Monthly Archives: May 2025

Client Focus

EXPOSED AGGREGATE IN THE SPOTLIGHT AS DEMAND FOR SURFACE RETARDERS RISES

An upward trend in the use of surface retarders in South Africa’s construction and infrastructure sector is shining a spotlight on the increasing popularity of exposed aggregate concrete finishes. According to Michelle Fick of Chryso Southern Africa, this trend reflects a growing appreciation for both the aesthetic and functional benefits that exposed aggregate offers.

“Exposed aggregate is no longer just a decorative finish; it’s being adopted across a wide range of applications from pavements and driveways to architectural facades and public infrastructure,” says Fick. “The textured non-slip surface offers a safer option for high traffic zones, while the natural stone aesthetic enhances the visual appeal of buildings and outdoor spaces.”

The finish is also ideal for preparing concrete surfaces that will receive a subsequent layer. Whether it is a waterproofing membrane, screed or cladding, the roughened texture created by the exposed aggregate allows for superior bonding, improving the durability and lifespan of the entire system. This makes it a preferred solution not only in aesthetic applications but also where structural performance is key.

Chryso Southern Africa offers surface retarders designed specifically to meet these evolving needs. The company’s products facilitate reliable consistent exposure of the aggregate to the required depth – up to a maximum of 3 mm – ensuring a uniform and high quality result. This is essential for specialist applicators who rely on precision and repeatability, particularly in large-scale or architecturally sensitive projects.

“The simplicity of the application process is another advantage,” Fick explains. “After the concrete is poured, the surface retarder must be applied evenly before the concrete begins to set. Following a predetermined curing period the surface is washed with water, removing the top layer of cement paste and revealing the aggregate below. A final sealant is then applied to enhance the surface’s durability and finish.”

Sealants can be selected to suit different environments and project need including internal and external use, UV resistance and finishes ranging from matte to high-gloss. This flexibility allows architects and contractors to customise the final appearance while ensuring long term performance.

Significantly, Chryso was the first manufacturer to offer a mineral solvent-free water-based retarder designed to prevent soil and groundwater pollution during the cleaning of treated concrete. The product contains no toxic substances, is 85% biodegradable, classified as harmless and complies with EEC Directives 88/379 and 93/18.

Fick notes that Chryso’s surface retarders are developed with the applicator in mind, offering not only technical consistency but also ease of use in site conditions that can often be challenging. “Our retarders provide reliable performance even under variable temperature and humidity conditions, which is critical for projects with tight timelines and complex environmental demands.”

With sustainability and safety continuing to drive specification choices in the built environment, the use of exposed aggregate finishes is expected to grow. “The combination of visual impact, surface durability, slip resistance and improved bonding makes it a smart choice for both new builds and renovations,” Fick concludes. “As the trend gains momentum, we are committed to supporting the market with reliable solutions that ensure consistent high quality results.”

As urban spaces evolve and developers seek more creative yet practical finishes, the role of surface retarders – and particularly exposed aggregate – is likely to become even more prominent in shaping the look and functionality of tomorrow’s concrete structures.

Client Focus

THE PINES IS CONRADIE PARK’S STYLISH CLINCHER 

The Pines, a convenience retail zone with an aspirational edge, will be one of Conradie Park’s final achievements – helping to put this mixed-use housing development head and shoulders above anything comparable in South Africa.

Developed by Concor, the 22 hectare Conradie Park project has been under construction since 2019, and is bringing an added sense of community to the Pinelands area of Cape Town. According to Mark Schonrock, Property Development Executive at Concor, the quality of the housing units and the project’s carefully designed features and landscape is unmatched.

“An important element of the Conradie Park concept is its mixed-use zoning, ensuring that residents will have easy access to key retail outlets within walking distance of their homes,” says Schonrock. “At the same time, The Pines complex has convenient parking for shoppers – adding to the amenities available to the local community.”

There will be 13,000 m2 of retail space at The Pines, he explains, including a supermarket as well as fast foods, fashion and service outlets. Another 2,200 m2 will be dedicated to co-working space and play areas. To accommodate car-owning shoppers, there will be 230 ground level parking spaces in front of the centre, as well as 330 roof top covered parking bays on the first floor of the complex. 

