Capital Equipment News August 2016

For informed decision-making JULY 2016

TRANSCOR: Firmly rooted in renewables sector BELL: uThukela Municipality deploys seven TLBs IPD PARTS: Increasing fleet operators’ performances

FINLAY PLANT IMPROVES ASH QUALITY FOR BRICK-IT – PAGE 19

Southern African Hyster customers are reaping the benefits of aftermarket initiatives undertaken by Barloworld Handling and Hyster to enhance lift truck uptime and productivity and lower their total cost of ownership.

CONTENTS Capital Equipment News is published monthly by Crown Publications cc Temporary Editor: Wilhelm du Plessis

capnews@crown.co.za Advertising manager: Claudia Bertschy claudiab@crown.co.za Design: Anoonashe Shumba Publisher: Karen Grant

COVER STORY 2 BARLOWORLD HANDLING AND HYSTER TAKE PARTS BACKUP TO NEXT LEVEL MATERIALS HANDLING 6 I-CAT launches new stockpile dust suppression solution 8 CAT ® 816K landfill compactor designed for optimum compaction performance 9 Reducing material degradation, dust and noise CONSTRUCTION 10 Burma Plant Hire adds analytics to fleet management 11 Wacker Neuson: cost effective equipment for Catmech 12 uThukela deploys seven Bell TLBs to boost service delivery 16 The basics of soil compaction – oscillation 17 Mobile on-site air, power, light and pump solutions OPEN CAST & CRUSHING EQUIPMENT 18 Robust and reliable equipment for harsh cement environment 19 Finlay plant improves ash quality for Brick-It 20 The screen test – achieving maximum efficiency in screening

MINING 22 Redesigned centrifuge basket improves coal dewatering process 23 Protecting mining vehicles from fire ELECTRA MINING AFRICA 24 Driving profit throughout declining commodity price cycle 28 Leading electronic technology development for safer mines TRANSPORT & LOGISTICS 30 Transcor firmly rooted in renewables sector 31 Local truck sales constrained, exports into Africa increase 32 Bus drives solo 34 Naamsa comments on new vehicle sales at year’s midway mark PARTS AND MAINTENANCE 35 Informed supply of electrical components, tooling and machinery 36 IPD parts rev fleet operators’ performances 38 Refurbishing tired valves AGRICULTURE 39 Tyres designed for haymaking operations 40 Where’s the fire: range of water-friendly fire fighters

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Tel: (011) 622-4770 Fax: (011) 615-6108 www.crown.co.za Printed by Tandym Cape The views expressed in this publication are not necessarily those of the editor or the publisher.

Total circulation Q1 2016: 3 740

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COVER STORY

Inside Hyster’s state-of-the-art new automated parts warehouse in Nijmegen in the Netherlands.

BARLOWORLD HANDLING AND HYSTER TAKE PARTS BACKUP TO NEXT LEVEL

designed. Supported by Hyster, we are able to offer our customers genuine parts that are competitively priced, ensuring not only robust performance and reliability under the most demanding conditions, but also adding to a lower total cost of ownership.” As an added benefit, local Hyster ® fleet owners are now also given access to Hyster’s Hypass parts service system, which enables them to check parts availability at Barloworld Handling and Hyster worldwide online. A dedicated parts team at Barloworld Handling supplies lift truck parts, attachments and accessories through regional parts centres around the country. A parts person is on call 24 hours a day, seven days a week, including public holidays, in all major branches. “The Barloworld Handling sales and aftersales teams continuously strive to meet and exceed customer expectations,” says Mazibuko. “The key differentiator in our industry is service capability and we are committed to providing our customers with some of the best value add in the industry and proactively assisting them to improve their productivity and bottom line.” b For more information on Barloworld Handling, its product range and solutions, please contact your nearest Barloworld Handling branch, call 0860 HYSTER (497837) toll-free or visit barloworldhandling.co.za

S outhern African Hyster customers are reaping the benefits of aftermarket initiatives undertaken by Barloworld Handling and Hyster to enhance lift truck uptime and productivity and lower their total cost of ownership. Building on a successful partnership of close to 90 years, Barloworld Handling and Hyster Company are committed to being much more than lift truck suppliers, says Boikanyo Mazibuko, deputy CEO at Barloworld Handling. “In addition to supplying a full range of warehouse equipment, IC and electric counterbalanced trucks, container handlers and reach stackers, we offer a complete partnership capable of responding to the full spectrum of material handling requirements. These include the highest levels of responsive aftersales support.” Mazibuko and other members of the Barloworld Handling management team recently visited the Hyster Europe/Middle East/Africa aftermarket headquarters in Nijmegen in the Netherlands to ensure the partnership keeps improving capability and delivering on its commitment to service excellence.

given impetus by Hyster’s state-of-the-art new Nijmegen automated partswarehouse.“Hyster’s new parts and accessories programme offers a convenient and competitively priced source for Hyster ® lift truck parts, a complete range of products with 24/7 access to the on-line computer network for truck parts identification, order entry, parts availability checks and back order status information, and an excellent first-fill availability and fast parts delivery available to dealers,” says Mazibuko. Stocking well over 10 000 line items, Barloworld Handling already offers local customers 97% off-the-shelf availability of fast-moving parts and overnight delivery to most South African destinations, says Robin Albany, general manager aftermarket at Barloworld Handling. “The new Hyster system speeds up the processing of parts ordered from Nijmegen, with emergency orders placed before 14:00 pm now ready for shipment to Johannesburg by 5:00 am. Our customers, who often run highly-paced 24/7 operations, are thus able to rely on faster response times, improving their productivity and uptime.” Another focus has been the competitive pricing of genuine Hyster ® parts, adds Albany. “Hyster ® approved replacement parts ensure Hyster ® lift trucks perform as

On the parts side, this commitment has been

CAPITAL EQUIPMENT NEWS AUGUST 2016 2

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EMAIL: INFO@BWHANDLING.CO.ZA CALL US NOW PARTS TOLL-FREE: 0800 012 076

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Offer valid until 30 September 2016. Errors and omissions excepted. Terms and conditions apply.

