Monthly Archives: October 2024

Client Focus

METSO LT300HP CONE CRUSHER CLOCKS 30 000 HOURS AND COUNTING

As is customary with Metso equipment, in another show of unparalleled longevity, a Metso LT300HP mobile cone crusher owned and operated by Danoher Group, a leading mining contractor in southern Africa, has clocked more than 30 000 hours, and counting. 

Acquired in 2012, the Metso LT300HP mobile cone crusher is currently deployed at a job in Mbombela, Mpumalanga, where Danoher Group is contracted to produce 350 000 tonnes of road stone for the rehabilitation and upkeep of the N4 Toll Concession. 

Previously, the machine has been deployed on some flagship projects in South Africa and Botswana. In the past 12 years, the machine has been in Botswana on four occasions, where it executed some major projects at flagship mines such as Debswana’s Orapa Diamond Mine and Khoemacau, a long-life copper-silver mine located in the Kalahari Copper Belt. In addition, it has also been deployed at Danoher’s own Kgale Quarry in Gaborone.

With just over 30 000 hours on the clock, the machine is one of the several Metso units in Danoher’s crushing and screening fleet with such a long lifespan. In fact, says CEO Scott Danoher, the company has neither retired nor scrapped a single unit in the past 15 years, shining the spotlight on its drive to achieve extended operational lifecycles out of its capital assets and a testament to the quality of the Metso products. 

Danoher Group places value on several factors when investing in capital equipment, such as standardisation of equipment and relationships with suppliers. However, one of the principle factors that informs the company’s buying decisions is equipment longevity. While there are various elements that influence longevity, Danoher stresses that the fundamental ‘raw material’ is the design of the machine, which is why the company trusts Metso for its comminution equipment needs. 

“We do not necessarily buy a crusher or a screen, for example, for whatever amount, we buy the number of hours that the machine gives us,” says Danoher. “For us, it is also not about the price tag, it is more about the cost per tonne or cost per hour – ‘cradle to grave’, which is a totally different approach. We are prepared to pay a premium upfront in exchange for, say 30 000 trouble-free hours out of our crushing equipment.”

By sticking to a trusted brand like Metso and Pilot Crushtec as well as implementing proactive maintenance strategies, Danoher Group not only extends the operational lifespan of its capital assets, but also optimises equipment performance, minimises downtime and reduces costs to ensure smooth and efficient operations. 

“Proper maintenance and care throughout the lifespan of equipment significantly contribute to its longevity. To get the best out of our maintenance efforts, we largely use Metso OEM parts and spares from Pilot Crushtec International,” says Danoher. 

Over the years, Danoher Group and Pilot Crushtec, the Metso dealer in southern Africa, have built a strong working relationship. “Relationships play a crucial role in what we buy. For us, Pilot Crushtec are more than just suppliers: they have become trusted business partners,” concludes Danoher.

Client Focus

BOOYCO ENGINEERING AND COBRA TEAM UP IN SY-KLONE SOLUTION FOR AUSTRALIAN MINE

Meeting world class standards in air quality, South Africa-based Cobra Projects is producing 14 ventilated operator cabins for a Tier 1 mining company in Australia – fitted with Sy-Klone filtration systems supplied by local HVAC specialist Booyco Engineering. 

The cabins allow operators to remotely operate heavy mining equipment in their line of sight, providing a cool and dust-free environment to enhance their concentration and performance. Adhering to tight lead times, two of the units have already been shipped and the remainder will be on site in Australia in the last quarter of 2024. 

“One of the critical aspects of a sealed cab is allowing the entry and recirculation of fresh air, to provide a safe and conducive environment for the operator,” says Neal Forman, Business Development Manager at Cobra Projects. “We achieved this through our collaboration with Booyco Engineering who supplied the Sy-Klone fresh air pre-cleaner as well as the recirculation component and monitor.”

