AMS-Online Issue 03/2011

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201103

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Automatic Geo-Monitoring in Engineering Geodesy

iSURE – Tunneling Projectmanagement Software

Evaluation of Hard Coal Mines in emerging Nations in Terms of Mine Safety

HeidelbergCement and BirdLife International become co-operation partners - jointly preserving biological diversity

Sandvik – cone crusher Sandvik introduces two new mining cone crushers

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Tudeshki, H. Institute of Mining | TU Clausthal | Germany

Basics of Geo-Mechanics and Hydrology Part IV - ContinuationBasics of Hydromechanics

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Reiter, A.Department of Geodesy | TU Munich | Germany

Rathner, R.Sandvik Mining and Construction | Essen | Germany

KeestrackBilzen | Belgium

Sandvik Mining and ConstructionEssen | Germany

HeidelbergCement AGHeidelberg | Germany

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Hanke, A.F.E. Schulte Strathaus GmbH & Co. KG | Werl | Germany

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EDUCATIONNew crushing mantle for increased productivity and reduction

Sandviks Crusher manganese know-how ensures maximum productivity for customers

New Sandvik WR screening media focuses on aggregate producer profitability

Hitachi EX1200-6 the best machine for demanding job - Maximising potential

Hitachi wheel loader range have been well received throughout Europe - Powerful performers!

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CDE Asia - introduce mobile washing to iron ore processors

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A future grown out of tradition: 50 years of Wirtgen

New Kleemann Mobirex EVO plants - a global success story

EVENTS The AMS-Event calender 2011

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BBM Operta GmbHContinental/ContiTechVermeer

SandvikMetsoMTC

Liebherr

Hitachi Construction MachineryAmsterdam | Netherlands

Hitachi Construction MachineryAmsterdam | Netherlands

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Doosan Infracore Germany GmbHLangenfeld-Fuhrkamp | Deutschland

BEUMER Group GmbH & Co.KG Beckum | Deutschland

Kleemann GmbHGöppingen | Deutschland

Volvo Trucks Central Europe GmbHIsmaning | Deutschland

Sandvik Mining and ConstructionEssen | Deutschland



BEUMER Group GmbH & Co.KG Beckum | Deutschland

Doosan Infracore Germany GmbHLangenfeld-Fuhrkamp | Deutschland

Wirtgen GmbHWindhagen | Deutschland

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CATERPILLAR Inc.

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EDUCATION

Basics of Geo-Mechanics and Hydrology Part IV - Continuation Basics of Hydromechanics by Univ.-Prof. Dr.-Ing. habil. H. Tudeshki

Surface Mining and International Mining | TU Clausthal | Germany

Stress State in Waterlogged SoilIn soil that is partly to fully water-logged, the following

stresses can be differentiated :

Total stress • σ,

Neutral stress u ( pore pressure) and •

Effective stress • σ‘

The total stress σ is composed of the soil weight, water weight in all existing pores, and where applicable, the occurring outer loads.

Following to the hydromechanic characteristics mentioned in the AMS-online issues 01/2011 and 02/2011 earlier this year, dealing with permeability and strength of soil, as well

as with principles of hydromechanics, this article discusses the importance of water and further elaborates principles of hydromechanics. Core topics of the article are stress state of waterlogged soil and groundwater flows.

Fig. 1:Change in effective stress σ’

The neutral stress u or pore pressure corresponds to the hydrostatical pressure of water.

WW hu ⋅= γ Term 1

with hw = = hydrostatic pressure in observed horizon

The effective pressure σ´ demonstrates the actual grain-to-grain stress. The effective stress is characterized by the following formula.

U−=′ σσ Term 2

The stress state of soil can be influenced by de-watering. Pore pressure is reduced through extraction of water from the soil. According to the above-mentioned formula of effective pressure, the effective pressure σ´ increases, if the pore water pressure u decreases. In a constant, material-dependent friction angle ϕ, the friction force increases with increasing load or with effective normal stress. As a result, the shear strength τ increases. Thus, the following is valid:

c′+⋅′= ρστ tan Term 3

In case of reduction of the pore pressure, the effective stress increases from a value of σ’1 to σ’2. Thus, the shear strength of soil increases from τ1 to τ2. Soil can be subjected to a higher load, until it fails (picture 1).

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In case of an increase of groundwater level, for example after completion of a measure to lower groundwater, the reverse effect can occur. The groundwater and the pore pressure increases. As a result, effective stress and shear strength of soil decrease.

Groundwater FlowsAs described above, the grain form of soil particles

leads to occurrence of pores in soil, through which water can flow.

The reason for a flow is always a potential difference between two points in the underground, as a result of which water flows from the point with higher potential to the point with lower potential. The potential difference is called hydraulic gradient i:

lhi∆∆

= Term 4

withΔh: vertical filter distance [m]Δl: horizontal filter distance [m]

In case water flows because of a hydraulic gradient, neutral stress u (pore pressure) is reduced by the amount Δh – γw, while effective stress σ´ is increased by this amount. The increase of effective stress is the flow pressure f, which is caused by the friction of flowing water at the pore walls.

ilhf WWS ⋅=∆∆⋅= γγ Term 5

with γw: Water density [N/m³]

Subject to the size of pores and grains, soil offers a flow resistance to the water which flows through it. This resistance is described by the already mentioned permeability coefficient kf. The permeability coefficient can be determined through pumping tests in a laboratory or in situ, and has the dimension of velocity, i.e. m/s.

“The amount of water that flows through a filter with a constant diameter is proportional to the product of pressure head, permeability and size of filter area.”

ikv f ⋅= Term 6

with v: filter velocity (the flow rate Q, based on the entire area F, which is flown through) [m/s]kf: permeability coefficient, [m/s]i: hydraulic gradient H/L, [/]

The permeability coefficient of soil is not constant, but rather dependent on the hydraulic gradient I and the flow velocity.

DARCY’s law is applicable to creeping flows, for which inertial forces can be neglected. This is applicable to most aquifers. Exceptions are karst systems, as well as immediate surroundings of wells. The prerequisite of the validity of DARCY’s law are low flow velocities, the parameter is the Reynolds number Re, in analogy to the classic fluid dynamics.

η

ρυ

⋅⋅=

⋅=

dvdvRe

Term 7

withRe: Reynolds number [/]v: Flow rate [m/s]d: Grain diameter [m]υ: Kinematic viscosity [m²/s]η: Dynamic viscosity [Ns/m²]ρ: Density[t/m³]

Viscosity is understood as toughness of a fluid or a gas. It results from intermolecular forces in a fluid; therefore it depends on the cohesion between molecules or particles. The substance becomes increasingly more viscous with higher viscosity.

Experimental analysis has shown that DARCY’s law is valid with Reynold numbers of Re < 10.

In order to examine soil that consists of various layers and differing permeablities, a mean flow rate has to be determined.

Figure 2 shows soil with various layers and varying thickness d (d1 to d4). Each one of the layers shows a different permeability k (k1 to k4).


EDUCATION

In soil aquifers, the permeability in horizontal direction kv is mostly higher than the permeability in vertical direction kv. The reason for this is the different storage of soil grains, which leads to more effective pore channels in horizontal direction. It is for this reason that permeabilities for horizontal and vertical directions have to be calculated separately.

Permeability in horizontal direction

d

kdk

n

ihii

h

∑=

⋅= 1

Term 8

Permeability in vertical direction

∑=

= n

i vi

iv

kd

dk

1

Term 9

The relation between horizontal and vertical rock permeability of an aquifer is called anisotropy factor. Typical anisotropy factors for sands lie between 2 to 10. In case permeability of soil is identical in all directions, it is called isotropy.

Most of the natural aquifers are anisotrop, due to the arrangement of the system of clefts, the grain alignment and the microlayering:

1>v

h

kk

Term 10

Measurement of Groundwater LevelsThe groundwater level in a region is dependent on

many factors, like for example on the development of the underground (geological circumstances), precipitation, precipitation rates and evaporation. The changing level of groundwater is highly influenced by these factors. Knowledge about prevailing groundwater levels is of great importance for the extraction of mineral raw material,

Fig. 2:Layered soil with differing permeabilities


EDUCATION

as well as for agriculture and water supply. It is for this reason that the groundwater level is regularly measured by many groundwater measuring stations. This is mainly done with two methods, water level contact meters and well whistles.

In case of reaching the groundwater surface, water level contact meters (figure 3) give an optical signal, and well whistles (figure 4) give an acoustic signal.

The water level contact meter serves to measure water levels in wells, observation tubes and narrow drill holes. A probe tip (zero point) at a measuring tape gives an optical signal, as soon as it touches the water surface. In case the light plummet leaves the water surface by elevation, the light turns off. Thus the water surface can be located and read through the measuring tape. The immersion depth of the measuring device is measured at the upper edge of the tube. The immersion depth can be deducted from the exactly measured upper edge of the tube, determining the gauge level in meters above sea level.

The measuring devices can be read on site, however there are also other digital recording methods with data storage or direct transmission.

The groundwater level in a well can also be measured with a well whistle. In order to measure it, the well whistle is lowered into the well with a measuring tape. In case of contact with the groundwater the air in the whistle is pushed out and a whistling sound can be heard. When the signal is given, the reached depth can be read from the tape. Subsequently, the depth has to be corrected by the number of the water-filled, funnel-shaped outer rings, which determine the immersion depth. The described method is suitable for depths of up to 30 m, the reachable accuracy of measurement lies at approximately 1 cm.