“In line with our conceptual design to make the most of the available space at Conradie Park, the parking arrangement will be counter-cyclical,” he says. “During the day, the parking serves mainly the retail area, while overnight there is availability for the residents of the adjacent blocks.”

The Pines is ideally placed for the five residential buildings – each of which will be four or five storeys high – to be constructed around the retail area. Units in four of the five blocks will be available to the open market, while one of the blocks will be designated for first-time home buyers who are recipients of the Finance Linked Individual Subsidy Programme (FLISP), a government subsidy promoting affordable home ownership. 

The five blocks will add over 850 living units to the Conradie Park community. He adds that the location of The Pines complex on the edge of the development also gives it attractive views of Devil’s Peak and Lion’s Head the mesmerising Cape Town sunset.

“Our choice of retail tenants will ensure that The Pines delivers a differential offering, providing some variety to what the area already offers to residents,” says Schonrock. Construction work on The Pines has started with completion expected in the early months of 2026. 

Client Focus

WEBA CHUTE SYSTEMS LEADS SHIFT FROM REACTIVE TO PROACTIVE CHUTE MAINTENANCE

Technological advancements in the digital space are paving the way for a key trend in the management of transfer points: a transition from reactive to proactive maintenance. 

Mark Baller, Managing Director of Weba Chute Systems, notes that chutes were traditionally replaced or repaired only after failure, resulting in unplanned downtime and higher costs. However, today’s leading mines are leveraging digital technologies to monitor equipment and processes in real time, enabling them to identify and resolve potential issues before they escalate.

“This is certainly the direction in which transfer point technology is evolving,” says Baller. “Mining operations are increasingly leveraging data to prevent unplanned downtime and optimise equipment performance.”

He explains that the value of data begins with building a historical record of equipment condition and performance, enabling more accurate maintenance predictions. To support this, Weba Chute Systems has developed an inspection app that allows clients to monitor chute performance remotely. The app simplifies data collection and storage, enabling Weba to analyse trends and provide customers with informed maintenance recommendations.

“With remote monitoring, we can identify trends and build a predictive maintenance model, allowing customers to schedule maintenance more efficiently,” Baller explains. “This level of transparency strengthens our partnership with clients and enhances the overall efficiency of their operations.”

He emphasises that an improved maintenance strategy not only increases operational uptime but also extends equipment lifespan. This reduces capital expenditure and minimises steel wastage while maximising the customer’s return on investment in the chute. Enhanced predictability also streamlines the supply chain, allowing both the OEM and the customer to anticipate spare parts requirements in advance.

Another key advancement for Weba Chute Systems is the move towards standardising chute components. While the company is renowned for its custom-built transfer chute solutions, it has been developing standardised components that can be used across multiple chute installations. This approach enhances efficiency, reduces lead times and streamlines maintenance.

“Previously, every chute required custom components, forcing clients to keep a variety of different parts in stock,” Baller explains. “Now, we are shifting towards more standardised components, enabling clients to streamline their stockholding while still maintaining the flexibility to meet their maintenance requirements efficiently.”

This transition is especially advantageous for large mining operations with multiple chutes. By introducing component interchangeability, Weba Chute Systems is helping clients reduce operational costs while enhancing equipment longevity and overall efficiency.

Health and safety continue to be key considerations in chute selection, and Weba Chute Systems’ advanced designs optimise material flow while minimising turbulence, significantly reducing dust generation. Baller emphasises that a well-designed chute is often a more effective solution for dust control than relying on dust extraction systems.

The cost of installing and maintaining a dust extraction system can be significant and if the chute design itself generates excessive dust, the system may not be very effective,” says Baller. “Our chutes have demonstrated that a well-engineered design can eliminate the need for a separate dust extraction system, helping customers avoid unnecessary expenditure.”

A prime example is a coal mine in the United States that was at risk of being shut down due to environmental concerns over excessive dust. After switching to Weba Chute Systems’ innovative technology, the results were remarkable.

