Capital Equipment News November 2015

Everything on mining and construction equipment NOVEMBER 2015

CAT EQUIPMENT PREFERRED FOR ZAMBIA PROJECT

DRIVETRAINS & COMPONENTS: Metric provides savings SAFETY: Muster II fire suppressant systems TRANSPORT: FUSO Trucks introduces FA9-137

XYLEM OPENS THE LARGEST

PUMP RENTAL HUB IN AFRICA. PAGE 6

COVER STORY: Cat equipment preferred for Zambia project.

CONTENTS Capital Equipment News is published monthly by Crown Publications cc Editor: Pierre Sanson capnews@crown.co.za Advertising manager: Claudia Bertschy

claudiab@crown.co.za Layout and design: Anoonashe Shumba

Circulation: Karen Smith

2 EDITOR’S COMMENT COVER STORY: 4 CAT EQUIPMENT PREFERRED FOR ZAMBIA PROJECT EARTHWORKS & CIVILS 6 Xylem provides water solutions 8 CAT introduces new mini excavator MINING: 10 BBE Group celebrates 25 years EXHIBITIONS: 13 HPE shows extensive range at Bauma LIFTING: 14 Potain tower cranes sets the pace 16 Vanguard heavy lift solution

DRIVETRAINS & COMPONENTS:

Total circulation Q2 2015: 3 675

21 Hydrotrac GFT 8000 gearbox 22 Metric increases profitability with remanufacturing 24 Split roller bearing technology TRANSPORT: 25 Mercedes-Benz delivers one millionth Actros 26 Volvo opens new Bloomfontein branch 28 Scania focuses on mining at Bauma 30 Driver training reaches new heights with FleetBoard 31 Barloworld Logistics acquires SmartMatta 32 Hino vice president delivers new truck personally 34 Fuso FA9-137 medium truck launch HEALTH & SAFETY: 36 Lincoln introduces Muster II fire suppressant 38 Saliva testing for female employees AROUND THE GLOBE: 40 Terex cranes nominated for Swedish steel prize

Publisher: Karen Grant Director: Jenny Warwick PO Box 140 Bedfordview 2008

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.

18 Lambson Hire offers large range 19 Terex tower cranes in Hamburg 20 Genie SX-150 from Goscor

http://crown.co.za/capital-equipment-news

COMMENT

The challenges OF DRIVER TRAINING

T ruck driving or driving of any form of construction or materials handling equipment has a certain stigma at- tached to it and is regarded as a somewhat lowly job in most countries. However, the responsibilities the average driver faces on a daily basis, far exceed those of a busi- ness executive. The driver’s smallest mis- take could claim lives. So, the professional driver should be treated in the same way as middle management in industry and the pay scales should be commensurate with that responsibility. Performance bonuses should be based on fuel economy and presentation rather than the ability to stay awake for the longest periods of time. In order to achieve these levels of competence, more attention should be paid to training. Driver training is not something to be included only when new drivers are required. It should be part of the standard operation of every transport company so that long term employ- ees get regular performance checks. This is becoming increasingly important as technol- ogy changes and torque outputs demand a different driving style for the best results in

efficiency and fuel economy. When analysing the documented performance of drivers on a before and after basis the cost of the exercise is more than recouped by the reduction in op- erating costs. Interestingly, it is not only some transport op- erators that need to be aware of the benefits of driver training. The vehicle and transmis- sion manufacturers themselves constantly advocate the advantages of specific driving techniques for their products. But, as far as I am aware, only the major European man- ufacturers employ dedicated driver trainers. While some truck/equipment dealers may feel confident in the ability of truck sales- men to provide on-the-job instruction at the time of vehicle delivery, it’s my opinion that most salesmen are simply not much good themselves behind the wheel. Perhaps one of the criteria when employing salesmen is for them to have a heavy duty licence or, if not, well on the way to acquiring one. After all, most car salesmen are able to drive the vehicles they sell.

all aspects of the industry depends on compa- nies recognising the degrees of expertise re- quired and providing the right levels of training to achieve the desired results. It’s only when this expertise is recognised, along with per- sonal skills that we can expect the public to recognise driving as a profession and attract the right calibre of person. Making the job of being a professional transport driver more attractive will no doubt solve the recruitment shortage. Many of the larger truck manufacturers have invested in dedicated training facilities and personnel to provide driver training pro- grammes for their clients. Going one step further, these programmes now entail training the trainers who will ultimately be qualified to go into the field and pass on their expertise to current and aspiring drivers. We can only hope that the age of true professional drivers is not too far away so operators can enjoy the eco- nomic benefits of improved fuel consumption and minimal damage to their vehicles.

Pierre Sanson, Editor

The future of truck driving as a profession in

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 2

CAT CONTRIBUTES TO GRAVEL ROAD UPGRADES IN ZAMBIA China Geo-Engineering Corporation’s road projects in Zambia are being supported by the addition of Cat hydraulic excavators that form a core component of the construction mix.

