Quarrying Africa ISSUE 6 2025

BEYOND REGULATORY COMPLIANCE

Globally, mines and their quarrying counterparts generally face a heavy price for regulatory compliance – a multifaceted process covering everything from environmental protection and water management to occupational health and safety.

While the costs associated with meeting these regulatory requirements can be significant, mines understand that proactively adhering to the evolving regulatory landscape is crucial, not only for legal operation, but also to maintain their ‘social licence to operate’ and to unlock sustainable value.

Beyond regulatory compliance lies one of the most difficult challenges facing mining companies in today’s operating landscape – the complex issue of local community engagement and partnership. There is a general consensus among several industry captains that I have spoken to recently, that the most difficult part of mining today is not mining itself; it has become even more difficult to deal with community issues.

Tthe influence of community affairs on business practice is not a one-way process. The growing significance of community affairs is creating pressures for mining companies to adopt resilient company-community relationships. This is no longer optional, or something to be disregarded by mining and quarrying companies.

So, how can the industry strengthen its company-community relationships? While community relations span a large scope of activities, it is critical to include local communities in future plans and keep them informed of progress being made towards sustainable mining within their areas. Where possible, companies should make use of local forums and employment portals to identify and hire local skills. It is also important to make use of local businesses where possible.

MUNESU SHOKO

Publishing Editor

Email: munesu@quarryingafrica.com

LinkedIn:

Munesu Shoko

Quarrying Africa

Consequently, community relations have become an increasingly important component of mining and quarrying companies’ strategic thinking. This is especially true for quarries that by their very nature are located close to communities. Given this close proximity, they ought to be at the receiving end of all community grievances, even when the complaints are not related to their activities. In some cases, it could be the lack of service delivery, which in the end is misdirected at these operations.

The growing importance of sound community relations to the success of quarries and mines calls for improved capacity to recognise and respond appropriately to community issues. This, in fact, is becoming an important mainstream management skill in the industry – a ‘core competence’, as it has often been described.

Quarrying companies should strive to provide neighbours and surrounding communities with a rapid-response platform to air grievances, complain and seek feedback. Communication has to be maintained both to and from stakeholders and it is important to do so timeously and with due care to avoid disputes.

Due to their proximity to communities, quarrying operations should establish ground rules that should never be broken, such as upholding quiet periods when communities may be resting, holding religious gatherings or writing exams, among others. Likewise, the community may be asked to maintain freeflowing traffic for mine vehicles, report crimes and assist with other activities to enhance the safety and security of the region.

When the management of a quarrying or mining company views community relations as a top priority, it starts from a position of fostering goodwill within the communities around the operation. This is a long-term view about doing the right thing but also maximising the operational value of mining assets. a

NEW QUARRYING STANDARDS

THE POWER OF DATA-DRIVEN INSIGHTS DRIVING INNOVATION AND COMPLIANCE

Publishing Editor: Munesu Shoko

Sub Editor: Glynnis Koch

Admin: Linda T. Chisi

Design: Kudzo Mzire Maputire

Web Manager: Thina Bhebhe

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.

© Quarrying Africa

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

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

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

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A major highlight at the recent official launch was the unveiling

MARKING

A NEW CHAPTER

Burgers Equipment and Spares has marked a new chapter with a distributorship agreement with XCMG. Effective March 2025, the partnership allows the established yellow metal equipment supplier to distribute the full range of XCMG equipment throughout South Africa. At a launch event attended by Quarrying Africa on October 23, 2025, the company showcased a wide range of XCMG equipment at its Pomona, Kempton Park facility, with one of the major highlights being the Hybrid Electric Vehicle (HEV) wheel loader. By Munesu Shoko.

At a time when the value segment of the yellow metal equipment sector is continuously gaining traction in South Africa, and Africa at large, Burgers Equipment and Spares has entered into a distributorship agreement with XCMG, China’s largest mining and construction original equipment manufacturer (OEM), and the fourth largest globally.

“Our decision to partner with XCMG is driven by its exceptional machine quality, global scale and consistency in manufacturing. The OEM’s ability to produce robust, innovative and reliable equipment aligns perfectly with our commitment to delivering highperformance solutions to our customers.

5-t

One of the flagship models in the XCMG range is the 5-t wheel loader, the XC958, a fully mine-spec machine powered by a 164-kW Cummins QSB6.7 engine

XCMG’s reputation as the number one construction machinery manufacturer in China and the fourth largest globally gave us confidence, not only in its products, but also the long-term support capabilities,” explains Tiaan Burger, MD of Burgers Equipment and Spares. With over 20 years of experience supplying and

KEY TAKEAWAYS

Burgers Equipment and Spares has entered into a distributorship agreement with XCMG, China’s largest mining and construction original equipment manufacturer

Under the agreement, Burgers Equipment and Spares will distribute a vast range of XCMG equipment in South Africa

Burgers Equipment and Spares strategically selected specific configurations of various XCMG machines that directly align with local customers’ needs

Opsicol Mining Services, a major mining contractor in South Africa, has become the first recipient of the XCMG HEV wheel loader range in South Africa

4

Burgers Equipment and Spares used the official launch event to hand over four XCMG HEV wheel loaders to Opsicol Mining Services

supporting equipment across industries, including mining, construction and agriculture, amongst others, Burgers Equipment and Spares has a strong understanding of the market in South Africa. Equally, XCMG, a globally recognised brand, has made its mark in South Africa since its first arrival back in 2007.

Burger stresses that the alliance between the two established partners will usher in a positive, seamless customer experience fostered by a strong OEM-dealer collaboration whose strategic intent is to maximise customer satisfaction – a crucial success lever in such a competitive market.

Broad range

Under the agreement, Burgers Equipment and Spares will distribute a vast range of XCMG equipment. The selected range comprises wheel loaders, excavators, motor graders, single-drum hydrostatic rollers, forklifts, backhoe loaders, skid steers loaders, drill rigs, cranes, cold recyclers and the 80-tonne (t) mining dump trucks, amongst others.

Commenting on the range, Burger says proper equipment selection is essential in earthmoving projects, as each machine is engineered for specific functions. Utilising the right machine for the right application maximises performance and project outcomes. With that

Major highlight

Apart from the conventional range, a major highlight at the recent official launch was the unveiling of the XCMG HEV wheel loader. The cutting-edge machine places both Burgers and XCMG at the forefront of the electromobility drive in South Africa.

“This machine combines XCMG’s proven expertise in advanced hybrid technology, delivering greater fuel efficiency, lower emissions and reduced operating costs. Designed for demanding earthmoving applications, it provides full performance while promoting environmental sustainability, reflecting the global shift towards greener solutions,” explains Burger.

in mind, Burgers Equipment and Spares strategically selected specific configurations of various XCMG machines that directly align with local customers’ needs.

“A prime example is our flagship 5-t wheel loader, the XC958. This fully mine-spec machine is powered by a 164-kW Cummins QSB6.7 engine, paired with a ZF 4BP210 transmission, and comes with both dry- and wet-brake axle options. Another machine that truly separates itself from its competitors is the 21,5-t excavator, the XE215G. Powered by a 128,5-kW Isuzu 6BG1 engine, complemented by a Kawasaki hydraulic system, this machine offers refined, operator-friendly hydraulic control,” explains Burger.

XCMG’s hybrid loader utilises a three-motor platform that offers high work efficiency, reliability and stable performance. The system recovers excess energy during braking, shovelling and unloading, converting it into electrical energy, thus optimising energy utilisation. Compared with traditional diesel-powered counterparts, the HEV loader can save over 30% in fuel consumption, significantly reducing operating costs for customers.

“The hybrid loader exemplifies XCMG’s commitment to innovation in new energy technologies. Guided by principles of ‘greenification’, intelligence, and sustainable development, XCMG continues to pioneer solutions that are both high-performance and environmentally responsible,” says Burger.

The XCMG 80-t mining dump truck was one of the major displays at the recent launch event.

Commenting on the uptake, Burger says that interest in electric and hybrid solutions is growing steadily in South Africa, particularly among environmentally conscious clients and those seeking to reduce operational costs. While adoption is still in its early stages, he adds, the response to the HEV range has been encouraging, and Burgers Equipment and Spares anticipates broader acceptance as awareness and infrastructure improve.

In fact, Opsicol Mining Services, a major mining contractor in South Africa, has become the first recipient of the XCMG HEV wheel loader range in South Africa. Burgers Equipment and Spares used the official launch event to hand over the four machines to Gurban Zeynalov, GM of Opsicol. The fleet – which comprises two 5-t XC958-HEV and two 7-t XC978HEV units – has been deployed in a coal handling application.

Tremendous potential

30%

Compared with traditional dieselpowered counterparts, the XCMG HEV loader can save over 30% in fuel consumption, significantly reducing operating costs for customers

Commenting on the outlook of the business, Burger sees tremendous potential for XCMG in South Africa under the stewardship of Burgers Equipment and Spares. With extensive local inventory, parts and service capacity, complemented by targeted solutions for mining and infrastructure customers, the company has the capacity to scale XCMG’s presence across the country.

“Our goal is to improve total cost of ownership for clients

while delivering unmatched reliability and aftersales support. We are confident that under our stewardship, XCMG will become a leading choice for customers seeking quality, performance and consistency,” says Burger. Following the commencement of the partnership agreement in March 2025, Burgers Equipment and Spares has already delivered a number of machines across construction, mining, and agricultural projects. These units are hard at work in bulk earthmoving, site development, infrastructure, and materials handling operations, highlighting a strong interest in the XCMG product. Among the standout performers in the range is the 21,5-t XE215G excavator –currently on special – renowned for its exceptional performance, fuel efficiency and value for money in the 20-t class.

“At Burgers Equipment and Spares, our business is built on strong ethical foundations and is guided by our core values of integrity, commitment, excellence, accountability and respect. For us, delivering a machine is just the beginning – our priority is to keep customers’ assets working harder, longer and smarter through high-quality service and parts support. Held on October 23 during the annual OktoBURGERSfest, the event was more than just a product launch — it was a celebration of partnership, innovation and the bright future ahead for XCMG in South Africa,” concludes Burger. a

in June this year,

SETTING NEW QUARRYING STANDARDS

To ensure profitable operations in a generally low-margin construction materials market, Vryburg-based Northwest Crushers has, over the years, put continuous improvement at the centre of its operations to enhance efficiency, productivity, safety and environmental sustainability through a combination of optimisation initiatives and capital investments. Munesu Shoko was recently on site and filed this report.

2,3-MWh

Northwest Crushers has invested in a massive 1,3-MW solar power plant with a 2,3-MWh battery storage capacity (which can be expanded to 3,6 MWh)

80 000

The brick plant, which produces about 80 000 bricks per day, consumes 43% of the quarry’s total production

8 m

A large 8-m surge pile just after the jaw crusher acts as a material buffer, allowing the processing plant to continue running even if there are temporary disruptions in the mining or hauling operations

What started out as a small-scale operation back in 2008 to service road construction and building projects in the small town of Vryburg and surrounding areas, has, over the years, transformed into one of the flagship quarrying operations in South Africa. A recent tour of the operations by Quarrying Africa revealed the extensive nature of process optimisation initiatives, complemented by large capital investments to modernise the operation in the quest for efficiency and productivity.

Initially, Northwest Crushers – relying on mobile crushing and screening equipment – processed basic aggregates for a few contracts in the area. Sensing growing market opportunity, the owners have, in recent years, committed large capital investments in capacity building. This was set in motion by the

2015 investment in a state-of-the-art CDE EvoWash 102 sand-washing plant, followed by the 2016 investment in a readymix concrete plant to maximise beneficiation and open up new market opportunities.

In 2020, the operation further expanded its business with the establishment of a brick manufacturing plant. In 2025, Northwest Crushers has not only commissioned a new static plant (allowing for the migration from costly mobile crushers) but also commissioned a completely off-the-grid solar plant with battery storage, allowing the operation to break free from unreliable grid power and costly generators.

Challenges to opportunities

From the onset, Northwest Crushers battled with its challenging geology – a quartzite rock with large intrusions of sand. Consequently, after blasts, the head feed would generally contain 60%

“Finding the market for the abundant sand, given the unfair competition from illegal sand mining activities, was a challenge. The market could only consume a certain portion of the vast sand stockpiles. The investment in a CDE EvoWash 102 sandwashing plant was strategic in the sense that it allowed Northwest Crushers to separate itself from competition, taking the lead in the supply of high-quality manufactured sand.

sand. As a result, explains commercial manager Michael John Wessels, the operation would end up with large stockpiles of sand – albeit good quality sand.

However, finding the market for the abundant sand, given the unfair competition from illegal sand mining activities, was a challenge. The market could only consume a certain portion of the vast sand stockpiles. The investment in a CDE EvoWash 102 sand-washing plant was strategic in the sense that it allowed Northwest Crushers to separate itself from competition, taking the lead in the supply of high-quality manufactured sand.

With a maximum processing capacity of approximately 120 tonnes per hour (tph), the EvoWash 102 utilises advanced hydrocyclone technology and a high-frequency dewatering screen to efficiently separate fine materials and eliminate the loss of valuable fines to settling ponds, which is a common issue with traditional sand washing systems.

The CDE plant at Northwest Crushers delivers two different, high-quality sand products – washed crusher dust and super sand – of consistent grade, simultaneously. This cyclonic materials technology guarantees the removal of the undesired 75 microns, while retaining quality fines and maximising dewatering of the product to between 10% and 15% moisture. The quarry is currently

investigating market opportunities for clay material from this plant (currently disposed as waste), possibly in clay brick and roof tile manufacturing.

While the sand washing plant enhanced quality, extra capacity remained a headache, especially given that 60% of the quarry’s output is sand. To take advantage of the excess sand capacity, the operation decided on a beneficiation route, which saw the investment in a readymix concrete plant and eventually a brick manufacturing plant. These investments have to date paid dividends, with the brick plant, which produces about 80 000 bricks per day, consuming 43% of the quarry’s total production, while the readymix plant takes 14% of the output, with the rest destined for external markets.

Blast optimisation

To win the cost control battle, Northwest Crushers places a major focus on optimisation of every aspect of its operations. This starts with good blasts, explains Wessels. As part of this process, Northwest Crushers has appointed an expert blasting company, B&E International, to take care of its blasting activities.

“Together with B&E International, we have gone through the process of optimising our blasts. We have placed a major focus on a blasting ‘recipe’ that suits our challenging geology, with a specific focus on burden and spacing. These factors are crucial for efficiently breaking rock by ensuring that explosive energy is used to its full potential, leading to better fragmentation,” explains Wessels.

