bht: oct 2010

BULK HANDLING TODAY October 2010 1

2 BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010 �

October 2010

ContentsCover Story5 Moving to New Heights

Crushers7 Protecting Steel9 Plastics for Wear Protection

Lifting Equipment11 Playing it Safe15 A Dire Need for Proper Training

Conveying17 A Pseudo 3D Analysis of the Indentation Rolling Resistance Problem

Trucking25 Shifting into Overdrive

29 Market Forum

Endorsing BodiesCMA (Conveyor Manufacturers Association)

HCASA (Hydraulic Conveying Association of SA)

LEEASA (Lifting Equipment Engineering Association of South Africa)

RFA (Road Freight Association)

SAIMechE (SA Institution of Mechanical Engineering)

SAIMH (SA Institute of Materials Handling)

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Our e-mail address is [email protected]

Visit our website on www.promech.co.za

The monthly circulation is 4 016

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

Featured on the cover:

Steinmüller

Marcelino Da CostaTel: (017) 624-5000Fax: (017) 647-6114Cell: 082 904 4568

E-mail: [email protected]

www.steinmuller.co.za

� BULK HANDLING TODAY October 2010

CONVEYOR MANUFACTURERS ASSOCIATION

From the Chairman’s Desk

Simon Curry

The focus of the event, whilst exploring all aspects of conveyor safety, was to be the promotion of safety during the design of

conveyor systems, with input from all stake holders. It is extremely unfortunate that on the day, not a single representa-tive from the DMR attended.

Nevertheless, the CMA was given a clear mandate to put forward the col-lective opinion from industry to obtain change where necessary and to insist on the DMR’s presence at the follow-up symposium planned for six months time.

Some of the topics discussed in the open debate following presentations from end us-ers, experts and supply specialists, were:

Hardwire system and intelligent pull-key systemsAnti-roll back idlersThe position of belt arrestorsTraining of idlers in the belt-stop conditionStored energyNip guards and palisade fencingFire protectionGuarding

If you were unfortunate enough to have missed attending the symposium, a full transcript of all presentations and the issues debated together with

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A safety symposium held on the last day of August, a CMA initiative that was endorsed by the DMR, was well attended by over one hundred representatives from industry.

All members subscribe to the CMA Code of EthicsCMA Members List as at October 2010

ABB IndustryAfripp ProjectsActomAtlanta ManufacturingBateman Engineered TechnologiesBauerBMGBearings InternationalBonfiglioli Power TransmissionsBosworthBrelko Conveyor ProductsCKIT Conveyor EngineersContinental Crushing & ConveyingConveyor WatchCMG Electric Motors South AfricaCPM Engineering

CPI TechnologiesCT SystemsDavid Brown Gear IndustriesDelras EngineeringDRA Mineral ProjectsDunlop Belting ProductsDymot Engineering CompanyELB Engineering ServicesFacet EngineeringFenner Conveyor Belting (South Africa)Flexible Steel Lacing SAHägglunds Drives South AfricaHansen Transmissions SAHosch - Fördertechnik (SA)Lesa Mining Equipment and Conveyor Belt

M & J EngineeringMartin EngineeringMelco Conveyor EquipmentMoret MiningMS Conveyor Pulleys SANepean ConveyorsOE BearingsOriental Rubber Industries SAOsborn Engineered ProductsPH Projects HoldingsRead Swatman & VoigtRema Tip Top South AfricaRenold CroftsRoymecRSV ENCO ConsultingRula Bulk Materials Handling

Sandvik Materials Handling SASchaeffler South AfricaSecrivestSENETSET AgenciesSEW EurodriveShaft EngineeringShaw Almex AfricaSKF South AfricaThyssenKrupp Materials HandlingTransmission ComponentsTransvaal Rubber CompanyUnitek EngineersVeyance Technologies AfricaVoith TurboZest Electric Motors

conclusions drawn and the agreed way forward, is available on the website www.cmasa.co.za under the tab “News and Views”.

New graduatesWe have a new batch of diploma graduates from the latest course in the design and operation of belt conveyors.

Six candidates achieved a pass-with-distinction:

Rikesh AmarialJonathan DaviesLouwrens de BruynRyan FernandesJohan KrugerAntonie le Roux

A further eight candidates from the September course, plus one re-write, achieved a pass:

Derek CliftonHerman MarxJohan MeintjesDennis MohlalaKhumi MokgabudiAlbert MontjaneClinton RichardsonPhilip RoussouwJanus van Zyl

Congratulations to you all – industry is richer for your efforts!

The next course will be held in April 2011.

Simon CurryChairman

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Not a single representative from the DMR attended


Steinmüller Plant and Equipment also carries out com-plex 3D rigging studies

S teinmüller Plant and Equipment Hire of-fers a comprehensive range of plant and equipment.

The plant and equipment is used in me-chanical construction and refurbishment projects in the power generation, petrochemical, general and industrial, paper and pulp, mining, and sugar industries.

Boasting a rich history in the business, Steinmül-ler Plant and Equipment Hire holds a large pool of equipment of over 24 000 items. These items, which were formally used to support steelwork and

mechanical construction projects, are now available for hire in the market place.

The company is dedicated to the highest level of customer satisfaction. “This is clearly evident from Steinmüller’s approach to personnel skills develop-ment and expertise, which ensures customers get more than top quality equipment – as well as the entire management of the equipment hire process, from site establishment to de-establishment,” ex-plains Marcelino Da Costa, the representative of Steinmüller Plant Hire.

Complex heavy lifts and 3D riggingThe fleet of equipment housed and serviced at Steinmüller’s Bethal and Middelburg depots, has expanded to include a large number of cranes rang-ing from a Gottwald MK600 (600 tonne capacity) to a 5 tonne mobilift hydraulic mobile crane, as well as trailers, tractors, welding machines, gen-erators, rigging equipment, grinding, drilling and other small industry-related tools.

Apart from the equipment available for hire, Steinmül-

Give your plant the tools it needs to move to new heights by using equipment from Steinmüller Plant and Equipment Hire.

The company offers the very best in plant hire, 3D rigging studies as well as experience and expertise in the plant

industry.

Moving to New Heights

Structural steelwork being erected for the SAS Reactor Project at Secunda

CRANEGottwald MK60077 m Main Boom at 80°75 m Luffing Jib (4.1° offset)Base: 100% OutriggersCounterweight: 152 Ton + 52 Ton Ballast37.734 m Lift Radius (360°)Crane Capacity at 37.734 m = 18 tLOADTOTAL LOAD = 1 t6% of capacity

CRANETadano ATF 220G-559.192 m Main Boom at 67.7°Base: 100% OutriggersCounterweight: 0 lbs21.214 m Lift Radius (360°)Crane Capacity at 21.214 m = 4.99 tLOADTOTAL LOAD = 1 t40% of capacity

CRANEGottwald AMK 306-8345 m Main Boom at 84°68 m Luffing Fly Jib (25.9° offset)Base: 100% Outriggers (10.5m x 10.3m)Counterweight: 50 Ton39.594 m Lift Radius (360°)Crane Capacity at 39.594 m = 4.3 t

CRANEAmerican 9299 Sky Horse270’ Main Boom w/ 150’ Mast at 70°90’ Jib (25° offset)Base: CrawlersCounterweight: 104,700 lbs + 138,000 lbsTrailing49.621 m Lift Radius (360°)Crane Capacity at 49.621 m = 9.843 t

Paraffin Plant at Sasol 1

COVER STORY

Include a large number of cranes ranging from a Gottwald MK600 (600 tonne capacity) to a 5 tonnemobilift hydraulic mobile crane


COVER STORY

First column being erected at Majuba Power Station using the Stein-müller MK600 lattice boom crane with luffing jib

Steinmüller has built in excess of 30 major plants in the power generation, petrochemical, general and industrial, paper and pulp, mining, and sugar industries.

It currently maintains in excess of 60% of the existing coal-fired generating plants in the country.

“Steinmüller Plant and Equipment Hire has supplied and managed all the logistics, site establishment, cranes, plant and equipment and small tools for these plants,” he adds.

