Capital Equipment News November 2016

For informed decision-making NOVEMBER 2016

SUCCESS IS BUILT ON PARTNERSHIP

COMPACT EQUIPMENT: Dynamite comes in small packages WORK AT HEIGHT: Standing up to tough terrain BUSINESS: Mining giant reawakens

PLUGGING THE HOLE– PAGE 34

SUCCESS IS BUILT ON PARTNERSHIP

PARTS AND MAINTENANCE 36 IPD proves quality can be cost effective GLOBETROTTING 38 Deutz to supply Terex with Xchange engines AGRICULTURE 40 Better traction in vineyards with BKT tyres CONTENTS Capital Equipment News is published monthly by Crown Publications cc Editor: Munesu Shoko capnews@crown.co.za Advertising manager: Claudia Bertschy claudiab@crown.co.za Design: Anoonashe Shumba Publisher: Karen Grant Deputy Publisher: Wilhelm du Plessis Circulation: Karen Smith PO Box 140 Bedfordview 2008 REGULARS

CONSTRUCTION NEWS 6 Increased longevity for new CP Red Rock compressors 7 CASE readies for Tunisian road construction MATERIALS PROCESSING NEWS 12 Metso helps B&E International break beyond 550 tph 13 Weir Group forges ahead with foundry investment MINING NEWS 15 Towards new mining solutions 16 Updated Cat MineStar Terrain optimises mining productivity MATERIALS HANDLING NEWS 17 New Potain Hup 40-30 sets new lifting standards 18 New Genie XC boom lifts offer more lifting capacity TRANSPORT & LOGISTICS 34 FAW’s 2 000 th truck milestone in just two years 35 New ED for MBSA’s Regional Centre Southern Africa

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.

FEATURES

COVER 4 ‘The road to success is built on partnership’ COMPACT EQUIPMENT 20 Dynamite comes in small packages WORK AT HEIGHT 24 Standing up to tough terrain BUSINESS 28 Mining giant reawakens PROFILE 34 Plugging the hole

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EDITOR'S COMMENT

NEW SOLUTIONS FOR NEW APPLICATIONS

F or a number of reasons, construction jobs are changing, presenting a new set of applications which require new solutions to undertake them. In this edition of Capital Equipment News , we look at the prospects of growth for compact equipment in the local mar- ket, all the way from TLBs and skid steers, through to newer solutions such as compact excavators and compact articulated loaders. These solutions are gaining preference for several reasons. Youwould find in the Compact Equipment feature (Page 20) that the first big driver for compact gear is urbanisation. As towns continue to grow, space is at a premium at many construction sites, hence the need for a compact machine that can manoeuvre through the tight spaces. More importantly, change in application is driving this range of equipment. There is gen- eral consensus that we ought to see more jobs in applications such as landscaping, sewage, trenching and cabling. These sorts of applications are continuously growing and compact equipment becomes a big need. Over the years, the TLB and the skid steer have been the most sought after smaller pieces of equipment in Africa, which earned them the “picks and shovels of the local in- dustry” accolade along the way. Even sales figures show that these are the “bread and butter” lines for the construction industry. In 2014, the two lines accounted for half of the total equipment sales in South Africa, as re- flected by CONMESA figures. But, many would agree that the next big thing may be the compact excavator. This solution already accounts for over 100 000 unit sales in the global market, a figure envisaged to double by 2020. There are several application opportunities in plumbing, electrical and telecommunication, as well as in the specialised agricultural sector, to mention but a few. It is also important to

note that the compact excavator, especially the mid-sized units such as the 8 t, is even taking trenching work away from the tried and tested TLB, and one of the suppliers argues that it is a matter of time before it upstages the TLB because of the comparative production speeds. The skid steer is also up for some serious challenge from the articulated loader. The likes of MultiOne, Avant Tecno, Wacker Neuson and Atlas Weyhausen, to mention a few, are leaving no stone unturned to prove the worth of this solution. The compact loader is said to be economical to run in terms of fuel consumption compared with the skid steer, consuming six times less fuel in some instances, while it can also load more material per run than the similarly sized skid steer. While there may be several comparisons between these solutions, for me, it is all about choosing the right solution for the job at hand. I believe these solutions can com- plement each other so well on sites, and they are distinctly different solutions, with a degree of overlap. For that reason, I believe they can co-exist in the market. In construction, planning goes beyond plans and permits; it also calls for the knowl- edge and experience to know what equip- ment is needed, when it will be used and for how long it will be on site. These factors contribute to determining what construction equipment is needed. Having the right equip- ment and tools to do the job is an essential part of any successful construction project. Each piece of construction equipment is designed for a specific purpose. When reviewing the projects, it is important to know what equipment is needed and when in the construction process it will be used. A skilled contractor can identify what construction equipment is needed by reviewing the project tasks. This knowledge and experience is guaranteed to save time, money and lots of headaches. b

Munesu Shoko – Editor

capnews@crown.co.za

@CapEquipNews

CAPITAL EQUIPMENT NEWS NOVEMBER 2016 2

AAE places primary importance on aligning its business with blue-chip manufacturers such as LeeBoy.

AAE is the sub Saharan Africa

distributor for LeeBoy, a VT Systems company with factories in Lincolnton, America, Brazil and India.

‘THE ROAD TO SUCCESS IS BUILT ON PARTNERSHIP’ In a challenging industry that places a premium on quality, efficiency and cutting edge technology, Associated Asphalt Equipment has quietly carved itself a niche, fast becoming known as “a one-stop shop” for global asphalt equipment brands, along with associated earthmoving hardware.