For Director Joe Deetlefs, the easiest way to break rock is through blasting, which is why Northwest Crushers does not leave anything to chance when it comes to this process. “Good blasts are the starting point for cost savings in quarries because they significantly increase efficiency and reduce expenses in all subsequent operations, such as loading, hauling and crushing. Poor blasting leaves behind large, oversized rocks that require additional, costly secondary blasting or mechanical breaking before they can be processed,” explains Deetlefs.

Blasts are kept fairly large at 30 000 to 50 000 tonnes of material on the ground, allowing the operation to at least blast once every three

months. Larger blasts lead to savings on drilling costs and other operational expenses due to the economy of scale.

Optimal operations

In a highly competitive and volatile aggregates market, the management team at Northwest Crushers closely monitors its cost per tonne to ensure profitability and operational efficiency. This metric is central to all strategic and operational decisions, including the selection of wear parts. “Over the years, we have trusted Caldas Engineering for our jaw and cone liners. Their alternative wear parts last longer, reducing the frequency of change-outs, offering better cost per tonne,” explains Wessels.

Technology adoption also forms part of the quarry’s focus on optimisation. A case in point is the use of belt scales from Loadtech Load Cells. With these scales, the production team can continuously measure the flow rate and totalised amount of material on a belt with high accuracy, typically within +/- 1%.

The belt scales also allow for tracking of plant downtime to identify bottlenecks and areas for improvement. In fact, says Wessels, the belt scales have allowed the quarry to reduce its ‘black belt’ time –the period when the conveyor system is running without actually transporting any material – by 10% at the primary section. Benefitting from a surge pile and a surge bin, the secondary curucit's 'black belt' time is well below 5%.

In addition, Northwest Crushers has deployed a fuel monitoring solution from SmartMix Technologies. The integrated system is designed to give the quarry total control, visibility and accountability over every drop of diesel purchased, stored and consumed. The SmartMix Fuel Solution uses high-precision fuel probes and AIpowered analytics to monitor fuel levels with an accuracy of 99,5% and can detect changes in real-time to the litre. Apart from fuel management, the system also assists in tracking movement of assets.

The fully automated brick plant, supplied by Pan Mixers South Africa (PMSA), was designed to move away from bulk batching to weight batching, providing greater accuracy, consistency and ultimately, a higher quality final product. A moisture control system ensures correct mix designs that allow for optimum curing on strength and time, while reducing waste batches due

to wet mixes. This quality control system is central to maintaining the prestigious CMA CS stamp of approval. The certification mark boosts consumer confidence and guarantees the quality of bricks.

Hauling run of mine (ROM) 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 for Northwest Crushers. Haul distances from the quarry face to the primary section of the plant are kept fairly short, between 300 and 500 m, allowing the haul trucks to complete more cycles per shift, transporting more material from the pit to the processing plant. Keeping haul distances short also reduces diesel burn, thus lowering operating costs.

People, states Deetlefs, are the “beating heart” of the business, which is why Northwest Crushers invests heavily in the development of its people. As part of that process, the quarry has engaged the services of Organisation Development International (ODI), a productivity and management consulting company.

“At Northwest Crushers, we see people as the most important pillar of the three keys (Process, Technology, People), which is why we have invested in training and

upskilling junior supervisors and upcoming talent, to not only be good in their respective functions, but also in leading and managing people. This is done with a holistic overview of the complete processes of the company. ODI helps with the upskilling of people and linking processes between all sections – quarrying, brick making, readymix and logistics,” says Deetlefs.

From mobiles to static

As part of the relentless focus on optimal processes, the quarry has also migrated from mobile crushing and screening equipment to a static plant. Commissioned in June this year, the plant has the capacity to produce up to 220 tph, confirms Wessels, producing a wide range of products. These include road stone (20 mm, 14 mm, 10 mm and 7 mm), concrete stone (14 mm and 20 mm) and various types of sand, amongst others.

“With a mobile train, diesel was a major cost, while downtime and costs related to maintenance were also a major driver in the decision to invest in a static plant, with the intention to lower operating costs and increase production efficiency over time,” explains Wessels.

When designing the plant, says Deetlefs, one of the key considerations was the adoption of the ‘doing more with less’ mentality, which involves a focus on maximising operational efficiency and output while minimising input costs and resource consumption. This, he says, is apparent in the pairing of a medium jaw crusher (a Finlay J1175) with a smaller Metso HP200 cone crusher, striking an effective balance between size and operational output for such a medium-scale operation.

“Our jaw is optimally sized to ensure constant chokefeeding of the cone crusher. Every ‘quarryman’ will tell you that a cone crusher is designed to operate with the crushing chamber full (choke-feeding). We have installed a 15 m³ surge bin to ensure a consistent, non-segregated feed of material, which allows for choke-feeding the crusher at all times. Choke feeding allows the cone crusher to operate at maximum capacity and throughput at all times, while promoting rock-on-rock crushing, which breaks down flat and elongated particles and results in a more cubical product shape,” says Deetlefs.

As part of the design of the process plant, all conveyors were kept flat (no single one has an angle over 16 degrees), wide and slow, primarily to maximise efficiency, enhance safety, and minimise equipment wear and material spillage. A flat angle, says Deetlefs, prevents material from rolling off the sides, especially for coarse or uneven aggregates. Wide conveyor belts accommodate a larger volume of material cross-sectionally, while lower speeds ensure a smoother, more controlled flow.

In addition, a large 8-m surge pile just after the jaw crusher acts as a material buffer, allowing the processing plant to continue running even if there are temporary disruptions in the mining or hauling operations. This ensures operational efficiency, increases productivity and reduces equipment downtime.

Going off grid

One of the major talking points at Northwest Crushers is

the recent decision to go completely off the grid through a large capital investment in a massive 1,3-MW solar power plant with a 2,3-MWh battery storage capacity (which can be expanded to 3,6 MWh). During Quarrying Africa’ s visit in November, the off-grid solar plant had been fully operational for two weeks, providing more than enough capacity to run the whole operation, including the processing plant, brick manufacturing plant, readymix plant and all other utilities on site.

Supplied and installed by Eco Trades, a leading Bloemfontein-based engineering, procurement and construction (EPC) company, which managed every stage from design to handover, Northwest Crushers’ solar plant is said to be one of the largest of its kind in South Africa.

“The reason for this major capital investment was to break free from unstable grid power. Our allocated municipal power supply was not enough for our needs. To provide context, we were using grid power only on our primary section and had to power the rest of the plant with generators. This was a costly exercise. Frequent power trips also resulted in costly downtime through jaw crusher blockages," explains Deetlefs.

The investment in a solar plant has also given the quarry a hedge against volatile and unpredictable grid electricity prices. With no access to Eskom power, Northwest Crushers was billed according to municipal peak demand charges, which often resulted in a high overall electricity bill. Due to significant cost savings, the solar plant investment is expected to pay for itself in six to eight years.

Unstable power, adds Deetlefs, was one thing, but the cost of running generators, was quite another, especially given the high cost of diesel and the high cost of maintenance associated with servicing engines. This was exacerbated by constant electrical surges which posed significant threats to electronic equipment, ranging from immediate destruction to gradual degradation.

“In our view, the transformation from traditional power to solar in quarrying and mining operations represents a strategic imperative for operational excellence and financial sustainability. With energy costs rising and environmental regulations becoming more stringent, solar power offers quarries and mines a clear path to reduced operational costs, improved reliability and enhanced environmental performance,” concludes Deetlefs. a

Quality Materials You Can Trust.

We provide contractors and builders with high-quality aggregates, bricks, and ready-mix concrete backed by reliable delivery and consistent performance. From our base in Vryburg, North West Crushers supports construction projects across the region with materials designed for durability, strength, and long-term results.

in Port

DRIVING INNOVATION AND COMPLIANCE

Established in 2010, Rossmin Mine has established itself as one of South Africa’s leading producers of high-quality calcitic and dolomitic limestone. At the centre of its success is not only a high-grade limestone deposit, but also a relentless focus on driving efficiencies, compliance, and reliability of supply. By Munesu Shoko.

Located in Port Shepstone, KwaZuluNatal, Rossmin Mine sits at the heart of the famous Marble Delta, a unique limestone formation near the confluence of the Umzimkulu and Umzimkulwana rivers, with a limestone deposit considered to be of the highest quality in South Africa. Since its formation in 2010, the innovative and community-driven operation, has established

itself as a major source of high-quality carbonate products for industrial, agricultural and food applications, supplying countrywide through distribution centres in Durban, Johannesburg and Cape Town.

Quality matters

A principal factor to the success of the operation is the high-quality nature of its limestone. The

operation, explains mine manager Fana Shozi, produces high-brightness, low-contamination marble limestone.

Part of the distinctive Marble Delta geological formation, the deposit allows the company to produce a versatile range of products, from agricultural lime and industrial fillers to food-grade ground carbonates.

Rossmin’s resource base includes both calcitic and dolomitic limestone, offering flexibility in product chemistry to meet the requirements of a diverse customer base across construction, manufacturing and agriculture.

“Our market is currently driven by a steady demand for local, high-quality limestone products in sectors such as agriculture, animal feed, plastics, coatings and food processing. Our focus on consistent product quality and reliable delivery has ensured a growing national

2010

Established in 2010, Rossmin Mine has established itself as one of South Africa’s leading producers of high-quality calcitic and dolomitic limestone

KEY POINTS

Since its formation in 2010, Rossmin Mine has established itself as a major source of high-quality carbonate products for industrial, agricultural and food applications

To rise above challenges, especially the escalating input costs, Rossmin has prioritised efficiency, local innovation and operational optimisation

The operation continues to improve processing plant performance and logistics reliability, while enhancing workforce capability through digitalisation

Looking ahead, Rossmin continues to invest in R&D to reduce environmental impacts, improve operational efficiency and meet evolving customer demands

footprint,” says Shozi.

To drive quality, Rossmin subscribes to the ISO 9001 and ISO 22000 Quality Management Systems, ensuring that all products, including food-grade ground calcium magnesium carbonate, are produced in accordance with Hazard Analysis and Critical Control Points (HACCP) and Good Manufacturing Practices (GMP) requirements. This integrated approach to quality control guarantees consistency, safety and reliability across its full product range.

ISO 9001

To drive quality, Rossmin subscribes to the ISO 9001 and ISO 22000 Quality Management Systems

1-million

Rossmin is approaching a milestone of 1-million lost-time injury free hours, with zero fatalities since inception

Not without challenges

While the business sees encouraging signs of recovery in certain manufacturing sectors, it remains under severe pressure from cheap imports originating from countries with less stringent labour, mining and environmental regulation.

“Despite these challenges and the inherent tight margins, we remain optimistic, largely due to the green shoots that we see in the economy and the growing recognition of the value of local manufacturing. However, import protection and reduced red tape for small and mid-tier mining companies are urgently needed to safeguard South African jobs and industry,” says Shozi.

Rising above challenges

To rise above challenges, especially the escalating input costs, Rossmin has prioritised efficiency, local innovation and operational optimisation. Key initiatives include local sourcing of maintenance components, particularly in metallurgy and mechanical fabrication, leveraging South Africa’s mining engineering expertise to reduce lead times and control costs.

In addition, the operation, says Shozi, continues to improve processing plant performance and logistics reliability, while enhancing workforce capability through digitalisation, thus ensuring data-driven decisions.

“Another major innovation is the adoption of artificial intelligence (AI) to enhance the training of employees and contractors on the complexities of mining regulations and codes of practice. This interactive system improves understanding and retention of safety-critical information and supports regulatory compliance across all levels of the operation,” says Shozi.

Prioritising compliance

Compliance in the mining industry is a significant expense, but it is indeed necessary for legal, safety, environmental and business reasons. The costs of non-compliance, which can include hefty fines,

Rossmin Mine drives operational efficiency to reduce costs, increase productivity and enhance safety.

operational shutdowns, and severe reputational damage, consistently outweigh the costs of maintaining a robust compliance programme.

With that in mind, health and safety compliance remains a cornerstone of Rossmin’s operations. Through a proactive safety culture supported by digital learning and strong leadership, Rossmin has established a track record for excellence in occupational health and safety management. To provide context, the mine is approaching a milestone of 1-million lost-time injury (LTI) free hours, with zero fatalities since inception.

Rossmin also operates under the ISO 14001 Environmental Management System principles, underpinned by a proactive commitment to sustainability and biodiversity protection. A highlight of this commitment is the management of an 80-hectare biodiversity offset area, developed in partnership with Ezemvelo KZN Wildlife and local specialists.

“The area conserves pristine grassland and is home to an endemic limestoneloving snail found only in the Marble Delta. Controlled harvesting of medicinal plants is managed collaboratively with local registered Inyanga (herbalists), combining environmental stewardship with cultural respect,” explains Shozi.

Beyond the mine gate

Beyond the mine gate, Rossmin is deeply invested in community development. The company supports nine local no-fee schools through the provision of boreholes, new classrooms and a sports field, improving access to education and well-being in an area of extremely high unemployment.

These initiatives form part of Rossmin’s Social and Labour Plan (SLP) and reflect its belief in education as a key driver of sustainable community growth.

The future

Looking ahead, Rossmin continues to invest in research and development to reduce environmental impacts, improve operational efficiency and meet evolving customer demands. Projects include optimisation of dust suppression and water management systems, as well as investments in lower-impact processing technology.

“Rossmin remains positive about the future. The company’s long-term strategy centres on sustainable growth, technological advancement and local value creation. In our view, Rossmin represents what is best about South African mining – innovation, resilience and a genuine commitment to community and environment. We are proud to be a local manufacturer creating real jobs while producing world-class limestone products,” concludes Shozi. a

STANDING UP TO TAXING CONDITIONS

Having acquired its first John Deere machine in 2021, South African-based construction and mining contractor, PGN Civils, has quickly grown its John Deere fleet to double-digit numbers. Central to the fleet expansion, explains director Keith Mnisi, is a product that has proven its mettle in taxing operating conditions, complemented by a good backup support structure. By Munesu Shoko.

When John Deere formally launched its own-branded construction machines in the South African market in March 2021, one of the first recipients was PGN Civils, a family-owned business established in 2008 with a major focus on construction projects, before branching out into contract mining in 2018. To further spread its wings, the company also added a plant hire component to its business.

While PGN Civils, which holds a Grade 9 CE grading

from the Construction Industry Development Board (CIDB), is still active in construction, the bulk of its business now comes from its contract mining business, which runs just over 100 pieces of equipment at two mines in the Phalaborwa mining area in Limpopo province.

Enter John Deere

In 2021, John Deere announced its decision to take full control of the marketing and support of its John Deere-

100

The bulk of PGN Civils’ business now comes from its contract mining business, which runs just over 100 pieces of equipment at two mines in the Phalaborwa mining area in Limpopo province

branded construction products in Africa. The expansion of the construction line-up targeted 18 countries across southern Africa and West Africa, where the Deerebranded construction offering was previously not available.