SteinmüllerMarcelino Da CostaTel: (017) 624-5000Fax: (017) 647-6114Cell: 082 904 4568E-mail: [email protected]

We also offer rigging services using the latest 3D rigging studies, covering both basic and advanced rigging

300 tonne mobile crane with luffing jib at Amonia plant

Arial view of Pontoon structure

ler also offers extensive experience in complex heavy lifts, in the petrochemi-cal and other plant industries.

“We also offer rigging services using the latest 3D rigging studies, cover-ing both basic and advanced rigging,” says Marcelino.

Safety standardsSteinmüller Plant and Equipment Hire conforms to the highest safety standards in the industry, holding certificates in OHSAS 18001: 2007 and ISO 14001: 2004.

All operators are trained and fully com-petent to operate the machinery and strict safety guidelines are in place to monitor this on an ongoing basis.

All equipment complies with nation-ally recognised Safety standards and is issued with safety certificates. Steinmüller Plant and Equipment Hire has a dedicated Lifting Machine Inspector (LMI), who is responsible for all machines and lifting equipment which leaves the depot.

Built in excess of 30 major plantsMarcelino further adds that since 1972,


CRUSHERS

Various materials and steel hardening methods have been used in the past as additional protection but

one of the most successful means of protecting steel seems to come from man-made compounds developed specifically for the different types of raw materials. One of these protec-tive linings is made by Wearcon in Nigel and to find out more, “Bulk Handling Today” speaks to director, Andre Vorster.

Liners“The company was founded fifteen years ago purely to supply protec-tive liners for mining and industrial

equipment,” he says. “Over the years, we started developing our own compound for a modified ep-oxy resin lining containing sapphire hard alumina ceramic beads which has become widely used in all industries in South Africa over the last eight years since 2002. We now offer a whole range of protective linings for various applications including crushers, impact grids, screens, conveyor pulleys, pipes and pumps.”

Protecting SteelMechanical equipment takes a hard toll in the first stages of mineral processing where the hard rock is re-duced through sheer mechanical force as it comes out the ground. Apart from impact damage, the abrasive nature of this raw material wears away surface areas in crushers, chutes, grids, screens and pipes very rap-

idly, calling for extra protection besides just the strength of steel.

Basically, Wearcon’s lining compound consists of two substances which are mixed together into a paste and then applied to the surface in a specific thick-ness determined by the type of application. “Clients have a choice of applying the lining themselves by simply following the instructions that come with the product, or one of our five dedicated applicator teams can do it for them on site,” Andre explains. “Our service teams also undertake lining repairs on site whenever possible, but if they can’t do in situ, it can be done at our factory.”

Formula“We make a promise to customers to extend production time and ensure significant savings on equipment and labour by supplying innovative solutions, premium products and quality workman-ship,” adds Andre. “We help to improve their bot-tom line as capital equipment repairs are done at 40% of replacement cost. Our products last up to ten times longer than non ceramic linings as they become ‘part of the furniture’, thereby increasing resistance to wear from foreign particles.”

The formula for epoxy resin compound is under-standably well-protected and as we walk through the facility, we soon discover that the method of application on certain equipment like pipes and pumps is also not for the public eye. Today, Wearcon’s range is extensive including solutions for abrasion protection, wear resistant linings, epoxy resin, acid-proof epoxy resin systems, epoxy steel putty, epoxy grout, epoxy ceramic pipe lining and crusher

backing material.

Pulley lagging“Our latest develop-ment, specifically for the bulk materi-als handling indus-try, is a world first as far as I know,” says Andre. “It’s a protective layer of our product applied to a conveyor pulley which we then fin-ish off in a diamond pattern impression

Andre Vorster

Our products last up to ten times longer than non ceramic linings


with a sound solution to make the diamond pattern into the layer of lining while it’s still malleable and before it sets to a hardened surface.

“This has turned out to be a very sought-after application which most of our clients now prefer,” adds Andre. “In terms of mining applications, it’s a nice complement to our crusher backing solution as well as the impact grid protection system that has become widely used in the mining industry over the years. Our impact grid solution, fitted into chutes, hoppers and underflow pans, has now proven to require less maintenance than the tiling systems used traditionally.”

Kit formThe crusher backing material is known as Wearback STD, a 100% solids modified epoxy resin material for use in all cone type crushers, grinding mills, primary crushers, gyratory crushers and any other heavy machinery that requires backing material. It is non-flammable and requires no special mixing or melting equipment and is simply prepared by mixing the resin and the hardener until a uniform colour is obtained. With an ambient temperature of around 25°C, a full kit is then poured into place directly where it hardens into a protective backing.

For more heavy duty crushing, a variant of this backing material comes in the Wearback HI product, specifically for large cone crushers and gyratory crushers. It is a solids modified epoxy resin system formulated for use as a superior backing compound for crusher liners. When cured, it provides a high compressive strength support for wear liners. Sup-plied in convenient kit form, it’s safe and makes for easy mixing and application.

Savings“The cost of applying Wearcon linings compares favourably with other linings,” Andre says in conclu-sion. “However, there is a tremendous saving over time due to the longer service life of our product. Our linings become part of the surface, increasing resistance to wear from foreign objects in slurry such as stones as well as moderate impact from large particles. The linings will withstand wear as they are manufactured from the finest wear-resis-tant materials including sapphire hard alumina ceramic beads, silicon carbide, zirconium, silica and chrome oxide.”

Andre Vorster, Wearcon, Tel: (011) 814-2983, Email: [email protected]

Our latest development is a protective layer of our product applied to a conveyor pulley which we then finish off in a diamond pattern impression

CRUSHERS

for better grip and water displacement. This develop-ment came about after one of the mines enquired about using our product for such an application. We played around a bit until our engineers came up

Pulley lagging for an extended life


CRUSHERS

Bulk Handling Today” visits Quadrant PHS South Africa in Jetpark to talk to National Sales and Marketing Manager, Harold

Pretorius, about engineering plastics for lining applications in general. “Different lining materials all have their place in the market, but you still often find the wrong one being used to solve a specific problem,” he says. “Our Tivar product, for example, handles wear very well, but its main function is to solve flow problems as opposed to ceramics which address wear difficulties or steel which is best used where impact is rife.

Flow properties“In terms of flow, it’s been proven

over and over that an ultra high molecular weight (UHMW) polyethylene, like one of our Tivar grades,

is the ultimate solution,” The Tivar 1000, G12, 1000ASTL and Tivar 88 grades have been around for a long time now and are well known in the

Plastics for WearProtection

Many people make the mistake of summarily installing ceramic linings in chutes, bins and bunkers as the an-swer to all material flow and wear problems, but this is not necessarily the solution, especially when it comes to a flow problem. In fact, the exceptional sliding properties of a polyethylene product like Tivar may very well

be a more cost-effective solution.

materials handling industry in terms of linings. The latest addition to our range, Tivar H.O.T, can handle high temperatures up 125ºC which addresses the shortcoming of plastics liners when it comes to high temperatures”

All the Tivar grades have a similar low coefficient of friction to enhance material flow and a long life in sliding abrasion applications and they frequently outlast steel. They are chemical and corrosion re-sistant, absorb noise and impact and are moisture repellent as well as shatter resistant. Specific grades include special properties such as the welding capabilities found in Tivar 88/2, a popular choice in bulk materials handling applications.

A special application“As Tivar 88 has the lowest friction coefficient of any material apart from PTFE, it has exceptional abrasion resistance characteristics and because it is easy to install, it’s widely used as a flow-promoting lining material,” says Harold. “Flow problems such as caking, bridging, or hanging up of dry or moist materials can be reduced and mostly eliminated. Scientific tests are used to predict flow patterns in bins and bunkers, thereby avoiding any stop-pages.

“We were involved in solving a huge problem in an ash conditioner application for a power station where the steel bin itself tends to rust very rapidly and had to be replaced on a regular basis at a huge cost,” Harold continues. “Being able to weld the Tivar 88/2 made it possible to design the whole bin out of this material, extending its life indefinitely. It’s been up for a couple of years now and is still in a perfect condition. This development opened up the opportunity to present an engineered solution to the other power stations as well. We assisted the client in the design and then built the complete unit in our workshop before shipping it to site for installation.”

Turnkey solutionThe entire range of Tivar products is manufactured in South Africa, with international turnkey support from Quadrant, from a conceptual design stage right through to the final installation, including

Harold Pretorius

Flow problems such as caking, bridging or hanging up can be reduced and mostly eliminated


any machining of custom-made parts that may be required for a lining solution.