To support its extensive earthworks require- ments, which included almost 4 km of rock fill to depths up to 1,7 m, CGC acquired a se- ries of Cat hydraulic excavators to fast-track the construction programme, comprising Cat 320D L and Cat 329D L units, supplied and supported by Barloworld Equipment Zambia. (Barloworld Equipment is the Cat dealer for southern Africa.) This fleet has subsequent- ly grown to five Cat 329D L’s and three Cat 320D L’s, which are now deployed on new construction works. (Three Cat units worked on the D152.) Previous Link Zambia 8 000 projects – car- ried out by a separate CGC construction team – include the upgrade to bituminous standard of 91 km of the Luangwa Bridge to Feira (D145) Road in Lusaka Province, which commenced in February 2013 and was com- pleted in February 2015. (CGC has six proj- ect teams working across Zambia, where ac- tivities outside Lusaka include township road upgrades in Mongu, Western Province, and township road upgrades in Kitwe, Copperbelt Province.) Meanwhile, the current CGC team responsi- ble for the D152 phase is now progressing with a new section, which is a continuation of the previous works along this undulating route. This latest project entails the upgrade to bituminous standard of 98 km of the

M embers of the local community, especially children, never seem to tire of watching the passing traffic: that’s because they’re now connected to Zambia’s national road network. This follows the upgrade to bituminous stan- dard of Leopards Hill road (D152) from State Lodge Junction to Katoba Basic School (junc- tion of D152/D151/D481) over a distance of 43,8 km in Zambia’s Lusaka province, with works carried out by China Geo-Engineering Corporation (CGC). The contract forms part of the Link Zambia 8 000 Project, which has set out to upgrade 8 000 km of national road in the country. The D152, D481 and D482 form a strate- gic corridor linking Lusaka and Chirundu via Chiawa. The road is also the shorter route to Zimbabwe through Chirundu from Lusa- ka. It is the objective of the Government of

the Republic of Zambia to improve the link to Chirundu District by constructing a road to the Chirundu border of which this recent CGC contract forms a core section. Construction works along the D152 be- tween State Lodge Junction and Katoba Basic School included the establishment of a 40 km carriageway with a lane width of 7,5 m together with a north and south bound 3 m shoulder. CGC started the main works in October 2012 and had completed all phases by November 2013. The biggest challenge faced was the area’s rough terrain, requiring cuts of more than 5 m, earth fill of more than 5 m, as well as rock fill. Notwithstanding the difficulties, CGC completed all the works ahead of the intended completion date and there were no major defects during or after the liability period.

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 4

COVER STORY

D481/D482 road from Katoba to Chirundu via Chiawa. The contract commenced in May 2015 with a scheduled completion date of November 2017. This project is divided into three stages of which the middle portion comprises an ap- proximately 17 km section in mountainous terrain that has not yet been awarded and is pending finalisation of the scoping report by Zambia’s Road Development Agency (RDA). At this stage, CGC’s current scope entails 81 km of road (featuring a 6,5 km carriage- way and a north and south bound 3 m shoul- der): the first 15 km starting from Katoba to the foot of the mountain; and the third 66 km portion commencing on the other side and heading to Chirundu. As on the D152, the condition of the existing gravel road is poor. The current total width on the D481/D482 is between 3 to 4 m and provides limited accessibility for non-four wheel drive vehicles, especially during the rainy season, which is in-between the sum- mer months from November to April each year. Over the present 81 km route award- ed to date, CGC will be sourcing around 540 000 m³ of aggregates from quarries established in the area. The 200 mm sub-

base layer on the D481/D482 will be cement stabilised using CGC’s rotary mixers.

Work since May 2015 has focused on the initial 5 km section handed over by the RDA, and construction is progressing well as CGC tackles the challenges of completing exten- sive excavations in the marshy ground condi- tions characteristic of this area. These large- scale excavations then need to be filled with rock to the level of the new road base. Here, alongside its Cat units for bulk earthworks, CGC is employing local labour for the rock fill placement. Cut to spoil quantities will be around 700 000 m³ for the current 81 km contract. To meet material requirements, a fleet of up to 60 tipper trucks is being deployed: 25 for aggregate and asphalt delivery, and the bal- ance for earthworks. To date, CGC reports excellent availability on its Cat hydraulic excavators, which form a core component in the multi-faceted earth- works programmes, as well as in the truck loading operation. CGC, established in 1982 and headquar- tered in Beijing, has been part of Zambia’s built environment landscape since 1998, with a dedicated focus on road construc- tion. According to US based Engineering

News-Record’s Top 250 International Con- tractors Survey, China Geo-Engineering Corporation is ranked in 215 th position. The company has 23 overseas branches, with a major presence across the African continent, where CGC continues to establish vital infra- structure projects. For Zambia, the Link 8000 (also known as the Accelerated National Roads Construction Programme) is a socio-economic initiative that will ‘transform Zambia into a truly land- linked country in the sub-region’ via a world class asphalt pavement network. b

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 5

EARTHWORKS & CIVILS

XYLEM WATER SOLUTIONS SOUTH AFRICA opens the largest pump rental hub in Africa

T he expert team at Xylem South Afri- ca, a part of the global water solu- tions behemoth, Xylem Inc., has been hard at work over the past few months in preparation for the opening of its new rental hub premises in Gauteng. This new purpose-built facility opened its doors on the 1 st October 2015 – expanding Xylem’s global investment into emerging markets and augmented rental development into Africa. The rental hub offers customers ease of access and greater affordability to world-class pump rental solutions within a centralised hub. Over the past few years, Xylem South Afri- ca has positioned itself as the go-to com- pany for pumping solutions. The company operates within the entire water cycle and is deeply entrenched as a trusted name in the mining; construction; municipal; agri- cultural; marine; disaster relief and resi- dential spheres. The company has greatly expanded its regional footprint with branches currently servicing clients in Gauteng; North-West; Western Cape, Limpopo; Eastern Cape and Mpumalanga. With this strong na- tional presence; the team at Xylem South Africa in conjunction with its global parent company, decided to invest into the expan- sion of Xylem’s rental service offering in Sub-Saharan Africa.