“The customer was able to remove their dust extraction systems entirely because our chutes alone produced even less dust than their previous system did with extraction in place,” Baller explains.

The proven success of Weba Chute Systems’ designs has driven strong growth across sub-Saharan Africa, with an expanding footprint in the Middle East, Australia, Canada and the United States.

“We are particularly excited about opportunities in the Middle East and North Africa,” Baller says. “In markets like Australia and North America, our strategy focuses on engineering and design, while local partners manage fabrication. This approach allows us to leverage our expertise while ensuring efficient service to local industries.”

Client Focus

LEADING THE WAY WITH LEVEL 9 PDS IMPLEMENTATION

Applying a Level 9 Proximity Detection System (PDS) to a mining operation is as much about changes in behaviour as it is about technical solutions, according to Pieter Wolfaardt from Apex, Booyco Electronics’ training partner of choice.

“An operational readiness assessment process conducted up front highlights all potential impacts on operations and pedestrian safety, giving the mine the opportunity to achieve seamless Level 9 integration with both the PDS and yellow fleet OEMs,” he says.

It is over two years since the South African Department of Minerals and Energy’s Level 9 intervention made it law to install PDS on all trackless mobile machines (TMMs). This is the latest step in the country’s journey as a global pioneer in this field. The advanced pace of regulation has also spawned a vibrant local economy of PDS developers and suppliers, in which Booyco Electronics has been a prominent player since 2006.

Wolfaardt highlights that there is well-proven Level 9 PDS technology available to mines, and it has been shown to significantly mitigate safety risk. However, the best results require more than technical installation; they require a systematic process of change management by all involved.

“Integrating a Level 9 PDS into a mining operation is not merely a technical upgrade; it fundamentally alters the way mines operate,” he explains. “Change management is the bridge that closes the disconnect between technology and people.”

He notes that the change process impacts safety culture, production and operator behaviour. Without structured change management, resistance to new protocols can undermine the system’s effectiveness.

“In our experience, a lack of change management often leads to a mine experiencing undue production stoppages, miscommunication and frustration among operators and managers,” he says.

By fostering better understanding and acceptance, change management ensures that safety improvements translate into long term shifts in behaviour – going beyond basic compliance to support a stronger culture of safety.

He explains that Apex, as the training service provider of choice to Booyco Electronics, addresses these challenges by ensuring that all stakeholders are involved and committed to the process. A vital starting point is a mine steering committee, ideally chaired by the general manager, to ensure alignment across departments from procurement and human resources to engineering and production. Apex then assumes its role as the Level 9 PDS change management facilitator and trainer on this committee.

“Leadership commitment is the driving force behind successful Level 9 PDS adoption so when a general manager champions the change, it signals to employees that safety is a core priority,” he says. “At the same time, every department must buy into the process and recognise their role.”

A key aspect of the change management process focuses on the mine’s traffic management plan, part of the baseline risk assessment prescribed by the Machinery and Occupational Safety Act. This plan will identify all the vehicles and zones of significant risk on the mine, and starts with a traffic analysis.

“Developing a sound traffic management plan will ensure that the mine understands their current traffic situation: Which vehicles are in the TMM fleet? Where do they travel? How often, and at what speeds?” he explains. “The plan must also analyse aspects such as road conditions, illumination levels and ventilation – as well as the critical issue of interaction between machines, and between machines and pedestrians.”

It is important to identify pre-emptive traffic management adjustments that will minimise any disruptions and ensure that mining operations continue efficiently. Structured training is conducted with operators and other stakeholders, to understand the mine’s new operating dynamics.

“Training is a cornerstone of effective Level 9 PDS implementation, and needs to be based on the gaps that we identify in the system,” he says. “It focuses on people change management, and educates personnel on new protocols. This often goes beyond classroom training and should be tailored to operational needs.”

Effective communication strategies, such as regular briefings and transparent discussions about challenges, help to build trust and buy-in from employees. Engaging workers in safety committees and seeking their input on system refinements also promotes ownership of the change.

