modern quarrying - crown publications · 2014. 3. 31. · possible terms that only oem parts and...

QUARRYINGMODERN

MARCH - APRIL 2014

Official magazine of the Institute of Quarrying Southern Africa www.crown.co.za

IN TH

IS IS

SUE

PRACTICAL GUIDE for blasters

IQSA celebrates 45 years in SA

AFRISAM's COEDMORE – past and present

B&E INTERNATIONAL expands design base

www.barloworld-equipment.com

www.mmdsizers.com

March - April 2014 MODERN QUARRYING 1

QUARRYINGMODERN

14 18SMASHING ROCKS TO POWDER AT COEDMORE

FORTY YEARS PLUS OVERTIME – A LIFETIME OF MEMORIES

MQ reports on an article by an unknown scribe written in 1927 on the Coedmore op-eration in Bellair. The surface of the earth is described as having been ‘rudely torn aside in order to disclose and reclaim that natural wealth beneath’. Written a few years after the end of the First World War, the writer says the ‘echoes of the explosions thunder-ing in the hills, might cause an ex-service-man to rub his badge reflectively’.

In this special feature, MQ continues with Henry Terblanche’s memoirs. Henry often describes some of his colleagues as colour-ful characters with the ability to tell a story in cinemascope, but clearly he is a master in this regard. Although his memoirs are light-hearted, mining was tough in those days, with quarrymen working extremely hard and playing just as hard.

4 ‘Non-original parts’ debacle rears up again

5 Babcock awarded major contract

7 Manufacturing needs to drive industrialisation

7 PPC to sponsor Fulton Awards

9 Upbeat Pilot Crushtec

Published quarterly by:Crown Publications ccP O Box 140Bedfordview, 2008Tel: +27 11 622 4770Fax: +27 11 615 6108www.crown.co.za

Average circulation2 457

Printed by:Tandym Cape

EditorDale [email protected]: 0834199162

AdvertisingBennie [email protected]

Design & layoutDarryl James

Circulation Karen Smith

PublisherJenny WarwickThe views expressed in this publication are not necessarily those of the publisher, the editor or the Institute of Quarrying Southern Africa.

ON THE COVER

AROUND THE INDUSTRY

Currently working on around 15 projects, B&E International’s sustained market penetration in the quarrying, construction and mining segments is sup-ported by an ongoing fleet modernisation programme that includes the acquisition of latest-generation Metso Mobile equipment. Deployed across South Africa and cross-border, the company is rapidly expanding its operating foot-print in the contract crushing and screening market. See full story on page 10.

36 Ciolli Bros takes first E-series in WCape

37 Screening media with value-adds

37 Blast design made simple

39 Match the track to the application

39 Belt rip detection increases productivity

PLANT and EQUIPMENT SOLUTIONS

24 SAFETY AND ENVIRONMENTAL STEWARDSHIP AT COEDMORE

This quarry feature looks at the showplace Coedmore operation, which has gone above and beyond the levels of compliance required by the DMR. The DMR has been so impressed with the company’s new safety plan that it has asked that all AfriSam quar-ries adopt it, and suggestions have been made by the KZN Tripartite Safety Alliance that it is rolled out to other quarries in the province.

Mining operations should be viewed as temporary land users, and owners should have long-term plans to develop properties far beyond the mining phase, in order to enhance surrounds and benefit local com-munities. According to environmental guru Alan Cluett, proper environmental planning can save companies a lot of money.

30 PRACTICAL GUIDE FOR BLASTERS – PART I

40 IQSA CELEBRATES 45th YEAR IN SOUTHERN AFRICA

29 VISIONARY ENVIRONMENTAL PLANNING IS REQUIRED

CONTENTS

www.beinternational.co.za

AROUND THE INDUSTRY


EDITOR’S COMMENT

This year, we celebrate a significant milestone in the history of the Institute of Quarrying Southern Africa. Readers may not be aware

that although the South African branch of the Insti-tute of Quarrying was established 45 years ago, the idea of starting the South African branch was origi-nally raised in a letter by Stuart Chandler, who was the City Engineer of Grahamstown in the 1920s.

Chandler’s letter was published in the Quarry Managers’ Journal in April 1923 under the head-ing ‘Hands across the Sea’ and the final paragraph reads as follows:

‘I envy your quarry managers being able to go to those instructive meetings, especially the one in the Channel Islands. The only thing we get in that line in this country is the annual meeting of the Institute of Municipal and County Engineers, of which there have been two held. The mileage I had to travel to those two was about 1 250 miles. The next one, to be held in Cape Town, is 800 miles away; and yet, in spite of these long distances, nearly all the members turn up. I only hope, one day, we shall see the same enthusiasm displayed in a meeting of the African Branch of the Institute of Quarry Managers’.

Forty-six years later, on 15 February 1969, the inaugural meeting of the South African branch of the British Institute of Quarrying was held at the Edenroc Hotel, Durban.

And 45 years later, on 11 April 2014, we cel-ebrate the IQSA’s 45th anniversary in style.

Letter of appreciationIt is not often that MQ gets a letter such as this one, which arrived last week from none other than Henry Terblanche. Henry is one of my most favou-rite people in the industry. He is a wealth of infor-mation and a well-respected quarryman, with an incredible sense of humour. His memoirs are being published in the magazine, with some special ones selected for the book I am writing in celebration of the people who made the Institute what it is today. The letter reads as follows:

Dear Dale,This is a letter of appreciation to yourself and Modern Quarrying, for giving me the exposure and showing interest; to the Institute of Quarrying, for seeing the need to uplift people though educa-tion and qualification; and to Xtract Training for developing and offering in-depth courses. The Rockbreaker/Blaster qualification is something to be proud of, once achieved.

A couple of decades ago in February 1985, I was

in the first intake of students to do the N2 mining qualification offered by the Institute of Quarrying. Alan Cluett was my class teacher. At that time I was already 38 years old and our class was referred to as ‘Oom Henry en die kinders se klas (Uncle Henry and the children’s class). Then, in 1988, I was again in the first intake to do the N3 mining qualification at the Roodepoort College of Mining. Karl Meissner-Roloff sent me to both, under great protest from myself as, at that time, I did not want to leave my wife and kids alone and stay in a hostel with a lot of youngsters for three months.

Therefore, the Institute has played a big role in my achievements and so has Karl Meissner-Roloff who saw potential in me, and would not take no for an answer. The knowledge I gained from these courses, combined with my practical experiences and observations, gave me the desire to write.

Writing this guide, my stories and other train-ing material has given me great pleasure. I would estimate that ‘The Practical Guide’ took me 200 hours plus in front of the computer. However, I never thought it good enough to be published until you came along and showed interest. I must therefore again say a very special thanks to you. (See Part 1 in this issue of MQ).

As you know, I am Afrikaans-speaking and writ-ing this guide in English took some effort and could not have been done without the help of my wife Marianne, who is German. Therefore, feel free to cor-rect the grammar. With the memoirs, however, the situation is different. I want the Afrikaans accent to come through as it is part of the humour. Sometimes you can tell a simple story in another language other than your home language and it becomes funny due to the sequence and choice of words. An example of this is in the following simple story that changed into a funny story due to an accent.

Years ago, my brother-in-law Diego Visicale, an Italian from Sicily, did a building job for a famer in the Clocolan district. Due to the farmer not having money, he paid him with a live sheep. As we were driving back from the farm with the sheep on the back seat of the 1948 Ford, I asked him: “How are we going to slaughter this sheep as we are both town boys?” His reply was: “Ag dit is maklik. Ons sny net sy keel af en dan skil ons hom!” (Oh that is easy. We just cut its throat and then we peel it!)

Thanks again for your effort and interest.Henry Terblanche

Happy 45th anniversary IQSA!

A warm welcome to the Institute of Quarrying’s

International Presidents and delegates and

suppliers to our annual conference and exhibition, this time in

beautiful Somerset West in the Fairest Cape. May it be a memorable one

for all!

4 MODERN QUARRYING March - April 2014

AROUND THE INDUSTRY

JVT Vibrating Equipment (Pty) Ltd is facing this issue at present, and as a result, has decided to clarify this im-

portant issue.Headed up by MD Fanie Swart, JVT

is the fully-fledged African subsidiary of JÖST GmbH. JÖST supplies an extensive range of vibrating equipment and drive units for most applications and industries, inclusive of vibrating screens, thermal processing equipment, vibrating tables, shake-out conveyors, dosing systems, fluidised bed coolers, discharge feeders, dosing feeders customised conveying systems and other bulk material handling equipment.

Reinforcing JÖST’s footholding in Southern Africa, JÖST terminated its licen-sor agreement in early 2012 with the pre-vious South African entity, with the aim of becoming directly involved in Africa via its own subsidiary.

JVT is recommending in the strongest possible terms that only OEM parts and components such as the JÖST drives (eg

Metso and Guangxi Liugong Group Ltd have obtained all the necessary approv-als from the Chinese authorities and the 50-50% joint venture between the two companies has been officially established.

Headquartered in Shanghai, Liugong Metso Construction Equipment (Shanghai) Co Ltd, will combine Metso’s know-how in track-mounted crushing and screening business and technology, with LiuGong’s extensive distribution resources (~ 900 customer service locations in China) and manufacturing capabilities in China.

Anglo notes passing of MPRDA billAnglo American has noted that the Mineral and Petroleum Resources Development Act (MPRDA) amendment bill has been passed by the National Assembly.

“We would like to express our apprecia-tion for the opportunity to engage with the Department of Mineral Resources (DMR) and the Parliamentary Portfolio Committee on Mineral Resources, which provided a forum for constructive engagement among various stakeholders,” says Khanyisile Kweyama, exec-utive director of Anglo American South Africa.

“We are encouraged that previous areas of concern have been substantially addressed, and we look forward to work-ing closely with national government and the DMR in the implementation of the bill,” Kweyama adds.

www.angloamerican.com

Placing your trust in a supplier to give you the best quality parts, made specifically to fit your particular equipment, is a risk every industry equip-ment user is nervous to do. Too often, end users are foiled into believing that ‘copy parts’ or ‘other manufacturers’ parts’, not specifically designed for that brand or model of equipment, are sufficiently suitable.

‘Non-original parts’ debacle rears up again

the unbalanced motors branded as ‘JVM’ and the exciter gearboxes branded as ‘JU/JR’ manufactured by/under full licence of JÖST, be installed on existing equipment.

“If you’re not buying the right part for the right machine, you are bound to suf-fer the consequences of short lifespan, increased downtime, costly repairs and process inefficiencies that ‘non-original parts’ have to offer,” Swart states. “There is a line being cast in industry to the unsuspect-ing end user, that JÖST’s JVM unbalanced motors as well as JU/JR exciter gearboxes are not available anymore. This is a blatant lie – don’t believe what you hear.

“JVT has an extensive spares stock-holding, ready for despatch from Jet Park, Gauteng. These parts are available

Readily available on our shores: the JR exciter gearbox.

The JVM unbalanced motor.

exclusively from JVT. Any product obtained from any other supplier, unless obtained via JVT, is not a genuine JÖST part. This specifically includes locally-manufactured exciter gearboxes which are not branded under the JÖST brand,” he says.

The benefits to end users in ensuring that they are dealing with the right sup-plier for the right equipment and parts, goes beyond that of service and supply. “JVT wants to reassure end users of con-tinued support and supply of OEM parts, as we have access to inter-company, state-of-the-art facilities and inter-group design and manufacturing experience approaching 100 years,” Swart confirms. “Furthermore, JVT is the exclusive African party licensed to supply JÖST drive sys-tems (JU/JR exciter gearboxes, JVM unbal-anced motors, MS electromagnetic drives, dosing drives), and many other JÖST OEM components.

“Customers are reassured of the high standards and service and quality JVT provides, through local support as well as through the access we have to the experi-ence of the JÖST group worldwide,” Swart adds. www.jvtvibration.co.za

www.joest.com/en/home/html

Metso/LiuGong JV The initial scope of the joint venture will cover the design and manufacture of localised versions of Metso’s Lokotrack mobile crushers and screens, the first of which is expected to be launched shortly. The products, whose range may be fur-ther expanded in the future, will be sold under dual branding: LiuGong Metso. The joint venture will also promote Metso’s global track-mounted crushing and screening equipment in China.

Founded in 1958 in Liuzhou, China, LiuGong is the largest wheel-loader man-ufacturer in the world.

www.metso.com

AROUND THE INDUSTRY

Babcock has been awarded a contract to implement service line replacement as part of a greater Blast Furnace N5 reline project at ArcelorMittal South Africa’s Newcastle Works. The project is expected to extend the life of the plant by 20 years.

A specialist Babcock team will execute the contract during a major plant shutdown from March to August 2014. The scope of work includes the removal and replacement of the

Babcock awarded major ArcelorMittal contractfollowing service lines: drinking water; com-pressed air; nitrogen; oxygen; cold blast; clean gas; coke oven gas; industrial water; main steam; steam; demineralised water; soft water; instrument air; Sasol and flare stack lines.

The work involves installing reticula-tion from 25 nominal bore furnace piping up to clean gas supply piping of 1 500 NB and includes demolishing and removing all redundant pipeline. www.babcock.co.za

ArcelorMittal’s Newcastle Works.

The Concrete Institute’s Information Centre has added another invaluable facility to its impressive collection of data for the building and construction industry – a detailed list of its forthcoming concrete technology conferences.

Martha de Jager who, with Susan Battison, is in charge of the Information Centre in Midrand, says details such as dates, venues and websites for registration for impor-tant industry conferences and seminars are not available on the website under the Information Centre tab. Forthcoming confer-ences in countries as far afield as Italy, Brazil and India are already among the list con-stantly updated by The Concrete Institute’s

Information Centre, regarded as one of the largest of its kind in the southern hemisphere.

De Jager says the new facility has been added in response to the growing quest for knowledge among members in the con-struction industry, from top executives to the younger leaders of the future. “The industry now truly operates in a global village and not only do South African engineers, consul-tants, professionals and contractors want to learn more about world trends, but they are personally also in demand to provide input to overseas conferences, based on local conditions and experiences in a developing country.” www.theconcreteinstitute.org.za

MQA sponsors R20MThe Mining Qualifications Authority (MQA) has handed over a cheque for more than R2-million as support for seven lecturers in mining engineering and bursaries for 236 students in the following disciplines: analytical; chemical; electrical; industrial; mechanical; metallurgical and mining engi-neering; and geology.

H e a d o f t h e S c h o o l o f M i n i n g Engineering Professor Fred Cawood, says the longstanding partnership between Wits and the MQA dates back to 2005 and has strengthened to the point where it was

valued at such a significant sum of money.Vice-chancellor and principal of Wits

Professor Adam Habib adds that the dis-enfranchisement of some South Africans has created enormous levels of inequality which can only be addressed through col-lective action. “The VC can no longer say that his responsibilities end at the gates of the university. The CEO can no longer say that his responsibilities end with the company’s shareholders. How we begin to bridge institutional boundaries has become important. This partnership with the MQA is testimony to what can be done,” he adds.

www.wits.ac.za

Invaluable Concrete Institute facility


www.bme.co.za

www.aelminingservices.com


AROUND THE INDUSTRY

The Minister of Trade and Industry Dr Rob Davies, says manufacturing should be the leader of industrialisation in the country. He was speaking at Bell Equipment’s man-ufacturing facility in Richards Bay, where he celebrated the handover of the com-pany’s 50 000th vehicle.