“We saw a greater need for tailor-made rental solutions developing in South Africa and its neighbouring countries,” explains Dirk Bekker, Rental Manager at Xylem South Africa. “There are many benefits to rental solutions. Clients can focus on core business; they can scale up their fleets; clients pay only for the equipment and ser- vices they need to minimise operating cost. Xylem designs, builds, tests and rents it own equipment – we’ll always select and apply the right solution for our clients’ needs. Rent- ing can assist clients to reduce capital ex- penditure while retaining access to top of the range, word-leading pump brands,” he adds. The hub operates nationally through Xylem’s regional depots and delivery and transport options to other areas can be discussed upon request. Flexibility and adaptability are key with the Rental Hub – the knowledge- able and experienced technical specialists at Xylem’s rental hub will be able to put together hands-on solutions for customers – while backing them up with solid techni- cal advice and comprehensive maintenance strategies. “This will ultimately result in less down- time and higher productivity for clients. Coupled with the costs saved on initial capital layout on pumps or related systems – the sky is the limit for our customers. We place great value on providing the best

solutions for businesses that place their trust in us,” Bekker explains.

With the rental hub ready to service both Southern Africa and the wider African con- tinent, with bespoke pump rental solutions – Xylem’s commitment to expansion into emerging markets is underscored. Water as a scarce resource – both in operations and for consumption, is of particular concern in Africa. Xylem is set to assist in addressing this concern through its constant technical developments and through investment into its areas of operation. Xylem (XYL) is a leading global water tech- nology provider, enabling customers to transport, treat, test and efficiently use water in public utility, residential and com- mercial building services, industrial and ag- ricultural settings. The company does busi- ness in more than 150 countries through a number of market-leading product brands, and its people bring broad applications ex- pertise with a strong focus on finding local solutions to the world’s most challenging water and wastewater problems. Xylem is headquartered in Rye Brook, New York, with 2014 revenues of $3.9 billion and approxi- mately 12 500 employees worldwide. Xylem was named to the Dow Jones Sustainability Index for the past three years for advancing sustainable business practices and solu- tions worldwide. b

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 6

EARTHWORKS & CIVILS

CAT MINI EXCAVATOR extended with new 307E

E stablishing the benchmark for con- ventional tail swing excavators in the seven to eight tonne size class, the latest generation Cat 307E meets industry demand for a robust machine that is high on output and low on operating costs, particu- larly when it comes to diesel consumption. The excavator weighs in at around 6 800 kg and comes equipped with the new Cat C2.6 DI Turbo engine, which generates a gross output of 43 kW. This power plant is matched with the machine’s load sensing hydraulic system to provide excellent dig- ging performance and precise operation in any application, from fine grading and doz- ing to backfilling. The 100 percent pilot controls deliver ex- cellent machine control with fine modulation while eliminating the need for linkage and cable maintenance. Stick and bucket digging forces are class leading at 37 kN and 50 kN, respective- ly; whilst maximum reach at ground lev- el is 6 300 mm, with a digging depth to 4 100 mm and dump height to 5 150 mm. The standard bucket size is 0,31 m³. Caterpillar’s Cat 307E can also be config- ured as a ‘front shovel’ by turning the bucket around for optimum flexibility. On-site tasks here include utility pipe services, backfilling along walls, and cleaning material from in- side truck beds. “Powerful bucket and stick digging forces, combined with fast cycle times, result in world class productivity and performance, making this an indispensible unit in any earthmoving fleet, especially where com- pact dimensions are a requirement,” says Barloworld Equipment product marketing manager, Desigen Naicker. (Barloworld Equipment is Caterpillar’s southern African dealer.) Standard features on units sold into the southern African market include air-condi- tioning; 2 speed travel mode; hydraulic lines for various Cat work tool attachments, such as hammers and augers; and a push blade with blade float function. Site clean-up and backfilling becomes easier as the operator does not have to adjust the blade height during travel.

Ease of maintenance access is another noteworthy design feature on the Cat 307E. Daily checks and regular service points – including fuel and hydraulic oil fill – are reached via the large steel rear door and two large side doors. The main hydraulic valve and lines are also quick to access through a removable floor plate and side panels. On the move, travel is via the machine’s standard 450 mm triple grouser steel tracks, which provide optimum stability, particularly when lifting over the side in demolition and heavy duty applications. Each track is driven by one independent two-speed motor. (Drive modules are integrated into the roller frame for total protection.) Low or high speed (at around 3,1 and 5 km/h, respectively) can be selected by a foot switch on the cab floor. This enables the operator to balance travel speed with the torque needed for turning and travelling on inclines. “Caterpillar’s research and development team continue to raise the bar on mini ex- cavators and the Cat 307E is a prime exam- ple of how advancements in key areas like hydraulics have revolutionised the return on investment owners can expect from a com- pact machine,” adds Naicker. The Cat 307E is manufactured at Caterpil- lar’s Wujiang factory in China for worldwide distribution across all industrial sectors,

from building and construction, to mining and agriculture. b

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 8

201508

30 17

500.000

Reduced oscillation. Improved precision.

