attachment systems, allows for swift and easy replacement of components, minimising downtime and maximising efficiency.

mining companies seeking to maximise output while minimising downtime and costs.

“The demanding conditions prevalent in African mining operations, including abrasive ores, have underscored the necessity for durable, high-performance materials that not only outlast traditional options, but provide additional benefits in optimising screening efficiency,” says Pelser.

According to Uys, the new generation of quarry and plant managers are more approachable to exploring innovative solutions beyond the traditional norms. “Gone are the days of the ‘we have always done it this way’ attitude. The availability of new technologies, combined with the desire to be proactive rather than reactive in plant management, is transforming the way the industry operates,” says Uys.

In response to this industry trend, MAJOR has introduced a suite of innovative screening solutions tailored to most of the unique challenges of African mining environments. Its patented high-performance OPTIMUMWIRE Technology combined with its FLEX-MAT High-Vibration screen media are engineered to extend wear life, reduce maintenance and provide consistent performance in even the harshest conditions.

“These solutions leverage advanced designs in both modular and tension screen media, making it easier for operators to customise screens for specific application changes, as well as to replace worn components more

KEY TAKEAWAYS

The screening and screen media market in Africa has witnessed significant transformation driven by the demand for increased efficiency and durability in challenging mining and quarrying environments

There is a definite shift towards alternative screening media solutions in applications where conventional options such as woven wire mesh no longer adequately address operational challenges

Digital monitoring technologies are gaining traction, allowing operators to track screen performance in real time and predict maintenance needs before issues arise

The availability of new technologies, combined with the desire to be proactive rather than reactive in plant management, is transforming the way the industry operates

efficiently,” explains Pelser.

The solutions introduced by MAJOR are distinguished by several key features and benefits designed to address the core demands of today’s African mining operations. FLEX-MAT High-Vibration screen media boasts high durability, offering increased production,

With Multotec side-tension MBV mats, only areas that have failed need to be replaced, instead of replacing the whole large sheet because of failures in smaller areas of the screening deck.

cleaner products passing through and extended wear life that translates into fewer replacements and lower overall maintenance requirements.

“Our FLEX-MAT modular design, manufactured in most of the existing attachment systems, allows for swift and easy replacement of components, minimising downtime and maximising efficiency. With a strong focus on mining, MAJOR developed the OPTIMUMWIRE PLUS technology. This patented wire technology challenges the wear resistance of synthetic screen media such as rubber and polyurethane in high impact zones, while also increasing screening efficiency,” details Pelser.

Multotec, says Uys, has consistently focused its efforts on developing and refining solutions to address these evolving client needs. Some of its solutions have been proven in mineral processing applications – such as the rubber screening solutions – while others have been designed specifically for the quarrying industry, including side tension polyurethane (PU) mats and side tension MBV mats.

Digital monitoring

In addition, says Pelser, digital monitoring technologies are gaining traction, allowing operators to track screen performance in real time and predict maintenance needs before issues arise. Sustainability, he adds, has also emerged as a significant trend, with mines seeking environmentally friendly screening solutions that minimise waste and enhance energy efficiency. These advancements are helping mining operations across Africa improve productivity, reduce downtime and adapt to evolving industry requirements.

“The rise of digitalisation across the industry has

encouraged adoption of smart monitoring technologies that empower operators with real-time data and predictive maintenance capabilities,” says Pelser. “Growing environmental awareness is also a significant driver, as both regulatory pressures and corporate sustainability goals push mines toward greener, more energy-efficient screening solutions. Collectively, these drivers reflect a broader shift in the industry toward innovation, resilience and responsible resource management.”

To support the industry’s digital transformation, MAJOR has rolled out its latest integrated ID Enabled monitoring technology using RFID Microchips in all its screen media. This enables real-time tracking of the screen and its full description. The next development phase of this technology, says Pelser, will focus on tracking performance, providing actionable insights, helping operators anticipate maintenance needs and optimise screening efficiency, ultimately reducing costly unplanned downtime.

