Worn Liner Removal

THUNDERBOLT Recoilless Hammers

Worn Liner Removal THUNDERBOLT 1500 Recoilless Hydraulic Hammer

THUNDERBOLT Recoilless Hammer
Liner Bolt Removal
Powerful and recoilless, THUNDERBOLT Recoilless Hammers represent the fastest and safest
method ever devised for removing worn Mill liners and liner bolts.
RME’s THUNDERBOLT Recoilless Hammers replace heavy manual sledge hammers, hydraulic
rock breakers, jack hammers and battering rams.
THUNDERBOLT 1500 Recoilless Hammers are hydraulically powered, possessing ten times the hitting power
of a typical man and delivering a precisely controlled, high-energy (1500 Joule) strike, sixty times per minute,
continuously. The THUNDERBOLT 1500 Recoilless Hammer is RME’s most powerful Recoilless Hammer and
finds application on the world’s largest Mills.
Developed specifically for relining Grinding Mills, the THUNDERBOLT 1500 Recoilless Hammer has also found
application in tasks as diverse as heavy earthmoving equipment maintenance and cone crusher maintenance
(mantle nut removal).
Each THUNDERBOLT 1500 Recoilless Hammer requires a THUNDERBOLT Power Pack to supply electrical
control and hydraulic power requirements.
The THUNDERBOLT 1500 weighs 460kgs.

RME’s THUNDERBOLT Recoilless Hammers are unlike any other powered hammer
They use a momentum balancing principle where the internal mechanism is dynamically balanced by the piston
acceleration, resulting in almost no recoil.
The great advantage of the THUNDERBOLT Recoilless Hammers over any person or team of people is their ability
to deliver their precise, high energy strike horizontally and continuously.
There are four THUNDERBOLT Recoilless Hammer models, two which are hydraulically powered and two which
are pneumatically powered.
8 The THUNDERBOLT Recoilless Hammer range has revolutionised worn liner and liner bolt removal on Mills of all 9
types and all sizes.

8 9

THUNDERBOLT 750 Recoilless Hydraulic Hammer
THUNDERBOLT 750 Recoilless Hammers are hydraulically powered, possessing five times the hitting power
of a typical man and delivering a precisely controlled high energy (750 Joule) strike, ninety times per minute,
continuously. This Recoilless Hammer finds wide application in the relining of AG, SAG and Ball Mills of all sizes.
Each THUNDERBOLT 750 Recoilless Hammer requires a THUNDERBOLT Power Pack to supply electrical
control and hydraulic power requirements.
The THUNDERBOLT 750 Recoilless Hammer weighs 285kgs.
This is equivalent to a strong man striking vertically down with a 6kg (14lb) sledge hammer, but this energy is
delivered horizontally and continuously, sixty times a minute.
10
8 9
Worn Liner Removal
THUNDERBOLT Recoilless Hammers
THUNDERBOLT 500 Recoilless Pneumatic Hammer
RME’s THUNDERBOLT 500 Recoilless Hammer is powered by compressed air from the plant supply.
Concentrator plant air can vary enormously in terms of supply pressure and available flow. The
THUNDERBOLT 500 Recoilless Hammer is supplied with an air intensifier which ensures full Hammer
performance from plant air pressures as low as 485kPa (70psi). It replaces sledge hammers, jack hammers
and heavy battering rams by delivering a precise, high energy (500 Joule) blow 60 times per minute.
This is equivalent to a strong man striking vertically down with a 6kg (14lb) sledge hammer, aided by
gravity. The THUNDERBOLT 500 Recoilless Hammer delivers this energy horizontally and continuously,
sixty times a minute.
The THUNDERBOLT 500 Recoilless Hammer weighs 250kgs.
11
 THUNDERBOLT 250 Recoilless Pneumatic Hammer
The THUNDERBOLT 250 Recoilless Hammer is RME’s “Sledgehammer for the 21st Century”.
Powered by compressed air from plant supply, the THUNDERBOLT 250 Recoilless Hammer finds application
on any Mill where liners and liner bolts can be removed by sledgehammer. Applications include Mills with
rubber or rubber/steel composite liners (lighter liners) and the feed ends of many Mills (where liners are easier
to remove).
The THUNDERBOLT 250 Recoilless Hammer delivers a high momentum, 250 joule blow sixty times per
minute, continuously.
The THUNDERBOLT 250 Recoilless Hammer weighs 20kgs.

12 13

8 9
 Worn Liner Removal
THUNDERBOLT T-MAGS

Worn Liner Removal

THUNDERBOLT T-MAGS
The T-MAG (THUNDERBOLT Moil Axis Guide) has been specifically developed for use with the range of
THUNDERBOLT Recoilless Hammers. The T-MAG uses a powerful switched magnet to adhere temporarily
to the Mill shell, eliminating the need for site personnel in the THUNDERBOLT Recoilless Hammer strike zone.

RME recommends T-MAGs for all THUNDERBOLT Recoilless Hammer applications.