The Minister says the manufactur-ing sector has proven that it can be the driver of industrialisation and Bell Equipment’s success is evidence of that. “Manufacturing is the driver of eco-nomic diversification and the generator of employment. Even if most of the jobs don’t reside in manufacturing, the sector also supports and sustains a range of ser-vice jobs which are high quality and more secure because they are rooted in a grow-ing manufacturing base.”

A strategy of government’s Infra-structure Development Plan is to drive industrialisation with all spheres and agencies of government requiring that a proportion of inputs used in infrastruc-ture development come from locally-manufactured sources, as a means to support local manufacture.

As the most industrialised country on the African continent, Davies says South Africa will also play a large role in the development of regional economic infra-structure on the continent and govern-ment is looking to support companies like Bell, which have the competitive ability and capacity to contribute towards this effort.

Commenting on the Industr ial Policy Action Plan, the Minister says that although IPAP has registered significant achievements over the last five years, it lacks the aspect of recognising champi-ons. “One of the areas of improvement and focus must be to increasingly identify and support ‘champions’, winning South African companies, and strengthen their efforts in a more focused and strategic manner with the range of policy instru-ments we have in our armoury – industrial financing, incentives, trade measures and export promotion. The reason for this is that South Africa’s growth path is currently consumer-driven, import-intensive and characterised by significant fault lines.”

In return, he explains, the dti will be looking to local manufacturers for a deepening of localisation and supplier development, employment creation, skills development and improving technologi-cal ability.

www.bellequipment.com

Manufacturing needs to drive industrialisation

Minister of Trade and Industry Dr Rob Davies, gets a deeper insight into Bell Equipment during a tour of the factory.

Bell celebrates 50 000 vehicles

Trade and Industry Minister Dr Rob Davies, recently visited Bell Equipment’s manufac-turing facility and head office in Richards Bay, KwaZulu-Natal, where he toured the factory and celebrated the handover of the compa-ny’s 50 000th vehicle.

According to CEO Gary Bell, in addition to celebrating the production of the 50 000th vehicle, this year Bell celebrates 60 years of manufacturing in South Africa to world-class quality standards. As such, the company is proud of the ground-breaking technological advances it has developed on South African soil with its team of local engineers, which has seen it emerge as a global leader in the articu-lated dump truck (ADT) market, with engineer-ing expertise and product quality comparable with other global industry players.

Appropriately, the 50 000th vehicle off the company’s production line was an ADT from the new E-series generation of trucks. This was presented to Radds Transport, which provides logistical support within the Port of Richards Bay.

Radd is currently the largest transport contractor in the Port of Richards Bay with a fleet of 40 Bell wheel loaders, eight Bell ADTs, as well as 10 tippers and nine specially-adapted excavators. The latest additions to the Bell fleet are 22 new wheel loaders deliv-ered during 2013 and two B30E ADTs, includ-ing the 50 000th vehicle.

The City of uMhlathuze in Richards Bay also took delivery of a Bell tractor loader backhoe (TLB). Handed over by the Minister, the TLB will assist the municipality in eradi-cating infrastructure backlogs.


Bell Equipment Group CEO Gary Bell and Minister Rob Davies, congratulate the Mayor of the City of uMhlathuze, Cllr Elphas Mbatha on the TLB acquisition.

PPC Ltd is to be the anchor sponsor of the Concrete Society of Southern Africa’s (CSSA) Fulton Awards in 2015. Considered as the ‘Oscars’ of the concrete industry, the Fulton Awards event is arguably the most prestigious award that a project team can receive in the built environment.

The Fulton Awards have been associ-ated with the celebration of achievements in the South African building industry for decades. It is also an indication of the highest standards of the skills and creativ-ity found in both the local construction professionals and contractors.

“These awards are also synonymous with the recognition of excellence in con-struction, and of excellence in concrete in

PPC to sponsor Fulton Awardsour country,” says Daniel van der Merwe, architectural concrete specialist at PPC.

At the last Fulton Awards in 2013, two PPC clients were presented with awards in the ‘Civil Engineering Structure’ and ‘Sustainable Concrete’ categories for its work on the De Hoop Dam project in the Limpopo Province.

The judging panel said the work at the De Hoop Dam project led to significant simplification of the construction process and allowed one of the highest construc-tion rates achieved in South Africa, with a peak of more than 130 000 m3 of Roller Compacted Concrete (RCC) placed in one month. The De Hoop Dam is a flag-ship project for the Department of Water

Affairs and will address a significant por-tion of future water needs in the Limpopo Province. www.ppc.co.za

www.wirtgen.co.za


AROUND THE INDUSTRY

PPC Limited, a pioneer in the southern African cement and infrastructure devel-opment industry is driven by its Kambuku philosophy. This is the company’s ‘way of life’ that creates a healthy, rewarding and satisfying working environment in which every employee has opportunities to con-tribute to the success of the organisation and their own development.

Kambuku is a Tsonga world mean-ing ‘great tusker’, referring to an elephant bull whose characteristics of tenacity and loyalty sum up PPC’s value-based man-agement philosophy. It is through what this philosophy stands for that last year, CEO Ketso Gordhan initiated a process to assess the effectiveness of the Kambuku initiatives during which he and senior managers engaged in conversations across the business. Discussions were held with over 3 000 employees across all levels at all PPC facilities.

It was during these engagements that some employees communicated their lack of affordability for decent houses. PPC has implemented an initiative which

PPC cementing changewill see over 300 of their employees, mainly semi-skilled and who do not qual-ify for either a state-funded RDP house or for a bank loan, acquire a decent house. This initiative will run over the next three to four years. The cement will also offer these employees the necessary training and the technological know-how to suc-cessfully transact for their new homes and maintain them.

“Last year, through our employee housing support initiative, we committed to help some of our employees to become home owners,” says Yogesh Narsing, an executive for special projects from PPC. He is resolute that the main difference between this initiative and other prior industry initiatives is that PPC will make sure that the employee receives all the training necessary to successfully manage and maintain their new home.

The first of the new homes, whose owner Edward Ringani, retired after more than 35 years of service to PPC, has been completed in his ances-tral home of Mmapela,

Upbeat crushing and screening specialistSouth African crushing and screening company Pilot Crushtec International, is upbeat about prospects for 2014, despite the trials and tribulations that beset local and international economies during 2013.

National sales manager Nicolan Govender gives his take on what to expect this year: “In our experience, one of the most reliable indicators of potential demand is the level of enquiries we receive from estab-lished customers, the people who are in business for the long haul and are constantly alert to developments within their own local markets.”

He says that the interest received from this core group over the last few months suggests an imminent resurgence in recycling and con-struction work. The former in Gauteng, while there has been a notice-able upswing in demand for infrastructural growth in KwaZulu-Natal and the Eastern Cape provinces.

Another reason for Govender’s cautious optimism is that the year has begun relatively well. A continuous flow of new products are being dispatched to customers and certain sectors within the mining indus-try are displaying a higher degree of confidence than was apparent six months ago.

“We believe in the resilience of our industry, so much so that we will be increasing our regional sales footprint into areas like the Northern Cape, eastern Cape and KwaZulu-Natal. Another develop-ment will be the introduction of more localised service centres fol-lowing the success of last year’s pilot project in the Eastern Cape,” he adds. www.pilotcrushtec.com

The first of the new houses was completed in retired employee Edward Ringani’s ancestral home of Mmapela, Mokopane, Limpopo.

Mokopane, in Limpopo. Four more houses will follow in quick succession. Rimpani had attempted to build his house in Mmapela since 1984 by manufacturing his own bricks and building himself over weekends. His house was built without a foundation or suitable living conditions in 1995.

“I believe that a happy employee is a loyal and productive one,” Narsing says. “This employee housing support initia-tive is just one aspect of how PPC cares for its people, and we remain committed to ensure that as an organisation, we go beyond the cement bag.”

www.ppc.co.za

www.aspasa.co.za


ON THE COVER

Deployed across South Africa as well as cross-border, B&E International is expand-ing its operating footprint in the contract

crushing and screening market with the parallel roll-out of a range of multi-disciplinary services to support regional projects in the fields of civil infra-structure, mining, and minerals processing. This ca-pability is backed by an in-house engineering and manufacturing arm for custom-designed benefi-ciation plants tailor-made to client specifications.

Namibia remains one of B&E International’s major cross-border markets and the company cel-ebrates its 21st year in this country during 2014. As Dewald Janse van Rensburg, B&E International’s managing director explains, business in Namibia has been predominately mining focused, chiefly for load and haul contracts ranging up to 2-mil-lion tpm, allied to which are recent orders for pro-cess plants.

Examples include an order from AIM-listed mining, development and exploration company, Weatherly International Plc, which focuses on cop-per extraction in Namibia. Still in the design phase, this will be a complete copper processing plant for

a project in Tsumeb, entailing primary, secondary, tertiary and agglomeration streams. The project scope includes the construction of the heap leach pad. B&E International will operate this plant on behalf of the client, with anticipated commission-ing scheduled for the first quarter of 2015.

Outside Namibia, other southern African terri-tories with potential include Mozambique, where B&E International is currently active. However, South Africa remains the major contributor to

Currently working on around 15 projects, B&E International’s sustained market penetration in the quarrying, construction and

mining segments is supported by an ongoing fleet modernisa-tion programme that includes the acquisition of latest-generation

Metso Mobile equipment.

Centre: B&E International’s three-stage crushing and screening plant set-up, deployed on the N8 project comprises a Metso Lokotrack LT120E primary jaw crusher, followed in turn by Lokotrack LT300GP and LT300HPB cone crushers, forming the secondary and tertiary stages respectively.

Below: The LT300HPB, fitted with a Nordberg HP300 unit and a B3100T horizontal screen, is a closed-circuit crushing and screening plant.

Below right: The Lokotrack LT300GP comes equipped with the proven Nordberg GP300 cone crusher and is an open-circuit plant equipped with a pre-scalper for fines removal.

B&E INTERNATIONAL expands design base


ON THE COVER

Below left: The Lokotrack’s LT120E’s Nordberg C120 crusher provides outstanding capacity due to an excellent nip angle and aggressive linear stroke. Additionally, the starting system of the crusher allows reverse running in case of oversize feed blockages.

Below: B&E International has an in-house engineering and manufacturing arm for custom-designed beneficiation plants tailor-made to client specifications.

group turnover, which in the past financial year was approximately R700-million.

Over the years, the company has chosen to standardise on Metso. In fact, historically B&E International is believed to be one of the first com-panies in South Africa to acquire a Metso Lokotrack unit, a LT1100 model that is still operational, its Cat engine having recorded around 47 000 hours to date.

Today B&E International owns a comprehensive

Lokotrack fleet, which is supplied and supported by Metso Mobile’s southern African dealer, Barloworld Equipment. Designed and manufac-tured in Tampere, Finland, Metso has supplied more than 6 000 Lokotrack plants over the past 29 years. The first Lokotrack series was launched globally in 1985.

“Featuring compact dimensions that enable rapid site-to-site on-highway deployment via low-beds, our Lokotrack crushers are ideally suited for high production output on short duration contracts,” says Janse van Rensburg. “Meanwhile, on longer-term projects, static plants provide the most economical option, given the availability of electric power, and here we also use Metso equip-ment when building our in-house designs both for own project requirements as well as for customer orders.”

Made-to-order examples include a complete three-stage coal processing plant commissioned for African Exploration in Mpumalanga. The group has just completed an aggregate crushing plant in Queenstown for client, Raumix, which was com-missioned in March 2014.

On the contracting side of the business, B&E International is currently involved in a range of crushing and screening projects, either using static or Lokotrack plant. This includes work at Khumani Iron Ore mine in the Northern Cape. “We originally processed around 300 000 t, but this figure has already exceeded 1-million t.”

Another major project is ongoing at Eskom’s greenfield Kusile Power Station project in Mpumalanga. Here B&E International has supplied a large portion of the concrete aggregate require-ments, with a purpose-built commercial static plant in place. The company was also responsible for producing around 3,5-million t of aggregate for Eskom’s other greenfield roll-out, namely the Medupi Power Station in Lephalale, Limpopo Province.

www.flsmidth.com


ON THE COVER

An aerial view showing B&E International’s Metso Lokotrack train processing quarried aggregate materials for the N8 project. The contract entails the supply of more than 1-million t of road aggregate, in multiple phases, for the upgrading and rehabilitation of Sections 11 and 12 of the N8 between Sannaspos and Thaba Nchu North.

A number of regional road projects are ongoing, which includes a contract for the sup-ply of road aggregates for a Trans African Concessions (TRAC) N4 toll road upgrade leading into Maputo, Mozambique.

Meanwhile, a major order entails the supply of more than 1-million t of road aggregate (in multiple phases) for the upgrading and rehabilitation of Sections 11 and 12 of the N8 between Sannaspos and Thaba Nchu North over a distance of 28,8 km. This is a South African National Roads Agency SOC Limited (SANRAL) project. Here B&E International is deploying a new three-stage crushing and screening plant set-up, which represents its largest investment in mobile plant to date.

These are also new models for the South African market, and comprise a Metso Lokotrack LT120E primary jaw crusher, followed in turn by Lokotrack LT300GP and LT300HPB cone crushers, forming the secondary and tertiary stages respec-tively. The LT300GP and LT300HPB units run on Cat diesel engines, while the LT120E is a hybrid unit where power can be supplied either via the electricity grid or from the machine’s onboard Cat 420 kVA diesel generator.

At the end of the process stream is a track-mounted Metso Barmac 9100 VSI (vertical shaft impactor) to optimise final G1 or G2 base course product shaping, which B&E International designed to match the high materials volume throughput.

“The Lokotrack 120E’s Nordberg C120 crusher provides outstanding capacity due to an excellent nip angle and aggressive linear stroke,” explains Barloworld Equipment sales professional, Michael Winterbottom, expanding on key machine fea-tures. “Additionally, the starting system of the crusher allows reverse running in case of oversize feed blockages.”

Next in line, the diesel-powered Lokotrack LT300GP comes equipped with the proven Nordberg GP300 cone crusher and is an open-circuit plant equipped with a pre-scalper for fines removal. The LT300HPB, fitted with a Nordberg HP300 unit and a B3100T horizontal screen, is a closed circuit crushing and screening plant. Both machines come standard with Metso’s IC (Intelligent Control) automated process control system.

“These latest machine acquisitions form part of our ongoing equipment modernisation

programme, ensuring that we have the flexibility to meet a wide range of project demands for high volume, quality-shaped materials,” says Kenneth Basson, director: plant and engineering at B&E International.

