Monthly Archives: August 2024

Client Focus

CONSTRUCTION TRANSFORMS THROUGH SHARING SKILLS, EXPERIENCE

Despite difficult market conditions in South Africa’s construction sector, Concor has never shied away from its commitment to social and economic transformation, which includes the strengthening of small businesses in areas where the company has projects underway.

According to Sheldon Mayet, Senior Transformation Manager at Concor, the procurement, skills development and recruitment process are valuable ways through which the company can empower small businesses in the communities where it works. This is particularly important in and around the country’s smaller towns, where business opportunities are more limited. 

“When we embark upon any project through or near a town, we always engage with local communities and businesses, firstly to inform them who we are and then to provide them with information about selected project requirements and opportunities which are available to them during the construction phase,” says Mayet. 

“In fact, the whole procurement process is carefully planned and managed, not only to give small businesses fair access to work but also to grow them with the relevant skills so they can become more viable in the long run.”

Among the first steps in each of these projects is for Concor to engage intensely with local structures of government and community members, to understand more about the area where the project will be located, he explains. This paves the way for compiling a database of skills availability, local businesses and for Concor to understand the dynamics of the community to ensure the company develops a trust relationship which is critical to the success of the project. 

“In addition to the small businesses from which we procure, we also draw our general workers for each project from the area we work in,” he says. “We talk to representatives from the nearby towns and villages to ensure that there is an equitable distribution of opportunities, while we also seek out the best available skills.”

At the same time, there is usually the need for work site training – such as health and safety, first aid and induction – which to a certain extent upskills these workers and makes them more employable when they seek their next jobs. 

In balancing its social contribution with its professional reputation and workmanship, Concor must ensure that the quality of its project deliverables is in no way compromised. Mayet highlights how the company focuses on the close and systematic supervision of all subcontractors, through its permanent team of experienced site managers, foremen and artisans. 

“Supervision is in fact an important aspect of the mentoring that we provide to small businesses who partner with us,” he says. “We help them to hone their construction-related skills, so they can participate more competitively in their markets.”

An important building block of any business in the construction sector, for instance, is its grading with the Construction Industry Development Board (CIDB). As a business moves up the nine CIDB grading levels, it can tender for projects of increasing value. Vital to any business’s progress to the next grade is its ability to improve its track record of actual projects competed. 

“We work constructively with emerging subcontractors to improve their profitability, systems and expertise, and to successfully complete their scope of work with us,” he says. “They are often able to achieve a better grading on the strength of our collaboration.”

Mayet emphasises the challenging but positive role of the Community Liaison Officer on each of its projects. The CLO is a community-based person appointed by Concor to help ensure that the company and community can work together and meet their common goals. 

“On every project, we upskill people and allow small businesses to gain more experience – which are the basic steps toward economic transformation,” he concludes.

Client Focus

TRU-TRAC BELT SCALE WINS THE DAY FOR AFRISAM COEDMORE QUARRY

Following worrying discrepancies in the monitoring of production output, sales and inventory, a belt scale from Tru-Trac is winning the day for KwaZulu-Natal-based AfriSam Coedmore Quarry. With groundbreaking static calibration accuracy error levels as low as 0,06%, the belt scale provides reliable data for sound decision-making.

Over the years, AfriSam Coedmore Quarry has had issues with stock capturing and evaluation. “Accurately measuring production, sales and stock levels is critical for effective management and efficient operations,” says Lloyd Maringa, Works Manager at AfriSam Coedmore Quarry.

“Traditionally, we conduct quarterly stockpile surveys though an independent third-party to gauge the levels of stock on the ground. It was during these surveys that we would always encounter huge discrepancies between what we had produced, what would have been sold and what should have been on the floor.”

In some instances, the variations were as high as 70 000 tonnes (t). In the quest to resolve the problem, the operation resorted to monthly surveys instead of the usual quarterly routines. The more frequent surveys, however, did not yield different results. Further investigations eventually pinpointed issues with the existing belt scale between the intermediate stockpile and the secondary crusher. Despite several interventions, including regular calibrations by the supplier and even the installation of a second belt scale, the challenge persisted.