PGN Civils was among the first South African companies to buy one of the first machines that came into the country, a 38-tonne (t) E380-II excavator. Supplied by AFGRI Equipment, one of the major John Deere dealers, the machine quickly proved its mettle in a taxing magnetite operation, prompting PGN Civils to purchase three more E380-II excavators within a short space of time. Deployed to load trucks, two of these 38-t excavators have just clocked over 14 000 hours and counting.

As part of the second phase of the construction equipment rollout, John Deere introduced its productionclass equipment in July 2022. At the heart of this range was the 42-tonne class John Deere 460E-II articulated dump truck (ADT). PGN Civils again went on to be one of the first recipients of this range in South Africa, taking delivery of two 460E-II ADTs in December 2022. With just over 13 000 hours on the clock to date, these machines continue to perform in tough operating conditions,

12

PGN Civils now runs a total of 12 John Deere machines, with prospects to significantly bolster the fleet in the next few years

KEY POINTS

When John Deere formally launched its own-branded construction machines in the South African market in March 2021, one of the first recipients was PGN Civils

PGN Civils was among the first South African companies to buy one of the first machines that came into the country, a 38-t E380-II excavator

PGN Civils again went on to be one of the first recipients of the John Deere 460E-II articulated dump truck in South Africa, taking delivery of two units in 2022

Apart from machine durability, PGN Civils places a high value on fuel consumption, and this is an area in which the John Deere product has proven itself

In early 2025, PGN Civils added a 30-t excavator to its growing John Deere fleet.

offering uninterrupted hours of efficient production.

In early 2025, PGN Civils went on to bolster its John Deere fleet with four 460P ADTs, one of the first model ranges to come to the local market under the John Deere Performance Tiering strategy in April 2024. The same year, the company also added two excavators – a 30-t E300-II and a 21-t E210-II. The 21-t unit has been deployed for pond maintenance at a magnetite mine, while the 30-t machine is used to load trucks at the very same ponds. In total, PGN Civils now runs a total of 12 John Deere machines, with prospects to significantly bolster the fleet in the next few years, confirms Mnisi.

Why John Deere?

Commenting on why PGN Civils continues to grow its John Deere fleet, Mnisi says he has been impressed by the performance of the product in tough conditions. “At one of our sites, some of these machines are deployed to handle magnetite material, which is known for its abrasive and heavy nature. To provide context, the specific gravity (SG) of magnetite is approximately 5,2. Our John Deere machines have proven to be equal to the task, standing up to this arduous application,” says Mnisi.

In addition, the operating environment is challenging due to the extreme temperatures synonymous with Phalaborwa. Average daily maximum temperatures in the summer months (December to February) typically range from 33°C to 38 °C, but temperatures exceeding 40°C can occur. In fact, the highest recorded temperature in Phalaborwa was 50°C in December 2018.

In such a sweltering environment, running hydraulic machines is generally challenging primarily because heat degrades the hydraulic fluid’s properties and damages the system’s seals and components, leading to performance issues and potential system failure. However, John Deere products have proven their mettle, with machines continuing to perform well with no major mechanical issues in such

taxing conditions.

“These environments challenge and push any product to the limits, but John Deere machines are standing up to these demanding operating conditions. We have given the product a proper testing ground and it is passing with flying colours,” says Mnisi.

“Durability is a key attribute in our buying decisions because we prefer running our machines for long periods. To provide context, we recently retired one of our wheel loaders with 34 000 hours on the clock. Because we prefer buying our equipment new, we know each piece of machinery’s history, which allows us to sweat these assets for extended periods,” he adds.

Some of the first John Deere excavators have to date clocked over 14 000 hours with no issues, while the first ADTs are pushing towards the 15 000-hour mark. Traditionally, PGN Civils has always shifted some of its excavators to the less demanding construction division when they reach high hours and start falling short of the mining performance requirements. However, says Mnisi, the company is now investigating the viability of giving its machines a ‘second life’ through OEM refurbishments. With John Deere

The 42-t John Deere ADTs are consuming about 19,05 litres of diesel per hour which, according to PGN’s benchmark, is within expectations.

machines, particularly ADTs, this will likely happen at 20 000 hours.

Apart from machine durability, PGN Civils places a high value on fuel consumption, and this is an area in which the John Deere product has proven itself. Despite hauling very heavy magnetite material, the 42-t John Deere ADTs are consuming about 19,05 litres of diesel per hour which, according to PGN’s benchmark, is within expectations.

As a company that also encourages data-driven decisions, Mnisi is impressed by the level of technology on the John Deere product. For example, the SmartWeigh load weighing system offers productivityenhancing capabilities by letting operators achieve correct loads the first time without return trips to the pile. It also reduces the possibility of overloading, especially given that the haulers are moving heavy material with a high SG.

Backup support

Apart from the John Deere product itself, Mnisi is impressed by the backup support behind it, both from AFGRI Equipment and John Deere. In a 24/7 operating environment where downtime is out of the question, Mnisi has been impressed by the two companies’ responsiveness to any issues, which maximises uptime for PGN Civils.

19,05 l ph

Despite hauling very heavy magnetite material, the 42-t John Deere ADTs are consuming about 19,05 litres of diesel per hour which, according to PGN’s benchmark, is within expectations

In addition, Mnisi makes special mention of John Deere’s Operations Centre fleet management system, powered by JD™Link hardware, which enhances efficiency through remote monitoring and data analysis, thus reducing costs by optimising machine performance and workflows. It also improves decision-making and provides tools for proactive maintenance to minimise equipment downtime.

Mnisi is particularly happy with the direct communication channels within both AFGRI and John Deere, citing no bureaucracy within the two organisations. “At both AFGRI and John Deere, we have direct access to even the top management structures, which allows for quicker responses and decision-making. In such a fast-paced mining environment, excessive bureaucracy, which often involves multiple layers of approval and communication, slows down decision-making, which is counter-productive,” says Mnisi.

“While John Deere is now such a big organisation, we feel that the company still maintains family business values more than it does a corporate culture. As a family business ourselves, we share the same values. Based on these experiences, we have become a big John Deere proponent and we will definitely buy more John Deere machines in future,” concludes Mnisi. a

PowerTech is a locally-made telematics and safety system developed to meet unique operating conditions of African fleets

HARNESSING THE POWER OF DATA-DRIVEN INSIGHTS

In response to the growing appetite for data-driven operations across industries, Ever Star Industries (ESI) has launched its PowerTech telematics system. For the first time, every Powerstar truck rolling off the company’s Pietermaritzburg assembly line will come standard with the system. Developed in partnership with Khulu Digital, the system provides a comprehensive view of fleet operations, leading to greater efficiency, safety and cost savings. By Munesu Shoko

In an increasingly complex operating environment, fleet operators across industries – from road transport to construction and mining – are seeking ways to increase efficiency and reduce costs. In today’s digital world, connected assets are a powerful first step towards lowering total cost of ownership.

With that in mind, ESI, in partnership with its strategic technology partner, Khulu Digital, have unveiled the PowerTech telematics system which is providing Powerstar truck owners with an opportunity to make data-driven decisions. The system offers advanced fleet oversight by

10 000

PowerTech was officially launched on August 22, 2025, at a grand event that also celebrated the 10 000 th Powerstar truck to roll off ESI’s Pietermaritzburg assembly plant

collecting and transmitting data from vehicles, allowing managers to track assets, monitor driver behaviour and analyse vehicle performance in realtime, amongst other parameters of importance to fleet owners.

Grand launch

The system was officially launched on August 22, 2025, at a grand event that also celebrated the 10 000 th Powerstar truck to roll off ESI’s Pietermaritzburg assembly plant. Alan Parry, GM at ESI, notes that the launch of PowerTech ushers in the age of ‘smart’ Powerstar trucks. The strategy centres on connecting Powerstar trucks to create a digital ecosystem that gathers vast amounts of data, aiming to improve customer productivity, efficiency and safety.

“In partnership with Khulu Digital, a leader in digital transformation and smart tracking solutions, we are proud to announce that every new Powerstar will now come equipped with PowerTech, an advanced

Euro 2-6

PowerTech provides future-proof technology that supports both Euro 2 vehicles and the most sophisticated Euro 6 engines on the same platform

KEY TAKEAWAYS

ESI, in partnership with its strategic technology partner, Khulu Digital, have unveiled the PowerTech telematics system to provide Powerstar truck owners with an opportunity to make data-driven decisions

PowerTech is a locally-made telematics and safety system developed to meet unique operating conditions of African fleets

With its fuel theft monitoring capabilities, PowerTech allows fleet owners to take back control by detecting siphoning in real time with sudden drop alerts

PowerTech has been designed with strict safeguards. Engine power is never cut in unsafe conditions such as coasting, ensuring brakes and steering remain operational

telemetry system, seamlessly integrated to deliver unmatched value and peace of mind for the customer,” explains Parry.

“For us, PowerTech is not just telematics; it is a promise of real-time connectivity, fleet information at customers’ fingertips, advanced security and operational excellence,” says Parry, adding that the technology, which was

PowerTech allows for proactive service scheduling, enabling managers to schedule maintenance based on actual conditions such as engine hours, mileage and sensor readings.

previously reserved for a select few on competitor offerings, is now standard for every Powerstar owner.

According to Parry, the PowerTech journey has been driven by a clear understanding of the challenges faced by fleet owners across industries – demanding terrains and an increasing need for safety and efficiency. By bringing digital innovation directly to its vehicles, ESI is powering fleet operators and business owners to navigate these challenges with confidence and agility.

Innovation in action

Neil Weideman, Tech Lead at Khulu Digital, says PowerTech is a locally-made telematics and safety system developed to meet unique operating conditions of African fleets. All hardware is manufactured in South Africa under automotive-grade standards. The commitment to local production, stresses Weideman, not only reduces lead times, but also strengthens the African supply chain, creating jobs and ensuring solutions are “designed for Africa, in Africa”.

“With this launch, ESI has reaffirmed its commitment to helping fleet owners reduce costs, improve uptime and maximise safety. By aligning its suppliers, dealer network and technology partners, ESI is delivering a system that evolves with customer needs and positions the brand as a trusted partner in sustainable fleet management,” says Weideman.

PowerTech provides customers with real-time insight into vehicle performance, driver behaviour and safety; critical service scheduling to reduce downtime and keep fleets on the road; integrated cost management, covering fuel, tyres, servicing and repairs; and future-proof technology that supports both Euro 2 vehicles and the most sophisticated Euro 6 engines on the same platform.

Key parameters

PowerTech, explains Weideman, monitors various

parameters of critical importance to the African fleet owner. Chief among them is fuel – the single largest operating cost for most transport, mining and construction businesses in South Africa. Yet, it is also the most vulnerable asset, regularly targeted through siphoning and skimming, translating into millions of rands in annual losses. With its fuel theft monitoring capabilities, PowerTech allows fleet owners to take back control by detecting siphoning in real time with sudden drop alerts.

Another critical parameter in today’s operating environment is safety. “Unlike one-size-fits-all imports, the Powertech system has been designed with strict safeguards. Engine power is never cut in unsafe conditions such as coasting, ensuring brakes and steering remain operational. This guarantees both driver and vehicle safety in all scenarios,” explains Weideman.

In light of growing concerns about road safety and the surge in traffic accidents, PowerTech elevates road safety by harnessing real-time data and automated control mechanisms to enforce speed limits, thereby minimising incidents of speeding-related accidents. Fleet managers can set up dynamic limiting in designated geo zones to limit speed in certain areas.

In addition, the system allows for monitoring of driver behaviour and performance, highlighting irregularities such as speeding and excessive idling. The real-time alerts and reports on driver behaviour allow managers and supervisors to identify areas for coaching based on the specific limitations or transgressions reported by the system.

More capabilities

In an environment where truck theft is prevalent, PowerTech adds another layer of asset security to Powerstar trucks. The truck can be placed in limp mode, operating at a maximum of 12 km/hour, in case of theft or unauthorised driving.

ENDURON® ELITE

Hard rock shouldn’t be hard work

The new ENDURON® ELITE Banana screens for hard rock mining. Increased throughput, superior e ciency.

Available in a range of sizes with the largest weighing in at close to 50 tonnes and a deck measuring 4.3m x 8.5m. Powered by Weir’s new patent-pending ETX exciters, providing an energy-e cient operation with just two exciters.

ENDURON® ELITE Banana screens deliver significant advantages in e ciency, lowering energy consumption, as well as simplified maintenance requirements, ensuring minimal downtime.

www.global.weir/ENDURON-ELITE

To ensure asset longevity, the system monitors all critical engine health sensors. By continuously collecting real-time data on engine performance and condition, such as temperature and diagnostic codes, PowerTech alerts fleet managers to potential issues before they become major problems, allowing for timely and efficient interventions. This proactive approach extends vehicle lifespan, lowers repair costs and improves overall operational efficiency for fleets.

With service scheduling, PowerTech allows for proactive service scheduling of services by collecting real-time data on vehicle health and usage, which enables managers to schedule maintenance based on actual conditions such as engine hours, mileage and sensor readings.

This predictive maintenance approach helps prevent costly breakdowns, extends vehicle lifespan and reduces downtime by identifying potential issues before they escalate into major problems.

In conclusion, Chris Watkins, Head of procurement at ESI, says the launch of PowerTech – a telemetry solution engineered to meet the evolving demands of industries across Africa – highlights ESI’s commitment to innovation and customer-focused solutions.

“From performance benchmarking to proactive maintenance, and everything in between, PowerTech helps fleet operators stay one step ahead – locally and across borders. The system delivers better fleet visibility, lower operational downtime, improved cost management, stronger safety standards, easier compliance, increased accountability, streamlined oversight, remote access, actionable insights and room to scale as customer businesses grow,” concludes Watkins. a

TRANSFORMING EARTHMOVING OPERATIONS

Amid an acute shortage of skills, especially in high-precision earthmoving and construction applications, coupled with stricter job specifications, particularly in road building, Leica Geosystems reports growing interest in machine control systems in southern Africa. In a oneon-one with Quarrying Africa, Hendrik Uys – Machine Control Sales Manager Southern Africa, states that even though the technology is becoming much more common on local jobsites, its full potential remains untapped in the region. By Munesu Shoko.

In today’s construction and mining projects, profit margins can be razor thin, with efficiency and precision often the difference between a great project and one you would rather forget. This is where machine control systems – a suite of technologies designed to enhance the accuracy and efficiency of heavy equipment – can make all the difference.

At the core of this technology are Global Positioning System (GPS) sensors, and other data to guide operators during tasks so as to minimise errors and reduce human intervention, especially in applications where high precision is principal.

One of the flagship names in this area is Leica Geosystems, a company that has revolutionised the world of measurement and survey for 200 years.