To help customers achieve their digital transformation targets, Multotec has invested heavily in smart technologies such as sensor panels, Hawkeye condition monitoring, Finite Element Analysis (FEA), Discrete Element Modelling (DEM) and various digital tools for equipment selection. Multotec also offers slurry pumps, another product the company delivers to the quarrying industry.

“Our primary objective is to reduce our clients’ total cost of ownership. These solutions improve equipment lifespan, reduce downtime, lower labour requirements, simplify and speed up maintenance, reduce operational noise, enhance screening accuracy, and boost overall screening efficiency. Additionally, by incorporating predictive maintenance

To support the industry's digital transformation, MAJOR has rolled out its latest integrated ID Enabled monitoring technology using RFID Microchips in all its screen media.

technologies, we enable clients to address potential issues before they result in equipment breakdowns – a proactive strategy that can save quarries significant time and money,” says Uys.

Apart from digital transformation, sustainability remains central to MAJOR’s approach. The company, says Pelser, has developed ecofriendly screening products using recyclable materials in the manufacturing processes, thus minimising environmental impact. These innovations help mines meet both regulatory standards and their own sustainability objectives, all while supporting productivity and operational resilience.

Future developments

Commenting on major developments likely to come to this market in the near future, Uys anticipates the continued rollout of new side tension and end tension PU and rubber screening solutions, specifically tailored for the sand and aggregate sectors. Furthermore, he says, predictive maintenance technologies will advance rapidly, offering even more accurate insights and operational efficiencies.

“The quarrying industry remains dynamic and highly competitive, with cost-per-tonne production metrics more crucial than ever. At Multotec, our solutions are designed to tackle longstanding industry challenges while paving the way for future operational improvements and efficiencies,” says Uys.

According to Pelser, sustainability will remain at the forefront, driving the development of new ecofriendly materials, closed-loop recycling processes and energyefficient manufacturing techniques. As mines continue to

face increasing regulations, he adds, solutions that reduce carbon footprint and resource consumption will become critical.

“The future will also likely see a more collaborative ecosystem, where manufacturers, operators and technology providers work closely together to codevelop customised solutions tailored to evolving operational demands. This spirit of partnership is expected to accelerate the pace of innovation and ensure that the industry is well-equipped to tackle both current and emerging challenges,” says Pelser.

In conclusion, Pelser says screen media is ultimately the mechanism that keeps the sellable rock from being sent to the crusher, and maximising its efficiency should not come with higher maintenance in the process. “Some manufacturers promising quieter or cheaper screen media have forced customers to compromise on the goal of performance and efficiency. High-vibration wire screens such as FLEX-MAT offer a solution, not another compromise,” reports Pelser.

At MAJOR, he adds, products are purpose-built to deliver performance, and the company would not recommend a solution unless it is confident that it will deliver the return on investment customers expect. MAJOR’s global dealer network, supported by experienced territory managers, is trained to offer on-site support, from inspections to application advice.

“We are also open to connecting with industry partners who share our values and are interested in growing with us. If you are exploring dealer opportunities, or you are interested in high-performance screen media, we would be happy to speak with you,” concludes Pelser. a

GAINING

EXTRACTIVE TRACTION

Having enjoyed construction-driven growth in the past five years, Machinery Exchange, part of the larger Industrial Exchange Group (IEG), a leading multi-brand capital equipment distributor based in Zimbabwe, has this year recorded major successes in the mining industry. In a one-on-one with Quarrying Africa, Group Sales & Marketing Manager Antony Dube, discusses some of the recent major deals and the prospects of growth in the mining sector. By

Munesu Shoko

.

8

Machinery Exchange has supplied Hwange Colliery with eight Shantui L68 wheel loaders, which have contributed significantly towards its efficiency and production improvement initiatives

70%

Machinery Exchange observes encouraging growth prospects in the gold mining industry. Mining remains a cornerstone of Zimbabwe’s economy, representing 10-12% of GDP and 70% of exports

In recent years, Zimbabwe has been actively investing in road infrastructure development as part of its broader National Development Strategy. The Zimbabwean government has embarked on massive reconstruction and rehabilitation projects on major road networks to enhance both domestic and regional connectivity.