Client Focus

REDUCE TOTAL COST OF OWNERSHIP WITH SANDVIK 800I X-CHANGE PROGRAMME

Sandvik Rock Processing is making it easier than ever for mining operations to cut costs and improve efficiency with its innovative X-change programme. This initiative allows mines to upgrade outdated spiderless and legacy hydrocone crushers with the next-generation Sandvik 800i series cone crushers – and the return on investment can be seen almost immediately.

According to PC Kruger, Business Line Manager – Crushing at Sandvik Rock Processing, the real value lies in how this programme helps operations reduce their total cost of ownership while optimising performance. “By taking advantage of the X-change programme customers can replace older technology with our high-performing Sandvik 800i range at a special price, while also gaining access to warranty support, ramp-up assistance and Sandvik’s advanced digital tools, all of which add up to significant operational savings.”

Kruger explains that customers upgrading through the X-change programme can expect up to 30% improved availability and up to 25% more final product delivered to downstream processes. This enhanced performance is due in large part to the Sandvik 800i’s state-of-the-art automation and robust mechanical design. 

Equipped with the Sandvik ACS-c 5 automation system, the 800i crushers offer rapid liner calibration – completed in just five minutes – helping to reduce downtime and boost productivity. The automation system also includes role-based functionality, guided alarm responses for operators and full access to historical and real-time data for maintenance teams, empowering proactive planning and accurate performance monitoring.

On the mechanical side, the Sandvik 800i series is built for durability and efficiency. It features a direct-drive design that reduces energy loss, a strong unibody structure and top-down maintenance access that simplifies servicing. Other enhancements, such as Constant Liner Performance (CLP) chambers as well as a huge variety of chamber profiles to adapt to every unique application, double-sealed pinion shafts and non-welded bottom shell wear liners with plastic-free fasteners, all contribute to reduced maintenance requirements and longer wear life.

The Sandvik 800i range supports sustainable efficient operations in a wide variety of applications including three-stage crushing circuits, SAG/AG mill pebble crushing, heap leach operations, lump ore processing and integration with HPGR systems. These cone crushers are designed to deliver finer particle sizes, enhancing downstream performance and reducing energy consumption across the board.

Importantly, every Sandvik 800i crusher is fully compatible with SAM by Sandvik, the company’s cloud-based digital assistant. Through SAM, customers can monitor equipment in real time, receive alerts, track performance and order parts – streamlining operations and enhancing decision-making.

Kruger emphasises that the X-change programme is more than an upgrade and is a strategic opportunity for mines under pressure to increase efficiency, reduce energy consumption and extend asset life. With structured pricing, digital support and reliable aftermarket services built in, the programme provides a clear and cost effective pathway to modernising crushing circuits.

“Upgrading to the Sandvik 800i via our X-change programme provides a structured path to improve safety, increase availability and enhance productivity across crushing operations,” Kruger concludes. 

Client Focus

BCCEI DRIVES STABILITY AND STRUCTURE IN CIVIL ENGINEERING SECTOR

As South Africa intensifies its focus on infrastructure development to stimulate economic growth, the need for a robust and well-regulated civil engineering sector has never been more urgent. At the centre of this stability is the Bargaining Council for the Civil Engineering Industry (BCCEI) which plays a strategic role in fostering fair labour practices, ensuring compliance and enabling collaboration across all levels of the industry.

“The BCCEI exists to ease the administrative and regulatory pressures that employers and labour face so they can focus on delivering infrastructure,” explains Lindie Fourie, Operations Manager at the BCCEI. “We manage key processes, provide clarity and offer a platform where both employers and employees can work together on fair enforceable labour standards.”

This is achieved through six collective agreements that define everything from working conditions to retirement benefits. These legally binding frameworks eliminate the inconsistency that often undermines project efficiency, especially on public sector jobs. With recent amendments to the Wage and Task Grade and Conditions of Employment Collective Agreements now in effect, it is crucial that all parties familiarise themselves with the updates to maintain compliance.

The BCCEI’s Dispute Resolution Collective Agreement allows for industry-specific arbitration, removing the need to approach general bodies like the CCMA. This streamlined sector-specific process enables timely resolution and prevents unnecessary project delays.