The Demag V-type girder – less is more. The revolutionary architecture of the Demag V-type girder provides greater load handling efficiency. Thanks to tapered diaphragm joints, the oscillation characteristics are reduced by up to 30 %. That cuts cycle times, boosts load handling rates and ensures improved precision in handling operations – above all in the upper load capacity range. This means that heavy loads can also be positioned even faster and more precisely without the need for electronic control systems.

Terex MHPS (Pty) Ltd 60 Atlas Road, Boksburg North Tel. +27 (0)11 898 3500 Email: enquiry.sa@terex.com www. demagcranes.co.za

MINING

BBE GROUP CELEBRATES a twenty five year history

Ventilation system at Maseve Fan Station.

B luhm Burton Engineering (Pty) Ltd (BBE) started business in 1989 pro- viding a specialised consulting ser- vice to the mining industry in the fields of mine ventilation, refrigeration and cooling. The two founders of the company, Drs Ste- ven Bluhm and Rod Burton, originally em- ployed by the Chamber of Mines Research Organisation, were shortly joined by two of their colleagues, Frank von Glehn and Russell Ramsden. With entrepreneurial flair and some fortuitous timing, they embarked on providing a specialised consulting ser- vice to the mines at a time when the min- ing companies were rationalising their in- house consultants and specialists. From humble beginnings, but with extensive experience gained in the world’s deepest and hottest mines, they gradually developed a hub for their expertise. Young and ener- getic, they adopted a simple philosophy; taking every phone call, paying attention to detail, meeting deadlines and honouring their commitments. This philosophy prevails

BBE’s comprehensive services range from conceptual investigations through technical feasibility studies and the analysis of alter- native ventilation and cooling distribution systems, to the selection of the optimum system, preparation of detailed engineering design specifications, estimating and proj- ect execution and management for existing mines and new projects. Computer software is an essential compo- nent of all planning and design work in the mining industry and the company prides itself on being up to date with innovation and state-of-the-art technologies. Over the years, BBE has been a major contributor to the development of customised software for the analysis of mine ventilation, refrigeration and cooling networks. The most modern package, VUMA, comprises a suite of mod- ules that determine air flows, pollutant lev- els and temperature distribution throughout ventilation circuits and cooling networks, all displayed in full 3-D colour graphics with the capability of real-time modelling. b

in the company today, 25 years on, and has earned BBE international recognition as a world leader in mine ventilation and cooling systems. Today, the BBE Group is a team of well over 100 strong, the majority of whom are pro- fessional consulting engineers with vast and varied experience in mine ventilation, refrigeration and cooling practices, across all mining methods in all types of ore bod- ies in all climates around the globe. BBE team members have authored some 350 published technical and scientific papers, been editors of technical journals and have co-authored a number of standard text books on mine ventilation, refrigeration and cooling. BBE engineers have also received numerous awards for engineering and sci- entific achievement over the years and can boast five past presidents and two honorary life fellows of the Mine Ventilation Society of SA.

Operating worldwide in all types of mines,

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 10

LIFTING

BABCOCK ACQUIRES latest Tadano ATF400G-6 all-terrain crane

B abcock’s plant services business can be regarded as the largest empow- ered crane and plant services pro- vider in Southern Africa today. Its Level 4 Broad- Based Black Economic Empowered (BBBEE) rating places them in the forefront of contention for any major infrastructure project development that requires its me- chanical construction plant hire. With a combined inventory of more than 40 000 items of plant for hire-from mobile cranes to welding and construction plant Babcock caters for the energy, process, marine, pet- rochemical and mining industries in South- ern Africa. The recent acquisition of a new Tadano AT- F400G-6, 400 ton, All-Terrain Crane has further extended the capabilities of Babcock and has enabled it to increase its level of service to a broader sector of industry. “With the acquisition of this 400 t crane, the big- gest Tadano unit in our fleet, we have beefed up our heavy rigging capacity to meet most of the demands of any infrastructure devel- opment, we can be called upon to quote,” explained Ian Kendrick, Managing Director, Plant Services. The ATF400-6 crane has been allocated to the Richards Bay branch, from where it will be operating at Richards Bay Minerals on a three year contract. The branch in Rich- ards Bay was established to cater for the proposed industrial expansion in the area. Richards Bay Coal Terminal and Mondi, in particular, will be high demand areas. Be- fore the ATF400-6 was placed in operation, a heavy rigging crew, of 12 personnel with an average of 20 years experience, received training at Tadano as they will be in constant attendance wherever the crane operates. The Tadano ATF400-6 All Terrain Crane boasts a spacious two man panoramic car- rier cab of composite structure with, tinted glass and air-cushioned adjustable seats. The ergonomic design of the cab ensures the driver has complete control of the ve- hicle for road travel at all times with all the basic functions at his fingertips. On the road, the six-axle vehicle is highly manoeuvrable with all six axles steerable and four driven. The driven axles incorpo- rate transverse differential locks. Power for the ATF400-6 carrier is provided by a Mercedes-Benz OM 502 LA 8-cylinder die-