Sy-Klone’s patented RESPA® air quality products reduce respirable dust and debris, providing clean air to HVAC systems and keeping recycled air safe and breathable. The system also includes specialised filters for the recirculated air inside the cab. 

“In line with the ISO 23875 global standard for cab air quality, we also included Sy-Klone’s RESPA Advisor cab monitors from Booyco Engineering,” he says. “These monitors raise safety levels by ensuring the operator or supervisor is always kept informed on the pressure and quality of the air in the cab.”

If there is a build-up of unsafe levels of carbon dioxide in the cab, which can lead to operator fatigue and loss of alertness, the monitor can sound an alarm. It will also detect a loss of pressure, which can allow harmful respirable particulate to enter the cab.

Forman highlights that health regulations dealing with air quality in countries like Australia are becoming more stringent – making it essential that their specifications on this contract complied with ISO 23875. 

“Our business is really about continuous improvement, so we work with partners like Booyco Engineering to incorporate high value technologies like Sy-Klone’s air quality solutions,” he says. Cobra Projects specialises in custom-built, special-use vehicles for opencast and underground mining, to provide services such as lubrication systems and diesel and water transportation. Prior to this Australian contract, the company had designed and constructed a range of self-contained cabins for remote equipment operation on mines.

He notes that, while the ISO 23875 air quality standards is not yet a mandatory requirement on South African mines, it is likely that this step is only a matter of time – especially for the dusty conditions at coal mines. 

Client Focus

CONCOR PROJECTS SHINE AT SAISC STEEL AWARDS WITH INNOVATION AND INDUSTRIAL EXCELLENCE

Two of Concor’s standout projects were recognised at this year’s Southern Africa Institute of Steel Construction (SAISC) Steel Awards, celebrating innovative and complex use of steel in the construction industry. SAISC CEO Amanuel Gebremeskel highlighted the growing complexity and creativity within the industry, and Concor’s projects were no exception, making significant impressions in two key categories.

The Eastgate Solar Phase 2 Project, which won the Innovation and Sustainability Category, is a prime example of Concor’s commitment to driving sustainable construction solutions. This project forms part of Liberty Two Degrees’ larger sustainability journey to achieve Net Zero, and it brought an additional 6.04MWp of solar power to the iconic Eastgate Shopping Centre in Johannesburg. The scale of the project was immense, covering an expansive 30,000 square metre rooftop area. The solar panel structure itself, which required over 560 tons of steel, was not only a technical feat but also an architectural highlight.

Nominated by steelwork contractor, Cadcon, the solar panel structure was constructed using circular and square hollow sections with the steel frame carefully designed to meet both functional and aesthetic demands. The use of tubular and square hollow sections allowed for the creation of a visually striking structure while ensuring the necessary strength and stability. These elements, including the trusses, columns, and edge plates, were fabricated to handle the load of the solar panels, while maintaining a lightweight and modern appearance. This careful balance between form and function was key to the project’s success. 

While Concor served as the main contractor, the steelwork contractor played a crucial role in delivering the detailed and precise work that was required for such an ambitious undertaking. The project was not only praised for its technical achievement but also received a commendation in the Tubular Category, further reinforcing its engineering excellence.

Another impressive project by Concor that garnered recognition was the West Chimney Repairs and Related Works at the Kusile Power Station, which received a commendation in the Mining & Industrial Category. This project involved the construction of three temporary 116 metre stacks and bypass ducts as part of critical repairs at the power station. Once again, the versatility and strength of steel were on full display, as these elements were essential in meeting the project’s demanding specifications and timeline.

The use of steel in this industrial application demonstrated its superior ability to withstand high temperatures, corrosion and structural load. Steel was the ideal material to ensure the durability and resilience of the temporary stacks, which had to be designed for long term stability despite their temporary nature. These structures were vital to keeping the power station operational while repairs were conducted, underscoring the importance of steel in critical infrastructure projects.