Flow Direction and GradientThe knowledge about flow direction and gradient is

important for:

Determination of the catchment area,•

Dimensioning of water management,•

Designing water resource recultivation and • reconstruction,

as well as determining possible dispersion of pollutants.•

At least 3 measuring points (wells, drillings) are needed to determine the flow direction and gradient of groundwater. These three measuring points shape a measuring triangle. In case the flow direction of ground water is to be determined in a larger area, it is recommended to establish several of such measuring triangles.

The following figures show the procedure during determination of the ground water flow direction and gradient. In the mentioned case there is a plan for mining of a gravel and sand. Before the approval procedure, there is a need to clarify groundwater conditions, since there is a groundwater protection zone in the south of the planned mining area. Therefore it has to be ascertained to what extent mining of raw material will affect this groundwater protection area. In order to do so, flow direction and gradient of the groundwater must be determined. In addition, the volume flow Q of the water flowing into the quarry lake has to be calculated. The deposit has a thickness of 25 m. The average overlying ground is 2 m, the excavation depth under the groundwater level is 18 m. The deposit is to be mined in a width of 2,000 m. The permeability coefficient kf was determined at 8•10-1 m/s.

Fig. 3:Water level contact meter [24]

Fig. 4:Well whistle


EDUCATION

Initially three locations were established to measure groundwater (well B1 to B3). The geographical height of the three measuring points was determined with a leveler (figure 5).

In the next step, the depth of the groundwater level is measured in all three wells with a light plummet. The lateral distances between the measuring points can be determined with a measuring tape or theodolite. The measurements have yielded the following groundwater levels:

B1 296,4 m above sea level,•

B2 295,6 m above sea level and•

B3 296,2 m above sea level.•

Looking at groundwater levels, the water level is highest in well 1. As a consequence, the groundwater will flow to the direction of gauge 2 and 3. The differences of groundwater levels of wells are always formed between the lowest and the two higher values. In this case it is between B1 and B2, as well as between B2 and B3.

In figure 6 the groundwater levels of the well B1 and B2 are plotted. The difference between the groundwater levels can be determined as follows:

mmmh 8,06,2954,29612 =−=∆ Term 11 The difference of the groundwater levels of B2 and B3

are calculated in the same way (figure 7):

mmmh 6,06,2952,29623 =−=∆ Term 12

The difference in height between the well with the lowest and the well with higher groundwater level can only be based on the distance between the respective wells. In the stated example the distance between wells is consistently 1,000 m. It is assumed that the groundwater has a linear course between the two measuring points. Therefore the distance between B1 and B2 can be divided into four sections, which each symbolize a difference in height of 0.2 m. The same is applied to the distance between B2 and B3. Consequently, on each of the two connecting lines there are now points for groundwater levels 295.8 m, 296 m and 296.2 m. These points can be connected with parallel lines (figure 8).

The flow direction of the groundwater now runs vertical to these lines (figure 9). If the gradient also has to be determined, a vertical has to be drawn through well B2. Here the intersection of this straight line with the connection between well B1 and B3 is of utmost importance. Due to the fact that the groundwater levels in wells B1 and B3 are known, and assuming a linear course of the groundwater, it is possible to exactly assign a groundwater level to each point on the connection between the two wells. This is given in the intersection with a groundwater level of 296.35 (figure 10).

With this information the gradient of groundwater

(hydraulic gradient i) can be calculated. The difference in height of the vertical drawn in figure 10 from the intersection with the connection of well B1 and B3 to well B2, amounts to exactly 0.75 m.

Fig. 5:Determining groundwater flow direction and gradient, Picture A

Fig. 6:Determining groundwater flow direction and gradient, Picture B


EDUCATION

0008,0920

75,0===

mm

lhi

Term 13

According to DARCY’s law and with the given permeability coefficient kf = 8•10-1 m/s for gravel and sand deposit, the following flow rate Q results:

( )s

m23,48m920m0,75m18m2000

sm108Q

31 =⋅⋅⋅⋅= −

Term 14

Fig. 7:Determining groundwater flow direction and gradient, Picture C

Fig. 8:Determining groundwater flow direction and gradient, Picture D

Fig. 9:Determining groundwater flow direction and gradient, Picture E

Fig. 10:Determining the flow direction of groundwater and gradient,

Picture F

Fig. 11:Determining hydraulic gradient


EDUCATION

Bibliography

[1] Dörken, W.; Dehne, E. Grundbau in Beispielen, Teil 1 Werner Verlag, 3. Auflage, Düsseldorf, 2003

[2] Schreiber, B. Mitteilungen zur Ingenieurgeologie und Hydrologie, Heft 35, Lehrstuhl für Ingenieurgeologie und Hydrogeologie der RWTH Aachen, Aachen 1990

[3] Schnell, W. Grundbau und Bodenmechanik 1 + 2 (Studienunterlagen), Institut für Grundbau und Bodenmechanik der TU Braun-schweig, 7. Auflage, 1990

[4] Arnold, I.; Schutze, D. Der Einsatz von Dichtwänden im Lausitzer Braunkohlerevier, Vortrag anlässlich des Clausthaler Kongress für Bergbau und Rohstoffe, Mining 2002, Clausthal

[5] Rheinbraun AG Informationsbroschüren

[6] Prinz Abriss der Ingenieurgeologie

[7] Sieb- und Schlämmanalyse Institut für Geotechnik und Tunnelbau, Baufakultät, Universität Innsbruck

[8] DIN 1054 DIN 1054 - Zulässige Belastung des Baugrunds, Beuth-Verlag, 1976

[9] Grundbautaschenbuch Grundbautaschenbuch, Teil 1, 5. Auflage, Verlag Ernst & Sohn, Berlin, 1996

[10] Schultze / Muhs Schultze / Muhs, Bodenuntersuchungen für Ingenieurbauten, 1967

[11] DIN 18124 DIN 18124 - Baugrund, Untersuchung von Bodenproben - Bestimmung der Korndichte - Kapillarpyknometer, Weithalspyknometer, Beuth-Verlag

[12] Computer gestütztes Lernen in den Bauingenieurwissen-schaften http://www.calice.igt.ethz.ch/bodenmechanik/classification_d/classification_d.htm

[13] PERO GmbH Prospektmaterial der Firma PERO GmbH, http://www.pero-gmbh.de

[14] DIN 4049 DIN 4049, Teil 1 - Hydrogeologie; Grundbegriffe; 1992, Ber-lin, Beuth-Verlag

[15] Deutsches Klimarechenzentrum, Deutsches Klimarechenzentrum, http://www.dkrz.de

[16] Chemischer Aufbau des Wassermoleküls, Hauptseminar Ernährung im IGTW an der Universität Hamburg, http://ernaehrungs-city.de/aqu-lv2.htm

[17] Schröder, D Schröder, Bodenkunde in Stichworten. 2. Auflage. Berlin 1992

[18] DIN 4021 DIN 4021 - Baugrund; Aufschluss durch Schürfe und Bohrungen sowie Entnahme von Proben, 1990, Berlin, Beuth-Verlag

[19] Precision Graphics, http://www.bartleby.com/61/imagepages/A4artwel.html

[20] University of Wisconsin University of Wisconsin – Stevens Point, Department of geography and geology, http://www.uwsp.edu/geo/

[21] Joanneum Research Institut für WasserRessourcenManagement, Tiefengrundwasser-vorkommen Kärntens

[22] Schmidt, F. Schmidt, Frank, Dipl.-Geol.: Hydrogeologische Aspekte und Konsequenzen bei der Rohstoffgewinnung in Kluft- und Karstaquiferen, AI Aggregates International 1/2006, Köln

[23] Geologisches Landesamt Nordrhein-Westfalen Im Grunde Wasser, Hydrogeologie in Nordrhein-Westfalen, Krefeld 1999

[24] Firma Ott Hydrometrie Informationsmaterial der Firma Ott Hydrometrie, Kempten, www.ott-hydrometry.de

[25] Ingenieurbüro für Energie- und Umwelttechnik Niederschlagsverteilung in Deutschland, Ingenieurbüro für Energie- und Umwelttechnik, www.schimke.de/niederschlag.htm

[26] Baumgartner & Liebscher Baumgartner, A. und Liebscher, H.-J.,: Allgemeine Hydrologie, Berlin, 1996

[27] Umweltbundesamt, Umweltbundesamt, http://www.umweltbundesamt.de/altlast/web1/berichte/

[28] Informationsportal Grundwasser-online, Informationsportal Grundwasser-online, http://www.grundwasser-online.de

[29] Stadtentwicklung Berlin, Stadtentwicklung Berlin, Senatsverwaltung für Stadtentwicklung, http://www.stadtentwicklung.berlin.de/umwelt/wasser/

[30] Der Brunnen Informationsportal Brunnenbau, www.der-brunnen.de

[31] Bieske, Erich, Bieske, Erich, Bohrbrunnen, 8. Auflage, 1998

[32] Dörken, Dehne Dörken, Wolfram und Dehne, Erhard, Grundbau in Beispielen Teil 1, 3. Auflage, 2002