L ed by a team of well-heeled consultants and technical experts, Associated Asphalt Equipment (AAE), a Durban-based agency boasts an impressive stable of asphalt and bitumen handling thoroughbreds. With the growing expectation that modern machinery plays a crucial role in the efficiency of construction site processes, the team at AAE is well aware that there are no substitutes for trusted expertise and even more reliable machinery. Knowing how to apply innovative technological solutions to enhance workflows and productivity, is what sets AAE apart, and what turns its customers into long-term partners. In its endeavour to live this out, the com- pany mantra is aptly stated – “The Road to Success is Built on Partnership”. With the constant evolution in asphalt technologies and techniques, AAE places primary importance on aligning its business

with blue-chip manufacturers, earning an exemplary track record that has developed with years of experience, research and development. Brief history AAE is a B-BBEEE Level 1 Contributor and 100% Black Female owned company with its head office in Durban, South Africa. Since its inception in 2013, the company has made significant strides in capturing market share based on its business philosophy of “Premium Products backed up by Premium Service”. Leveraging on the extensive experience of its core management, AAE has been highly sought after, being appointed by blue-chip manufacturers to represent their products, not only in South Africa, but throughout sub Saharan Africa. 2015 saw AAE broaden its product range from asphalt plants to asphalt surfacing and earthmoving equipment. AAE was

appointed by LeeBoy, a VT Systems company with factories in Lincolnton, America, Brazil and India. Backed by 50 years of experience as a manufacturer, LeeBoy manufactures a range of asphalt plants, earthmoving and paving equipment. To further complement the range of equipment, AAE was appointed by Romanelli of Brazil to represent its slurry pavers in southern Africa. Crucial to its strategy to offer comprehensive support to customers and limit downtime, AAE has dedicated technicians for each range of products backed by strategic spares warehoused at its stores in Durban. Trusted global brands in one stable Based on its trading and on-site experience in sub-equatorial Africa, AAE has been appointed for an impressive range of products and brands. In no order of priority, these include LeeBoy/Rosco earthmoving and paving equipment; LeeBoy/Ticel

CAPITAL EQUIPMENT NEWS NOVEMBER 2016 4

COVER STORY

AAE also supplies LeeBoy/Rosco earthmoving and paving equipment.

mobile asphalt plants; Romanelli slurry and microsurfacing pavers and rubber bitumen sprayers; Simem – Bison Cold in Plant systems; Dormashina asphalt and soil compactors; and Massenza emulsion plants, polymer modified bitumen and crumb rubber bitumen plants. AAE is particularly proud of its most recent signing of the Brazilian-born export – the Romanelli UHR700 and UHR 900 EFlow microsurfacing pavers. Investment in technology, innovation and a specialised team, make Romanelli the name of choice for asphalt equipment the world over. Hardware and technological integrity, as well as quickfire aftersales service is non-negotiable, especially in the harsh African terrain. This is where the Romanelli reputation comes into its own, with these machines performing beyond expectations. With the recent handing over to another satisfied client by AAE, the Romanelli brand is sure to be a regular feature on local sites. The team at AAE understands that not only is the equipment and technologies of importance, but also the ability to provide technical support to an industry whose margins are constantly under pressure with no room for prolonged periods of downtime. To this end, machinery that has performed in harsh environments is the company’s preference. This, in conjunction with local techni- cians, trained by the manufacturers, to- gether with strategic spares held at the company's premises, ensure quick turn- around, and can have a plant back to work on a “next day basis”.

AAE is particularly proud of its most recent signing of the Brazilian-born export – the Romanelli UHR700 and UHR 900 EFlow microsurfacing pavers.

The road ahead AAE is under no illusions that the road ahead in this industry is not a smooth one. Having come through periods of tough economic constraints and even tougher competition, AAE is much wiser and better equipped to navigate beyond the horizon. Confident in its technical and practical expertise, this “one-stop-shop” is surely poised to become a major player across the continent. With the industry’s big name brands on its team, AAE is sure to add val- ue to any project. THE AAE BRAND PROMISE For Asphalt Equipment, Bitumen Handling Equipment, Earthmoving Equipment or Professional Consulting, make Associated Asphalt Equipment your PARTNER of choice for prudent advice and expert industry knowledge. b

Products and services at a glance • Asphalt equipment • Bitumen equipment • Asphalt surfacing equipment • Slurry pavers