Both projects reflect the company’s ability to execute large scale, technically demanding projects with precision and innovation. Concor’s work on the Eastgate Solar Phase 2 Project and Kusile Power Station not only showcases the company’s expertise but also highlights the critical role that steel plays in modern construction, whether in sustainability-driven projects or essential industrial applications. Concor’s recognition at the SAISC Steel Awards reinforces its standing as a leader in the construction industry, particularly in projects that require the highest standards of engineering, sustainability and innovation.

Client Focus

FLS ON-SITE SUPPORT UNDERPINS MINE EFFICIENCY

With its service centres in strategic locations in Africa, FLS builds closer relationships with customers to help transform mine efficiency. 

According to Dirk Wesselman, Head of Field Services for sub-Saharan Africa and West Africa at FLS, being geographically close to customers is a vital starting point in providing high quality service support to the mining sector. Based at FLS’s Chloorkop Service Centre in Gauteng, Wesselman highlights that the visibility and responsiveness of the company’s field service technicians underpins its support commitment to customers in Africa.

“Our strategy of continuously growing our service centre footprint, and strengthening the capability of those centres, lies at the heart of operational efficiency and equipment reliability,” he explains. “Having technicians regularly on site with customers means they can frequently check the optimal performance of our crushers, screens and other equipment.” 

The service teams support the full range of FLS equipment in fields from liquid-solid separation to crushing, feeding and milling, including high pressure grinding mills, and even laboratory equipment. 

“Since the acquisition of TK Mining business, we also continue to support the large installed base of ThyssenKrupp legacy mining equipment in the mining sector,” he points out. “Our presence in key mining regions ensures that we can respond rapidly to customer callouts to ensure minimal downtime. More importantly, our regular on-site presence builds our understanding of customers’ needs – so that we can work with mines to plan maintenance and avoid unscheduled stoppages.”

In addition to facilitating planned maintenance for mines, Wesselman highlights that many customers rely on OEM maintenance contracts with FLS as part of their efficiency programmes. 

“These maintenance contracts are drafted to meet the customer’s specific requirements,” he says. “This arrangement puts a skilled team of specialised technicians at the service of the mine to ensure constant monitoring and rapid response. It can also be further enhanced with a ‘reliability engineer’ who focuses on detailed monitoring of all related equipment, to keep it performing optimally.”

Wesselman also highlights the company’s installation, commissioning and maintenance (ICM) contracts, which usually support a ‘plug and play’ plant upgrade involving a filter press or high pressure grinding roll (HPGR). 

“Working with contracting houses, we are involved from the manufacturing stage through to installation supervision, cold and hot commissioning, and the ongoing maintenance,” he says. 

The collaborative relationship between FLS service centres and mining customers is often built on the regular audits and inspections that the OEM’s technicians conduct on the equipment on-site. This creates the baseline for understanding the equipment’s condition, so that appropriate interventions can be specified to keep the equipment operating at OEM standards.

“We have developed our depth of infrastructure and expertise with exactly this goal in mind,” he says. “With the information gathered from our inspections, we can support customers as they systematically plan and prioritise their repair and maintenance requirements.”

Where components and equipment need off-site repair or refurbishment, these can be taken to the company’s well-equipped service centres where specialised artisans conduct the work with state-of-the-art equipment in accordance with OEM standards. 

Philip McCormick, Head of Service Centres – Chloorkop and Stormill, highlights that these centres’ depth of capability represents the company’s commitment to supporting customers with cost effective refurbishment and repair services that can be delivered in short turnaround times. McCormick also emphasises the value of FLS’s Training Academy in producing artisans and technicians who are specialised in the range of FLS offerings.

“With their specialisation in our products, our technicians are also able to identify any non-operational equipment on customers’ sites which could still be refurbished,” he says. “We even have examples where equipment like girth gears and mill drive pinions has not been stored correctly, and now requires refurbishment. Our workshops can add considerable value by restoring these items to functionality, so that they don’t need to be replaced with new units.”