A set of T-MAGs makes Mill relining faster and safer by:

• Improving THUNDERBOLT transition speed, bolt-to-bolt, by around 30%
• Avoiding Mill shell and bolt hole damage by guiding the moil accurately, even when the liner bolt is flush
with the Mill shell
• Minimising the probability of moil and bolt chipping by ensuring centred and controlled impact
• Effectively containing any metal shards within the T-MAG, in the event where shards are produced

B
A wide range of T-MAG D
Moil Axis Guides has been
developed to improve
knock-in safety on all Mills A C
(regardless of bolt and
washer dimensions) T-MAGs make liner
RME Liner Bolt Maximum Maximum Maximum Guide bolt knock-in safer
Part
Number
Diameter
Range
Bolt Stand
Out
Washer
Diameter
Washer
Thickness
Colour
and around 30%
(mm) (mm) (mm) (mm) more efficient.
A B C D

THUNDERBOLT 1500, 750 and 500 Recoilless Hammers

10121700 30-34 170 102 25

10104226 36-39 170 80 18

10105401 36-39 170 102 29

10104225 41-44 170 102 25

10103958 45-50 170 102 25

10105090 45-50 170 112 28

10105044 50-54 170 129 44

10125918 54-58 170 131 45

THUNDERBOLT 250 Recoilless Hammers

10105937 36-39 120 – –

10105935 30-34 120 – –

14 15
10105558 21-26 120 – –

8 9
 Worn Liner Removal
Suspension Methods for THUNDERBOLTs

Worn Liner Removal THUNDERBOLT 500 Mobile Elbow Jib Suspension

For smaller plants, the THUNDERBOLT 500 Recoilless
Suspension Methods for THUNDERBOLTs Hammer is an effective and reliable option for liner
bolt knock-in, and RME’s Mobile Elbow Jib offers a
versatile suspension option for the THUNDERBOLT 500
Recoilless Hammer and the various power tools used in
THUNDERBOLT Recoilless Hammer Suspension Options retorquing and bolt nut removal.
Three of the four THUNDERBOLT Recoilless Hammers require some form of overhead suspension. The THUNDERBOLT Mobile Elbow Jib is an excellent
THUNDERBOLT Recoilless Hammers could be suspended from existing facilities, such as an choice for suspending the THUNDERBOLT 500
overhead crane, with the THUNDERBOLT Recoilless Hammer’s positioning controlled by the crane Recoilless Pneumatic Hammer where adequate floor
operator. space is available and multiple Mills are to be serviced by
This arrangement may be adequate for a very short period of use such as a one-off sales the same equipment.
demonstration but is unsuitable for long term reline use, particularly if the plant needs to commit an The pneumatic winch which is connected to the Mobile
overhead crane to other uses during a plant shut-down. Elbow Jib is controlled by a separate pendant.
RME offers a number of suspension options, designed for a range of THUNDERBOLT Recoilless With 360-degree slewing on the primary boom and
Hammer sizes and site conditions. either 180-degree left or 180-degree right on the elbow,
any bolt on the face of the Mill within a window 2,100mm
high by 8,000mm wide can be reached.
Monorail Suspension for THUNDERBOLT Recoilless Hammers Mobile Elbow Jibs have a working load limit of 350kg
RME’s Twin-Tube Monorail and Winch assembly which is more than enough to carry the THUNDERBOLT
has been designed for the suspension of 500 Recoilless Pneumatic Hammer.
THUNDERBOLT Recoilless Hammers and other
tools. THUNDERBOLT Recoilless Hammers
are suspended from the larger tube, trolley and THUNDERBOLT Fixed Position
winch. The smaller inner tube and trolley support
other equipment such as a constant-rate, spring
Jib Suspension
suspender and heavy pneumatic air impacting The THUNDERBOLT Fixed Position Hydraulic Jib has
wrench used for liner bolt nut removal. been designed for THUNDERBOLT Recoilless Hydraulic
THUNDERBOLT 750 and THUNDERBOLT 1500 Hammers where adequate floor space is not available
Recoilless Hammers feature an RME hydraulic winch for a Mobile Suspension solution or where it is difficult to
for powered raise/lower. This hydraulic winch is move the THUNDERBOLT Recoilless Hammer around
powered from the THUNDERBOLT Hydraulic Power obstructions on the Mill such as drive guards.
Pack. The winch is controlled via thumb-switches on The height of the Fixed Jib Tower is designed according
the THUNDERBOLT Recoilless Hammer itself. The to your Mill’s requirements. In general terms, the longer
THUNDERBOLT 500 Recoilless Hammer requires the liner bolt, the taller the Fixed Jib requirement. This
a pneumatic winch with its own pendant control. is because long liner bolts require long THUNDERBOLT
THUNDERBOLT Recoilless Hammers are traversed Recoilless Hammer moils, which need to move through a
along the length of the Mill simply by pushing the long arc.
Hammer in the required direction. The Hydraulic Fixed Jib is powered from the
The RME Twin-Tube Monorail utilises a unique twin THUNDERBOLT Hydraulic Power Pack and controlled
tube design that offers reduced maintenance and from the THUNDERBOLT Recoilless Hammer. With
easier horizontal movement due to minimal dust build up on trolley wheel tracks. powered extend/retract and powered raise/lower
The RME Twin-Tube Monorail solution is particularly useful for THUNDERBOLT Recoilless Hammer functions and 360-degree slewing, liner bolts on the face
suspension where liner bolts are short, such as along the shell of larger SAG and Ball Mills and the ends of of the Mill within a window 2100mm high by 8000mm
Ball Mills. Fixed post Jib suspension is most
wide can be reached.

