BHT: Oct 2010

BULK HANDLING TODAY October 2010

October 2010
Featured on the cover:
Steinmüller
Contents
Marcelino Da Costa Cover Story 29 Market Forum
Tel: (017) 624-5000 5 Moving to New Heights
Endorsing Bodies
Fax: (017) 647-6114
Cell: 082 904 4568 Crushers • CMA (Conveyor Manufacturers
E-mail: marcelino.da.costa@ 7 Protecting Steel Association)
steinmuller.co.za 9 Plastics for Wear Protection
• HCASA (Hydraulic Conveying
www.steinmuller.co.za Lifting Equipment Association of SA)
11 Playing it Safe
15 A Dire Need for Proper Training • LEEASA (Lifting Equipment Engineering
Association of South Africa)
Conveying • RFA (Road Freight Association)
17 A Pseudo 3D Analysis of the Indentation
Rolling Resistance Problem • SAIMechE (SA Institution of Mechanical
Engineering)
Trucking
25 Shifting into Overdrive • SAIMH (SA Institute of Materials Handling)
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The monthly circulation

is 4 016 Proprietor and Publisher: Advertising Sales:
PROMECH PUBLISHING Surita Marx
Tel: (011) 781-1401 DTP: Zinobia Docrat and
Fax: (011) 781-1403 Sean Bacher
E-mail:
Our e-mail address is bulkhandling@promech.co.za Printed by:
bulkhandling@promech.co.za Website: www.promech.co.za Typo Colour Printing
Managing Editor: Tel: (011) 402-3468
Visit our website on www.promech.co.za
Susan Custers

CONVEYOR MANUFACTURERS ASSOCIATION
From the Chairman’s Desk

A safety symposium held on the last day of August, a CMA initiative that was endorsed by the DMR, was well
attended by over one hundred representatives from industry.
T
he focus of the event, whilst conclusions drawn and the agreed way forward, is
exploring all aspects of conveyor available on the website www.cmasa.co.za under
safety, was to be the promotion the tab “News and Views”.
of safety during the design of
New graduates
conveyor systems, with input from all
We have a new batch of diploma graduates from
stake holders. It is extremely unfortunate
the latest course in the design and operation of
that on the day, not a single representa-
belt conveyors.
tive from the DMR attended.
Six candidates achieved a pass-with-distinction:
Nevertheless, the CMA was given a
clear mandate to put forward the col- • Rikesh Amarial
lective opinion from industry to obtain • Jonathan Davies
change where necessary and to insist • Louwrens de Bruyn
on the DMR’s presence at the follow- • Ryan Fernandes
up symposium planned for six months • Johan Kruger
time.
• Antonie le Roux
Simon Curry Some of the topics discussed in the
A further eight candidates from the September
open debate following presentations from end us-
course, plus one re-write, achieved a pass:
ers, experts and supply specialists, were:
• Derek Clifton
• Hardwire system and intelligent pull-key
systems • Herman Marx
• Anti-roll back idlers • Johan Meintjes
• The position of belt arrestors • Dennis Mohlala
• Training of idlers in the belt-stop condition • Khumi Mokgabudi
• Stored energy • Albert Montjane
• Nip guards and palisade fencing • Clinton Richardson
• Fire protection • Philip Roussouw
• Guarding • Janus van Zyl
Congratulations to you all – industry is richer for
Not a single representative from the DMR attended your efforts!
The next course will be held in April 2011.
If you were unfortunate enough to have missed
attending the symposium, a full transcript of all Simon Curry
presentations and the issues debated together with Chairman
CMA Members List as at October 2010

All members subscribe to the CMA Code of Ethics
ABB Industry CPI Technologies M & J Engineering Sandvik Materials Handling SA
Afripp Projects CT Systems Martin Engineering Schaeffler South Africa
Actom David Brown Gear Industries Melco Conveyor Equipment Secrivest
Atlanta Manufacturing Delras Engineering Moret Mining SENET
Bateman Engineered Technologies DRA Mineral Projects MS Conveyor Pulleys SA SET Agencies
Bauer Dunlop Belting Products Nepean Conveyors SEW Eurodrive
BMG Dymot Engineering Company OE Bearings Shaft Engineering
Bearings International ELB Engineering Services Oriental Rubber Industries SA Shaw Almex Africa
Bonfiglioli Power Transmissions Facet Engineering Osborn Engineered Products SKF South Africa
Bosworth Fenner Conveyor Belting PH Projects Holdings ThyssenKrupp Materials Handling
Brelko Conveyor Products (South Africa) Read Swatman & Voigt Transmission Components
CKIT Conveyor Engineers Flexible Steel Lacing SA Rema Tip Top South Africa Transvaal Rubber Company
Continental Crushing & Conveying Hägglunds Drives South Africa Renold Crofts Unitek Engineers
Conveyor Watch Hansen Transmissions SA Roymec Veyance Technologies Africa
CMG Electric Motors South Africa Hosch - Fördertechnik (SA) RSV ENCO Consulting Voith Turbo
CPM Engineering Lesa Mining Equipment and Rula Bulk Materials Handling Zest Electric Motors
Conveyor Belt

COVER STORY
Moving to New Heights

Give your plant the tools it needs to move to new heights by mechanical construction projects, are now available
using equipment from Steinmüller Plant and Equipment Hire. for hire in the market place.
The company offers the very best in plant hire, 3D rigging The company is dedicated to the highest level of
studies as well as experience and expertise in the plant customer satisfaction. “This is clearly evident from
industry. Steinmüller’s approach to personnel skills develop-
ment and expertise, which ensures customers get
S
more than top quality equipment – as well as the
teinmüller Plant and Equipment Hire of-
entire management of the equipment hire process,
fers a comprehensive range of plant and
from site establishment to de-establishment,” ex-
equipment.
plains Marcelino Da Costa, the representative of
The plant and equipment is used in me- Steinmüller Plant Hire.
chanical construction and refurbishment projects
in the power generation, petrochemical, general
and industrial, paper and pulp, mining, and sugar
industries.
Include a large number of cranes ranging from a

Gottwald MK600 (600 tonne capacity) to a 5 tonne
mobilift hydraulic mobile crane
Boasting a rich history in the business, Steinmül-

ler Plant and Equipment Hire holds a large pool
of equipment of over 24 000 items. These items,
which were formally used to support steelwork and
CRANE
Structural steelwork being erected for the SAS Reactor
Gottwald MK600
77 m Main Boom at 80°
Project at Secunda
75 m Luffing Jib (4.1° offset)
Base: 100% Outriggers
Counterweight: 152 Ton + 52 Ton Ballast
37.734 m Lift Radius (360°)
Crane Capacity at 37.734 m = 18 t
LOAD
TOTAL LOAD = 1 t
6% of capacity
CRANE
Tadano ATF 220G-5
59.192 m Main Boom at 67.7°
Base: 100% Outriggers
Counterweight: 0 lbs
Crane Capacity at 21.214 m = 4.99 t
LOAD
TOTAL LOAD = 1 t
40% of capacity
CRANE
Gottwald AMK 306-83
45 m Main Boom at 84°
68 m Luffing Fly Jib (25.9° offset)
Base: 100% Outriggers (10.5m x 10.3m)
Counterweight: 50 Ton
CRANE
American 9299 Sky Horse
270’ Main Boom w/ 150’ Mast at 70°
90’ Jib (25° offset)
Base: Crawlers
Counterweight: 104,700 lbs + 138,000 lbs
Trailing
Paraffin Plant at Sasol 1
Complex heavy lifts and 3D rigging

The fleet of equipment housed and serviced at
Steinmüller’s Bethal and Middelburg depots, has
expanded to include a large number of cranes rang-
ing from a Gottwald MK600 (600 tonne capacity)
to a 5 tonne mobilift hydraulic mobile crane, as
well as trailers, tractors, welding machines, gen-
erators, rigging equipment, grinding, drilling and
other small industry-related tools.
Steinmüller Plant and Equipment also carries out com-
plex 3D rigging studies Apart from the equipment available for hire, Steinmül-

COVER STORY
ler also offers extensive experience in

complex heavy lifts, in the petrochemi-
cal and other plant industries.
“We also offer rigging services using
the latest 3D rigging studies, cover-
ing both basic and advanced rigging,”
says Marcelino.
Safety standards
Steinmüller Plant and Equipment
Hire conforms to the highest safety
standards in the industry, holding
certificates in OHSAS 18001: 2007
and ISO 14001: 2004.
All operators are trained and fully com-
petent to operate the machinery and
First column being erected at Majuba Power Station using the Stein-
strict safety guidelines are in place to
müller MK600 lattice boom crane with luffing jib
monitor this on an ongoing basis.
We also offer rigging services using the latest