5 REASONS WHY CAPITAL EQUIPMENT NEWS IS RIGHT FOR YOUR BRAND PRINT EDITION

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For the past 12 years the magazine has reached a carefully managed target audience every month: Audit Bureau of Circulation figure of 3 740 (Q1 2016). INDUSTRY SPECIFIC The magazine covers the latest trends in capital equipment for mining, logistics, agriculture, construction and transport. WEBSITE www.capitalequipmentnewsmagazine.com is updated regularly and includes news relevant to those capital equipment sectors covered by the brand. ONLINE EDITION It is powered by Flippingbook Publisher, a software application that allows the user to turn pages, zoom in, print and email articles. All advertisers in the print edition of the magazine receive a hyperlink In the online version to their websites. e-NEWSLETTER A growing electronic mailing list (in excess of 2 100) receives the bi-weekly e-newletter. It informs the audience and directs readers to the print edition and website.

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Online monthly statistics • Sessions: 6 282 • Unique visitors: 5 050 • Pageviews: 13 245 • CTR (Click Through Rate) on average: 5 – 8%

CAPITAL EQUIPMENT NEWS AUGUST 2016 4

MATERIALS HANDLING

BRENHAM APPOINTED GOSCOR DISTRIBUTOR in Gaborone

I n true Goscor Lift Truck Company (GLTC) style, it is moving fast. After a decision to increase its footprint in the SADC re- gion, it has recently appointed several new distributors in neighbouring countries. The latest is the appointment, in Gaborone, Bo- tswana, of Brenham, a general industrial sales and service organisation. It is owned and managed by Ronnie van der Nest and David Nunes, both highly experienced prac- titioners in the servicing and selling of ma- chinery. Randhir Haripersad, Goscor Group GM Africa, says that he is optimistic about the possibilities in Botswana with Brenham in place. “Both Ronnie and David are motivated and experienced and we know that they will do justice to the Goscor range of materials handling equipment (MHE) in Botswana.” I -CAT Technical Manager, Morne van Wyk explains that the R-SDR system creates a virtual curtain around material flow for outstanding particle containment. “Engineered to industrial strength and for longevity, the R-SDR system surrounds the discharge flow on all sides, providing sim- ple, focused dust management that is well suited to continuous duty applications, such as radial stackers.” The R-SDR system boasts a stainless steel misting ring designed for mounting at the end of conveyor belts to aid in dust sup- pression at the discharge point. A variable configuration allows nozzles to be added, removed or replaced with different types and sizes to suit specific applications. Van Wyk continues: “Thanks to variable particle sizing (VPS) technology, it also features a number of customisable options. It is an intrinsically safe, mounted option, with a fully retractable and serviceable configuration for ease of access, installation and nozzle maintenance.” He adds that Goscor and Brenham are up against some well-established competition

in the region. “But with our proven product excellence and Brenham’s skills, I believe that we will make significant inroads for lo- cal distribution and service in a short space of time,” says Haripersad. Van der Nest agrees. “We are very excited about the future here and have no doubt that our market share in the MHE space will grow quickly. Even though we only recent- ly concluded the rights to distribute GLTC products in Botwana, we have already been inundated with enquiries. There is no doubt that the Goscor reputation for excellence in both product and service precedes us in this country and we will use this to build an outstanding distribution and service busi- ness,” says Van der Nest. It has been agreed that Brenham will start with a few Goscor products and initially will sell mainly Doosan and the Crown range of MHE. “A slow and methodical start is the

Randhir Haripersad, Goscor Group GM Africa.

way we will go and soon we will be able to start increasing the product line,” concludes Haripersad. b

I-CAT launches NEW STOCKPILE DUST SUPPRESSION SOLUTION

The R-SDR system surrounds the discharge flow on all sides.

pipe threads on the ring. Water flow can be controlled between 12,3 to 200,44 ℓ/pm at 6,89 bar of input. A water filter can be added for use with non-potable water, for droplet sizes ranging between 50 and 200 microns,” he concludes. b

can be added to increase water flow and pressure. Van Wyk says a hose can be sup- plied with the unit, which also comes with the option of being equipped with a two- way valve for manual control of water flow.