Past project milestone examples include Eskom’s Ingula Pumped Storage Scheme (planned capacity: 1 352 MW), completed in 2013, where the total estimated concrete aggregate volumes were in the region of 2,7 million t; and the De Hoop Dam, forming part of the Olifants River Water Resources Development Project, which was also commis-sioned in 2013. The dam wall is approximately 1 015 m in length and 81 m in height.

Throughout its multi-faceted business, B&E International regards environmental management and health and safety as overriding priorities, and has now established a new business unit trading as Greenmined, which provides a range of services direct to the open market, as well as for its own internal requirements.

Greenmined focuses on environmental man-agement, with services that include the process-ing of quarry permit and mining right applications, water permits, and dust and emission control management testing. B&E International holds the licences/mining permits for around 15 quarries in South Africa to support nationwide projects, so this is an area where the group has extensive experi-ence. This includes blast design and optimum use of explosives, as well as exploration for aggregate materials.

“Greenmined serves as an excellent example of how B&E International continues to diversify its ser-vices across its contracting, design and consulting arms to meet and exceed customer requirements,” adds Janse van Rensburg. MQ


COEDMORE HISTORICAL FEATURE

In contrast to the peaceful surrounding country, a beautiful valley midway between Bellair and Sea View has been turned into a veritable hive of industry. Here, four years ago, the Coedmore quarries sprang up and

the devastating work began. At the present time, under skilful handling, the project has now devel-oped into a huge concern employing over 200 na-tives and extracting nearly 500 tons of whinstone, blue stone and quartzite every day; the only spot in Natal where the three types of stone are found together.

The huge whinstone reef, which has only been in operation for five months, is the mainspring of the Coedmore quarries. This stone is the most valuable of the three grades by virtue of its hard-ness and durability. It is supplied by contract to the Durban Corporation for roadmaking.

When viewed, some 100 natives were working the face of the reef, clearing what had been blasted the night before. The pinkiety, metallic clicking of the hammers was not unlike the old-fashioned music box.

Blasting – A risky jobBlasting is carried out at least three times a day, and each charge dislodges over 200 tons of rock. It is a hazardous business, this blasting; the air for a dis-tance of 100 yards becoming thick with 10-pound chunks of rock. The echoes of the explosions thun-dering in the hills might cause an ex-serviceman to rub his badge reflectively.

A Quartzite FlowAbove this main whinstone reef is a quartzite flow. As much as 150 000 tons of this quartzite stone was supplied by the quarries for the building of the new electrical power station at Colenso, while it was also brought into the construction of the new

Coedmore in the 1960s. Note the P&H shovels.

Smashing solid rocks to powder – a visit to Coedmore Quarries at BellairModern Quarrying is in possession of an article written by

an unknown newspaper journalist in 1927, for The Week-End Advertiser, after a visit to the Coedmore operation in Bellair. ‘The

surface of the earth in the beautiful valley midway between Bellair and Sea View’, is described as having been ‘rudely torn aside in

order to disclose and reclaim the natural wealth beneath’. The date of this submission was September 17, 1927, and the article, which is a ‘carbon-copy’ of the original typed story, was written MQ believes,

by a young woman, judging by the colourful and descriptive writing style. The news story below is quoted verbatim:

elevator at Congella and the gracing dock in the harbour here.

The rough whinstone from the quarry is put into small iron trucks of three quarter ton capacity and pushed on a nearly level grade of one-in-300 to the foot of the haulage incline. From here, by means of wire cables actuated by electric pullies, the trucks are drawn up in a one-in-eight slope, often as many as 10 at a time. The rail track is a double one, allowing empty trucks to go down again without hindering the upward flow of stone.

Devastating Rock CrushersNext in the system come the crushers. These dev-astating machines are almost terrifying in their intense power. They puff and roar like a mammoth train, and as soon as the rough chunks of rock are unceremoniously piled into their mouths, two great manganese jaws eagerly seize it and champ



Above: Kitchen facilities in the early 1960s.

Top: Hostel facilities in the 1960s.

Smashing solid rocks to powder – a visit to Coedmore Quarries at Bellair

it into pebbles. Forty horse-power engines drive the two main crushers.

Should there by any ‘rejects’ from these crush-ers, that is to say, blocks of rock still too large to be absorbed by the ‘screens’, the stone is directed by a shoot into a ‘lightning’ crusher, which works at 1,000 revolutions a minute, and produces pow-dered rock to the half-inch grade. Both the two main crushers and this lightning crusher can all cope with over 100 tons a day each. At the end of the month, a new crusher is to be installed, when the quarry’s output will increase to over 500 tons a day.

Safety FirstSafety is greatly emphasised in this branch of the works, independent switches to each engine being near at hand in case of any accident. The power plant, the crushers and the hoisting system

are all worked by separate engines, so that should one unit fail it only affects part of the system it is driving.

The ‘Screens’When the rock has been crushed into approxi-mately two-inch pieces, it is swept into screens, which are a kind of super-sieve. These screens are tubular and revolve at a great pace, separating the rock into half-inch, one-and-a-half inch and two-inch grades. The four separate grades run off into hoppers specially prepared for them, and chutes connect these hoppers into railway trucks.

www.pilotcrushtec.com


Hippo Quarries Natal – a brief history of Coedmore Quarry3 March, 1987: ‘Coedmawr; the Welsh name meaning ‘big trees’ was the name given by the Lloyd family in about 1860 to their farm, which is the present site of the quarry. In 1922/23, the Bawden brothers purchased from the late DLW Stainbank and Thos W Rutland, land to establish a quarry, which they named Coedmore Quarries.

In 1950, the quarry was taken over by NPC and in 1963, incorporated into SA Quarry Industries Ltd. Anglo-Alpha acquired Coedmore through its purchase of the Hippo Quarries group in 1975.

Coedmore Quarries is the largest aggregate-producing quarry in the Republic and is reputed to be the largest in the Southern Hemisphere. The quarry is capable of producing in excess of 3 000 m3/day and mines on 10 differ-ent levels, the deepest of which is 16 m below sea level.

Rock types quarried include quartzite, dolerite and sandstone. The plant processes the stone into 18 different-sized aggregates which are used in the construction of buildings, roads and railway lines.

Coedmore Quarries employs 98 people, ie Blacks, Asians and Whites. The quarry prides itself on its social policy and safety achievements. The quarry was awarded its 5-Star Nosa rating in 1986 and achieved 1 000 000 accident-free manhours in 1982. The quarry also has the distinction of winning for the third consecutive year, the coveted Anglo-Alpha DR Baker Trophy – Striving for Excellence. This competition is open to all of the 21 Hippo Quarry plants scat-tered strategically throughout the Republic.


Fine Railway FacilitiesThe Coedmore quarries flank the main line between Bellair and Sea View stations, and also have their own private siding capable of holding 20 trucks. The quarries are served by an afternoon train and one at noon.

Super Modern PlantAll the plant at these workings is of the most up-to-date kind. Even the dulcet tones of the electric jack-hammer, that instrument of torture that even now so impairs the nervous systems of strollers in Piccadilly, is heard here. There are also eight sepa-rate electric motors. The cost of the fittings must approach £30,000.

There is little or no fear of these quarries ‘drying up’. The whinstone vein alone extends back half a mile, and the other types of stone show evidence of being just as inexhaustible. A great factor is the absence of ‘slack’ on the surface. Rock is reached about a foot below ground level, which greatly reduces cost.

All these natural advantages alone should pres-age a great future for the Coedmore quarries, but with such a capable man as Mr J Bawden holding the reins, this enterprise is an almost assured con-tinuous success.

– The Weekend Advertiser, Saturday, September 17, 1927.

Photographs courtesy Henry Terblanche

www.osborn.co.za


FACE TO FACE

Henry often describes some of his colleagues as colourful characters, with the ability to tell a story in cin-emascope, but clearly he is a mas-ter in this regard.

He looks back at some more of his blasting experiences: Mount Frere, in the old Transkei, was a particularly difficult rock to blast, with a lot of oversize generated. “Tarmac had a plant on site with a big prefab laboratory to do all the tests on the product. Not having enough drilling capacity to drill and blast these oversize rocks, Frank and I decided to do a mud blast with high velocity gelig-nite slabs,” Henry explains.

“The blast was prepared and we were ready to blast late on a Friday afternoon,” he recalls. “Everybody had already left site and we were keen to get the job done and return to Durban, when a thick mist rolled in. We decided to do the blast which went off with a hell of a bang, rattling our eardrums, and we felt the air pressure against our bodies as the echo rolled into the valley.

“Monday morning back at work, the manager of Tarmac came across to see me, saying that ‘these bastards had broken into the lab again over the weekend’. What he was puzzled about was why they had to break all the windows and pull the fluo-rescent light tubes out of the ceiling.” Henry never told him what had really occurred.

“Willie de Beer was the boiler workshop fore-man at the time, and we were neighbours staying in company houses. We walked to work using a footpath through the bush and over a little stream called Londonspruit. To get over this little stream, you had to jump onto a rock in the middle of the stream and then jump again onto the bank on the other side. Approaching from the house side, the rock was a bit far away, and you had to pick up speed before launching into the air.

“As we had been doing this for years, it became automatic ... pick up speed, launch, and land on the rock with momentum taking you over to the other side. One day, I decided to put a massive rubber snake on this rock and hide in the bush to wait for Willie.

“Now Willie is a big guy,” Henry says, “over six-foot tall, and as predicted, he arrived, picked up speed, launched and while airborne, saw the snake on his landing rock. It was too late to change

Forty years plus overtime – a lifetime of wonderful memoriesIn this special feature, MQ continues with Henry Terblanche’s memoirs. In 1972, he started working for the old Alpha Stone

(AfriSam), at the Effingham operation as a blaster, moving on to Coedmore from 1976-1977 as a blaster, then as plant foreman from

1977-1979. From 1981-1996, he was quarry foreman, and in 1997 took on the responsibilities of production superintendent. Henry

is still very much involved with training for AfriSam, among other companies, and this is why his response to anyone enquiring about his length of service at the company, is: “Forty years plus overtime!”

Centre: “Mistakes happen,” Henry admits. “We were back in production 58 hours later. Those days you stayed on the job until it was completed. That is why, if someone asks me about my length of service, I say: 40 years plus overtime!”

Below: A snake-spooked Willie trying to take off in reverse.


FACE TO FACE

Forty years plus overtime – a lifetime of wonderful memories

course; his hands were going backwards like in the comics, trying to reverse. I saw the whites of his eyes disappear as his pupils got bigger, and he let out a scream straight from hell.

“He then landed with both his feet on either side of the rock in the water. With super-human strength and litres of adrenaline, he picked him-self up and deposited himself on the other side of the bank. That is when I fell out of my hiding place in the bush laughing. Willie didn’t take well to this trick and I had to plead for my life. He had a memory like and elephant and got me back many years later.

“It was about this time, that a man by the name of Karl Meissner-Roloff started with us at Coedmore as a trainee works manager (MSR for short). It was my duty to teach him all about blasting and min-ing,” Henry explains. “At that time, we were still using cartridge explosives and detonating cord. To make a primer you had to tie the detonator to a cartridge with a clove hitch knot, before lowering it into the hole. Now Karl kept on tying his fingers up with the detonating cord, and that is why I told him he would never make it as a blaster, and it would be better for him to become GM or something. Karl followed my advice, and as we all know, he made it to MD,” he says with a smile.

As Coedmore is a vast area to cover, all the foremen used scramblers to get around and these bikes were ridden hard and took severe punish-ment. One day James Kennedy’s bike was in for repairs. On this day Kobie, the apprentice, was out-side the workshop trying to start James’ bike after a service, but failing to do so. James saw this, swag-gered over the road to Kobie and said: ‘Now let me show you okes how a bike should be started’.

“He then put his bike into gear, took a run down the road next to the bike and dropped the clutch, holding the accelerator fully open,” Henry says. “The bike started with James still running next to it, holding onto the ape hangers for dear life. The front wheel came up and the bike flipped over back-wards with the throttle stuck at full open. James let go of the bike, which fell down with the engine at full rev and the back wheel spinning. He sort of made an 180o rotation and fell with his bum on the still-turning knobbly tyre. Now things got ugly.

“The knobbly tyre would bite into his bum, pull him into the bike frame, and let go when his bum overcame the resistance of the tyre. This sequence happened a few times before James managed to save himself by rolling off; no-one else could help him due to laughter-induced paralysis. He still bears the mental and physical scars of that incident.”

Henry says it was soon his turn to have a mis-hap on his bike. “My right knee started to give me problems when kick-starting the bike. I improvised by standing on the left side, holding the bike with my right hand on the throttle; giving it a bit of juice and then kick-starting with my left foot. As soon as the bike started, I would mount and take off. This worked well until James borrowed my bike and

James demonstrating the correct way to start up a motorbike.


FACE TO FACE

Bad parking of an excavator. “We used a 300 t crane to recover it. It was back on track at 03:00 the next morning and back in production the following day. Karl Meissner-Roloff, our manager at the time, found it necessary to open a bottle of whiskey at 03:00 am to celebrate our achievement. When I got home around 06:00 that morning, I told my wife Marianne that I was very tired. She commented that she did not know ‘tired’ smelt like that,” Henry says.

unbeknown to me, left it in gear. I did my trick with the left foot again and the bike started first shot in gear with the throttle half open. The bike took off with me running next to it, holding it by the handlebar with my right hand. Ten metres down the road, I eventually gained control, with due applause from the bystanders.

“Some time later, I was going down the quarry with my bike at quite a speed. The next minute, the front wheel stopped suddenly and I found myself airborne. As I was flying through space, my first thoughts were ... I didn’t see a rock or any obstruc-tion on the road so why had this happened? Eventually I landed, got up quickly, looked around to see if anybody had seen me, licked my wounds, and started to look for the cause. It had me baf-fled for a while. Picking up the bike I found that the front wheel was jammed solid. On taking the front wheel off, we found that the spring holding the break-linings in place had broken due to rust, causing the wheel to lock solid at speed.”

James was Henry’s neighbour for many years. He had four dogs that barked incessantly during the night, and the two men would take turns at getting up and chasing them away, causing much anger and frustration. “One morning after a night of chasing barking dogs, James came into my office with a worried look on his face,” Henry says. “He sort of mentioned to me that he bit one of his dogs the previous night. I told him not to be too worried, as it wasn’t abnormal to bite your own dog if it annoyed you.”

A few weeks later he came into Henry’s office, looking even more worried. He told James that he thought he had a huge personal problem, as he had bitten his dog again. “For the first time in my life, I had no advice for him,” Henry laughs. “As Pitso the plant foreman at Coedmore says in summing James up: ‘Mr James, he has got a different ingredi-ent than other white men’.”