This includes rebuilding and rehabilitating existing road networks, particularly key highways such as the Beitbridge-Harare-Chirundu Highway, a crucial trade route for the southern African region at large. The busy highway leads through five provinces of Zimbabwe and is one of the most important links between the TransAfrica Highway and South Africa.

KEY TAKEAWAYS

On the back of a massive road construction project rollout in Zimbabwe, Machinery Exchange has enjoyed construction-driven growth over the past five years

The growing uptake of the Kleemann range of mobile crushers and screens has been one of the notable growth stories for Machinery Exchange

While construction remains a key pillar of Machinery Exchange’s business in Zimbabwe, the company has a strong focus on growing its footprint into the mining sector this year and beyond

Machinery Exchange has recently delivered three Hitachi EX1200 excavators, its largest excavator model in Zimbabwe to date, to JR Goddard Contracting, the main contractor at a large-scale gold mine

On the back of this massive road construction project rollout, Machinery Exchange, part of the Industrial Exchange Group – a multibrand capital equipment distributor that represents leading brands such as Wirtgen Group, Hitachi Construction Machinery, Powerstar, Shantui, Sinotruk, Bobcat, Rokbak and Cummins Power Generation, amongst others – has enjoyed construction-driven growth.

Crushing and screening growth

While this construction-driven growth has been felt across several brands within the group’s stable, Dube notes the growing uptake of the Kleemann range of mobile crushers and screens as one of the notable growth stories for Machinery Exchange.

Since the start of the road construction initiatives in Zimbabwe, the company has sold a number of Kleemann trains in the country, with some of the major contractors taking delivery of these units, deploying them on quarries that supply main road works in the country.

As the Kleemann growth trajectory continues, Tensor Systems and Masimba Holdings, two leading infrastructural development companies in Zimbabwe, are the latest contractors to take delivery of Kleemann trains – each comprising an MC 110 EVO2 jaw crusher, an MCO 9 EVO2 cone crusher and an MSC 703 EVO screen.

“The recent delivery and commissioning of these two trains is

testimony to the continued success of the Kleemann brand under the stewardship of Machinery Exchange in Zimbabwe. We look forward to the sustained uptake of these units, especially with major road projects such as the Harare-Chirundu and Bulawayo-Victoria Falls set to commence soon,” says Dube.

Focus on mining

While construction remains a key pillar of Machinery Exchange’s business in Zimbabwe, Dube says the company has a strong focus on growing its footprint into the mining sector this year and beyond. Given a reduction in construction activity, Dube says the mining sector offers better prospects for growth, particularly in the precious metals market, especially gold, which is currently experiencing a bull run.

To provide context, gold has had a remarkable rally, with prices soaring from around US$1 618 in late 2022 to an all-time high of US$3 509 by July 2025, with historical trends suggesting that there is still room for growth, especially in the second half of the decade.

Dube is also encouraged by prospects in the country’s platinum mining industry. Platinum mining in Zimbabwe is experiencing significant growth, driven by increasing global demand for the mineral – a critical component in the emerging hydrogen economy. Zimbabwe is home to the world’s second largest platinum deposit and the current price environment unlocks major opportunity for the country’s major producers.

On the back of this favourable market environment, Machinery Exchange has supplied two Hitachi ZX690s excavators to leading platinum producers, further cementing its status as a leading earthmoving equipment supplier within the industry. The company provides 24/7 aftersales support and maintenance for all the equipment sold.

Coal, adds Dube, is another commodity of interest to Machinery Exchange. Coal mining in Zimbabwe is experiencing a period of growth, with increased investment in the sector. Various factors contribute to this upward trend, including increased exports into the Democratic Republic of Congo (DRC), where demand for both steel and coal is surging.