3D rigging studies, covering both basic and
advanced rigging
All equipment complies with nation-

ally recognised Safety standards and
is issued with safety certificates.
Steinmüller Plant and Equipment
Hire has a dedicated Lifting Machine
Inspector (LMI), who is responsible
for all machines and lifting equipment
which leaves the depot.
Built in excess of 30 major
plants
Marcelino further adds that since 1972, 300 tonne mobile crane with luffing jib at Amonia plant
Steinmüller has built in excess

of 30 major plants in the power
generation, petrochemical, general
and industrial, paper and pulp,
mining, and sugar industries.
It currently maintains in excess
of 60% of the existing coal-fired
generating plants in the country.
“Steinmüller Plant and Equipment
Hire has supplied and managed all
the logistics, site establishment,
cranes, plant and equipment and
small tools for these plants,” he
adds.
Steinmüller
Marcelino Da Costa
Tel: (017) 624-5000
Fax: (017) 647-6114
Cell: 082 904 4568
E-mail:
marcelino.da.costa@steinmuller.co.za
Arial view of Pontoon structure www.steinmuller.co.za

CRUSHERS
Protecting Steel
Mechanical equipment takes a hard toll in the first stages of mineral processing where the hard rock is re-
duced through sheer mechanical force as it comes out the ground. Apart from impact damage, the abrasive
nature of this raw material wears away surface areas in crushers, chutes, grids, screens and pipes very rap-
idly, calling for extra protection besides just the strength of steel.
V
arious materials and steel Basically, Wearcon’s lining compound consists of two
hardening methods have substances which are mixed together into a paste
been used in the past as and then applied to the surface in a specific thick-
additional protection but ness determined by the type of application. “Clients
one of the most successful means of have a choice of applying the lining themselves by
protecting steel seems to come from simply following the instructions that come with
man-made compounds developed the product, or one of our five dedicated applicator
specifically for the different types of teams can do it for them on site,” Andre explains.
raw materials. One of these protec- “Our service teams also undertake lining repairs
tive linings is made by Wearcon in on site whenever possible, but if they can’t do in
Nigel and to find out more, “Bulk situ, it can be done at our factory.”
Handling Today” speaks to director,
Formula
Andre Vorster.
“We make a promise to customers to extend
Liners production time and ensure significant savings
“The company was founded fifteen on equipment and labour by supplying innovative
Andre Vorster years ago purely to supply protec- solutions, premium products and quality workman-
tive liners for mining and industrial ship,” adds Andre. “We help to improve their bot-
equipment,” he says. “Over the years, we started tom line as capital equipment repairs are done at
developing our own compound for a modified ep- 40% of replacement cost. Our products last up to
oxy resin lining containing sapphire hard alumina ten times longer than non ceramic linings as they
ceramic beads which has become widely used in become ‘part of the furniture’, thereby increasing
all industries in South Africa over the last eight resistance to wear from foreign particles.”
years since 2002. We now offer a whole range of The formula for epoxy resin compound is under-
protective linings for various applications including standably well-protected and as we walk through
crushers, impact grids, screens, conveyor pulleys, the facility, we soon discover that the method of
pipes and pumps.” application on certain equipment like pipes and
pumps is also not for the public eye. Today, Wearcon’s
Our products last up to ten times longer range is extensive including solutions for abrasion
than non ceramic linings protection, wear resistant linings, epoxy resin,
acid-proof epoxy resin systems, epoxy steel putty,
epoxy grout, epoxy ceramic pipe lining and crusher
backing material.
Pulley lagging
“Our latest develop-
ment, specifically
for the bulk materi-
als handling indus-
try, is a world first
as far as I know,”
says Andre. “It’s a
protective layer of
our product applied
to a conveyor pulley
which we then fin-
ish off in a diamond
pattern impression

CRUSHERS
with a sound solution to make the diamond pattern

into the layer of lining while it’s still malleable and
before it sets to a hardened surface.
“This has turned out to be a very sought-after
application which most of our clients now prefer,”
adds Andre. “In terms of mining applications, it’s a
nice complement to our crusher backing solution as
well as the impact grid protection system that has
become widely used in the mining industry over the
years. Our impact grid solution, fitted into chutes,
hoppers and underflow pans, has now proven to
require less maintenance than the tiling systems
used traditionally.”
Kit form
The crusher backing material is known as Wearback
STD, a 100% solids modified epoxy resin material
ext en de d life for use in all cone type crushers, grinding mills,
Pu lley lag gin g for an
primary crushers, gyratory crushers and any other
heavy machinery that requires backing material. It
for better grip and water displacement. This develop- is non-flammable and requires no special mixing or
ment came about after one of the mines enquired melting equipment and is simply prepared by mixing
about using our product for such an application. the resin and the hardener until a uniform colour is
We played around a bit until our engineers came up obtained. With an ambient temperature of around
25°C, a full kit is then poured into place directly
where it hardens into a protective backing.
Our latest development is a protective

layer of our product applied to a
conveyor pulley which we then finish off
in a diamond pattern impression
For more heavy duty crushing, a variant of this

backing material comes in the Wearback HI product,
specifically for large cone crushers and gyratory
crushers. It is a solids modified epoxy resin system
formulated for use as a superior backing compound
for crusher liners. When cured, it provides a high
compressive strength support for wear liners. Sup-
plied in convenient kit form, it’s safe and makes
for easy mixing and application.
Savings
“The cost of applying Wearcon linings compares
favourably with other linings,” Andre says in conclu-
sion. “However, there is a tremendous saving over
time due to the longer service life of our product.
Our linings become part of the surface, increasing
resistance to wear from foreign objects in slurry
such as stones as well as moderate impact from
large particles. The linings will withstand wear as
they are manufactured from the finest wear-resis-
tant materials including sapphire hard alumina
ceramic beads, silicon carbide, zirconium, silica
and chrome oxide.”
Andre Vorster, Wearcon, Tel: (011) 814-2983, Email:
andre@wearcon.co.za

CRUSHERS
Plastics for Wear

Protection
Many people make the mistake of summarily installing ceramic linings in chutes, bins and bunkers as the an-
swer to all material flow and wear problems, but this is not necessarily the solution, especially when it comes
to a flow problem. In fact, the exceptional sliding properties of a polyethylene product like Tivar may very well
be a more cost-effective solution.
B
ulk Handling Today” visits materials handling industry in terms of linings. The
Quadrant PHS South Africa in latest addition to our range, Tivar H.O.T, can handle
Jetpark to talk to National Sales high temperatures up 125ºC which addresses the
and Marketing Manager, Harold shortcoming of plastics liners when it comes to
Pretorius, about engineering plastics for high temperatures”
lining applications in general. “Different All the Tivar grades have a similar low coefficient
lining materials all have their place in of friction to enhance material flow and a long life
the market, but you still often find the in sliding abrasion applications and they frequently
wrong one being used to solve a specific outlast steel. They are chemical and corrosion re-
problem,” he says. “Our Tivar product, sistant, absorb noise and impact and are moisture
for example, handles wear very well, repellent as well as shatter resistant. Specific grades
but its main function is to solve flow include special properties such as the welding
problems as opposed to ceramics which capabilities found in Tivar 88/2, a popular choice
address wear difficulties or steel which in bulk materials handling applications.
is best used where impact is rife.
A special application
Harold Pretorius Flow properties “As Tivar 88 has the lowest friction coefficient of
“In terms of flow, it’s been proven any material apart from PTFE, it has exceptional
over and over that an ultra high molecular weight abrasion resistance characteristics and because it is
(UHMW) polyethylene, like one of our Tivar grades, easy to install, it’s widely used as a flow-promoting
lining material,” says Harold. “Flow problems such
Flow problems such as caking, bridging or hanging up as caking, bridging, or hanging up of dry or moist
can be reduced and mostly eliminated materials can be reduced and mostly eliminated.
Scientific tests are used to predict flow patterns
is the ultimate solution,” The Tivar 1000, G12, in bins and bunkers, thereby avoiding any stop-
1000ASTL and Tivar 88 grades have been around pages.
for a long time now and are well known in the
“We were involved in solving a huge problem in
an ash conditioner application for a power station
where the steel bin itself tends to rust very rapidly
and had to be replaced on a regular basis at a huge
cost,” Harold continues. “Being able to weld the
Tivar 88/2 made it possible to design the whole bin
out of this material, extending its life indefinitely.
It’s been up for a couple of years now and is still
in a perfect condition. This development opened up
the opportunity to present an engineered solution
to the other power stations as well. We assisted
the client in the design and then built the complete
unit in our workshop before shipping it to site for
installation.”
Turnkey solution
The entire range of Tivar products is manufactured
in South Africa, with international turnkey support
from Quadrant, from a conceptual design stage
right through to the final installation, including