Univ.-Prof. Dr.-Ing. habil. Hossein H. Tudeshki studied from 1977 to 1980 at the Mining College of Shahrud (Iran); following several years of work in the mining industry, he completed his mining study at the RWTH Aachen in 1989. Since 1992 he was Chief Engineer at the Institute for Surface Mining (Bergbaukunde III) of the RWTH Aachen, main-ly active in the field of open cast mining and drilling technique. He did his doctor degree in 1993 and qualified as a university lecture in 1997. In 1998 the Venia Legendi was awarded to him be the RWTH Aachen for the field “Rock and Earth Open Pit Mining”. In November 2001 he was appointed as Professor for Surface Mining and International Mining at Clausthal University of Technology.He already has over 25 years of experience in the field of project planning and cost-benefit analysis within the frame of various mine planning projects. The international tasks rendered by him mount up to more than 300 international raw material-related projects.

| [email protected] | www.bergbau.tu-clausthal.de |

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13Issue 03 | 2011



Automatic Geo-Monitoring in Engineering Geodesy by Dr. A. Reiterer

Munich Technical University, Department of Geodesy Munich | Germany

IntroductionGlobally, one of the most frequent natural hazards are

rock slides, landslides and slope movements, which claim many victims and high costs every year. In the Unites States, for example, such events cause costs of 2 billion US$ (U.S. Geological Survey, 2007). Similarly, this applies to Europe, Asia, Africa and South America. Apart from direct costs, such incidents also cause very high indirect costs, like for example the disruption of important transport connections, losses in tourism, etc. Due to the increase of populated areas in the alpine terrain, a significant increase in dangerous incidents is to be expected. In addition, the changed climatic conditions, like for example the increase of rainfall, lead to an increased occurrence of slides and rock falls. This results in a high demand for productive and reliable monitoring systems for endangered objects (see picture 1).

This demand can on one hand be met through application of extensive sensor systems (e.g. geo-technical and geodetic sensors), on the other hand through novel data analysis strategies. Generally, in such monitoring systems, data processing, which can include all steps from data fusion up to data interpretation, has a central role. In future, high attention has to be paid to automation in all steps of the process – the aim should be a fully automated data gathering and analysis system. In this regard Wunderlich

The rise of natural hazards in populated areas increases the need for fast acting and user-friendly deformation measuring and alarm systems. This need can only be met through increased automation of monitoring

processes, analysis and interpretation of data. The development and installation of such monitoring systems can be seen as one of the core areas of geological science. For many years the installation and automation of new sensor components has taken the center stage of development. The interpretation of data is mostly done by experts – although some pre-processing steps exist, it is difficult to achieve full automation. However, new techniques are making it possible to also automate this last step of the proccess chain, so that a fully automated operation can be achieved, at least in theory. The current article gives an overview over the possibilities of automating geo-monitoring processes – in doing so, emphasis is given to a selected inter-disciplinary research project.

Pic. 1:Examples for landslides –

a) Austria (above),b)Germany (middle),c) Malaysia(below)

14Issue 03 | 2011



(2006) mentions completely new challenges in the area of monitoring measurements, which on one hand can be attributed to multidisciplinary extensive projects, on the other hand to highly complex sensor technology of modern multi-sensor systems. Examples of such systems can be found in Kahmen und Niemeier (2003), Thuro et al. (2009) or Schmalz et al. (2010).

The current article gives an overview over possibilities for automation of geodesic monitoring systems. Hereby the focus is on an extensive research project, which deals with data gathering, data fusion and interpretation of data.

Automation of Technical Processes In general, automation technique is about monitoring

and controlling of technical systems. Recent research works seek to achieve not only a fully automated, but also an autonomous cycle. Examples of such systems are driverless transport systems, analysis systems in chemical laboratories, or robots in the automobile industry.

In principle any automated process can be divided into two steps (Lunze, 2003):

Monitoring, which includes determining, gathering, and •processing of measured data.

Controlling, which includes targeted influencing of process •cycles.

„Regulating “does not necessarily have to be done through the system, but can also be done by a user from outside. It is crucial for the automation of a system to design a form to describe the process in its details. On one hand this can be a mathematical description, but it can also adopt any other form of process mapping.

The composition of an automated system is roughly divided into two structural elements: (1) the process, which is to be automated, and (2) the actual automation system. The process to be automated is the real technical core system and is often simplified as system or process.

It is crucial for the automation system that a detailed description of the system process is available and all input and output parameters are known. The communication between the

process and the automation system is solely done through these input and output parameters. In this connection we also speak of process data (process output) and actuating variables (process input). Therefore the process to be automated is not restructured, but only influenced from outside, so that it shows a given behavior. The goal of the automation, which has to be formulated by the operator, is also called regulation goal. In turn the system gives the operator the current status of the process (operating point). This basic structure of an automated system is shown in figure 2.

In principle the automation system can be converted into conventional programming language, such as C/C++, suitable simulation environments like MATLAB/SIMULINK or approaches from the fields of artificial intelligence, like artificial neuronal networks.

There are a number of works in the field of geodesy, which deal with the automation of system processes. Examples of recent works can be found in Beetz und Schwieger (2010), Berkhahn et al. (2010) or Chmelina and Rabensteiner (2010).

Fig. 2:Basic structure of automated systems (Lunze, 2003)

15Issue 03 | 2011



Basically today’s automation systems are developed and applied to increase efficiency and minimize sources of errors. Recent research works (Weller, 2008) show that it is important to designate a person in an automated process, at least as a monitor. However, it is better to include that person in the decision-making design.

Automated Geo-monitoring – Practical Example

In the interdisciplinary research project i-MeaS („An Intelligent Image-Based Measurement System for Rock Fall Monitoring“) currently work is being done to develop an approach, in which many different sensors are merged into a highly complex multi-sensor system to monitor natural objects. Hereby a main component of the system design, apart from the analysis, is the partially automated interpretation of data, which is often neglected in conventional systems.

The process of i-MeaS has been designed as fully automated –the algorithms, methods and techniques that are applied, from data collection to data interpretation, allow for a high degree of automation. This process is supported by a knowledge-based decision-making system, which takes care of regulating individual system components and supports the user in possibly needed interactions. The direct communication between the user and the individual process steps is done through a sub-component of the decision-making system. Therefore it is insignificant for the process, whether the decision is taken by the system itself or by an expert. The system architecture is roughly outlined in figure 3.

(a) Data collection:As already mentioned, i-MeaS is based on the application

of the most different sensors. But the central component is a new sensor, which exhibits a merger of conventional tachymeter and optical imaging elements. Hereby it is essential that a CCD- or CMOS-sensor is integrated in the optical path of the tachymeter of the telescope. This allows for selecting the content of the visual field and the processing of the geo-referenced pictures that are captured in this way. With the help of this modern measuring system it is possible to capture surfaces and surface processes for typical geo-monitoring tasks with an accuracy of sub-cm (the reachable accuracy is highly dependant on the measurement configuration – see Reiterer et al. 2010) The result of such image-based measurements are 3 D vectors that describe the deformation of the object surface.

Naturally, capturing the surface only is not sufficient for a reliable monitoring system – it is imperative to look into the underground and explore respective processes. For this part of data collection it is possible to use different geotechnical sensors, like for example extensometers. In order to do so, the design of i-MeaS foresees an array of different sensor intersections = as such, future implementation is easily possible.

A further essential component of i-MeaS is composed by meteorological components. Information about precipitation (type, intensity, etc.) can on one hand be obtained with a so-called distrometer, on the other hand national and international meteorological services can be used to recall and include large-scale meteorological conditions (including precipitation forecasts).

Fig. 3:Diagram of the automated process of i-MeaS

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In addition to these sensor data, it is possible to include additional information about the ongoing object into the system (object-specific knowledge). Furthermore a specific user interaction component, which allows incorporating unstructured knowledge from experts experiences or from other sources (e.g geological maps), is available. This step is completed with the help of a digital questionnaire, which is available online and can be used by the user on site (in the field).

The result of data collection is a pool of data sets and files that need to be processed in a further step (data processing).

The task of the decision system in data collection is only the support of the user. Necessary parameters for measurement (spot spacing at the object, time between measuring epochs, etc.) are suggested by the operator, based on the respective recording situation. The final decision, however, lies with the user.

(b) Data processing:Data processing in i-MeaS is currently limited to simple

processing steps and the merging of individual data streams. The data that are currently processed are tachymetric measuring elements (from imaging tachymeter systems), as well as local and global meteorological data and object-specific knowledge. 3D object coordinates are calculated from measured values of the imaging tachymeter, and consequently , motion vectors are calculated through a geodesic Mehrepochenanalyse.

During the merger of various sensor data it absolutely important to obtain synchronous data sets (one exception is the object-specific expert knowledge, which does not have to be synchronous with the up-to-date data). The time stamp used is the Network Time Protocol (NTP). Due to the fact that all sensors are regulated by a control center, all sensor streams have the same time-basis – the merger therefore only consists of merging individual data sets. The result of this step is a uniform structure, consisting of all available data. The so-called Extensible Markup Language (XML) is the basis for this data pool. This data processing/data merger is done fully automated through the system.

(c) Data interpretation:The assessment and appraisal of the risk of a natural

object needs the evaluation of geology, hydrology, morphology and the relation between environmental

conditions and human activities. During development of i-MeaS, currently an automated data interpretation system is developed on the basis of a knowledge-based approach (Vicovac et al., 2010). Here it is essential that a high number of various data and knowledge sources are included – on one hand the above-mentioned data sets, on the other hand heuristic and factual knowledge.