Hwange Colliery, a major player within the Zimbabwean coal mining industry, has invested over US$3-million in a new coal wash plant as the company seeks to improve efficiency and production. Machinery Exchange has supplied the company with eight Shantui L68 wheel loaders, which have contributed significantly towards Hwange Colliery’s efficiency and production improvement initiatives.

“As one of the leading suppliers of premium capital equipment in Zimbabwe, we are excited about the prospects of growth in the mining

and quarrying value chain. We have therefore set our sights on growing our foothold in these markets. In fact, we have already set the ball rolling with some major mining equipment deals this year,” says Dube. “A case in point is the recent delivery of three Hitachi EX1200 excavators, our largest excavator model in Zimbabwe to date, to JR Goddard Contracting, the main contractor at a large-scale gold mine.”

The EX1200 units, delivered in May this year, joined another Hitachi excavator, a ZX670LCH-5G unit delivered to JTL Equipment at the same mine in March this year. At the time of writing, the company also expected to deliver a second Hitachi excavator to one of the major platinum mines in the country, highlighting the quick growth of this range in the mining sector.

Growth drivers

One of the major drivers behind Machinery Exchange’s recent growth in the mining sector, explains Dube, is the fact that some of its existing construction customers are confident of high levels of after sales support services provided by the company. By establishing itself as a one-stop heavy equipment shop, Machinery Exchange has an unrivalled aftersales support team comprising Customer Support Division (CSD), Engineering Division (ENG) and Spare Parts Exchange (SPE).

The CSD division is responsible for the aftersales support of all the equipment sold and rented into the field. It prides itself on its commitment to supporting its customers with a comprehensive aftersales infrastructure, designed to improve equipment uptime while lowering total cost of ownership. Furthermore, the division offers on-site or on-call Maintenance Agreements for select customers, allowing Machinery Exchange to carry out all service, repairs and maintenance of a customer’s fleet of equipment as required.

The equipment is monitored 24/7 through Machinery Exchange’s Fleetrack system which is designed to systematically log and monitor all aftersales issues that may arise with customers’ machines and trucks. The equipment does not necessarily have to be supplied by Machinery Exchange to utilise this service.

The ENG division, with its team of highly experienced boilermakers, machinists, welders and undercarriage technicians, is able to repair and recondition buckets, H-frames, swing levers, Z-bars and

Machinery Exchange has recently delivered three Hitachi EX1200 excavators to JR Goddard Contracting, the main contractor at a large-scale gold mine.

associated linkages, as well as machining of pins, bushes and line boring – both in the shop and on site. Furthermore, with its 200-t track press, it offers rehabilitation and reconditioning of all undercarriage components and field service repairs.

Lastly, the SPE business unit specialises in the stocking and sale of OEM parts for all Machinery Exchange dealerships and aftermarket parts to cover a full range of other associated brand equipment, in addition to assisting customers with all their technical queries. In addition, it manages the dynamic Wear Track Service (WTS), which provides customers further product support for their tracked machines.

“In addition to existing customers, we have also seen a number of new customers who have previously preferred other brands making a switch to us. Apart from the fact that we are home to some of the leading premium brands, customers in Zimbabwe are starting to appreciate the importance of a strong aftermarket regime, which is becoming a big factor in their buying decisions.

With branches in Bulawayo and Hwange, potential and existing customers such as Hwange Colliery have realised the benefits of having Machinery Exchange’s support services within reach. This is particularly the case in mining, where any form of downtime is out of the question,” says Dube.

Having previously been driven by price, capital equipment owners in Zimbabwe, says Dube, are increasingly placing aftermarket support at the core of their buying decisions because it directly impacts the long-term operational efficiency, reliability and costeffectiveness of their investments. Effective aftermarket support ensures smooth operation, minimises downtime and optimises the equipment’s overall lifecycle, which is vital for maintaining productivity and profitability.

