Monthly Archives: February 2025

Client Focus

CONCOR POWERS PROGRESS ON FOURWAYS MAIN ROOF WORKS PROJECT

Concor has made substantial headway on the Fourways Main Roof Works Project, a pivotal component of the ongoing Fourways Mall Repositioning Project. As the largest shopping centre in Africa, with a Gross Lettable Area (GLA) of 178 000 m², Fourways Mall is undergoing significant upgrades to improve functionality and ensure future sustainability.

Martin Muller, Contract Manager at Concor, emphasises the importance of this initiative. “This project is significant not only for its sheer size—covering 50 000 m² of roof—but also for the complex logistical and technical challenges it presents. Despite these challenges, we are on track for completion by June 2025, a testament to Concor’s expertise in managing fast track projects in live retail environments.”

The project involves constructing a roof over the existing rooftop parking on Level 7 to provide covered parking for visitors while enabling the future installation of a solar photovoltaic (PV) system. As part of the scope, a steel structure is being constructed to support an 10 200 m² PV installation on the Northeastern rooftop parking area, further enhancing the mall’s sustainability. 

Additionally, Concor is rehabilitating the access ring road, ensuring it meets the demands of the future.

Construction of the roof involves the installation of 550 concrete columns, ranging from 2.1 metre to 4.8 metre in height, to support a structural steel roof with sheeting. Rainwater drainage systems are being installed as part of the roof design. 

Muller explains that the methodology requires the existing concrete surfaces to be prepped before drilling and dowelling the new columns into the mall’s current column structure. This ensures the load from the roof is transferred safely through existing columns and beams down to the foundations. 

“Lightweight construction methods are being employed due to load restrictions on the rooftop, with spider cranes and dumpers used for erection activities,” he says. “Materials, including readymix concrete and structural steel, are delivered at street level and transported via trailers and dumpers to minimise disruption to mall operations.

On the Northeastern rooftop of Fourways Mall, a steel structure to support the installation of a solar PV system is being constructed on pre-existing concrete columns. This addition will not only provide renewable energy capability but also align with the broader goals of sustainability and energy efficiency.

Rehabilitation of the 8 000 m² access ring road is also well underway. “The completed ramp from Witkoppen Road to Fourways Boulevard has already been opened to the public, and this is a good indication of how our construction programme is geared to facilitate access for visitors to the mall.” 

The process involves removing old kerbs and road components, addressing construction and bridge joints, upgrading drainage, applying waterproofing and laying a final asphalt layer. Traffic control measures including speed humps and road markings, are also being installed to ensure a safe and user-friendly experience for visitors.

Working within a live shopping environment poses unique challenges, but Concor is leveraging its extensive experience to minimise disruptions. Detailed construction management plans have been implemented including comprehensive signage to guide traffic and ensure the safety of visitors. In partnership with the Fourways Mall team, Concor is actively keeping stakeholders informed about project developments.

“This project showcases our ability to execute large-scale, technically demanding construction within active environments,” Muller says. “It’s all about balancing efficiency and safety while delivering high quality results.”

Scheduled for completion by June 2025, the Fourways Main Roof Works Project exemplifies Concor’s commitment to delivering complex infrastructure solutions that elevate both functionality and sustainability for South Africa’s retail sector.

Client Focus

LARGEST PILOT MODULAR AGGREGATE PLANT COMMISSIONED IN THE DRC  

In a milestone project, Pilot Crushtec International has commissioned its largest ever Pilot Modular plant. Supplied to produce five aggregate sizes for an existing customer in the Democratic Republic of Congo (DRC), the plant is designed to produce 350 tonnes per hour (tph), with a peak design capacity of 440 tph to account for peaks and troughs in day-to-day production. 

Having operated a Pilot Modular plant for a long time, a major aggregates producer in the DRC looked no further than Pilot Crushtec when it was time to invest in another greenfields plant to meet the rising demand for aggregates in the DRC. This comes on the back of ongoing private mine expansion projects, coupled with government infrastructure development projects aimed at closing the infrastructure gap in the country. 