In a first step the system carries out an analysis of the current risk level of the object, and makes an adaptation of this risk-level available in a second step, with the help of the continuously recorded data. The first part of the system is based on historical recordings, geological knowledge about the object, information from geological maps, etc., while the second part of the system includes current measurements and findings about the object and its surroundings. In addition, the appraisal of the initial status is naturally a direct input for the running risk analysis. The initial state can be seen as status quo of the object, with regard to the risk of occurrence of a dangerous incident (before the object is instrumented. Therefore it only has to be done once for each installation.

In determining the current risk, not only the captured data from divers geodesic and geo-technical measuring sensors, but also metrological data and weather prognoses play a major role. On the basis of this extensive data pool, an attempt should be made to determine the trend, in addition to the level of the risk. The data flow for the interpretation component is exemplarily sketched in figure 4.

The difficulty of the interpretation system that is currently being developed is gathering of knowledge (so-called knowledge-engineering). In order to do so, the research project has access to a number of different experts (geologist, geodesist, rock mechanic, etc.), who actively support knowledge acquisition in form of interviews, demonstrated case studies and discussions. It is then up to the respective development engineer to appropriately implement this knowledge. For this implementation a rule-based approach was used, which allows the expert to cross-check the provided knowledge without much knowledge of programming. Each “knowledge package” is available in the system in form of a simple rule (e.g. “when FACT 1 applies, ACTION 1 follows”), whereby the facts correspond to the above-mentioned data and the actions basically produce new facts – the i-MeaS interpretation system currently contains several hundred of such sets of rules. Like in all knowledge-based systems, the processing is done through a suitable interference component. The final result of this process is a fact, which corresponds to the current risk.

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Figure 5 shows exemplarily a section of the decision-making of the interpretation section. Hereby the rules are marked in green; the produced or used facts are marked in blue. It can be seen that for example the rule „MAIN::IS_ROCKFALL“produces an array of new facts (left part of the diagram), however only one fact („MAIN::recent_deformation_medium“) is used for further processing. During the further course of development these facts should also be used by system components and through that a whole decision making network should develop. For a detailed description of the entire decision-making process, please refer to Vicovac et al. (2010).

The current project clearly shows that a fully automated operation of a geo-monitoring system, including data analysis is possible. There are, of course, difficulties in case of incorporation of very extensive expert knowledge. A prerequisite for this complex development step is a pool of experts from neighboring science disciplines and the right communication strategy. It is planned to fully implement the interpretation part until mid 2011 and to evaluate it with the help of independent experts.

Summary and OutlookThe present article gives an overview over possible

automation techniques in geodesic monitoring systems. Hereby, applied methods and algorithms, as well as the selected automation strategy play a major role. Apart from discussing the basics, an overview over a current research project is given.

The biggest problem arising from the successful automation of complex systems is the acquisition and incorporation of expert knowledge. The application of knowledge-based techniques has proven to be successful in several independent projects (Chmelina und Rabensteiner, 2010; Riekert et al., 1990; Vicovac et al., 2010). The difficulties of “knowledge-extraction” can successfully be overcome by a well-thought-out “knowledge-engineering”. A combined usage of questionnaires, case studies and interviews is advisable. It is essential, although at times difficult, to use an expert pool, at best consisting of more than three experts from different, but neighboring technical disciplines.

It is important to emphasize that the aim of development and implementation of such automated systems is not to replace the experts, but rather to support and relieve them.

BibliographyBeetz, A. / Schwieger, V.: Enhancement of the Control Quality by an Automatic Calibration Procedure using the Example of a Construction Machine Simulator. 2nd International Conference on Machine Control & Guidance, 2010.

Berkhahn, V. / Berner, F. / Hirschner, J. / Kutterer, H. / Rehr, I. / Rinke, N. / Schweitzer, J. / Schwieger, V.: Effizienzoptimierung und Qualitätssicherung ingenieurgeodätischer Prozesse im Hochbau. In: Der Bauingenieur, Nr. 11, S. 491-501, 2010.

Chmelina, K. / Rabensteiner, K.: Improvement of the Safety and Profitability of Tunnel Drives through the Use of

Fig. 4:i-MeaS-system concept for data interpretation

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Fig. 5:Section of the decision-making for the interpretation part

Automated Measurement and Alarm Systems – Examples in Practice. Geomechanics and Tunnelling, Nr. 3/2, S. 215–224, 2010.

Kahmen, H. / Niemeier, W.: OASYS – Integrated Optimization of Landslide Alert Systems. Österreichische Zeitschrift für Vermessungswesen und Geoinformation, Nr. 91/1, S. 99-103, 2003.

Lunze, J: Automatisierungstechnik. Oldenbourg Wissenschaftsverlag, 2003.

Reiterer, A. / Huber, B.N. / Bauer, A.: Image-Based Point Detection and Matching in a Geo-Monitoring System. Allgemeine Vermessungsnachrichten (AVN), Nr. 4, S. 129-139, 2010.

Riekert, W.F. / Gunther, O. / Hess, G.: Architecture of a Knowledge-Based System for Remote Sensor Data Analysis. In: Proceedings of the third International Conference on Industrial and Engineering Applications of Artificial Intelligence and Expert Systems, Nr. 1, S. 228-232, ACM Press, 1990.

Schmalz, T. / Eichhorn, A. / Mair am Tinkhof, K. / Preh, A. / Tentschert, E.-H. / Zangerl, C.: Untersuchungen zur Implimentierung eines adaptiven Kalman-Filters bei der Modellierung instabiler Talflanken mittels des Finite-Differenzen-Codes FLAC3D. In: 16. Internationaler Ingenieurvermessungskurs (München), Wichmann Verlag Berlin, S. 255-265, 2010.

Thuro, K. / Wunderlich, Th. / Heunecke, O. / Singer, J. / Schuhbäck, St. / Wasmeier, P. / Glabsch, J. / Festl, J.: Low Cost 3D Early Warning System for Instable Alpine Slopes – The Aggenalm Landslide Monitoring System. Geomechanik und Tunnelbau, Nr. 2/3, S. 221-237, Ernst und Sohn Verlag, 2009.

Name: Alexander ReitererBirth: 7. August 1974Birthplace: Meran (Südtirol/Italien)

Adress: Vorgartenstraße 186/17, 1020 Wien,Austria

Academia:Diploma of Surveying Engineering (Dipl.-Ing.), 2001 Technical •University of Vienna Doctor of Technical Sciences (Dr. techn), 2004 Technical Uni-•versity of Vienna

Current employment: Post Doc (Humboldt Research Award)•

| Munich Technical University - Department of Geodesy |Arcisstraße 21 D-80333 Munich

| [email protected] | www.geo.bv.tum.de |

U.S. Geological Survey: http://landslides.usgs.gov/ (letzter Zugriff: 12/2010)

Vicovac, T. / Reiterer, A. / Egly, U. / Eiter, T. / Rieke-Zapp, D.: Knowledge-Based Geo-Risk Assessment for an Intelligent Measurement System. Artificial Intelligence in Theory and Practice III, S. 215-224, Springer Verlag, 2010.

Weller, W.: Automatisierungstechnik im Überblick, Beuth, 2008.

Wunderlich, Th.: Geodätisches Monitoring – Ein fruchtbares Feld für interdisziplinäre Zusammenarbeit. Vermessung & Geoinformation, Nr. 1+2, S. 50-62, 2006.

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ISURE – Tunneling Projectmanagement Software Drill plan design and the accuracy of drilling equipment have a

significant role in the overall control and productiveness of a tunneling construction site. Effects cover many sectors of the tunneling cycle through the quality of excavation. The profile of the excavated tunnel can be controlled by blast management and correct placing of drill holes. A good excavated profile within the limits of the excavation tolerance range creates the basis for effective drilling of the next round. Achieved accurate and smooth profile also makes the need for support works smaller and potentially reduces the amount of required sprayed concrete.

by Dipl.-Ing. Roy Rathner Sandvik Mining and Construction Europe

Essen | Germany

The aim of the design is to provide needed information for the drilling unit to be able to drill a whole round in automatic mode under supervision of the operator. Normally the first step has been designing of theoretical profile which is the profile that the finished tunnel should have. This is commonly determined by the client. This step has been followed by determining the locations of holes and by defining separate directions for each hole. After the information concerning locations and directions of holes has been defined some functional settings for the drilling machine has to be determined. Most commonly this step includes designing the sequence for drilling booms i.e. the order in which the holes will be drilled for each drilling boom and determination of roll over angles i.e. how the boom is positioned while drilling the hole.

In addition to drilling pattern design some information related to tunnel line has usually been provided e.g. to be able to navigate the rig into the tunnel and to be able to fix the rig’s coordination system to the tunnel coordinate system.

Modern system for drilling pattern design has been taken into a new level of thinking. Consideration of hole locations is made in the most critical part of the drilling pattern i.e. in the end of the round where the blasting initiates. Taking design into the blast plane also enables burden calculation and parameterization of the design. By using parameter based blasting modeling aim is to optimize the drilling pattern and consequently achieve better quality in excavation resulting savings in overall costs.

IntroductionThorough navigation and caution in phases of drilling

cycle are factors influencing the accuracy of the drilling equipment. The importance of these factors has to be realized and observed by all involved in the process.