The off-set between the Mill shell and the RME Twin-Tube Monorail is important if optimum ergonomics
practical where plant floor space is limited. Tall Fixed Position Jibs are usually deployed at the
is to be achieved. For sites with local detailed design and manufacturing capability, RME can provide discharge end of AG and SAG Mills due to the shortage
16 of space around this area and the greater length of 17
Monorail guidelines. RME provides a full design and manufacturing service, delivering pre-fabricated Twin-
Tube Monorails for installation at site utilising RME or local resources. discharge end liner bolts.

8 9
 THUNDERBOLT Mobile Jib Suspension
The THUNDERBOLT Mobile Jib Suspension
has a larger base with four legs. Therefore
THUNDERBOLT Recoilless Hammers can be
supported by RME’s telescoping Mobile Hydraulic
Jib only where adequate floor space is available.
During liner bolt removal, the Mobile Hydraulic Jib
is controlled entirely from the THUNDERBOLT
Recoilless Hammer.
With powered extend/retract and powered raise/
lower functions and 360-degree slewing, liner bolts
on the face of the Mill within a window 1800mm
high by 8000mm can be reached.
The Mobile Jib Suspension unit is able to be moved
about the concentrator by either forklift or overhead
crane. Safe lifting points are provided for both lifting
methods on the Jib.

Innovation in design
Both the Fixed and Mobile THUNDERBOLT Jibs use a unique winch cable setup to ensure
the THUNDERBOLT Recoilless Hammer stays at the same height above the floor while the
Jib is extended and retracted. This results in increased operator safety and efficiency.

18 19

8 9
 Worn Liner Removal
RUSSELL Elevating Platforms

Worn Liner Removal
RUSSELL Elevating Platforms
A Grinding Mill’s worn liners can only be accessed ‘Mill shell segment’ by ‘Mill shell segment’.
As one segment of liner bolts are completely removed using THUNDERBOLT Recoilless Hammers from
the outside of the Mill Shell during “Knocking In”, the Mill Relining Crew who operate the Mill Relining
Machine then collect the segment’s worn liners which have fallen to the Mill charge.
These worn liners are safely picked up using RME O-ZONE Liner Lifting Tools, attached to the Mill Relining
Machine’s grapple head. The worn liners are then and placed onto the Mill Relining Machine’s Liner
Transport Carriage for transport out of the Mill (“Mucking Out”).
In 2004, RME engaged the services of ex-Escondida Concentrator Manager, Stephen Kittel, a metallurgist
who undertook detailed time and motion studies of RME’s Mill Relining System in action at a range of sites
world-wide. These studies revealed new opportunities for RME’s Mill Relining System.
One of the insights from the Kittel Time and Motion Studies was the time taken to move the
THUNDERBOLT from liner bolt to liner bolt during ‘Knocking In’. This particular insight precipitated the
invention of the THUNDERBOLT Moil Axis Guide device known as the T-MAG, and ultimately to RME’s
RUSSELL Elevating Platforms, acknowledged as a Grinding Mill Relining Crew must.
THUNDERBOLT Recoilless Hammer raise/lower function can be used independently of, or in conjunction
with, the raise/lower function of the RUSSELL Elevating Platform.
The RUSSELL Elevating Platforms are sturdy, with profile-following, floor extension on the Mill edge of the
RUSSELL Elevating Platform providing for safe work operation at all points along the curvature of the Mill.
The THUNDERBOLT S3 Power Pack with its visual control and diagnostics panel, provides the power for
the RUSSELL Elevating Platform and on board equipment.
THUNDERBOLT Recoilless Hammer Jibs are mounted on the RUSSELL Elevating Platforms, freeing up
space around the Mill and providing a safe and clear plant floor.
RUSSELL Elevating Platforms are powered by the THUNDERBOLT S3 Power Pack, and are also fitted
with an on-board swing arm Jib with a spring balance for pneumatic tools, eliminating the need for
Monorails around the Mill. Hydraulic and pneumatic outlets with common attachments are accessible on
board the RUSSELL Elevating Platforms, offering additional redundancy in the case of hose or lead failure.

“It is so much easier, we just take the platforms to the row of bolts we want to work on”
“We eliminated about half of the normal amount of required Mill inchings”
“I don’t want to work on a Mill without elevating platforms from now on”
– Kaltech NZ Mill Relining Crew

RUSSELL
Elevating Platforms
– the only ‘built for
purpose’ elevating
equipment to
enable quicker and
safer bolt removal
on Grinding Mills.
Improving
maintenance
efficiency by
reducing the
number of inchings
during relining
and retorquing,
RUSSELL
Elevating Platforms
also ensure site
crew safety by
providing a strong,
stable and flexible
operating platform.

20 21

8 9 13 14 24