The PLC-controlled system also consumes low amounts of water, and a booster pump

“The water hose connects directly to male

CAPITAL EQUIPMENT NEWS AUGUST 2016 6

Making a great product even better

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CAT ® 816K LANDFILL COMPACTOR designed for optimum compaction performance T he new Cat ® 816K landfill compactor builds on the established performance, durability, and reliability that the model

816 has demonstrated since 1972. The new K Series model, designed with heavy-du- ty main structures that support multiple life cycles, features a fuel-efficient Cat C7.1 ACERT™ engine, single-lever steering, pres- surised cab, and wheel/tip options that provide extended service life. Available Cat COMPACT Technologies, such as Compaction Control, further enhance compaction performance and consistency by providing accurate compaction values and 3D mapping. Structures/guarding/wheels/tips The foundation of the 816K’s purpose-built design is its massive, robotically welded main structures, featuring a full box-section rear frame that resists torsional shock and twisting forces, heavy-duty steering cylinder mounts to efficiently transmit steering loads into the frame, and an axle-mounting design that is optimised for increased structural integrity. Three new wheel and tip configurations allow matching the 816K to the application. The Paddle Tip reduces weight and provides high performance with reduced fuel burn. The Plus Tip provides increased side-slope stability, and the Combination Tip provides an effective compromise of performance, fuel economy, and side-slope stability. In addition, specialised guarding protects components from damage, debris accumu- lation, chemicals, and premature wear, in- cluding axle guarding that prevents material from wrapping and binding around the axles. The transmission oil tube is guarded, and the fuel tank is positioned away from debris in the front frame. A screened air inlet for the radia- tor is placed high at the rear of the machine to prevent debris from blocking airflow, and the grille’s design allows trash to fall away. Striker bars are designed to keep wheels free of de- bris, and optional cleaner fingers are available for use in cohesive soils and in material that packs between tips. Power train The C7.1 ACERT engine meets U.S. EPA Tier 4 Final/EU Stage IV emissions standards with advanced technologies that do not interrupt the machine’s work cycle. (A Tier 3/Stage IIIA equivalent configuration is available in certain areas.) The Cat Next Generation high-pressure/common-rail fuel

Serviceability and sustainability Routine service points for the 816K, including grease fittings, are grouped for convenience and reached from ground level via swing-out doors or from non-slip platforms. A ground-level service panel includes a master disconnect switch with integrated lock-out/tag-out, DEF purge lamp for Tier 4 Final/Stage IV machines, circuit breakers, fuel-shutoff switch, and jump-start receptacle. Ecology drains help prevent spills, and side doors facilitate cleaning of the cooling system. The 816K is designed for multiple machine lives and component rebuilds utilising Cater- pillar’s sustainable options such as the Reman and Certified Rebuild programmes. These op- tions could save a customer up to 70% of purchasing a new comparable machine by reusing components or replacing with man- ufactured components. Cat Connect Technology The Cat Vital Information Management sys- tem (VIMS™) notifies operators and tech- nicians about potential problems, allowing issues to be resolved quickly, preventing unscheduled downtime. In addition, Cat LINK technologies wirelessly provide equip- ment managers with critical information, via the VisionLink ® interface, including ma- chine location, hours, fuel usage, idle time and event codes. Cat COMPACT technologies combine ad- vanced compaction measurement, in-cab guidance, and reporting capabilities to help consistently meet compaction targets, uni- formly, in fewer passes, saving rework time and fuel. The factory-installed Cat Compaction Control system measures compaction values and provides 3D pass-mapping guidance that indicates when layers have reached optimum density. Mapping helps eliminate voids, opti- mises cell space, and documents results. b

system delivers fuel in a precise series of micro-bursts during each cycle, providing extremely efficient combustion, and control systems lower the engine’s average working speed for reduced heat loads and added fuel efficiency. An engine-idle-shutdown system saves fuel by eliminating excess idling. The 816K’s Caterpillar built planetary pow- er-shift transmission features special met- allurgy and gear heat-treating to ensure long term durability. The transmission’s Ad- vanced Productivity Electronic Control System (APECS) is designed to improve transmission shifting performance, provide a higher level of operator comfort, and increase production. Heavy-duty planetary axles complete the pow- er train, the front is fixed and the rear oscil- lates ± 6 degrees. Operator’s environment The 816K’s Cat STIC™ Steering and Transmission Integrated Control combines steering and transmission control (directional and gear selection) into a single lever. Simple side-to-side movements of the low-effort lever provide precise steering manoeuvres through 42 degrees of articulation right and left. Electro-hydraulic implement controls use soft detents, and cylinders use electronically controlled stops for smooth operation. The left pedal serves as a brake, transmission neutraliser, and decelerator that overrides the engine-speed setting. The operator’s environment is kept clean via filtered air that pressurises the cab, and temperature is maintained with an auto- matic climate-control system. The cab is isolation-mounted to reduce vibration, and operator comfort is enhanced with an air-sus- pension seat or the available Cat Comfort Se- ries III seat. Back-lighted membrane switches have LED indicators and ISO identification, and a standard rear view camera system en- hances operator awareness.

CAPITAL EQUIPMENT NEWS AUGUST 2016 8

MATERIALS HANDLING

REDUCING MATERIAL DEGRADATION, dust and noise T he recent installation of three Weba Chute Systems at the Isdemir Steel Plant in Turkey has significantly reduced noise levels as well as material degradation and dust levels.

Weba Chute Systems are custom engineered to meet the specific criteria of each transfer point, and factors such as belt speed, belt width, material size, shape and throughput are taken into account.