It is essential to be conscious of the fact that the ability of a drilling jumbo to drill the hole into the planned location, direction and length is a feature that the whole economical excavation is based on.

The iSURE (intelligent Sandvik Underground Rock Excavation) software tool offers a project tree approach combining all tunnel plans related in project. A tunnel plan, in turn, combines a curve table, tunnel profiles, drill plans, lasers and data collection files, all of which can also be controlled separately. A complete tunnel plan or drilling pattern can be transferred to i-series jumbo. Transfer to TDATA/TCAD hardware is also supported.

Basics of Drill Plan DesignDrilling pattern design for DATA-controlled drilling unit

has traditionally included steps related to full automatic drilling cycle such as positioning of holes, determining directions for holes, defining the boom sequences and roll-over angles. Some general steps in the design process are still the same but many improvements and new features are included in the process.


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Basic terms and definitions used in design

One step during the design process is to determine the length of the drilling pattern. This is defined to be the distance between the navigation and the blast plane. Length of the drilling pattern is dependent on the feed length of drilling jumbo which also specifies the maximum length of the drill steel and hence maximum length of the drilled hole. It is possible to specify varying depths for different hole classes in the pattern to be able to shape the round end (Fig. 1). By controlled round shape benefits such as optimized blasting effect, maximized pull-out, better collaring of next round and better loadability can be gained. Different hole classes in the design have been categorized in five different types: contour-, aidrow 1-3- and field type of holes (Fig. 1).

As mentioned above the design for hole locations is based on parameter based blasting modeling i.e. burden calculation. Burden V [m] is defined to be the shortest distance from the hole to be blasted to an open space which also could be the space created on a blasting just moment ago (Fig. 2). The burden is dependent on the strength of the explosive, rock factor, inclination of holes and spacing between the holes. The maximum allowed burden is considered at the end of the round where the situation is most critical.

The spacing between the holes E [m] is the distance between adjacent holes in the same hole class or in the same element i.e. the distance between the holes in the contour for example (Fig. 2). In theory, better quality of excavation will be achieved if the spacing in the contour holes is reduced. In practice, this is not always the situation due to scattering of drilling and drill hole deviation. Too short distance between the holes may lead to an uncontrolled situation where explosion gases may burst into the next hole blowing out the explosives or compress the hole so that the explosion can not take place.

The ratio between spacing and burden is typically in the range of 0,8 for the profile i.e. contour holes. In such case the explosion in the contour holes breaks the rock between the holes before pushing rock towards the center of the profile. Specific charging q [kg/m3] is defined to be the needed amount of certain explosive (with a certain strength kg/m) to loosen a certain volume of rock.

The average degree of packing I [kgREF/m] is used in the calculation to be able to use different explosives during the design i.e. the explosives are comparable to each other. The strength is specified as a proportion to a known reference explosive such as dynamite or ANFO as an example.

Fig. 1:Shaping of the round end by adjusting hole lengths for different hole classes. The green plane is representing the navigation plane and reddish

is the end of the round in picture on the right

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Burden calculation When blast is considered from the charge initiation point

of view (starting from the middle of the drill plan or where the cut is located) it could be stated that the most optimal location of the next charge row is such that has enough power to break the rock to the open space just created by the previous holes initiated. Additionally enough power is needed to move the expanded rock mass and to create an open space for the next charge row to be blasted. To be able to utilize burden calculation in drill plan design, the situation has to be considered at the end of the round i.e. at the blast plane. In practice the hole endings are designed and displayed at the blast plane for calculation purposes. By this procedure the calculation can be performed in 2D (Fig. 2).

Drilling pattern designDrilling pattern design has a direct influence on

the employment of time of a drilling rig. Roughly, the employment of time for a drilling cycle consists of setup time and navigation of the rig, drilling of holes according

to drill plan, boom movements between holes and some auxiliary time after drilling. If the drilling pattern is properly designed, the employment of time can be affected. By the shape of the round end the collaring of a new hole can be influenced. Equal drilling time for each boom is important i.e. avoidance of standing time of booms. This can be controlled by proper designing of drilling sequences. By sequence design possible danger of booms crashing each other can be avoided as well.

Appropriate design for aligning the holes, drilling sequences and roll over angles means that the accuracy of the automated rig and repeatability of the designed pattern is fully applied. The selection of cut type and design of the cut have an extensive impact on pull out and evenness of the shape of the round end. The design and type of cut also determines whether there is a need to change a reaming bit during round drilling and if relatively slow reaming has to be done. The amount of drill holes in drilling pattern has an

effect on pull-out, fragment size and quality of excavation. Drilling time of one round can be influenced by length of the round. Typically, in time-wise, it is productive to drill as long rounds as possible but in this case possible limitations in excavation and in vibration control near populated areas have to be considered.

Essential part of tunnel worksite management is predictability of the excavation cycle. Not only to be able to be systematically prepared that the needed capacity is available in correct place at correct time but also because possible limitations in blasting can be considered.

In a large construction site the fixed costs form a significant portion of the total costs. This means that every delay in the cycle or lost round leading to site idling is very expensive.

The drill plan design substantially affects the drillability of the pattern. The design of direction angles, drilling sequence and roll over angles can ease the drilling of the pattern, which equals to decreased need of manual boom alignment movement. Mechanical failures of a rig can be avoided as well by the criteria referred to above. All this means less deviation in round drilling time, which reflects as better predictability of the cycle.

Fig. 2:Hole positioning at the blast plane. Red profile is representing the lookout profile. Burden and spacing also represented

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At its best, the role of drill plan design software in a tunnel construction worksite is a tool for total excavation process management.

Different working phases in designIn the software one tunnel project can be processed

at a time. A project tree approach is used for project management. Tunnel project consists of tunnel lines and navigation sets. Tunnel line includes curve table points, theoretical profiles, drilling- and bolting patterns, tunnel lasers and data collection files. Curve table comprises information such as peg numbers, coordinates and cambers and all this can be imported from MS Excel for example. Theoretical profile can be designed manually by using drawing tools but also a selection of standard profiles is included in the software. Designed profile is defined for a certain peg number range. Different profiles may be used for different peg numbers and interpolation from profile to another is managed by the software (Fig. 3).

Subsequently locations for tunnel lasers can be defined. In the navigation sets some information concerning the navigation is prefilled. This action decreases some manual work needed on the rig.

Drilling pattern can be designed for the theoretical profile that was defined in previous step. There is a possibility to make the design in the navigation plane or in the blast plane as described above. Blast plane design is recommended way since all the features and strengths of the software will be then utilized. Design for a predetermined profile starts by defining some assistance profiles (Fig.4). These profiles include start and end (lookout) profiles, minimum and maximum tolerances for the excavation and maximal allowed fracture zone.

Some parameters for the software have to be defined before the actual positioning of holes can be made. For calculation purposes information such as list of used explosives and their individual degree of charge [kg/m] plus degree of charge in reference to some commonly used and known explosive e.g. dynamite or ANFO [kgREF/m] needs to be determined. Additionally the size of fracture zone for each explosive has to be defined.

As described above the design is made in the blast plane i.e. in the end of the round. Another difference compared to present design methods is that the design is started from the contour and thereafter gradually moved towards the center of the drill plan. Reason for this is the logic used in the calculation. Based on the information given to the software it automatically defines the most optimal place for the next row of holes. So for example when the blasting has reached 1st aidrow, the contour holes are charged heavily enough to break the rock in front of it.

Hole positioning is made for one element at a time i.e. contour, 1st aidrow, 2nd aidrow, etc. In practice the first step is to define a few so called position master holes. Purpose of these position master holes is to separate elements like wall, roof and bottom from the current profile. After position master holes have been placed it is possible to specify the element between two position master holes and bind the parameters used for the calculation purposes for specified element (Fig. 5).

Needed amount of aidrows (maximum 3) are added into drill plan. The cut is designed and placed manually by the user and finally some field elements can be added if needed. If applicable cut exists in an existing drill plan there is also a possibility to import it.

Next phase in design is to direct the holes. By this an individual direction and angle for each hole can be defined. Different procedures are available for the user in this phase.

After directing holes the drilling sequence needs to be defined. Drilling sequence specifies how many holes each boom will drill and in which order. Carefully designed sequence makes the round drilling optimal in order to utilize the booms effectively. Also overlapping between booms and possible crashes can be avoided.

Roll-over angle, which is specified as next, defines the angle of the roll-over joint in which the hole will be drilled. This is needed to be able to drill and place the boom effectively and smoothly.

Fig 3:DPicture showing a tunnel project containing a tunnel plan for the ac-cess tunnel and for the main tun-nel. Profile expansion and an inter-polation from profile A to profile B shown in the main tunnel

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The order of detonation is an important part of the excavation design even though this information is not needed for the drilling pattern design. However the software offers a possibility to plan the order of detonation. The information can be utilized as guidance for charging crew and for calculating momentary amount of explosives for example. There is also possibility to include surface delay detonators in the design to be able to ease the charging design in urban areas or areas where vibrations are strictly limited and controlled (Fig. 6).

Final stage is to define a hole type for each hole. By setting this info the drilling machine will use the preset parameters bound to the hole type for drilling each hole. This feature increases the accuracy of drilling when for example lower pressure levels are used for drilling contour and cut holes.