Henry continues: “One early morning, I forgot my newspaper at home and decided to quickly fetch it with the bike. Being in a rush and with the quarry vehicles busy going into the quarry, I was travelling quite fast, looking leftwards into the quarry to see what was happening. At the same time, Mike Hut, also on the same road but in the opposite direc-tion, was whistling a happy tune and looking into the bushes. The next minute, we collided head on, on our bikes. Mike was flung into the air over me and was injured pretty badly with a broken finger, broken ego and severe roasties on his backside! People ask me all the time, how it is possible to have a head-on collision with two bikes, my answer to that is what do they expect on a 20 m narrow road?

“We took Mike home, and his wife Jackie had him bending over with his pants down his knees, while removing small stones from his bum with a

James – the desperate dog biter.

tweezer, when the doorbell rang. She left Mike in that position while answering the door and unfor-tunately his injuries prevented him from pulling his pants up. All he could do was to scream ‘Jackeeee!!” And that is how Rachel the nursing sister found a very embarrassed Mike.

“In 1995, Darryl Snyman was employed as a plant foreman,” Henry says. “Darryl is a very ener-getic and colourful person who tends to overtake himself sometimes. He is dynamically funny and can also tell a story in colour and cinemascope. We found out, too late unfortunately, that he and James are a dangerous combination. Once at a party they caught the band stealing our beers. James and Darryl didn’t waste any time sorting them out physically. There were broken guitars and band members all over the place. Dave was carried home in a bath full of cold water, beers floating around him, with a satisfied smirk on his face, for a job well done. And from that day, we never got a live band again for our parties as we were afraid that they would arrive alive and leave half dead!”

Shortly after Darryl joined the company, the new washing plant was erected. It is a tall structure with a lot of stairways which he had to climb contin-uously on a daily basis. “He requested the workshop to install a cat ladder in one section to make his life easier getting down,” Henry recalls. “This was not done fast enough to his liking, and the next minute I heard him threatening the workshop over the radio

www.scaw.co.za


FACE TO FACE

A17 t Barford tipping at the primary. “These trucks were tough. If it rolled, all you needed to do was to take the driver to the clinic for a checkup, check the oil, put in a new battery, and you were back to work.”

that if they did not install this ladder immediately, he would start abseiling the building. Knowing that Darryl meant every word, I had to take quick correc-tive action to prevent this, as there were some hes-sian ropes lying around ready for him to use. I think it was these ropes that gave him the abseiling idea in the first place; he is an opportunist that will not let any opportunity go by without doing something out of the ordinary. Darryl is also able to tell a story in colour and cinemascope, and he has entertained us on many an occasion.

“Redge Strike was our workshop foreman. He was an ex-racing driver and a wild man with a short temper. Once coming back from attending a min-ing show in Johannesburg, he was driving with me sitting on the backseat holding on and praying for safe delivery, with Pieter Jacklin seated next to Redge in front. At one stage, Pieter told Redge that he was going too fast. Redge said that he was only doing 140 km/hour to which Pieter replied: ‘Yes Redge, but it is around a hairpin bend!’

“Our prayers were answered and we arrived back in Durban in record time. I was tempted to have a Tee-shirt printed with the wording: I sur-vived a trip with Redge Strike from Johannesburg to Durban!” Henry says.

“During this time, I had a blasting assistant by the name of Manjala. He was short, funny looking and smelly. Manjala kept nagging me to allow him to set the blast off just once. I eventually gave in to his pleading. Now, the exploder we used was a Shaffner pushing out 1 200 V but with a very low amperage of 1,2. You had to clamp the exploder between your feet on the ground, insert the key into a keyhole and Manjala had to hold the exploder down with his left hand while winding

with his right hand. Unfortunately, he had his hand over the terminals. As he set the blast off, he got the shock of his life.

“Being from a rural area and never having been shocked before, he thought the tokoloshi was upon him. He took off from his bended position on all fours for about 10 m, and then decided to try the upright position. This was too slow and he went back on all fours. I think he reasoned that the more limbs on the ground, the faster he would go. When I eventually caught up with him, all he could say was: ‘Bliksem baas, daar is ‘n lelike fokken ding in daardie fokken machine!’ He used the same words again sometime later when he picked up an empty ammonia tin, opened the lid, and smelt inside.”

Report by Dale Kelly. The cartoon sketches were done by Henry Terblanche’s daughter-in-law Carol.

Photographs courtesy Henry Terblanche.

MQ will continue with Henry’s memoirs in the July-August issue.

www.hpeafrica.co.za


AT THE QUARRY FACE

Environmental stewardship is impor-tant to the AfriSam Group as a whole and Coedmore Quarry has managed to go above and beyond the levels of compliance required by the Depart-

ment of Mineral Resources (DMR). According to Henry Terblanche, ex-master blaster at the quarry and the driving force behind the rehabilitation of the quarry, not only does the vegetation provide a pleasant work backdrop for its employees, but it has won favour with the neighbours in the sur-rounding residential area.

“It is critically important to the ongoing opera-tion of the quarry that we find ways of cultivating our harmonious relationship with local residents. We have instituted a number of measures that fur-ther add to our intention to make our operation as non-disruptive as possible. These include the

installation of sound, air quality and dust meters to monitor levels at strategic points throughout our site. In addition, we undertake systematic clean-ing of the Londonspruit which enters and exits our property,” Terblanche explains.

Terblanche, who assists AfriSam in a part-time specialist capacity, has been assisted in the monu-mental task of removing all alien invader plant spe-cies and replanting with thousands of indigenous trees, shrubs and plants, by local company Natal Landscapes for the past 13 years. Interestingly and very aptly, the name ‘Coedmore’ is derived from the Welsh name for the farm on which the quarry is situated – Coedmawr – which means ‘big trees’.

Dave Haigh from Natal Landscapes points out that since the implementation of the Environmental Development Programme at Coedmore Quarry in 2002, the following statistics are noteworthy: total of 11 896 trees, shrubs and ground covers have been planted; approximately 21 800 ground cover cuttings were taken from site and planted; a total of approximately 265 000 m² of alien invasive weed has been cleared; approximately 150 large gum trees have been cut down; 1 150 trees and shrubs have been propagated on site and approximately 41 kg of indigenous grass seed has been spread where required.

The environmental rehabilitation is tackled sys-tematically and strategically. “By spreading the cost

Safety and environmental stewardship predominate at CoedmoreSituated in Bellair near Durban, AfriSam’s Coedmore Quarry has

been a shining example of responsible mining since its inception in 1924. A report published in The Natal and Zululand Annual in 1929

states that: ‘Coedmore is quarried aesthetically and artistically’.Today the pit, whose highest face is 110 m (46 m below sea level),

is surrounded by a vast array of strategically planted and nurtured indigenous vegetation.


AT THE QUARRY FACE

Above left: AfriSam Coedmore’s readymix plant, with trucks waiting to be loaded.

Centre: The in-pit crusher at AfriSam’s Coedmore quarry. Inset: A view of the 252 m long in-pit conveyor which transports material from a gyratory crusher to the intermediate stockpile.

Above: A view from the top of the in-pit gyratory crusher.

Left: Part of the AfriSam Coedmore quarry team. From left: Pobbi Naiker, Henry Terblanche, Sagie Jaganaikulu and Kopano Pitso.

Safety and environmental stewardship predominate at Coedmoreof rehabilitation over a number of years, at the end of the quarry’s lifespan, which is anticipated to be in excess of 30 years, AfriSam will be in the enviable position that no further capital will need to be allo-cated for this purpose,” says Terblanche.

Safety In 2013 Coedmore Quarry completely rewrote its safety policy with input from Southern Rock, suppliers of all ropes and harnesses used by AfriSam at the quarry, and drilling contractors Eire Contractors. Sagie Jaganaikulu, works manager at AfriSam’s Coedmore quarry, explains that part of the revised plan entailed the placement of 1,2 m high and 1,2 m wide (at the top) earth berms on the quarry edge of all haulage roads. This ensures that trucks and other vehicles are safeguarded from accidentally driving off the edge of the road. The haul roads were widened to take the berm footprint into consideration.

Jaganaikulu joined AfriSam 33 years ago and transferred from the company’s Verulam Quarry to Coedmore in late 2013 to Coedmore quarry.

“In addition,” he says, “when drilling or blast-ing takes place, blue poles (supplied by Glassfibre Products) are sunk into the ground 3,0 m away from the crest and a red wire is strung between the poles to indicate the start of the no-go area. The drilling operators are then required to attach the

harness they are wearing to a double rope which is in turn hooked onto the red wire.”

The DMR was so pleased with the company’s new safety plan that it has asked that all AfriSam KZN quarries adopt it and suggestions have been made by the KZN Tripartite Safety Alliance that it is rolled out to other third-party quarries in the province. The quarry, which is considered a showplace, maintains a healthy relationship with the Aggregate and Sand Productions Association of Southern Africa (Aspasa) and has won favour for its exemplary safety record of no lost time


AT THE QUARRY FACE

Above: The BC 2 Underpass. “As you can see we have now successfully blasted through underneath this conveyor without damage to the conveyor. The closest blasthole to this conveyor was 2,5 m. Before we could start blasting the actual underpass, we had to first blast a face that ran parallel and 3,0 m away from the conveyor over a length of 40 m. The neatening up and blasting of the western tail end of the underpass ramp can now start,” Terblanche says.

Above right: Cladded screen towers contain noise and dust.

Below: The crushing plant is controlled from the plant control room, which is fully automated.

injuries (LTIs) over the last five and a half years. “We achieved 99,16% compliance on our most recent Aspasa ISHE audit and we find that our member-ship is valuable in terms of knowledge sharing and standardisation of best practice,” says Jaganaikulu.

This obviously places a massive focus inter-nally on AfriSam being able to service its custom-ers within these parameters. In spite of this, the plant has been able to run at an overall operational equipment efficiency (OEE) of in excess of 73%. All interactions, both internally and externally, are conducted within the relevant legislation as well as internal safety drivers.

OperationThe quarry produces a wide variety of aggre-gates including 53 mm ballast, 53 mm concrete, 37 mm, 26,5 mm, 6,7 mm, scour (armour rock), selected first crush, G2, G4, G5 and G7. In addi-tion, it also produces 19 mm, 13,2 mm and 9,5 mm which can be supplied washed on request.

The quarry has an A plant and a B plant. The A plant comprises a primary crusher (Allis Chalmers 3655) which produces between 500 and 700 tph and is fed into the intermediate stockpile. A series of crushers and screens that can be adjusted to optimise the required production requirements from the market follows with the final products being either discharged into product bays or load out bins. There is an option to recrush non-saleable product on the recrush circuit, using a 3,0’ stan-dard Symons crusher and the 36” Gyradisc crusher which can break 26 mm aggregate down into smaller aggregate.

The B plant utilises a 3042 Osborn jawcrusher which produces 250 tph of base material, together with the 1144 Omnicone crusher and screen.

All products are regularly tested in the quarry’s onsite laboratory and if there is any non-confor-mance, measures are immediately taken to rectify the issue. Normally one sample in every 500 t of product produced is tested, but whenever plant changes are made or specialised products, such as roadstone, are required, the laboratory undertakes more regular tests on samples. In addition, samples are sent to an independent laboratory for regular testing to ensure complete correlation.

The quarry was extremely busy during 2013, supplying 120 000 t of 50 and 200 kg scour to the project for widening the Durban harbour as well as ongoing G5 and G7 base course material to the Umgeni Road Interchange project. Coedmore has been able to supply to several fixed address cus-tomers such as asphalters and readymix opera-tions for a number of years. UTFC (ultra thin friction course) seems to be the road engineer’s product of choice and a steady flow of road stone orders have been received over the years. Together with a number of smaller projects, the quarry supplied over 1 000 000 t of product last year. Jaganaikulu says that there are a number of projects in the pipeline, including the construction of the taxi and bus lanes, in which AfriSam hopes to be involved.


AT THE QUARRY FACE

Drilling operations taking place using the new approved safety barrier system.

Implementation of the safety berms at Coedmore.

The plant receives regular maintenance and impact beds were recently fitted to all conveyors to prevent spillage and extend conveyor belt life. “We also galvanised a number of sections on convey-ors throughout the plant as corrosion in KwaZulu-Natal is an ongoing issue. We have installed new walkways between the screening towers to ensure ease of access and electrical upgrades have been undertaken on the substations. We are currently busy emptying the old reservoir and we are replac-ing it with a new reservoir,” says Jaganaikulu.

Other work includes the diversion of the Londonspruit and the removal of rock from under-neath the belt conveyor to provide haulage trucks with easier access via a new underpass. Plans are underway to move the workshop to provide access for further quarrying and the repositioning of the input crusher to extend its life.

The quarry operates two Volvo LT150G 25 t front-end loaders for sales loading and Acme Plant Hire is the load and haul contractor. This includes one Hyundai 50 t and one Volvo 38 t excavator, five Volvo 30 t ADTs, a Hyundai 25 t front-end loader and an 18 000 ℓ Bell water truck, all on A Plant. B Plant uses a 30 t Volvo excavator, two 30 t Volvo ADTs, two Hyundai 25 t front end loaders and an 18 000 ℓ Bell water truck.

Coedmore Quarry boasts a number of employ-ees with long service records. According to pro-duction plant supervisor Kopano Pitso, the success of the quarry is built on the incredible team spirit engendered by AfriSam. “I started as a truck leveller then became a machine operator. I have worked on all the loading equipment and ADTs within the

plant, I have done a stint in the workshop and I am now in a supervisory position. AfriSam believes in providing their employees with opportunities for career growth and development. All that you need to bring to the table in return is passion about what you are doing, a willingness to learn and the ability to adopt the company’s health, safety and environ-mental policies.”

The AfriSam credo ‘Building our future together’ is very evident in this highly-productive quarry, which is characterised by the perfect bal-ance it maintains between safety, environmental stewardship, customer and contractor relations, and quality output. MQ

www.barloworldpower.com


ASPASA UPDATE

While much of the workshop was focused on new legisla-tion and best practices, Cluett

also took the time to explain the impor-tance of effective environmental planning to drive environmental policies within companies.

Addressing an audience which included members from most of the country’s top quarry operators, he points out that by simply planning ahead and aligning environmental management systems (EMS) with these plans, quarries can extract the required riches from the earth, while simultaneously rehabilitat-ing their properties in line with the next planned land use.

With an eye on the future, Cluett says in most instances, this type of rehabili-tation costs nothing or very little extra, and can be budgeted for right from the outset. “As long as the rehabilitation is done in line with legal requirements, and complies with all the stipulations of the mining licence granted to the mine, then concurrent rehabilitation is usually the best way to go.

“For example, quarries can be stabi-lised and prepared to be used as large-scale property developments where the quarrying activity actually comprises the necessary earthworks to level an area for development,” he explains. “Or deep quarries can be stabilised and prepared to become dams and water reservoirs to sustain surrounding communities. Shopping centres, landfills, recreational areas or farmland, etc; there are hundreds of different uses for quarries once they are closed.