Alwin Nienaber, Technical Director of Weba Chute Systems, says that the custom en- gineering of the transfer points addressed the challenges previously experienced at the plant. Describing the operation, Nienaber says that incoming material is transported from barges to the raw materials handling section of the plant using a series of conveyors. When the plant was assessed by Weba Chute Sys- tems’ engineers, it was confirmed that the ex- isting transfer points were old and there was an urgent need to reduce the degradation of the material as the high levels of fines were impeding the performance of the furnaces. In addition to this, the unacceptable levels of dust and noise pollution had to be addressed. Customised for the transfer point Weba Chute Systems are custom engineered to meet the specific criteria of each transfer point, and factors such as belt speed, belt width, material size, shape and throughput are taken into account. “Use of a custom design allows for the control of direction, flow and velocity of a calculated volume and type of material. This minimises the impact of the material, including belt presentation. Absolute control produces a significant reduction in material degradation as well as dust and noise,” Nienaber says. The three new Weba Chute Systems are being used to move sinter, coke and iron ore pellets through the plant, and the materials handling system has been engineered with a redun- dancy component to ensure optimum reliabil- ity and continuous operation. The first transfer point is a conveyor to conveyor chute with a belt width of 1 600 mm and a material feed of 2,1 m/sec. It has been designed to handle a maximum lump size of 60 mm and 2 106 tph of sinter, 522 tph of coke or 1 496 tph of iron pellets. The other two chutes are bifurcated chutes with integral sampling systems. The trans- fer points are being fed at a maximum rate of 700 m 3 /hr and receive material from and present material to a 1 200 mm wide belt travelling at 1,98 m/sec.

of the material runs on material at the same time. This results in a controlled tumbling motion as opposed to material rushing down the chute,” Nienaber explains. “Further, by engineering the internal angle of the trans- fer point to match the product with the belt speed we can guarantee a marked reduction in product degradation.” Leveraging its exten- sive experience in custom engineered chute systems, Weba Chute Systems eliminated the conventional flopper door arrangement in the bifurcated chutes. This was replaced with a custom engineered articulating trolley section. The reduction in material degradation results in reduced fines, reduced dust and substan- tially reduced noise pollution. It also decreas- es wear resulting in longer life for the trans- fer point wearing parts. The wear rate of the chute lips has been monitored on an ongoing basis and after 15 months of operation these show relatively no wear. This reduction in wear translates into reduced maintenance costs with associated savings. Such was the seriousness of both the material degradation and noise pollution at Isdemir Steel Plant, that both the customer and Weba Chute Systems conducted studies to determine the actual reduction in each. The old chute systems recorded a breakage rate of 25% on the -5 mm sinter. The level of fines in the -5 mm sinter increased from 7,78% to 9,71% after passing through the old transfer points. This 25% increase in material degradation was considered a major problem for the furnaces; however, high degradation rates were recorded with coke having 69% rating and iron pellets 43%. Following the installation and successful commissioning of the Weba Chute Systems, the tests were repeated. Nienaber says that the custom en- Material degradation and noise pollution

Weba Chute Systems eliminated the conventional flopper door arrangement in the bifurcated chutes. This was replaced with a custom engineered articulating trolley section.

gineered transfer points achieved a significant reduction in degradation with the sinter break- age rate dropping to 12,4%. This translates in to a 50% improvement. The noise level recorded with the previous chutes was 95 dB, and had a detrimental ef- fect on plant maintenance as the permitted exposure time for personnel at this extremely high noise level is between 30 minutes to an hour. This made equipment inspections diffi- cult and thorough evaluation almost impossi- ble. Operating with the Weba Chute Systems the plant has seen the noise level decrease by more than 10 dB to 83 dB, which allows a period of eight hours to this level of exposure. “Our primary objective remains engineering a tailor-made best practice chute solution for every customer,” Nienaber concludes. b Operating with the Weba Chute Systems in the plant has seen the noise level decrease by more than 10 dB to 83 dB, which allows a period of eight hours to this level of exposure.

“Weba Chute Systems uses a ‘supertube’ effect with a cascade scenario, where 95%

CAPITAL EQUIPMENT NEWS AUGUST 2016 9

AIR PRODUCTS SOUTH AFRICA announces new Managing Director

BOMAG BW 900 for asphalt and earthworks

Air Products South Africa’s Board of Direc- tors announced the appointment of Robert Richardson as the new Managing Director of Air Products South Africa. Richardson succeeds Mike Hellyar who recently an- nounced his retirement. Hellyar was at the helm of the industrial gas company for nine years. Richardson has an M.Sc. degree in engi- neering, and over two decades of experi- ence in the industrial gases industry. He has served on Air Products South Africa’s executive management committee for the past eight years in the position of Gener- al Manager On-Sites. Prior to this, he held various operations and project management positions within Air Products, and also with the Linde Group. Richardson will be the fourth Managing Director appointed in Air Products South Africa’s 47 year history. b B urma Plant Hire, the largest earthmov- ing plant hire company in the Western Cape, will be adding Ctrack’s Fleet Analytics Service to its existing Ctrack MaXx fleet management solution. This advanced dashboard management software will pro- vide powerful in-depth analysis on critical fleet performance factors, such as green band driving, excess idling time and earth moving machinery hours. Burma Plant Hire has operations across South Africa and Namibia. With a fleet of 531, the company has been using Ctrack’s Yellow Equipment Solution for the past four years to monitor the performance, use and behaviour of its yellow machinery as well as its LDVs. The Ctrack advanced fleet management solution has also been deployed across the company’s fleet of lowbeds, tipper trucks and dumper trucks, as well as its more than 100 light delivery vehicles (LDVs). Over the years, the solutions have enabled them to accurately monitor their yellow equipment by saving countless hours in downtime and maintenance costs.