When design is ready the software will run a check list to be certain that each hole has a charge ( if not specified as a reamer hole), is part of a drilling sequence, has a roll-

Fig. 4:Different profiles used in the design

Fig. 5:Hole positioning by defining separate elements in the pattern (left picture). Finished

drill plan showing fracture zones for contour and 1st aidrow (right picture)

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over angle defined, is part of a detonating order and has a hole type defined. Also some checking is made concerning the detonator design especially if surface delay detonators are used.

Software offers also possibility to generate printable documents from the plans. Printouts can be used as legitimate documents. Nevertheless it has to be noticed that reports related to explosives are created on the basis of the explosive type defined in the charge table and bottom and column charge related to corresponding explosive type. Therefore the reports are only theoretical.

Complete drill plan can be transferred to a drilling jumbo via memory stick. Additionally related information such as tunnel line, lasers and bolting plans can be transferred to jumbo.

Depending on the project the life cycle of a drilling pattern may be fairly long. However due to possibility of rapidly changing conditions and rock type it is important to be able to make changes to the drill plan fast and efficiently. This way the pattern can be adjusted to suit current circumstances and the results in excavation, in quality- and in cost-wise, can be optimized while the tunnel advances and the rock conditions vary.

ConclusionAn accurate tunnel line requires accuracy both in

drilling and blasting. To be able to excavate an accurate tunnel profile the general geology of the area and the mechanical properties of the rock should be known and the excavation should be designed according to their challenges. A good result usually requires many blasted rounds and improvement of the drilling pattern should be continued after every round.

The design of a drilling pattern starting from the end of the round is a new and revolutionary way of designing an economical drilling pattern excavation wise. A substantial part of the design is to find the needed specific charging values for each section of the drilling pattern. Once these values are found for a certain rock type, the optimization of the drilling pattern and appliance to other drilling patterns go smoothly.

Only seamless interaction of drilled pattern, charged explosives and detonator delays can provide optimum excavation results in terms of round bottom and profile control, drilled meters, powder factor, pull out rate, vibration control, tunnel advance and costs. Therefore, an overall approach is an absolute necessity for a tunneling project when the focus is on excavation quality.

References

[1] “Drill Plan design – Orientation Instructions”, Sandvik Mining and Construction, 2008

[2] “Sandvik iSURE revolutionizes professional tunneling”, Press Release, Sandvik Mining and Construction, 2008

[3] ”Sandvik Underground Rock Excavation Software – iSURE”, Training material, Sandvik Mining and Construction, 2008

Fig. 6:Features of detonator design and explosion summary

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Evaluation of Hard Coal Mines in emerging Nations in Terms of Mine SafetyOn the basis of relevant experience in mining related development assistance

a system for the evaluation of deep shaft hard coal mines in emerging nations, which do not conform to safety standards comparable to Western Europe, is suggested here. With the aid of a matrix, suggestions for a step-by-step improvement of the mine safety can be determined. Incorporated in this matrix is the safety status encountered at the evaluated mine as well as the dangers associated with the coal deposit itself.

by Dr. Walter Hermülheim RAG Aktiengesellschaft

Herne | Germany

By gradually introducing the exemplified measures geared to the present dangers, a mine in an industrially emerging nation can, in the medium term, be brought to an acceptable mine safety standard in a suitable manner.

Added to the explanation are practical hints regarding risk evaluation before entering a mine in an industrially emerging nation, including a checklist.

BasicsBased on experience, four levels of technical safety can

be defined for hard coal mines (Fig. 1):

Mines of the level 0 have no noteworthy standard of •technical safety. This applies e. g. for illegal small scale mining. The reason for the problem is mainly a lack of awareness and technical competence of those responsible, combined with equally missing or inadequate government structures such as rules and mining authorities. Therefore even the most fundamental safety precautions, as described below under level 1, are often not present.

Mines of the level 1 are pro-•tected against total loss of the deposit, loss of the mine wor-kings, and to an extent, depen-ding mainly on the quality of the explosion protection and self rescue apparatus, against ac-cidents with catastrophic loss of life. This is about the level of protection which was preva-lent in Germany into the 1950s / 1960s. The last massive incident in a mine of the level 1 in Germa-ny was the Luisenthal explosion in 1962. Following this incident

water barriers against explosions as well as coal dust binding methods with salt solution were introduced in the 1960s.

Mines of the level 2 are protected against severe loss of life •and equipment. This corresponds to the protection level into the 1970s / 1980s. After the explosion at Camphausen in 1986 rules for fighting spontaneous combustion fires, including criteria for the stringent necessity of an inertisation with Nitrogen in the case of a mine fire, were laid down in Germany.

Mines of the level 3 correspond to the current state of •mine safety in German and Western European hard coal mining.

Regarding the possible danger corresponding to the appropriate safety level, a distinction between non gaseous and gas rich mines, and furthermore of gas rich mines with coal which tends to spontaneous combustion, must be made. In this third level are also other, rather special

Fig. 1:Evaluation Matrix for Hard Coal Mines

http://www.rag.de

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risks such as danger of e. g. gas outbursts, rock bursts or water ingress. The safety characteristics corresponding to the levels mentioned above are documented with detailed examples in the tables in appendix 1. However, these tables are not in the main focus of the following explanations, they are intended for further studies and as check lists for a later application and implementation.

In an evaluation matrix like the one suggested here the levels are inevitably blurred in the real world, or some safety measures may be associated with the neighbouring level in some areas of the world. This matrix is based on the German safety standards, and e.g. the technical level of implemented explosion suppression was and is generally one level below that standard. The following considerations put special emphasis on these circumstances.

When evaluating the safety standard of a mine, it is, besides using the presented evaluative matrix, also necessary to evaluate the safety measures actually implemented on site, which, compared with the matrix, may be reason to further devaluate the mine. The actual degree of implementation can only be determined via random examination or by asking specific questions. This will also be the basis of the decision whether one can dare to enter the mine as consultant or guest and at which point to abort the underground visit.

In the following a few examples from the field of mine rescue, mine safety evaluation and ventilation will be given with no claim to be complete. Obvious black humour is not added for entertainment value, but actually in the situations and dialogues, which happened as described or in a similar fashion.

So, imagine your first consultation with your local counterparts on the fictions November 17th Colliery in the equally fictions emerging mining nation Transcarbonia … (Fig. 2).

The Core Questions - Self Rescue and Explosion Protection

The most important topics for an on site safety evaluation of the mine are, especially in one’s own interests, the escape precautions, the self rescue devices, and all measures concerning risks associated with mine gas (Fig. 3).

Fig. 2:… 17. November Colliery,

People‘s Republic of Transcarbonia

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Based on experience, the most common answers to the obvious question regarding escape and rescue precautions are:

People know their mine.1.

There will always be an overman present who precisely 2. knows what to do.

In any emergency they will hear what to do from the 3. control room via telephone.

The professional mine rescue brigade will take care of 4. that.

In any case everyone can walk to the next clean air 5. current well within the duration of their self rescue apparatus.

the containers of the self rescue apparatus are dented •and worn (KO2-Oxygen self rescuers have a shelf life as well as filter self rescuers and soon become useless when exposed to air) or if the self rescuers are older than 3 - 5 years (standard shelf life may differ slightly in different countries),

only visitors are equipped with brand new self rescuers •and the rest of the workforce is equipped with old, dented ones or none at all (in the case of an incident certain troubles are sort of foreseeable…).

Regarding the question of explosion suppression devices, one tends to get rather aspiring, but often nevertheless outdated answers (Fig. 4):

Your water barriers in Western Europe are by far not 1. safe enough (most of the time under reference to local scientists).

Stone dust barriers are as useful against methane 2. explosions as water barriers.

Using stone dusting for inertisation is entirely sufficient 3. (USA!).

We have stone dust barriers to separate ventilating 4. districts, conveyer belt roadways, and brake inclines.

… and the answer we desire is of course …

A few years ago we have installed water barriers which 5. conform to the EU standard.

Experience tells that the only (barely) acceptable answer in emerging industrial nations is number 4. If there is, at least when reaching one of the described workings, no barrier with 400 kg/m² pulverised Lime or Dolomite stone dust which is capable of becoming airborne (i. e. not sticking) on wooden platforms or in small plastic bags, there definitely is a considerable deficit in this field.

In gas rich mines there must of course theoretically be water barriers in any case, because stone dust barriers are indeed not effective against pure methane explosions and therefore suggest a false feeling of safety. Therefore it is wise to stay away from gas rich mines without water barriers … but then one has to stay away from almost all mines in the world!

Therefore: In the case of the common standard of using stone dust barriers instead of water explosion barriers (Fig. 5), there must be, if one wants to risk a quick glance anyways, at least ample air flow and appropriate measures for dilution and removal of Methane influx in inseam roadways and rock dusting must be carried out area wide, frequently, and carefully.

Answer number 5 is the only acceptable answer! If one gets an answer between number 1 and 4 the first backlog demands are identified, because these solutions are by far not failsafe enough. This also applies if

Fig. 3: Self Rescue

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This may sound severe, but the circumstances stated above are common knowledge and well documented in the mining world for the last 40 years. The time of leniency in this matter must be over for some time now! (Sadly, just as a side note, this also applies for some well industrialised nations.)