• Earthmoving equipment • New & used equipment

CAPITAL EQUIPMENT NEWS NOVEMBER 2016 5

CONSTRUCTION NEWS

Increased longevity for new CP Red Rock compressors

International construction equipment man- ufacturer Chicago Pneumatic recently launched Red Rock, said to be its toughest ever range of portable air compressors. The Red Rock range is made tough by its durable polyethylene canopy supplied as standard on all 10 models. “With the Red Rock range, our portable compressors have taken a massive leap forward in durability,” says Manu Claes, spokesperson for portable compressors at Chicago Pneumatic. “To show just how tough the canopies are, we threw everything at them, from bricks to logs, and are happy to say they passed the test with flying colours! As a result, operators can be rest assured the compressors are highly protected, ensuring performance over time and increased longevity.” “Remarkably these compressors weigh less than 750 kg and two of the models in the range feature a built-in generator as standard and still weigh below the 750 kg mark,” says Jacques van der Westhuizen, business development manager for Chicago Pneumatic in South Africa. Thanks to the compact design, the compressors boast a small footprint. As a result they take up less space on the job site and can be simply transported on a single truck. The compressors can also be easily and NEW MB DRUM CUTTERS FOR CONFINED SITES Renowned bucket crusher manufacturer MB Crusher has expanded its product portfolio with its range of MB-R hydraulic drum cutters, available in three models for excavators from 6 t to 35 t. The range of drum cutters is particularly suit- able for rocks and levelling concrete surfaces, in quarry excavation, tunnelling, demolition and road works. Reduced size makes them ideal for applications in urban areas and confined con- struction sites, where it is generally difficult to deploy large machines. The range’s compact design with a low centre of gravity significantly improves the overall balance and drastically reduces the strain and vibrations on the excavator arm. The range’s patented system, the twin direct drive motor, allows force distribution in the two drum heads. In case of materials with different hardness, MB drum cutters mould by using a proportional force depending on the tenacity of the material, thus resulting in increased sta- bility and reduced stress on the excavator arm. The special MB custom hydraulic system limits the demand for fluid and provides a significant cooling effect, prolonging the excavator life. b

Chicago Pneumatic’s recently launched Red Rock is said to be the toughest ever range of its portable air compressors.

conveniently towed by a standard passenger vehicle. For added peace of mind, Red Rock compressors are easy and affordable to maintain requiring a simple service every 500 hours or once a year. The machines are also quick to service; a simple-to-follow process ensures that service can be done in a matter of minutes instead of hours and no special

tools are required. The range is available in working pressures between 7-12 bar and flow ranges between 2-5 m³/min. “The introduction of this range enables us to offer a complete solution of portable diesel air compressors required in the local construction industry,” adds Van der Westhuizen. b ucts over the past 18 months. “Our tests have determined that the products are of world class quality and design that make them highly suitable for our local market conditions, especially in construction,” says Bester. One of the most important design features of the Rato engine is the dou- ble balancer crankshaft running on roll- er bearings which enables it to operate in vibratory conditions typically found in the tough construction environment. For further reliability, GPP has also in- troduced a specialised air filter system on all its construction equipment en- gines. The Rato product range available to the African markets from October 2016 includes petrol driven genera- tors (2-10 KVA and inverters), engines (7-15 hp), as well as fertiliser pumps and trash pumps (3 and 4”). Bester adds that there are plans to later ex- pand the range to include water pumps (15-100 ml), high pressure cleaners, fire fighter equipment and twin engines from 20 hp upwards. b

Goscor powers Rato engines into local market Goscor Power Products, a leading Southern African distributor of generators, engines and pumps, has been appointed as the of- ficial distributor of the Rato power product line up for the Southern Africa and East African regions.

“In accordance with the agreement we signed with Chongqing Rato Power, our entire construction equipment range will all be powered by Rato engines,” says Mark Bester, managing director of Goscor Power Products (GPP). Bester says that following extensive research, GPP took on Rato, a Chinese brand already well-known and proven within the middle and high-end custom- er sectors across Europe and in North America. Rato is manufactured in the Subaru, Wacker, Koshin, Ellemax ap- proved 470 000 m 2 factory, in Chongqing and is said to be one of the most com- petitive enterprises in general-purposed engine fields in China. Rato also has a manufacturing facility in the United States where the brand is, according to Bester, “taking the market by storm.” GPP has been testing the Rato prod-

CAPITAL EQUIPMENT NEWS NOVEMBER 2016 6

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CONSTRUCTION NEWS IN BRIEF

Greater flexibility with new Atlas Copco XATS 900E Shown for the first time at MINExpo International, Atlas Copco Construction Equipment’s new XATS 900E electric portable air compressor features four pre- set flow and pressure selections to give contractors versatility and rental centres greater flexibility in their fleet offering for improved return on investment. The compressor features a high- efficiency 160 kW WEG 22 motor. The electric motor gives contractors a cost-effective alternative to traditional diesel-powered air compressors because electricity prices are less volatile than fuel costs. The XATS 900E operates at a very quiet 73 decibels, about the same as a vacuum cleaner, which allows contractors to work in noise-sensitive areas, such as near hospitals or schools. Hiller to take the reins at DEUTZ Dr Frank Hiller (50) is to be appointed as a member of the Board of Management of DEUTZ AG and its Chairman with effect from 1 January 2017. He succeeds the current Chairman of the Board of Management, Dr Helmut Leube (63), who is retiring on 31 December 2016. Dr Hiller has spent his entire career in industry, most recently as a member of the Executive Board at MAN Truck & Bus AG (from 2009) and of the Management Board at Leoni AG (since 2014). “We are delighted to have appointed someone as the new Chairman of the Management Board of DEUTZ AG who has considerable experience within our industry both on the engineering side and in sales and market- ing,” says Hans-Georg Härter, Chairman of the Supervisory Board. Atlas Copco Construction Technique has handed over an RTEX handheld pneu- matic breaker to Dries Fouché and Shaun Sirchia, franchise owners of Talisman Hire in Kya Sand, Johannesburg, which they won in a lucky draw during the Talisman Suppliers Day held in August 2016. The relationship between Atlas Copco and Talisman Hire spans over more than a decade. Fouché, who attributes the good relationship between the two companies to the shared synergies of quality products backed by service excellence, says that it is an absolute pleasure doing business with Atlas Copco. Talisman Hire Kya Sand carries the Atlas Copco TEX32 heavy duty pneumatic general demolition breaker which is designed for medium-hard to hard material applications and is also suited . RTEX breaker for Talisman Hire Kya Sand

CASE READIES FOR TUNISIAN ROAD CONSTRUCTION

CASE recently demonstrated the prowess of its machines in extreme weather and terrain conditions.