“The design department works on CAD and we also have sophisticated software to arrive at the optimum layout of sheets for an application thereby saving the customer time and money by minimising off-cuts,” explains Harold. The computer-aided manufactur-

ing system allows the CAD layout and design to be transferred to a CAM programme which operates the CNC panel cutting equipment. This provides high accuracy and saves a significant amount of time while allowing easy reproduction of a design for future manufacturing. To complete the cycle, Quadrant’s installation teams take everything to site where the product is installed according to the specified design.

A friendly warningInstallation is an area where people often make

the mistake of having it done by contractors who are not familiar with the finer points of installing lining correctly. “There are two areas in our indus-try where end-users should tread very carefully,” warns Harold in conclusion. “The one is to fall for an inferior product that may look the real thing and carry a similar colour, but is in fact a much lower grade than the one specified. The other is to have the installation done by someone who doesn’t know how to do it the right way.

“Also, in terms of material grades, users often fall into the trap of opting for a lower grade polyethylene, PE 500 for example, because it’s cheaper than a UHMW grade, but the lower grade will simply not last as long as the UHMW material, costing them much more in the long run,” he says. “Again, correct installation is vital. If it’s not done properly, dirt or moisture getting behind the lining will quickly pry it loose causing it to separate from the substrate. The solution is to always use reputable companies and ask for the necessary material certificates.”Harold Pretorius, Quadrant PHS, Tel: (011) 397-4715, Email: [email protected]

CRUSHERS

Users often fall into the trap of opting for a lower grade polyethylene


LIFTING EQUIPMENT

Bulk Handling Today” speaks to Peter Tur-chetti, a director of Elephant Lifting Equip-

ment in Centurion who says, “The fight against non-conform-ing lifting equipment flooding the South African market is intensifying.”

“We, the suppliers who conform to the requirements of safety critical lifting equip-ment, are not only waging a battle against the ignorance of some end-users, we’re also competing against the very low prices at which non-compliant equipment is coming into the country.

Unscrupulous suppliers“Unfortunately the cost pressures on the South African industry mean that non-compliant imports have become increasingly attractive, especially when you have a growing number of unscrupulous suppliers who are preying on an uninformed user base,” Peter adds. “Even prestigious construction companies and fabricators are often not well enough informed to know what complies and what does

Playing it Safe

The potential of a Marie Antoinette style guil-lotine execution taking place on a South African

industrial site and making the headlines is huge. A large steel plate falling from height onto someone be-

low and causing serious injury or even death is a very real threat, unless somebody does something about the inferior lift-

ing equipment being used all over the country every day.

not. Although we are making some progress in informing end-users, it’s far too slow to stem the tide against the influx of inferior equipment.

“Management and purchasing staff tend to forget that the onus of purchasing and using lifting equip-ment that complies with prescribed quality, technical and safety standards lies with them,” he explains. “Company owners mistakenly think that the person who handles the equipment is responsible.

The onus“A large corporate company, for example, may very well be aware of the legal requirements and even have a safety policy in place, but this does not necessarily filter down to the hundreds of contractors and sub-contractors who do work for them. “The reality of the matter is that if something goes wrong and somebody is hurt or killed, the corporate, as the owner of the company, will be held responsible and not the person, or contractor using the equipment,” stresses Peter.

“It’s therefore essential for the owner of the company to make sure that every contractor and subcontractor is fully aware of the legal requirements for quality as well as conforming to the various manufacturing standards available in South Africa.” These include applicable South African National Standards (SANS) published by the Standards Division of the SABS

Peter Turchetti

Remember, what goes up must come down.....


and/or other international standards such as ISO and EN (European Norm). In the case of engineered and fabricated lifting equipment products, where an item is custom-made for a specific lifting application, prescribed best-practice engineering standards also apply, in addition to published quality standards,

where these exist. It is important to buy and use only equipment that is supplied with a ‘Manufac-turers Certificate of Confromance.’

Clamp example“Compliance with any of these standards is a key factor today as well as meeting those requirements of the various statutory acts, such as the OSH Act and MHS Act and their regulations such as the Driven Machinery and Construction Regulations of the OHS Act,” says Peter. “Any lifting environment, whether it’s underground or on a construction site, is inherently dangerous. If companies don’t start with the right equipment, made to the right design standards, they’re in trouble already. Mine manage-ment should also ensure that written procedures covering the use, care, maintenance and quality requirements are implemented and maintained.”

However, the problem starts when construction and fabrication companies rely on their contractors to do the right thing by complying with these standards. “Lifting steel plates are like lifting guillotine blades into the air. Can you imagine the consequences if the load comes down on people working below it?” asks Peter. “Just such a clamp was brought to us for repairs the other day from a huge construc-tion development up north. Apart from the clamp having a non-existent supplier’s name plate on it,

The real thing, lifting clamps clearly marked with all the necessary details to trace it back to the manufacturer

Lifting steel plates are like lifting guillotine blades into the air

LIFTING EQUIPMENT

BULK HANDLING TODAY October 2010 1�

The plate lifting clamp that failed. It has no manufacturer marking or any traceable specification on it

there was nothing else we could use to trace the manufacturer, never mind the standards to which the clamp was made and verified.”

BoomerangSimilarly, a manufactured lifting device such as a lifting beam or spreader beam has to be designed and engineered properly in certified engineering steps, otherwise it is doomed to fail. To prove his point, Peter shows us photos of a beam bent into the shape of a boomerang within just a few weeks of use on site. The caption across it says, ‘Beware, bad design can boomerang on you…!’

Remember, what goes up must come down.....

“It’s immediately clear that these beams were not designed by an engineer, they obviously just had a boilermaker weld together steel plate to look more or less like a lifting beam,” says Peter. “The beams we manufacture, for example, are each accompanied by paper work with the design engineer’s signed-off drawing, a certificate indicating the standard to which it was designed, material certificates, the welder’s competence certificate and a certificate proving it has been tested.”

Marking and traceabilityAlthough compliant equipment does cost more, the user not only has the benefit of operating legally, but he’s assured of a better quality product that is likely to outlast the cheap one ten times anyway. “A simple guideline is that each piece of lifting

equipment has to be traceable all the way back to the manufacturer and even as far back as the batch of material that was used to make it,” Peter says in conclusion.

“Therefore, each piece of equipment must not only bear the name of the manufacturer, a serial num-ber, its capacity and so on, but most importantly, customers should only buy approved brands from approved suppliers who have the infrastructure in place to trace equipment all the way back to origin.”Peter Turchetti, Elephant Lifting Equipment, Tel: (012) 661-6105, Email: [email protected]

LIFTING EQUIPMENT

1� BULK HANDLING TODAY October 2010


A company forks out big bucks or, even worse, the person takes his hard-earned bit of savings to go on a technical course, only to be ripped off when he still can’t do

the job properly. To make it worse, some of these jobs are in safety critical industry sectors such as the lifting inspection industry where substandard training can pose a serious threat to life.

Dedicated workTo talk about the important role of proper training for the lifting industry, “Bulk Handling Today” meets with the CEO of the LMI Academy, Ken Greenwood, who is also chairman of Leeasa (Lifting Equipment Engineering Association of South Africa). Ken is a pioneering veteran in the South African lifting industry who has dedicated his career, not only to setting standards in the industry, but also to having the profession recognised as a professional trade by the authorities.

“We have found instances in South Africa where contracts to write training material in lifting have been given to people who are not even in the lifting industry,” says Ken.

Much like flying“One example is where a person, who has never even been in a crane in his life, was asked to write the training material for LMIs (Lifting Machine Inspectors) for cranes. How can you write com-prehensively if you don’t have practical experience in the subject?

“It’s not fair on the candidate who expects to be-come a competent professional,” adds Ken. “It’s

A Dire Need for Proper Training

Not training people properly for the right job is not only embarrassing for the institution that did the training but also for the individual when he or she

finds out that they actually know very little when it comes to applying their knowledge in practice. This situation is not as uncommon as one may think because training material is often compiled by people who aren’t even from

the industry sector in question.

not very different from learning to fly a Boeing 747 on a home computer simulator or the internet and then claiming to be a qualified pilot. This is not the way to teach people. Training material needs to contain refinements gained from practi-cal experience in terms of the ethics and safety perspectives as well.