“We therefore went into the market for a new belt scale supplier,” explains Dustin Naidoo, Maintenance Superintendent at AfriSam Coedmore Quarry. “Tru-Trac proposed a proof-of-concept approach, whereby they installed a belt scale on a trial basis for a month. Upon evaluation of the results, we were impressed by the high levels of accuracy.”

Since the installation of the Tru-Trac belt scale, the stock management and evaluation problems are a thing of the past. “We have now reverted to the usual quarterly stockpile surveys, which saves us both time and money,” says Maringa.

Tru-Trac’s flagship TTR FI-4 belt scale system installed at AfriSam Coedmore uses a fully floating pivotless weigh frame supported by four load cells, making it ideal for high-precision applications. It is a simple and extremely accurate system engineered to produce precise data. With a proven accuracy margin under 0,1%, the belt scale sets industry standards in metallurgical accounting.

“In addition to the accuracy of the technology, we are equally impressed by the service provided by Tru-Trac. Although they taught us to do in-house calibrations, a technician visits our site every month. Choosing Tru-Trac has proven to be one of the best business decisions we have made in recent times,” concludes Naidoo.

Client Focus

UPTICK IN DEMAND FOR BOOYCO HVAC SYSTEMS BY SOUTH AFRICA’S OEM SECTOR

There has been a noticeable uptick in demand for the locally manufactured Booyco HVAC systems by South Africa’s Original Equipment Manufacturers (OEM). Brenton Spies, Managing Director of Booyco Engineering, says that the upswing is seen as a promising indicator of growth within the South African OEM landscape, highlighting a robust response to local manufacturing capabilities and innovation.

Booyco Engineering, known for its high quality locally engineered and manufactured HVAC solutions, has received an influx of orders from a range of local OEM facilities. Some of these facilities specialise in producing underground mining machinery such as Load-Haul-Dump (LHD) units and utility vehicles, while other manufacture surface mining equipment and construction machinery. 

Spies say that the growing demand for Booyco’s HVAC systems underscores their reputation as a reliable and purpose-built solution, capable of enduring the extreme conditions often found in Africa’s challenging environments.

“South Africa’s mining and construction sectors, in particular, are notorious for their demanding operational contexts, where equipment must withstand not only physical stresses but also extreme temperatures,” he says. “With summer temperatures frequently exceeding 34 degrees Celsius, the need for durable and efficient HVAC systems has never been more critical. By designing for T3 conditions of ambient temperatures up to +46 degrees Celsius, our offerings stand out in this regard, providing a range of standard HVAC systems alongside the ability to partner with OEMs for custom-designed solutions tailored to specific equipment requirements.”

A key differentiator for Booyco Engineering has been its commitment to local production underpinned by rigorous in-house testing. Each HVAC system is developed and tested under the harshest conditions to guarantee performance reliability in the field. This local manufacturing approach not only supports the South African economy but also ensures that products are ideally suited to local conditions.

Supporting these systems in the field, Booyco Engineering operates a team of skilled artisans as part of their field service crews. These professionals are essential for maintaining the high performance and reliability of Booyco HVAC systems in the field, with the company even offering man on-site contracts where necessary to provide continuous support.

Moreover, Spies says, Booyco Engineering is aggressively expanding its reach within Sub-Saharan Africa by appointing distributors and service providers. This strategy aims to provide localised support and service to customers across the region, further enhancing the accessibility and reliability of Booyco’s HVAC solutions.

“We believe the increased demand for Booyco Engineering’s HVAC systems from South Africa’s OEM sector is a testament to the company’s innovation, quality and commitment to supporting local industries,” Spies concludes.

Client Focus

AFRISAM CONSTRUCTS VERULAM COMMUNITY HALL, DEMONSTRATING COMMITMENT TO SUSTAINABLE DEVELOPMENT

AfriSam, a leading construction materials company, has reaffirmed its dedication to the sustainable development of the communities surrounding its operations with the completion of the Verulam Community Hall. This initiative not only showcases AfriSam’s commitment to social responsibility but also highlights its support for local small, medium, and micro enterprises (SMMEs) and the creation of employment opportunities for community members.