CRUSHERS
any machining of custom-made parts that may be the mistake of having it done by contractors who
required for a lining solution. are not familiar with the finer points of installing
“The design department works on CAD and we also lining correctly. “There are two areas in our indus-
have sophisticated software to arrive at the optimum try where end-users should tread very carefully,”
layout of sheets for an application thereby saving the warns Harold in conclusion. “The one is to fall for
customer time and money by minimising off-cuts,” an inferior product that may look the real thing and
explains Harold. The computer-aided manufactur- carry a similar colour, but is in fact a much lower
grade than the one specified. The other is to have
Users often fall into the trap of opting for a lower grade the installation done by someone who doesn’t know
how to do it the right way.
polyethylene
“Also, in terms of material grades, users often fall
ing system allows the CAD layout and design to be into the trap of opting for a lower grade polyethylene,
transferred to a CAM programme which operates PE 500 for example, because it’s cheaper than a
the CNC panel cutting equipment. This provides UHMW grade, but the lower grade will simply not
high accuracy and saves a significant amount of last as long as the UHMW material, costing them
time while allowing easy reproduction of a design much more in the long run,” he says. “Again, correct
for future manufacturing. To complete the cycle, installation is vital. If it’s not done properly, dirt or
Quadrant’s installation teams take everything to moisture getting behind the lining will quickly pry
site where the product is installed according to it loose causing it to separate from the substrate.
the specified design. The solution is to always use reputable companies
and ask for the necessary material certificates.”
A friendly warning Harold Pretorius, Quadrant PHS, Tel: (011) 397-4715,
Installation is an area where people often make Email: harold.p@qplas.co.za
10 BULK HANDLING TODAY October 2010

LIFTING EQUIPMENT
Playing it
The potential of a Marie Antoinette style guil-
lotine execution taking place on a South African
industrial site and making the headlines is huge. A
large steel plate falling from height onto someone be-
Safe
low and causing serious injury or even death is a very real
threat, unless somebody does something about the inferior lift-
ing equipment being used all over the country every day.
B
ulk Handling Today” not. Although we are making some progress in
speaks to Peter Tur- informing end-users, it’s far too slow to stem the
chetti, a director of tide against the influx of inferior equipment.
Elephant Lifting Equip-
“Management and purchasing staff tend to forget
ment in Centurion who says,
that the onus of purchasing and using lifting equip-
“The fight against non-conform-
ment that complies with prescribed quality, technical
ing lifting equipment flooding
and safety standards lies with them,” he explains.
the South African market is
“Company owners mistakenly think that the person
intensifying.”
who handles the equipment is responsible.
Peter Turchetti “We, the suppliers who conform
to the requirements of safety critical lifting equip- The onus
ment, are not only waging a battle against the “A large corporate company, for example, may
ignorance of some end-users, we’re also competing very well be aware of the legal requirements and
against the very low prices at which non-compliant even have a safety policy in place, but this does
equipment is coming into the country. not necessarily filter down to the hundreds of
contractors and sub-contractors who do work for
them. “The reality of the matter is that if something
Remember, what goes up must come down..... goes wrong and somebody is hurt or killed, the
corporate, as the owner of the company, will be
Unscrupulous suppliers held responsible and not the person, or contractor
“Unfortunately the cost pressures on the South using the equipment,” stresses Peter.
African industry mean that non-compliant imports “It’s therefore essential for the owner of the company
have become increasingly attractive, especially to make sure that every contractor and subcontractor
when you have a growing number of unscrupulous is fully aware of the legal requirements for quality
suppliers who are preying on an uninformed user as well as conforming to the various manufacturing
base,” Peter adds. “Even prestigious construction standards available in South Africa.” These include
companies and fabricators are often not well enough applicable South African National Standards (SANS)
informed to know what complies and what does published by the Standards Division of the SABS
BULK HANDLING TODAY October 2010 11

LIFTING EQUIPMENT
where these exist. It is important to buy and use

only equipment that is supplied with a ‘Manufac-
turers Certificate of Confromance.’
Clamp example
“Compliance with any of these standards is a key
factor today as well as meeting those requirements
of the various statutory acts, such as the OSH Act
and MHS Act and their regulations such as the
Driven Machinery and Construction Regulations of
the OHS Act,” says Peter. “Any lifting environment,
whether it’s underground or on a construction site,
is inherently dangerous. If companies don’t start
with the right equipment, made to the right design
standards, they’re in trouble already. Mine manage-
ment should also ensure that written procedures
covering the use, care, maintenance and quality
The real thing, lifting clamps clearly marked with all the necessary details requirements are implemented and maintained.”
to trace it back to the manufacturer
However, the problem starts when construction and
fabrication companies rely on their contractors to do
Lifting steel plates are like lifting guillotine blades into the right thing by complying with these standards.
the air “Lifting steel plates are like lifting guillotine blades
and/or other international standards such as ISO into the air. Can you imagine the consequences if
and EN (European Norm). In the case of engineered the load comes down on people working below
and fabricated lifting equipment products, where an it?” asks Peter. “Just such a clamp was brought to
item is custom-made for a specific lifting application, us for repairs the other day from a huge construc-
prescribed best-practice engineering standards also tion development up north. Apart from the clamp
apply, in addition to published quality standards, having a non-existent supplier’s name plate on it,

LIFTING EQUIPMENT
there was nothing else we could use to trace the

manufacturer, never mind the standards to which
the clamp was made and verified.”
Boomerang
Similarly, a manufactured lifting device such as a
lifting beam or spreader beam has to be designed
and engineered properly in certified engineering
steps, otherwise it is doomed to fail. To prove his
point, Peter shows us photos of a beam bent into
the shape of a boomerang within just a few weeks
of use on site. The caption across it says, ‘Beware,
bad design can boomerang on you…!’
Remember, what goes up must come down.....
“It’s immediately clear that these beams were not
designed by an engineer, they obviously just had a The plate lifting clamp that failed. It has no manufacturer marking or any
boilermaker weld together steel plate to look more traceable specification on it
or less like a lifting beam,” says Peter. “The beams
we manufacture, for example, are each accompanied equipment has to be traceable all the way back
by paper work with the design engineer’s signed- to the manufacturer and even as far back as the
off drawing, a certificate indicating the standard batch of material that was used to make it,” Peter
to which it was designed, material certificates, the says in conclusion.
welder’s competence certificate and a certificate “Therefore, each piece of equipment must not only
proving it has been tested.” bear the name of the manufacturer, a serial num-
ber, its capacity and so on, but most importantly,
Marking and traceability customers should only buy approved brands from
Although compliant equipment does cost more, the approved suppliers who have the infrastructure
user not only has the benefit of operating legally, in place to trace equipment all the way back to
but he’s assured of a better quality product that is origin.”
likely to outlast the cheap one ten times anyway. Peter Turchetti, Elephant Lifting Equipment, Tel: (012)
“A simple guideline is that each piece of lifting 661-6105, Email: petert@elephantlifting.co.za

LIFTING EQUIPMENT
A Dire Need for Proper

Training
Not training people properly for the right job is not only embarrassing for the
institution that did the training but also for the individual when he or she
finds out that they actually know very little when it comes to applying their
knowledge in practice. This situation is not as uncommon as one may think
because training material is often compiled by people who aren’t even from
the industry sector in question.
A
Ken Greenwood
company forks out big bucks or, even not very different from learning to fly a Boeing
worse, the person takes his hard-earned 747 on a home computer simulator or the internet
bit of savings to go on a technical course, and then claiming to be a qualified pilot. This is
only to be ripped off when he still can’t do not the way to teach people. Training material
the job properly. To make it worse, some of these needs to contain refinements gained from practi-
jobs are in safety critical industry sectors such as cal experience in terms of the ethics and safety
the lifting inspection industry where substandard perspectives as well.
training can pose a serious threat to life.
CPD training
We’re rooting out badly-trained tradesmen and getting Ken should know what he’s talking about, he’s
written no fewer than 60 courses for LMI training
them up to speed in terms of the laws governing their
over the years besides assisting in the drafting of
profession lifting standards as well as qualification material.
“I still run my regular courses throughout the
Dedicated work country in all the main cities but at the moment
To talk about the important role of proper training
we’re concentrating on the continued professional
for the lifting industry, “Bulk Handling Today” meets
development (CPD) courses,” he says.
with the CEO of the LMI Academy, Ken Greenwood,
who is also chairman of Leeasa (Lifting Equipment “This course comprises about fifteen modules
Engineering Association of South Africa). Ken is and is presented to a large slice of the market,
a pioneering veteran in the South African lifting focussing on future qualifications. Besides helping
industry who has dedicated his career, not only to people over the last two years to register correctly
setting standards in the industry, but also to having as qualified professionals with ECSA, we’re now
the profession recognised as a professional trade concentrating on turning technicians into profes-
by the authorities. sionals through CPD training. Through this we’re
rooting out badly-trained tradesmen and getting
“We have found instances in South Africa where
them up to speed in terms of the laws governing
contracts to write training material in lifting have
their profession.”
been given to people who are not even in the lifting
industry,” says Ken. Expanding business
All this has kept Ken fairly busy
Much like flying lately and he’s therefore had to
“One example is where a person, who has never
make a decision to either stay
even been in a crane in his life, was asked to write
small and not get involved
the training material for LMIs (Lifting Machine
in the broader aspects
Inspectors) for cranes. How can you write com-
of the industry as he
prehensively if you don’t have practical experience
has been doing, or to
in the subject?
expand his training facil-
“It’s not fair on the candidate who expects to be- ity and appoint people to run
come a competent professional,” adds Ken. “It’s it for him.