A imed at smaller-sized or emerging construction companies as well as the plant hire industry, the proven Bomag BW 900 tandem vibratory roller provides a cost effective entry level solution by delivering competitive pricing and lower maintenance costs. The machine has been introduced into Southern Africa by Bell Equipment, Bomag’s alliance partner in the region, which pro- vides customer and technical support through its well established network of cus- tomer service centres. Bell Equipment’s Product Marketing Man- ager: Bomag, Johan Hanekom says that comparatively the Bomag BW 900 is only slightly more expensive than a pedestrian roller, and thus requires a lower capital out- lay than other tandem vibratory rollers on the market. “Ideally, the machine is suited to smaller contracts that have no need for onsite die- sel tanks. The key is the Honda GX630 pet- rol engine, which is easy to run and operate and is a more cost effective option com- pared to the diesel models on the market.” He adds: “The petrol engine is more cost ef- fective to maintain and the machine has no grease nipples and a maintenance free bolt on articulated and oscillating joints, which together result in lower overall maintenance of the BW 900.” The Bomag BW 900 has an operating weight of 1 197 kg. Standard equipment includes: hydrostatic travel and vibration drives, front drum vibration, series hydro- static travel drive, foldable ROPS to offer flexibility for transport and storage, hy- drostatic articulated steering, mechanical parking brake, vibration control in travel lever, two scrapers per drum and a pres- surised sprinkler system. b

Robert Richardson is the new Managing Director of Air Products South Africa.

BURMA PLANT HIRE adds analytics to fleet management

the vast amounts of telematics data gen- erated. Using rich fleet analytics and smart interpretation of data, the software provides the information needed for critical deci- sion-making, from cost savings to future investments. This solution is outsourced to enable the company to receive expert anal- ysis, without the added overheads of em- ploying analysts. “By utilising the Ctrack Analytics platform to its fullest capacity, we can improve our pro- ductivity, offering the best service and solu- tions to our clients in order to meet the high standards that Burma Plant Hire sets for it- self. We can also continuously strive to find solutions to eliminate vehicle abuse and re- duce diesel costs, while ensuring the utmost safety of our staff members and clients,” says Theuns Burger, CEO of Burma Plant Hire. “Since being selected in 2012, Ctrack has worked closely with Burma Plant Hire to address the inevitable operational risks that companies who specialise in the yellow metal fields face. Including fleet analytics in their solution will no doubt add further value to this successful and mutually beneficial partnership,” says Hein Jordt, MD of Ctrack Fleet Management Solutions. b

Incorporating Ctrack Fleet Analytics gives Burma Plant Hire the means to analyse

CAPITAL EQUIPMENT NEWS AUGUST 2016 10

CONSTRUCTION

THE LONG TERM BENEFITS OF QUALITY DRUG and alcohol testing equipment B enjamin Franklin once said: “The bitterness of poor quality is remem- bered long after the sweetness of a with accidents. It also lowers absenteeism rates and reduces alcohol abuse in the workplace, with the result that employees also perform better. low price.”

Why cheap instruments cost more In many instances, the initial cost of a breathalyser may be cheaper, but the cost of the product over its lifespan can easily be triple that of the initial cost outlay should you purchase inferior equipment. A cheap instrument is likely to break very quickly and will require frequent repairs. It will certainly need to be replaced much faster than a quality instrument, which can last from seven to 10 years. It also needs to be recalibrated more often, with some of them requiring recalibration after every 500 tests. A cheap breathalyser may also cost the company a fortune in legal fees. According to the Occupational Health and Safety Act of 1993, employers may not allow any person who is, or appears to be, under the influ- ence of alcohol or drugs to enter into the workplace. The Act also recommends that employers use reasonably practical means to make sure that they enforce the Act.

This rings true for all South Africans, espe- cially when a low price is so tempting during the economic decline that we are currently faced with. Often we go for price over qual- ity, and this is no different when it comes to the procurement of health and safety prod- ucts within a company such as breathaly- sers and drug testing equipment. It is strategic to think of the purchase of business equipment as an investment and the company’s substance abuse testing equipment is no different. The business owner should take into consideration the repercussions and expense that he would face, should the equipment not deliver accurate readings or worse yet, fail when being used. Factors to consider when buying equipment Long term benefits of investing in a quality system A quality alcohol and drug testing system can help a company lower its accident rates and reduce its financial losses associated W acker Neuson South Africa, local subsidiary of the global light in- dustrial and compact equipment manuacturing giant, Wacker Neuson GmbH, has supplied more than 35 machines to key customer, Catmech Plant & Services. Initially established in 1990 to repair machines for customers, Catmech developed into a leading plant equipment hiring company based in Gauteng, South Africa. “We decided to start the plant hire when we recognised the excellent market potential for hiring compact and light equipment,” explains Catmech Plant & Services owner, Sean van Heerden. With construction as Catmech’s core industry, typical machines required by customers in this market segment include wheel loaders, excavators, concrete breakers and compaction equipment.

By Rhys Evans, Managing Director of ALCO Safe.

Empowering the procurer For many companies, the most effective purchasing method is for the department using the testing equipment (the end-user). to first provide the procurement department with clear specifications of what they require. The procurement department is then tasked with finding the cheapest supplier that meets those requirements. b

WACKER NEUSON: cost-effective equipment for Catmech

to Catmech a couple of years ago, Van Heerden decided to try out the Wacker Neuson product. “My customers were ini- tially reticent to try out a new product but after experiencing the Wacker Neuson machines’ reli- ability, versatility and us- er-friendliness, they were sold.”

Vertical Digging System on Wacker Neuson's excavator has impressed customer Catmech Plant & Services.

Van Heerden is impressed by some of the features offered by the Wacker Neuson equipment, highlighting in particular, the VDS (vertical digging system) available on the excavator range. The VDS adds to the excavator’s versatility and can lead to sub- stantial savings in material and time for the end-user by enabling progressive tilting of the machine by up to 15° to compensate for slopes.