The Verulam Community Hall, constructed by a local SMME, stands as a testament to AfriSam’s ongoing efforts to uplift and empower the communities in which it operates. The hall, which has been thoughtfully designed to meet the needs of the community, features a fully equipped kitchen and modern ablution facilities, ensuring a comfortable and functional space for various community activities.

In line with AfriSam’s commitment to environmental sustainability, the Verulam Community Hall incorporates several eco-friendly features. A water tank has been installed to collect rainwater, promoting water conservation and reducing reliance on municipal resources. Additionally, the hall’s surroundings have been enhanced with the installation of paving, providing a safe and accessible area for community members, and a dedicated parking area has been provided to accommodate visitors.

By engaging a local SMME for the construction of the Verulam Community Hall, AfriSam has not only contributed to the economic growth of the community but has also fostered skills development and job creation. The project has provided employment opportunities for local community members, empowering them to contribute to the development of their own community and improve their livelihoods.

Commenting on the completion of the Verulam Community Hall, AfriSam’s Community Development Professional, Senzi Mabaso, stated, “We are proud to have partnered with a local SMME for this project, as it aligns with our commitment to supporting local businesses and uplifting the communities in which we operate. The Verulam Community Hall will serve as a hub for various community activities, fostering social cohesion and providing a space for personal and collective growth.”

AfriSam remains dedicated to its sustainable development initiatives, continuously seeking opportunities to make a positive impact on the communities it serves. The completion of the Verulam Community Hall is a testament to AfriSam’s commitment to creating concrete possibilities for all.

Client Focus

CUTTING COSTS OR CUTTING CORNERS? THE TRUE PRICE OF POOR MAINTENANCE IN MINING OPERATIONS

General maintenance service providers often overlook the intricate engineering design of specialised on-mine equipment, leading to significant long term costs for mining operations. This issue extends to transfer chutes and other mining infrastructure, Farouk Abrahams, Sales Director at Weba Chute Systems, notes. He explains that poor maintenance typically results in unscheduled stoppages due to equipment failure,  compromising mining operations.

Abrahams points out that mines often outsource maintenance to general service providers in an effort to cut costs. Ironically, this approach often results in the opposite effect, with production revenue suffering due to these misguided cost-saving measures. He emphasises that inadequate maintenance undermines the value that original equipment manufacturers (OEMs) promise.

“For Weba Chute Systems, our chutes are custom-engineered for specific duties; any shortcuts in maintenance, such as using inferior materials, can significantly reduce performance and lifespan. This can lead to costly operational consequences including increased impact on conveyor belts, resulting in damage, spillage at transfer points and higher dust emissions—all requiring immediate attention,” he says.

The value brought by OEMs extends beyond just the physical products they supply. OEMs bring a wealth of specialised experience to each product, adding considerable value to a mine’s overall efficiency, safety and profitability. Their deep understanding of the equipment’s design and operational demands ensures maintenance performed will uphold the equipment’s performance standards.

“This expertise translates into smoother mining operations, as our team’s extensive practice in the field allows them to guarantee the outcome of every intervention. The reliability offered by OEMs such as Weba Chute Systems, extends to the timely sourcing or delivery of spares and the convenient scheduling of necessary maintenance.”

Abrahams shares that poor maintenance can drastically reduce plant availability. For instance, by collaborating with a customer on maintenance, Weba Chute Systems was able to maintain plant availability as high as 98%. However, when the mine switched to a general contractor to save costs, availability plummeted to below 90%. Such a decline in performance can be catastrophic for a mine, with minimal operating expenditure savings far outweighed by revenue losses.

Moreover, the impact of inadequate maintenance on specialised equipment like transfer chutes can extend beyond immediate operational issues. The cascading effects of reduced equipment efficiency can strain other parts of the mining operation. “For example,” Abrahams says, “compromised chutes can lead to irregular material flow affecting downstream processes and equipment, increasing wear and tear and necessitating more frequent repairs and replacements. This not only disrupts production schedules but also inflates maintenance budgets.”