“The high quality of the machines we supply, complemented by short lead times, good technical support and rapid availability of genuine original

equipment manufacturer (OEM) spare parts has been key to our growth in mining. Over the years, we have invested significantly in our parts stockholding, as well as having a large pool of highly competent technicians to look after our customers’ equipment on the ground,” says Dube.

Traditionally, he adds, the company only kept parts for the machinery it supplies, but this has been expanded to include fast-moving items for competitive brands not necessarily distributed by Machinery Exchange. The decision, explains Dube, was influenced by the realisation of an apparent gap in the market created by some equipment suppliers who do not put emphasis on parts stockholding for the machinery that they supply. By offering parts for a variety of equipment, including competing brands, Machinery Exchange has captured a larger share of the parts market and become a more valuable partner to customers operating in the country.

Looking ahead

Looking ahead, Dube observes encouraging growth prospects in the gold mining industry. Mining remains a cornerstone of Zimbabwe’s economy, representing 10-12% of GDP and 70% of exports.

“The earthmoving equipment industry has noted a rise in the interest of excavators, including Hitachi EX1200 units, which have been supplied to key clients such as JRG, Shamva Mine and Plant Support Africa, amongst others, operating in the gold mining sector. Notably, Shamva Mine and TN Gold are potential customers that could benefit from these investments. Production has risen through the modernisation of existing mines and new underground projects. Refinery throughput has increased, retaining more value locally, which further supports the sustainable growth of these mining operations. Zimbabwe boasts over 63 minerals across all 64 districts, including gold, platinum, lithium, chrome, diamonds and coal,” concludes Dube. a

AXXIS delivers favourable outcomes from complex blasting.

FACILITATING

COMPLEX PIT DESIGN CHANGE

The blasting expertise of BME’s AXXIS Product Support and Global Blasting Technical Services (GBTS), together with the drill and blast team at an open-cut metallurgical coal mine, successfully implemented complex pit design changes. This collaboration enabled the adoption of a more efficient blasting method, significantly enhancing operational efficiency.

This project was essential to overcome the limitations on excavation caused by the previous bench design philosophy implemented. Difficult geology in the lower 20 m of the blast bench also contributed to poor fragmentation results, which further impeded performance.

By integrating production benches across multiple pits and increasing the blasted depth from 24 m to 48 m, the mine has significantly reduced both costs and cycle times. These improvements stem from faster overburden removal using excavators and haul trucks, streamlining the overall extraction process.

“The mine has since reduced downtime due to inefficient blasting and achieved the desired fragmentation which, together with optimised load and haul operations, has increased overall productivity,” says BME’s GM of Marketing and Technology, Nishen Hariparsad.

Overcoming challenges

2

An innovative blast initiation sequence was designed to activate two central lift points within the blast zone, thereby creating relief by incrementally increasing the timing from these points

Hariparsad says that the project posed a number of challenges, including the need to maintain optimal fragmentation and blast performance when integrating the benches.

“A poor result could have resulted in a large area that would be difficult to excavate – which would also require costly remediation,” he explains.

BME’s GBTS team and AXXIS Product Support and the mine’s drill and blast team also had to work around limiting pre-existing conditions. While the mine already had a sound drill and blast process, the face of the lower bench could not be drilled due to the original bench design and high wall standoff. “As such, we had to adopt a

different blast style,” he says.

During the planning phase, the amount and use of explosive energy – as well as how these would be impacted by initiation – were carefully considered.

“Blast area size and rock response time were also important factors as these would ensure that adequate burden relief was introduced to facilitate blast movement and secondary fragmentation,” says Hariparsad.

He adds that an innovative blast initiation sequence was designed to activate two central lift points within the blast zone, thereby creating relief by incrementally increasing the timing from these points.

“Ensuring sufficient timing was of utmost importance to effectively blast rock so as to maintain the desired fragmentation,” he elaborates.