Part of Hexagon, Leica Geosystems offers a diverse range of machine control solutions for earthmoving, grading and other applications of excavators, graders, dozers, pilers, drillers and compaction, amongst others.

In southern Africa, the focus is largely on grader, dozer and excavator solutions, where a suite of both 2D or 3D solutions is available. The 2D machine

control systems provide real-time guidance and accuracy for tasks such as grading and levelling, without the use of 3D models to get level data from either sensors placed on the machine or with the help of rotating lasers, ensuring that the grader blade or excavator bucket achieves the desired slope or elevation. This entry-level solution is ideal for projects that involve simple terrain or require basic grading.

Customers looking for even greater accuracy and more precision on earthmoving applications can go the 3D route. Leica 3D machine control, explains Uys, works by combining a machine’s real-time position, a 3D design model, and sensor data to guide an operator to grade or dig accurately according to digital plans. It uses Global Navigation Satellite System (GNSS) receivers with a correction source for centimetre-level accuracy, calibrated sensors on the machine’s moving parts, and in-cab displays to show the operator where to move the bucket relative to the design.

Increased uptake

While African contractors generally lag behind

63

Based on the research that Leica conducted recently, the average age of a final-level operator in South Africa is 63 years

KEY TAKEAWAYS

Part of Hexagon, Leica Geosystems offers a diverse range of machine control solutions for earthmoving, grading and other applications of excavators, graders, dozers, pilers, drillers and compaction

In southern Africa, the focus is largely on grader, dozer and excavator solutions, where a suite of both 2D or 3D solutions is available

Amid an acute shortage of skills, especially in highprecision earthmoving and construction applications, Leica Geosystems reports growing interest in machine control systems in southern Africa

Zimbabwe is leading the uptake of the technology, with most of the major road construction contractors in the country using the Leica Geosystems technology

their European counterparts in terms of adoption of machine control systems, Uys is encouraged by the growing uptake in southern Africa. Central to this uptake, he says, is principally the shortage of skilled operators. For example, there is a widely recognised shortage of highly-experienced and final-level specialist grader operators.

This scarcity is not only unique to Africa, but is a global issue, particularly affecting industries such as construction, mining and roadworks, where qualified operators with ‘final cutting’ expertise are in short supply. The scarcity is driven by several factors, mainly an ageing workforce and the complexity of the skill.

“A significant number of older, experienced operators

US$25 000

In a case study conducted by Masimba in 2024, the company concluded that the use of a Leica grader control system was saving them US$25 000 per kilometre of road

“Using Leica Geosystems machine control systems helps to improve accuracy, increase efficiency, reduce costs and enhance safety on job sites. Tasks are done correctly the first time, minimising rework. This leads to faster project completion, better profitability, and a more competitive business.

are retiring. Based on the research that I conducted recently, the average age of a final-level operator in South Africa is 63 years, while their cost-to-company package averages R85 000 per month. A major challenge is that as these ageing operators are retiring, there are fewer young people entering the field to replace them,” explains Uys.

The complexity of the skill, he adds, also makes it difficult to easily replace these skills and attract a new breed of operators. Achieving final-level or final-cutting expertise requires precision and years of practical experience, which cannot be quickly replicated by basic training alone.

The advent of machine control systems from leading suppliers such as Leica Geosystems has therefore changed

the face of earthmoving operations, allowing the industry to address the critical shortage of qualified operators by offering enhanced features to simplify machine operation.

Another major challenge driving the uptake, especially in South Africa, is the stricter nature of SANRAL road projects. A few years ago, the national road authority introduced road rideability (ride quality) tests using various automated methods and specific indices, primarily the International Roughness Index (IRI). Meeting these stringent requirements can be a daunting task, but with the use of 3D systems, contractors can easily achieve the level of accuracy and precision required for rideability passes.

“From an accuracy perspective, with a basic GPS system, customers can expect up to 1,5 cm grading accuracy. If one needs to be better than that, a hybrid system – one that comprises GPS and a total station – a 5 mm grading accuracy can be achieved, highlighting the precision with which grading operations can be executed using these systems,” explains Uys.

Key markets and products

South Africa remains a major earthmoving equipment market in the region, and the uptake of machine control systems has over the years been “fair”, says Uys. Interestingly, Zimbabwe is leading the uptake of the technology, with most of the major road construction contractors in the country using the Leica Geosystems technology.

Zimbabwe is currently experiencing a significant road construction and rehabilitation boom, driven by the government’s renewed focus on road infrastructure, involving the upgrading of major highways to improve connectivity, boost trade and stimulate economic growth.

According to Uys, no major road construction in the country has been undertaken without machine control technology, with Leica Geosystems delivering about 90% of the systems deployed on all major highways to date.

Some of the major Zimbabwean contractors making use of Leica systems include Bitumen, Masimba and Tensor Systems. In a case study conducted by Masimba in 2024, the company concluded that the use of a Leica grader control system was saving them a ‘whopping’ US$25 000

per kilometre of road.

“While these solutions seemingly come at a premium initial capital investment, which often scares some contractors away, the quick return on investment (ROI) justifies the expense,” says Uys. “Using the Masimba case study, where the company is saving US$25 000 per kilometre of road, the system can literally pay for itself in 2-3 km of road constructed. The longevity of these systems is also unmatched. To provide context, a Leica system installed in a harsh salt harvesting application in Namibia has outlived three earthmoving machines and still going strong.”

Prominent solution

While Leica Geosystems offers a comprehensive range of solutions, the big seller at this stage is the Leica iCON grade iGG3 Dual GNSS Grader solution, confirms Uys. The system uses GNSS or robotic total stations to provide millimetreaccurate control and enable operators to work independently with 3D design surfaces inside the cab.

The iGG3 system dramatically increases productivity and optimises material usage on fine-grading jobs by providing precise, automatic control of the blade, thus minimising rework. Another key feature is its user friendliness – it uses the common Leica MC1 software platform, which has an intuitive user interface designed for ease of use, reducing the learning curve and operational errors.

Amid the industry’s quest for data-driven decisions, the system interfaces with Leica ConX, a cloud-based platform for easy data transfer from office to machines, remote support, fleet management and productivity analysis. In conclusion, Uys says the benefits of using Leica Geosystems machine control systems abound and adoption is a ‘no brainer’ for contractors seeking to improve their profitability. “Using Leica Geosystems machine control systems helps to improve accuracy, increase efficiency, reduce costs and enhance safety on job sites. Tasks are done correctly the first time, minimising rework. This leads to faster project completion, better profitability, and a more competitive business,” states Uys. a

Volvo Trucks South Africa has launched its Volvo Uptime Centre, highlighting the company’s commitment to increasing customer uptime and profitability.

KEEPING TRUCKS ON THE MOVE

To help customers avoid costly unplanned truck downtime and keep their assets in operation, Volvo Trucks South Africa has established its local Volvo Uptime Centre. Currently located at the company’s Jet Park headquarters, the support hub uses vehicle data to proactively monitor components, predict issues before they cause breakdowns, and assist with service scheduling. By Munesu Shoko.

Truck owners pay ‘big bucks’ for their mission-critical assets to keep their fleetdriven businesses running. Therefore, uptime is of paramount importance in trucking because it directly translates to productivity and ultimately profitability.

Speaking to Quarrying Africa, Werner du Toit, senior manager Uptime and Connected Services at Volvo Trucks South Africa, says every minute a truck is not operational (downtime) represents lost revenue and increased costs, making uptime essential for truck operators across sectors.

With that in mind, Volvo Trucks South Africa has launched its Volvo Uptime Centre, highlighting the company’s commitment to increasing customer uptime and profitability. Leveraging advances in telematics and connectivity, Volvo Uptime Centre uses vehicle data to remotely monitor critical components to help

predict and prevent breakdowns from happening. In addition, remote software downloads maximise uptime by allowing some software updates to be downloaded remotely to the truck, thus reducing workshop visits.

“The Volvo Uptime Centre leverages connectivity and data analysis to transition from a reactive to a proactive service model, ensuring maximum vehicle availability and profitability for customers. The service is standard for all vehicles purchased with a service/ maintenance contract. However, customers without a service contract on their vehicles can still make use of the Uptime Centre at a very reasonable fee,” explains Du Toit.

Five parameters

As part of the Uptime Centre’s predictive intervention, the team uses the truck’s in-built telematics gateway to monitor a truck’s critical components. According to

432

Between January and September this year, the Volvo Uptime Centre has helped avoid a total of 432 breakdowns

5

The Volvo Uptime Centre pays attention to five key components – air filter, oil changes, clutch wear, brake pads and the Air Production Modulator

The Volvo Uptime Centre leverages connectivity and data analysis to transition from a reactive to a proactive service model.

KEY TAKEAWAYS

Every minute a truck is not operational (downtime) represents lost revenue and increased costs, making uptime essential for truck operators across sectors

With that in mind, Volvo Trucks South Africa has launched its Volvo Uptime Centre, highlighting the company’s commitment to increasing customer uptime and profitability

The Volvo Uptime Centre leverages connectivity and data analysis to transition from a reactive to a proactive service model, ensuring maximum vehicle availability and profitability for customers

The Volvo Uptime Centre monitors five key parameters – air filter, oil changes, clutch wear, brake pads and the Air Production Modulator

Du Toit, five key components are monitored.

The first one is the air filter, which acts as the engine’s ‘lungs’, keeping harmful dirt and debris out while allowing sufficient clean air in for combustion. Keeping the truck’s air filter under watch ensures optimal engine performance and prevents expensive engine damage.

The combustion process in an engine, explains Du Toit, requires a precise mixture of air and fuel. A clogged or dirty filter restricts airflow, forcing the engine to work harder. This can result in diminished horsepower and overall sluggish performance.

“In addition, filter clogging has a direct negative impact on fuel consumption. When airflow is restricted, the engine’s computer may compensate by using more fuel to generate the same power, leading to decreased fuel efficiency and higher fuel costs,” says Du Toit.

The second parameter monitored is oil change intervals/mileage. Neglecting these intervals allows the oil to degrade and accumulate debris, which can lead to severe engine damage, costly repairs and operational downtime. Managing these intervals optimises service schedules and helps plan maintenance based on actual

usage, reducing unnecessary factory visits.

“The third aspect that we monitor is clutch wear. For commercial vehicles, unexpected breakdowns due to clutch failure can lead to significant operational delays and financial losses. A proactive maintenance schedule based on wear monitoring allows for planned, efficient servicing,” explains Du Toit.

Brake pads are the fourth parameter monitored. By monitoring a truck’s brake pads, the Volvo Uptime Centre team can estimate the remaining life of the pads to help with planning replacements. Replacing just the pads is far less expensive than changing the pads together with other components such as rotors and callipers, which will likely be necessary if the pads are completely worn out.

The final component monitored is the Air Production Modulator (APM), the central control unit for the vehicle’s entire compressed air system, which is essential for the brakes, suspension and auxiliary equipment. Monitoring a truck’s APM is critical for safety, maintaining optimal braking performance, and ensuring overall system reliability to prevent unexpected breakdowns.

The APM ensures the independence and proper pressure levels of various air circuits – brakes, suspension, trailer and clutch, amongst others – using overflow

and safety valves. Monitoring helps detect issues such as internal leaks or stuck valves before they cause a complete system failure.

Benefits and successes

The primary goal of the Volvo Uptime Centre is to minimise unexpected stops and keep customer vehicles operating as much as possible. By preventing breakdowns, productivity is increased and operations become more profitable.

“By continuously monitoring critical components, the Uptime Centre’s specialists can detect potential issues early and schedule preventive maintenance, often combining it with existing service visits to reduce factory visits,” explains Du Toit.

With the right support, about 80% of expected breakdowns can be avoided or at least mitigated through proactive measures.

“The primary benefit of the Volvo Uptime Centre is the ability to predict and prevent unplanned downtime by using real-time vehicle data and remote diagnostics. Within a short space of time, the Volvo Uptime Centre has recorded major successes. To provide context, between January and September this year, we have avoided a total of 432 breakdowns,” concludes Du Toit. a

The FJ range stands out as a leader in the construction sector.

The FJ26-280C is ideal for ready-mix operations.

FUSO: A TRUSTED CHOICE IN THE CONSTRUCTION INDUSTRY

When it comes to construction, reliability and durability are non-negotiable. FUSO trucks have earned a reputation for delivering exactly that, making them a top choice for businesses operating in demanding environments.

Built for Tough Conditions

Construction sites are harsh, with heavy loads, uneven terrain, and tight deadlines. FUSO trucks are engineered with robust chassis designs, powerful engines, and reinforced suspension systems to handle these challenges effortlessly. Their ability to perform under pressure ensures minimal downtime and maximum productivity.

Proven Reliability

The FJ range stands out as a leader in the construction sector. These models rarely present issues, offering peace of mind to fleet managers and operators. Their durability translates into lower maintenance costs and longer service life, both critical factors for businesses looking to optimise operational efficiency.

Versatility Across Applications

Whether it is ready-mix concrete delivery, material transport, or heavy-duty hauling, FUSO trucks adapt seamlessly. Models like the FJ26-280C are ideal for ready-mix operations, while the FJ16-230 & FJ18-280 offers flexibility for medium duty tasks.

This versatility ensures that construction companies can find the perfect fit for their specific needs. “The FA9-137 is steadily gaining traction among customers in the construction sector,

thanks to its versatility and dependable performance.”

The Bottom Line

In an industry where time is money, FUSO trucks deliver the reliability, strength, and efficiency that construction businesses demand. With proven performance and a range of models tailored for heavy-duty work, FUSO remains a trusted partner for building the future.

Feedback from customers

“We very rarely encounter issues with these models, which speaks volumes about their engineering quality and resilience in demanding environments.”

“For companies seeking dependable solutions for construction projects, the FJ range remains a solid investment, offering peace of mind and long-term value.”

Key Features of Each Model FJ26-280C

• Robustness: Durable FUSO Super Frame Structure for heavy-load performance.

• Comfort: Improved ride with bogie suspension and stabilizer bar.

• Traction: Inter-wheel differential lock for better grip on slippery surfaces.

• Customisation: Standard PSM (special module) for easy electrics integration.

• Versatility: Engine & transmission PTO for multiple applications.

• Convenience: Instrument Integrated engine hourmeter for quick monitoring.

FJ16-230 & FJ18-280

• Robustness: Shot-peened frame for added strength and resistance to cracks and stress.

• Efficiency: Electronic viscous fan for faster engine warm-up, reduced load, and better fuel economy.

• Control: Exhaust/Engine brake switch with override for enhanced braking performance.

• Maintenance: Clutch wear indicator for easy preventive maintenance

• Versatility: Transmission PTO for multiple operational applications on the FJ16-230

• Comfort: Cruise control to reduce driver fatigue on long highway trips.

FA9-137

• Robustness: Durable chassis and suspension for assured road safety and cargo protection.