“When we maintain our own equipment, we uphold the high standards to which the equipment is designed and manufactured. This commitment ensures reliability and has earned our customers’ trust, demonstrating the true value of specialised maintenance over general service providers,” he says. By ensuring that every component and material used meets the stringent requirements of the original design, OEM maintenance preserves the integrity and efficiency of the equipment, safeguarding the mine’s operational continuity and profitability.

In addition, partnering with OEMs for maintenance can provide mines with access to the latest technological advancements and updates. OEMs are continually improving their designs and incorporating new technologies to enhance performance and efficiency. By engaging with the OEM for maintenance, mines can benefit from these innovations, ensuring their equipment will perform reliably.

Client Focus

RUBBER LININGS RESIST COARSE PARTICLE ABRASION IN PUMPS

Weir has found that its customers dealing with large particle abrasion in their pumps can save significantly on components and maintenance downtime by using rubber linings.

According to Marnus Koorts, General Manager for Pump Products at Weir, these linings excel in applications where particles are being driven by a great deal of energy. 

“Rubber is very good at absorbing and transferring the energy from moving particles , whereas metal liners are more readily worn away by those impacts,” says Koorts. “This makes rubber linings ideal on the larger mill pumps and similar applications, which is where our customers get optimal value from this solution.”

He notes that Weir has spent decades developing its elastomer technology and trialling it in the field, giving it considerable advantage over competitors – many of whom have only recently begun introducing rubber lining on their pumps.

“We have helped customers to deal with some of the most abrasive applications to be found in mining. These conditions are commonly found where hard rock is mined, crushed, and milled, and the coarse particles leave the mill to be pumped further,” he says. “Among our case studies are installations where the pump’s wear life was improved significantly after it was lined with rubber.”

Another benefit of using rubber in these large pumps is that it is relatively lightweight compared to unlined metal pumps, enhancing safety and easing maintenance of rubber parts. 

“A mill pump is a mission-critical item of equipment, so maintenance really needs to be as fast and infrequent as possible,” emphasises Koorts. “The whole plant process often comes to a halt when the mill stops if there is no standby pump, what we call a Service Class 5 pump.”

Replacing a rubber lining on a pump can be done quickly, and less often – giving the plant optimal uptime. He points out that this also provides a higher level of safety against the risk of particle wear actually breaking through the shell of the pump. In cases where these incidents have occurred, the high pressure inside the pump can spray slurry up to a couple of hundred metres – presenting considerable safety and environmental hazards. 

“Where the rubber lining is present, it is encapsulated by a metal shell for added support,” he says. “Maintenance planning can be enhanced by using Weir’s Synertrex wear monitoring technology, which would alert the operators to the need for parts replacement, avoiding failures.”

He highlights that many of Weir’s pump ranges are available with the option of either rubber or metal liners. This has allowed many customers to easily trial the rubber lined option, as this can be done through a simple swap-in process during the plant’s shutdown period.

“We’ve seen a definite shift in the mining industry towards rubber lining on pumps, as mines recognise their value in these applications,” he concludes. “This is also a time when mining companies are starting to consider their upstream and downstream carbon impact. They can gain from the lower carbon footprint associated with rubber linings compared with steel.”

Client Focus

RUBBER LININGS RESIST COARSE PARTICLE ABRASION IN PUMPS

Weir has found that its customers dealing with large particle abrasion in their pumps can save significantly on components and maintenance downtime by using rubber linings.

According to Marnus Koorts, General Manager for Pump Products at Weir, these linings excel in applications where particles are being driven by a great deal of energy.

“Rubber is very good at absorbing and transferring the energy from moving particles , whereas metal liners are more readily worn away by those impacts,” says Koorts. “This makes rubber linings ideal on the larger mill pumps and similar applications, which is where our customers get optimal value from this solution.”

He notes that Weir has spent decades developing its elastomer technology and trialling it in the field, giving it considerable advantage over competitors – many of whom have only recently begun introducing rubber lining on their pumps.