With its wide range of equipment for the road-building industry, CASE Construction is positioning itself for planned large-scale projects for the development of Tunisia’s road infrastructure, which will require highly productive and reliable equipment to meet the country’s objectives. The Tunisian government views the extension and upgrading of the country’s road infrastructure as a major challenge in its aim to improve access between its regions – vital for the development of its transport sector and its economy. The country’s presidency has allocated €3,5 billion for the construction, refurbishment and maintenance of roads and motorways through to 2020. The country’s infrastructure development projects are also attracting funds from in- ternational financing organisations. For ex- ample, in July 2015, the World Bank granted a €180 million loan to refurbish 146 km of roads in some of the least developed regions in Tunisia, and in February 2016, the Europe- an Investment Bank signed a €150 million framework loan agreement to modernise German compact equipment specialist Wacker Neuson says maximising produc- tivity and minimising operating costs are always top of mind during its product de- sign, and the new 3503 excavator is cer- tainly no exception. “The 3503 features a unique vertical dig- ging system (VDS) which not only makes it possible to work safely on slopes but can lead to savings in material and time by as much as 25%,” notes Eugene Brown, re- gional president for Wacker Neuson Africa. “With local industry currently in an econom- ic strangle-hold, savings of this substantial nature are welcome news for customers and end-users.” Operator fatigue is not only a safety risk, but it can also affect productivity levels, says Brown. “The cabin is the operator’s office so it is imperative that this work

main arteries in the south of Tunis to ease traffic congestion. CASE recently used a road building event in the country to demonstrate the performance and capabilities of its machines in extreme weather and terrain conditions. CASE invit- ed construction companies operating in the infrastructure sector to see its road-building equipment in action and test-drive the ma- chines in real job site conditions. The event, organised jointly with importer Sotradies at its premises in Sousse, highlight- ed the qualities of the CASE machines devel- oped specifically for road building operations in North Africa. The star of the show was the 18 t CASE 865B grader. It is one of three mod- els in the B Series, which has gained good reputation for the ability to work in all environ- ments and their high productivity. For higher performance, the Variable Horse Power on the 865B model maximises operation thanks to the triple horsepower engine curve. The transmission combines the torque converter typical smoothness for fine grading with the direct drive solution for full power transfer. b

New Wacker Neuson 3503 excavator maximises productivity

space offers all-round comfort and safety. The 3503’s large door provides fast, easy and safe access to and from the excavator’s well dimensioned cabin which also meets the ISO 6394 specified sound pressure level of 74 dB(A),” he adds. b The machine’s vertical digging system can lead to savings in material and time by as much as 25%.

CAPITAL EQUIPMENT NEWS NOVEMBER 2016 7

CONSTRUCTION NEWS

MERC SHOWS NEW OFF-ROAD VEHICLES AT IAA

Mercedes-Benz used the 66 th IAA Interna- tional Motor Show for Commercial Vehicles to present a cross-section of its wide range of two, three, and four-axle chassis, trac- tor units and tippers for the construction industry and ancillary trades. The range of models on show featured a wealth of tech- nical innovations and customer-oriented advancements. The centrepiece was the Arocs – the specialist construction vehicle from Mercedes-Benz. It is available with two, three or four axles, with drive configurations from 4x2 to 8x8. With versions ranging from the Arocs Loader tractor unit and concrete mixer for on-road use to the Arocs Grounder for frequent off-road use, it covers all the bases for building contractors. Meanwhile, the latest generation of heavy- duty OM 470 and OM 471 diesel engines are now available as standard for the Mercedes- Benz Arocs, too. The OM 936 and OM 473 engine families remain part of the line-up. New flagship versions include the Arocs “46” models with 335 kW (460 hp/2200 Nm) OM 470 and the “53” models with 390 kW (530 hp/2600 Nm), powered by the latest generation of the OM 471. Both six-cylinder in-line common-rail engines Bell launches new L-series TLB Bell Equipment has launched its new L-Se- ries Tractor Loader Backhoe (TLB). Though regarded as an entry-level machine for gen-

have been optimised by implementing a raft of technical measures for even lower fuel consumption and improved performance characteristics. Examples include the new X-Pulse injection system with enhanced pressure boosting, an asymmetrical exhaust gas turbocharger produced in-house at Mercedes-Benz and the use of new low- friction engine oils. When paired with the Mercedes-Benz PowerShift transmissions, which have been further optimised in terms of efficiency, the new six-cylinder engines can reduce fuel consumption and therefore carbon emissions by up to 3%. For low-body applications with an overall height below that of the Arocs cab roof, ap- plications with roof recesses such as timber or crane transporters, as well as applications on routes with limited headroom due to low bridges or height restrictions at construction site or yard entrances, the Mercedes-Benz Arocs is now also available with a lower driver’s cab. The M and L versions of the new ClassicSpace LowRoof cab with a width of 2 300 mm feature an all-new design in the roof area. It is 100 mm lower than the ClassicSpace cab and will bridge the gap between the ClassicSpace cab and the

The new Mercedes-Benz Uptime service increases vehicle availability.