From the onset, says Wayne Warren, Sales Manager Africa at Pilot Crushtec, the customer was well aware of the benefits of the Pilot Modular solution, ranging from lower capital and operational costs compared with bespoke plants to quick lead times and flexibility to operational changes. Pilot Modular systems are readily available modules that can be deployed to site rapidly and operational within a short space of time. 

“To provide context, this particular plant was delivered within about four-and-a-half months of its order, while the erection, assembly and commissioning took a further three months, highlighting the short lead times for which the Pilot Modular concept is renowned,” says Warren. 

For this plant, says Warren, Pilot Crushtec did not ‘reinvent the wheel’; the company largely used standard proven off-the-shelf products from its Pilot Modular range. The primary crusher is a Metso C120 jaw crusher, which takes a maximum feed size of 700 mm. From the jaw, material goes into the TKG 16 modular scalping screen. Incorporating the TKG 16 modular scalping screen allows for maximising the efficiency of the secondary crusher’s capacity by taking out fines just after the jaw crusher, especially considering that the environment is notorious for having a lot of fine material in the feed. 

Oversize material (plus 90 mm) from the TKG 16 modular scalping screen is sent directly to the secondary cone crusher, a Metso HP300, a high capacity machine known for not only its ability to take large feed sizes but also its large throw which provides for a decent material shape at the secondary stage of crushing. 

“Making use of Metso HP cone crushers and correct reduction ratios ensures that the end product has the best possible shape without having to deploy a vertical shaft impact (VSI) crusher,” says Warren. 

From the HP300, material is sent to a twin surge hopper comprising two Pilot Modular MFH25 feed hoppers. From here, material is fed onto two separate screens, the Pilot Modular Metso CVB2060-3M units, where fines are further removed. Any oversize material is recirculated to two Metso HP200 cone crushers via two MFH25 surge hoppers located on either side of the two screens. From the HP200 crushers, material is conveyed back to the two screens for final screening, where four product sizes – 0-6 mm, 6-10 mm, 10-15 mm and 15-25 mm – are stockpiled. 

While both delivery and commissioning were on time, the logistical process of transporting such a large plant to the DRC was not without its challenges. “The biggest hurdle was that the plant constituted a lot of equipment – it is the biggest we have ever done. We therefore had to split the delivery into three shipments comprising between 10 to 12 trucks per shipment to free up space in our workshop,” explains Warren. 

In addition, transporting the plant to site came with its fair share of challenges, especially the border-related delays. Making use of two transporters with knowledge of this challenging logistical environment was helpful. “Cross-border shipments to the DRC are also not new to Pilot Crushtec. We have experienced personnel to manage this, while the customer helped with pre-clearance and all the other necessary paperwork in the DRC. Close collaboration between Pilot Crushtec, the customer and the transporters was key to smooth delivery in the face of several challenges,” he says. 

In such an environment where logistics can be a nightmare, the customer keeps a sizeable inventory of most critical wear and spare parts on site to avoid possible production disruptions. With most of the equipment on the new plant very similar to what is on the customer’s existing plant, parts commonality increases operational flexibility and reduces procurement and logistical costs for the customer. 

“This project is testimony that the Pilot Modular concept works well for the African environment where large infrastructure projects are on the go and suppliers need their crushing and screening solutions as a matter of urgency. The Pilot Modular solution is quick to deploy and set up, while it does not need a whole lot of civil works and extensive infrastructure to set up,” concludes Francois Marais, Sales and Marketing Director at Pilot Crushtec. 

Client Focus

SEW-EURODRIVE PLANETARY GEAR UNITS FOR HIGH TORQUE REQUIREMENTS

Packing a compact design, along with high torque and low-speed outputs, the new SEW PPK and SEW P2.e planetary gear units from SEW-EURODRIVE offer new capabilities in continuous heavy duty applications where space is at a premium.

Speaking directly to SEW-EURODRIVE’s ‘close the loop’ strategy, the arrival of the SEW PPK and SEW P2.e planetary gear opens up a whole new world of possibilities, particularly in heavy duty, challenging operating conditions with high torque and low speed requirements. 