“Planned concurrent rehabilitation of land also allows owners to constantly

Visionary environmental planning is required

Mining operations should be viewed as temporary land users, and owners should have long-term plans to develop properties far be-

yond the mining phase, in order to enhance surrounds and benefit local communities. This is according to environmental specialist Alan

Cluett, who was speaking at a specially convened workshop, held in Randburg recently.

assess their efforts and it gives them time to react to any unforeseen prob-lems. Similarly, it gives vegetation time to establish itself and ground time to stabi-lise, which ultimately makes it easier for inspectors to assess and issue certificates of closure,” Cluett confirms.

Concurrent rehabilitation and other environmental best practices are actively encouraged by Aspasa, and he appeals to other roleplayers to become involved with the industry association to ensure sustainability for the future.

“When done right, environmen-tal management saves millions of rand and benefits everyone in the loop. As a committed industry association, Aspasa helps by providing members with all the required checklists and information to develop individual EMS systems. It also provides the documentation needed to help implement Aspasa’s own, spe-cially-developed EMA, which is based on ISO 14001.

“Whether we choose to be vision-ary in our thinking about protecting the environment, or simply comply with the legislation of the day, it pays to plan far ahead and try to visualise the impact of our actions in years to come,” Cluett says. “We have got to learn that the more effort we put into planning a mine at start up, the easier it is to maintain and rehabilitate it at the end of its profitable life.”

By joining Aspasa and being accred-ited on its About Face programme, quar-ries are able to access information from global experts and peers on the latest developments in progressive planning, as well as gaining access to the Association’s industry-specific EMS, policies, proce-dures, related resource and more. MQ

Proper environmental planning can save companies millions, says environmental specialist Alan Cluett.

Rehabilitation at its best. Bass Lake in Henley-on-Klip consists of a 10 ha body of spring-fed water. Considered by the top certifying agencies (PADI, NAUI, SSI, CMAS, IANTD) to be the best Scuba Training venue in South Africa. Depths vary from a walk-in slope to 23 m at the deepest point.


PRACTICAL GUIDE FOR BLASTING

This manual has been drawn up as a practical guide for everyday drill-ing, blasting and mining activities.

Blasting is a demanding job and is dan-gerous by nature. The blaster’s position carries a lot of responsibilities and is gov-erned by the Mine Health & Safety Act and the in-house procedures for drilling and blasting at an operation, and by the Explosives Act.

The blaster is in complete control of the entire blasting process and must be present at all times until the final guard has been removed.

The efficient and optimal running of a mine depends a lot on the blast results. If the blast is good, then the rest of the operation will run smoothly and effi-ciently. A good blast will result in high production rate and low maintenance costs with good availability of equipment.

A good blast depends on the follow-ing steps:• knowledge of the geology and rock

type;• competence and experience of the

rockbreaker/blaster;• blast design. Use guidelines and tech-

nical advice from your explosives sup-plier to assist in the design;

• drilling accuracy; and• charging of the blast with attention to

detail.Loading out a poor blast can lead to poor production, operator fatigue, accidents and incidents.

The technical aspects are covered in the Xtract courses for the rockbreaking qualification and include the following: geology and rock properties; surface mine machinery; introduction to explosives; initiation systems; blast layouts; drilling;

special blasting techniques; environmen-tal and health; procedures and safety; transport and storage of explosives; and blast layouts and calculations.

Duties of a blasterA blaster is expected to carry out the fol-lowing duties:• Do a daily pre-entry quarry inspec-

tion and enter findings into a ganger’s report.

• Prepare benches for drilling.• Install bench marks.• Mark holes for drilling.• Calculate mark on last rod.• Check holes for accuracy.• Calculate tons blasted.• Supervise drilling operations.• Design blasts.• Prepare blasting and other reports

that may be required from time to time. The blast report should include the following information: number of holes; hole diameter; face height; hole depth; subdrill; burden; and spacing and stemming length.

• Ensure that the quarry standards are followed.

• Ensure compliance with the MHSA.• Schedule blasts.• Order the correct amount of explo-

sives and accessories for the blast.• Set up vibracorders. The monitoring

report should include: date and time; serial number; PPV trigger level; air-blast trigger level; and location and distance from blast.

• The analysis report should include: radial PPV and frequency; vertical PPV and frequency; transverse PPV and frequency; and vector sum and airblast level.

• Set out guards for the blast and ensure no-one is in danger of being injured by the blast.

• Execute the blast.• In some operations, the rockbreaker/

blaster will also supervise the load and haul fleet.

Procedures affecting a blaster’s duties• Establishing the face height with a

tape measure.• Determine and install a bench mark.• Installing a bench mark using sur-

veyed elevations.• Determine hole depth to be drilled

using a bench mark and dumpy.• Calculate mark on last rod to be

drilled.• Change bench mark due to uneven

floors.• Drilling from a bench mark.• Check holes for accuracy.• Six steps to prime and pump a

blasthole.• Calculate tons blasted.

Blaster duties –Design a blastBlasting is not an exact science; therefore one needs sound judgement and obser-vation to design a good and safe blast. Geology plays a very big part in blasting and, if not taken into account, it can have serious consequences. Good information on the geology can be obtained from looking at the drill chips, looking at the free face and studying the results from previous blasts. Furthermore, the group, Mining Services, can assist and reference can be made to the slope stability COP.

In designing a blast, the following steps must be taken:• Identify the area.• Observe geology.• Identify rock type and density.• Establish distance to the nearest

structure and neighbour.• Decide on type of explosives to be

used. The choice of explosives will normally depend on wet or dry holes and what type of energy is required.

• Calculate and decide on stemming height.

• Decide on type of initiation sys-tem. The choice of initiation system depends on what level of timing accu-racy is required and the importance of

Practical guide for blasters – Part Iby Henry Terblanche

Henry Terblanche, who ‘retired’ from AfriSam some two years ago, is still very much involved in the industry. He has a wealth of experience and his

input and knowledge is an invaluable resource to an industry which is battling with a lack of skills in many instances. Mentorship from people of

his calibre is vital if our young quarrymen are to continue the legacy left by people of his ilk. In this regular feature, MQ will be publishing a series of

practical guides, written in simple and easy to understand terms, which we believe will benefit our up and coming blasters.



blast vibration control.• Decide on hole diameter. The choice

of hole diameter will depend on bench height, vibration restrictions and equipment available.

• Calculate and decide on burden and spacing. Burden and spacing in turn will depend on face height and hole diameter. Remember that smaller hole diameters will result in a better and more even distribution of explo-sives in the rockmass. However, a small hole diameter can easily result in blockages by small stones. Give special care when calculating the cor-rect burden. A too small burden can cause severe flyrock due to face burst-ing and early venting of the first row of holes. A too big burden can choke the blast and restrict rock movement.

• Decide on inter-hole and inter-row delays. Inter-hole and inter-row will again depend on burden and spac-ing and all the above will depend on rock type and hardness. A blast where all the ratios are correct to suit condi-tions can still result in a poor blast if the timing is inaccurate or an incor-rect delay is used.

• Design blast using the above informa-tion. Blast design has everything to do with correct rations to ensure the effi-cient use of explosives and controlled blasting.

Progressively reducing the burden to the back of the blast is a good mea-sure to control backbreak; improve loadability, as there is more energy in the back where it is needed; and improve floor conditions while main-taining the same powder factor.For example:

Blast 1 with four rows

Blast 2 with four rows

Spacing = 3,0 m Spacing = 3,0 mBurden 1 = 2,5 m Burden 1 = 2,8 mBurden 2 = 2,5 m Burden 2 = 2,6 mBurden 3 = 2,5 m Burden 3 = 2,4 mBurden 4 = 2,5 m Burden 4 = 2,2 mAverage burden = 2,5 m

Average burden = 2,5 m

The small burden on row four will have a post-split effect

Marking of drillholesBefore marking the face, the design must be completed.

• Remove all loose material by an exca-vator or front-end loader.

• Check for overhangs, overbreaks and geological discontinuities in the face.

• Establish the position of the first row by working off a baseline installed with the previous blast and observing overhangs, overbreaks and geology.

• Rock type, hole diameter and face height must be used to determine burden and spacing.

• Proceed to marking the rest of the face.

• Make a sketch of the layout of holes.• Use a dumpy and bench mark to cal-

culate the depth of each hole.

Charging the blastGroundwater plays a major role in the way a blast is charged up and also the selec-tion and type of explosives. Therefore wet holes must be clearly marked and indi-cated to the pump-truck operator. A blast plan must be given to the pump-truck operator.

The following must be recorded on the blast plan: all deviations from the blast plan; estimated explosives for each hole; estimated explosives for complete blast; total tons to be blasted; actual explosives used; and location of the blast.• Lay accessories out as per blast plan.• Assemble booster and detonator

units and lower into holes.• Mark wet holes.

• If hole is wet, push delivery hose to the bottom of the hole. This will ensure that the booster is pushed all the way down with the pipe.

• Lift the delivery pipe 500 mm above the booster position to prevent the booster being pumped up.

• Pipe operator to signal the pump operator to start pumping. Good coor-dination is needed between the pipe operator and the pump operator. The pipe operator must feed the pipe out of the hole at the correct speed. If he feeds too fast, water gaps can result in the hole. If he feeds too slowly, the emulsion can overtake the pipe in the hole. Correct pumping speed is very important.

• If the hole is dry, it can be pumped from the collar of the hole.

• Pump operator must pump as per estimated kilograms of explosives on the blast sheet. If there is a variance of more than 5,0 kg, pumping must stop immediately and the blaster in charge notified to reassess the hole.

• The pipe operator must signal to the pump operator if the indicator mark on the pipe is coming out of the hole.

• The blaster will calculate column rise before gassing; check the hole and adjust the mark on the pipe, if required.

• Complete charging the blast in sequence.

Table 1: Six steps to charge blasthole.



• Cup samples must be taken at regular intervals for quality control.• Provide enough time for gassing and check for stemming height.

Take into account that the explosive column will rise as gassing takes place.

• Top up undercharged holes, but never more than the design kg/hole.

• Remove excess explosives from overcharged holes with the sucker pipe. The correct stemming length is very important as too much stemming can lead to oversize and too little stemming can lead to flyrock.

• Tag blast if it is an electronic blast.• Install stemming using the correct method.• Connect the harness wire if it is an electronic blast.• Notify all affected parties of the blast time.• Set up the vibrocorders. The correct use and proper set-

up is very important for accurate and valuable readings.Each blast should be evaluated, and with time and good judgement, come up with an optimum blast design for the operation. Attention to detail will ensure a well-fragmented and controlled blast.

Install bench marks• Determine the correct face height at a specific spot and

mark the spot.• Set up the dumpy.• Shoot a staff reading at the marked spot.• Add the staff reading plus the face height plus the over-

drill required. The result is the bench mark.• Swing the dumpy over and shoot a mark on the adjacent

face or planted drillrod and mark with a painted line. The result of the staff reading plus face height plus required overdrill.

Drilling from a bench markThe following procedures are required:• Set up the dumpy at a convenient place for drilling, ie in

order for the drill mast and bench mark to be seen from the dumpy. Make sure that the dumpy is level and stable.

• Move the dumpy up or down until the indicator line cor-responds with the bench mark.

• Calculate the mark on the last rod and paint or tape the mark.

• Set the drillrig up on the first hole to be drilled.• Shoot the bench mark onto the drillmast and mark.• Drill the full rods required.• Install the last rod and drill until the mark on the last rod

corresponds with the mark on the drillmast.• Move the rig to the next hole and reinstall a new mark

on the drillmast.If the mark on the last rod is below the mark on the boom before drilling commences, a lower bench mark needs to be adopted, and a new mark calculated on the last rod. It may be necessary to remove one complete rod. If a mark cannot be obtained on the boom due to the boom being too high, use a higher bench mark and recalculate the new mark on the drillmast. It may be necessary to add an extra rod.

To calculate the mark on the last rod to be drilled,

Bench mark = 12 m

Rod length = 3,7 m

Therefore you will need 12 m/3,7 m = three full rods

To calculate mark on last rod = three rods x 3,7 m = 11,1 m

Therefore 12 m/11,1 m = 0,9 m on last rod to be drilled

Table 2: Determine and install benchmark.

www.jvtvibration.co.za



determine how many full rods must be drilled. Add the length of the rods together and deduct the sum from the bench mark. The result of this calculation is the mark on the last rod. For example:

It is very important that the holes are drilled accurately. If the holes are not drilled to the correct position and direction, it can lead to under or overburdening with poor blast results and possi-ble flyrock. Holes that are not drilled to the correct depth will result in uneven floors and difficult loading out with loss of production.

Special attention must be given to charging instructions, record-keeping, loading of the blastholes and proper gassing before stemming.

Part 2 will cover changing the bench mark due to uneven floors, in the next issue of MQ.

About the authorHenry Terblanche tells MQ that he ‘retired’ some two years back and started work-ing again for two reasons. “The first is that Marianne sent me back to work until I could prove to her that I was able to sit still for one day – a test I failed badly; and the second reason was at the request of AfriSam and other companies.”

He started off in 1964-1967 as a learner miner at St Helena Gold Mines, moving on to Cossiante & Santucci between 1967-1968 as tunnelling blaster, shutter hand and erector. In 1969, Henry worked at Alpha Stone’s (now AfriSam) Effingham opera-tion as a blaster, with responsibilities for dimensional stone-making and farming. He returned to Cossiante & Santucci from 1969-1971, where he worked as tunnelling shutterhand and erector, and development blaster.

Henry moved on to Hippo Quarries (AfriSam) in 1972 through to his ‘retirement’ in 2012, firstly as blaster at Effingham; blaster at Coedmore; plant foreman at Coedmore; subordinate manager at Effingham; quarry foreman at Coedmore; and pro-duction superintendent at Coedmore.

All in all, he has spent some 40 years in the opencast min-ing industry working for AfriSam, “plus overtime,” he says with a smile; and three years in the construction industry working for various construction companies.

Henry’s qualifications include, among others: Diploma Surface Blasting Technology; N3 Surveying; N3 Mining Machinery; N3 Geology; and N3 Opencast Mining. He is also an ETDP Seta -accredited facilitator and evaluates learning NQF:5.

Table 3: Drilling from a benchmark.

www.hosch-international.com

www.elbequipment.com

AROUND THE INDUSTRYPLANT and

EQUIPMENT SOLUTIONS


At around the time that Bell Equip-ment held its E-series launch in Johannesburg in mid-2013, curi-

ous onlookers were greeted by the sight of a bright yellow ADT as it wound its way from Bell Equipment’s Cape Town Cus-tomer Service Centre to the Ciolli Bros Potsdam quarry site.

Tony Ciolli manages the quarry and works with his cousins Vincent and Stephen, the latter who manages the readymix concrete side of the business.

Rapid response is keyPilot Crushtec International pulled out all the stops when it delivered a new Sandvik QJ331 jaw crusher in just 24 hours from receipt or order to Seneca Civils, a large contract and hire company based in Johannesburg’s northern suburbs.