LIFTING EQUIPMENT
is concerned and when we presented them with

our training methods, even the international guys
working on the oil rigs were impressed with the
standards they saw us applying when we tested
the operators,” Ken adds.
“This confirmed my philosophy; if you’re going to
do it, do it properly right from the start. Training
shouldn’t be about making a quick buck and then
sending the people into the field unprepared for
the real responsibilities they need to face.”
Ken’s approach to training is not only to make a
professional out of a tradesman, but more importantly,
to give the person confidence and pride in the work
he or she does. “I have taken the material from the
standards we wrote originally and re-worked it to be
used for decent CPD training,” he explains. “Apart
from the fact that all these courses are recognised
by the ECSA (Engineering Council of South Africa),
we’re turning out proper LMIs.”
The future
“I’ve gone the second route and used the opportu- It takes several years to train a LMI well which has
nity to appoint two managers, one for a new LMI to be done in stages to ensure that all aspects of the
Academy branch in Cape Town and the other for different lifting disciplines are thoroughly covered.
Durban, both of whom are doing amazingly well,” “What I’d like to see in our industry in the future
he says. is a dedicated programme with dedicated schools
Training shouldn’t be about making a quick buck training people to become competent.
I foresee that trade testing may even be introduced
“In Cape Town, for instance, we’ve now become at the end of the day,” Ken says in conclusion. “This
involved in the oil and gas industry with full ac- will ensure that we will have young, competent LMIs
creditation of all our training material. Subsequently, to take the legacy we’ve created to date, into the
we’ve been accredited by SAMSA, the South African future. This industry holds lucrative opportunities,
Maritime Safety Authority, for training. not only in South Africa, but also into Africa where
Right from the start there is a dire need for proper training.”
“Both these industries have challenges of their Ken Greenwood. LMI Academy, Tel: (011) 789-7610, Email:
own in terms of operator training as far as safety ken@lmi-academy.co.za

CONVEYING
A Pseudo 3D Analysis of
the Indentation Rolling
Resistance Problem
This article takes a look at a pseudo three dimensional analysis to predict the indentation rolling resistance
of belt conveyors. Conventional methods used to analyse the indentation rolling resistance problem typically
assume a bottom cover of uniform thickness bonded to a rigid substrate with no consideration of the carcass
properties.
D
ue to the presence of steel cords embed- idler roll. The reaction loads are then used in a
ded in the conveyor belt, the pressure two dimensional viscoelastic finite element model
distribution at the interface between to determine the indentation rolling resistance for
the belt and a conveyor idler roll is not the steel cord belt.
uniform. To solve this problem, a static three di- This article investigates the influence of the conveyor
mensional finite element model was developed to belt carcass and bottom cover properties on the
determine the pressure distribution and reaction resulting stress distribution throughout the belt and
forces transmitted through the belt to the conveyor consequently on the indentation rolling resistance.
The influence of the steel cord diameter and pitch,
applied load, bottom cover thickness and strain rate
is investigated. A finite element method is detailed
for the analysis of the stress distribution through-
out the belt. A range of carcass configurations is
investigated and experimental verification of the
calculated stress distribution undertaken using a
Tekscan pressure measurement system.
Background
The indentation rolling resistance for a belt con-
veying system is influenced by a number of design
(a) FEA of conveyor belting under simulated loading parameters. These typically include the idler roll
diameter, belt speed, normal load, bottom cover
thickness and viscoelastic properties of the bottom
cover compound. Generally, it is assumed that the
bottom cover is subjected to a pressure distribution
determined by the self-weight of the belt and the
loading induced by the bulk solid being conveyed.
A finite element analysis of the stresses within a
loaded conveyor belt is shown in Fig. 1(a). This
analysis highlights the stress distribution throughout
a typical conveyor belt across the width of an idler
set, and in particular the peak contact stresses
around the idler junction. Similar contact pres-
sures were calculated by Nordell and measured
by Grabner et al.
Clearly, due to the presence of the steel cables and
the large difference between the elastic moduli of
the rubber compounds and the cables, the contact
(b) Contact pressure at belt and idler roll interface
pressure across the belt will fluctuate. The spacing,
or pitch of the cables, determines the frequency of
the pressure fluctuations, while the magnitude of
Figure 1: Contact pressure distribution at conveyor belt and roll interface

CONVEYING
tance is then calculated by integrating across the
width of the belt. The two part process involves the
use of separate finite element methods leading to
a pseudo three dimensional analysis. This paper
details the numerical approach and specifically
analyses the influence of the cable diameter and
pitch, applied load, bottom cover thickness and
strain rate on the stress distribution and conse-
quently the indentation rolling resistance.
Theoretical analysis:
Finite element analysis
A static three dimensional finite element model
was developed to determine the stress distribution
and reaction forces transmitted through the belt to
the conveyor idler roll. The reaction loads and an
apparent bottom cover thickness can then be used
in a conventional one dimensional analytical model,
(a) Finite element model components or as in the case presented, a two dimensional
viscoelastic finite element model to determine the
indentation rolling resistance.
The finite element analysis (FEA) models a section
of steel cord conveyor belt with a width of half the
cable pitch and long enough to ensure that the full
contact path is modelled. For reasons of symmetry,
the particular section of belt modelled started at
the centreline of the cable and finished half way
(b) Belt - Idler roll contact model between the cables, and in the other direction,
begins at the conveyor idler apex and models one
Figure 2: Finite element model side only.
Fig. 2 shows a typical model used within the
the normal force and the cover thickness determines analysis. The model incorporates the three differ-
the amplitude. Fig. 1(b) shows pictorially the nature ent rubber compounds and the steel cable. The
of the contact pressure at the belt and idler roll steel cable is modelled as a solid, since its only
interface across the width of a loaded belt. purpose is to transmit load it therefore does not
As previously noted, the influence of the fluctuating need to accurately represent the properties of the
pressure distribution across the belt and idler roll steel cable.
interface will directly influence the magnitude of the The model itself is composed entirely of eight
indentation rolling resistance. Experimental evidence node bricks and six node wedges. The model was
of the influence of the steel cords on the indentation restricted to using simple brick elements to avoid
rolling resistance was first reported by Hager and any issues relating to conservation of energy in
Hintz. This work showed significant variations in the contact area that are associated with higher
indentation rolling resistance for a number of belts order elements.
with varying carcass construction. The influence of A key element to the model is the modelling of the
the steel cord diameter was investigated and belts contact area. This area allows the bottom of the belt
with larger diameter cords, having identical rubber segment to be initially flat, and then allows it to
compounds and cover thicknesses were found to gradually conform to the shape of a conveyor idler
have greater indentation rolling resistance. roll as the load is applied. In Fig. 2, the surface of
the conveyor idler roll was suggested by the vertical
Significant variations in indentation rolling resistance for “zero gap” elements on the bottom of the model.
a number of belts These elements were designed to have no strength
when they have a length other than zero, and then
König presented a numerical analysis that modelled to possess strength when they have zero length,
the carcass and bottom cover as two distinct layers. thereby imitating contact in their location between
The viscoelastic finite element method analysed the the belt and the shell of the conveyor idler roll. The
carcass as a single layer of material that simulated “zero gap” elements are forced to remain vertical
the combined properties of the steel cords and by a “master slave” link connected in parallel to
insulation rubber. each one, and the bottom end of each “zero gap”
Wheeler and Munzenberger adopted a two part element is held at the radius of the idler roll by a
process to model the influence of the carcass on “pinned link” which connects it to what would be
the indentation rolling resistance. The first involves the centre of the roll. This arrangement is shown
calculating the stress distribution throughout the in Fig. 2(b).
cross-section of the steel cord belt at the interface The restraint, or boundary conditions used in the
between the idler roll and the belt. Secondly, given model were designed to best represent the actual
the stress distribution, the indentation rolling resis- loading situation while bearing in mind that symmetry