Airspeeds of under 0.5 m/s in inseam roadways (this can be estimated e. g. by throwing up fine dust) must be considered to be critical. If Methane concentration or influx is higher, it should/ must be even more; this can be calculated quite precisely with the so called Layering Index. Furthermore, it must be clear that in the case of a maximum permissive Methane concentration of 2 % - which is acceptable in many countries - the return air side of U-ventilation longwall faces is quite unmanageable. Whoever wants to use modern equipment must use advance ventilation in gaseous seams and must run a gas drainage system from at least one goafside road kept open behind the face line!

If advance ventilation is not possible because of certain rock mechanical reasons (difficulties with keeping gate roads open, e. g. no means for proper gateside packing) or not desirable for small scale mining operations in gaseous seams, one is safe for as long as the Methane concentration on the return air side of the longwall remains below 0.5 Vol.-%.

The only acceptable answer to the obvious and pressing question regarding the treatment of coal dust with rock dust (dust binding with calcium or magnesium chloride solution is something you cannot even ask for in most of the cases) is that at least 80 weight percent of rock dust are spread for 20 weight percent of coal dust.

The professional skills of the local engineers can normally quite easily be judged after some conversation. Since the ventilation engineer is the key person in matters of mine safety especially in industrially emerging nations, special attention is advisable here. Besides the topics already discussed, the procedures regarding potential gas outbursts, e. g. test and pressure relaxation drilling, should be explored. Some attention should also be placed on the safety rules and equipment which apply to the use of shearing roadheading and winning equipment.

Fig. 4:Water Trough Barriers

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An especially Precarious Problem - Spontaneous Combustion

One of the main problems which causes mining disasters with massive loss of life worldwide is, besides naked flames and electricity, spontaneous combustion in the goaf (in flat seams) and in the roof of inseam roadways (in steep seams).

Entering a gaseous mine with coal prone to spontaneous combustion requires additional investigations, especially if there is, next to compulsory procedures for the early detection of gasses, no method for effective goaf inertisation which is put into action at the slightest overstepping of the maximum values (as e. g. in Germany, the UK and the Czech Republic).

A visit to the safety control room (Fig. 6), which should be visited for a number of reasons actually, gives a good overview of whether there is such a problem. Do not be fooled by the ventilation network programmer with a marvellous demonstration of his computer program, which runs offline, of course… You are visiting to see the actual and current values!

To be worthy of its name, the control room of a 1.5 million ton mine should gather data regarding CH4, CO and airflow from at least 20 remotely controlled measuring sites. The CO production from the mining sites should not exceed 10 l/min. For any relevant calculation or estimate, the connected air stream must be measured or be well known in terms of dimension to the responsible persons at the control room … possibly there is another certain embarrassment round the corner here!

It also greatly pays to flip back a few pages in the records to make sure one is not touring a Potemkin village here. Special attention should be paid whether the CH4 figures are plausible around the week or if the fans are turned off periodically to safe electricity. The latter is rather dangerous every time the fans are turned back on and there is an increased risk of spontaneous combustion in the goaf. Conclusion: if there is a functioning control room and under 10 l/min CO from each coal winning area underground, the mine can be entered from a spontaneous combustion point of view.

Fig. 5:Stone Dusting to Render Coal Dust Inert

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Further evaluation of the precautions regarding fire hazards (water supply, combustible supports, fire protection of the belt conveyors, spraying and cooling of shearing equipment) and the condition of the auxiliary ventilation systems can quickly and easily be inspected underground. Reasons for immediate abortion (e. g. welding at the face, stalled auxiliary ventilation systems) are quickly detected … judging the quality of the employed flame safety explosives will be rather difficult, however.

Other peripheral Facts - a few Considerations regarding the Human Element

Finally, there is the rest of the peripheral facts. There are, among others, two main factors regarding the operation of a mine: payment of wages (or rather non-payment) and alcohol. If the wages are not paid for some time (in Russia e. g. in Kuzbass for many months in the mid nineties) there is a considerable effect on mine safety for a number of reasons, which cannot be discussed within the frame of this paper.

The same applies for drinking habits. Sometimes a conversation which makes sense is only possible during the late morning, when the worst hangover from yesterday has passed and lunch with fresh streams of hard liquor is still not there.

Both factors are identified rather easily and should be seen as criterions for the exclusion of entering that mine.

Check Lists for the Real WorldTo have the ability to evaluate the dangers connected

with entering a mine abroad without having extensive knowledge of mine safety, the considerations which have been explained so far have been summarised into a guideline in Appendix II. General risks abroad, especially outside the EU, will not be discussed here; an overview can be gathered under www.auswaertigesamt.de in Germany. It is also advisable to find out whether insurance policies regarding health and safety apply outside the EU and if necessary additional insurance should be purchased. Most companies take care of these matters in the form of special policies before sending employees abroad.

Effective Measures against Disasters with massive Loss of Life - the Solution

So finally the question remains of what was the decisive step away from the once dreaded horrible disasters in coal mining with such massive loss of life in Western Europe and especially in Germany.

Fig. 6:The Safety Control Room

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We should forget the direct measures of defence of a moment. Those are present on the highest possible standard, but they are luckily not really needed anymore … they have about the meaning of suspenders going with a belt or of the lifeboats on a modern cruise ship. For a mine in an industrially emerging nation they are of the utmost importance until sufficient prevention has been introduced here too

From the very beginnings of deep shaft hard coal mining •in the 19th century up to today, a powerful ventilation system with exhaust main ventilators and blow auxiliary ventilators (Fig. 7) is at the very base of any preventive measure against explosion. The airstreams in gaseous mines of Western European layout are - not only because of the hot and wet climate - in the neighbourhood of 2 to 3 m³/min for each ton per day, half of that in the coal winning areas. So the minimum airspeed everywhere in the mine is high enough to prevent any Methane layers from forming anywhere in the mine. All airstreams of importance in mined areas, salvage, roadway drivages and around conveyors are surveyed for CH4, CO and airspeed by stationary detectors. The data is transmitted to the surface control room and evaluated by an online computer system.

In the case of the multiple seam mining in deep, gassy •seams typical for Germany, it is only possible to use a system of advance ventilation with active gas drainage from the mined seam and the neighbouring seams in the bottom and roof layers to control the gasses which are set free during mining

We should forget the direct measures of defence of a moment. Those are present on the highest possible standard, but they are luckily not really needed anymore … they have about the meaning of suspenders going with a belt or of the lifeboats on a modern cruise ship. For a mine in an industrially emerging nation they are of the utmost importance until sufficient prevention has been introduced here too.

From the very beginnings of deep shaft hard coal mining •in the 19th century up to today, a powerful ventilation system with exhaust main ventilators and blow auxiliary ventilators (Fig. 7) is at the very base of any preventive measure against explosion. The airstreams in gaseous mines of Western European layout are - not only because of the hot and wet climate - in the neighbourhood of 2 to 3 m³/min for each ton per day, half of that in the coal winning areas. So the minimum airspeed everywhere in the mine is high enough to prevent any Methane layers

Fig. 7:Mine Ventilation, Methane Control

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from forming anywhere in the mine. All airstreams of importance in mined areas, salvage, roadway drivages and around conveyors are surveyed for CH4, CO and airspeed by stationary detectors. The data is transmitted to the surface control room and evaluated by an online computer system.

In the case of the multiple seam mining in deep, gassy •seams typical for Germany, it is only possible to use a system of advance ventilation with active gas drainage from the mined seam and the neighbouring seams in the bottom and roof layers to control the gasses which are set free during mining

When no combustible material is used for support as a first step of preventive fire control measures, the conveyors remained for a long time as the decisive factor along which an unstoppable wildfire could most rapidly spread. From the eighties on only socalled self extinguishing conveyor belts are used (Fig. 8). Such a conveyor belt will burn if

subjected to a sufficiently large fire, but it is required to self-extinguish at least 10 m downwind from such a fire. This quality is tested in a large scale trial before the sample belt is certified

Since the 1970s the abandoned mine workings and fire •zones have been dammed off with explosion proof seals (Fig. 9). Research on a full scale trial by the Society for Experimental Mining Tremonia at Dortmund has shown that such a seal must be of sufficient dimension, airtight and permanent, and that it must be able to stand up to a static load of 5 bar. Explosion proof seal tubes are always installed in a sufficient number to be able to keep up ventilation while the seal is constructed and has to be cut off only after the material of the seal has fully set. For a roadway cross section of about 20 m² the seal has to be two to four meters thick, depending of the quality of the employed material.

Fig. 9:Explosion Proof Seal

Fig. 8:Fire Drill/ Test of Conveyor Belt in Self Extinguishing Quality

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To keep spontaneous combustion in the goaf under •control, a system of local inertisation within the goaf to the rear of the advancing face by means of Nitrogen has been developed in the nineties to such a degree that mining can be resumed safely under certain conditions while the fire control operation is still underway (Fig. 10). The precondition for that is an advance ventilation layout and tightly set boundary values for explosive gasses in the goaf. The concentration of explosive gasses in the stray ventilation airstreams should never exceed 50 % of the Lower Explosive Level (LEL) when regularly tested through the sniffing pipes. If necessary Nitrogen must be injected into the goaf on the basis of the values gathered from the sniffing pipes to uphold safe conditions in the stray ventilation.

Special attention should be placed on gasses appearing •close to possible fire hazards such as e. g. shearing winning or roadheading equipment. Therefore the spray systems installed on shearing winning or roadheading equipment are not only designed to keep down respirable dust, but to also suppress a possible ignition of a possibly present Methane Air Mixture. Furthermore, the problem of gasses which locally enter the mine requires, most of all, a keen eye for ventilation to be able to introduce systems of dilution and ventilation in due time.