Van Heerden says that in addition to the fact that he has had zero breakdowns with his Wacker Neuson equipment, the machines are easy to maintain and the company provides excellent after-sale service with a quick response time to all customers. Catmech’s current 35 plus strong Wacker Neuson fleet includes wheel loaders, exca- vators, rammers, plates and rollers. b

When Wacker Neuson was first introduced

CAPITAL EQUIPMENT NEWS AUGUST 2016 11

CONSTRUCTION

uTHUKELA DEPLOYS SEVEN BELL TLBs to boost service delivery

With the current drought, the uThukela Municipality is grateful to have the Bell TLBs at its disposal and is able to undertake repairs to any water supply lines very quickly as a result.

T he uThukela District Municipality in northern KwaZulu-Natal covers a large district of some 11 500 km 2 and its vision is to provide a stable, sustainable and prosperous district with committed servants who serve with excellence in governance, service delivery and economic development. When it comes to service delivery, the uThukela District Municipality has turned to a truly South African brand to assist it in achieving that goal. Founded in 2000 during the time of trans- forming South Africa, the uThukela District Municipality houses around 669 000 peo- ple in over 147 000 households, as per the census figures of 2011. “All these people live in five municipalities, one district management area and proba- bly around 80 small villages,” says Jabulani Mkhonza, Communications Manager for the uThukela District Municipality. “To give you an idea of the vast size of the area under our mandate, we have 1 820 km of paved roads and over 8 100 km of gravel roads.” “Our main focus in terms of infrastructure and service delivery is water and sanitation and this sees us supplying water to our citizens from water treatment plants via a system of pipes. We also manage sewage to treatment plants and stormwater,” he adds. “Roads are maintained by the KwaZulu-Natal Department of Transport and some local municipalities.”

the uThukela District Municipality’s area and attend to digging up water pipes that need repair, digging and backfilling trench- es for water supply, sewage lines and drain- age ditches. Speed is key “With the current drought, we need to repair any water supply lines quickly. Having the Bell TLBs available all the time is a real bonus,” Sithole explains. “Even though the machines are still under their standard warranty, we’ve happily had no technical issues and their mechanical availability is top notch.” Sithole is keen to point out that operators adhere to strict pre-startup and post-oper- ation checklists and believes this will add to the longevity of the fleet of Bell TLBs. “With any machine or piece of earthmoving equipment, downtime has a negative effect on production or, in our case, service deliv- ery,” he says. According to Sithole, Bell Equipment of- fered some basic training to the Municipal- ity’s TLB operators at the handover of the machines. The Municipality is considering further advanced training from Bell Equip- ment for its operators and is considering a maintenance contract for the fleet. “We believe we did the correct thing in buy- ing our own fleet of Bell TLBs as our citizens see we operate a locally produced machine, which in the long run adds value to our prime goal of sustained service delivery,” he says. b

the uThukela District Municipality’s Fleet Management. He oversees a fleet of 135, consisting of vehicles and yellow machines. It comprises utility vehicles, 16 000 litre water tankers, tractors and trailers and some new Bell 315SK 4x4 Tractor Loader Backhoes (TLBs). Own fleet of TLBs The Municipality used to outsource the services for water tankers and TLBs but often found that the equipment was not reliable, which had a negative effect on its service delivery. The Municipality then decided to purchase seven TLBs, and this has significantly reduced costs and improved efficiency. Sithole points out that although he has not been privy to all the criteria the Munici- pality’s supply chain management set, he would think that price, reputation, local con- tent and an established dealer network to ensure proper maintenance would all have played a role in selecting an appropriate original equipment manufacturer (OEM). According to Fleet Management, the Munic- ipality is happy to see that Bell Equipment, with its Bell 315SK 4x4 TLB, was the pre- ferred and successful supplier as this is a machine that has certainly made its mark on the local market. The Municipality took delivery of seven of these machines in July 2015 and has not looked back.

The seven Bell 315SK 4x4 TLBs have been deployed across the length and breadth of

Mondise Sithole is currently responsible for

CAPITAL EQUIPMENT NEWS AUGUST 2016 12

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CONSTRUCTION

LINDEN COMANSA hooks up with a tall Swede

R ental company Edins Byggkranar sup- plied two Linden Comansa tower cranes for the construction of the Kista tower, Stockholm’s tallest residential building. Construction company JM Sverige is about to finish the Kista Torn (‘tower’, in Swedish), a residential building located in the district of Ki- sta, in Stockholm, the capital city of Sweden. The complex is formed by the 120 m high Ki- sta tower (35 floors) and the smaller K2 build- ing (15 floors), which together will house 362 apartments. For the construction of the Kista tower, Lin- den Comansa’s long-time partner, Edins Byg- gkranar provided JM Sverige two brand new Linden Comansa tower cranes in September 2013. The first crane to arrive to the job- site was a Linden Comansa 21LC750 48 t, erected with 50 m of both radius and height. This flat-top tower crane helped to assemble the second Linden Comansa tower crane, a

16LC185 8 t, with 35 m radius and height of 32 m.

Both cranes first collaborated in the construc- tion of thick concrete walls in the basement of the building. Soon afterwards the 21LC750 48 t started with the rising and positioning of the prefab walls that shape the building. From floor eight, both walls and floors were all pre- fabricated allowing the crane to build each floor very fast. The 21LC750 always worked three floors ahead of a team of workmen who set the electrical and pipe installations and used a concrete pump to fill the floors, always leaving two empty levels between the tower crane and the workforce for safety reasons. When the building gained in height, the Edins Byggkranar erectors team jacked up the 21LC750 crane with the hydraulic cage up to 78 m. To reach the final height of 132 m, the 21LC750 had to be tied once to the building, and had to be jacked up four more times.