• Repairability: Robust steel bumper designed for easy and quick repairs.

• Load Capacity: Laminated multi-leaf springs with taller stack for improved load carrying ability.

• Durability: Banjo-type heavy-duty rear axle for increased load capacity and long life.

• Security: Lockable fuel cap and anti-theft mesh for essential protection and reduced downtime.

• Convenience: Instrument cluster with multiinformation display including distance-to-empty and hour meter. a

The dual-powered Sandvik QA452e offers the flexibility to run on diesel or electricity, significantly reducing fuel consumption and carbon emissions.

MAKING THE SHIFT

As the electromobility shift gathers pace in the mobile crushing and screening space, Sandvik Rock Processing has brought its first dualpowered machine into southern Africa, a QA452e tracked mobile, three-deck sizing screen with Doublescreen technology. Sold by S&R Enterprises, the southern African distributor, the unit has immediately been delivered to a contractor working on a flagship dam project in Lesotho. By Munesu Shoko

50%

The dual-powered QA452e three-deck sizing screen consumes up to 50% less hydraulic oil over 10 000 hours of usage

4 000

Hydraulic service intervals have been increased from 2 000 to 4 000 hours, subject to oil sampling

24 /3 000

The Sandvik mobile equipment warranty has gone up from the traditional 12 months/1 000 hours to 24 months/3 000 hours

In line with global trends, mines and quarries in southern Africa are increasingly pursuing energy efficiency due to the significant financial benefits of reducing energy consumption, which is generally a major operational cost. The move simultaneously allows operations to meet their sustainability goals by lowering their carbon footprint. Essentially, by using less energy, the industry can save money and operate in a more environmentally responsible way.

Consequently, there is an apparent growing uptake of electric mobile crushing and screening solutions, particularly hybrid solutions. To meet the growing need for these solutions, Sandvik Rock Processing and its southern African distributor, S&R Enterprises, have delivered their first dual-powered unit to a customer in southern Africa.

“We are excited to bring our first dualpowered machine into southern Africa,” says PC Kruger, Business Line Manager Crushing at Sandvik Rock Processing. “We have seen a growing appetite for hybrid mobile crushing and screening solutions in the region, particularly driven

by the need for cost savings, reduced environmental impact and increased operational flexibility. These solutions offer the best of both worlds – the ability to connect to the electrical grid or renewable energy sources and also run them with an on-board generator.”

Straight to site

Upon its arrival, the machine was straightway headed to its first project. Stephen Smith, MD of S&R Enterprises, says the prompt sale of the first unit highlights the immediate need for these solutions in southern Africa.

“The machine has been deployed on a major dam and related road infrastructure project in Lesotho, where it will specifically be used to produce G2 and G5 material. It will be paired with a refurbished Sandvik QJ240 jaw crusher that we have also supplied to the customer,” says Smith.

On this particular project, the customer will power the unit using an on-board generator. Given the high altitude on site, S&R Enterprises has specified a 130 kVA generator, instead of the standard 90-100 kVA generally ideal for this size of a machine. Smith explains that altitude

We are excited to bring our first dualpowered machine into southern Africa. We have seen a growing appetite for hybrid mobile crushing and screening solutions in the region, particularly driven by the need for cost savings, reduced environmental impact and increased operational flexibility.

KEY POINTS

There is an apparent growing uptake of electric mobile crushing and screening solutions, particularly hybrid solutions

To meet the growing need for these solutions, Sandvik Rock Processing and its southern African distributor, S&R Enterprises, have delivered their first dual-powered unit to a customer in southern Africa

A major talking point on the Sandvik QA452e screen is its hybrid “e” drive option, which provides the flexibility to operate in diesel or electric mode for lower operating costs and reduced carbon emissions

The QA452e features Sandvik’s patented Doublescreen technology for high throughput and efficiency

affects generators by reducing air density, which contains less oxygen, leading to inefficient fuel combustion, lower power output and a risk of overheating.

For every 300 m above sea level, naturally aspirated engines typically experience a power loss of 3-4%, so a generator’s output is significantly derated at higher elevations. To compensate, one must use a larger, higherrated generator, which is exactly what S&R has done in this particular instance.

On the Lesotho project, the Sandvik QA452E is being used to produce G2 and G5 materials and is paired with a refurbished Sandvik QJ240 jaw crusher supplied by S&R Enterprises.

Major talking point

A major talking point on the Sandvik QA452e screen is its hybrid “e” drive option, which provides the flexibility to operate in diesel or electric mode for lower operating costs and reduced carbon emissions.

When connected to an external power source, the cost of electricity is often lower than diesel, leading to significant savings. To provide context, says Kruger, the QA452e requires 54 kW of power to run it. “Using a diesel engine, the machine will consume about 14 litres of diesel per hour, which in South Africa translates to about R300 per hour. Conversely, electricity comes at R1,80 to R2,40 per unit (kWh), which translates to about R100 per hour to power this unit,” he says.

While the machine comes at a significantly higher capital cost than its traditional diesel-powered counterpart, Kruger says the massive operational savings offer a quick return on investment. Given the high diesel prices, particularly in South Africa and other neighbouring countries, the savings on diesel help offset the premium capital price of the machine within a short period.

In addition, says Smith, the electric motor drive reduces the need for diesel engine servicing and hydraulic oil, thus increasing machine availability and reducing costs. In fact, the machine consumes up to 50% less hydraulic oil over 10 000 hours of usage. Consequently, hydraulic service intervals have been increased from 2 000 to 4 000 hours, subject to oil sampling. In addition, the standard Sandvik mobile equipment warranty has gone up from the traditional 12 months/1 000 hours to 24 months/3 000 hours, with extended warranty options up to six years.

Other key features

The QA452e features Sandvik’s patented Doublescreen technology for high throughput and efficiency. It is a revolutionary design that utilises two high velocity

screen boxes that work independently of each other; the primary screen works as a fines extractor, while the secondary screen operates as a grader.

Doublescreen advantages over competing products include greater material control, greater adjustability, increased accuracy and higher screening efficiencies, making this unit ideal for producing massive volumes of high specification products, without compromising on productivity.

“The patented Doublescreen design features three independent 20’ x 5’ (6 m x 1,5 m) screens, each providing a screening area of 9 m³/ 9,3 m², with the bottom deck being 11% longer for more screen area and fines extraction. Compared to conventional 20’ x 5’ screen boxes, the Doublescreen technology typically outperforms traditional screens by up to 30%. It also allows up to 42 screen angle options due to the two screen boxes,” explains Smith.

Several features of the machine speak directly to increased safety. The mandatory audible and visual warning ensures safe operation during tracking and start-up or shut-down of the machine. The emergencystop buttons and conveyor pull-stop cords around the plant offer easy access during operation. The wireless radio handset and two-speed control ensure safe tracking on site. The wrap-around, hydraulicallyoperated maintenance platforms provide safe access for service and maintenance. The oversize conveyor features both hydraulic raise lower and slew functions, eliminating the need for a crane on site.

With productivity in mind, the new oversize cross conveyor handles more oversize material. The integrated hydraulic conveyors offer large stockpiling capability. The machine also comes with a user-friendly PLC control system with sequential start-stop for speed and ease of set up. It is also connected to Sandvik My Fleet with a 7-year data subscription, 24/7 fleet management, geofencing and remote support.

X X MARKS THE SPOT WITH MARKS THE SPOT WITH THE

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On its first project, the Sandvik QA452E has been paired with a refurbished Sandvik

has been supplied to

Towards fully electric

As the move towards electric mobile crushers and screens in southern Africa continues apace, Sandvik Rock Processing is expanding its electric offering with the launch of the fully electric UJ443E mobile jaw crusher. At the time of writing, the first unit in southern Africa was expected to arrive in October.

Aligning with Sandvik’s “make the shift strategy”, the UJ443E has been designed with an increased focus on sustainability, productivity and durability, while retaining the look, feel and value proposition that customers demand. The fully electric UJ443E is said to provide customers with up to 30% reduction in fuel consumption and up to 30% increase in throughput, versus previous generation products.

The machine is built on a new, fully electric track platform. It features electric final drives and an on-board genset, which can be operated more sustainably, either by an external electricity supply, hydrotreated vegetable oil (HVO) or diesel. The fully

electric track drives provide better control and agility when tracking and loading and significantly reduces the need for hydraulics on the plant and long-term service costs.

“Powering the machine using an external electric source can bring several advantages, including lower running costs, extended drivetrain service intervals, reduced onsite emissions and noise levels. Using fully electric track drives and final drives, the unit reduces the use of hydraulic oil by up to 91%,” explains Kruger.

“We believe there is a notable appetite for this technology in southern Africa, particularly in South Africa. Central Africa will follow closely when it comes to the uptake of the technology. While many UJ440 diesel powered units have been sold in the region, it is significant that the UJ443 is a fully electric version of the reliable UJ440, and the arrival of these units marks a significant step towards a more sustainable and cost-effective future for the local mobile crushing and screening industry,” concludes Smith. a

PUTTING DATA AT THE CENTRE OF MINING OPERATIONS

As part of its efficiency drive, Afrimat has rolled out the AVA Load and Haul system on about 300 assets across 25 sites. Speaking to Quarrying Africa, Andre van Heerden, Head: Operational Efficiency at Afrimat, says the results of putting data at the centre of load and haul operations have been remarkable, with the fleet’s throughput doubling at some sites through paying attention to the basics, which is often where the biggest wins are. By Munesu Shoko.

The importance of data-driven operations in quarrying and surface mining in general cannot be stated enough. According to Van Heerden, this is not something the industry has to debate anymore. Relying on opinions, gut feelings, or luck, might work occasionally, he says, but it is never consistent.

When decisions are grounded in data, one removes guesswork from the equation.

“Data gives you clarity, objectivity and accountability. It does not necessarily imply that there is need to ignore experience or intuition, but what data does is that it ensures those instincts are backed up by facts. In my view, data-driven decision-making is not just

As part of its efficiency drive, Afrimat has rolled out the AVA Load and Haul system on about 300 assets across 25 sites

KEY POINTS

Data-driven decision-making is not just important for mining and quarrying, it is the only way to achieve long-term, repeatable success

Based on this understanding, Afrimat first rolled out the AVA Load and Haul system in 2020, initially at its iron ore operation in Kathu, Northern Cape

From the onset, the goal was simple – Afrimat wanted to improve fleet output and bring down its cost per tonne

At some sites, Afrimat has seen the fleet’s throughput double, which, of course, means that the cost per tonne has been halved

important for mining and quarrying, it is the only way to achieve long-term, repeatable success,” says Van Heerden. Based on this understanding, Afrimat first rolled out the AVA Load and Haul system in 2020, initially at its iron ore operation in Kathu, Northern Cape. AVA’s Load and 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.

At the time, says Van Heerden, Afrimat was in a bit of a

2020

Afrimat first rolled out the AVA Load and Haul system in 2020, initially at its iron ore operation in Kathu, Northern Cape

“One of the biggest lessons was just how much value lies in getting the basics right. Parameters such as startup and shutdown delays, idle time and unproductive movements often go unnoticed, yet they quietly add up to huge losses over time. AVA helped us visualise those inefficiencies and tackle them head-on.

tricky spot; the company had plenty of data, but very little trust in it. Most of the existing systems relied heavily on manual input, which made the data unreliable and easy to manipulate.

“We realised that before we could drive efficiency, we first had to rebuild confidence in the numbers. That meant finding a system that could provide accurate data without any operator intervention. AVA gave us exactly that,” explains Van Heerden. “We also knew that once you have accurate data, not everyone will know how to react to it. We needed more than just a data platform, but a partner who could walk the journey with us, helping our sites to not only collect information but to truly understand and use it.”

At the time, some of the Afrimat operations were already quite advanced in terms of efficiency, while others were just starting out. AVA became the tool, and the partner, that helped the company bring all sites onto the same playing field.

Assets and parameters

To date, Afrimat has installed the AVA system on its load and haul gear – articulated dump trucks (ADTs), excavators and wheel loaders. The system, says Van Heerden, has proven especially valuable in helping Afrimat better manage its ADT fleet. The company is now working closely with the AVA team to deepen its insights on excavators and front-end loaders as well.

Commenting on the strategic intent behind going the AVA route, Van Heerden says that from the onset, the goal was simple – Afrimat wanted to improve fleet output and bring down its cost per tonne. But once the company started using the system, it made the team realise where the real opportunities to improve lay.

“One of the biggest lessons was just how much value lies in getting the basics right. Parameters such as startup and shutdown delays, idle time and unproductive movements often go unnoticed, yet they quietly add up to huge losses over time. AVA helped us visualise those inefficiencies and tackle them head-on,” explains Van Heerden.

The system also gave Afrimat the tools to design more efficient haul cycles, removing unnecessary delays within each cycle. In short, it helped the company focus not only on doing more, but on doing it smarter.

a potential opportunity for improvement. The company also keeps an eye on average speeds – when those drop, it immediately triggers an investigation to understand whether it is due to road conditions, operator behaviour, or congestion at loading or dumping areas. The idea, stresses Van Heerden, is to catch small inefficiencies before they grow into major bottlenecks.

Key outcomes

Commenting on the benefits realised since rolling out the AVA system, Van Heerden says the results have been remarkable. At some sites, Afrimat has seen the fleet’s throughput double, which, of course, means that the cost per tonne has been halved. The first success was at Afrimat’s iron ore mine, where the company managed to double its fleet’s throughput. The same success was later achieved at the company’s anthracite operation.

“Achievements like that do not come easy; they are a result of committed site management teams putting in the work. But it is also important to note that the effort would have meant little without accurate, real-time data to guide decisions,” he says.

Even at sites where performance has not dramatically improved yet, he adds, the benefits are still clear. The system gives Afrimat engineers and managers a reliable view of what is happening on the ground. They can monitor trends quietly in the background, and when an issue does arise, it is far easier to pinpoint the root cause and take corrective action quickly, because the data is already available, accurate and ready to use.

AVA’s Load and 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

“We pay close attention to the basics, because that is often where the biggest wins are. Startup and shutdown inefficiencies are among the easiest to spot and fix, and improving them has a direct impact on throughput, so they have become key performance indicators (KPIs) for us,” says Van Heerden.

Beyond that, Afrimat closely monitors all stationary times within the haul cycle. Any period where machines are not moving or producing is

“Even at our smaller operations, we have seen meaningful changes. The moment operators realised that inefficiencies, such as excessive idling or poor cycle discipline, would be visible, behaviour began to shift almost overnight. The system created a healthy sense of accountability,” he says.

Beyond performance, AVA has also become an invaluable tool for safety

investigations. Having precise, time-stamped operational data allows Afrimat to reconstruct events with clarity, identify root causes faster and prevent similar incidents in the future.