sel engine rated at 480 kW @ 1 800 rpm and 3 000 Nm of torque @ 1 300 rpm. The ZF-TC-Tronic HD transmission with torque convertor and integrated intarder, electro pneumatically operated dry-type clutch and automatic gear-shifting incorporates 12 for- ward and two reverse gears. The superstructure frame of the ATF400-6 is a torsion resistant, all welded structure of high strength steel. It is connected to the carrier by a triple roller bearing, slewing ring with external gearing for 360 degree contin- uous rotation. A full central lubricating sys- tem is fitted as standard. The slewing sys- tem consists of an axial piston motor with three-stage planetary gear with automatic service and parking brake. The telescopic boom extends to a full length of 60 m making it the highest capacity in its class and with the additional 'Power Sys- tem', allows the crane to increase its lifting capacity. The boom consists of five sections, made of high tensile, fine grained steel con- sisting of 1 base section and 4 telescoping sections extended by means of a single tele- scopic cylinder. The Hydraulic Telescoping Luffing Jib (HTLJ), when fitted on top of the main telescopic boom, gives the crane an additional 36 m and allows it to operate in narrow areas. Major feature of the ATF400-6 is the 138 ton counterweight combination that is infinitely divisible depending on the application. The

counterweight can be assembled and dis- assembled by hydraulic cylinders operated by remote control. This feature ensures a minimum site establishment time before the crane commences operation. One of the safety features incorporated into the design of the ATF400-6 is the Lift Adjuster function, which completely pre- vents the load from swaying. Operated by the driver at the touch of a button, the Lift Adjuster is particularly advantageous when having to pick up non visible loads or loads at height. The operator can concentrate on the load and the load environment, includ- ing all the workers around the load because the crane radius is automatically maintained without having to keep an eye on the crane instruments. The result is a sway free load pickup, thus ensuring the safety of the load and personnel in the vicinity. Owing to its comparatively high load capac- ity, the ATF400-6 rarely operates at its limit compared to competitors' cranes. This is not only an advantage for the safe handling of the material but also reduces operating er- rors from the operator's cab. With its ever increasing fleet of highly spe- cialised cranes and, being the only plant services company in South Africa with full ISO accreditation, Babcock is well geared to enter into any partnership on any major project in Southern Africa. b

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 12

EXHIBITIONS

HPE’S EXTENSIVE RANGE at Bauma Conexpo Africa 2015

H igh Power Equipment Africa (HPE Africa) – a division of the Capital Equipment Group (CEG) Invicta Holdings Limited – participated at Bauma Conexpo Africa 2015. “This international trade expo, with an extensive outside display area, was the perfect opportunity to showcase the company’s range of Hyundai earthmoving equipment and Soosan hydraulic breaker attachments,” says Alex Ackron, managing director, HPE Africa. “We were impressed with the high calibre of visitors to the show this year – largely from mining, quarrying, construction, plant hire and agricultural sectors. “We used the Bauma platform to introduce our new finance solu- tions that are now in place with Standard Bank Vehicle and Asset Finance. HPE Africa, is one of Standard Bank’s approved suppliers of earthmoving equipment, structures finance deals that give cli- ents a competitive advantage and increased value derived from the bank’s funding structures.” On display at the exhibition were Hyundai wheeled and tracked ex- cavators, mini excavators, wheel loaders and backhoe loaders – all known for efficient performance, low operating costs and minimal maintenance requirements. The recently launched Hyundai H930s backhoe loader series is supported by a two year/3 000 hour war- ranty. Also on the HPE Africa stand were Soosan hydraulic hammers. These attachments, which enhance the flexibility of earthmoving equipment, are designed to withstand harsh operating conditions. b “Through Bauma, HPE Africa is expecting to conclude a number of deals with new customers.

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 13

LIFTING

POTAIN TOWER CRANES set the pace for contractors

A lthough the majority of contractors see a tower crane as simply another piece of materials handling equip- ment, this is not how Manitowoc views this vital tool which is a common fixture on most construction sites around the world. Tower cranes are often the determining factor when it comes to productivity on a construction site, and ongoing product de- velopment by Manitowoc is aimed specifi- cally at enhancing the return on investment (ROI) for customers. David Semple, Manito- woc VP Sales Middle East & Africa, explains that there are a number of things that define the ROI on a tower crane and chief amongst these is productivity of the machine. “The speed at which a tower crane can lift and place loads is directly linked to the pro- ductivity that a site will be able to achieve on any given day,” Semple says. “Fast track projects have become the standard through- out the world today and being able to build rapidly is a major benefit to any contractor. This makes the speed of materials handling the all-important difference between meet- ing the construction programme or not.” “There is a significant difference in the speed at which construction can take place based on the amount of materials moved in a single working day. For example, whether you can pour 100 buckets of concrete or 120 buckets can have an impact on the dai- ly build programme,” he adds. In addition to operational productivity, the speed of erection and disassembly of the tower crane is just as important. This also receives attention during engineering as the speed at which the tower crane is erected will dictate the site’s accessibility to mate- rials. Furthermore, the speed at which the unit can be climbed also has an impact, es- pecially where the building being construct- ed is high rise. “An example where advanced engineering has made a difference is in the tying of the Potain tower crane into a high rise building as it climbs. This can be done in six hours as opposed to the conventionally accepted eight hours with other similar cranes,” Semple says.