Typical applications in the mining industry include crushers, apron feeders, clarifiers and thickeners. Other industrial applications range from screw presses and slewing gears to wood panel shredders, ring pan mixers and batch plants, amongst others.

The SEW PPK planetary gear units complement SEW-EURODRIVE’s product line in the torque load range under the proven P-series, explains Jonathan McKey, National Sales and Marketing Manager at SEW-EURODRIVE. Offering a torque range from 10 to 18 kNm, the SEW PPK covers a gear ratio range from 65 to 390:1. The ratio can be further reduced by adding a primary reducer before the planetary head, allowing for ratios up to 10 650:1 for a much lower speed capability.

Available with torque ratings from 2 to 124 kNm, the SEW P2.e range covers gear ratios from 15,2 to 332:1. While most planetary gearboxes have a three-stage design only, the SEW P2.e can also be supplied in a two-stage model. The SEW P2.e encompasses all the benefits of the SEW PPK, but goes a step further with a broader spectrum of diversity in its speed – up to 100 rpm – as well as in ratio and torque.

“The high strength, durable materials with advanced heat treatment allow the gear units to withstand extreme loads and resist wear, thus making light work of high-torque requirements,” says McKey. “In essence, these planetary gear systems produce high torque by distributing the load across several gears and using gear ratios to multiply the input torque. The efficient and compact design allows for the high torque in a relatively small package.”

One of the major talking points is the exceptional thermal limit rating, which is made possible by the integrated fan in the motor interface. The fan aspirates air radially, accelerates it and generates a cooling stream of air with a high flow rate.

“The SEW P2.e is the only planetary gear unit on the market with an integrated fan coupled directly between the motor and the planetary head. Consequently, it boasts a large cooling area (two to four times larger than some of the competitor offerings in this size class) – a condition which is central to the high thermal limit rating. Despite its high power density, the SEW P2.e series therefore boasts a best-in-class thermal limit rating,” explains McKey. 

Reduced weight is another major benefit of going the SEW P2.e route. With its lightweight gear unit design, the SEW P2.e is 24% lighter and 10% shorter in length, compared with some of the same-sized units on the market.

Given its nearly century experience in developing and constructing gear units for numerous customer applications, SEW-EURODRIVE has over the years amassed vast tribological expertise. Based on this and the results of long term testing, the company has developed a special formulation for its premium gear unit lubricants.

“By using our premium gear unit lubricants, end users have peace of mind that their investments are protected – a high level of resistance to ageing reduces wear and increases the service life. Customers can expect up to 50% longer service intervals and a long shelf life of up six years if they are using the special SEW-EURODRIVE approved lubricants and implementing appropriate maintenance conditions,” concludes McKey. 

Client Focus

OPTIMISING MATERIAL TRANSFER ACROSS INDUSTRIES WITH ADVANCED HANDLING SOLUTIONS

Efficient material transfer is a critical component of any materials handling operation, regardless of the commodity being moved. Whether handling coal, minerals, aggregates or other bulk materials, achieving seamless transfer is essential for boosting productivity, minimising costs and maintaining operational safety. Weba Chute Systems, a global leader in transfer point technology, offers advanced solutions that address the unique challenges of materials handling, ensuring enhanced efficiency and reliability across diverse industries.

In materials handling operations, issues such as dust generation, spillage, material degradation and equipment wear can significantly impact productivity and operating costs. Weba Chute Systems employs a custom-engineered approach to mitigate these challenges. By focusing on optimised material flow and impact management, these systems reduce maintenance requirements, extend equipment lifespan and create safer working environments.

Dewald Tintinger, Technical Manager at Weba Chute Systems, explains that Weba Chute Systems adopted a scientific approach. “This,” he says, “is unlike conventional chute designs that often rely on high velocity material transfer. We use advanced simulation tools and our engineers analyse material trajectories, particle interactions and flow dynamics to develop solutions tailored to the specific needs of each customer’s operation. Our precision driven methodology ensures controlled material flow, minimising wear and tear on critical components and reducing downtime.”