Based on these successes, Van Heerden says the goal is to eventually have AVA implemented across all Afrimat sites, adding that the results have so far proven the value of reliable, real-time data in driving performance, so expanding the rollout is a natural next step.

“Each new site that comes online strengthens our overall ability to compare, learn and share best practices across the group. Over time, that collective visibility will help us move from isolated improvements to a truly standardised culture of operational excellence,” he says.

Living up to expectations

From the onset, Afrimat’s decision to opt for AVA as a technology supplier really came down to expertise and value. According to Van Heerden, the AVA team exhibited a deep understanding of open-pit

• Extra effort does not necessarily mean extra profit

• 3 minutes per cycle saving

• 1000 cycles daily

• 50 machine hours each day

The AVA system has given Afrimat the tools to design more efficient haul cycles, removing unnecessary delays within each cycle.

mining operations.

At the time, he adds, no other solution could offer the same level of miningfocused information at that price, “and we still have not found any other company with the same level of mining know-how and refined product at this price.”

“Like with any technology partner, there is always a feeling that development is never fast enough, especially when you are excited about what is possible and want the next feature ‘as soon as yesterday’. That being said, our relationship with AVA has been built on mutual trust, and the team’s support has been consistently strong,” he says.

Van Heerden commends AVA for showing a genuine commitment to understanding Afrimat’s business and adapting its system to meet the mining company’s evolving needs. It has been a true partnership rather than a supplier-client relationship, and that has made all the difference in keeping the momentum going.

In conclusion, Van Heerden says there is still a lot to learn, and that is what makes this journey exciting. “The more we share ideas, successes, and even challenges as an industry, the faster we all grow. Publications such as Quarrying Africa play an important role in that – they help us learn from one another and push the boundaries of what is possible in South African mining and quarrying. If we keep that spirit of collaboration alive, I truly believe we can unlock the full potential of our industry,” he concludes. a

October 2025,

BUILDING ON THE STRONG FOUNDATION

Having previously served as financial director, Tim Ward has been appointed managing director of Babcock’s Equipment business. Building on the strong foundation already in place and his extensive organisational knowledge, Ward – who has been with the company since 2002 – will oversee operations across southern Africa, ensuring Babcock continues delivering quality support and long-term value to its customers in the region. By Munesu Shoko.

As part of the recent leadership changes at Babcock, Tim Ward has been appointed MD of the Equipment business, effective October 2025. He replaces David Vaughan, who had been in the same role since 2016. Vaughan remains closely connected to the business, having taken on a new

position as Executive Chairman of the Equipment business. In his new capacity, he will continue to guide and support the business until his planned retirement in October 2026, ensuring a seamless leadership transition in the process.

Ward, who has been the financial director of the Equipment business since 2003 and served under seven previous MDs, brings not only strong commercial insight, but also a deep understanding of the business and the yellow metal equipment sector in general. Born in the UK, Ward graduated with a Mechanical Engineering degree and went on to become a salesman in the pump sector.

During his time in the pump industry, he was introduced to finance and quickly developed a strong interest, leading to a career switch. His first accounting role came at the age of 26, and by 30, he was already a financial director for a yellow metal equipment company based in the UK.

In 1997, he was deployed to work in South Africa by his UK company and never looked back. He later joined Babcock’s Equipment business in 2002, initially

2003

Tim Ward, who has been the financial director of the Equipment business since 2003, brings strong commercial insight and a deep understanding of the business

20-40

Babcock plays an active role in the development of its people through a good training institution, taking between 20 and 40 apprentices every year

Tim Ward is responsible for the strategic management of OEM partnerships with Babcock’s principals such as Volvo Construction Equipment.

KEY POINTS

As part of the recent leadership changes at Babcock, Tim Ward has been appointed MD of the Equipment business, effective October 2025

In his new role, he takes responsibility for the day-to-day running of the Equipment business and is responsible for creating and implementing strategies to achieve growth and meet company objectives

Speaking to Quarrying Africa, Ward highlights that one of his immediate objectives is to grow market share for the BULL brand

To meet specific customer needs, Babcock has just started offering Volvo CE’s Equipment as a Service (EaaS) solution, a long-term, fleet-based service where customers do not buy a machine but rather purchase hours from the supplier to use it

in a business development capacity, before landing the financial directorship role the following year, a position he held until his recent appointment as MD.

In his new role, he takes responsibility for the day-today running of the Equipment business and is responsible for creating and implementing strategies to achieve growth and meet company objectives. In addition, he is also responsible for the strategic management of original equipment manufacturer (OEM) partnerships with Babcock’s principals such as Volvo Construction

Equipment (Volvo CE), Sennebogen and BULL.

“My role also entails active involvement in fostering a company-wide customer-oriented culture. Customer interactions are something that I am already familiar with from my previous role as financial director. The biggest change, however, is the people aspect – overseeing the human resources function, approving key hiring decisions, overseeing performance management frameworks and ensuring the retention of personnel,” explains Ward.

Key focus areas

Speaking to Quarrying Africa , Ward highlights that one of his immediate objectives is to grow market share for the BULL brand. Since taking over the distributorship of BULL backhoe loaders and skid steers in July 2023, Babcock has put the brand on a growth trajectory, but Ward believes that there is potential to gain even more market share.

Despite the competitive nature of the market, with more than 24 brands competing for market share, backhoe and skid steer loaders remain high-volume units in the South African equipment market. To provide context, available industry figures show that the backhoe loader market ranges between 1 600 and 1 700 units per annum, with skid steer loaders in the region of 300-350 units per year, based on CONMESA figures.

In BULL, he says, Babcock has a great product to challenge for more market share. Having first entered the market in November 2011, BULL is said to be the youngest and fastest growing backhoe loader manufacturer in the global market. Within a span of a decade, the brand is now among the top three backhoe loader manufacturers

in India, demonstrating its competitive edge in the backhoe and skid steer market.

Ward’s tenure also coincides with the arrival of an array of new Volvo products. In fact, Volvo CE has renewed over 35% of its total product range in the past year, marking the company’s largest product portfolio renewal in decades. While some of the new products such as the New Generation Volvo articulated haulers and the new F-Series excavators have already been rolled out in southern Africa, Ward says more are still to come in a staged approach.

“We have already introduced the first three models of the New Generation range of articulated dump trucks (ADTs), namely the A40, A45 and A50. Next year, we will be rolling out the A30 and the A60,” says Ward. “Having been launched globally in September this year, the new generation Volvo wheel loaders are set to arrive in November this year. One of the key objectives is to ensure the immediate success of these new products in the market.”

Commenting on the uptake of the ADTs, Ward says customers in southern Africa have shown significant interest in the range. One of the central pillars of the early interest has been the technological

advancements that speak directly to better productivity and efficiency.

“In an environment where datadriven decisions continue to take root, the new Volvo ADTs place high value on ‘Connected Solutions’ – a suite of digital services and on-board technologies that use real-time data and telematics to improve productivity, efficiency, safety and maintenance. Customers are also particularly impressed by technological options such as the OEM proximity detection system (PDS) interface and OnBoard Weighing,” says Ward.

Trends

Commenting on some trends driving the local yellow metal equipment market, Ward notes the growing uptake of ‘value’ products – machinery that emphasises price competitiveness and sufficient functionality for the required task, rather than the most advanced technologies found in premium offerings.

Through its range of value-brand offerings, Babcock provides fit-for-purpose solutions for customers seeking costefficient equipment options in emerging market segments. Through Volvo Financial Services, customers have access to fast and flexible finance solutions that speak directly to their needs.

Another notable trend is the fact that the industry is grappling with the dearth of technical skills, says Ward, adding that it is difficult to retain technicians due to a combination of a significant skills mismatch and a high rate of brain drain, where skilled professionals are continuously seeking better opportunities abroad.

To help plug the skills gap, Babcock invests in skills through a comprehensive apprenticeship programme that combines structured theoretical training with extensive practical workplace experience in order to develop a skilled and dedicated workforce. This initiative not only nurtures talent but also helps address skills gaps in the industry.

“We play an active role in the development of our own people through a good training institution that trains our own apprentices whereby we take between 20 and 40 apprentices every year. During the last intake, we were able to retain almost the whole intake. Where we do not retain, we offer these skills to the industry, especially our customers. We have successfully done this since the early 2000s and some of the initial apprentices have

now progressed through the business and occupy middle to senior management positions,” explains Ward.

Rental and service contracts

Another notable trend, adds Ward, is the growing uptake of service contracts. Capital equipment owners, he says, now prefer service contracts primarily for the predictability, risk reduction and operational efficiency they offer. These contracts shift the burden of maintenance and unexpected repairs to a service provider, allowing the owner to focus on their core business operations.

“In recent times, we have been successful with our service contracts, which we take as the first stage of the relationship with the customer. We are taking it to another level with Volvo ACTIVE CARE, which allows us to flag potential problems before they happen,” he says.

Traditionally, with CareTrack, Volvo CE’s telemetry platform, the customer is alerted every time a machine fault code goes off – no matter how critical or not – and it is up to them to contact the dealer with the alarm details and monitor progress. ACTIVE CARE takes the burden of monitoring and initial diagnosis off the customer, who is only notified when a specific action is necessary. With ACTIVE CARE, Babcock manages the data on behalf of the customer, providing remote diagnosis and catching problems before they occur.

Another trend that Ward has observed is the growing used machine market in Africa. After renting their assets for the first life, several rental companies in South Africa have found a thriving market for their used machines in countries such as Zimbabwe and the Democratic Republic

of Congo, amongst others.

To meet specific customer needs, Ward tells Quarrying Africa that Babcock has just started offering Volvo CE’s Equipment as a Service (EaaS) solution. EaaS is a long-term, fleet-based service where customers do not buy a machine but rather purchase hours from the supplier to use it. It is a tailor-made service because one uses the fleet when and where they need it, with all necessary support included and managed by Babcock.

A key aspect of EaaS is the ‘pay as you go’ concept. There is no up-front investment required, plus it is scalable. “Essentially, customers purchase a set number of operating hours for the equipment at a fixed hourly rate, paying only for the time they actually use it. EaaS has been a successful concept in Europe, and we believe it will generate interest locally, particularly from those who do not want to hold assets on the balance sheet,” explains Ward.

State of market

Commenting on the state of the market, Ward says despite the marked dip in commodity prices, especially coal, the local equipment market generally remains resilient, as has been the case during the past three to four years.

“The coal industry is a big recipient of our machines. With export volumes under pressure, customers are generally in cost-cutting mode. However, Eskom remains a major consumer of coal locally for its power stations, and I believe that coal exports can be the ‘cream on the top’ for local producers, which gives the industry the edge to survive the tide of low coal prices,” says Ward.

Apart from coal, Ward says other commodity areas such as chrome and gold are doing well. In fact, gold prices hit record highs in 2025, surpassing the US$4 000 per ounce mark in October. “The gold industry is enjoying a bull run, and we find gold reclamation to be quite a good sector at the moment.

The chrome industry, despite the closure of smelters, is also enjoying a good run,” says Ward.

Looking ahead, Ward expects the market to see improved conditions next year, most likely from the second quarter onwards. “This is premised on the outlook that coal prices will rebound and smelters will be turned back on,” says Ward.

As he steps into his new role, Ward is focused on building on Babcock’s strong foundation and purposeled approach. “Our business has always been defined by trusted partnerships, technical capability and customer uptime. That won’t change,” he says. “What will continue to evolve is how we deliver lifetime value – through new products, digital solutions and skilled people who go the distance for our customers. I am confident that, together with our OEM partners and our teams across southern Africa, we will continue to engineer progress that lasts –for our customers, our people and the industries we serve.” a

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ON A GROWTH TRAJECTORY

This year marks Ralf Hennecke’s 30th anniversary at BME, a division of the Omnia Group. Having joined the company in 1995, Hennecke rose through the ranks to become MD in August 2021. Under his leadership, the company has been on a five-year growth trajectory –not only bottom line growth, but also the growth of people. In a one-on-one with Quarrying Africa, he discusses the pillars of this growth and unpacks how the explosives industry – and the mining sector in general – has evolved over the past three decades. By Munesu Shoko

50-60%

New regions have over the years continued to grow, with 50-60% of BME’s business now coming from markets outside South Africa

In 1995, Ralf Hennecke, a mining engineer by profession, joined BME as a technical representative from the mainstream mining sector. At the time, the plan, he says, was just to experience the other side of the industry –the supply chain – for a year or two and then head back to mainstream mining, which never materialised.

Some 30 years later, Hennecke is still with BME. Over the years, he has moved through the ranks – business operations, business development, commercial management, and marketing and technology, before assuming the top job as MD in August 2021.

Industry changes

During this three-decade period, a lot has changed – both from a product and mining industry perspective. From a product standpoint, initiation systems have significantly evolved, says Hennecke, from capped fuse and igniter cord

1995

Having joined the company in 1995, Hennecke rose through the ranks to become managing director in August 2021

Aerial view of BME’s Losberg manufacturing plant, situated approximately 75 km southwest of Johannesburg.

KEY POINTS

30th anniversary at BME, a division of the Omnia Group

Having joined the company in 1995, Hennecke rose through the ranks to become MD in August 2021

Under his leadership, BME has been on a rapid growth trajectory, achieving a 41% CAGR over the past five years

The globalisation strategy will continue to be a source of growth for the foreseeable future

systems to non-electric detonators, electric detonators and ultimately electronic detonators.

Capped fuse and igniter cord systems, he says, are hardly used anymore, while non-electric detonators are mainly deployed in quarries, small to mid-tier mines and waste blasting in Tier 1 mines. However, he says, electronic detonators “have become the flavour of the blasting

40

When it comes to emulsions, BME is one of the pioneers of dual-salt, cold emulsion products, which it first introduced some 40 years ago

About Ralf Hennecke

Ralf Hennecke, MD at BME, is a seasoned mining engineer with extensive production experience in South Africa’s historic mining industry, having worked with prominent mining houses such as Rand Mines and JCI. Since joining the Omnia Group in 1995, Hennecke has held key technical roles in explosives and has been an integral member of BME’s Executive Committee since 2001. He holds a Master of Business Administration (MBA) degree, which he earned in 2005.

From 2015 to 2019, Hennecke served as GM: Customer Commercial and Marketing, before assuming the role of GM for BME’s Marketing and Technology division. In this capacity, he oversaw a broad range of critical functions, including Global Blasting Science, Global Underground Business, Global Product Management, and Global Marketing and Branding. His responsibilities also extended to Global Software Development and Technology, as well as leading the development and marketing of BME’s AXXIS electronic detonator systems.