tower crane has been engineered to facili- tate speed of erection and dismantling, and its ergonomic design makes it easier for rigging crews and ensures optimal safety during both activities. Productivity of a tower crane can be com- promised if it is not correctly configured. An example of this could be if the winch were undersized the tower crane could then be- come a bottleneck on site, slowing down materials handling and subsequent con- struction activities. Torre Lifting Solutions, SA French division, is the southern African distributor for Potain tower cranes and Quentin van Breda, tech- nical director says that it is important that contractors partner with a reputable equip- ment supplier who has the depth of techni- cal skill to appropriately configure a tower crane for a specific application. “Tower cranes should be constructed to maximise productivity without breaching operational performance or safety proto- cols,” he says. “And this requires the input of experienced people who understand both the technical ability of the crane and the site requirements.” Underpinned by its strategy of improving the ROI on materials handling equipment, this leading OEM is focused on engineering its tower cranes with features that will facili- tate the requisite speed of handling yet still offer the level of reliability and performance for which Potain tower cranes have become recognised.

Semple says that Potain tower cranes are known for their fail-proof design and the excellent lifespan that these engineered machines offer customers. The cranes are produced in accordance with world class manufacturing processes ensuring that the highest levels of quality and reliability are maintained. This extends to ensuring the optimum integrity and life cycle of all major components that make up a tower crane. Manitowoc operates a Product Verification Centre (PVC) in France where all major components are tested to ensure structural and operational integrity. Components are subjected to climatic extremes and stress through simulated tests. Manitowoc is the only crane manufacturer that invests to this level to ensure the absolute integrity of its final product. Significantly, Potain has remained the world leader in tower crane production since its inception in France in 1928 and over 120 000 cranes have been manufactured and installed across the globe. Today, the company produces over 60 models from manufacturing plants in France, Germany, Italy Portugal, China and Brazil and these highly productive machines are found not only on traditional construction sites, but also on power stations, minerals benefici- ation plants and smelters, in shipbuilding yards and on civil engineering projects in- cluding dams and bridges. b

Dismantling of the machine is also import- ant as this too is time related. The Potain

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 14

LIFTING

VANGUARD HEAVY-LIFT STRAND JACKING SOLUTION – safe, precise, cost effective

T he application of strand jacking tech- nology by international heavy-lift specialist Vanguard is proving to be an economical solution for clients, while enhancing worker safety and performance quality. The strand jacks form part of Vanguard’s extensive range of specialised heavy-lift equipment, which includes hydraulic lift systems, jack and slide systems, rigging and installation equipment and a variety of specialised cranes. Recently, Vanguard was asked to assist with lifting and placing preassembled sections of a stockpile conveyor gantry into position 30 m above ground level. The initial request was to execute these works using large cranes, with the final construction being done at height. Vanguard conceptualised and engineered an alternative project solution using strand jacks, according to Vanguard’s Roger Rous- seau. “While strand jacks have been in use glob- ally for some time, their versatility and ben- efits are not well known in the field of steel construction in Southern Africa and there- fore are often unobserved, ” said Rousseau.

the assembly of each gantry section on the ground, improving the level of safety and the speed of the work, while facilitating closer quality control. It was also more economical, as the cost of deploying large cranes for an extended period is very high and uncompro- mising in the face of any unforeseen delays in schedule.” The sections that were lifted comprised three weighing 115 tonnes each, and a fourth weighing 150 tonnes including a trip- per car; each gantry section was 50.4 m in length. The strand jacks have a lifting ca- pacity of 70 tonnes each, and the contract employed four jacks at different points to lift the load. The conveyor gantries were con- nected to, and lifted by, the strand jacks using high-tensile steel cables, known as strands. The lifting itself was computer-controlled through intelligent software that operated the four jacks in unison, so they could grip and pull the strands over a ‘stroke’ distance of about half a metre at a time. To construct the framework in which the jacks could operate, four lattice towers were erected and connected horizontally by two pairs of header beams, one pair on either end of the load. Two platforms – each car- rying two strand jacks –were individually placed on a pair of headers beams. This ar- rangement allowed for the lateral movement

of the load to the required position.