CONVEYING
Figure 3: Typical stress distribution and assumed apparent bottom cover

thickness for a steel cord conveyor belt.
has been used to simplify the model. Imagining belt. For example, if the apparent bottom cover
an actual piece of belt resting on a conveyor idler thickness is assumed to be approximated by a sine
roll, the sides of the segment are restrained from relationship (shown by the dashed line in Fig. 3)
moving in the conveyor idler roll’s axial direction, then the indentation rolling resistance increases by
the surface normal to the roll’s surface at its apex approximately 8% to 10% over a uniform thickness
is restrained from movement across the roll, and equal to the actual bottom cover. While the present
the points representing the centre of the roll are analysis was undertaken using a two dimensional
fully fixed. A final boundary condition was ap- viscoelastic finite element method by Wheeler,
plied to the fourth face of the belt model and is similar results are also directly obtainable from
designed to imitate longitudinal strain in the belt one dimensional analytical methods.
before it is loaded. All other degrees of freedom
Results and discussion:
are free to move.
Material property testing
Since the FEA model contains non-linear materi- The mechanical properties of the individual rubber
als and a contact problem, the solution of the layers are each tested experimentally. From these
model was found using a non-linear solver. The tests the constants for the Mooney-Rivlin model
main feature of the non-linear solver is the way in are derived and utilised by the FEA program. Fig.
which the load is applied. For this model the load 4 shows typical experimental data for both a bot-
was gradually increased from zero to a full load of tom cover rubber and insulation rubber compound
5 kN/m in ten percent increments. The software at 25oC. Additionally, testing was also undertaken
further reduced each ten percent load increment at a number of strain rates, with 5 mm/min and
into approximately 12 to 16 sub increments in 2000 mm/min shown for comparison in Fig. 4. The
order to meet convergence criteria. The total solu- results highlight the strain rate dependency of the
tion times for each individual model ranged from rubber compounds and the variation in mechanical
four to six hours. properties of the two compounds for the different
Indentation rolling resistance applications. Clearly, the belt speed will dictate
To accommodate for the fluctuating pressure distri- the strain rate required, with typical belt speeds
bution across the belt and idler roll interface, both requiring time-temperature-superposition techniques
the vertical reaction forces and an apparent, or to simulate higher strain rate tests.
non-uniform bottom cover thickness is considered. Solution of the model was found using a non-linear
The vertical reaction forces across the width of the
solver
belt are directly obtainable from the FEA results,
while the apparent bottom cover thickness is Finite element analysis -
determined by the stress propagation through the
stress distribution
bottom cover into the insulation rubber.
Fig. 5 shows the results for the compression stress
By way of an example, Fig. 3 shows an analysis on the surface of the bottom cover for Ø127 mm
of a section of conveyor belt under a simulated and Ø178 mm idler rolls. The belt designation
load of 5 kN/m in contact with a Ø152 mm idler for this analysis was an ST1750, and had a top
roll. The simulated load refers to the applied load cover thickness of 8.3 mm, an insulation layer
per unit length of the idler roll. The results for this thickness of 4 mm, a steel cord diameter of 5.2
particular belt construction indicate high stress mm, bottom cover thickness of 5.3 mm and a
regions occurring well into the insulation rubber. cable pitch of 12 mm.
This will have the effect of increasing the apparent
In each plot, the centreline of the roll is indicated
thickness of the bottom cover when calculating the
with the highest stress (towards the top of each
indentation rolling resistance.
diagram) located beneath the steel cable. Each
Given the vertical reaction forces across the width square represents one quarter of a millimetre. These
of the belt and the apparent bottom cover thickness, results clearly show that the pressure distribution
the indentation rolling resistance can be calculated is not only influenced by the diameter of the idler
by integrating across the width of the conveyor roll, but the presence of the steel cables.

CONVEYING
(a) Bottom cover rubber compound (b) Insulation rubber compound
Figure 4: Stress strain functions for bottom cover and insulation rubber compounds at different strain rates
(a) Ø127 mm conveyor idler roll (b) Ø178 mm conveyor idler roll
Figure 5: Bottom cover surface stress for a simulated 5 kN/m load
tation rolling resistance is well established,

the results shown in Figures 5 and 6 show
the fundamental reason for this occurring.
The finite element solution clearly shows a
larger contact area and resulting lower stress
levels for larger diameter rolls, resulting in
an overall reduction in indentation rolling
resistance. Additionally, the influence of the
steel cable is also evident, highlighting the
need to consider its influence in calculating
the indentation rolling resistance.
Experimental verification
Fig. 7 shows the experimental setup. The
pressure sensor used for the analysis con-
sisted of a matrix of pressure sensels each
Figure 6: Belt pressure along roll centreline with respect to roll diameter for a 5 1.27 mm x 1.27 mm. The sensor was
kN/m load placed between the idler roll and the belt
surface and a steadily increasing load ap-
Fig. 6 shows a plot of the pressure values along plied. The pressure acting on each sensel in the
the centreline of the idler rolls, from the centre of contact zone and therefore the contact width for
the steel cable to the midpoint of the cable spacing each load was recorded.
for a number of idler roll diameters. The results Fig. 8 demonstrates typical output from the test-
demonstrate the influence of the idler roll diameter ing program and shows the peak pressure along
on the vertical stress distribution across the width of the centreline of the idler roll for a Ø127 mm roll
the belt. For the belt analysed, the stress fluctuates under a simulated load of 5 kN/m. Good correla-
by approximately ± 20% from the mean pressure tion between the FEA and the experimental results
across the width of the belt. were found. The overall pressure levels are in good
While the influence of idler roll diameter on inden- agreement, while the frequency of the peak pres-

CONVEYING
(a) TekScan pressure pad (b) Experimental setup

Figure 7: Experimental pressure measurement
Figure 8: TekScan™ pressure measurement results for a Ø127 mm roll under a 5 kN/m load
sures directly above the cables correlate well with of the calculated vertical reaction forces and an
the theoretical analysis. Tests were undertaken for a apparent bottom cover thickness to calculate the
number of idler roll diameters for a range of loading indentation rolling resistance in both situations is
conditions, with experimental results comparing warranted.
favourably with the FEA predictions.
Bottom cover thickness, cable diameter
Applied load and pitch
The influence of the magnitude of the applied To determine the influence of the bottom cover
load on the induced stress distribution was also thickness, cable diameter and pitch a range of
investigated. Fig. 9 shows the stress distribution simulations were undertaken. Nominal cable di-
for the ST1750 belt described earlier under a 1 ameters of 3.6 mm and 5.2 mm were modelled
kN/m and 5 kN/m simulated vertical load. While for a 5 kN/m simulated load acting on a Ø152
the stress levels differ according to the magnitude of mm idler roll. The cable pitch and bottom cover
the applied load, the overall distribution throughout thickness was varied and the pressure along the
the cross-section remains similar. centreline of the idler roll (peak pressure) plotted
From an indentation rolling resistance perspec- in Fig. 10.
tive, the peak stress occurs beneath the cable For the configurations analysed the results indicate
and propagates well into the insulation layer dur- minimal change in the peak pressure with cable
ing both loading conditions. As a result the use pitch. As expected, for the same load the smaller

CONVEYING
(a) 1 kN/m applied load (b) 5 kN/m applied load
Figure 9: Belt stress distribution – Ø152 mm idler roll under 1 kN/m and 5 kN/m applied loads
of applied strain will

influence the stress-
strain relationship and
therefore the stress
distribution throughout
the belt.
Clearly, from Fig. 4 the
elastic moduli of the
rubber samples are
greater at higher strain
rates and thus the
belt acts stiffer. This
results in less contact
area between the belt
and the idler roll, and
therefore higher stress
levels in the contact
zone, as shown in Fig.
12. Of significance to
this analysis is that the
stress still propagates
well into the insulation
layer, highlighting the
need to consider the
properties and configu-
ration of the belt car-
cass when calculating
Figure 10: Peak pressure versus bottom cover thickness and cable pitch for a Ø152 mm idler roll under a
5 kN/m simulated load the indentation rolling
resistance.
diameter cable shows a higher peak stress. Fig. Indentation rolling resistance
11 shows the results for a 14 mm cable pitch and Given the results from the finite element analysis
highlights that the thickness of the bottom cover the influence on the indentation rolling resistance
had a significant influence on the magnitude of is best demonstrated by an example. Fig. 13
the peak stress. shows the variation in indentation rolling resis-
Rubber compounds used in the insulation layer tance versus bottom cover thickness for a Ø152
and the top and bottom covers are viscoelastic mm idler roll under a 5 kN/m load operating at
materials, and thus exhibit both time and tempera- a belt speed of 2 m/s. The indentation rolling
ture dependent behaviour. Consequently, the rate resistance calculations were undertaken using a

CONVEYING
two dimensional finite

element analysis.
Variations from an as-
sumed uniform bottom
cover thickness range
from 8% to 17% higher.
Greater variations from
the uniform bottom
cover analysis occur
for the larger diam-
eter cables due to the
increased thickness of
the insulation layer.
This trend fits well
with the experimental
data of Hager and Hintz
[3]. Similarly, as the
bottom cover thickness
increases the variance
decreases as the influ- Figure 11: Peak pressure versus bottom cover thickness for a Ø152 mm idler roll under a 5 kN/m
ence of the insulation simulated load and a 14 mm cable pitch
layer reduces.
(b) 5 kN/m applied load – high strain

rate
Figure 12: Belt stress distribution – Ø152 mm idler roll under a 5 kN/m applied load for low and high strain rates
Conclusion determine the indentation rolling resistance for