Ensuring high accuracy

BME’s AXXIS digital initiation system was critical to ensure the high accuracy required to undertake the blast. The flexibility of the AXXIS system enabled the calculated initiation timing to be programmed down to submillisecond accuracy, providing absolute control. He said that the timing was designed in elliptical form to facilitate favourable surface movement under given conditions.

“The blast was then simulated using BME’s BLASTMAP software, an enabling tool of the AXXIS digital initiation system. In this way, we were able to commit predictable outcomes before actual detonation,” he explains.

To ensure that the correct blast design was implemented, the rock geology was assessed ahead of time. He adds that explosive type, strength and loading

KEY TAKEAWAYS

The blasting expertise of BME’s AXXIS Product Support and GBTS, together with the drill and blast team at an open-cut metallurgical coal mine, successfully implemented complex pit design changes

The project posed a number of challenges, including the need to maintain optimal fragmentation and blast performance when integrating the benches

During the planning phase, the amount and use of explosive energy – as well as how these would be impacted by initiation – were carefully considered

BME’s AXXIS digital initiation system was critical to ensure the high accuracy required to undertake the blast

for each hole were also considered and the powder factor adjusted around the central initiation points to ensure that there was sufficient energy to create relief within the blast. As anticipated, the blast design achieved the desired fragmentation at deeper levels, which was previously a key concern considering its potential impact on performance.

“Based on the success of this blast, the mine has continued to use this method to merge benches and the new mining approach. This positive project outcome has enabled our customers to work towards achieving their goal of establishing a new benchmark for coal mining productivity and efficiency, further showcasing how BME’s AXXIS system delivers predictable outcomes,” concludes Hariparsad. a

24-48 m

Difficult geology in the lower 20 m of the blast bench also contributed to poor fragmentation results, which further impeded performance

By integrating production benches across multiple pits and increasing the blasted depth from 24 m to 48 m, the mine has significantly reduced both costs and cycle times

PASSIVE DUST CONTROL

IN CONVEYOR LOADING ZONES

Historically, transfer points have been designed primarily for material throughput and secondarily for fugitive material control. However, dust control and spillage have come to the forefront as serious workplace safety issues and have also been linked to a greater cost of operation from cleanup and equipment fouling. This makes addressing dust and spillage through engineered transfer chute design both critical and practical, writes Todd Swinderman, President Emeritus at Martin Engineering.

“P

assive dust control” is any measure not involving dust bags, mechanical dust cleaners, hooded air cleaners and HVAC, amongst others.

The testing and application of passive dust control measures in a wide range of bulk handling applications

using dust curtains and skirting have proven to be an effective control measure for dust. However, this equipment needs to be installed correctly and strategically to maximise results and the return on investment.

When redesigning a dust control enclosure at a conveyor belt transfer point, skirtboard extensions (wear

75 m

Using the commonly applied Stoke’s Law, a 10 μm respirable limestone dust particle in an air stream travelling 1 m/s is predicted to take 75 m to settle by gravity alone

liners, polyurethane skirting, clamps, etc.) to seal the environment and the placement of dust curtains to control airflow are essential.

Most engineering firms use the American Conference of Governmental Industrial Hygienists (ACGIH) Industrial Ventilation Handbook design criteria for active dust control (dust machines, dust bags, sprayers, etc.). The design rules for skirtboard extensions are based primarily on lump size and the length necessary for the bulk material to settle down into a stable profile.

By understanding the environment inside the transfer point and how the structural components work together during operation, dust and spillage can be mitigated and the external environment will improve.