Client Focus

IPR CUSTOMISES ITS SLURRYSUCKER TO TREAT ACID MINE DRAINAGE

Two treatment plants for Acid Mine Drainage (AMD) near Johannesburg have received a boost to their efficiency, thanks to IPR’s innovative SlurrySucker dredging unit. 

The problem of AMD has beset historic mining areas around Johannesburg, where water in deep underground mining areas has become contaminated through its contact with broken rock containing sulphur-bearing minerals. As it rises and decants on surface, it poses a serious health risk – and contaminates other water resources. 

As part of the treatment process, this highly acidic water is treated with lime and flows through two reactors at the AMD plant, where sediment settles and gradually fills up the concrete channels of each reactor. According to Ruaan Venter, Business Development Manager at IPR, this was causing extensive downtime for the plant, as each reactor had to be emptied of water before the acidic silt could be excavated.

“To allow one reactor to be cleaned, it had to be closed off – reducing plant throughput and placing extra strain on the other reactor,” Venter explains. “The customer needed a solution that would allow them to gain more uptime from the plant, as digging out the silt was disruptive and time consuming.”

IPR’s SlurrySucker is a dredging system that suspends a heavy duty submersible slurry pump from a specially designed flotation raft, allowing continuous dredging with minimal supervision. For the AMD plant, a customised solution was required due to the specific structure of the reactors. Initially, IPR had made a standard version of its smaller unit – the Mini SlurrySucker – available on rental to the plant. This proved itself in the application, and the plant chose to invest in its own unit, but required some special adaptations to be made – especially to improve mobility.

“Using our depth of in-house design and engineering expertise, we created a custom version of our Mini SlurrySucker,” he explains. “A key aspect of the customer’s requirement was that the unit would not require any lifting by an on-site crane, from one part of the reactor to another.”

As a result, the custom-engineered Mini SlurrySucker was designed to pass under the walkways of the reactor, allowing it to manoeuvre through the channels. To resist the acidic water, the construction frame is stainless steel. 

“We equipped the unit with a Toyo heavy duty GR20 submersible slurry pump, which is part of our range – as the official distributor in Southern Africa,” he says. “This heavy duty pump, with its solids handling capability of up to 30 mm particles, is ideally suited to this application, where the slurry comprises about 60% water and 40% solids.”

This 15 kW pump can deliver up to 190 m3 an hour at a maximum head of 30 metres, although the plant will be required to meet the volume limits of the downstream gold processing plant. This model was chosen due to its robust performance and low maintenance requirements, which deliver low total cost of ownership to the user. 

In addition to this, the SlurrySucker is equipped with an Atlas Copco Weda D50 pump which will be used to force clean water to the main slurry pump assisting with agitating the slurry. This unit is capable of handling dirty water with a specific density of up to 1,1 and has a solids handling capability up to 12 mm particles. 

Client Focus

SAFEGAUGE SOLUTIONS FROM BOOYCO ELECTRONICS ENHANCE SAFETY FOR HEAVY EQUIPMENT OPERATORS

The strategic partnership between Booyco Electronics, a leader in proximity detection systems and safety solutions, and SafeGauge offers owners and operators of large mining, construction, forestry, agriculture and earthmoving equipment access to advanced wireless diagnostic tools designed to enhance safety and operational efficiency.

SafeGauge technology is renowned for enabling remote monitoring and testing of critical systems on heavy machinery without exposing workers to the dangerous conditions typically associated with live testing and equipment maintenance. Louis Venter, Area Sales Manager at Booyco Electronics, says that by allowing artisans to conduct tests and gather real-time data remotely, SafeGauge eliminates the need for workers to be in close proximity (line of fire) to large machines during potentially hazardous procedures. This innovation significantly reduces the risk of injury, creating a safer work environment across operations.