Tintinger says that one of the standout benefits of these systems is their ability to suppress dust and prevent spillage. In industries where dust emissions can lead to environmental hazards and safety concerns, Weba Chute Systems’ solutions provide an effective way to optimise material flow while maintaining compliance with environmental regulations. The controlled flow of material also eliminates spillage and blockages, reducing operational disruptions and improving overall process efficiency.

“Customisation is a hallmark of Weba Chute Systems’ designs. Each system is tailored to match the unique characteristics of the material being handled including particle size, moisture content and flow rate,” he continues. It is this bespoke approach that ensures the transfer system performs optimally under real-world conditions, while its modular design allows for seamless integration with existing infrastructure, minimising installation time and costs.

Safety remains a key focus in materials handling, and Weba Chute Systems delivers on this front by reducing the risk of material ejection and incorporating features such as inspection doors and easy-access panels for safe maintenance. Additionally, the energy efficiency of these systems supports sustainability goals, as optimised material flow reduces power consumption and lowers an operation’s carbon footprint.

“We believe that our innovative designs and customer-centric approach makes Weba Chute Systems a trusted partner across industries requiring efficient material handling solutions. By addressing common challenges and delivering measurable improvements in productivity, safety and cost savings, these systems are helping companies to enhance their operations and achieve long term success,” Tintinger concludes. 

Client Focus

SANDVIK ROCK PROCESSING INTRODUCES REMOTE MONITORING SERVICE IN AFRICA 

At a time when quarries and mines seek to optimise their operations and ensure continuous improvement, remote monitoring of crushing data is becoming a crucial element of day-to-day procedures. To meet this growing need, Sandvik Rock Processing is piloting its Remote Monitoring Service (RMS) in Africa.

Crushing operations in Africa can look forward to a new set of digital services following Sandvik Rock Processing’s announcement at Electra Mining Africa 2024 that it is piloting its RMS – a digital system that allows for monitoring of crushing processes remotely. 

“RMS is the latest addition to our suite of existing digital technologies. It complements our ever evolving Automation and Connectivity System (ACS) and SAM by Sandvik cloud-based digital assistant,” explains Nils-Peter Ahlqvist, Sales Support Manager Africa & Latin America – Crushing Division at Sandvik Rock Processing. “RMS translates vast amounts of data acquired from Sandvik crushers into actionable recommendations, reducing operating costs and boosting productivity and sustainability.”

RMS utilises a data-driven study of abnormal behaviour in terms of both crusher performance and health to generate tangible remedial action informed by data. In essence, it provides real-time data that allows customers to anticipate problems before they occur, thus avoiding surprises. 

In addition, the machine visibility RMS provides allows for the replacement of wearing parts before they wear out. Collected data over a period of time will provides insights into parts that are replaced frequently, allowing customers to keep these in stock at all times and avoid unnecessary downtime.

With RMS, mines and quarries can expect increased efficiency within their operations. Continuous analysis of real-time data round-the-clock helps operations get the most out of their equipment, minimising downtime and maximising uptime. Higher uptime translates into higher machine utilisation which, in turn, reduces cost-per-hour. 

“In addition, the data gathered on crusher performance makes optimisation easier with the ultimate goal of enhancing business performance. The alerts, available 24/7, also help reduce high wearing of crusher components, which is detrimental to material consistency and has negative cost implications,” says Ahlqvist. 

Keeping machines running in optimal condition translates into reduced energy consumption which not only results in cost effective operations, but also allows customers to reduce their environmental impact. 

“Energy efficiency and sustainability have over the years become a key part of business decisions for mining companies, especially on the back of growing pressure for the industry to improve its sustainability performance. With RMS, we are bringing yet another set of advanced digital services to help the industry increase efficiency while reducing carbon emissions,” concludes Ahlqvist.

Client Focus

TRU-TRAC APPOINTS BREC LTD AS MASTER DISTRIBUTOR FOR THE UK

Tru-Trac, a global leader in conveyor belt alignment solutions, has appointed BREC Ltd as its exclusive master distributor in the United Kingdom. This partnership will provide UK-based industries with direct access to Tru-Trac’s advanced belt tracking solutions, supported by local expertise and service.

Since 1995, Tru-Trac has been a pioneer in conveyor belt alignment technology offering patented solutions that enhance efficiency, reduce downtime and lower maintenance costs. Its products are widely used in mining and bulk material handling industries to address belt misalignment challenges effectively.