26 mm lower CompactSpace cab. Features that enhance comfort and enhance resale value include the new- ly introduced SoloStar-Concept for the Mercedes-Benz Arocs StreamSpace and Big- Space cabs. Numerous configuration options in the cab allow a combination of workplace and comfortable, generously proportioned living and sleeping quarters. b pletely sealed to protect against moisture, dust and debris. The SSM comes standard with keyless start and a machine-security system, which requires a passcode to pre- vent unauthorised operation of the TLB. To boost productivity, the new L-series TLB has improved cab ergonomics, making the operator’s workspace even more us- er-friendly. “An enhanced Loader control grip has a new ergonomic design that in- tegrates fingertip controls into the grip for ease of use. Additionally a multi-function lever has been introduced on the steering column to control lights, wipers and indi- cators to create a feel more like a modern car, keeping the operator focused on his surrounds while operating in the Loader po- sition,” says Oldridge. In keeping with proven concepts from the very first Bell TLBs, the L-series retains its unitised mainframe and excavator-style boxed structures which are light weight to provide maximum rigidity and structur- al integrity for the life of the machine. A welcome enhancement is the addition of external shimming of the stabiliser legs to reduce machine movement and improve accuracy during backhoe operation. b

eral earthworks, the newly launched Bell L-series TLB is said to come with a wide range of features often found on much larg- er and more sophisticated equip- ment.

Driven by a John Deere Pow- erTech engine, the 315SL has a top speed of 40km/h when travelling to a jobsite. The five-speed Power- Shift transmission provides smooth shifting and reliable performance with on-the-fly all-wheel drive en- gagement. These features, togeth- er with the standard limited-slip differential on the front axle and fully locking differential on the rear, deliver greater tractive effort and overall 4WD performance. The rear differential lock protection can also be enabled through the machine’s monitor, which prevents potential damage from rear differential lock engagement at high speeds. According to Dale Oldridge, Bell product manager, the Sealed Switch Module (SSM) in the cab offers a central location for the machine’s functions and is com-

The Bell 315SL is an entry-level machine ideal for general earthworks.

CAPITAL EQUIPMENT NEWS NOVEMBER 2016 8

ROAD CONSTRUCTION

VÖGELE TECHNOLOGIES LEND FLEXIBILITY TO REHABILITATION PROJECTS

I n many countries, construction com- panies are hired to rehabilitate exist- ing roads frequently than to build new ones. In addition to the conventional process of milling off the surface and replacing the asphalt pavement, two other methods exist that are gaining ground world- wide: paving thin overlay on spray seal and the “hot on hot” paving of compact asphalt pavements. The two methods were made possible by Joseph Vögele AG, part of the Wirtgen Group, and its specially developed machine technologies. The road construction machin- ery specialist has now combined the two innovations into one. The solution emerged with and for Rask Brandenburg GmbH, a cus- tomer that specialises extensively in modern methods of rehabilitation. The machines behind the modern methods of road rehabilitation are the SUPER 1800- 3i SprayJet paver (for thin overlay) and the Vögele InLine Pave train (for compact asphalt pavements). The latter comprises a Vögele MT 3000-2i Offset PowerFeeder, a SUPER 2100-3i IP for placing binder course and another Vögele paver for the surface course. “With our InLine Pave train and the SUPER 1800-3i SprayJet as the surface course paver, we really have a jack of all trades in our machine fleet,” says Bernd Malcharek, president of Rask Brandenburg GmbH. The combination of leading technolo- gies from Vögele gives us maximum flexibili- ty.” The underlying idea is that Rask Branden- burg can take on conventional paving jobs in future, and still be prepared for thin overlay and compact asphalt paving. The future Malcharek belives that paving thin overlay and compact asphalt are the future. Just a few weeks after shipment, the SUPER

are one of the main reasons why more and more companies are choosing InLine Pave,” says Ray Löffler, general manager of Wirtgen Zwickau, who is responsible for Rask Bran- denburg GmbH. “The InLine Pave process is fully developed and increasingly winning over the market.” Meanwhile, a durable binder course is ensured, thanks to Vögele high compaction technology. Equipped with an AB 600 TP2 Plus Extending Screed, the SUPER 2100-3i IP places a highly compacted binder course that the surface course paver can travel over it without prior rolling. This is made possible by another core innovation: high compaction technology with Vögele’s unique pulsed- flow hydraulics. In this step, the asphalt is pre-compacted during paving by a tamper and two pressure bars. Advantages of SprayJet technology For Rask Brandenburg, VÖGELE adapted the technology on the SUPER 1800-3i SprayJet in such a way that the machine can take over the job of paving the surface course in the InLine Pave train. The machine operates here in the conventional manner, i.e. not in spray mode. This is because the “hot on hot” method achieves a perfect bond between layers and strong interlocking, even without spraying bitumen emulsion. The modifications made to the SUPER 1800-3i SprayJet include the incorporation of a water spray system and wider crawler tracks. For spray applications, the paver is equipped with a removable SprayJet module, which enables it to simultaneously pave and accurately spray the emulsion. After the surface course is paved (by the SUPER 1800-3i SprayJet in the case of Rask), rollers are used as usual to achieve final compaction. b