The method adopted a two part process involving the steel cord belt.
the use of separate finite element programs. Analysis The research investigated the influence of the
of the stress distribution throughout the conveyor conveyor belt carcass and bottom cover properties
belt provides the reaction loads and an apparent on the resulting stress distribution throughout the
increase in bottom cover thickness based on the belt and consequently on the indentation rolling
stress propagation. This data is then used in a two resistance. The influence of the steel cable diameter
dimensional viscoelastic finite element model to and pitch, load, bottom cover thickness and strain

CONVEYING
rate was investigated. The

results show the magnitude
of the indentation rolling
resistance will increase due
to the presence of the steel
cords and is predominantly
influenced by the diameter
of the cables. For the con-
figurations analysed, smaller
diameter cables showed
higher peak stress levels for
the same loading conditions,
but lower indentation rolling
resistance values due to a
decrease in thickness of the
insulation layer.
This paper has been condensed
due to space constraints. The au-
thor is Craig Wheeler and Paul
Munzenberger. This paper was
first presented at Beltcon 15 held
in Johannesburg on September
2 and 3, 2009 and copyright is
vested with the IMHC. Enquiries
can be made through the website;
www.beltcon.org.za
Figure 13: Indentation rolling resistance versus bottom cover thickness

TRUCKING
Shifting Into Overdrive

From sitting behind the wheel while putting the widest range of trucks through their paces, to getting up close
and personal with Ministers and Commissioners, if you were unable to attend the RFA Convention 2010, you
missed out.
T
he RFA Convention 2010 which took place menting relationships between the RFA and several
from 22 to 24 August at the Wild Coast Sun government departments,” says Gavin Kelly, the
was one of the best-supported conventions RFA’s Technical and Operations Manager. “We
held over recent years. It featured more than already have good interactions with the DoT and
25 speakers and panelists, 29 sponsors and over SARS and the convention reinforced this.”
245 delegates from around the country.
Networking
Making your voice heard A number of government departments and parastatals
Deputy Transport Minister Jeremy Cronin delivered were represented at the convention, apart from the
the convention’s opening address, appealing for DoT and SARS, including the Department of Public
closer co-operation between the private sector Enterprises (DPE), the KwaZulu-Natal Department
and Government. of Transport (KZNDOT) and Transnet Freight Rail
Jeremy outlined some of the recent successes the (TFR). Attendees had the chance to interact with
Ministry has had when working with the private them and have their questions answered.
sector in the early stages of the planning process. There was also an opportunity for manufacturers
This echoed the recent creation of a quarterly forum and delegates to discuss the business of trucks,
between the Department of Transport (DoT) and highlighting challenges and issues affecting their
the RFA which will go far in ensuring better com- operations with each other and learn from one
munication and consultation on issues that could another’s experiences.
affect the road freight transport industry.
Trucks put through their paces
In what is believed to be an industry first, RFA members In what is believed to be an industry first, RFA
had the opportunity to test drive a range of trucks members had the opportunity to test drive a range
of trucks. Vehicles from DAF, Freightliner, Hino,
SARS Commissioner Oupa Magashula also ad- Man, Mercedes-Benz, Navistar International Trucks,
dressed the convention, briefing delegates on trade UD Trucks (Nissan Diesel), Renault, Scania and
facilitation initiatives that SARS and its partners Volvo were all available for test drives. Delegates
are introducing as part of the Customs Modernisa- were able to test drive all these vehicles, enabling
tion programme. them to do “on-site” comparisons and have all their
“The RFA Convention definitely succeeded in ce- questions answered by the manufacturers.
Jeremy Cronin Jake White Nazir Alli (left) with Frank Wagner (right)

REBUILD
YOUR THINKING
Register now for CONEXPO-CON/AGG 2011, the most information-packed
show in construction. Get close and compare the newest equipment,
technologies and strategies for profitability. See how the construction
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Be there to experience the latest innovations and enjoy the attractions
of Las Vegas!
March 22–26 Go to www.conexpoconagg.com/intl for details on how to register.

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TRUCKING
Keeping up to date learn from one of our leading industry experts. The
Nazir Alli, Chief Executive of the SA National Roads SMMEs will be mentored by Otto van Griethuysen,
Agency (Sanral), briefed delegates on the fiercely who has 35 years of technical, operational and
debated toll roads. “A number of issues still need financial experience in the industry. This intense
to be clarified,” says Gavin. “The most important of programme covers the entire spectrum of what it
these is the exact fee that will be charged. Thereafter, takes to run a successful trucking business.
a simplified understanding of how the fee will be The Road Freight Association (RFA), Tel: (011) 974-4399,
structured (taking into consideration any discounts Fax: (011) 974-4903, email: management@rfa.co.za,
that will be applied needs to be made available). www.rfa.co.za
We were grateful to Nazir for clarifying a number
of issues that have been misunderstood.”
Gavin also shared with delegates the latest devel-
opments on the points demerit system, dispelling
some of the myths and misconceptions about
the proposed scheme and outlining some of the
harsh, unintended consequences that the system
may have for operators. The new implementation With South Africa being mining country, it
date for AARTO is 01 April 2011, although this
is expected that the country ranks among
date may well be postponed due to a number of
the top in the world when it comes to con-
improvements and changes that need to be done
veyor installations. This creates healthy
to the system.
competition in the market in terms of sup-
There was an opportunity for pliers of power transmission components,
manufacturers and delegates to discuss each vying for a slice of the cake in a highly
active industry.
the business of trucks
SARS Commissioner, Oupa Magashula behind the wheel of a Freightline
Some of the latest developments included allowing Argossy truck
an access period (six months or annual) to driver
and/or vehicle information (the exact fees and
procedure yet to be determined). Aspects of driver
re-training have also not been finalised.
Prasanth Mohan of the Department of Transport
provided the latest news on RTMS - an industry–led,
government-supported, voluntary, self-regulation
scheme that encourages consignees, consignors and
road transport operators to implement a manage-
ment system (a set of standards) with outcomes
that contribute to preserving road infrastructure,
improving road safety and increasing productivity.
Its focus areas are load optimisation, driver well-
ness, vehicle maintenance and productivity. RTMS
has been piloted in the forestry, sugar and coal
industries with extremely positive results.
Award-winning green trailer
On show was the Green Trailer from Barloworld
Logistics, which recently won the “Best Product
under R1 million” in the Green Supply Chain
Awards. This interlink taut-liner-trailer combina-
tion achieves, through some practical innovation,
significant reductions in the amount of fuel it
uses, which will result in significant environmental
benefits and savings with existing transport fleets.
The expected reduction in fuel consumption on the
green trailer project for the next six months will be
between 6% and 8%.
SMME mentorship
The RFA’s new Mentorship Programme is a part of
the Association’s SMME growth and development
strategy offering SMME operators an opportunity to

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Market Forum
First crane back consisting of a hand-held meter attached to an optical sensor
The first construction crane to grace the skies at Century City via an electronic cable. The sensor uses an infrared beam
in almost a year has gone up. It has been erected for the to detect the vibration of a belt strand and sends a signal to
construction of a new 7000 square metre “green” regional the meter.
office block for Aurecon The sensor in-
The last construction cranes seen at Century City were for cludes an LED
the mega R750million Crystal Towers development and two that produces
high-rise office developments, Gateway and The Gatehouse. an orange light
Greg Deans, director of Rabie Property Group, the develop- beam to help
ers of Century City, says while one crane is a far cry from aim the invis-
three years ago when the skyline was dotted with 12 or so ible infrared
cranes, it was cause for cheer and hopefully indicative that ray. For op-
the market is now turning. erator in-
put, simply
“We have generally tended to see the number of cranes at
“pluck” the
Century City as being a barometer of the state of the property
belt and
market. Although some low-rise construction has been taking
point the
place in the past year, the dearth of cranes which are used
sensor
on larger, high-rise projects is very indicative of the hard
directly
times the industry has been experiencing.”
above the
Greg says that during the upturn they have colloquially re- vibrating belt.
ferred to the yellow cranes as the “national bird of Century
Comparing this
City”. “And it is heartening that the first bird is back although
input to the vibra-
we are probably still some way off before the whole flock
tion of a quartz cr ystal, the
returns!”
meter computes the natural frequency of the belt. The result
Rabie Property Group, Greg Deans, Tel: (021) 550 7000, Fax: (021) is shown in the display window as hertz (oscillations per
550 7002, Email: info@rabie.co.za, Website: www.rabie.co.za second). The internal programming of the meter is also able
to report the belt tension in units of force
(either newtons or pounds-force) provided
the operator has entered the belt mass
and span length using the manually
operated key pad.
SKF South Africa (Pty) Ltd, Samantha Joubert,
Tel: (011) 821 3500, Fax: (011) 821 3501,
Email: samantha.joubert@skf.com, Website:
www.skf.co.za
Exploring rough terrain