Jonathan Rogoff, CEO of Tru-Trac, emphasised the strategic importance of the collaboration: “BREC Ltd’s extensive industry expertise and customer-centric approach align with our commitment to delivering innovative and reliable conveyor solutions worldwide.”

With decades of experience in the conveyor sector, BREC Ltd is well-positioned to support Tru-Trac’s expansion in the UK. Steve Perruzza of BREC Ltd highlighted the significance of the alliance: “Partnering with Tru-Trac allows us to bring world class belt tracking solutions to the UK market, enhancing reliability and performance for our customers.”

To ensure broad market coverage and efficient service, BREC Ltd will collaborate with a network of exclusive partners across the UK. A UK-based warehouse will facilitate faster deliveries, manufacturer-backed installation support and ongoing maintenance assistance.

Tru-Trac has installed more belt trackers globally than any other company, offering a product range of over 1,000 variations tailored to diverse operational needs. Its solutions provide a lower total cost of ownership through extended product lifespan and minimal maintenance requirements.

Client Focus

CONCOR JV BUILDS BRIDGES TO GROWTH IN LESOTHO

Work is surging ahead on the two bridges over the Mabunyaneng and Khubelu Rivers, part of the Polihali Dam programme of the Lesotho Highlands Water Project Phase II.

Driving this progress is the Concor-Nthane Brothers M&K Bridges Joint Venture, which began work in January 2024 on the two structures. The bridges will provide crucial access to the town of Mokhotlong once the existing roads and tracks are inundated by the Polihali reservoir. The road network is being realigned to accommodate the expected full supply water level of this dam. 

In terms of dimensions, the Khubelu Bridge will comprise nine spans of 30 m each, making up a 270 m stretch across the Khubelu River. The bridge across the Mabunyaneng River is 120 m long with four 30 m spans. Both bridges will have two abutments and will be 13,5 m wide. Located in the higher regions of the valleys, the bridges will be 30 to 35 m above ground level. According to Concor Contracts Manager Jaco Verreynne, much of the work to date has been creating the foundation structures for the bridges. 

“There has been a more or less even spread of piling and founding on competent rock,” says Verreynne. “The basic design includes standard pillar type piers, with a pier head to receive the precast beams, completed by a reinforced concrete deck.”

At the Khubelu Bridge, piers are dowelled into competent rock while the abutments each receive 12 piles. While the one abutment on the Mabunyaneng Bridge is on competent rock and can be dowelled, the other will be piled – as with the piers. He notes that the pile depth is between 8 m and 12 m.

“We drive a metal casing through the soft material after which the drilling can be conducted through the casing,” he says. “Once we reach the required rock strength, we can socket into this competent material. Steel reinforcement is then put in place, followed by the casting of concrete using the tremie method, ensuring that the concrete does not segregate.” 

Rivers have been relatively low during the winter of 2024, which is the dry season, but the rainy season from September brought more challenging conditions. There is always a risk of flooding, says Verreynne, but the project has planned for the piers in the river to be at least 6 m high by the time the rivers rise. This will ensure that the structure remains secure, and work can continue safely. 

“Another component of the project is a reinforced earth wall at the eastern abutment of the Mabunyaneng Bridge, where a vertical wall is being built next to the new road to accommodate traffic during bridge construction,” he says. “This retaining wall is about 8 m high and will run for some 180 m long.”

The Concor-Nthane Brothers M&K Bridges Joint Venture has also been tasked with several road cuttings involving blasting and earthworks. Bypasses are also being constructed at the outer abutments to allow traffic to continue as some of the bridge abutments are in the existing road. 

Precast beams are being manufactured on site close to the project’s concrete batching plant, allowing the beams to be transported just 1 to 2 km to the bridges. There will be a total of 91 beams cast – 28 for the Mabunyaneng Bridge and the balance for the Khubelu Bridge. Each beam will measure 2,130 m in height and 30 m in length. 