1800-3i SprayJet had already clocked 600 operating hours, all of them spent on spray paver jobs; “hot on hot” jobs using InLine Pave technology. “The future belongs to this process. Construction projects can be completed quickly, and that benefits traffic flows. They are cost-efficient, in part because the step of pre-spraying emulsion is entirely eliminated. And the results are high-quality, because the bond between layers is outstanding,” says Roland Schug, head of Marketing at Vögele. When it comes to rehabilitation with the compact asphalt method alongside flowing traffic, in the InLine Pave process, the bind- er and surface courses are paved “hot on hot” in a single pass. In other words, the two Vögele pavers work “in line”, with just a few metres between them, so that one lane can remain open to traffic. A Vögele MT 3000-2i Offset PowerFeeder with pivot- ing conveyor and automatic distance control ensures a continuous supply of material. The paver operators can therefore concen- trate entirely on paving. Placing binder course The central technological component of the InLine Pave process is the SUPER 2100-3i IP for placing binder course. Apart from the innovations of the latest “Dash 3” paver generation, the advanced machine has an entirely redesigned transfer module whose heated conveyor system has been extended by 1 m. It transfers the mix for the surface course to the downstream paver. At a defined point, the new transfer mod- ule can easily be removed, a feature that boosts the machine’s capacity utilisation. What is more, the height of the seats on the two operator’s platforms can now be adjust- ed hydraulically. “Advancements like this

In the middle of the Vögele InLine Pave train is the new SUPER 2100-3i IP for placing binder course.

CAPITAL EQUIPMENT NEWS NOVEMBER 2016 10

MATERIALS PROCESSING NEWS

MULTOTEC GV CYCLONE THE ANSWER FOR TAILINGS DAMS Tailings dams are sensitive to operating costs, and while these operations require quality process equipment, there is a definite need for equipment with a low mass capable of functioning at the required capacity and that will be cost-effective over the life span of the installation. Designed specifically for tailings dam applications, the Multotec GV Cyclone is engineered to ensure sound operational performance while keeping the cost of individual components as low as possible. RichardHaydon, processmanager atMultotec Process Equipment, says it is important that this has been achieved without affecting the structural integrity or quality of the locally developed and manufactured cyclone. “When it comes to cyclone operation on a tailings dam, it is critical to ensure that the right volumetric split between the overflow and underflow is achieved to match the re- quired tailings dam rate of rise,” explains Haydon. Available in different configurations to suit varying application and commodity requirements, Haydon says it is the ability to interchange the spigot and vortex finder on the Multotec GV Cyclone that enables a fit-for-purpose product installation. Optimum flexibility is possible due to the different spigot sizes and vortex finder sizes that are available. By altering the combination of the spigot and vortex finder, it is possible to meet the specific operational parameters. Selection of the size of either component is dependent on the material characteristics, and the tailings dam requirements. Each cyclone is designed for an individual application which ensures that the feed parameters are matched to the cyclone capacity and by doing so the lifespan of the cyclone is optimised. “Where an application is that specific, Multotec will collaborate with the customer to find a unique and appropriate solution, and this hybrid solution will take all factors into account,” says Haydon. This will include materials of construction specific to the application, assuring the customer the best possible wear life. b

Metso helps B&E International break beyond 550 tph

pleted in an existing Metso 9100 vertical shaft impact crusher,” explains Sandro Scherf, CEO of Pilot Crushtec Internation- al, the sole southern African distributor for Metso Mobile aggregates products and services. He adds that the cone crushers play com- plementary roles in obtaining production volumes of this magnitude. The Lokotrack 300GPS is capable of a huge output and key to the success of the train as a whole is the LT330D combination product’s ability to process, screen and recirculate massive volumes of secondary material. According to Scherf, both of the cone crushers were specially purchased by B&E to produce high volumes of aggregate. B&E, which is expected to achieve a turnover of R1 billion in 2016, is an experienced user of Metso Mobile products, operating a fleet of more than 40 Metso units. b

Thanks to the innovative use of Metso Mobile crushing and screening units, South African crushing contractor B&E International has set up a production train that consistently produces G1 road stone product at a rate in excess of 550 t/hour. Incorporating the first Metso Lokotrack 330D combination cone crusher and the 11  m² triple deck screen to be put into action on the continent, this is regarded as one of the first mobile trains in the region to achieve these volumes. “The train consists of four Metso prod- ucts: 700 mm dolerite feed material is first processed by an LT120 jaw crusher and is then fed into a Lokotrack 300GPS sec- ondary cone crusher which is capable of accepting material up to 320 mm in size. This in turn feeds the Lokotrack LT330D combination cone crusher and triple deck screen before quaternary crushing is com-

Metso Lokotrack LT300GP mobile cone crusher and LT120 mobile jaw crusher are being used in a train of four Metso machines.

New MDS M412 for low capacity requirements

BLT has launched the new M412 trom- mel, said to offer cost-effective solutions for smaller production requirements in mineral processing and recycling appli- cations. “This lightweight machine, with a compact design, is able to efficiently handle various materials, from compost recycling to blasted rock,” says Ken Mouritzen, managing director, BLT (Africa and Indian Ocean Islands). “M412 trommels have interchangeable screens for different size rocks – between 10 mm and 500 mm – and are capable of producing four products concurrently, at an output rate of 150 t/hour.” The machines are available as static units or on tracks, depending on customer preference. Other features include the hydraulic push feeder mechanism, an electric/hydraulic power system and easy to operate control panel. The trommels can be used with conveyors and are also fitted with a washing system as an option. The M412 trommels weigh in at

18 t and have a 1,25 m drum diameter and 4,5 m drum length, making them easy to be transported in a container. Other machines in the MDS trommel range include mobile and semi-mobile units, as well as heavy duty static machines for maximum output. Also in the range are static and tracked trommels for light and heavy duty recycling. MDS trommels and apron feeders, which are available from BLT on a purchase or rental basis, are supported by strong technical advisory and maintenance service throughout Africa and the Indian Ocean Islands. b

The recently launched M412

trommel is ideal for smaller production requirements in mineral processing

and recycling applications.