CPD trainingKen should know what he’s talking about, he’s written no fewer than 60 courses for LMI training over the years besides assisting in the drafting of lifting standards as well as qualification material. “I still run my regular courses throughout the country in all the main cities but at the moment we’re concentrating on the continued professional development (CPD) courses,” he says.

“This course comprises about fifteen modules and is presented to a large slice of the market, focussing on future qualifications. Besides helping people over the last two years to register correctly as qualified professionals with ECSA, we’re now concentrating on turning technicians into profes-sionals through CPD training. Through this we’re rooting out badly-trained tradesmen and getting them up to speed in terms of the laws governing their profession.”

Expanding businessAll this has kept Ken fairly busy lately and he’s therefore had to make a decision to either stay small and not get involved in the broader aspects of the industry as he has been doing, or to expand his training facil-ity and appoint people to run it for him.

We’re rooting out badly-trained tradesmen and getting them up to speed in terms of the laws governing their profession

Ken Greenwood

LIFTING EQUIPMENT


“I’ve gone the second route and used the opportu-nity to appoint two managers, one for a new LMI Academy branch in Cape Town and the other for Durban, both of whom are doing amazingly well,” he says.

“In Cape Town, for instance, we’ve now become involved in the oil and gas industry with full ac-creditation of all our training material. Subsequently, we’ve been accredited by SAMSA, the South African Maritime Safety Authority, for training.

Right from the start“Both these industries have challenges of their own in terms of operator training as far as safety

Training shouldn’t be about making a quick buck

LIFTING EQUIPMENT

is concerned and when we presented them with our training methods, even the international guys working on the oil rigs were impressed with the standards they saw us applying when we tested the operators,” Ken adds.

“This confirmed my philosophy; if you’re going to do it, do it properly right from the start. Training shouldn’t be about making a quick buck and then sending the people into the field unprepared for the real responsibilities they need to face.”

Ken’s approach to training is not only to make a professional out of a tradesman, but more importantly, to give the person confidence and pride in the work he or she does. “I have taken the material from the standards we wrote originally and re-worked it to be used for decent CPD training,” he explains. “Apart from the fact that all these courses are recognised by the ECSA (Engineering Council of South Africa), we’re turning out proper LMIs.”

The futureIt takes several years to train a LMI well which has to be done in stages to ensure that all aspects of the different lifting disciplines are thoroughly covered. “What I’d like to see in our industry in the future is a dedicated programme with dedicated schools training people to become competent.

I foresee that trade testing may even be introduced at the end of the day,” Ken says in conclusion. “This will ensure that we will have young, competent LMIs to take the legacy we’ve created to date, into the future. This industry holds lucrative opportunities, not only in South Africa, but also into Africa where there is a dire need for proper training.”

Ken Greenwood. LMI Academy, Tel: (011) 789-7610, Email: [email protected]


Due to the presence of steel cords embed-ded in the conveyor belt, the pressure distribution at the interface between the belt and a conveyor idler roll is not

uniform. To solve this problem, a static three di-mensional finite element model was developed to determine the pressure distribution and reaction forces transmitted through the belt to the conveyor

idler roll. The reaction loads are then used in a two dimensional viscoelastic finite element model to determine the indentation rolling resistance for the steel cord belt.

This article investigates the influence of the conveyor belt carcass and bottom cover properties on the resulting stress distribution throughout the belt and consequently on the indentation rolling resistance. The influence of the steel cord diameter and pitch, applied load, bottom cover thickness and strain rate is investigated. A finite element method is detailed for the analysis of the stress distribution through-out the belt. A range of carcass configurations is investigated and experimental verification of the calculated stress distribution undertaken using a Tekscan pressure measurement system.

BackgroundThe indentation rolling resistance for a belt con-veying system is influenced by a number of design parameters. These typically include the idler roll diameter, belt speed, normal load, bottom cover thickness and viscoelastic properties of the bottom cover compound. Generally, it is assumed that the bottom cover is subjected to a pressure distribution determined by the self-weight of the belt and the loading induced by the bulk solid being conveyed. A finite element analysis of the stresses within a loaded conveyor belt is shown in Fig. 1(a). This analysis highlights the stress distribution throughout a typical conveyor belt across the width of an idler set, and in particular the peak contact stresses around the idler junction. Similar contact pres-sures were calculated by Nordell and measured by Grabner et al.

Clearly, due to the presence of the steel cables and the large difference between the elastic moduli of the rubber compounds and the cables, the contact pressure across the belt will fluctuate. The spacing, or pitch of the cables, determines the frequency of the pressure fluctuations, while the magnitude of

This article takes a look at a pseudo three dimensional analysis to predict the indentation rolling resistance of belt conveyors. Conventional methods used to analyse the indentation rolling resistance problem typically assume a bottom cover of uniform thickness bonded to a rigid substrate with no consideration of the carcass

properties.

A Pseudo 3D Analysis of the Indentation Rolling Resistance Problem

CONVEYING

(a) FEA of conveyor belting under simulated loading

(b) Contact pressure at belt and idler roll interface

Figure 1: Contact pressure distribution at conveyor belt and roll interface


the normal force and the cover thickness determines the amplitude. Fig. 1(b) shows pictorially the nature of the contact pressure at the belt and idler roll interface across the width of a loaded belt.

As previously noted, the influence of the fluctuating pressure distribution across the belt and idler roll interface will directly influence the magnitude of the indentation rolling resistance. Experimental evidence of the influence of the steel cords on the indentation rolling resistance was first reported by Hager and Hintz. This work showed significant variations in indentation rolling resistance for a number of belts with varying carcass construction. The influence of the steel cord diameter was investigated and belts with larger diameter cords, having identical rubber compounds and cover thicknesses were found to have greater indentation rolling resistance.

König presented a numerical analysis that modelled the carcass and bottom cover as two distinct layers. The viscoelastic finite element method analysed the carcass as a single layer of material that simulated the combined properties of the steel cords and insulation rubber.

Wheeler and Munzenberger adopted a two part process to model the influence of the carcass on the indentation rolling resistance. The first involves calculating the stress distribution throughout the cross-section of the steel cord belt at the interface between the idler roll and the belt. Secondly, given the stress distribution, the indentation rolling resis-

(a) Finite element model components

(b) Belt - Idler roll contact model

Figure 2: Finite element model

CONVEYINGtance is then calculated by integrating across the width of the belt. The two part process involves the use of separate finite element methods leading to a pseudo three dimensional analysis. This paper details the numerical approach and specifically analyses the influence of the cable diameter and pitch, applied load, bottom cover thickness and strain rate on the stress distribution and conse-quently the indentation rolling resistance.

Theoretical analysis:Finite element analysisA static three dimensional finite element model was developed to determine the stress distribution and reaction forces transmitted through the belt to the conveyor idler roll. The reaction loads and an apparent bottom cover thickness can then be used in a conventional one dimensional analytical model, or as in the case presented, a two dimensional viscoelastic finite element model to determine the indentation rolling resistance.

The finite element analysis (FEA) models a section of steel cord conveyor belt with a width of half the cable pitch and long enough to ensure that the full contact path is modelled. For reasons of symmetry, the particular section of belt modelled started at the centreline of the cable and finished half way between the cables, and in the other direction, begins at the conveyor idler apex and models one side only.

Fig. 2 shows a typical model used within the analysis. The model incorporates the three differ-ent rubber compounds and the steel cable. The steel cable is modelled as a solid, since its only purpose is to transmit load it therefore does not need to accurately represent the properties of the steel cable.

The model itself is composed entirely of eight node bricks and six node wedges. The model was restricted to using simple brick elements to avoid any issues relating to conservation of energy in the contact area that are associated with higher order elements.

A key element to the model is the modelling of the contact area. This area allows the bottom of the belt segment to be initially flat, and then allows it to gradually conform to the shape of a conveyor idler roll as the load is applied. In Fig. 2, the surface of the conveyor idler roll was suggested by the vertical “zero gap” elements on the bottom of the model. These elements were designed to have no strength when they have a length other than zero, and then to possess strength when they have zero length, thereby imitating contact in their location between the belt and the shell of the conveyor idler roll. The “zero gap” elements are forced to remain vertical by a “master slave” link connected in parallel to each one, and the bottom end of each “zero gap” element is held at the radius of the idler roll by a “pinned link” which connects it to what would be the centre of the roll. This arrangement is shown in Fig. 2(b).