The SafeGauge range of equipment includes various specialised tools designed for different measurement needs. The PT (Pressure Transducer) Series is used to measure pressures in hydraulic and pneumatic systems, while the DI (Dial Indicator) Series is designed for measuring clearance, tolerance and wear on machine components. The TM (Tacho Meter) Series measures fan speeds and other rotating components, the LD (Laser Displacement) Series tracks wear on moving parts and the PR (Push Rod) Series is used to measure displacement between two fixed points.

Venter explains that all data collected by these tools can be processed through the Multitool Pro, which allows for real-time generation of reports and graphs. “With its built-in cloud connectivity, the system makes it easy to export or share data instantly, streamlining operations and improving decision-making efficiency,” he adds. 

Key Advantages for Equipment Owners

Venter says that one of the most prominent benefits of SafeGauge equipment is the enhancement of artisan safety. “Heavy-duty machinery in the mining and construction industries can present significant risks during maintenance or diagnostic processes, particularly when it involves hydraulic systems or high-pressure environments,” he continues. “SafeGauge’s wireless system allows these tasks to be performed without workers needing to be near the equipment, mitigating the danger of exposure to moving parts or sudden pressure releases.”

In addition to safety improvements, SafeGauge contributes to increased operational efficiency. By enabling real-time monitoring and remote diagnostics, equipment issues can be identified and addressed faster, reducing unplanned downtime and preventing costly failures. This proactive maintenance approach not only keeps operations running smoothly but also extends the life of key machinery components, minimising the need for expensive replacements.

A Valuable Solution for Heavy Equipment Operations

“For businesses in mining, construction, forestry, agriculture and earthmoving, where operational continuity is crucial, SafeGauge’s ability to deliver timely diagnostics and maintenance insights is invaluable. It allows maintenance teams to perform their duties more effectively, ensuring equipment remains in optimal condition,” Venter says. “The result is higher productivity and lower maintenance costs, adding value to both day-to-day operations and long-term capital investment.”

“Through Booyco Electronics’ distribution of SafeGauge in Southern Africa, local operations now have access to this world class safety and efficiency solution, helping companies meet stringent safety standards and drive operational excellence in even the most demanding environments,” Venter concludes.

Client Focus

RISING POPULARITY FOR SANDVIK LEOPARD DI650I IN SOUTHERN AFRICA

On the back of its global debut at the 2018 edition of Electra Mining Africa, the Sandvik Leopard™ DI650i down-the-hole (DTH) drill rig has earned its stripes in the southern African surface mining sector, particularly in high-capacity production drilling applications. 

When Sandvik Mining and Rock Solutions first brought the Leopard™ DI650i to market, the message was clear – the company had ushered in a tool that would constitute a strong challenger for a market leadership position in the larger than 6” segment, which was previously dominated by a competitor. Some six years later, the Leopard™ DI650i has surpassed expectations with a high uptake in markets across southern Africa and the world at large.

“In southern Africa alone, we have over 60 machines operating in the field, which is remarkable,” says Trinity Nkosi, Sales Engineer, Surface Drills Department at Sandvik Mining and Rock Technology. “Over the years, we have had a positive uptake, especially in South Africa, with coal, platinum group metals (PGMs) and iron ore among the key recipient commodity markets to date.”

Scalable automation, ease of maintenance and efficient operation are some of the drill’s value propositions that have made it popular in the market. 

The Leopard™ DI650i features scalable automation packages to fully automate systems and increase overall productivity. iDrill onboard automatics cover all steps of the automated drilling cycle, ensuring consistent high-quality drilled holes. It is also compatible with AutoMine® Surface Drilling to enable fully autonomous fleet operation from a control room.

“The machine’s ground-level access for daily service and maintenance tasks has led to up to 20% more availability compared with conventional DTH rigs at a similar technology level. The modular design of the machine further allows for easier repair or replacement of components,” says Nkosi. 

To provide context, an Australian lithium operation has seen an improvement in availability, largely due to ease of maintenance, resulting in 1 900 hours of drilling in four months. Despite the tough 400 MPa rock, the mine achieved a penetration rate of about 23 m/hour – completing close to 400 m per day – drilling 203-mm holes.