“We hold strategic stock of this product and our Sandvik-trained installation team immediately conducted a full pre-delivery inspection before collection and deliv-ery,” says national sales manager Nicolan Govender, adding that an additional

purchase motivation was productivity.The Sandvik QJ331 is ideal for larger

scale contracts and is a natural partner for the customer’s Sandvik QA331 mobile screen bought in October 2013.

The company recently sold a Sandvik US440i heavy-duty cone crusher to Britanor, a construction company based in Cuamba, northern Mozambique. In partnership with Sandvik, Pilot Crushtec International trav-elled to the site in Mozambique to ensure the crushing plant’s optimal performance.

According to sales manager Wayne Warren, installation and commissioning took place without a hitch at the quarry site. “This further reinforces Pilot Crushtec International’s claim that it supplies prod-ucts and services to meet African conditions and, no matter where the plant is, we will support the equipment.”

www.pilotcrushtec.com

Ciolli Bros supplies stone aggregates and sub-base material to the civil and road construction industries within a 30 km radius from the Potsdam operation as well as further up the West Coast.

“We first bought a used Bell B20C ADT with about 6 000 hours on its clock in 2005,” Tony says. “The Bell ADT really earned its keep and gave us a further 14 000 hours of service before its engine was overhauled.”

Operating a typical drill, blast, load and haul operation, the quarry’s longest haul is about 1,5 km to the primary crush-er’s tip, up ramps that are not steeper than 1:10.

“We operated for many years using rigid tipper trucks but once we got to expe-rience the better traction and load capabil-ity that ADTs give us, there was no looking back,” he says. “The Cape’s wet winters have no mercy for underfoot conditions and the Bell ADTs simply don’t get stuck.”

Increasing production demands cre-ated the need for bigger payloads and in 2006 Ciollo Bros bought its first new Bell B30D ADT and a year later, another one. These machines have done between

When brothers Anthony and Vincenzo Ciolli started a quarry in Cape Town back in 1951, little could they know that the third generation of their family would, in 2013, be the first owners in the entire Western Cape to take deliv-ery of a brand new E-series articulated dump truck, which heralded a whole new range for a market-leading manufacturer.

Ciolli Bros takes first E-series ADT in WCape

In addition to the new B30E, Ciolli Bros operates two Bell B30D ADTs. Retrofitted with greedy boards to increase their capacity, these units have each clocked between 15 000 and 18 000 hours, while delivering consistently good mechanical availabilities.

Julian Hoorn, Ciolli Bros quarry manager; Louis Fontini, Ciolli Bros mechanic; and ADT operator Pieter Michaels, in front of the company’s new B30E trucks, the first Bell E-series to be delivered in the Western Cape.

15 000 and 18 000 hours each and are now being overhauled. They had been retrofitted with greedy boards to increase their capacity, but despite this, still deliver consistently good mechanical availabili-ties while only using 13,5 ℓ/diesel an hour.

“In this business, total control of pro-duction costs is very important, and that is why we have opted to go the Fleetmatics route,” Tony confirms. “We’re excited about our new Bell B30E-series ADT as we’ve had it fitted with the Bell Fleetm@tic Limited package to give us instant feed-back on hours worked, fuel consumption, distance travelled and tons of material moved. This information, coupled with Bell Equipment’s improved drive and electronic systems, should give us lower product cost-per-ton of material moved.”

Asked why the company has stayed with ADTs manufactured and maintained by Bell Equipment, Tony is adamant that product reliability and relationships play an important role. “Bell Equipment’s ADTs have been designed and built in Africa, for African conditions, and even though our first Bell ADT was a used model, we’ve built solid relationships with Bell as they under-stand our business and what we’re about,” he says. “We’ve learnt that by investing in Bell machines, we can look forward to many years of service judging by the high hours our earlier Bell fleet has given us.

The ADTs owned by Ciollo Bros are serviced by mechanics from Bell’s Equipment’s Cape Town Customer Service Centre while still under warranty, and the company is well satisfied with levels of service such as response times and parts available. Ciolli Bros also operates a Bell 1206 haulage tractor that hauls an 18 000 ℓ tanker which is used to dampen down the haulroads and loading plat-forms. www.bellequipment.com

January - February 2014 MODERN QUARRYING 37

PLANT and EQUIPMENT SOLUTIONS

Blast design made simpleExplosive’s company BME has developed an innovative applica-tion which provides a quick and simple way of calculating a pow-der factor, checking charge mass per hole, estimating vibration at a point or even working out the cost of a blast. Called the BME Blast Calculator, it is aimed at providing straightforward, speedy solutions to blast design difficulties for clients who do not have access to BME’s advanced blast design software, BlastMapIII.

“The Blast Calculator also provides suggested design values. For example, if you enter a hole diameter of 250 mm, the applica-tion will suggest a stemming length of 5,0 m,” says BME technical director Tony Rorke. “Similarly, a burden of 7,0 m will return a sug-gested spacing of 8,05 m. If you don’t like the suggested values, it is easy to just over-type them with your own.”

The blast calculator application is available for use from www.bme.co.za or www.mobi.bme.co.za.

Screening media with value-addsFLSmidth is the largest manufac-turer and distributor of screening media surfaces in the southern hemisphere, offering an innova-tive spectrum of proven prod-ucts and new technologies, designed to reduce cost per ton and increase revenue.

“O u r co m p e t i t i ve e d g e derives from the added value we’ve built into our extensive product range, David Sibley, FLSmidth’s GM of Screen Media says. “We’re the only company in the local market manufacturing a complete range of screening media products that each carries individual ISO accreditation. Underpinned by FLSmidth’s process knowledge based and ongo-ing R&D, we’re able to support not only the screening media in customer applications Africa-wide, but also the complete screen systems. This offer is unique in the region.

“As part of our commitment to mitigating plant downtime and optimising processes, and in keeping with our core phi-losophy of being a single-source provider, we’re playing an increasingly active role in the operation and maintenance of our equipment at customer sites throughout the lifetime of the equipment,” Sibley confirms. “Selecting the most appropriate screening media for a given application requires a high level of skill, while precise installation of screen media and maximum product availability are also very important to mitigate costs.”

He says the company’s field service team is in high demand, with team members trained to conduct plant surveys that deter-mine the cost per ton and to work alongside customers to reduce costs, resolve issues and increase operating efficiencies. They also support maintenance contracts, offer site-specific solutions and are able to do any necessary repairs, provided the appropriate spares are at hand. “Inventory management is part of this service and we can help plant personnel with their planning, to ensure that the necessary spares are ordered in good time.”

www.flsmidth.com

FLSmidth is the only company to manufacture wire conveyor belts.


AROUND THE INDUSTRYPLANT and EQUIPMENT SOLUTIONS


BLT SA, the exclusive distributor in sub-Saharan Africa for bulk materials han-dling equipment manufacturer Samson Materials Handling Limited – supplies an extensive range of fixed and mobile conveying equipment to diverse sectors, including mining, agriculture, shipping, transport, power and general industry.

New to the range are telescopic con-veyors for radial telescopic stacking and

Belt rip detection increases productivityBecker Mining South Africa has launched its new BRS-2 belt rip detection system, designed to increase the productivity of con-veyor belts by detecting belt rips as soon as they occur.

“This belt rip detection system, which is based on the highly-efficient design of the original BRS-1 system, is used to detect longi-tudinal rips on steel cable and fibre conveyor belts,” says Johann Smit, chief sales officer for Becker Mining South Africa. “The BRS-2 uses real-time loop diagnostics to continuously monitor the status of the belt and, in the event of a rip, stops the belt drives, reducing further damage and minimising downtime.”

This advanced belt rip detection system is designed for use in diverse industries, includ-ing manufacturing, food and beverage con-veying, packaging and mining applications.

www.za.becker-mining.com

D esigned for use in low to moderate impact applications, Caterpillar ’s new General Duty product line – a form of Grease Lubricated Track (GLT) – provides a cost-effective alternative for medium-size machine owners and was specifically developed fol-lowing extensive global research. Essentially, General Duty is built as a ‘run to destruction’ undercarriage, although in some circumstances a turn can be completed.

Customers now have the option of specifying either a General Duty or Heavy Duty undercarriage, depending on job site demands and the requirement for extended wear life. Both products are covered by Caterpillar’s Undercarriage Assurance Programme (three years or 3 000 hours for General Duty, and 4 000 hours or four years for Heavy Duty).

“While General Duty undercarriage is a new product, it is not a new design,” explains Barloworld Equipment group product specialist Deon Delport. “In fact, General Duty undercarriage is built on the same principle as the Sealed and

Match the track to the application

Lubricated Track (SALT) system developed in 1974.”

Essentially, General Duty offers another alternative to help customers balance product performance and cost, where the extra rugged durability of Cat Heavy Duty undercarriage is not always required. However, for extreme conditions such as forestry or waste handling or where high abrasion, impact and packing occur, Heavy Duty remains the best option. Other fac-tors to consider include high machine usage, shoe width and grading.

“General Duty and Heavy Duty are not built to the same performance speci-fications,” Delport expands. “However, the quality and reliability are the same in the intended applications.”


Grease Lubricated Track (GLT).

Fixed and mobile conveyor equipment rangetracked Stormajor® boom feeders. The new boom feeder BF0415T, which is an advancement of the wheeled system to the tracked version, improves perfor-mance, reliability and manoeuvrability. This machine, with a 15 m boom length and a maximum capacity of 1 000 tph, is designed for efficient stockpiling, barge loading, shiploading and rail wagon loading.

The boom feeder operates safely and efficiently in all conditions, even in ardu-ous environments. Tracked Stormajor boom feeders have been designed for utilisation with ADTs up to 30 t capacity, road tipping trucks hauling 30 t trailers, and wheel loaders with a bucket capacity of up to 8,0 m3.

www.biglifttrucks.com

www.alcoholtesting.co.za

Conference Programme

Thursday 10 April07:45-08:10: Aspasa AGM08:00-08:30: REGISTRATION – TEA AND COFFEE08:30-09:00: IQSA AGM09:15-09:30: Welcome by IQSA and Aspasa chairpersons Best Paper award for 201309:30-10:30: Keynote Speaker – David Grier

10:30-11:00: EXHIBITION OPENING – TEA AND COFFEE

11:00-11:10: IoQ UK President – Colin Jenkins11:10-11:20: IoQ Australian President – John Stanton11:20-11:30: IoQ New Zealand President – Gordon Laing11:30-11:40: IoQ Hong Kong Chairman – David Hogan 11:40-11:50: IoQ Malaysian President11:50-12:10: Question Session for International Presidents12:10-12:40: Institute of Quarrying worldwide overview –

IoQ UK – Phil James

12:40-13:30: LUNCH

13:30-14:00: Diesel Update – Freek van Rooyen, Shepstone & Wylie

14:00-14:30: Global Trends and Evolution of Tracked Mobile C&S – Neil McIlwane, Terex Finlay

14:30-14:00: Pump Selection: System Resistance Curve Calculations – Edwin Swanepoel, AfriSam

15:00-15:30 TEA AND COFFEE

15:30-16:00: From Fire Setting to Electronics – Simon Tose, AEL

16:00-16:30: Digital Health and Safety – Adrian Damant, ATK IT

16:30-16:40: History Book – Institute of Quarrying16:40-17:00: Aspasa awards

19:00: DINNER: MAYO – SPIER, STELLENBOSCH

Friday 11 April08:20-08:30: Announcements by chairperson08:30-09:30: Keynote Speaker – Daniel Silke09:30-10:00: Materials Testing and Downstream Quality –

Johan van Wyk, Sarma10:00-10:20: Redressing the Past Imbalances through the

Social Labour Plan - Nondumiso Radebe, Lafarge Mining SA

10:20-11:00: TEA AND COFFEE

11:00-11:30: Mining in South Africa – Roger Baxter, Chamber of Mines

11:30-12:00: Control of Aggregate Sizing using Visual Analysis – Edgar King, Split Engineering

12:00-12:30: Louis Bezuidenhout, DMR Principal Inspector of Mines, Western Cape Region

12:30-13:00: RAFFLE and EXHIBITION AWARDS

13:00-13:30: LUNCH

13:30: EXHIBITION BREAKDOWN

Please contact Terry Pop at the IQSA for further detailsTelephone: (011) 704 5037E-mail: [email protected] Website: www.iqsa.co.za

Celebrating 45 years in Southern AfricaInstitute of Quarrying 45th Conference and Exhibition

Incorporating Aspasa10-11 April 2014


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2013/2014 DirectorsChairman: Glenn JohnsonDeputy Chairman: Dennis OosthuizenDirectors: Piet Booysen Deon Bosman Gert Coffee Marcel Fynn Terry Gillham Stephen Marx Lazarus Meko Felix Motsiri Nico PienaarSecretary: Terry Pop

Institute of Quarrying Southern AfricaPO Box 6068, Cresta 2118Tel: +27 11 704 5037 Fax: +27 11 704 3323Email: [email protected] Web: www.iqsa.co.za

AEL Mining ServicesStand 5AEL is a world-class mining services company with global tech-nologies that create wealth and growth in South African, African and selected international markets. Consisting of a capable team of leading explosives services, engineers and scientists, AEL has over a century of expertise and knowledge in developing ground-breaking and innovative blasting solutions that contribute to the creation of infrastructures in countries throughout the world. AEL unearths wealth by meticulously providing the mining industry with carefully-controlled energy.

AEL’s proven capability of deploying infrastructure to global standards in a fast turnaround time, coupled with the expertise to rapidly develop customised premier products to suit specific applications and mandatory quality standards, gives the group a competitive edge in expanding into new markets.AEL Mining ServicesTel: +27 11 606 000www.aelminingservices.com

ALCO-Safe (Pty) LtdStand 11ALCO-Safe is the foremost supplier of quality electronic breath alcohol detectors and accessories in South Africa with 43 years of industry experience. In addition to the mining and quarrying sec-tor ALCO-Safe supplies drug- and alcohol-detecting equipment to major industry.

Only professional grade instrumentation is distributed. ALCO-Safe (Pty) Ltd represents Lion and CMI, world-leaders in alcohol detection technology as well as Concateno, whose business is directed at various aspects of drug and other forensic testing.ALCOHOL TESTING EQUIPMENT: Lion Laboratories pioneered the fuel cell breathalyser, making it possible for police and companies to test persons accurately and fairly in the shortest amount of time. Lion Laboratories won the Queen’s Award for Technological Achievement for the product in 1980. Lion contin-ues to be a world-leading manufacturer of breath alcohol testing equipment. ALCO-Safe is the sole distributor of Lion breathalys-ers in South Africa.DRUG TESTING EQUIPMENT: ALCO-Safe is the South African dis-tributor for the organisation Concateno UK Limited, a grouping of several companies, which is Europe’s largest and most experi-enced provider of drug testing products and services. Concateno is the manufacturer of the DDS2 saliva drug testing instrument, the most user-friendly digital drug tester available.