Dust dynamics

Air is very compressible and will find the path of least resistance. With current enclosure designs, the air is sped up significantly to flow under or around a single exit dust curtain with narrow

300-450 mm

When multiple curtains were tried, the best combination was with a curtain 300-450 mm from the beginning of the skirtboards, one curtain in the centre and an exit curtain 300 to 450 mm from the end of the enclosure

50 mm

Testing has shown that, in most cases, curtain strips were nominally 50 mm wide with a gap between the strips of at least 5 mm being necessary to cause airflow through the curtain rather than under it

KEY TAKEAWAYS

Historically, transfer points have been designed primarily for material throughput and secondarily for fugitive material control

However, dust control and spillage have come to the forefront as serious workplace safety issues and have also been linked to a greater cost of operation from cleanup and equipment fouling

When redesigning a dust control enclosure at a conveyor belt transfer point, skirtboard extensions to seal the environment and the placement of dust curtains to control airflow are essential

Retaining a proper seal using skirting set in the modern skirtboard extension configuration will eliminate gaps where air can escape taking dust and fines with it

slits, resulting in re-entraining the dust particles in the exhaust. Therefore, it is necessary to create recirculation regions inside a transfer point to improve dust settling.

The basic concept is the trajectory of a dust particle can be modelled based on the terminal velocity (Vt) of the dust particle settling in still air and the velocity of the airflow in the transfer point (Vair). The result of these two velocities using the enclosure height (H) as the vertical drop distance indicates the length (L) necessary to settle the dust particle. If the terminal velocity of the particle is very small and the transfer point air speed is relatively large, the settling distance can be quite long.

Using the commonly applied Stoke’s Law, a 10 μm respirable limestone dust particle in an air stream travelling 1 m/s is predicted to take 75 m to settle by gravity alone. This makes a well-designed enclosure with the proper height, seal and air control with curtains essential to controlling dust.

Preferred embodiments

When reducing dust emissions, field tests have shown the difference in performance for longer and taller skirtboards of 4 800 mm long and 900 mm high compared to 3 600 mm long and 600 mm high is negligible. It was the placement of dust curtains that had the greatest impact on dust settling.

In both transfer point sizes, enclosures with three curtains spaced 300 mm apart from the entrance and exit and one in the centre offered superior performance as compared to one dust curtain at the end. The best value for the cost of the skirtboard enclosure and its effectiveness is 600 mm high and 3 600 mm long,

using either the retrofit or metered discharge chute-toskirtboard connection.

The junction between the discharge chute and the skirtboards was found to be an important design detail for creating recirculation. Most conveyor engineers and manufacturers use 300 mm high skirtboards, because this height is about the minimum for installing a sealing system and wear liners.

In most of the models, the discharge chute was 200 mm narrower than the skirtboards. Making the width of the discharge chute narrower than the width of the skirtboard helps to fold the airflow going into the first curtain, and that encourages the distribution of the airflow toward the top of the enclosure rather than along the surface of the bulk material. Extending the head chute back to the first full troughing idler on the carrying side and using two curtains plus sealing the area between the top and bottom runs is critical in reducing induced airflow.

Height of the tail box

The tail box had little effect on dust emissions out of the exit end of the skirtboards. In most configurations, the height of the tail box was set at 300 mm. The tail box length was set at 600 mm to match the typical 600 mm idler spacing used in the load zone by most conveyor manufacturers and engineers.

Very little airflow or pressure increase was observed in the tailbox for most configurations, so its main function should be considered reducing roll back of material and creating a means to effectively seal past the corner of the loading chute.

Let us talk about air flow

In field tests, three different airflow volumes of 0,25, 0,50 and 0,75 m³/s were used to represent induced air (for reference, 0,50 m³/s is about 1 000 cfm, or cubic feet per minute). As would be expected, the average air velocity through the skirtboards was directly proportional to the induced airflow.

The maximum air velocities in the skirtboard are almost always found where the air flows under the curtains. Air velocities of 30 m/s were common under the curtains, with up to 90 m/s observed. These high air speeds keep the respirable dust suspended, so lowering induced air into the chute is important for improving performance.

The length of the skirtboard had some effect on dust discharges for the standard conveyor with a single exit curtain. With three curtains spaced 25 mm above the belt, there was a similar reduction in the emission ratios, but at a much lower percentage of particles escaping. Keeping the airflow (and therefore the flow of bulk material) consistent through the transfer is important to improving dust settling. Different baffle arrangements were tried to encourage recirculation within the discharge chute and the skirtboards, with little effect.