“We have helped customers to deal with some of the most abrasive applications to be found in mining. These conditions are commonly found where hard rock is mined, crushed, and milled, and the coarse particles leave the mill to be pumped further,” he says. “Among our case studies are installations where the pump’s wear life was improved significantly after it was lined with rubber.”

Another benefit of using rubber in these large pumps is that it is relatively lightweight compared to unlined metal pumps, enhancing safety and easing maintenance of rubber parts.

“A mill pump is a mission-critical item of equipment, so maintenance really needs to be as fast and infrequent as possible,” emphasises Koorts. “The whole plant process often comes to a halt when the mill stops if there is no standby pump, what we call a Service Class 5 pump.”

Replacing a rubber lining on a pump can be done quickly, and less often – giving the plant optimal uptime. He points out that this also provides a higher level of safety against the risk of particle wear actually breaking through the shell of the pump. In cases where these incidents have occurred, the high pressure inside the pump can spray slurry up to a couple of hundred metres – presenting considerable safety and environmental hazards.

“Where the rubber lining is present, it is encapsulated by a metal shell for added support,” he says. “Maintenance planning can be enhanced by using Weir’s Synertrex wear monitoring technology, which would alert the operators to the need for parts replacement, avoiding failures.”

He highlights that many of Weir’s pump ranges are available with the option of either rubber or metal liners. This has allowed many customers to easily trial the rubber lined option, as this can be done through a simple swap-in process during the plant’s shutdown period.

“We’ve seen a definite shift in the mining industry towards rubber lining on pumps, as mines recognise their value in these applications,” he concludes. “This is also a time when mining companies are starting to consider their upstream and downstream carbon impact. They can gain from the lower carbon footprint associated with rubber linings compared with steel.”

Client Focus

LEADING GROUT INJECTION PLANT EARNS SAFETY ACCOLADE FOR 20 YEARS INJURY FREE

There are few mining-related operations that have operated for two decades without a lost time injury – but Murray & Roberts Cementation has achieved just that at its grout injection plant between Northam and Thabazimbi in South Africa’s Limpopo province.

The 36 strong team at this grout plant oversees the logistics of mixing on surface, managing over 5 km of pipeline to underground destinations, and injecting grout at the workface to prevent inundation where water is intersected during mine development. Andre van Buuren, Murray & Roberts Cementation Project Manager, highlights the depth of experience that underpins the facility’s safety culture.

“Achieving 20 years without an injury is a real testament to the collective effort of our team, applying our corporate strategies and taking personal accountability for everything that happens on site,” says van Buuren. “It is no coincidence that there is very low staff turnover at this plant – where it is not unusual for our people to have up to 25 years of service.”

The average term of current staff is 10 to 15 years, with Northam injection plant site supervisor Hendry Collins having been with the operation for over 20 years. This has allowed a culture of safety to mature, and to be passed down from the more experienced staff to the newer entrants. Without overloading people with systems and procedures, he explains, everyone is imbued with a commitment to uncompromising safety principles that emphasise personal responsibility. This is expressed in key messages such as “If you see it, you own it” – which hold everyone to an exacting safety standard.

“Everyone is also steeped in the discipline of identifying the highest safety risk in every task they undertake and to ensure that it is mitigated,” he says.

As in any mining environment, this work certainly includes its fair share of risks. The Northam grout injection plant regularly pumps specialised grout mixtures at pressures of up to 10 MPa to underground workings. Over 20 tonnes of cementitious material are commonly injected into designated areas over a three to four day period, according to Murray & Roberts Cementation Senior Project Manager Pieter Oosthuysen. A recent water intersection incident required as much as 56 tonnes to be injected at high pressure to stem the flow of groundwater at a single point.

“A compact surface team oversees the running of the plant, which includes two 100 tonne silos among a range of equipment and backup units,” says Oosthuysen. “Most are part of the underground teams, working in day shifts and night shifts. They follow the mining teams as the mine deepens, extending the grout range to allow injection to be conducted whenever necessary.”