The crane 21LC750 reached a final height of 132 m.

To ensure an optimal performance at such height, and with heavy loads of up to 22 t, the crane was delivered with the optional 110 kW hoist motor that allows speeds of up to 88 m per minute. Also, although it was not necessary for the Kista tower, Edins Byggkra- nar ordered the crane with the optional high capacity Lebus drum for 1 450 m of rope, to be used in upcoming projects. The 21LC750 48 t, which dismantled the 16LC185 8 t in April 2015, remained at the Kista Torn project until March 2016. b

NEW WEARCHECK APPOINTMENTS W earCheck has further enhanced its oil analysis and reliability solutions services with the recent appointment and promotion of several skilled specialists:

Josephine Rakolota has been appointed as Sales and Customer Support at WearCheck Steelpoort. She has an in depth knowledge of WearCheck’s customers, having provided cus- tomer support for 17 years.

Sharon Pieterse has joined WearCheck Rustenburg to handle Business Development and Technical Sales.

Josephine Rakolota

Sharon Pieterse

Steven Lara-Lee Lumley

Thomas Madlala

David Schumacher

Steven Lara-Lee Lumley has been pro- moted to Technical Manager for WearCheck in Durban. Lumley has served at WearCheck for eight years as a senior diagnostician and in technical development.

Thomas Madlala has been promoted to Business Development and Technical Sup- port at WearCheck Steelpoort.

David Schumacher has been appointed as Diagnostician at the Durban laboratory of condition monitoring specialist, WearCheck.

CAPITAL EQUIPMENT NEWS AUGUST 2016 14

THE BASICS OF SOIL COMPACTION – Oscillation

I n its previous column (CEN May 2016) Wirtgen discussed Compaction Methods namely, Static and Dynamic. It further noted that Dynamic Compaction could be divided into Vibration and Oscillation.

Oscillation

What then is oscillation, introduced by Hamm in 1983, and what are the benefits?

During oscillation, the drum is equipped with two eccentric imbalance shafts rotating in sync. The imbalanced weights on the two shafts are arranged opposite each other and force the drum to rotate rapidly, alternating in a forwards-backwards movement. In contrast to the vibrating drum, the oscillating drum does not lose contact with the surface and in effect ‘massages’ the material to achieve compaction. During oscillation compaction, both the forward and backward ro- tating movements of the roller drum transmit shearing forces into the soil or asphalt. This ‘double frequency’ and permanent contact of the rollers’ own static weight causes the material to compact more quickly. On the other hand, the vibration drum executes an up and down movement and each time the imbalance weight rotates, it transmits a vertical force to the material along with the static weight of the machine one vibration at a time. As with vibration, the compaction performance of the oscillation is based on well matched amplitudes and frequency. However, an ad- vantage of the oscillation technology is its self-regulating amplitude which is regulated by the material that is being compacted. This means that as compaction causes the material to become more rigid, the amplitude decreases automatically and over-compaction is avoided. Compaction has evolved from the 1800s when rollers were made of stone or cast iron and drawn by man or beast during construc- tion. Today, we are faced with physical, environmental, human and statutory challenges during construction work. Therefore having the right equipment and choice of technology is important. Of even greater importance is knowing when and how to apply this technology. b

Vibration

During compaction, the vibration of the roller drum is generated by the rotating imbalance weight whose rotation speed determines the vibration frequency. The imbalance weight consists of a fixed part and a moveable weight. The position of the moveable weight depends on the direction of rotation of the exciter shaft. The effective weight of the imbalance weight increases or decreases depending on the direction of rotation. This allows the roller drum to vibrate at two different amplitudes.

Oscillating technology has an effect on the operator, machine, compaction and the surrounds:

Operator & Machines

Compaction

Soil Compaction

Asphalt Compaction

Surrounds and Environment

Less vibratory impact provides better driver comfort

High compaction through combination of static and horizontally applied shear forces Constant contact with the surface, load and shear forces

No particle destruction due to high impact forces

Effective compaction at lower temperatures

Lower impact level so less effect on already compacted surfaces in adjacent areas

Lower noise levels

Good surface compaction and avoidance of unravelling from over compaction

Good surface sealing and finish Lower impact and noise levels so less effect on surrounding buildings, underground services and inner city neighbourhoods

are continually applied to achieve density quicker

Fewer resonances so less stress on the machine structure

Fewer passes means lower fuel consumption

Good course bonding

No particle destruction on existing material during hot-on-cold seam compaction

Risk-free compaction in multi-story carparks or on concrete structures

CAPITAL EQUIPMENT NEWS AUGUST 2016 16

CONSTRUCTION

MOBILE ON-SITE AIR, POWER, LIGHT and pump solutions A tlas Copco Portable Energy leads the market as a single source supplier of turnkey on-site mobile solutions with

the development and extension of its pump portfolio to complement the division’s already well-established range of compressors, gen- erators and light towers. “The shared synergies between Portable En- ergy’s three pillars – compressors, generators and light towers – made the development of our dewatering pump ranges to form a fourth pillar within the division a natural pro- gression,” explains Portable Energy Business Line Manager, David Stanford. He notes that pumps are not newcomers to the Atlas Cop- co portfolio with small hydraulic as well as pneumatic and electrical submersible pumps having been part of the offering for quite a few years. “We have now made a solid stra- tegic commitment that will ensure our pumps enjoy the same focus and investment as our compressors, generators and light towers.” Roll out of the expanded pump portfolio which relates to both pressure and flow-rate capac- ities, will take place over the coming months. The efficient and safe removal and disposal of water from a job site is fundamental to main- taining safety and productivity. “Performance under pressure within the most challenging environments is where our pump ranges