The BCCEI also plays a powerful enabling role in skills development. Its ability to engage with Sector Education and Training Authorities (SETAs) opens access to training grants and initiatives that are vital to tackling the ongoing shortage of technical skills. “We use our position to link decision-makers and industry players, driving conversations that result in practical action,” says Fourie.

Ultimately, the BCCEI’s impact extends well beyond its immediate stakeholders. By creating a stable labour environment, it supports infrastructure projects that improve public services, enable job creation and stimulate investment. “Our collective agreements bring structure, order and fairness. That’s not just good for industry – it’s good for the country,” Fourie concludes.

Client Focus

AFRISAM GEARED UP FOR MORE MEGA-PROJECTS IN SA

Mega-projects in the construction sector typically demand an intense level of inputs over short periods, which can put significant pressure on supply chains that may be underdeveloped or unprepared. 

This makes it essential for South Africa to maintain and strengthen its capacity to deliver the expertise and materials needed for such large-scale projects, according to Amit Dawneerangen, Construction Materials Executive: Sales and Product Technical at AfriSam. He emphasises the strategic role that established companies like AfriSam play in supporting the economy’s recovery and growth through their resilience and long-standing industry presence.

Dawneerangen explains that mega-projects, such as roads, dams and energy infrastructure, have the potential to accelerate economic development significantly. However, the extended downturn in the construction sector has raised concerns about its readiness to meet the demands of these massive undertakings. AfriSam, he notes, has consistently positioned itself as a reliable partner in these kinds of projects, drawing on nearly 90 years of experience in the industry. 

“This longevity is no accident; it is the result of a deliberate effort to retain capabilities and world class expertise throughout various economic cycles,” he says. 

AfriSam’s ability to service large-scale projects stems from its network of strategically located cement manufacturing facilities, quarries, crushing operations and batching plants across the country. These resources allow the company to supply material from multiple sites while maintaining strict quality standards. Dawneerangen stresses the importance of early-stage collaboration in mega-projects – ideally at the bidding or even pre-bidding phase – to ensure that all players in the supply chain are aligned and prepared for the high production volumes and extended shifts such projects often demand.

Changes in project scope, even minor ones, can trigger widespread impacts throughout the supply chain. AfriSam addresses this by working closely with customers during the planning process to anticipate and mitigate risks. With mega-projects pushing production volumes to levels beyond what many contractors and suppliers typically handle, Dawneerangen insists that quality must never be compromised. This requires robust quality control systems supported by cutting-edge technology.

For example, AfriSam employs computerised batching systems in its readymix operations to ensure precise adherence to engineer-approved mix designs. Quality checks are implemented at every stage – from pre-dispatch testing of readymix concrete to on-site sampling – ensuring the required strength and performance of the final product. Batch printouts further guarantee that mixes consistently meet specifications.

To ensure uninterrupted material delivery – a key factor in staying on schedule – AfriSam relies on its extensive footprint of facilities and vehicle fleets, all managed through advanced flexible planning systems. This logistical strength enables the company to support demanding projects across the country including landmark developments such as the Leonardo in Sandton, the PwC headquarters in Midrand, and various major road upgrade initiatives.

Client Focus

SEW-EURODRIVE’S DDI TECHNOLOGY AND SINGLE CABLE SOLUTION SIMPLIFIES CONNECTIVITY

Cabling can be one of the most challenging aspects of automation and drive system installations, often leading to delays, faults and inefficiencies. As a global leader in drive and automation technology, SEW-EURODRIVE understands that reliable cabling is critical to the success of any project.

Recognising the complexity and risks that traditional cabling can introduce, SEW-EURODRIVE offers a solution that simplifies connectivity: its innovative DDI (Digital Data Interface) technology combined with a single cable system. Designed to meet the demanding needs of modern industry, this approach eliminates the potential for cable connection faults that so often delay commissioning and compromise long term performance.