“We will manufacture and stress the beams on site, using two 275 tonne cranes to move these onto bogey-type trucks with self-steering dollies,” he says. “This will allow us to navigate the turns in the road as we transport the beams to the bridge areas.”

Cement and fly ash for the concrete is ferried by road to site, with aggregate coming from a source near the Senqu Bridge as well as from local suppliers. 

“By the end of the project, we will have used about 11,000 m3 of concrete for the two bridges, with another 2,000 m3 for the temporary works that we executed in establishing infrastructure such as the batch plant and gantry crane,” he explains. “The piling work consumes about 1,000 m3 of concrete.”

The Concor-Nthane Brothers M&K Joint Venture is planning to start installing precast beams in March 2025, with a manufacturing programme to have the beams ready in good time. This will allow the bridge decks to be completed by the middle of 2025.

The contract includes the upgrading of community roads and maintenance of the main A1 road where small contractor packages are being managed by the joint venture. This work includes fixing of guardrails, potholes, line markings and signage. 

“We will have about 20 subcontractors in various disciplines on site at different times in the project,” he says. “These are mainly small businesses, for tasks such as gabions and minor concrete works.”

This is an important part of the joint venture’s commitment to train and upskill small subcontractors, and forms part of Concor’s ongoing efforts to build capacity in the local areas around each project. He emphasises that site work is the basis upon which these businesses can build their experience and establish sustainable operations into the future. 

“Concor sees all our projects as valuable opportunities not only to build economic infrastructure for growth, but to enhance skills and livelihoods in local economies,” says Verreynne. “This includes the approximately 230 workers on site, of which about 70% are Lesotho nationals.”

The bridges are scheduled to be competed in October 2025.

Client Focus

MAJOR SAFETY MILESTONE FOR AFRISAM  

Testimony to the high levels of health and safety standards maintained across its quarry operations, AfriSam’s Construction Materials division marked a four year Lost Time Injury (LTI) Free milestone in October 2024. 

The latest Occupational Health and Safety (OHS) milestone follows hard on the heels of the 2022 and 2023 Top Corporate Performer accolades in the annual ASPASA ISHE Awards. According to Vernon Brown, National Health & Safety Manager Construction Materials at AfriSam, the latest achievement once again demonstrates the company’s total commitment to creating a safe environment where every employee returns from work unharmed every day.

For AfriSam, OHS compliance goes beyond simply controlling and preventing the risks inherent in mining activities – it is a comprehensive strategy that seeks to instil a safety culture rooted in active awareness of the importance of safety protocols. 

“Within our construction materials business, and the AfriSam organisation at large, there is an understanding that improving health and safety performance is a long term goal that requires sustained effort, resources and commitment,” says Brown. “What sets us apart is an executive leadership that shows a genuine and visible commitment to the achievement of a safety culture, treating health and safety as a line management responsibility.” 

Commenting on some of the key initiatives that contribute to the company’s exceptional safety record, Brown makes special mention of the inter-plant safety competition. The main aim of this initiative is to “change the hearts and minds of employees” when it comes to safety. The inter-plant competition focuses on four key areas – statistics, audits (both internal and external), housekeeping and continuous improvement. 

Audits, he says, go beyond just the score and provide a platform to address any shortcomings that might have been pinpointed by the auditor. Meanwhile, good housekeeping – one of the basic pillars of successful health and safety practices – can help prevent accidents such as slips, trips and falls which are common in quarries and mines. 

“Safety leadership, not only at executive level, but also at operations level has been key to our successful OHS performance. Quarry managers are empowered to take initiative in developing their site-level safety interventions. These initiatives are inclusive and speak directly to the people at these operations,” says Brown.

Technology, says Brown, has dramatically changed the way the industry operates and its impact on workplace safety is no exception. Over the years, AfriSam has leveraged technological advancements to create a safer work environment. 

One area where this is apparent is in trackless mobile machinery where the company is among the first quarrying groups to adopt Proximity Detection Systems (PDS) and Collision Prevention Systems (CPS). This is aimed at eliminating vehicle-to-vehicle and vehicle-to-people interactions. 