The restraint, or boundary conditions used in the model were designed to best represent the actual loading situation while bearing in mind that symmetry

Significant variations in indentation rolling resistance for a number of belts


has been used to simplify the model. Imagining an actual piece of belt resting on a conveyor idler roll, the sides of the segment are restrained from moving in the conveyor idler roll’s axial direction, the surface normal to the roll’s surface at its apex is restrained from movement across the roll, and the points representing the centre of the roll are fully fixed. A final boundary condition was ap-plied to the fourth face of the belt model and is designed to imitate longitudinal strain in the belt before it is loaded. All other degrees of freedom are free to move.

Since the FEA model contains non-linear materi-als and a contact problem, the solution of the model was found using a non-linear solver. The main feature of the non-linear solver is the way in which the load is applied. For this model the load was gradually increased from zero to a full load of 5 kN/m in ten percent increments. The software further reduced each ten percent load increment into approximately 12 to 16 sub increments in order to meet convergence criteria. The total solu-tion times for each individual model ranged from four to six hours.

Indentation rolling resistance To accommodate for the fluctuating pressure distri-bution across the belt and idler roll interface, both the vertical reaction forces and an apparent, or non-uniform bottom cover thickness is considered. The vertical reaction forces across the width of the belt are directly obtainable from the FEA results, while the apparent bottom cover thickness is determined by the stress propagation through the bottom cover into the insulation rubber.

By way of an example, Fig. 3 shows an analysis of a section of conveyor belt under a simulated load of 5 kN/m in contact with a Ø152 mm idler roll. The simulated load refers to the applied load per unit length of the idler roll. The results for this particular belt construction indicate high stress regions occurring well into the insulation rubber. This will have the effect of increasing the apparent thickness of the bottom cover when calculating the indentation rolling resistance.

Given the vertical reaction forces across the width of the belt and the apparent bottom cover thickness, the indentation rolling resistance can be calculated by integrating across the width of the conveyor

belt. For example, if the apparent bottom cover thickness is assumed to be approximated by a sine relationship (shown by the dashed line in Fig. 3) then the indentation rolling resistance increases by approximately 8% to 10% over a uniform thickness equal to the actual bottom cover. While the present analysis was undertaken using a two dimensional viscoelastic finite element method by Wheeler, similar results are also directly obtainable from one dimensional analytical methods.

Results and discussion:Material property testingThe mechanical properties of the individual rubber layers are each tested experimentally. From these tests the constants for the Mooney-Rivlin model are derived and utilised by the FEA program. Fig. 4 shows typical experimental data for both a bot-tom cover rubber and insulation rubber compound at 25oC. Additionally, testing was also undertaken at a number of strain rates, with 5 mm/min and 2000 mm/min shown for comparison in Fig. 4. The results highlight the strain rate dependency of the rubber compounds and the variation in mechanical properties of the two compounds for the different applications. Clearly, the belt speed will dictate the strain rate required, with typical belt speeds requiring time-temperature-superposition techniques to simulate higher strain rate tests.

Finite element analysis - stress distributionFig. 5 shows the results for the compression stress on the surface of the bottom cover for Ø127 mm and Ø178 mm idler rolls. The belt designation for this analysis was an ST1750, and had a top cover thickness of 8.3 mm, an insulation layer thickness of 4 mm, a steel cord diameter of 5.2 mm, bottom cover thickness of 5.3 mm and a cable pitch of 12 mm.

In each plot, the centreline of the roll is indicated with the highest stress (towards the top of each diagram) located beneath the steel cable. Each square represents one quarter of a millimetre. These results clearly show that the pressure distribution is not only influenced by the diameter of the idler roll, but the presence of the steel cables.

Figure 3: Typical stress distribution and assumed apparent bottom cover thickness for a steel cord conveyor belt.

CONVEYING

Solution of the model was found using a non-linear solver


(a) Bottom cover rubber compound (b) Insulation rubber compound

Figure 4: Stress strain functions for bottom cover and insulation rubber compounds at different strain rates

(a) Ø127 mm conveyor idler roll (b) Ø178 mm conveyor idler roll

Figure 5: Bottom cover surface stress for a simulated 5 kN/m load

Fig. 6 shows a plot of the pressure values along the centreline of the idler rolls, from the centre of the steel cable to the midpoint of the cable spacing for a number of idler roll diameters. The results demonstrate the influence of the idler roll diameter on the vertical stress distribution across the width of the belt. For the belt analysed, the stress fluctuates by approximately ± 20% from the mean pressure across the width of the belt.

While the influence of idler roll diameter on inden-

Figure 6: Belt pressure along roll centreline with respect to roll diameter for a 5 kN/m load

tation rolling resistance is well established, the results shown in Figures 5 and 6 show the fundamental reason for this occurring. The finite element solution clearly shows a larger contact area and resulting lower stress levels for larger diameter rolls, resulting in an overall reduction in indentation rolling resistance. Additionally, the influence of the steel cable is also evident, highlighting the need to consider its influence in calculating the indentation rolling resistance.

Experimental verificationFig. 7 shows the experimental setup. The pressure sensor used for the analysis con-sisted of a matrix of pressure sensels each 1.27 mm x 1.27 mm. The sensor was placed between the idler roll and the belt surface and a steadily increasing load ap-

plied. The pressure acting on each sensel in the contact zone and therefore the contact width for each load was recorded.

Fig. 8 demonstrates typical output from the test-ing program and shows the peak pressure along the centreline of the idler roll for a Ø127 mm roll under a simulated load of 5 kN/m. Good correla-tion between the FEA and the experimental results were found. The overall pressure levels are in good agreement, while the frequency of the peak pres-

CONVEYING


sures directly above the cables correlate well with the theoretical analysis. Tests were undertaken for a number of idler roll diameters for a range of loading conditions, with experimental results comparing favourably with the FEA predictions.

Applied loadThe influence of the magnitude of the applied load on the induced stress distribution was also investigated. Fig. 9 shows the stress distribution for the ST1750 belt described earlier under a 1 kN/m and 5 kN/m simulated vertical load. While the stress levels differ according to the magnitude of the applied load, the overall distribution throughout the cross-section remains similar.

From an indentation rolling resistance perspec-tive, the peak stress occurs beneath the cable and propagates well into the insulation layer dur-ing both loading conditions. As a result the use

(a) TekScan pressure pad (b) Experimental setup

Figure 7: Experimental pressure measurement

Figure 8: TekScan™ pressure measurement results for a Ø127 mm roll under a 5 kN/m load

of the calculated vertical reaction forces and an apparent bottom cover thickness to calculate the indentation rolling resistance in both situations is warranted.

Bottom cover thickness, cable diameter and pitchTo determine the influence of the bottom cover thickness, cable diameter and pitch a range of simulations were undertaken. Nominal cable di-ameters of 3.6 mm and 5.2 mm were modelled for a 5 kN/m simulated load acting on a Ø152 mm idler roll. The cable pitch and bottom cover thickness was varied and the pressure along the centreline of the idler roll (peak pressure) plotted in Fig. 10.

For the configurations analysed the results indicate minimal change in the peak pressure with cable pitch. As expected, for the same load the smaller

CONVEYING


(a) 1 kN/m applied load (b) 5 kN/m applied load

Figure 9: Belt stress distribution – Ø152 mm idler roll under 1 kN/m and 5 kN/m applied loads

diameter cable shows a higher peak stress. Fig. 11 shows the results for a 14 mm cable pitch and highlights that the thickness of the bottom cover had a significant influence on the magnitude of the peak stress.

Rubber compounds used in the insulation layer and the top and bottom covers are viscoelastic materials, and thus exhibit both time and tempera-ture dependent behaviour. Consequently, the rate

Figure 10: Peak pressure versus bottom cover thickness and cable pitch for a Ø152 mm idler roll under a 5 kN/m simulated load

of applied strain will influence the stress-strain relationship and therefore the stress distribution throughout the belt.

Clearly, from Fig. 4 the elastic moduli of the rubber samples are greater at higher strain rates and thus the belt acts stiffer. This results in less contact area between the belt and the idler roll, and therefore higher stress levels in the contact zone, as shown in Fig. 12. Of significance to this analysis is that the stress still propagates well into the insulation layer, highlighting the need to consider the properties and configu-ration of the belt car-cass when calculating the indentation rolling resistance.