Increased efficiency is yet another principal design benefit that has propelled the Leopard™ DI650i to the summit of the DTH market. Thanks to the intelligent control technology applied in both the compressor and the hydraulic system’s cooler fan, customers can expect to reduce their fuel consumption significantly compared with conventional DTH rigs. 

“Up to 15% less fuel consumption per hour is achievable largely due to our efficiency-driven design of minimising recirculation of hot air to coolers and having an energy-on-demand principle across the entire machine,” says Nkosi. “In addition, the compressor management system reduces compressor load for non-drilling activities, thus reducing fuel consumption.”

The intelligent control system of the machine contributes to high levels of operational precision and efficiency. For example, Sandvik’s aligning system guarantees parallel direction holes while the GPS technology allows for pinpoint accurate hole placement. The one-hole full cycle drilling automatics with auto collaring and rock detection minimise hole losses and maximise drill bit life. 

“Based on these capabilities, the machine has proven its performance clout at several mines in southern Africa. For example, a coal mine in South Africa has seen an improvement in average penetration rate of 60 m/hour in a sandstone rock formation where hardness is between 60 and 80 MPa, drilling 165-mm diameter holes. In fact, the mine drills close to 1 000 m of holes per day,” concludes Nkosi.

Client Focus

SAFEGAUGE SOLUTIONS FROM BOOYCO ELECTRONICS ENHANCE SAFETY FOR HEAVY EQUIPMENT OPERATORS

The strategic partnership between Booyco Electronics, a leader in proximity detection systems and safety solutions, and SafeGauge offers owners and operators of large mining, construction, forestry, agriculture and earthmoving equipment access to advanced wireless diagnostic tools designed to enhance safety and operational efficiency.

SafeGauge technology is renowned for enabling remote monitoring and testing of critical systems on heavy machinery without exposing workers to the dangerous conditions typically associated with live testing and equipment maintenance. Louis Venter, Area Sales Manager at Booyco Electronics, says that by allowing artisans to conduct tests and gather real-time data remotely, SafeGauge eliminates the need for workers to be in close proximity (line of fire) to large machines during potentially hazardous procedures. This innovation significantly reduces the risk of injury, creating a safer work environment across operations.

The SafeGauge range of equipment includes various specialised tools designed for different measurement needs. The PT (Pressure Transducer) Series is used to measure pressures in hydraulic and pneumatic systems, while the DI (Dial Indicator) Series is designed for measuring clearance, tolerance and wear on machine components. The TM (Tacho Meter) Series measures fan speeds and other rotating components, the LD (Laser Displacement) Series tracks wear on moving parts and the PR (Push Rod) Series is used to measure displacement between two fixed points.

Venter explains that all data collected by these tools can be processed through the Multitool Pro, which allows for real-time generation of reports and graphs. “With its built-in cloud connectivity, the system makes it easy to export or share data instantly, streamlining operations and improving decision-making efficiency,” he adds. 

Key Advantages for Equipment Owners

Venter says that one of the most prominent benefits of SafeGauge equipment is the enhancement of artisan safety. “Heavy-duty machinery in the mining and construction industries can present significant risks during maintenance or diagnostic processes, particularly when it involves hydraulic systems or high-pressure environments,” he continues. “SafeGauge’s wireless system allows these tasks to be performed without workers needing to be near the equipment, mitigating the danger of exposure to moving parts or sudden pressure releases.”

In addition to safety improvements, SafeGauge contributes to increased operational efficiency. By enabling real-time monitoring and remote diagnostics, equipment issues can be identified and addressed faster, reducing unplanned downtime and preventing costly failures. This proactive maintenance approach not only keeps operations running smoothly but also extends the life of key machinery components, minimising the need for expensive replacements.