CAPITAL EQUIPMENT NEWS NOVEMBER 2016 12

MATERIALS PROCESSING NEWS IN BRIEF

Metso recognised Metso has been presented with an award by Freeport-McMoRan Inc. for the long-term partnership between both companies. “Your long-time support of Freeport-McMoRan has been a cornerstone of our success. Most recently, your highly motivated team has partnered with us as we weather the difficult cycle that brought copper prices to near six-year lows. Thanks to this team effort, both our companies have worked to reduce costs, gain efficiencies and remain competitive. I am confident in the long-term future of commodities and our industry. We look forward to further strengthening our partnership and moving ahead together,” says Richard C Adkerson, president and CEO of Freeport-McMoRan. CDE’s research buy-in CDE Global recently participated in the first meeting of the EU-funded RE4 Project in Brindisi, Italy. Over the next three-and- a-half years following the first landmark gathering on September 15, CDE shall contribute to this group to develop new technologies to increase the reuse and recycling of construction and demolition waste material in energy efficient prefab- ricated elements for building refurbish- ment and construction. “To be involved in the first Horizon 2020 funded research project in this area is an exciting prospect and a great oppor- tunity to make significant advancements in reducing the environmental impact of construction and demolition activities,” said Sean Kerr CDE representative, the Northern Ireland firm’s head of engineer- ing, speaking about the project. Terex AggreScalp to boost quarries’ bottom line Terex Washing Systems (TWS) has launched its new Terex AggreScalp scalp- ing unit and new Finesmaster UltraFines recovery system, both said to boost any quarry operation’s bottom line. The Terex AggreScalp is a versatile, high-perfor- mance heavy-duty electric screening ma- chine that has the flexibility to operate as a two-way or three-way split screener. The aggressive screen can accept media including bofor bars, finger screens, woven mesh and 3D punch plates, which allows it to be used across a wide variety of applications. With on-board hydraulic folding product conveyors, hydraulic screen angle adjustment and single lift set-up, it is easy to transport and to set up. The AggreScalp can work in conjunc- tion with the Terex AggreSand range by providing a consistent feed material even in difficult applications. b

Weir Group forges ahead with foundry investment

Since the 2013 acquisition, Weir HBF is now ISO9001, OHSAS18001 and ISO1400 accredited.

Weir Group’s investment into itsWeir Heavy Bay Foundry (HBF) continues at pace, and is set to position the operation as a best cost producer of quality castings. The recent commissioning of an advanced secondary sand plant at Weir HBF will allow the Port Elizabeth foundry to reduce manufacturing costs, further enhance the quality of its castings and mitigate the impacts of the operation on the environment. Grant Ramsden, operations director at Weir Minerals Africa, says the new sand plant deploys magnetic separation technology to extract chromite sand added to furan sand during the moulding process. The plant also scrubs the resin from the sand by a process of attrition. The recovered furan sand can now be reused, resulting in significant savings in sand disposal costs, resin costs and the purchasing of new sand. “In addition, Weir HBF will be able to improve the efficiencies of its casting processes by reducing ‘sand Haver & Boecker, an equipment manufacturer and solutions provider in aggregates and mining applications, has introduced its Tyler brand of hooked engineered screen media as a solution to the problem of expensive deck conversions. Tensioned screen media can be used on a cambered deck, eliminating the need for a deck conversion when switching from woven wire to polyurethane screen media. The media includes products such as Ty-Max and Ty-Wire. “Hooked screen media allows operations to easily switch from woven wire to modular polyurethane products without the expense of a deck conversion,” the company says. Retrofitting a machine from a cambered deck to a flat deck can cost as much as US$15 000 per deck. Tyler’s tensioned screen media is used on a cambered deck to eliminate the need for that conversion. This also allows operators to test the media on a vibrating screen with no additional cost or commitment. Another benefit is that Ty-Max and Ty-Wire can be blended with woven wire or

burn-on’ caused by excess chromite sand in the furan sand,” says Ramsden. The secondary sand plant incorporates German proprietary chromite separation technology, and state-of-the-art program- mable logic controllers. In line with lean manufacturing principles, the plant only runs when there is a demand for sand. It was installed and commissioned using Weir engineering expertise. The lion’s share of the overall investment has gone into improving safety and productivity of workers at the operation. A sound example of this is the seven new fettling booths that have all been equipped with dust extraction systems. “Equipped with state-of-the-art equipment and its strategic location close to the deep water Port of Ngqura, there is no reason why this operation will not be able to contribute to Weir Minerals Africa seizing a larger share of the niche one ton to 17 t castings market,” says Ramsden. b self-cleaning screens on cambered decks. In many applications, operators are looking for more wear life on the feed end of the screen. This can be accomplished by installing a section of Ty-Max at the feed end. Ty-Wire can be used in the middle of the deck, for example, where basic screening takes place to give operators the ideal combination of wear life and open area. Using woven wire or self-cleaning screens at the discharge end will provide maximum open area at the end of the deck. The polyurethane screen media is manufactured out of Tyrethane, Haver & Boecker’s signature blend of polyurethane. Chemists developed Tyrethane to offer the best combination of open area and wear life for both wet and dry applications. Tyrethane is poured open cast, resulting in 1,5 to two times longer wear life than comparable injection-moulded products. In addition, open cast polyurethane permanently hardens when cured to maintain its chemical properties, so it resists wear and tear. b