Hyster dealer Barloworld Handling has
expanded its range to include Mast Ex-
plorer rough-terrain lift trucks, comprising
Coenie Fick of Aurecon and Colin Anderson, a director of Rabie Property Group, on the 15 models with lifting capacities from
site where construction of Aurecon’s new R150million offices is now underway 1.3 to 7 tons.
“Manufactured by Mecano Continental of Spain, Mast
Explorer lift trucks have been delivering the goods on five
continents, in a diverse range of mining, industrial and ag-
ricultural applications,” says Rudolph Briedenhann, senior
GM of Barloworld Handling. “They have proven their mettle
Belt frequency meter in tackling dirt tracks, sand dunes in a desert, loading the
SKF has added a new product to their power transmission middle of the jungle and working in mines, and will do the
range – the SKF Belt Frequency Meter, one of the most ac- same here.”
curate and reliable tools when it comes to measuring belt
The first batch of Mast Explorer trucks to arrive in South Africa
tension.
has been hard at work in local manufacture and agriculture
The SKF belt frequency meter is a two-component system applications for some months now, and initial feedback from

Market Forum
customers and their operators has been overwhelmingly posi- Says IMS Engineering’s Deon Visser, “the manufacture of
tive. “Based on this, we believe Mast Explorer lift trucks will sand is the ultimate crushing task in aggregate production
add value to the operations of our existing customer base since it entails the progressive crushing of large feed mate-
and also open doors to new market sectors.” rial, generally run-of-quarry, in various crushing reduction
“An attractive feature of the Mast Explorer range is its no-frills stages to sand. Hazemag sand impactors are suited to the
design,” says Rudolph. “The machines are unencumbered by task because of their ability to achieve a high reduction
complicated electronic ratio in a single pass while delivering a quality cubical
technology that would sand product in the -6.75 and -4.75mm size ranges. This
have rendered them high reduction ratio is achieved because the mechanical
more expensive and construction of the impactor, combined with the high-speed
difficult to maintain horizontal shaft rotor, generates high levels of kinetic energy
and operate.” that maximise breakage.”
Barloworld Handling, Ru- The new impactor has two large service doors on each
dolph Briedenhann, Tel: side of the crusher housing, providing easy access
(011) 898 0480, EMail: to the rotor and wear parts, while the blow bars
rbriedenhann@bar- are slid in from the side to permit quick and
loworld-equipment. easy turning and replacement. The crusher
com housing is lined with easy-to-change wear
plates and approximately 97% of the wear
liners are interchangeable, for a reduction in
spares holding.
IMS Engineering (Pty) Ltd, Shannon McEwan, Tel:
(011) 445 2111, Email: scmcewan@imsgroup.co.za,
Website: www.imsengineering.co.za
Side view of the 2.5 ton model from the Mast Explorer rough terrain
lift truck range recently launched by Barloworld Handling
Suited to the task

An increasing number of quarries are turning to impact
crushing technology to manufacture sand from rock. Now
comminution solutions provider IMS Engineering has raised
the bar with the introduction of a next generation Hazemag
horizontal shaft hard rock sand impactor.
The new-generation Hazemag AP-KVH horizontal shaft hard rock

sand impactor has two large service doors on each side, providing
easy access to the rotor and wear parts for reduced downtime

SPECIALIST PRODUCTS
FOR THE MINING
INDUSTRY
Fabform Graphics cc (011) 622-9917

The Scaw Metals Group (Scaw) is an international group, manufacturing a diverse range of steel products. Its principal
operations are located in South Africa, South America, Canada and Australia. Smaller operations are in Namibia, Zimbabwe
and Zambia. Scaw’s Specialist products manufactured for the shaft mining and surface mining industries include:
Haggie® Steel Wire Rope Products: Scaw has produced these products for the mining industry since 1921 and is a
• Double drum winder ropes technological leader in this field and manufactures to national and international
• Koepe / Friction winder ropes standards.
• Shaft sinking ropes
• Mine hoist ropes Scaw provides a full range of customer support services. A team of qualified
• Scraper and haulage ropes engineers with extensive experience in all aspects of steel wire ropes, chain and
• Dragline and hoist- and drag-ropes cast products are available to advise on the selection, handling, installation and
• Face shovel ropes maintenance of products as well as provide on-site inspection of products and
Chain Products: equipment.
• Round link welded chain and chain fittings in
grades 3 to grade 8 to national and Scaw supplies globally and also offers nationwide distribution in South Africa
international standards. through its strategically located branches throughout the country.
Cast Products:
• Mantles and bowl liners Haggie® Steel Wire Rope: Tel: +27 11 620-0000 • Fax: +27 11 620-0009
• Mill liners Chain Products: Tel: +27 16 428-6000 • Fax: +27 16 428-1212 / 1089
• Rope sockets Eclipse East Foundry: Tel: +27 11 747-5000 • Fax: +27 11 421-4943
• Track shoes Cast Products: Tel: +27 11 749-3600 (GET) • Tel: +27 11 842-9303 (Other)
• Dragline parts Fax:+27 11 421-8032 (GET) • Fax: +27 11 842-9710 (Other)
• Ground engaging tools (GET)
Website: www.scaw.co.za
Market Forum
Seven more trucks new concept. The hammers are easily fitted to all ranges of
Hino SA recently added a further seven trucks to the large excavators, skidsteers, back-hoe loaders and wheel loaders,
number already being employed in various projects by the and could save capital projects millions on expenditure,
Department of Water Affairs and Forestry. Over the past two while the crusher bucket fits onto the end of an excavator
years more than 100 Hino’s have been delivered to this fleet. like a normal bucket.
These have included water and diesel tankers, dropside freight Peter Van Rensburg, sales representative at HPE Africa
carriers, 5m3 and 10m3 tippers and mobile workshops. explains the advantages of the Soosan range of hammers:
The latest batch of seven 28-41 6x4’s are for general purpose “The Soosan products complement HPE Africa’s equipment
usage and are fitted with dropside bodies made by Anchor as it is a top quality brand – the Rolls Royce of Korean ham-
mers. The attachments are ideal for quarries, mines,
demolition, plant hire, or anywhere where breakers
and drills are necessary. We only bring in the sturdier
models to be fitted to our machinery, because they
get abused in a very harsh local environment, so they
need to be extra strong.”
High Power Equipment, Peter van Rensburg, Tel: (011) 397
467, Fax: (011) 397 4683, Website: www.hpeafrica.co.za
Auto Body in Springs, with Palfinger PK 15 500 15-ton/metre

cranes mounted between the cab and the load body. The
New heavy-duty truck models
Five new Isuzu FX models, positioned as the heavy-duty end
bodies have fittings and latches to handle 6m containers,
of the F-Series range, are now on South African soil. The
while special Ringfeder automatic coupling systems have
entire Isuzu F-Series model line-up now consists of more
been specified, as have metal protectors for the front and
than 18 models with gross vehicle masses (GVM) from 10
rear lights, a front draw bar and amber rotating lights on
000kg to 28 000kg, and gross combination masses (GCM)
the cab roof.
from 16 000kg up to 45000kg.
These trucks will be deployed at Department of Water Af-
Isuzu FX models form an important niche-market link between
fairs and Forestry projects all over South Africa, including
F-Series models and Isuzu Gigamax at the extra-heavy end.
at the De Hoop Dam at Roosenekal which is the largest
Standard Isuzu F-Series models are equipped with maximum
dam currently under construction in South Africa and due
engine power rating of 206kW (280hp) @ 2 400rpm and
for completion in three years’ time.
Hino, Ignatius Muthien, Tel: (0)11 809 2064,
Fax: (0)11 809 9064, Email: imuthien@hino.
co.za, Website: www.hino.co.za
Demolition made easy

For the past 3 years, HPE Africa has
been the sole importer of Korean-built
Soosan hydraulic hammers and drills
– ideal for any project that requires
high volumes of rock to be broken
swiftly and safely. Added to this exclu-
sive selection is the Italian-crafted MB
crusher buckets – designed to meet
international demands for more goods
to be recycled on site.
Although hydraulic hammers are rela-
tively well known in the South African
market, the crusher bucket is a fairly