Unlike conventional cabling that requires multiple cables for power, feedback and control, SEW-EURODRIVE’s single cable solution integrates both energy transmission and data communication seamlessly. This not only reduces installation time and costs but also streamlines project planning, improves machine design flexibility and increases system reliability. With fewer connection points and reduced wiring complexity, the risk of installation errors is dramatically decreased – ensuring faster, smoother start-ups and greater operational confidence.

“From our experience across industries worldwide, we know that even minor cabling issues can escalate into major project setbacks,” says Willem Strydom, Business Development Electronics Manager, at SEW-EURODRIVE South Africa. “With our DDI technology and single cable design, customers can eliminate these risks, enabling more efficient installations and maximising system uptime from day one.”

The DDI system transmits both digital encoder signals and motor temperature information through the same cable used for supplying power. This integrated communication ensures real-time feedback from the motor without the need for additional wiring, delivering high levels of accuracy and process control while simplifying maintenance requirements.

“SEW-EURODRIVE’s commitment to simplifying industrial automation while improving reliability continues to set new standards,” Strydom says. “By offering a complete drive solution that reduces cabling, improves diagnostics and enhances overall system efficiency, we help businesses across sectors achieve operational excellence.

The single cable solution, underpinned by proven DDI technology, empowers businesses to achieve faster, more secure and more cost effective drive installations – keeping operations running at full potential while supporting future-ready automation strategies.

Client Focus

CELEBRATING 40 YEARS OF EXCELLENCE IN SPECIALISED HVAC

Celebrating 40 years in business, Booyco Engineering has successfully evolved its specialised heating, ventilation and air conditioning (HVAC) offerings while remaining true to its commitment to quality and reliability, says Managing Director Brenton Spies.

“As a South African company, we are proud to have thrived through the many national and global shifts and challenges of the past four decades,” says Spies. “Our achievements speak to the value customers have gained from our engineering quality and innovation over the years.”

Initially focused on HVAC solutions for demanding military applications, Booyco Engineering soon diversified into the rail, mining and other industrial sectors – driven by the robustness of its products and strong manufacturing capability. In the rail sector, its specialised HVAC units commonly last up to 20 years, providing users with the lowest total cost of ownership while reducing the indirect costs of unplanned repairs and maintenance.

Grant Miller, Executive Director at Booyco Engineering, highlights that the company’s solutions are designed for applications where conventional HVAC systems simply cannot withstand the conditions. 

“As in military applications, the rail and mining sectors require solutions that can cope with high vibration levels, dust contamination and extreme temperature variations,” he explains. “Over the years, the strength of our solutions has been proven to customers who avoid frequent replacement or repair costs. This, combined with reduced downtime, ensures the lowest total cost of ownership.”

HVAC’s Growing Role in Workplace Safety

In recent decades, industries such as mining and earthmoving have seen a tightening of health and safety regulations. Employers are now required to ensure that mobile plant operators work in comfortable conditions, necessitating HVAC systems in sealed cabs.

“In many parts of Africa and beyond, hot daytime conditions make an HVAC system in mobile machinery indispensable for outdoor work,” says Spies. “When an HVAC system malfunctions, operations can come to a halt. The reliability of our solutions is not just a health issue – it’s a production issue. This is where customers see the real value of investing in quality and certainty.”

Another challenge arising from stricter health and safety standards is the common practice of operators idling their machines when stationary – such as when trucks wait to be loaded in an open pit – just to keep the HVAC running. This increases fuel costs and carbon emissions.

“A major advantage of being in business for so long is the depth of technical expertise and experience in our company,” says Miller. “We tackled this challenge on behalf of the sector by developing a dedicated Anti-Idle Auxiliary Power Unit (APU) that keeps the HVAC system running while the engine is switched off – significantly reducing fuel consumption and emissions.”

Driving Innovation and Expanding Reach

Booyco Engineering’s strong reputation has been built on its expertise in designing bespoke HVAC solutions for demanding applications. More recently, the company has also standardised many of its systems to enhance cost competitiveness and significantly reduce lead times.

“Our ability to deliver quickly is vital for Africa’s mining sector, where projects are often fast tracked and customers do not have the luxury of waiting for a bespoke design,” says Miller. “However, where a custom solution is required, our full design and engineering team ensures an optimal outcome including finite element analysis and ducting flow optimisation.”