Safety is also a key aspect of the training that injection plant staff receive at the Murray & Roberts Training Academy at Bentley Park near Carletonville. This dedicated training facility includes a mock-up of a grout plant, where the experiential value of the training is enhanced.

Van Buuren highlights the importance of engaging every member of the team in the safety strategies employed, right down to the selection and adoption of protective equipment. In line with regulations and best practice, there is considerable time invested in deciding on even the most appropriate PPE such as boots or glasses to ensure these serve the purpose – before these are rolled out for use.

“This is part of visible leadership, a corporate strategic imperative that provides an example to our younger people,” he explains. “It prevents the ‘old worker’ syndrome where experienced personnel are tempted to take short cuts despite knowing better. Constant reinforcement – including positive recognition – is vital to ensure that complacency never creeps in.”

Louis Neethling, Foreman at the grout plant, emphasises the culture of care which is nurtured within each team – where every member is expected to look after not only themselves but those around them.

“We recognise that promoting safety is rather like sweeping water uphill,” says Neethling. “If you stop sweeping, the water will run back again; it is an ongoing task to ensure safe behaviour, and to find ways of improving safety performance.”

Client Focus

ECONOMIC IMPORTANCE OF ENGAGING CIVIL ENGINEERING COMPANIES AND CONTRACTORS REGISTERED WITH BCCEI

When it comes to infrastructure and civil engineering projects, the importance of selecting companies registered with the Bargaining Council for the Civil Engineering Industry (BCCEI) cannot be overstated. This registration signifies a commitment to adhering to established wage agreements, fostering fair labour practices and ensuring a stable and ethical industry. Prioritising these companies that are in good standing is crucial for the economy for several compelling reasons.

All civil engineering companies and contractors, including many of those working within the surface mining sector, are bound by the wage agreements set forth by the BCCEI, and are furnished with a Letter of Good Standing by the Council. This ensures that employees receive fair compensation, aligned with the legislated minimum wage standards. By maintaining these standards, companies that are in good standing help ensure fair compensation, enhance worker morale and productivity, and reduce income inequality. “Fair wages contribute to higher job satisfaction, which in turn boosts productivity and overall project quality,” says Lindie Fourie, Operations Manager at the BCCEI.

The adherence to wage agreements by registered and compliant companies ensures that contracts are not secured through unethical cost cutting measures, such as underpaying employees. This is critical for creating a level playing field where companies compete based on the quality of their work and efficiency rather than exploiting labour costs. 

“Ethical labour practices lead to sustainable business models, which benefit the industry in the long run and help stabilise the market, ensuring that all players have an equal opportunity to succeed,” she says. 

When projects are awarded to companies that are in good standing with the BCCEI, it drives the entire industry towards higher standards. This encompasses not only fair wages but also compliance with safety regulations, investment in training and development and quality assurance. These companies are more likely to adhere to safety standards, reducing workplace accidents and promoting a culture of safety, and such compliant companies significantly reduce the risk of job stoppages and unnecessary delays on a project. 

Further, Fourie says, ensuring fair wages allows companies to invest in their workforce through training and development, leading to a more skilled labour force. Higher standards in labour practices often translate to higher quality in project execution, benefiting clients and the community at large.

The positive impact of engaging companies that are compliant extends beyond the industry itself. It contributes to broader economic growth by creating more job opportunities and reducing unemployment rates, especially at a time when South Africa needs this most. It also increases consumer spending as workers receiving fair wages have more disposable income, which stimulates demand for goods and services in the economy. 

A stable, ethical industry is also more attractive to investors, leading to increased investment in infrastructure and development projects. “By prioritising companies that are registered with the BCCEI and adhere to BCCEI regulations, we not only support fair wages but also drive economic growth through job creation and increased consumer spending,” Fourie emphasises.

“Lastly, choosing companies that adhere to BCCEI regulations reflects a commitment to corporate social responsibility, and demonstrates the industry values ethical practices, community engagement and long-term viability,” she continues. “These companies are seen as responsible employers who value their workforce, strengthening the relationship between companies and the communities they operate in, and such ethical companies are more likely to be viewed as long-term partners in development, fostering ongoing economic collaboration.”