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34 BULK HANDLING TODAY October 2010 Advanced Materials Today September 2007 39
Market Forum
calculations, precise
boom switching ca-
pabilities and control
of lock pins.
The Hirschmann
systems are also
designed for har-
bour, marine, gantry
cranes, container
loaders and stack-
ers. With full work-
shop facilities and a
882Nm @ 1 450rpm. On the FX range power is delivered
from one model-type Isuzu common-rail turbo-intercooled
engine providing 265kW (360hp) @2 000rpm and 1 422Nm
@1 400rpm - this represents 61% more torque for any task
than the standard F-Series. Standard exhaust gas recircula-
tion (EGR) ensures that reduced combustion temperatures
are an effective means of controlling NOX – nitrous oxides
– exhaust emissions. This engine exceeds the South African
Euro 2 specification and is classed as a Euro 3 unit as part
of Isuzu’s environmental care package.
Isuzu has matched tyre load-ability to axle capacity
– 315/80R22,5 tyres are standard to match Isuzu’s front
axle rating of 7 500kg which is also the legal permissible
(A rating) for the entire range. This is particularly useful Custom Crane staff
for freight carrier models where front axle capacity can be
fully utilised. Isuzu FX models also have installed rear axle full stockholding of OPD100 and Hirschmann equipment,
capacity that exceeds the permissible rating of 9t on a single Custom Crane Safety is geared for service.
axle and 18t on a double drive unit. Custom Crane Safety, Richard Harvey, Tel: (011) 900 3390, Email:
Isuzu Truck SA, Hanlie du Preez, Tel: (011) 563 4125, Fax: (011) Richard@safecrane.co.za, Website: www.safecrane.co.za
806 4693, Email: hanlie.dupreez@isuzutrucksa.co.za, Website: www.
isuzutrucks.co.za Errata
The Gremlins were at it again and an error sneaked into one
of our captions in the story about ThyssenKrupp Materials
Handling in our previous issue of “Bulk Handling Today”.
The picture shows Dietmar Pratz while the caption says
it’s Sybrand Visagie. We apologise for the error Dietmar
and Sybrand.
Easy versatility
Custom Crane Safety has over 20
years experience in the mobile crane
safety market. The company offers
a comprehensive range of crane
safety products to the crane rental,
construction, industrial and marine
industries. This includes safe load
indicators for cranes, forklifts and
reach stackers. They can custom
design and fit of safe load indicators
for any lifting machine or any special
application.
Custom Crane Safety manufactures
and markets the OPD100 System.
This robust and economical system
provides ease of use and versatility
to a crane fleet. Custom Crane Safety
also offers the Hirschmann iVisor
Range of products. These feature
cutting edge technology such as ac-
curate and measured boom deflection

Market Forum
Georg Weiberg, Head

of Truck Product
Engineering;
Hubertus Troska,
Head of Mercedes-
Benz Trucks;
Andreas Renschler,
Member of the Board
of Management,
Head of Daimler
Trucks and Daimler
Buses and
Gianenrico Griffini,
Chairman
International Truck
of the Year Jury
Truck of the year 2011

On the occasion of the International Motor Show (IAA) Com-
mercial Vehicles in Hanover a jury of international experts
voted the new Mercedes-Benz Atego 12-tonner “Truck of
the Year 2011”.
The International Jury Truck of the Year commented on the
victory of the Atego: “In the new Atego family, Mercedes-Benz
presents a versatile medium-duty truck with ‘two souls’. On
the one hand, the short-radius distribution driver now gets
equipment which not long ago was reserved for long-haul
drivers. On the other hand, the progressive parallel hybrid
drive promotes the reduction of the CO2 emissions of com-
mercial vehicles within the European Union.”
According to its rules, the jury awards the Truck of the Year
title each year to the truck that makes the biggest innovative
contribution to road haulage in terms of economy, emissions,
safety, drivability and comfort. The Mercedes-Benz Atego
scored a total of 127 points to win the competition; the
truck that placed second received 82 points, the number
three 45 points.
Hubertus Troska, head of Mercedes-Benz Trucks, said on
the occasion of the award presentation at the commercial
vehicle show in Hanover: “We are pleased that with this
high honour the Truck of the Year jury has confirmed our
efforts in two significant points: firstly, that we devote to the
distributor vehicle the attention it deserves on account of its
performance in the daily supply of the needs of our society;
secondly, that it was right to continue our investments and
developments in technologies of the future like hybrid drive
even in economic crisis situations. That now pays off.”
Mercedes-Benz, Shirle Greig, Tel: (012) 677 1904, Fax: (012) 677 1682,
Email: shirle.greig@daimler.com, Website: www.media.daimler.com

Market Forum Subscription
Please fax us if you wish to subscribe to “Bulk Handling Today” at

R400,00 (incl postage and VAT) per year; R945,00 per year for Af-
Helping make history
From the invention of the world’s first manual chain hoist rica/Overseas. We will post you an invoice on receipt of your fax.
in America in 1877 to the lifting of extremely expensive ad-
PROMECH PUBLISHING Fax No: (011) 781-1403
vanced aviation equipment into the control towers at the new
King Shaka International Airport in Durban, from the supply Email: editorial@promech.co.za
of urgently needed equipment after the Haiti earthquake to
the provision of tailor made solutions for construction of From:.........................................................................................
the multi-billion rand stadiums for the 2010 Soccer World
Cup, the Columbus McKinnon Corporation (CMCO) is well (insert your name)
positioned to help engineer history.
Title: ..........................................................................................
Company: .................................................................................
Address: ..................................................................................
....................................................................................................
......................................................................Code: ..................
Telephone: (.......) ....................................................................
Fax: (.......) ................................................................................
Email: .......................................................................................
Index to Advertisers
AST Pyroscan Inside Front Cover
Bearings International 36
Brelko 35
Conexpo 26
Both the South African subsidiary (formerly known as Yale East Rand Cranes 14
Industrial Products) and its multinational parent are world
renowned for the design and manufacture of a comprehen- FLSmidth 24
sive range of lifting, pulling and jacking products as well as
Hägglunds Inside Back Cover
materials handling systems.
Worldwide, the company is all about precision engineer- ILS 30
ing, superior quality and safety. All products are ISO 9001 Linde 10
certified.
LMI Academy 31
The most crucial thing of all, however, is the fact that CMCO
focuses not only on the supply, servicing and installation of Multotec 12
its products and systems, but also on providing an all round,
total service solution that meets each of its customer’s Quadrant 16
technical needs. Rema Tip Top 8, Outside Back Cover
In Africa, with its harsh conditions and lack of infrastructure,
this is no mean feat. The South African operation forms SAID 34
the hub of an important network of branches and distribu- Scaw Metals 32
tors that serve customers across the continent. All offer a Steinmüller Outside Front Cover
wide selection of products and systems that enable users
to find the most suitable option for their particular needs ThyssenKrupp 13
and conditions.
Wearcon 28
Columbus McKinnon Corporation (Pty) Ltd, Graham Campbell, Tel:
(031) 700 4388, Fax: (031) 700 4512, E-mail: sales@cmcosa.co.za, Wirtgen Group 37
www.yale.co.za

Tough demands have
met their match.
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JHWFRPSDFWGXUDEOHSRZHUZLWKRXWIRXQGDWLRQVRU
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WRWDODVVXUDQFHHYHQLQWKHPRVWGHPDQGLQJDSSOLFDWLRQV
Let us know your demands.
Hägglunds Drives South Africa (Pty) Ltd

P.O.Box 2851, 1610 Edenvale, Johannesburg
Phone: + 27 (0)11 454 4933, Fax: +27 (0)11 454 5088
E-mail: info@za.hagglunds.com, www.hagglunds.com
Our drive is your performance.


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BULK HANDLING TODAY October 2010 

 BULK HANDLING TODAY October 2010

Featured on the cover:

The monthly circulation

BULK HANDLING TODAY October 2010 

From the Chairman’s Desk

CMA Members List as at October 2010

 BULK HANDLING TODAY October 2010

Moving to New Heights

Include a large number of cranes ranging from a

Boasting a rich history in the business, Steinmül-

Paraffin Plant at Sasol 1

Complex heavy lifts and 3D rigging

BULK HANDLING TODAY October 2010 

ler also offers extensive experience in

We also offer rigging services using the latest

All equipment complies with nation-

Steinmüller has built in excess

 BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010 

with a sound solution to make the diamond pattern

Our latest development is a protective

For more heavy duty crushing, a variant of this

 BULK HANDLING TODAY October 2010

Plastics for Wear

BULK HANDLING TODAY October 2010 

10 BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010 11

where these exist. It is important to buy and use

12 BULK HANDLING TODAY October 2010

there was nothing else we could use to trace the

BULK HANDLING TODAY October 2010 13

A Dire Need for Proper

BULK HANDLING TODAY October 2010 15

is concerned and when we presented them with

16 BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010 17

18 BULK HANDLING TODAY October 2010

Figure 3: Typical stress distribution and assumed apparent bottom cover

BULK HANDLING TODAY October 2010 19

(a) Bottom cover rubber compound (b) Insulation rubber compound

Figure 5: Bottom cover surface stress for a simulated 5 kN/m load

tation rolling resistance is well established,

20 BULK HANDLING TODAY October 2010

(a) TekScan pressure pad (b) Experimental setup

BULK HANDLING TODAY October 2010 21

(a) 1 kN/m applied load (b) 5 kN/m applied load

of applied strain will

22 BULK HANDLING TODAY October 2010

two dimensional finite

(b) 5 kN/m applied load – high strain

Conclusion determine the indentation rolling resistance for

BULK HANDLING TODAY October 2010 23

rate was investigated. The

Figure 13: Indentation rolling resistance versus bottom cover thickness

24 BULK HANDLING TODAY October 2010

Shifting Into Overdrive

BULK HANDLING TODAY October 2010 25

March 22–26 Go to www.conexpoconagg.com/intl for details on how to register.

BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010

BULK HANDLING TODAY October 2010

E-MAIL : TELEPHONE : ____

BANK : _ BRANCH : _______