“As part of our Traffic Management Plans, we have identified areas with significant risk which led to the adoption of PDS/CPS technology. We have currently done a full installation at our Verulam Quarry in KwaZulu-Natal. We have also done trials at our Rheebok Quarry in the Western Cape and we are busy with trials at our Jukskei operation in Gauteng,” concludes Brown.

Client Focus

TRANSFORMING CONVEYOR EFFICIENCY: TRU-TRAC’S EXHD DYNAMIC IMPACT IDLER BED

Conveyor belts are crucial components in mining and heavy aggregate handling operations, where efficiency and reliability are paramount. However, these systems often encounter significant challenges, particularly in the loading zones where the impact of falling materials can cause severe belt damage. Tru-Trac’s EXHD Dynamic Impact Idler Bed offers a robust solution designed to protect belts and enhance system reliability in the most demanding applications. 

COO of Tru-Trac, Shaun Blumberg unpacks the design, benefits and broader impact control capabilities of Tru-Trac’s innovative solution.

Blumberg says the challenge of managing impact control in loading zones is a significant one for all materials handling operations. “These transfer zones are the points where materials are introduced onto the belt from chutes, often from considerable heights ranging from 2 metres up to 10 metres. The force of this impact can lead to various issues including belt damage, material spillage and belt misalignment. Insufficient support and impact control ultimately results in frequent maintenance needs, increased downtime and higher operational costs.”

“Traditional impact rollers, while commonly used due to their low cost, often provide inadequate shock absorption particularly in high-drop applications,” he continues. “Furthermore, poorly designed chutes and under-specified impact beds can worsen the problem.”

It is a known fact that improperly engineered loading zones that fail to distribute material evenly or align with the belt’s trajectory create uneven wear, and this significantly increases the likelihood of belt damage.

According to Blumberg, Tru-Trac’s EXHD Dynamic Impact Idler Bed represents a unique and significant advancement in addressing these issues. Specifically engineered for applications with drop heights between 2 metres and 10 metres, this system is designed to absorb heavy aggregate impacts safely, preventing belt damage and extending the belt’s life. 

The Tru-Trac EXHD Dynamic Impact Idler Bed combines dynamically adjusting impact idlers with robust shock-absorbing springs to provide superior impact control.

The impact idlers in the Tru-Trac EXHD system oscillate to adjust dynamically to the load, significantly reducing the force transmitted to the belt. This movement allows the system to absorb and dissipate impact energy more effectively than static systems. The heavy duty springs enhance this absorption, capable of handling loads up to 11.4 tons, working in tandem with the idlers to manage high impact conditions effectively. This advanced design ensures minimal stress on the belt, preventing damage and enhancing durability.

Blumberg says that Tru-Trac offers a range of impact control solutions tailored to specific application requirements ensuring that conveyor systems are protected from various types of impact forces. This includes standard impact beds, impact rollers and slider frames; all of which are engineered for easy installation and minimal maintenance.

Tru-Trac’s capabilities also extend to addressing dust and spillage around the impact or loading zone. “Proper dust and spillage control are essential for maintaining a clean and efficient conveyor environment and our solutions help to minimise material loss and prevent the accumulation of debris which can lead to additional wear and operational inefficiencies,” he says. 

A recent case study from a copper mine in the DRC highlights the effectiveness of the Tru-Trac EXHD Dynamic Impact Idler Bed. The mine faced extreme challenges with its conveyor system, where high impact loads in the loading zone frequently caused belt damage, leading to significant downtime and maintenance costs. The existing impact system, which used traditional rollers, proved inadequate for handling the high drop heights and abrasive materials. 

“Our local team conducted a comprehensive site assessment, collecting the necessary data and analysing various factors such as material properties, drop heights, existing system configurations and operational challenges,” Blumberg says. “This detailed evaluation included observing the wear patterns on the existing conveyor belt, identifying the sources and magnitude of impact forces and assessing the overall condition of the loading zones.” 

“By gathering the necessary information first hand and gaining a thorough understanding of the specific conditions and requirements, our engineering team could offer a solution that would effectively address the unique challenges faced by the site and this saw the installation of our Tru-Trac EXHD Dynamic Impact Idler Bed,” he says. 