In addition to the above, we offer the following: Operator competency training for breathalysers and drug testing equip-ment; substance abuse awareness presentations; assistance in developing substance abuse policies and control programmes; full repair capability; and information backup.ALCO-SafeTel: +27 12 343 8114www.alcosafe.co.za

Atlas Copco Mining and Rock Excavation TechniqueStand 9When it comes to mining, Atlas Copco Mining and Rock Excavation Technique is able to offer a wide range of capital equipment that fulfils a variety of needs in the mining industry. We supply an extensive range of drills and drillrigs for surface, underground and exploration applications; as well as for trackless equipment such as load-haul-dumpers and trucks, and develop-ment drillrigs for underground use.

In SA, the Mining and Rock Excavation business area operates through six divisions: Underground Rock Excavation; Surface and Exploration Drilling; Drilling Solutions; Rock Drilling Tools; and Mining and Rock Excavation Service.

With our head office in the East Rand, the company has a nationwide presence with branches in Rustenburg, Lydenburg, Steelpoort, Middelburg, Kuruman, Kimberley and Springbok.

Atlas Copco South Africa recently relocated to a new, world-class, state-of-the-art facility occupying a total land area of 78 000 m2. The new building is strategically located in Jet Park, east of Johannesburg, within close proximity to OR Tambo International airport.

The substantial investment made by our Sweden-based par-ent company into the establishment of Atlas Copco House, shows strong commitment to and confidence in South African and cross-border business, mining and industry. The company plans on making use of all the capabilities offered by the new facility to full capacity, to deliver world-class product and service solutions for sustainable productivity.Atlas Copco MRTel: +2711 821 9000www.atlascopco.com

Institute of Quarrying 45th Conference and ExhibitionExhibitor listing


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AutoTech Weighing SystemsStand 6Autotech is a specialised weighing company serving industry, mining and quarrying throughout SA, will full SANAS accredita-tion for legal and trade (assized) equipment. Autotech is the sole agent for:TAMTRON: The largest manufacturer and supplier of dynamic on-board weighing equipment worldwide. Tamtron on-board scales are designed to enable accurate weighing during loading. The weighing performance is dynamic allowing for operation in all conditions. The state-of-the-art on-board weighing instru-mentation compensates for variations of moving speeds and unevenness of ground. The weighing equipment can be fitted to wheel loaders (FELs and LHDs), forklift trucks, haul trucks, etc. The Tamtron Power and PKV Pro+ wheel loader scales have NRCS approval for use in trade.RAILWEIGHT AND WEIGHLINE: Railweight is division of the world-leading weighing company Avery Weigh-Tronix. Railweight has the largest number of in-motion rail weighing installations in global operation and has supplied systems to SA for over 40 years. When coupled with Railweight’s Weighline rail transducers, the Railweight in-motion weighing system has full SA approval for the weighing of individual trucks in a train at speeds up to 80 km/h. Railweight’s Streamline in-motion rail transducers offer a low-cost, high-performance check weighing solution specifically developed for both underground and surface mining conditions.Autotech Weighing Systems (Pty) LtdTel: +27 11 794 2939www.autotechonline.co.za

BMEStand 1BME is a member of the Omnia Group, a listed company consist-ing of an agricultural, chemical and mining division. BME supplies and manufactures a full range of underground and surface emul-sion products, initiation systems, cartridge explosives, PGAN, emulsifiers and related accessories. Today, BME has operations in most African countries and will continue to expand to where opportunities present themselves.

BME prides itself in providing world-class technical services to our customers and our value-add services include down-the-hole, full blasting services, blast consulting, auditing and moni-toring, blast software, mine to mill optimisation, fly rock control, muckpile profiling and fragmentation analysis.

R&D is a cornerstone of BME’s success and regarded as essential in order to find better and more cost-effective blasting solutions. This innovative approach has been with us since the start, when we were the first to introduce cold emulsions into South African opencast mines. Consequently, our HE brand of bulk explosives has become synonymous with high quality and reliability.

Catering for the African market requires security and conti-nuity of supply. To ensure that we provide this to our custom-ers, BME has made considerable investments with two nitric acid facilities, two ammonium nitrate facilities, 13 emulsion plants throughout Africa, a manufacturing facility for cartridge explo-sives, AXXIS™ Detonator plant and an Ammonium nitrate prilling plant. BME is renowned for the rapid supply and commission of

emulsion plants when and where they are required.For explosives, think BME.BMETel: +27 11 709 8888www.bme.co.za

Barloworld EquipmentStand 8Barloworld Equipment is the sole dealer for Cat earthmoving machines and power systems in all its southern African territories – South Africa, Lesotho, Swaziland, Namibia, Botswana, Angola, Malawi, Mozambique, and Zambia. We are also the Cat dealer in the Democratic Republic of Congo’s Katanga Province (in joint-venture with Tractafric Equipment).

Barloworld Equipment’s footprint increased in 1993 when the Cat dealerships in Spain and Portugal were included in our operations.

South-west Siberia was incorporated into our dealership ter-ritories in 1998. This has since been expanded into a dealership 9,8-million km2 in extent and covering six time zones that also includes Eastern Siberia, Yakutia and the Russian Far East.

Today Barloworld Equipment provides a total integrated capability that covers the full spectrum of Cat mechanised requirements for mining, construction and associated industries in all its facets. The Cat mining line-up meets world-class demand for opencast and underground operations in both hard rock and coal development and extraction applications. Allied to these activities, the company represents Metso Mobile tracked and portable crushing and screening plants for construction, quar-rying and mining. Cat, MaK and Perkins diesel engine brands are sold and supported across all market segments, providing an extensive range of industrial, marine and electric power genera-tion options.

Barloworld Equipment has built its reputation and compre-hensive customer base not on selling machines, but on providing solutions.

Barloworld Equipment believes in mutually-beneficial part-nerships with customers. Our strategic planning therefore looks ahead not only to the future of our business, but to the future of our customers’ businesses so that we can continue to provide appropriate, value-adding solutions to meet their equipment procurement and management needs.Barloworld EquipmentCall Center: +27 (0) 800 21 22 48www.barloworld-equipment.com

Bearings InternationalStand 13Bearings International is one of Southern Africa’s leading distribu-tors of bearings and power transmission products. As a customer-focused company, Bearings International has a network of over 50 branches to meet the needs of our customers. These branches are conveniently located throughout all the provinces of South Africa and Namibia. We offer a comprehensive range of world-leading brands covering general and specialist bearings and accessories. For many of these brands we are the sole distributer in South Africa.

Bearings International is active in all major industrial sectors

www.powerstarsa.co.za


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in Southern Africa and offers an extensive range of power trans-mission products including elevator chain, conveyor chain, agri-cultural spares, gear boxes and electric and geared motors.

Our ISO ratings include quality systems, environmental com-pliance, social responsibility and health and safety. We are an accredited Level 2 contributor to Broad Based Black Economic Employment which enables our customers to claim 125% ie (R1,25) of each Rand spent with us as Black spend.

Bearings International offers specialised product training to our customers to ensure they have the optimum understanding of product handling, fitment and maintenance. Our Engineering Division has the capability to design and manufacture to cus-tomer specification, and can offer guidance and assistance on Engineering Projects.

We pride ourselves on maintaining a substantial stockhold-ing of brands across the full spectrum of customer requirements, ensuring immediate availability through our nationwide network of branches.Bearings InternationalTel: +27 11 899 0000www.bearings.co.za

Bell Equipment Company SA (Pty) LtdStand 3Proudly South African original equipment manufacturer Bell Equipment, has been an Associate Member of the SA Institute of Quarrying for over 30 years. During this time the company has grown its range, through strategic partnerships with premium equipment manufacturers, to offer a one-stop shop for the African quarrying industry.

Bell Equipment provides machines ideally suited for all sizes of quarry operations. An extensive range of both excavators and front-end loaders provide equipment for loading while the haul-ing cycle is covered by the comprehensive and well-matched range of above ground articulated trucks from the smaller B20E through to the flagship B50D.

Graders, rollers and stabilisers provide solutions for haul road maintenance and site development. A range of tracked dozers are used at the tip area and for both mine development and rehabilitation.

Our range of mobile crushing and screening plants includes jaw, impact and cone crushers that are internationally renowned for their versatility and flexibility in the reduction and sizing of aggregates for mining and quarrying. Tri-wheeler forklifts and tractor loader backhoes are also popular on quarry and mining sites, being suited to a variety of day-to-day tasks.

As a leading global manufacturer, distributor and exporter, the Bell product range is manufactured locally to world-class quality standards and the company is driven by a passion for providing customers with uncompromising value in both heavy equipment solutions and support.Bell Equipment CompanyTel: +27 11 928 9700www.bellequipment.com

Big Lift Trucks/SamsonStand 20BLT SA, a predominantly female-owned BEE-based company, is

the exclusive distributor in sub-Saharan Africa for bulk materials handling equipment manufacturer, Samso Materials Handling Limited. BLT distributes Samson’s extensive range of fixed and mobile conveying equipment to diverse sectors throughout Africa, including mining, aggregates, agriculture, ports and ter-minals, transport, environmental, and the power industry.

Samson has been designing and manufacturing bulk mate-rial handling equipment for over 45 years and boasts more than 3 000 installations worldwide. The range encompasses link con-veyors, grab hoppers, Samson material feeders, Stormajor boom feeders and mobile shiploaders. Samson equipment ensures flex-ibility and reliability from truck intake, through to stacking and ship loading. The main distinctions of these machines are quality, autonomy and mobility, as well as a wide range of applications. Samson equipment is designed for specific handling require-ments, taking into consideration the widely differing handling characteristics of each bulk material.

BLT SA supports this equipment with a technical advisory, spare parts, maintenance and 24-hour support service. Operator training and a condition-monitoring facility are also provided.

Close international associations set BLT SA aside in a highly-competitive sector and enable the company to offer the local market the latest products and trends. An ongoing, in-house staff and management training programme ensures efficient equip-ment selection, application and repair.BLTTel: +27 31 274 8270www.biglifttrucks.comwww.samson-mh.com

Brooke Pattrick PublicationsStand 7QUARRY SA: Focused on Africa south of the Sahara, Quarry Southern Africa is well positioned to highlight the operational challenges, solutions and business dealings of an industry crucial to the expected infrastructure boom.

As growth and development in the region continues, the magazine stands at the frontline, publishing insightful news and views while highlighting opportunities in a vital sector of the supply chain. It provides business intelligence, comparison and debate about the sustainable extraction, beneficiation and utili-sation of construction materials in southern Africa.Brooke Pattrick PublicationsTel: +27 11 603 3960www.brookepattrick.com

ELB EquipmentStand 10ELB Equipment is one of a few South African companies who can offer the construction, mining and quarrying industries a broad range of world-renowned equipment from a single supplier. Products ideally suited to these industries include:MINING, QUARRYING AND RECYCLING EQUIPMENT: Power-screen mobile screens; Powerscreen mobile crushers; Terex washing systems; Terex mineral processing systems; Terex static and modular crushers and screens; Furukawa drillrigs; Furukawa hydraulic breakers; Furukawa excavator attachments; Telestack tracked telescopic conveyors; Taurus heavy-duty static & mobile

www.volvoce.com


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barrel screens; Dressta bulldozers; M-Range modular plants; McGirr mobile blockmakers; Kiverco recycling systems; CMH con-veyor belting; and Sensortechnik optical belt scalesEARTHMOVING EQUPMENT: Dressta bulldozers; Kawasaki front-end loaders; and Sumitomo tracked excavators.CONSTRUCTION EQUIPMENT: Ammann compaction equip-ment; Sakai compaction equipment; Ditch Witch chain tren-chers; Ditch Witch horizontal directional drills; HammerHead® Mole pneumatic piercing tools; Terex backhoe loaders, Mini/Midi excavators and wheel Loaders; and Mustang skid-steer loaders and telescopic handlers.

ELB Equipment has well-established branches and dealers with a proven track record throughout South Africa and Southern Africa to effectively service its client base. A new branch has been opened in Nairobi, Kenya.

ELB Equipment is a division of ELB Equipment Holdings (Pty) Limited, a JSE-listed company.ELB EquipmentTel: +27 11 306 0700www.elbequipment.com

Eugene Pretorius & Associates (Pty) LtdStand 19Eugene Pretorius & Associates (Pty) Ltd, or EPA Survey as it is commonly known, provides a comprehensive mine survey and technical service to the mining industry. It was established in 1993 and today forms part of the Pretorius Group of Companies, which provides opencast contract mining, exploration core drill-ing, drilling and blasting, and a host of other mining-related ser-vices within the group.

Over the years, EPA Survey has maintained a competitive edge by utilising state-of-the-art technologies such as GPS, robotic total stations, terrestrial static laser scanners, airborne lidar, mile lidar and aerial photography from an unmanned plat-form. These technologies combined, provide a powerful solution for any size project or operation.

The company’s competitive edge ahead is further advanced by a full geological, mine planning and technical service, also employing the latest technology in the form of a Robertsons Geologging wireline logging unit and a Ceasium Vapour Magnetometer.

Qualified surveyors and geologists, as well as highly-skilled and technically-trained staff complement this technology to form an effective and fully-integrated mine technical solution offered by EPA Survey into the mining, construction and engineering industries in SA.EPA SurveyTel: +27 13 243 5864/5www.epasurvey.co.za

FamdraStand 12Famdra is a wholly-owned South African company involved in design, manufacture and maintenance of industrial weigh-ing equipment. Its ability to create quality weighing products together with innovative design has set Famdra apart from other conventional suppliers within the belt weighing sector

Since its establishment 19 years ago, Famdra has dedicated

much of its existence to research and development, with as much as 50% focused on belt weighers. Between the years 1997 and 2010, Famdra has developed seven new models boasting mod-ernisation and innovation in platform design. Five of these are approved for trade accuracy. Its proudest moment was for the development of the single idler weigher – also a trade accurate weigher and tested at 2 000 tph.

Currently the company is in its final stages of developing the ultra-low budget weigher based on the trade accurate single idler. The model is aimed at users with smaller budgets which provides the benefit of improved production management at a greatly reduced cost.

The affordability was achieved by having designed a weigher with less sophisticated components, an integral indicator and speed sensor. The installation and commissioning process has also been reduced.FamdraTel: +0861 326 372www.famdra.co.za

KLT Machinery and Plant HireStand 23KLT Machinery and Plant Hire, was established in the early seven-ties. KLT operates in the civil and mining Industries and provides services including opencast mining, crushing and screening, materials handling, rehabilitation, bulk earthworks, road con-struction and plant hire. The company has substantial experience in different mining sectors like coal, platinum, chrome, iron, dia-mond, dolomite, clay and gold.

KLT also supplies earthmoving equipment to various major infrastructure projects on a plant hire basis.

Equipment and resources available in KLT’s fleet are: excava-tors, articulated dump trucks, bulldozers, front-end loaders, grad-ers, water bowsers, service vehicles and support vehicles. The focus of the business is customer orientated, aiming to perform at the highest levels of production and safety.