In 2021, Hennecke was appointed MD of BME, where he has been steering the company’s global corporate strategy, leading to significant growth in key mining regions such as Australia, Indonesia and Canada. His leadership is characterised by a strong commitment to prioritising people and safety, as he continues to focus on retaining and expanding BME’s presence in crucial markets.

game” due to the accuracy, safety and ultimately good blast outcomes associated with these solutions.

From an emulsion perspective, the industry has migrated from Ammonium Nitrate Fuel Oil (ANFO) and water-gel explosives, to bulk emulsions, as they are known today.

As far as technology is concerned, Hennecke has witnessed the shift from after-the-event reporting to real-time reporting, allowing the industry to move from retrospective, delayed data analysis to a system that provides instantly actionable insights as data becomes available.

With the advent of data collection and data visualisation platforms, this technology evolution allows for trend analysis and ultimately predictability of blast outcomes. This evolution, says Hennecke, is basically today’s artificial intelligence (AI) concept – collecting data and learning from it to provide solutions.

One of the major industry changes in the past 30 years, he adds, has been the move from solely selling

The consolidation of the PMC business allows BME to offer solutions beyond the mining bench, extending the value offering to the milling and comminution circuit.

explosives to offering integrated solutions that include the product and ongoing services to deliver sustained value for the mining industry. This transformation is part of a fundamental change from a product-centric to a customer-centric mindset.

While the mining industry itself, he adds, is generally sluggish to change, it continues to go through cycles. Apart from the cyclical commodity price cycles, the mining industry has largely shifted from owner-mining to contract-mining due to benefits such as reduced capital expenditure, access to specialised expertise, and flexibility in managing fluctuating market cycles.

Adapting to changes

As these changes unfolded, BME has adapted accordingly, positioning itself as one of the leaders in expert commercial blasting solutions in the global market. “To adapt to these industry changes, we have either developed solutions in-house or partnered with other technology companies, bolting-on their solutions to our own capabilities to offer the industry comprehensive blasting solutions,” says Hennecke.

The 2021 launch of the AXXIS Titanium, one of the world’s most advanced electronic blast detonation systems, represented one of the flagship in-house product developments in the history of the company, securing BME’s position among the global leaders in electronic delay detonator (EDD) design.

To date, the AXXIS electronic blast initiation system includes the advanced AXXIS Titanium and the streamlined AXXIS Silver for smaller operations. The AXXIS system provides high accuracy and safety through features such as dual safety capacitors and a programmable ASIC chip. In 2024, BME expanded the range with the Centralised Electronic Blasting System (CEBS) for underground mining, integrating with other BME tools such as BLASTMAP and the XPLOLOG for better planning and analysis. When it comes to emulsions, BME is one of the pioneers of dual-salt, cold emulsion products, which it first introduced some 40 years ago. Fast-forward to 2025, the

environmental benefits these products offer (relative to single-salt variants), have become even more important, including improved energy efficiency, lower nitrate contamination, and reduced greenhouse gas emissions.

On the partnership front, BME recently strengthened its blasting software offering beyond its premium Blastmap blast planning platform through a partnership with technology leader, Strayos. The alliance has brought together BME’s blasting expertise and Strayos’ advanced image processing and AI capabilities, delivering enhanced functionality, precision and next-generation software solutions to the mining industry.

The announcement of a strategic partnership and acquisition of a minority equity stake in Swedish company Hypex Bio Explosives Technology represented another major technology partnership. Hypex has developed a ground-breaking emulsion using hydrogen peroxide (HP). Said to be the first non-nitrate explosive emulsions in the market, the Hypex technology reduces carbon content by 90% over traditional sources. This technology, says Hennecke, has the potential to completely change the explosives supply industry.

Growth trajectory

Under the leadership of Hennecke, BME has been on a rapid growth trajectory, achieving a 41% Compound Annual Growth Rate (CAGR) over the past five years. Central to this growth are a number of initiatives, including expansion into new regions and commodity areas, commercialisation of new products and technologies, and the establishment of new partnerships.

However, for Hennecke, a principal factor in this growth has been the people. A people-centric approach adopted under Hennecke’s leadership has created a positive culture which has aligned employees with company goals and created an engaged, resilient and adaptable workforce, ultimately leading to better performance. This has not only resulted in bottom line growth, but also the growth of people.

“A strong focus on culture has transformed the company

Local manufacturing of BME’s flagship AXXIS electronic initiating systems.

from what it was five years ago. Bearing in mind that all aspects of culture cannot be simultaneously addressed in any organisation, we deliberately chose three aspects of our culture journey that we felt were important to us. Firstly, every person must understand the purpose of the organisation through the strategy and what they individually contribute to that strategy. Secondly, we created a culture of ownership – employees need to operate as if they own the business. The third leg of our culture strategy is courage – allowing people to speak up freely and voice their opinions without retribution,” explains Hennecke.

New markets

One of the key growth pillars has been the expansion into new market areas. In fact, Hennecke says one of the major milestones in the history of the company was when the company first expanded its footprint into the SADC region in the early 1990s, with Namibia and Zimbabwe being among the first countries of focus.

The late 1990s saw BME expanding into West Africa, a strategic region where the company has been present for 25 years now. In 2015, the company planned to expand beyond Africa, over time establishing a footprint in North America, Australia and Indonesia. These new regions have over the years continued to grow, with 50-60% of BME’s business now coming from markets outside South Africa.

The expansion into new regions continues unabated with investments and complementary partnerships across specific markets. “We are still in the infancy of building our business in Australia and Canada. We have laid foundations with infrastructure builds such as plants and teams on the ground, signalling our commitment to these markets,” says Hennecke.

Complementary partnerships in some markets have created a strong footprint, while unlocking new commodity areas. For example, in 2023, BME marked a major step in its globalisation strategy with the formation of a strategic joint venture (JV) with PT Multi Nitrotama Kimia (MNK), a leading Indonesian producer of ammonium nitrate. While the JV has created an integrated offering with an expanded suite of products and services for both

surface and underground mines, it has also allowed for the JV’s expansion from primarily coal, into the metals market.

In Canada, combining BME’s global experience with local expertise and infrastructure through a complementary 2019 JV with Canadian civil drilling and blasting contractor Consbec, has positioned the company well to meet and exceed the expectations of local customers. Having completed its local electronic detonator manufacturing plant – only the second such plant in Canada – BME Mining Canada is forging ahead with advanced plans to build its first hydrogen peroxide emulsion plant in the next six months, highlighting its commitment to this market.

Extended value offering

During his MD tenure, Hennecke has overseen the 2024 consolidation of Protea Mining Chemicals (PMC) business under the unified mining division, BME. As part of the rebrand, the mining division focuses on two revitalised offerings, BME Blasting Solutions, specialising in explosives and initiation systems, and BME Metallurgy, dedicated to mining chemicals and metallurgical solutions for enhanced mineral recovery.

While the alignment is still in its infancy, Hennecke says it will transform the business through the provision of integrated solutions to the mining industry. It allows BME to offer solutions beyond the mining bench, extending the value offering to the milling and comminution circuit.

Growth opportunity

Looking ahead, Hennecke says the globalisation strategy will continue to be a source of growth for the foreseeable future. In SADC, the Central African Copperbelt, driven by critical minerals, is a major growth area, while Namibia, with its uranium deposits, also provides compelling growth opportunity.

“Looking inward, doing the basics right – maintaining excellent safety and service records, hiring and retaining the right people, maintaining the right quality product and providing fit-for-purpose solutions to an evolving mining industry – will provide us with a strong platform to take our business to new heights,” concludes Hennecke. a

The Bell motor grader range places value on four key elements – precision, technology, intuitive cab and the ZF hydromechanical transmission.

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AT THE GRADING EDGE

In what represented the largest research and development (R&D) project as part of the company’s strategy to expand its original equipment manufacturer (OEM) range, Bell Equipment launched its own motor grader range in 2025. At the heart of the initial three-model range are four key differentiators –precision, technology, intuitive cab and the ZF hydromechanical transmission. By Munesu Shoko.

The unveiling of its own motor grader range in 2025 marked a major milestone in Bell Equipment’s strategy to develop and enhance its OEM products. Headquartered in Richards Bay, South Africa, the OEM’s entrance into this market segment comes at a time when the global motor grader market is witnessing robust growth globally, driven by increasing demand across sectors, particularly in road construction, mining and agriculture.

According to Market Growth Reports, the global motor grader market size was valued at US$1,62-billion in 2024, and is projected to grow from US$1,8-billion in 2025 to US$4,7-billion by 2035, at a compound annual growth rate (CAGR) of 11,4% during the forecast period. In 2023, over 32 000 units were sold globally, on the back of a noticeable increase in government infrastructure spending, especially in emerging economies.

Despite this growth, the market is highly competitive, featuring a mix of large, established premium OEMs and new players with ‘value’ offerings. Given this fierce competition for market share, innovation is central to competitiveness. With that in mind, Bell Equipment has left nothing to chance in terms of R&D, leading to the development of what product manager Jeremiah Mokhomo terms “a compelling offering”.

The initial three models, the G140, G160 and G200, place value on four key elements – precision, technology, intuitive cab and the ZF hydromechanical transmission – which Mokhomo believes set this range apart from competition.

Precision

The importance of precision in grading applications – especially in projects with strict final-level cutting

US$1,8-billion

The global motor grader market size was valued at US$1,62billion in 2024, and is projected to grow from US$1,8-billion in 2025

“We have seen great interest from international markets, especially in regions where reliability, simplicity and total cost of ownership are key buying factors. Operator acceptance has been exceptional as well, with the sealed slew ring and the hydromechanical transmission standing out for many operators.

ISO 21815-2

Bell provides a PDS gateway controller (ISO 21815-2) that enables third-party PDS or CAS to connect to the machine.

KEY POINTS

The unveiling of its own motor grader range in 2025 marked a major milestone in Bell Equipment’s strategy to develop and enhance its OEM products

The initial three models, the G140, G160 and G200, place value on four key elements – precision, technology, intuitive cab and the ZF hydromechanical transmission

Bell Equipment has set a new benchmark in precision through the standardisation of a sealed slew ring across the range

Feedback to date has been positive, largely because Bell incorporated the ‘voice of the customer’ from design to development

tolerances such as highways and airport runways – cannot be stressed enough. With that in mind, Bell Equipment cast a special design focus on this area.

“When it comes to precision, we have set a new benchmark through the standardisation of a sealed slew ring across the range. This is one of the key differentiators from most of the competitor offerings that come with an open cycle system,” says Mokhomo. “The sealed slew bearing delivers consistent mouldboard accuracy due to minimal wear. It also requires less maintenance compared to open gear designs which come with expensive brass inserts and require frequent adjustment.”

The sealed slew ring features integrated seals that form a robust barrier, keeping dirt, dust, moisture, and other contaminants out of the internal raceways. This is ideal for harsh construction and mining environments where motor graders are deployed. The effective contamination prevention and reduced wear also contribute to a longer service life, reduced maintenance costs and increased reliability.

In addition to the sealed slew ring, a larger hydraulic pump ensures smooth hydraulic functions, thus maximising precision. A motor grader, he says, operates up to 15 hydraulic functions, and a larger hydraulic pump therefore provides high flow rates and immense power output necessary for the multiple functions and heavyduty tasks, resulting in precise control and increased efficiency.

Technology

As part of the technology focus, Bell Equipment’s motor graders come with a standard proximity detection system (PDS) or Collision Avoidance System (CAS) interface, a key feature for compliance-focused sectors

such as mining.

Bell provides a PDS gateway controller (ISO 21815-2) that enables third-party PDS or CAS to connect to the machine. This means customers can select the PDS/CAS solution that best suits their specific needs and budget.

“Our PDS/CAS interface is a plug-and-play system that ensures seamless integration of any third-party PDS/CAS system. This eliminates the need for complex, custom retrofitting efforts for each different system, saving engineering time and effort for customers,” explains Mokhomo.

The same agnostic approach applies to machine control technology, with Bell motor graders designed to seamlessly integrate with Leica Geosystems, Topcon and Trimble grade control systems, depending on customer preference.

Intuitive cab

Another major design feature is the intuitive cab. The range features a spacious and comfortable cab with intuitive control options, including a choice between traditional antler controls or advanced joysticks.

The operator environment, explains Mokhomo, was engineered with ergonomics and simplicity in mind to enhance operator comfort and ultimately high productivity and precision. The controls layout, the sitting position and switch placement all speak to ease of operation.

“Control is a crucial factor in motor grader operation and the Bell range offers intuitive controls with a 30-button sealed switch module (SSM) and a sealed 6 WD controller for applicable models. The 7-inch colour display serves as a multi-functional monitor for machine operation and diagnostics, navigated by an automotive-style mouse (B-drive),” he says. “The diagnostic information is also available to the fleet owner through our Fleetm@tic® telematic system.”

ZF Transmission

One of the standout innovations on the Bell motor grader range is the ZF cPower hydromechanical transmission on the G160 and the G200 models –

a

making Bell the first motor grader OEM to deploy this system, according to Mokhomo.

Smooth transmission, he says, is a fundamental requirement that translates directly to the accuracy, efficiency and quality of the final grading application. The cPower hydromechanical transmission maintains a steady, uninterrupted flow of power to the wheels and hydraulic systems for consistent grading.

Power interruptions, common in rough gear shifts associated with conventional transmissions, can cause the machine to lunge or slow unexpectedly, compromising the smoothness of the grade. The smoothness of the transmission also translates in fuel economy and operator comfort.

Positive feedback

In a staged approach, Bell Equipment is initially rolling out the range in Stage 3 markets such as Africa, Australia and South East Asia. Initial commercial units have been deployed in a mix of construction, road maintenance and mining support applications in South Africa and Namibia. Bell is currently running several demos in Australia.

Feedback to date, he says, has been positive, largely because Bell incorporated the ‘voice of the customer’ from design to development. Consequently, operators and fleet owners have seen immediate value in precision, reliability and ease of operation.

From next year, Bell will be rolling out the range to international markets. Customers will be able to choose between joystick and antler control options, giving them choices in line with their operational needs. A case in point is Australia, where over 80% of the market is joystickdriven.

“We have seen great interest from international markets, especially in regions where reliability, simplicity and total cost of ownership (TCO) are key buying factors. Operator acceptance has been exceptional as well, with the sealed slew ring and the hydromechanical transmission standing out for many operators,” concludes Mokhomo. a

SAVE THE DATE

Welcome to our international guests from United Kingdom | New Zealand | Hong Kong Australia | Malaysia

Annual conference & exhibition

Venue: SCAN QR CODE FOR DIRECTIONS

Elangeni Hotel Snell Parade, Durban, KwaZulu-Natal

16 - 17 APRIL 2026

OUR CONFERENCE will feature international speakers from The Institute of Quarrying affiliated branches from the UK, Australia, New Zealand, Malaysia and Hong Kong. Including 2 Keynote addresses and other industry presentations.