Time to arrange the curtains

Testing has shown that, in most cases, curtain strips were nominally 50 mm wide with a gap between the strips of at least 5 mm being necessary to cause airflow through the curtain rather than under it. While it varies by application, it appears that a gap of 10 to 15 mm produces the best combination of recirculation and keeping the average air speed inside the skirtboards more uniform and at a lower velocity.

When multiple curtains were tried, the best combination was with a curtain 300-450 mm from the beginning of the skirtboards, one curtain in the centre and an exit curtain 300-450 mm from the end of the enclosure. This pattern was found for all skirtboard lengths, heights and belt widths. A minimum of two chambers created by the spaces between curtains was necessary to create recirculation patterns within the skirtboards.

Recirculation within the chambers created longer settling paths for the respirable dust, which improved dust control performance. A slight improvement was found by increasing the number of curtains and spacing them evenly. Configurations of up to six curtains were tried. Staggered curtains and combinations of full width and staggered curtains did not improve performance. And above all, the dust curtain systems must be accessible and maintainable to gain the benefits of passive dust suppression.

Case study

A copper mine in Arizona was having serious issues containing dust and spillage at a main conveyor transfer point carrying raw material from the mine to the processing plant. Fugitive material spilled into the walkway, requiring manual cleaning/shovelling every day by a team of workers, taking over an hour. Dust emissions limited visibility and posed a possible workplace violation due to low air quality. Several solutions were tried but nothing worked, so plant operators bought a temporary conveyor to help alleviate the issue until a solution could be installed.

Martin Engineering technicians assessed the situation and installed heavy-duty Martin ApronSeal Skirting along the entire enclosure to seal the loading zone, stilling zone and settling zone. The skirting created an effective, low-maintenance, multiple-layer seal to keep fines on the belt and dust inside the enclosure. The primary seal acts as an inner barrier, keeping material inside the chute, while the secondary seal captures dust. With external access, the low-pressure seal requires minimal adjustment.

Revisiting the system five months after the installation, technicians found that cleanup was reduced to being performed by one employee for only ten minutes once per week. The temporary conveyor was removed and reassigned elsewhere. The customer was “very pleased with the excellent service” provided by Martin Engineering. The plant is no longer concerned with incurring MSHA violations for this system and continues to work with Martin Engineering for other solutions.

Conclusion

Controlling the amount of airflow through the transfer is also critical. The results of field tests and applied techniques clearly indicate that when dust curtains are properly spaced and kept adjusted close to the bulk material profile, the passive reduction of dust emissions is significant. Retaining a proper seal using skirting set in the modern skirtboard extension configuration will eliminate gaps where air can escape taking dust and fines with it.

Passive dust control has gone beyond merely adding some skirting and a dust curtain at the end of a chute. New retrofitted curtain and skirting designs require little monitoring and only occasional maintenance while significantly improving the work environment around the transfer point. The amount of labour saved in the cleanup around the transfer point and the cost of replacing fouled equipment lowers the cost of operation and improves the return on investment. a

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PRECISION IN EVERY BLAST. PREDICTABLE OUTCOMES.

BME’s AXXIS™ range – Silver, Titanium, and CEBS – delivers world-class electronic initiation trusted by mines across five continents.

Built for precision, safety, and sustainability, AXXIS™ empowers engineers and blasters to achieve consistent, high-performance blasts – even in the most demanding conditions.

• AXXIS™ Silver – Proven reliability for quarries and mid-sized mines.

• AXXIS™ Titanium – Advanced control with best-in-class safety and data capabilities.

• AXXIS™ CEBS – Centralised blasting with unmatched scale and efficiency.

With AXXIS™, you don’t just initiate blasts –you initiate progress.

Designed with a unique combination of power and intelligence the TA 230 features market leading technology, an innovative weighing system, automatic traction contre, hill start assist, not to mention the superior cabin design to leave your operator feeling good. Simply put, a perfect mix of agility with outstanding performance.