“We hold most of the equipment needed for this kind of job. For this application, we engineered additional height on the towers to reach the 43 m required, and joined the header beams to achieve the 22 m horizon- tal distance required between the towers,” said Rousseau. The equipment was translocated from Van- guard’s Johannesburg yard to site in Namib- ia, where it was assembled, ready for the first lift. “Lifting each section of the gantry required us to build our structure, conduct the lift, and break it down so that it could be moved to where the next gantry section needed to be lifted and placed, he said. The relative novelty of this approach to the client meant that it was also unfamiliar with strand jacking and extensive engagement on the concept was necessary. “Many in the industry prefer to stay with what they know. It was therefore pleasing to be able to successfully implement this concept on this job within client deadlines and budget. This is testament to Vanguard’s innovative engineering solutions, show- casing our capabilities and capacity,” said Rousseau. b

“Using this technology, our engineered proj- ect solution allowed the client to complete

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 16

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LAMBSON’S HIRE OFFERS COMPREHENSIVE RANGE of aluminium scaffolding products

E leven of the Lambson’s Hire branches have a dedicated range of alumini- um scaffolding products available, including steppers, mobile folding towers and scaffolding. “We have introduced the new products in our ongoing effort to en- sure that the construction, industrial, min- ing, DIY/building and related industries have easy access to the latest trends and devel- opments in equipment. This is particularly important to encourage adherence to strin- gent health and safety standards and to help reduce costs and boost productivity,” Devin van Zyl, CEO of Lambson’s Hire, says. The aluminium scaffolding from Lambson’s Hire is a high quality, hassle free product that is safer, lighter and faster to erect and dismantle, with rest platforms every 2 m. This product is lightweight and easy to ma- noeuvre, and can be conveyed on a half ton bakkie or light trailer for ease of transporta- tion. The platform heights range from 2.3 m up to 10.7 m.

malls, offices and other similar develop- ments,” van Zyl says. “Scaffolding that is visible is essentially on public display and therefore has to look presentable.” Another feature of aluminium scaffolding is its structural integrity, which is a critical as- pect of health and safety compliance. “This applies to the individual components and sections that make up the various scaffold- ing products, which range from steppers to mobile folding platforms and scaffolding.” Lambson’s Hire has stringent procedures in place to ensure that all frames and re- lated components are operational and ful- ly compliant with all safety standards and regulations. “It is important not to compro- mise on safety, which is why any scaffolding returned from a rental is subjected to this safety and quality assurance process,” van Zyl emphasises. b

Aluminium steppers are manufactured from 6061-T6 aluminium and feature five working heights for all applications, easy folding for storage, a 300 mm step distance, a 200 kg safety load and an anti slip platform. Plat- form heights range from 320 to1250 mm. Mobile folding towers boast a new design innovation where the tower windows closes automatically. The automatic locking hook has an easy release design while the anti slip platform is 10 mm thick plywood with a high quality birch core. The safety load is 280 kg and the step distance is 280 mm. Additional features include adjustable cas- tors for ease of movement and outrigger stabilisers for increased safety. They have a maximum platform height of 1.8 m with a working height of 3.6 m. “One of the most important aspects of alu- minium scaffolding is that it is aesthetically pleasing, especially seeing that it is often used in maintenance activities in shopping

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 18

LIFTING

TEREX ® TOWER CRANES working at the St. Pauli Landungsbrücken Piers in Hamburg

T he two Terex tower cranes spent about twelve months in view of the world-famous St. Pauli Landungs- brücken Piers in Hamburg while working under unique conditions. “Projects in urban downtown settings are always associated with special challenges, and that’s espe- cially the case when it comes to a big, live- ly city like Hamburg,” explains Proschwitz GmbH General Manager Detlev Proschwitz. The first challenge was the lack of space around the areas where the two Terex tower cranes would be erected. Just getting the cranes from Proschwitz’s headquarters in Trittau to the work site with 13 trucks was a small logistical challenge despite the short distance of 35 km – after all, cramped downtown areas are hardly the natural hab- itat of heavy goods vehicles. Despite this and the limited space conditions at the ac- tual work sites, the Proschwitz team was able to erect the two cranes on time, with each one taking only one day and three assembly technicians. “We didn’t have any more time available anyway, as we had to keep the necessary road closures to a minimum. That’s where the CTT cranes’ ease of erecting really came through for us,” Proschwitz emphasizes. And it is one of the key reasons why his company con- sistently relies on Terex products when it comes to tower cranes: The Proschwitz Group’s rental fleet features a total of over 100 flat top and hammerhead tower cranes – all Terex models. “The feature with the transfer masts that work on both model ranges enables us to use a variety of com- binations and tackle all kinds of challenges in a flexible and cost-effective manner,” Proschwitz says. He mentions Terex's com- petitive prices, and the fact that experience has shown that they keep their value well, as additional points in their favour. The two Terex tower cranes have another feature that make it seem as though the units were destined to work on the project at the Hamburg site – their variable frequency drives, which guarantee low inrush currents, protecting the city grid from unmanageable voltage fluctuations. “If there was one thing we really didn’t want to do, it was to leave the Landungsbrücken Piers without electric- ity,” says Detlev Proschwitz.

ed the CTT 91-5 flat top tower crane free-standing on a C38 cruciform base, and the CTT 161A-8 flat top tower crane on cast-in-place anchors. With a jib length of 40 m and a hook height of 49.5 m, the CTT 161A-8 was perfectly set up to lift construc- tion materials weighing up to 4.15 tonnes from the jib tip. Its maximum lifting capacity was eight tonnes. The CTT 91-5 was set up with a jib length of 30 m and a hook height of 40.8 m. With this setup, it was able to pick up loads of up to 3.3 tonnes. With these configurations, the two Terex tower cranes performed their work smooth- ly and reliably for a total of twelve months, even when exposed to wind and inclement weather. As a result, Construction Manager Robert Friske from Köster AG, the primary contractor on the project, was also com- pletely satisfied with the Terex machines: “The high-pressure deadlines normally in- volved in this type of construction projects mean that we can’t afford any equipment downtimes. This means that dependable machinery, such as these two tower cranes,

is crucial to a successful project completed on time,” Robert Friske pointed out.