Our theme for the year is “Thriving in Uncertainty”.

OUR EXHIBITION will feature 36 stands and will be open for the duration of the conference.

Young Professionals – We will host a group of young professionals from Australia, New Zealand and other affiliated branches of the Institute of Quarrying. They will visit operations in Johannesburg and Cape Town.

COST SAVING?

Existing mines and quarries often regard Environmental Due Diligence as a ‘grudge purchase’ because it is generally perceived as a costly regulatory burden rather than a value-adding investment. Yet, according to Lynn Jones of Umhlaba Environmental Consulting, this proactive process helps owners identify, assess and manage potential environmental risks before they escalate into major costly problems or disruptions. By Munesu Shoko.

In any type of business, the importance of a due diligence (DD) cannot be stressed enough. Inadequate DD can lead to disastrous consequences. These can range from financial losses to legal complications.

Speaking at the recent joint Institute of Quarrying Southern Africa (IQSA) and ASPASA October Symposium, Lynn Jones, principal environmental management consultant at Umhlaba Environmental Consulting, highlighted the importance of Environmental DD for existing operations, the benefits and the various phases of the process.

What is Environmental DD?

A due diligence is an evaluation/assessment undertaken by a party before making a decision, usually a financially related decision. In a private capacity, Jones explains, one would undertake a DD before making a big financial decision, such as buying a house, buying a car, changing

KEY TAKEAWAYS

An Environmental Due Diligence includes an evaluation of all the necessary information to identify what environmental risks are associated with the operation/mine that may have an impact on the continued existence of the operation/mine

The concept of doing a DD for an existing operation is part of good planning. One needs to know where things can go wrong and take steps to avoid the challenges down the line

Start by using the information that is available online – this information is made available by the National Departments as they want to avoid transgressions and damage to the environment

The key benefit of the Environmental DD process is to save money in the long term by avoiding the manifestation of environmental risks

jobs, or even getting married (depending on your culture, there is a lot of money involved in marriage).

An Environmental DD follows a similar concept: it includes an evaluation of all the necessary information to identify what environmental risks are associated with the operation/mine that may have an impact on the continued existence of the operation/mine.

“In the context of an aggregate and sand mine, an Environmental DD would consider the interactions between the mining activities and the environment. We would evaluate the activities taking place on-site, the resources that are necessary for continued operation, the state/validity of the environmental authorisations, and the environmental receptors impacted upon or influenced by the mine (both on-site and off-site),” explains Jones.

A comprehensive Environmental DD, she adds, will consider the presence of the authorisations, the content of the authorisations, and the implementation requirements of the authorisations, to understand if environmental risks have been identified, and also the cost of managing these risks for the duration of the operation.

Why Environmental DD?

An Environmental DD, says Jones, is necessary for existing operations as it is very likely that there are risks at the mine that may threaten the continued existence of the operation, and often the mine operators and/ or mining right-holders are not aware of these. These risks may be unidentified/unknown because of changes in environmental legislation; the poor quality of Environmental Management Programmes (EMPr); the mediocre competence of the ‘competent’ authority (it must be noted that this statement is not applicable to all officials, but is unfortunately applicable to more officials than is desirable for effective implementation of robust legislation); and the use of corporate window dressing that glosses over the real environmental risks.

“Environmental DD for existing operations is really

about money – it is about spending some money to know what the environmental risks are, so one can avoid spending even larger sums of money mitigating the impacts of unexpected risks, or paying the fine after legal prosecutions, or implementing unnecessary conditions of authorisations,” says Jones.

The concept of doing a DD for an existing operation, she stresses, is part of good planning. One needs to know where things can go wrong and take steps to avoid the challenges down the line.

Facets and phases

Environmental DD would essentially be identifying the sensitivities of the environment in which the mine operates, the risks where activities rely on finite resources, and determining the spatial extent of the long-term plans for the site in order to determine whether there is overlap with environmental sensitivities (remembering that there are buffers to these sensitivities).

The phases of an Environmental DD include:

Phase 1: Desktop Assessment

Start by using the information that is available online – this information is made available by the National Departments as they want to avoid transgressions and damage to the environment. Hence, they are making it easier for stakeholders to do screening assessments to identify where ground truthing is needed and what specialist input will be required.

The ‘desktop assessment’ is necessary to guide the next phases and allows for budget planning of the next phases.

Phase 2: Site Verification Planning

Once the theoretical risks are known, these can be considered in the context of mining activities and future plans. Where there are obvious clashes, the mine can draw up a plan of action for site verification (specialist studies). “It is necessary to partner with qualified

specialists and obtain confirmation / input as to where detailed assessments are required, or where the desktop assessment provides enough information,” says Jones.

The benefit of Site Verification Planning is the discussion of the scope of work with the specialists before they are appointed. The specialists need to know the context of the studies, i.e. what the outcomes will be used for so that they can provide constructive input.

Phase 3: In-depth Assessments/Specialist Studies

Based on the outcomes of the Site Verification Planning, the specialist studies can be commissioned, using the scope of work identified. During this phase, it is necessary to ensure that the outcomes can actually be used by the mine. If not, then the scope of work has not been met.

Key benefits

The key benefit of the Environmental DD process is to save money in the long term by avoiding the manifestation of environmental risks. The risks that Jones refers to are those that could stop operations, such as running out of water, flooding of the pit/mining area, damage to infrastructure (or loss of life) due to flooding, or environmental prosecutions as a result of legal transgressions.

An additional benefit – one that is more important to Jones than saving money for a client – is the protection of resources. All of the environmental resources are finite, and the world cannot live without them.

“We may value material possessions, but the reality is that we can survive without them, but we cannot survive without arable land to grow crops and raise livestock. Clean water to drink and to grow our food is an absolute essential, and our health will deteriorate if we do not have clean air to breathe. It is also important to remember that we can live in many places but crops and livestock require

A settlement dam that shows the settling of sediment in the foreground and clean water further in.

arable land (not just soil),” she explains.

Success story

Over the years, Jones has worked closely with clients across the mining value chain. One of the flagship success stories during this time is that of an aggregate mine that undertook a floodline delineation for a site where the aggregate plant is located on the banks of a river. The site has been operational since the 1960s and the catchment up-stream of the site has been developed through urban expansion. This has resulted in a change in the stormwater inflows to the water course (river), increasing the flood volumes during storm events.

“The floodline delineation identified that the part of the workshop that included the ‘oil stores’ would be below the 1:50 year floodline. In a flood event, there was the risk of the release of hydrocarbons into the water course. As a result of this study, the mine has relocated the oil stores outside of the floodline and has also relocated any waste storage receptacles that were previously located below the floodline,” says Jones.

Subsequent to this delineation, the plant has twice been inundated by floodwaters. Had the oil stores not been relocated, the mine would have been liable for the downstream clean-up operation of hydrocarbon contamination.

Missed opportunities

Jones also cites a summary of the examples of where Environmental DD should have been undertaken (as advised):

Ground Water Investigations: A dolomite mine did not follow advice and did not undertake a ground water investigation to determine if there were any cavities in the vicinity or if they could intersect a geological feature that would result in flooding of the pit.

Result: A few years later, the mine was flooded by

ground water. The mine spent a lot of money trying to pump the water out before they acknowledged this was a futile exercise and went from having a life span of over 100 years to running the risk of having to close because the pit was flooded.

“A proactive Environmental DD would have helped them plan, either identifying where mining could take place without flooding the pit or, calculating the actual cost of mining – allowing them to plan for the management of the ground water. An Environmental DD would have been a long-term cost saving,” says Jones.

Wetlands: There are many examples where mines have not delineated the wetlands before doing resource calculations. The life of mine is then calculated or the mine is purchased assuming all sand is available for mining. As members of the public are now more knowledgeable and the Department of Water and Sanitation (DWS) is more active than it used to be, mines are now being instructed to delineate the wetlands where desktop assessments have identified the potential for wetlands.

Result: The available resources are decreased as land is sterilised by wetland habitat and the buffers required to allow for the continued functioning of the wetlands. An Environmental DD would have identified the true resource availability and allow for more accurate life of mine predictions and/or sale values to be calculated. The examples that follow relate to environmental resources that need to be understood and managed. But there is also a link between operational activities and environmental risks which can put the operational activities at risk.

Water Sources/Volume of Water Use : Most aggregate mines abstract water from the pit for use in the plant, but many are unaware of how much water they need for operations (it is estimated, but not measured), and how much flows into the pit annually.

There are also mines that utilise borehole water and

After failing to follow advice to undertake a ground water investigation, this dolomite mine was flooded by ground water a few years later.

where management is equally unaware of the volumes of water required, as well as being unaware of the capacity of the ground water resource. Advice to undertake the necessary pump tests and ground water investigations are typically met with resistance, often stating that “the pit has/the boreholes have never run dry before”.

Result: There are cases where mines have had to shut down because they have run out of water (due to insufficient Environmental DD regarding water supply).

In other cases when boreholes run dry, they simply sink another borehole to continue operations. These unplanned changes and use of a resource that has not been quantified by appropriately skilled personnel put the operation at risk in the long-term.

“The saying, ‘necessity is the mother of invention’ is true also in the context of aggregate and sand mining, and necessity is the mother of ‘n boer maak ‘n plan’, but we must not forget the cousin; ‘assumption is the mother of all disasters’,” warns Jones.

Ground water supplies, she adds, are not infinite/ endless/limitless, and the unmanaged abstraction may have off-site implications that the mining industry will have to compensate for when the time comes. Abstraction from the pit and/or a borehole creates a drawdown cone, and the shape and special extent of this cone will depend on the volume of abstraction and the rate of recharge. If abstraction exceeds recharge, the mine will be depleting a ground water supply that feeds river and other ground water users, such as farmers.

Result: There is an ongoing case where the mine may have to compensate a farmer as he can no longer irrigate his crops. Better planning and an Environmental DD relating to operational needs versus available resources, could have avoided this scenario.

Managing process: Where the quality of the resource changes, there may be impacts on the processing and waste management. The quality of the sand at a sand

mine changed and this had an impact on the output from the washing plant. Despite advice that investigations were necessary to change the sediment management system, the site made no changes and after a few years the settlement dams filled up and overflowed to a wetland and clogged the ‘clean water dam’.

Result: The mine is now abstracting water from a nearby river, which essentially is unnecessary use of resources. In addition, the spill into the wetland was reported by a concerned citizen and the mine has received a directive from DWS. The mine now has no time to approach this problem in a timely manner and is having to do a lot of work in a short space of time, having just spent R500 000 on engineering feasibility (that does not yet include the design).

“The lack of Environmental DD and long-term planning is having a big financial impact on this sand mine. The cost of the engineering work is only part of the expense, as they are also likely to be instructed to clean up and rehabilitate the wetland,” says Jones.

Competence matters

When undertaking an Environmental DD, stresses Jones, it is important to partner with competent and knowledgeable professionals who understand aggregate and sand mining, and not to look for the cheapest options. Operations should conduct some background research on the professionals they are considering appointing.

“Make sure the specialists are SACNASP- (South African Council of Natural Scientific Professions) registered in the relevant field. Ask for examples of similar work (although they may not always be able to share this information). If you do not have in-house personnel who have enough knowledge to filter out the’ fly-by-nights,’ or personnel with the time to manage this process, partner with a consultant to guide you and review the specialist work once drafted,” concludes Jones. a

AfriSam

AfriSam is a leading construction materials group in southern Africa. Since establishing its first cement plant in 1934, the company has grown into a formidable construction materials group with operations in South Africa, Lesotho and Eswatini.

www.afrisam.co.za

Babcock

Through several business units, Babcock offers a range of products and services, including construction and mining equipment, engineering solutions for steam generation and power plants, crane hire and gear rental, industrial generators, welding equipment and DAF truck sales and service www.babcock.co.za

Booyco Electronics

With more than 16 years of experience in Proximity Detection Systems solutions, Booyco Electronics has supplied over 6 500 sets of mining vehicle equipment installations across southern Africa, as well as more than 55 000 pedestrian RFID installations.

www.booyco-electronics.co.za

VEI Group

In 1986, when VEI pioneered On Board Weighing Solutions and Payload Monitoring, we based them on the knowledge we acquired by listening to customers so that we took particular care of the details that make their jobs easier and our products simpler to use.

www.veigroup.com/en

IPR

IPR is recognised across the SADC region as the pump, heavy duty slurry handling and dredging specialist operating in underground and surface mining, quarrying, construction, wastewater, petrochemical and oil and gas sectors. www.pumprental.co.za

Loadtech

LOADTECH Load cells Onboard Weighing are specialists in onboard weighing providing complete solutions onboard your heavy goods vehicle, primarily in the application of load cell and transducer systems for payload protection and accuracy in the commercial vehicle sector. www.loadtech.co.za

JBI Industrial Solutions

JBI Industrial Solutions specialises in a diverse range of weighing systems in partnership with PFREUNDT GmbH. We provide solutions for both mobile and static weighing needs. The PFREUNDT weighing systems are versatile and deliver significant benefits across various industries, including extraction, disposal, recycling, industry and agriculture. www.jbisolutions.co.za

Pilot Crushtec International

Pilot Crushtec International (Pty) Ltd is South Africa’s leading supplier of mobile and semi-mobile crushing, screening, recycling, sand washing, stockpiling, compacting and material handling solutions. www.pilotcrushtec.com

Sandvik

As a world-leading mining equipment manufacturer, Sandvik Mining and Rock Solutions is committed to improving your productivity and profitability. Our products and services provide you maximum value in terms of performance, quality, safety, flexibility and total economy. www.rocktechnology.sandvik/en/

Astec

Astec Industries has been a global leader in providing innovative Rock to Road™ solutions since 1972, specialising in equipment for asphalt road building and aggregate processing. www.astecindustries.com

John Deere

John Deere offers a comprehensive range of construction equipment, including ADT’s, excavators, loaders, dozers, graders, skid steers and TLB’s, designed to enhance productivity, efficiency, and performance on job sites of all sizes. www.deere.africa/en/construction

Lintec & Linhoff

Lintec & Linnhoff is a global manufacturer and distributor of leading-edge solutions for the asphalt and concrete industries under the Lintec and Linnhoff brand names. Its products include asphalt mixing plants, concrete batching plants, pavement related technologies, and specialist concrete cooling solutions.

www.lintec-linnhoff.com

Weir Minerals

Weir Minerals Africa offers a wide range of equipment solutions including pumps, hydrocyclones, valves, dewatering equipment, wear-resistant linings, rubber products, screens and crushers – backed throughout the product lifecycle by high levels of aftermarket support. www.global.weir

SANY

Sany Southern Africa is a subsidiary of Sany Group, a leading manufacturer of construction, mining and port machinery with over 20 R&D centres and manufacturing bases all over the world. www.sanysouthafrica.com

BME

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