Atlas Copco offers a small and large professional pump range as well as light range for construction and mining industries. 60 electrical submersible pumps has resulted in improved power to weight ratios. The Weda hydraulic parts deliver enhanced performance with flow management from 225 to 16 500 ℓ per minute with a maximum head of 85 m. Stanford reveals that as a result of customer demand, a diesel driven open canopy range will also be introduced in Q4 2016. Portable Energy’s value proposition differen- tiates it as a preferred supplier of portable energy products that are inherently energy efficient, light-weight, compact, easy to move and transport. This meets customers’ exact needs and contributes to enhanced customer productivity at the lowest cost of ownership over the products’ lifetime. Stanford points out that Atlas Copco Portable Energy customers invest in so much more than just a product, they invest in a massive support network that includes factory trained technicians who de- liver fast, reliable, expert service to help main- tain uptime and production levels. b

Light range of submersible pumps from Atlas Copco for the construction sector.

perform to their maximum,” affirms Stanford. Suitable for transporting or lifting water with abrasive solids in suspension, the pumps are ideal for applications such as construction and mine-site dewatering and diversion of flood water or streams. The comprehensive range of electrical submersible and self-priming die- sel pumps available from Atlas Copco Porta- ble Energy provide solutions for virtually any mobile dewatering application within the flow range of 210 to 16 500 ℓ/min. The portable dewatering pump range saw further extension in January 2016 with Atlas Copco’s acquisition of Varisco. “Varisco’s Padua location has become the dedicated global competence centre for pump development within Atlas Copco Portable Energy complementing our other two global competency centres in Antwerp (air) and Zaragoza (power and light),” says Stanford.

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ROBUST AND RELIABLE EQUIPMENT for the harsh cement environment

C ement plant depend on drive tech- nology that is sufficiently robust to provide reliable operation in de- manding applications and challenging envi- ronments. SEW-EURODRIVE upgrades and supplies reliable gear units and drives for this industry. SEW-EURODRIVE Business Development Manager for heavy industrial solutions, Steffen Reiblein, notes that cement plant operators can benefit from an innovative partnership with such a global drive tech- nology manufacturer, as it is not only offers drive solutions, but also ongoing service and support. “The backing of our company’s global pres- ence enables us to provide support, regard- less of where any new plant is constructed. We can also accommodate international cement groups,” Reiblein highlights. It is a global player, with a product range and application knowledge allowing it to provide innovative engineering solutions from Greenfield projects to retrofits on existing plants. Its drive technology has been used on such notable projects as the construction of a new ± 6 000 tpd cement plant in Limpopo Province. “SEW-EURODRIVE South Africa carried out the cold commissioning at the Limpopo plant to guarantee that all the drive tech- nology was installed correctly and ready to run,” Reiblein continues. The brand has partnered with many pres- tigious names in the cement industry to design and install upgraded long-distance limestone reclaimers at various plants in order to increase efficiency, reduce main- tenance and improve performance and op- eration. For example, it reduced production los- es at a reclaimer where the drive broke down frequently. The subsequent upgrade allowed for smoother operation and in- creased efficiency, as well as significantly less inventory requirements and reduced maintenance. In New South Wales, Australia, SEW-EURO- DRIVE’s engineers were able to increase the productivity of a limestone crusher at Boral Cement plant by up to 25% with the addition of a custom-designed wobble

Girth gears are used to drive large rotating systems such as dryers, rotary kilns or horizontal mills.

feeder. Prior to the introduction of the feed- er, Boral Cement’s engineering manager Dean Beltrame indicated that the crushing capacity of the machine was constrained by the lack of any pre-screening. “With the help of SEW-EURODRIVE’s engi- neers, we designed a wobble feeder that pre-screens the material prior to the jaw crusher. By preventing the fine materials from entering the jaw crusher station, we only crush the large rocks that need crush- ing. That has given us a 20-25% average increase in production capacity on our 1928 vintage crusher,” Beltrame explains. Table 1 stipulates inspection and main- tenance intervals, and serves as a useful guideline for the appropriate measures to be taken.

“With the help of SEW- EURODRIVE’s engineers, we designed a wobble feeder that pre-screens the material prior to the jaw crusher. By preventing the fine materials from entering the jaw crusher station, we only crush the large rocks that need crushing. That has given us a 20-25% average increase in production capacity on our 1928 vintage crusher.”

Table 1: Guideline to inspection and maintenance intervals

TIME INTERVAL

ACTION

Every 3 000 hours of operation – at least every six months

• Check oil and oil level • Check running noise for bearing damage • Inspect seals for leakage • Check and replace rubber buffers, if necessary, on units with torque arm • Change mineral oil • Replace rolling bearing grease • Replace oil seal (do not install it in the same track) • Change synthetic oil • Replace rolling bearing grease • Replace oil seal (do not install it in the same track) • Touch up or renew the surface’s anti-corrosion coating as and when required

Every three years (at the latest, depending on operating conditions)

Every five years (at the latest, depending on operating conditions)

Varying (Dependent on external factors)

CAPITAL EQUIPMENT NEWS AUGUST 2016 18