Indentation rolling resistanceGiven the results from the finite element analysis the influence on the indentation rolling resistance is best demonstrated by an example. Fig. 13 shows the variation in indentation rolling resis-tance versus bottom cover thickness for a Ø152 mm idler roll under a 5 kN/m load operating at a belt speed of 2 m/s. The indentation rolling resistance calculations were undertaken using a

CONVEYING


Figure 11: Peak pressure versus bottom cover thickness for a Ø152 mm idler roll under a 5 kN/m simulated load and a 14 mm cable pitch

(b) 5 kN/m applied load – high strain rate

Figure 12: Belt stress distribution – Ø152 mm idler roll under a 5 kN/m applied load for low and high strain rates

two dimensional finite element analysis.

Variations from an as-sumed uniform bottom cover thickness range from 8% to 17% higher. Greater variations from the uniform bottom cover analysis occur for the larger diam-eter cables due to the increased thickness of the insulation layer. This trend fits well with the experimental data of Hager and Hintz [3]. Similarly, as the bottom cover thickness increases the variance decreases as the influ-ence of the insulation layer reduces.

ConclusionThe method adopted a two part process involving the use of separate finite element programs. Analysis of the stress distribution throughout the conveyor belt provides the reaction loads and an apparent increase in bottom cover thickness based on the stress propagation. This data is then used in a two dimensional viscoelastic finite element model to

determine the indentation rolling resistance for the steel cord belt.

The research investigated the influence of the conveyor belt carcass and bottom cover properties on the resulting stress distribution throughout the belt and consequently on the indentation rolling resistance. The influence of the steel cable diameter and pitch, load, bottom cover thickness and strain

CONVEYING


Figure 13: Indentation rolling resistance versus bottom cover thickness

CONVEYING

rate was investigated. The results show the magnitude of the indentation rolling resistance will increase due to the presence of the steel cords and is predominantly influenced by the diameter of the cables. For the con-figurations analysed, smaller diameter cables showed higher peak stress levels for the same loading conditions, but lower indentation rolling resistance values due to a decrease in thickness of the insulation layer.

This paper has been condensed due to space constraints. The au-thor is Craig Wheeler and Paul Munzenberger. This paper was first presented at Beltcon 15 held in Johannesburg on September 2 and 3, 2009 and copyright is vested with the IMHC. Enquiries can be made through the website; www.beltcon.org.za


The RFA Convention 2010 which took place from 22 to 24 August at the Wild Coast Sun was one of the best-supported conventions held over recent years. It featured more than

25 speakers and panelists, 29 sponsors and over 245 delegates from around the country.

Making your voice heard Deputy Transport Minister Jeremy Cronin delivered the convention’s opening address, appealing for closer co-operation between the private sector and Government.

Jeremy outlined some of the recent successes the Ministry has had when working with the private sector in the early stages of the planning process. This echoed the recent creation of a quarterly forum between the Department of Transport (DoT) and the RFA which will go far in ensuring better com-munication and consultation on issues that could affect the road freight transport industry.

SARS Commissioner Oupa Magashula also ad-dressed the convention, briefing delegates on trade facilitation initiatives that SARS and its partners are introducing as part of the Customs Modernisa-tion programme.

“The RFA Convention definitely succeeded in ce-

TRUCKING

Shifting Into Overdrive

From sitting behind the wheel while putting the widest range of trucks through their paces, to getting up close and personal with Ministers and Commissioners, if you were unable to attend the RFA Convention 2010, you

missed out.

menting relationships between the RFA and several government departments,” says Gavin Kelly, the RFA’s Technical and Operations Manager. “We already have good interactions with the DoT and SARS and the convention reinforced this.”

NetworkingA number of government departments and parastatals were represented at the convention, apart from the DoT and SARS, including the Department of Public Enterprises (DPE), the KwaZulu-Natal Department of Transport (KZNDOT) and Transnet Freight Rail (TFR). Attendees had the chance to interact with them and have their questions answered.

There was also an opportunity for manufacturers and delegates to discuss the business of trucks, highlighting challenges and issues affecting their operations with each other and learn from one another’s experiences.

Trucks put through their paces In what is believed to be an industry first, RFA members had the opportunity to test drive a range of trucks. Vehicles from DAF, Freightliner, Hino, Man, Mercedes-Benz, Navistar International Trucks, UD Trucks (Nissan Diesel), Renault, Scania and Volvo were all available for test drives. Delegates were able to test drive all these vehicles, enabling them to do “on-site” comparisons and have all their questions answered by the manufacturers.

Jeremy Cronin Jake White Nazir Alli (left) with Frank Wagner (right)

In what is believed to be an industry first, RFA members had the opportunity to test drive a range of trucks


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With South Africa being mining country, it is expected that the country ranks among the top in the world when it comes to con-

veyor installations. This creates healthy competition in the market in terms of sup-pliers of power transmission components,

each vying for a slice of the cake in a highly active industry.

Keeping up to dateNazir Alli, Chief Executive of the SA National Roads Agency (Sanral), briefed delegates on the fiercely debated toll roads. “A number of issues still need to be clarified,” says Gavin. “The most important of these is the exact fee that will be charged. Thereafter, a simplified understanding of how the fee will be structured (taking into consideration any discounts that will be applied needs to be made available). We were grateful to Nazir for clarifying a number of issues that have been misunderstood.”

Gavin also shared with delegates the latest devel-opments on the points demerit system, dispelling some of the myths and misconceptions about the proposed scheme and outlining some of the harsh, unintended consequences that the system may have for operators. The new implementation date for AARTO is 01 April 2011, although this date may well be postponed due to a number of improvements and changes that need to be done to the system.

Some of the latest developments included allowing an access period (six months or annual) to driver and/or vehicle information (the exact fees and procedure yet to be determined). Aspects of driver re-training have also not been finalised.

Prasanth Mohan of the Department of Transport provided the latest news on RTMS - an industry–led, government-supported, voluntary, self-regulation scheme that encourages consignees, consignors and road transport operators to implement a manage-ment system (a set of standards) with outcomes that contribute to preserving road infrastructure, improving road safety and increasing productivity. Its focus areas are load optimisation, driver well-ness, vehicle maintenance and productivity. RTMS has been piloted in the forestry, sugar and coal industries with extremely positive results.

Award-winning green trailerOn show was the Green Trailer from Barloworld Logistics, which recently won the “Best Product under R1 million” in the Green Supply Chain Awards. This interlink taut-liner-trailer combina-tion achieves, through some practical innovation, significant reductions in the amount of fuel it uses, which will result in significant environmental benefits and savings with existing transport fleets. The expected reduction in fuel consumption on the green trailer project for the next six months will be between 6% and 8%.

SMME mentorshipThe RFA’s new Mentorship Programme is a part of the Association’s SMME growth and development strategy offering SMME operators an opportunity to

learn from one of our leading industry experts. The SMMEs will be mentored by Otto van Griethuysen, who has 35 years of technical, operational and financial experience in the industry. This intense programme covers the entire spectrum of what it takes to run a successful trucking business.

The Road Freight Association (RFA), Tel: (011) 974-4399, Fax: (011) 974-4903, email: [email protected], www.rfa.co.za

SARS Commissioner, Oupa Magashula behind the wheel of a Freightline Argossy truck

There was an opportunity formanufacturers and delegates to discuss the business of trucks

TRUCKING

REBUILDYOUR THINKING

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Register now for CONEXPO-CON/AGG 2011, the most information-packed show in construction. Get close and compare the newest equipment, technologies and strategies for profitability. See how the construction industry has become environmentally friendly, safer and more efficient. Be there to experience the latest innovations and enjoy the attractions of Las Vegas!

Go to www.conexpoconagg.com/intl for details on how to register.

CONEXPO-CON/AGG 2011 is co-located with:


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consisting of a hand-held meter attached to an optical sensor via an electronic cable. The sensor uses an infrared beam to detect the vibration of a belt strand and sends a signal to the meter.

The sensor in-cludes an LED that produces an orange light beam to help aim the invis-ible infrared ray. For op-erator in-put, simply “pluck” the belt and point the s e n s o r d i rect ly above the vibrating belt.