Spies highlights that Booyco Engineering’s success is reflected not only in Africa but also in global markets with its HVAC units operating in Europe, North America and South America.

“Our recent focus on mining is opening doors in Asia and Australia as well, where many of our OEM customers are deploying their machines with our equipment,” he says. “Our value is especially evident in remote locations, where replacements and repairs are difficult and customers can rely on Booyco Engineering for a product that performs reliably under the harshest conditions.”

Client Focus

TRU-TRAC INCREASES CONVEYOR UPTIME AT MAURITANIA MINE

An iron ore mine in Mauritania was facing considerable safety risk and maintenance costs due to misalignment of its conveyors, until Tru-Trac implemented the solution.

According to Ian King, Sales Manager Africa at Tru-Trac, the customer was visited by Tru-Trac’s representative in West Africa, and an on-site assessment was conducted to analyse the challenges being experienced.

“We recognise that no two conveyors are the same, so it is important to start with a thorough physical inspection,” says King. “This provides the basis for our customised solutions, and allows us to apply the right expertise and equipment.”

This led to the involvement of Tru-Trac’s Technical Sales Engineer, Muller Joubert, who provided further technical assistance in developing the optimal solution. Joubert then spent time at the site, ensuring speedy installation.

“Our on-site survey revealed that several of the mine’s conveyor belts were running into the sides of the structure,” he explains. “This prolonged misalignment had caused significant damage to the conveyor sidewalls. A more serious risk was that this grinding against the structural framework posed a serious safety risk – as the potential build-up of heat in the conveyor belt could escalate into a fire hazard.”

Tru-Trac reported on its findings, highlighting the urgency of the situation to prevent further damage and to allay the safety risk. The company’s recommendation was to install the trusted Tru-Trac V-Return self-alignment trackers, he explains. 

“These innovative solutions are designed to correct belt misalignment automatically, ensuring that the conveyor stays centred even under challenging conditions,” he says. “Even though the conveyor belts had been slightly damaged by the contact with the structures, our solution ensured that the belt could continue operating safely for some time – saving on considerable replacement costs.”

The Tru-Trac trackers’ effect was immediate, he says, aligning the belts centrally within the conveyor structures and preventing any further damage to the belt’s sidewall. As importantly, Tru-Trac’s work on the conveyor system was able to stop spillage from the belt and avoid downtime for maintenance – with both these factors contributing to the mine’s production capability. A total of eight Tru-Trac V-Return trackers were installed across three of the mine’s conveyors, located about 40 metres apart. 

As it was no longer necessary for employees to work next to the conveyor to clean up the spilled material, the operation became safer and more efficient. It was also important to ensure that the trackers could operate sustainably in the harsh desert-like environment with extreme temperatures and frequent dust storms.

“Our trackers are built with sealed mechanisms, ensuring that no dust or debris can compromise their performance,” says Joubert. “This design ensures long-lasting functionality, even in the severe climates and punishing operating conditions so often found on mining sites across Africa and elsewhere.”

He also highlights that the design facilitates quick and hassle-free maintenance to reduce downtime, including a simple roller replacement process and adjustable mounting brackets. 

“Our self-alignment frames are designed for maximum efficiency,” he explains. “The maintenance technician simply loosens two screws on the side of the frame, then releases tension. They drop the frame and remove one more bolt before swopping out the idler and installing a new one.”

This only takes about 20 minutes, which is a dramatic improvement on traditional maintenance times. The result is less standing time and higher productivity, he points out.  

“To customise our solutions, we manufacture our trackers to suit the specific belt width, belt speed and tonnage per hour carried by the conveyor,” says Joubert. “In this case, our trackers were designed for the specific conveyor running between 2,7 metres and 3,2 metres per second.”

He concludes that Tru-Trac’s confidence in its trackers is based on global experience, where they have seen the units performing well after more than seven years. 

“With proper maintenance and regular support, we expect the same outstanding performance from the units we have installed at this mine in Mauritania,” he says.