A Valuable Solution for Heavy Equipment Operations

“For businesses in mining, construction, forestry, agriculture and earthmoving, where operational continuity is crucial, SafeGauge’s ability to deliver timely diagnostics and maintenance insights is invaluable. It allows maintenance teams to perform their duties more effectively, ensuring equipment remains in optimal condition,” Venter says. “The result is higher productivity and lower maintenance costs, adding value to both day-to-day operations and long-term capital investment.”

“Through Booyco Electronics’ distribution of SafeGauge in Southern Africa, local operations now have access to this world class safety and efficiency solution, helping companies meet stringent safety standards and drive operational excellence in even the most demanding environments,” Venter concludes.

Client Focus

WEAR RESISTANCE REVOLUTION AS SANDVIK LAUNCHES UNIQUE HX900 IN AFRICA

Having demonstrated a step-change in wear resistance on mines globally, Sandvik Rock Processing’s HX900 wear protection plates are now being launched in Africa. 

The results achieved by the HX900 plates have been remarkable, extending wear life by many multiples in real life mining applications. The plates are mainly used in applications such as feeders, feed chutes, transfer chutes, skirt liners, rock box edge liners, load-haul equipment and buckets – in countries including Australia, Brazil, Peru, Sweden and the US. 

“What makes our HX900 wear protection plate so effective is the unique combination of two different mechanical properties in a single piece,” says Phumi Motsamai, Regional Manager Screening Media & Wear Protection Africa at Sandvik Rock Processing. “The nodular iron resists the high impact of material, while the cemented carbides provide outstanding resistance to abrasion.”

The performance of carbide, for instance, has been shown to last up to five times longer than white iron, and up to 20 times longer than quenched steel. The longer wear life means extended replacement intervals and lower total cost of ownership (TCO), says Motsamai. This brings a range of operational benefits including higher productivity through less downtime, and improved safety as maintenance technicians are less frequently in contact with equipment. There is also less need for high volumes of replacement inventory to be stored on site.

She explains that the nodular iron – also known as ductile iron – is a special type of cast iron with a characteristic microstructure that enhances its mechanical properties. It contains graphite in the form of nodules or spheroids, which impart ductility and toughness. 

“Nodular iron has a higher tensile strength and can undergo significant deformation without failing,” she says. “It absorbs energy well and has good fatigue resistance, making it ideal for components that are subject to dynamic and cyclic loading conditions.”

The cemented carbides in HX900 consist of hard carbide particles bonded together by a metallic binder of primarily tungsten carbide. With a hardness of about nine on the Mohs scale, tungsten carbide is one of the hardest known materials, just behind diamonds and cubic boron nitride. 

“This extreme hardness gives HX900 outstanding resistance to wear and abrasion,” she says. 

“Compared to quenched and tempered 500 HB steels, cast-in-carbides can last up to 10 times longer; this improvement can be up to 50 times longer compared to regular chromium carbide overlays and white iron.”

Motsamai cites a case study in which HX900 replaced Hardox 400 plates lining a transfer chute in a Brazilian gold mine. After the Hardox 400 plates had worn through after only two weeks and just 108,000 t of material throughput, the HX900 plates lasted 75 weeks – withstanding the passage of over 3,8 million tons of material. In a similar application, the HX900 replaced Hardox 500 wear plates – and extended wear life from 18 weeks to 52 weeks. 

“In a copper mine in Sweden, the wear life of Hardox 500 in an accelerator chute was just two weeks – or 600,000 t of production,” she says. “After they installed HX900 plates, the mine was able to achieve a wear life of 32 weeks or 9 million tons.”

This innovation also has important sustainability benefits for customers, she continues, as the carbide production makes a key contribution to the circular economy. 

“Our HX900 plates embody high levels of good sustainability practice, as they utilise 99% recycled nodular iron and 100% recycled cemented carbides,” she says. “Research has shown that using recycled materials in this way consumes 70% less energy and cuts overall carbon dioxide emissions by 40%.”

Client Focus

QUALITY DRIVE TAKES CONCOR FROM GOOD TO GREAT

Continued dedication to quality management allows Concor to raise the performance bar, thereby streamlining projects for customers and ensuring the highest levels of workmanship.