After the work was completed, the cranes needed to be disassembled quickly, as both the port’s anniversary celebration and the Hamburg Marathon were just around the corner. Due to the extremely constrained space conditions, it was not possible to tear down the CTT 91 crane using a mo- bile crane. However, the fact that the tower crane can be easily dismantled into smaller components meant that the CTT 161 crane was able to take care of the task and safe- ly disassemble its 'smaller sibling.' “The option of being able to disassemble the slewing unit came in really handy,” explains Proschwitz. “There’s no other machine with that available!” After the CTT 91 was dismantled, the CTT 161 was disassembled in six hours with the help of a mobile crane. b

For the project at the St. Pauli Landungs- brücken Piers, the Proschwitz team erect-

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 19

LIFTING

GENIE SX-150 FROM GOSCOR HI-REACH – market-beating stability at 48 metres working height G oscor Hi-Reach extends the Genie boom lift family with the introduc- tion of the Genie SX-150, a compact “Low operational costs, fast set up, ease-of-use and service are inherent in the SX-150, workhorse that features excellent stability and an impressive working height of 48 m.

With a market-beating 340 kg load chart of- fering an impressive horizontal outreach of 21.34 m at 36.6 m, one SX-150 unit pro- vides two workers and their tools the ability to handle tasks that often require the support of several machines. The compact footprint, which is unique for a machine in this category, a minimal tail swing of 1.06 m and unrestrict- ed 340 kg capacity across its full working en- velope, makes the SX-150 in many cases a convenient and cost-effective alternative to truck-mounted booms. The boom lift’s re- duced dimensions also enable fast set-up and the machine is easily transportable on a standard trailer making it a quick cost-ef- fective solution for urban jobsites, bridge and stadium inspections and maintenance. The Genie SX-150 boom lift features the company’s universal factory-installed state- of-the-art telematics-ready connector as well as a Trackunit ® Track and Trace Fleet Man- agement Module from Trackunit Telematics as standard. Linked to the unit’s telemat- ics-ready connector, this system offers the benefits of a wide range of functions includ- ing hour-meter reporting, location, machine utilisation and security abilities such as geo-fencing, alarms by movement and re- mote machinery disabling, all factors that will optimise fleet management. The Genie range is known for its serviceabil- ity and the SX-150 boom lift is certainly no exception. In addition to the commonality of components and parts, this product is also designed with service technicians in mind. All manifolds offer easy wrench access while a swing out engine tray provides easy main- tenance access. The boom features easy-to- which ticks all the productivity and profitability boxes; factors which are absolutely crucial for sustainable operation and even more so in a tough economical climates,” concludes Landsberg.

“This remarkable new machine which follows on from its big brother, the 57 m SX-180, is a welcome addition to the family as it conve- niently addresses a working height gap be- tween the current 40 m and 57 m telescopic boom offering,” says Goscor Hi-Reach Man- aging Director, George Landsberg. Fifteen years of experience in large boom development is built into the DNA of the Ge- nie SX-150. Proven quality and performance combined with practical, innovative design features deliver reliability, efficiency and ease of operation and service across the Genie equipment range. Highlighting the machine’s outstanding sta- bility, Landsberg says, "the SX-150 is built on Genie’s pioneering and proven XChassis™ design, a technological breakthrough that po- sitions the range in a league of its own." Add to this a horizontal outreach of up to 24.38 m as well as an industry-leading capacity through its full working envelope, and the result is a boom lift that delivers unequalled versatility and productivity. "For our custom- ers and end-user, these features importantly signify profitability and a rapid return on in- vestment," says Landsberg. The machine has four pre-programmable platform heights (46 m, 41.2 m, 36.6 m and 30.5 m). In addition to being well-suited to fleet owners’ needs, this new and increas- ingly important feature also benefits rental companies by optimising returns on utilisa- tion and consequently a reduction in total rental cost of ownership as they can charge a fixed rental rate according to height. The new model will without any doubt give rental com- panies looking to meet increasing demands in the 30 m to 48 m range, a competitive edge. “Goscor Access Rental has already pur- chased some of these machines with the first one starting work in KwaZulu-Natal and the second arrival going to the Gauteng region,” states Goscor Access Rental Managing Direc- tor, Dean Jones, adding that, “the machines have immediately proven to be an instant hit with our rental customers.”

reach hydraulic filters, with a ‘drop-in’ in-tank filter for easy cleaning and replacement, as well as bulk-headed hydraulic lines so hoses can be removed and replaced in one piece. A boom extend system features a cylinder and wire rope cartridge for fast service or replace- ment. The boom lift is ideally suited for a wide range of industries providing work-at-height solutions for sectors such as mining, petro- chemical, energy, construction, oil and gas refineries, etc. “Low operational costs, fast set up, ease-of- use and service are inherent in the SX-150, which ticks all the productivity and profitabil- ity boxes; factors that are absolutely crucial for sustainable operation and even more so in a tough economical climates,” concludes Landsberg. b

CAPITAL EQUIPMENT NEWS NOVEMBER 2015 20