KLT prides itself on the quality of workmanship of operations through good training and upliftment of staff in the field in order to maintain the company’s reputation in the industry. We pride ourselves in our people, integrity, technical expertise, support, experience, flexibility, superior products and SHEQ compliance.KLT Machinery and Plant Hirewww.kltconstruction.com

Loadtech Onboard WeighingStand 18Loadtech Onboard Weighing specialises in providing solutions to control and remotely monitor the loads on heavy-duty goods vehicles. There is a small window of opportunity during which the payload on a truck can be maximised. Most often at this point there is no way of measuring the load, resulting in the truck trav-eling to its destination with an unprofitable load. (Over or Under load). Loadtech OnBoard Weighing has designed systems that, when fitted to the truck, measure and display the increase in load during the loading process. A range of different weight sensors are available to suit different truck and trailer combinations and the latest electronic technology is used to display both the axle and total weights. Record keeping can be accomplished by using

www.metso.com


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a local printer, sending the information to a computer via the internet or connecting the system to your tracking system.

In addition to this, Loadtech offers the Loadrite systems. Loadrite has a comprehensive range of equipment to fit a wide range of bulk loading machines, from small skid steer machines up to 300 t face shovels. Consistent loading of 1,0% using front end loaders and 3,0% using excavator or face shovels is possible and will increase your profits. Our service team is available to install and support the product and provide operator training as required. They are well-trained, eager to assist and equipped with all the tools, parts and knowledge to ensure that you get first-class service.LoadtechTel: +12 661 0830www.loadtech.co.za

MMD Mineral SizingStand 22The MMD Group of Companies was founded in 1978, to design and manufacture equipment for the UK underground coal min-ing industry. Today, MMD sizes over 60 different minerals world-wide, in many varied process industries. MMD Sizing equipment is available for surface or underground installations, stationary or mobile, and for climatic conditions ranging from arctic to tropical.

Since 1978, the company has refined and improved the sizer design, progressing from a 500 mm centres machine, through to a 1 500mm centres machine, capable of over 10 000 tph. The MMD size range now includes primary, secondary and tertiary sizes for wet and dry processing of metallic and non-metallic minerals for mining, industrial minerals and quarrying industries.APRON PLATE FEEDERS: To complement the robust Twin Shaft mineral size, MMD has designed and developed a range of heavy-duty apron plate feeders, which convey unbroken material to the crushing plant. Standard widths available are 1 500, 2 000, 3 000 and 4 000 mm on D4, D7, D9 and D11 Caterpillar sealed and lubri-cated tractor chain.IN-PIT SIZING AND CONVEYING (IPSC): The mobile and semi-mobile size systems developed by MMD are both high in capacity and compact in size when compared to the traditional technol-ogy in this field.

The latest range of MMD mobile sizes have the ability to offer mine operators unprecedented levels of productivity, and there-fore very low operating costs per ton. These energy-efficient elec-trically-driven ‘Green Mining Solutions’ are all designed to assist mining companies to achieve the double bottom line of being both economic and environmentally friendly.MMD Mineral SizingTel: +27 11 608 4801www.mmdsizers.com

Metso MineralsStand 4Metso Minerals is a global supplier of sustainable technology and services for the mining, construction, power generation, automa-tion and recycling industries. It employs approximately 16 000 employees in more than 50 countries. The product and supply range comprises process equipment and systems, such as rock crushing, grinding mills automation and field systems including

valves, solid waste and metal recycling.The southern African market, with its strong mining, as well

as versatile energy industry, is an extensive market for Metro’s technologies. The local mining sector is significant in global terms, and this encouraged the company to develop a substantial manufacturing capacity to support its equipment. Its rock crush-ing equipment, systems and service, are renowned throughout the construction sector.

An extensive network of service outlets, close to customers, ensures optimum backup. Metro’s SA hub is the base of service operations and supports this network as well as sub-Saharan markets. Its local manufacturing facility exports over 50% of its manufactured components globally.

Metso’s ownership-compliant black-empowered company celebrates a year since registration. Ukulele Trust, the owners of partners Ukulele Capital, plays a pivotal role in the company’s drive to provide sustainable solutions. The company has the capability to provide onsite servicing solutions with full plant optimisation to drive operational costs down. This strong win-ning formula not only yields savings but also fully complies with BBBEE and Mining Charter legislation. A key value of the Metso group is driving customer success and embracing transformation.MetsoTel: +27 11 961 4000www.metso.com

Osborn Engineered ProductsStand 15Osborn is a member of the Astec Industries Incorporated group of companies, a leading American manufacturer of plant and equipment for aggregate processing, asphalt road building and pipeline and utility trenching.

From design concept and manufacture to installation and commissioning, Osborn provides the African mining and quarry markets with a full range of crushers, feeders, screens and con-veyors. Osborn also specialises in mobile and fixed crushing and screening plants.Osborn’s core products are:• jaw crushers;• cone crushers;• double roll crushers;• rotary breakers;• conveyor idlers;• vibrating screens and feeders; and• apron feedersOsborn Engineered ProductsTel: +27 11 820 7600www.osborn.co.za

Pilot Crushtec International (Pty) LtdStand 21Pilot Crushtec International (Pty) Ltd is SA’s leading supplier of mobile and semi-mobile crushing, screening, recycling, sand wash-ing, stockpiling, compacting and material handling solutions. Our product range includes jaw crushers, cone crushers, vertical shaft impact (VSI) crushers, impact crushers, screens, conveyors and washing equipment. Throughout our 23-year existence, we have achieved continuous long-term growth and sustainability in our


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business, by providing our customers with the ultimate sales expe-rience, high-quality products and legendary after sales support.

We have an annual turnover exceeding R450-million and employ more than 160 people at our head office and assem-bly factory in Jet Park. Our innovative, high-tech products are designed, manufactured and produced in our ultra-modern and purpose-built 9 500 m2 facility.

We market our products and services in over 40 countries and are active in industries as diverse as coal, diamonds, gold, cobalt and platinum mining, aggregate and sand quarrying, con-struction, civil engineering and recycling. We provide the best industrial solutions for our customers by sharing our vast experi-ence and knowledge; by innovating and pushing the accepted boundaries; and we always conduct business based on long-term, enduring relationships, trust and perseverance.

To supplement our range of locally-manufactured products, Pilot Crushtec also imports selected crushing, screening and washing solutions from world-leading manufacturers such as Sandvik Construction, Rubble Master, TRIO Engineered Products, DF Ecology and Tower Light.

Pilot Crushtec has three divisions that provide a vital after-market support link between manufacturer and customer for all its products namely: InstalLink, SupportLink and PartsLink.Pilot Crushtec InternationalTel: +27 11 842 5600www.pilotcrushtec.com

Split Engineering AfricaStand 17Split Engineering provides systems, software and services for the worldwide mining industry. Split Engineering is truly a cus-tomer-oriented company dedicated to providing quantifiable information of the highest integrity to enable process control and measurement. Systems and software include: Split-Online®, Split-ShovelCam™, Split-Desktop®, Split-Net™ and Split-FX®.

Since 1997, Split Engineering and its affiliates have installed over 120 Split-Online® fragmentation size measurement sys-tems monitoring more than 500 different camera locations for companies on five continents. Split Engineering provides inte-grated imaging systems consisting of hardware and proprietary software and also provides consulting and service solutions for quantifying rock fragmentation size, shape and color.

The new Split-Online® Version 4.1 is an automated digital image analysis system designed to offer continuous, accurate, and rapid measurement of rock fragmentation. Cameras are installed along key stages of the crush, convey and milling pro-cesses to determine rock fragmentation size. The critical data for mining operations including particle size, shape, colour and tex-ture are calculated by the industry’s most advanced algorithms and are reported to the mine control systems and databases to enable real-time evaluation by mine operators and management.

Benefits from using the Split-Online System at your operation from mine to mill include: automated system that does not dis-rupt operations; real-time particle size data to monitor operation performance; a complete solution with software, hardware and installation customized to the operation; produces accurate data that enables historical data analysis; and enables early detection of equipment wear and failure.

Split Engineering AfricaTel: +27 11 794 8666www.spliteng.com

TRC Conveyor BeltingStand 16Originally Nu-Sec Conveyor & Hose established in 1976, TRC Conveyor Belting and Conveyor & Plant Services were split and have been operating from their joint premises in Springs since 1996.TRC CONVEYOR BELTING: The company is a stockist and supplier specialising in new conveyor belting, Imported from a well-estab-lished factory, the conveyor belting carries a fully international guarantee and is manufactured to SANS or DIN specifications. TRC has its own slitting, splicing and warehousing facility and holds a large volume of standard specifications in stock which include ‘N’ rubber conveyor belting and various heat-resistant and chevron conveyor belting.CONVEYOR & PLANT SERVICES: The company is a dealer and stockist of used conveyor belting, plant and equipment and holds a large stock of quality used rubber, solid-woven PVC and steel cord conveyor belting. We have a truck that is fitted with a roll-up trestle, designed to perform on-site rolling up of con-veyor belting, which assists in cleaning up the scrap belt safely and effectively.INGWE BELT SPLICING: A manufacturer of new steel and HDPE conveyor idler and conveyor pullers.SPECIALIST ROLLER MANUFACTURING: A manufacturer of new steel and HDPE conveyor idlers and conveyor pulleys.TRC Conveyor BeltingTel: +27 11 813 2760www.conveyor-belting.co.za

Techroq EngineeringStand 14Techroq Engineering was established in 1999. After a consider-able period of research and development, a new Techroq T-series range of crushers was launched. These T-series crushers operate in aggregate and mineral processing plants all over the world. The Techroq T-series VSI crushers have a track record of durability, ruggedness and cost-savings in various applications.

Techroq’s fabrication facility is located in Chamdor, Krugersdorp. At this facility, the T-model VSI crushers are repaired. Our fabrication facility is self-sufficient, which drastically reduces any outsourcing. Techroq can say with pride that all our products are manufactured in-house and we support our product with well-equipped field service teams 24/7.

Techroq boasts a range of rotors that can be retrofitted to any make and VSI crusher model. Techroq launched its mobile series of VSI crushers in 2010 with big success in either tracked or wheeled units. In 2012, we introduced a new range of products including: vibrating screens, vibrating feeders and conveyors. We have had considerable interest in our products from the outset and have secured turnkey projects which, in the past, would not have been possible.Techroq EngineeringTel: +27 11 762 6148www.techroq.co.za


Exerpts from the IQSA’s 40th celebration featureOn 15 February 1969, the inaugural meeting of the South African branch of the British Institute of Quarrying was held at the Edenroc Hotel, Durban. Following his election as chairman, Trevor Woollatt stated that the first aim was to build up membership by recruit-ment. The first committee comprised:• Trevor Woollatt, chairman (man-

ager, South African Crushers (Pty) Ltd)

• Fred Davis, secretary (Associated Quarries (Pty) Ltd, Durban)

• SG Cambitzi (chairman, Cape Quarry Owners Association)

• PJ Cumming (general manager, Pretoria Amalgamated Quarries)

• Ed B Gezernik (sales manager, Samuel Osborn SA Ltd)

• HO Plichta (managing director, Namib Quarries, Keetmanshoop)

• Jimmy A Cook (group consulting engineer, Pioneer Crushers)

• Reg J Ferris (Nordberg Manu-facturing company)

• E ‘Mingo’ Lamberti (managing director, Hilton Quarries)

Do you remember the ‘vomit comet?In 2001, the then IQSA secretary Lynne Montgomery, reported that the Institute’s Symposium held from 13-14 September in Richards Bay was held over a very wet period: “In fact, nearly the whole of South Africa was suffering at the hands of a huge cold front with KwaZulu-Natal virtually cut off from the rest of the country except for the road via Ermelo and Piet Retief.

“The chartered flight from Johan-nesburg after delays due to weather, finally managed to take off for a very

turbulent flight during which even the air hostess was sick! The plane landed safety in Richards Bay – wet but in one piece – and was immediately renamed the Vomit Comet – not a trip anyone would care to repeat,” she writes.

“We also found that only in Richards Bay can you have semi-luxury buses with built-in showers.”

She recalls that several delegates refused to fly back to Johannesburg but hired vehicles for the return trip.

LAST BLAST

Index to advertisersAEL Mining Services .......................................................................6Alco-Safe ..........................................................................................39ASPASA ...............................................................................................9B&E International ............................................................................2Babcock ............................................................................................46Barloworld Equipment ............................................................ OFCBarloworld Equipment ................................................................37Barloworld Metso ..........................................................................20Barloworld Power Allied Lighting Towers ........................... IBCBarloworld Power Industrial ......................................................38Barloworld Power Industrial Pumps .......................................50Barloworld Power Rental ............................................................28Bell Equipment Company ..........................................................42BME ......................................................................................................5ELB Equipment .......................................................................34, 35FLSmidth ..........................................................................................12High Power Equipment...............................................................23Hosch-Fordertechnik SA .............................................................33JVT Vibrating Equipment ...........................................................32Liugong Machinery SA ............................................................OBCMetso Crushing & Screening.....................................................48MMD Mineral Sizing ................................................................... IFCOsborn Engineered Products ...................................................17Pilot Crushtec .................................................................................16Powerstar NHL ...............................................................................44Scaw Metals Group .......................................................................22Wirtgen South Africa .....................................................................8

Henry Terblanche has shared another story on bees with MQ and the now

infamous Londonspruit.He says: “Londonspruit had to be

diverted to open reserves for mining. This was the second official diversion since I started with Coedmore and the task fell on me.

“I specify ‘official’ because in those days, we did a lot of things unofficially. At the time, ACME was doing the load and haul and Piet Maffa was the site foreman who supervised the fleet. Piet was a big, overweight Sesotho man who was fluent

Piet Maffa and the beesting curein Sesotho, Zuly, English and Afrikaans. He also suffered severely from backache due to his big size.

“Not only was he my right-hand man, but also a very close friend. Sadly, he passed away six months after his retirement. He shared the same sense of humour as I did, and was an observer of people.

“We started to clear the bush with an excavator to prepare for the first cut. Piet was in the area when the excavator opened a beehive. The excavator opera-tor was safely in the cab and the only

target for the bees was Piet Maffa. He was a big, easy and slow target and the bees attacked him like fighter planes.

“After Piet’s recovery he told us of the sequence of events. According to Piet, the first bee stung him on his ear, and his first thought was: “Ouch, hoe bel my vrou my nou? He knew that he had to get to the clinic superfast and get rid of the bees on the way there, otherwise they would visit the clinic with him. He managed to outrun the bees and we removed 32 bees stings from his body.

“Always a positive person, he said that the exercise did him well as his backache was better!”

Edmund Ermengardo Lamberti, better known as Mingo.

www.bwep.co.za

www.liugong.com

modern quarrying - crown publications · 2014. 3. 31. · possible terms that only oem parts and...

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