Comparing this input to the vibra-tion of a quartz cr ystal , the meter computes the natural frequency of the belt. The result is shown in the display window as hertz (oscillations per second). The internal programming of the meter is also able

to report the belt tension in units of force (either newtons or pounds-force) provided the operator has entered the belt mass and span length using the manually operated key pad.

SKF South Africa (Pty) Ltd, Samantha Joubert, Tel: (011) 821 3500, Fax: (011) 821 3501, Email: [email protected], Website: www.skf.co.za

Market ForumFirst crane backThe first construction crane to grace the skies at Century City in almost a year has gone up. It has been erected for the construction of a new 7000 square metre “green” regional office block for Aurecon

The last construction cranes seen at Century City were for the mega R750million Crystal Towers development and two high-rise office developments, Gateway and The Gatehouse. Greg Deans, director of Rabie Property Group, the develop-ers of Century City, says while one crane is a far cry from three years ago when the skyline was dotted with 12 or so cranes, it was cause for cheer and hopefully indicative that the market is now turning.

“We have generally tended to see the number of cranes at Century City as being a barometer of the state of the property market. Although some low-rise construction has been taking place in the past year, the dearth of cranes which are used on larger, high-rise projects is very indicative of the hard times the industry has been experiencing.”

Greg says that during the upturn they have colloquially re-ferred to the yellow cranes as the “national bird of Century City”. “And it is heartening that the first bird is back although we are probably still some way off before the whole flock returns!”

Rabie Property Group, Greg Deans, Tel: (021) 550 7000, Fax: (021) 550 7002, Email: [email protected], Website: www.rabie.co.za

Coenie Fick of Aurecon and Colin Anderson, a director of Rabie Property Group, on the site where construction of Aurecon’s new R150million offices is now underway

Belt frequency meterSKF has added a new product to their power transmission range – the SKF Belt Frequency Meter, one of the most ac-curate and reliable tools when it comes to measuring belt tension.

The SKF belt frequency meter is a two-component system

Exploring rough terrainHyster dealer Barloworld Handling has expanded its range to include Mast Ex-plorer rough-terrain lift trucks, comprising 15 models with lifting capacities from 1.3 to 7 tons.

“Manufactured by Mecano Continental of Spain, Mast Explorer lift trucks have been delivering the goods on five continents, in a diverse range of mining, industrial and ag-ricultural applications,” says Rudolph Briedenhann, senior GM of Barloworld Handling. “They have proven their mettle in tackling dirt tracks, sand dunes in a desert, loading the middle of the jungle and working in mines, and will do the same here.”

The first batch of Mast Explorer trucks to arrive in South Africa has been hard at work in local manufacture and agriculture applications for some months now, and initial feedback from

�0 BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010 �1

Market Forum

Side view of the 2.5 ton model from the Mast Explorer rough terrain lift truck range recently launched by Barloworld Handling

customers and their operators has been overwhelmingly posi-tive. “Based on this, we believe Mast Explorer lift trucks will add value to the operations of our existing customer base and also open doors to new market sectors.”

“An attractive feature of the Mast Explorer range is its no-frills design,” says Rudolph. “The machines are unencumbered by complicated electronic technology that would have rendered them more expensive and difficult to maintain and operate.”

Barloworld Handling, Ru-dolph Briedenhann, Tel: (011) 898 0480, EMail: [email protected]

Suited to the taskAn increasing number of quarries are turning to impact crushing technology to manufacture sand from rock. Now comminution solutions provider IMS Engineering has raised the bar with the introduction of a next generation Hazemag horizontal shaft hard rock sand impactor.

The new-generation Hazemag AP-KVH horizontal shaft hard rock sand impactor has two large service doors on each side, providing easy access to the rotor and wear parts for reduced downtime

Says IMS Engineering’s Deon Visser, “the manufacture of sand is the ultimate crushing task in aggregate production since it entails the progressive crushing of large feed mate-rial, generally run-of-quarry, in various crushing reduction stages to sand. Hazemag sand impactors are suited to the task because of their ability to achieve a high reduction ratio in a single pass while delivering a quality cubical sand product in the -6.75 and -4.75mm size ranges. This high reduction ratio is achieved because the mechanical construction of the impactor, combined with the high-speed horizontal shaft rotor, generates high levels of kinetic energy that maximise breakage.”

The new impactor has two large service doors on each side of the crusher housing, providing easy access

to the rotor and wear parts, while the blow bars are slid in from the side to permit quick and

easy turning and replacement. The crusher housing is lined with easy-to-change wear plates and approximately 97% of the wear liners are interchangeable, for a reduction in spares holding.

IMS Engineering (Pty) Ltd, Shannon McEwan, Tel: (011) 445 2111, Email: [email protected],

Website: www.imsengineering.co.za

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Market Forum

New heavy-duty truck modelsFive new Isuzu FX models, positioned as the heavy-duty end of the F-Series range, are now on South African soil. The entire Isuzu F-Series model line-up now consists of more than 18 models with gross vehicle masses (GVM) from 10 000kg to 28 000kg, and gross combination masses (GCM) from 16 000kg up to 45000kg.

Isuzu FX models form an important niche-market link between F-Series models and Isuzu Gigamax at the extra-heavy end. Standard Isuzu F-Series models are equipped with maximum engine power rating of 206kW (280hp) @ 2 400rpm and

Website: www.scaw.co.za

Haggie® Steel Wire Rope Products:• Double drum winder ropes• Koepe / Friction winder ropes• Shaft sinking ropes• Mine hoist ropes• Scraper and haulage ropes• Dragline and hoist- and drag-ropes• Face shovel ropes

Chain Products:• Round link welded chain and chain fittings in

grades 3 to grade 8 to national and international standards.

Cast Products:• Mantles and bowl liners• Mill liners• Rope sockets• Track shoes• Dragline parts• Ground engaging tools (GET)



The Scaw Metals Group (Scaw) is an international group, manufacturing a diverse range of steel products. Its principaloperations are located in South Africa, South America, Canada and Australia. Smaller operations are in Namibia, Zimbabweand Zambia. Scaw’s Specialist products manufactured for the shaft mining and surface mining industries include:

Haggie® Steel Wire Rope: Tel: +27 11 620-0000 • Fax:+27 11 620-0009

Chain Products: Tel: +27 16 428-6000 • Fax:+27 16 428-1212 / 1089

Eclipse East Foundry: Tel: +27 11 747-5000 • Fax:+27 11 421-4943

Cast Products: Tel: +27 11 749-3600 (GET) • Tel: +27 11 842-9303 (Other)

Fax:+27 11 421-8032 (GET) • Fax:+27 11 842-9710 (Other)

Scaw has produced these products for the mining industry since 1921 and is atechnological leader in this field and manufactures to national and internationalstandards.

Scaw provides a full range of customer support services. A team of qualifiedengineers with extensive experience in all aspects of steel wire ropes, chain andcast products are available to advise on the selection, handling, installation andmaintenance of products as well as provide on-site inspection of products andequipment.

Scaw supplies globally and also offers nationwide distribution in South Africathrough its strategically located branches throughout the country.

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7SCAW MINING/ECLIPSE ADVERT 27/2/09 10:24 Page 1

Seven more trucks Hino SA recently added a further seven trucks to the large number already being employed in various projects by the Department of Water Affairs and Forestry. Over the past two years more than 100 Hino’s have been delivered to this fleet. These have included water and diesel tankers, dropside freight carriers, 5m3 and 10m3 tippers and mobile workshops.

The latest batch of seven 28-41 6x4’s are for general purpose usage and are fitted with dropside bodies made by Anchor

Auto Body in Springs, with Palfinger PK 15 500 15-ton/metre cranes mounted between the cab and the load body. The bodies have fittings and latches to handle 6m containers, while special Ringfeder automatic coupling systems have been specified, as have metal protectors for the front and rear lights, a front draw bar and amber rotating lights on the cab roof.

These trucks will be deployed at Department of Water Af-fairs and Forestry projects all over South Africa, including at the De Hoop Dam at Roosenekal which is the largest dam currently under construction in South Africa and due for completion in three years’ time.