According to David Akinnusi, Senior Quality Assurance and Quality Control (QA/QC) Manager at Concor Construction, the quality journey has led to significant advances in the company’s key performance indicators (KPIs). For instance, there has been a 30% improvement in the company’s pass rate for first-time inspections in recent years. 

“Our continuous attention to quality is taking us from good to great,” explains Akinnusi. “An important factor driving this process has been our ‘Build to Last’ quality initiative, which we launched two years ago.”

This commitment, he says, means creating an enabling environment for high performance by all Concor employees – to build long lasting structures that satisfy clients. The quality philosophy drives this performance through excellent workmanship, delivered consistently in every project.

“By carefully managing our work processes, we ensure the quality of our outputs or end-results,” he says. “Our quality system also benchmarks these processes against world class standards; the system itself complies with ISO 9001:2015, while our workmanship meets both SA National Standards (SANS) and each project’s specifications.”

Concor’s quality assurance is therefore closely tied to established standards and procedures, which undergo internal auditing. This is followed by the quality control function, in which the necessary measures are applied through work area inspections and material testing, for example. 

“What is important is that we allocate designated QA/QC personnel to each project,” says Akinnusi. “They are dedicated to monitoring and ensuring compliance to both internal and external procedures and specifications.”

He notes that Concor’s quality philosophy extends beyond the physical structures that the company builds, to the people who build them. This relates to creating a culture of excellence where everyone feels proud, valued, respected and empowered to do their best work.  

“We believe the work done by every individual connects us as a team,” says Akinnusi. “This makes training and development paramount to our operations; it is vital that our employees are well equipped to champion excellence on every site.”

This staff development is done through a range of ongoing programmes to bring the latest knowledge and skills into each field of work. Among Concor’s development initiatives for employees are its study assistance programme, its engineer-to-project-manager programme for graduate engineers, its performance enhancement programme and its career path and succession planning for key functions.

Combining its systems with its depth of experience and skills, Concor is able to manage its quality at every stage of the project lifecycle. At planning stage, for instance, detailed tender reviews are undertaken by the project contract director and the estimating team. This helps to understand the detailed project requirements in relation to resourcing, scheduling and costing of projects. 

“When we get to the design stage, we use only professionally registered engineers to produce drawings for construction,” he explains. “Collaborative efforts are made to identify constructability concerns with the designers, both at the design and construction phases of a project.”

During execution, strict quality control plans are compiled and agreed between Concor and the client – which outline the specific testing and inspection requirements for different activity trades in the project.

“The handover of works is done progressively through trade data book reviews,” he says. “Clients are contractually allowed to snag the works, ensuring the handover is done to their satisfaction.”

There is also a post-handover stage when a contractual defects liability period is applied. Depending on the latent root cause of a defect, Concor remedies any defects that arise during this period. He notes that concreting, brickwork and waterproofing are fields in which contractors commonly experience quality challenges. Overcoming them demands proactive mitigation, with Concor using robust root cause analysis and lessons learnt to apply preventative measures. 

“We also allocate sufficient supervision to these specific high risk trades, and ensure that the personnel involved are competent and trained,” he says. “Our success in doing this is reflected in our non-conformance reporting (NCR) – another of our KPIs – and has direct cost benefits. In recent years, we have trimmed our NCR rates by 20%.”

A crucial outcome of all these quality efforts is the strengthening of relationships with clients, says Akinnusi, so Concor’s KPIs include regular feedback surveys to measure client satisfaction. An intensive 20-item questionnaire is conducted with clients each year to gauge this important factor, so any issues can be quickly identified, discussed and resolved. 

“This level of customer engagement helps to underpin the excellence we deliver, which leads to repeat business,” he says. “In the Oxford Parks Precinct developments, for instance, we have been engaged in five separate contracts over the years – a good sign of client trust in our ability.”