In this application, the system’s oscillating idlers and heavy duty springs work in tandem to absorb and disperse the severe impacts. The oscillating idlers dynamically adjust to the load, allowing them to move with the material as it falls onto the belt. This dynamic adjustment significantly reduces the direct force transmitted to the belt, preventing sudden shocks that can cause damage. The heavy duty springs complement this action by providing robust shock absorption, further minimising stress on the belt. 

“Together, these components ensure that the belt remains aligned, preventing issues such as misalignment, tearing and edge wear. By maintaining proper alignment and reducing impact related damage the system increases the belt’s longevity and reliability and has ultimately led to reduced maintenance costs and increased uptime at this customer,” Blumberg says. 

It is apparent that the broader impact of poorly designed loading zones cannot be underestimated. Inadequate impact protection can lead to increased spillage, belt misalignment and structural damage to the conveyor system. Misalignment causes the belt to drift leading to additional wear on the edges and other components which, in turn, increases maintenance requirements and potential operational downtime. Chutes that are not properly aligned with the conveyor can misdirect materials, creating irregular impact points and causing excessive localised stress on the belt. This can result in belt failure and significant operational disruptions. 

“Tru-Trac’s EXHD Dynamic Impact Idler Bed represents a significant advancement in conveyor belt protection, effectively addressing the complex challenges of impact control in loading zones and we believe that investing in high quality impact beds and ensuring proper chute design is crucial for maintaining efficient and reliable conveyor operations,” Blumberg concludes. 

Client Focus

UNDERGROUND OPPORTUNITIES EMERGE AS OPEN PITS MATURE

With many open pit mines in Southern Africa reaching maturity, the scope for underground mining promises to create new opportunities for shaft sinking and underground mining specialists.

As a leader in this field for many years, Murray & Roberts Cementation has been busy with complex and long term projects, reinforcing its safety performance and honing its innovative practices and technologies. According to Japie du Plessis, Managing Director of Murray & Roberts Cementation, the current market looks full of potential.

“Among our differentiators has always been our depth of expertise and experience, with many of our people having served up to 35 to 40 years with us,” says du Plessis. “But what makes us most proud in recent years is how we have continued to pioneer safe execution in a field which is known for its risks and hazards.”

The company, recognised in 2024 by the Association of Mine Managers South Africa (AMMSA) with a safety award for achieving seven million fatality free shifts, reached another benchmark milestone in January 2025 when it achieved eight million fatality free shifts over a period during which it sunk numerous shafts for mining companies in Southern Africa. Underpinning this safety record is a substantial and ongoing investment in skills, he notes, driven by the Murray & Roberts Training Academy at Bentley Park near Carletonville. 

“Safety is at the core of our extensive range of training interventions in shaft sinking and trackless mining,” he explains. “Our blended learning methodologies – and particularly our mock-up facilities – are recognised as benchmarks for the industry; many mines visit Bentley Park to learn from what we have developed.”

He highlights the way the company has engineered safety into all its processes, systems and equipment – based on a thorough analysis of past incidents. This has allowed the safe deployment of innovative shaft sinking methods and spurs on continuous improvement in designs and methodologies. 

“Each project brings its own challenges and working conditions, so we apply our tailored approach to the specific needs of the customer,” says du Plessis. “This could include solving construction challenges underground, developing appropriate mining methods for underground crusher chambers or finding solutions for hoisting.”

Among its recent projects was the innovative adaptation of a ventilation shaft to include hoisting infrastructure that would operate where air is required to move at high velocities. There have also been shaft sinking contracts – including a recent 1,200 metre shaft – where conventional methods failed to deliver results due to the poor quality of ground conditions. 

“We applied accepted sinking methodologies in creative ways to deal with those difficult ground conditions,” he says. “In the same way, we tailor solutions in trackless mining, pumping, hoisting, high pressure plug construction, dewatering, ore pass rehabilitation and drilling and blasting practice.”

The skills development capabilities in Murray & Roberts Cementation adds a vital sustainability element to its contract mining work which has recently included numerous projects in platinum and coal. The training and knowledge sharing with customers’ people lays the necessary groundwork for in-house mining to continue productively after handover.