Hino, Ignatius Muthien, Tel: (0)11 809 2064, Fax: (0)11 809 9064, Email: [email protected], Website: www.hino.co.za

Demolition made easy For the past 3 years, HPE Africa has been the sole importer of Korean-built Soosan hydraulic hammers and drills – ideal for any project that requires high volumes of rock to be broken swiftly and safely. Added to this exclu-sive selection is the Italian-crafted MB crusher buckets – designed to meet international demands for more goods to be recycled on site.

Although hydraulic hammers are rela-tively well known in the South African market, the crusher bucket is a fairly

new concept. The hammers are easily fitted to all ranges of excavators, skidsteers, back-hoe loaders and wheel loaders, and could save capital projects millions on expenditure, while the crusher bucket fits onto the end of an excavator like a normal bucket.

Peter Van Rensburg, sales representative at HPE Africa explains the advantages of the Soosan range of hammers: “The Soosan products complement HPE Africa’s equipment as it is a top quality brand – the Rolls Royce of Korean ham-

mers. The attachments are ideal for quarries, mines, demolition, plant hire, or anywhere where breakers and drills are necessary. We only bring in the sturdier models to be fitted to our machinery, because they get abused in a very harsh local environment, so they need to be extra strong.”

High Power Equipment, Peter van Rensburg, Tel: (011) 397 467, Fax: (011) 397 4683, Website: www.hpeafrica.co.za

�� BULK HANDLING TODAY October 2010 Advanced Materials Today September 2007 39


Market Forum

Easy versatilityCustom Crane Safety has over 20 years experience in the mobile crane safety market. The company offers a comprehensive range of crane safety products to the crane rental, construction, industrial and marine industries. This includes safe load indicators for cranes, forklifts and reach stackers. They can custom design and fit of safe load indicators for any lifting machine or any special application.

Custom Crane Safety manufactures and markets the OPD100 System. This robust and economical system provides ease of use and versatility to a crane fleet. Custom Crane Safety also offers the Hirschmann iVisor Range of products. These feature cutting edge technology such as ac-curate and measured boom deflection

882Nm @ 1 450rpm. On the FX range power is delivered from one model-type Isuzu common-rail turbo-intercooled engine providing 265kW (360hp) @2 000rpm and 1 422Nm @1 400rpm - this represents 61% more torque for any task than the standard F-Series. Standard exhaust gas recircula-tion (EGR) ensures that reduced combustion temperatures are an effective means of controlling NOX – nitrous oxides – exhaust emissions. This engine exceeds the South African Euro 2 specification and is classed as a Euro 3 unit as part of Isuzu’s environmental care package.

Isuzu has matched tyre load-ability to axle capacity – 315/80R22,5 tyres are standard to match Isuzu’s front axle rating of 7 500kg which is also the legal permissible (A rating) for the entire range. This is particularly useful for freight carrier models where front axle capacity can be fully utilised. Isuzu FX models also have installed rear axle capacity that exceeds the permissible rating of 9t on a single axle and 18t on a double drive unit.

Isuzu Truck SA, Hanlie du Preez, Tel: (011) 563 4125, Fax: (011) 806 4693, Email: [email protected], Website: www.isuzutrucks.co.za

calculations, precise boom switching ca-pabilities and control of lock pins.

The Hirschmann systems are also designed for har-bour, marine, gantry cranes, container loaders and stack-ers. With full work-shop facilities and a

full stockholding of OPD100 and Hirschmann equipment, Custom Crane Safety is geared for service.

Custom Crane Safety, Richard Harvey, Tel: (011) 900 3390, Email: [email protected], Website: www.safecrane.co.za

Custom Crane staff

ErrataThe Gremlins were at it again and an error sneaked into one of our captions in the story about ThyssenKrupp Materials Handling in our previous issue of “Bulk Handling Today”. The picture shows Dietmar Pratz while the caption says it’s Sybrand Visagie. We apologise for the error Dietmar and Sybrand.

�� BULK HANDLING TODAY October 2010


Market Forum

Georg Weiberg, Head of Truck Product

Engineering; Hubertus Troska,

Head of Mercedes-Benz Trucks;

Andreas Renschler, Member of the Board

of Management, Head of Daimler

Trucks and Daimler Buses and

Gianenrico Griffini, Chairman

International Truck of the Year Jury

Truck of the year 2011On the occasion of the International Motor Show (IAA) Com-mercial Vehicles in Hanover a jury of international experts voted the new Mercedes-Benz Atego 12-tonner “Truck of the Year 2011”.

The International Jury Truck of the Year commented on the victory of the Atego: “In the new Atego family, Mercedes-Benz presents a versatile medium-duty truck with ‘two souls’. On the one hand, the short-radius distribution driver now gets equipment which not long ago was reserved for long-haul drivers. On the other hand, the progressive parallel hybrid drive promotes the reduction of the CO2 emissions of com-mercial vehicles within the European Union.”

According to its rules, the jury awards the Truck of the Year title each year to the truck that makes the biggest innovative contribution to road haulage in terms of economy, emissions, safety, drivability and comfort. The Mercedes-Benz Atego scored a total of 127 points to win the competition; the truck that placed second received 82 points, the number three 45 points.

Hubertus Troska, head of Mercedes-Benz Trucks, said on the occasion of the award presentation at the commercial vehicle show in Hanover: “We are pleased that with this high honour the Truck of the Year jury has confirmed our efforts in two significant points: firstly, that we devote to the distributor vehicle the attention it deserves on account of its performance in the daily supply of the needs of our society; secondly, that it was right to continue our investments and developments in technologies of the future like hybrid drive even in economic crisis situations. That now pays off.”

Mercedes-Benz, Shirle Greig, Tel: (012) 677 1904, Fax: (012) 677 1682, Email: [email protected], Website: www.media.daimler.com

�� BULK HANDLING TODAY October 2010

Index to Advertisers

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AST Pyroscan Inside Front Cover

Bearings International 36

Brelko 35

Conexpo 26

East Rand Cranes 14

FLSmidth 24

Hägglunds Inside Back Cover

ILS 30

Linde 10

LMI Academy 31

Multotec 12

Quadrant 16

Rema Tip Top 8, Outside Back Cover

SAID 34

Scaw Metals 32 Steinmüller Outside Front Cover

ThyssenKrupp 13

Wearcon 28

Wirtgen Group 37

Market ForumHelping make historyFrom the invention of the world’s first manual chain hoist in America in 1877 to the lifting of extremely expensive ad-vanced aviation equipment into the control towers at the new King Shaka International Airport in Durban, from the supply of urgently needed equipment after the Haiti earthquake to the provision of tailor made solutions for construction of the multi-billion rand stadiums for the 2010 Soccer World Cup, the Columbus McKinnon Corporation (CMCO) is well positioned to help engineer history.

Both the South African subsidiary (formerly known as Yale Industrial Products) and its multinational parent are world renowned for the design and manufacture of a comprehen-sive range of lifting, pulling and jacking products as well as materials handling systems.

Worldwide, the company is all about precision engineer-ing, superior quality and safety. All products are ISO 9001 certified.

The most crucial thing of all, however, is the fact that CMCO focuses not only on the supply, servicing and installation of its products and systems, but also on providing an all round, total service solution that meets each of its customer’s technical needs.

In Africa, with its harsh conditions and lack of infrastructure, this is no mean feat. The South African operation forms the hub of an important network of branches and distribu-tors that serve customers across the continent. All offer a wide selection of products and systems that enable users to find the most suitable option for their particular needs and conditions.

Columbus McKinnon Corporation (Pty) Ltd, Graham Campbell, Tel: (031) 700 4388, Fax: (031) 700 4512, E-mail: [email protected], www.yale.co.za

Our drive is your performance.

Hägglunds Drives South Africa (Pty) LtdP.O.Box 2851, 1610 Edenvale, JohannesburgPhone: + 27 (0)11 454 4933, Fax: +27 (0)11 454 5088E-mail: [email protected], www.hagglunds.com

Tough demands have met their match.

Let us know your demands.

BULK HANDLING TODAY October 2010 ��Our drive is your performance.

Hägglunds Drives South Africa (Pty) LtdP.O.Box 2851, 1610 Edenvale, JohannesburgPhone: + 27 (0)11 454 4933, Fax: +27 (0)11 454 5088E-mail: [email protected], www.hagglunds.com

Tough demands have met their match.

Let us know your demands.

�0 BULK HANDLING TODAY October 2010

bht: oct 2010

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