Alternative to costly deck conversions

CAPITAL EQUIPMENT NEWS NOVEMBER 2016 13

MINING NEWS

Demystifying urban legends of beating the breathalyser

Improving operational efficiency

MBE Minerals is expanding its service centre in Kathu, South Africa. Officially launched in the second quarter of 2015, the facility supports the company’s large installed base of equipment in the Northern Cape Province. Johannes Kottmann, managing director of MBE Minerals, explains the importance of providing support on customers’ doorsteps. “It is imperative that we can provide technical support and backup services to customers in this region from a local facility and the decision to expand our existing service centre will see a sizeable investment by the company.” MBE Minerals is a leading supplier of iron ore and coal beneficiation technology, and is focussed on providing the greater aftermarket support. Kottmann says that this approach enables the company to meet customer-specific requirements. He “This is something often attempted at roadblocks where there is police presence to monitor drunk drivers and it has even been attempted where substance or alcohol testing is implemented randomly in a manufacturing, mining or construction environments,” says Evans. “Such tricks have evolved into an urban legend with most people able to pass on a story of how a friend or acquaintance fooled a breathalyser test, but these tricks are nothing but myths.” In short, there is no way to beat a breathalyser test, unless the test subject has not been drinking. Despite this, companies and law enforcement agencies are having to test more often, illustrating the fact that employees and citizens are unfamiliar and misinformed about the extent of alcohol testing, whether for recreational or professional purposes, which means it’s time to demystify these urban legends, says Evans. Designed to test for blood alcohol content (BAC), breathalysers are used in industries and scenarios where intoxication is hazardous to health and life. South African law has two levels for permissible BAC percentages – the professional driver limit is 0,10 mg/l. For obvious reasons, alcohol consumption is banned by the OSH Act and When it comes to breathalysers, there are many misconceptions that exist (and persist) about what these tests can and can’t do that have led to the belief that it is possible to beat the breathalyser, so says Rhys Evans, MD of ALCO-Safe.

is predominantly enforced in the mining, civil engineering, construction, manufacturing, transportation and other industries with a zero tolerance approach, given the serious ramifications of operating dangerous machinery under the influence. Testing for alcohol is mandatory in certain industries, and this is done using a breathalyser before entering the workplace. While there are a number of different types of breathalysers, the good ones gen- erally work the same, and they are all de- signed to be used by an operator. “It’s important to know upfront that if the operator is using the test device correctly by not handing it to the person to test him- self, and if the device used is a good-quali- ty breathalyser, there is no way to cheat it. However, in order to ensure that the device delivers accurate readings, it is important to calibrate the breathalyser,” says Evans. “Good breathalysers use something called an electro-chemical fuel cell, which is the heart of the instrument detecting alcohol. This can go up in sensitivity or drift down in sensitivity.” b

Michelin XDR3 increases tyre life by a minimum of 10%.

Mining operations experience difficulties with their vehicles on a daily basis due to the rigid landscape, operational inefficiency and lack of safety within the workplace. The new 40.00 R 57 and 53/80 R 63 Michelin XDR3 tyres have been designed to improve these factors. The new Michelin XDR3 is said to re- spond to the needs of mine operators by incorporating three key innovations, which together increase tyre life by a minimum of 10% compared with its predecessor, the Michelin XDR 2. Compared with its predecessor, the tyres’ new tread pattern offers multiple benefits. It offers better endurance due to improved heat dissipation capabilities – 8°C cooler in the tread area. A greater volume of tread rubber is in contact with the ground, which improves wear and ensures better load dis- tribution throughout the contact patch due to a lower contact pressure. Interlocking shoul- der blocks resist excessive movement during cornering and further reduce tyre wear. With four innovative rubber compounds – the MB4, MB, MC4, MC – the exclusive new mixing process ensures a more uniform com- position of rubber compounds and a greater level of carbon black dispersion that increas- es wear resistance. Each unique compound offers specific performance characteristics adapted to site conditions and usage, from high wear resistance to high thermal capac- ity for speed. The high-strength corrosion isolating steel cables used in the tyre’s casing are 10% stronger than in the previous XDR2 and are encapsulated in rubber to prevent the spread of corrosion within the casing, which extends the life of the tyre. The 40.00 R 57 Michelin XDR3 is available from September 2016, while the 53/80 R 63 will roll into the market in January 2017. b

MBE MINERALS EXPANDS KATHU SERVICE CENTRE

says that mines need OEM suppliers that are committed to work with them to ensure the optimum efficiency of equipment. “It is not sufficient to just provide qual- ity OEM equipment that is engineered to be fit-for-purpose, it is also essential that technical support is readily available to en- sure optimum uptime and productivity for the mine,” he says. The MBE Minerals Service Centre, which is under the management of Rudi van Deventer, will be doubled in size to allow for the reconditioning and assembly of bucket chains and jigging panels. The fully equipped workshop will accommodate the inspection, repair and assembly of various other components as well. A comprehensive spare parts stockholding matches with the company’s equipment footprint, allowing customers ready access without the need to wait for these to be shipped from Gauteng. b

CAPITAL EQUIPMENT NEWS NOVEMBER 2016 14