OutlookIndustrialization and democratization of a community

raise the meaning of workplace safety. Higher wealth for mentionable parts of the general public as well as a perspective for the future give way to an increasing general acceptance of ethical fundamentals with regard to the protection of human life. In a balanced action and reaction with the process described, in a more technology-based and wealthier society the costs resulting from accidents may grow higher than the costs of preventive and protective safety measures. Together with this, occupational health and safety becomes, along with productivity, an essential prerequisite for a profitable business. The steps towards more health and safety require a realistic view and the acceptance that the introduction of workers safety according to international best practice will be a sensitive process lasting years. Since for economical reasons the safety level in emerging nations mining usually cannot be adapted to international standards in one go it is recommended to proceed towards improvement stepwise according to a list of priorities. The proposed priority list with examples reflects the experiences out of mines rescue work and of development projects gained since 1990 in Turkey, Estonia, China, Russia and Bulgaria

Bibliography[1] Langer, G.; Hermülheim, W.; Bresser, G.: Better fire and explosion protection and improved mine rescue in hard coal mining of countries in transition to industrialization. 27th International Conference of Safety in Mines Research Institutes, New Delhi 1997

[2] Hermülheim, W.: Organization and Training of Volunteer Mine Rescue Brigades. 32nd Int. Conf. of Safety in Mines Research Institutes, Beijing 2007

[3] Hermülheim, W.; Beck, K.-D.: Inertization as Means for Reducing Down Time and the Explosion Risk in Cases of Spontaneous Combustion. Proceedings 6th Int. Mine Ventilation Congress, Pittsburgh, 1997, S. 299 - 303.

Fig. 10:Preparation of a Goaf Inertisation

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Dr. Walter Hermülheim is a graduate of Aachen Technical University where he started his career in mining in 1984 as research assistant in the field of strata mechanics.After subsequent line- and staff-positions in the German coal mining industry he is since 2009 deputy to the head of the main department for occupational health, safety and environment of RAG Aktiengesellschaft, Herne. His research projects and practical experience cover various aspects of mine safety and resulted in more than 40 papers, including a new mines rescue handbook which was published in 2007. He is holding a lectureship on underground fire fighting and mines rescue at Clausthal Technical University. Dr. Hermülheim is member of the German Mines Rescue Committee (DA GRW), deputy member of the EC Advisory Committee on Safety and Health at Work (ACSH) as well as Chairman of the EC Standing Working Party for the Mining and other Extractive Industries (SWP) in Luxembourg.

Contact:Central Division for Health

Safety and Environmental Protection ZB 3RAG Aktiengesellschaft

44620 Herne

| [email protected] | www.rag.de |

[4] Hermülheim, W. et al.: Handbuch für das Grubenrettungswesen im Steinkohlenbergbau. VGE-Verlag, Essen, 2007

[5] Hermülheim, W.; Schumachers, R.; Dauber, C.: Occupational Health and Safety and Hazard Control in Coal Mines. Safety Projects in Countries in Transition to Industrialization - Part 1: Fundamentals of Mine Safety and Hazard Control. Glückauf Mining Reporter I/ May 2009 (e-journal www.mining-reporter.com)

[6] Hermülheim, W.; Schumachers, R.; Dauber, C.: Occupational Health and Safety and Hazard Control in Coal Mines. Safety Projects in Countries in Transition to Industrialization - Part 2: Safety Management Systems, Safety Training and Pilot Projects. Glückauf Mining Reporter III/ Oct. 2009 (e-journal www.mining-reporter.com)

[7] Martens, P. N.; Hermülheim, W.: Disaster Prevention in deep Hard Coal Mining - a German Review. Keynote Lecture - Proc. SME Annual Meeting, Phoenix, Arizona, Febr 28th - March 3rd, 2010

[8] Hermülheim, W., Betka, A.: A safe method for cutting down Production Loss after a Mine Fire. Glückauf Mining Reporter IV/ Apr.2010 (e-journal www.mining-reporter.com).

www.advanced-mining.comWWW.ADVANCED-MINING.COM

http://www.rag.de

http://www.advanced-mining.com


35Issue 03 | 2011



HeidelbergCement and BirdLife International become co-operation partners -

ON 16 SEPTEMBER 2011, HEIDELBERGCEMENT AND THE INTERNATIONALLy RECOGNISED NATURE CONSERVATION ORGANISATION BIRDLIFE INTERNATIONAL HAVE SIGNED A CO-OPERATION AGREEMENT. THE PRIMARy GOAL OF THIS PARTNERSHIP IS TO FURTHER IMPROVE THE PROTECTION OF BIODIVERSITy AT qUARRyING SITES.

HeidelbergCement AG Heidelberg | Germany

Jointly preserving biological diversityHeidelbergCement expects that this collaboration will

further strengthen its leading role in the promotion of biodiversity at quarrying sites. As early as 2009, the Group was the first company in the international building materials industry to issue a binding guideline on biodiversity management.

„We are pleased that, in BirdLife International, we have been able to attract a highly competent partner for the further development of our biodiversity management”, said Dr. Bernd Scheifele, Chairman of the Managing Board of HeidelbergCement AG, who personally signed the co-operation agreement. “Together, we will analyse and optimise our existing work and define new activities in order to promote the preservation of biodiversity at our quarrying sites even more effectively.“

„This open and cooperative collaboration should also send a message to our stakeholders. We will give BirdLife insight into the workings of our quarries and sand and gravel pits throughout the Group and implement biodiversity management projects at these sites together. These projects should make our impact on flora and fauna transparent, assess the effects, and deliver improved approaches that will allow us to give back to nature more than we have taken.“

“We are delighted to enter in this relationship with HeidelbergCement, a pioneer in integrating environmental sustainability in the activity of extracting resources, and we feel confident that together we can not only reduce the impact but actually obtain an overall positive net benefit for biodiversity at HeidelbergCement quarries all over Europe“, said Dr. Marco Lambertini, Chief Executive of BirdLife International.

”Through the unique BirdLife structure of national and membership based nature conservation organizations across the whole of Europe, we will be able to support action at site level while maintaining an overall strategic oversight. I am confident that the outcomes of this collaboration with HeidelbergCement will prove to make a real difference in fulfilling the potential many quarries hold for biodiversity.“

The co-operation is initially scheduled to last three years. In the first year, a biodiversity strategy for the partnership will be developed jointly. The strategy will also include goals for the protection of species and habitats. In the second year, joint biodiversity projects will be formulated in different countries. Local management, in particular, will be involved, alongside the national partners of BirdLife International. From the third year, the first pilot projects in Europe will then be implemented and documented.

Fig. 1:Dr. Bernd Scheifele,

Chairman of the Managing Board of

HeidelbergCement AG

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About HeidelbergCementHeidelbergCement is the global market leader in

aggregates and a prominent player in the fields of cement, concrete and other downstream activities, making it one of the world’s largest manufacturers of building materials. The company employs some 55,000 people at 2,500 locations in more than 40 countries.

About BirdLife InternationalBirdLife International is the world’s largest partnership

of national civil society nature conservation organisations and the world leader in bird conservation. It holds a large grassroots membership, in 117 countries and territories. BirdLife works to conserve wild birds, their habitats and global biodiversity, by working with people towards sustainability in the use of natural resources. Within the framework of its global strategy, BirdLife seeks to work together with business towards sustainable use of natural resources. BirdLife particularly wants to engage where the partnership‘s unique structure and skills can make a special contribution. www.birdlife.org

About BirdLife EuropeBirdLife Europe is the European Division of BirdLife

International and is one of the six BirdLife regional offices around the world. Stichting BirdLife Europe supports the European and Central Asia Partnership of BirdLife International, which consists of 45 independent, grassroots civil society organisations, governed by a democratic programme. http://europe.birdlife.org

HeidelbergCement is the global market leader in aggregates and a prominent player in the fields of cement, concrete and other downstream activities, making it one of the world’s largest manufacturers of building materials. The company employs some 53,400 people at 2,500 locations in more than 40 countries

Contact:HeidelbergCement AG

Berliner Straße 6 69120 Heidelberg

Tel.: +49 (0)62 21 - 481-0 | Fax: +49 (0)62 21 - 481-540| [email protected] | www.heidelbergcement.com |

MORE INFORMATION AND CONTACT:

BirdLife EuropeAvenue de la Toison d‘Or 67

1060 Brussels | BelgiumTel.: +32 (0) 22 - 800 830Fax: +32 (0) 22 - 303 802

Internet: www.birdlife.org

http://www.heidelbergcement.com

37Issue 03 | 2011



Sandvik – cone crusherSandvik introduces two new mining cone crushers - CH890 and CH895

Sandvik Mining and Construction Sandviken | Sweden

The specially designed, strength-optimized topshell and dedicated crushing chambers of the CH895 model make it ideal for tertiary and pebbles crushing while the CH890 topshell and crushing chambers are dedicated to secondary crushing. Both units have more power and increased crushing force in order to increase productivity. Manfred Schaffer, President Surface Mining at Sandvik Mining and Construction, says: “The heavy-duty structure and 1000 horsepower are what first meet the eye. But it is the specialized geometries and smart crushing features that uniquely drive efficiency and throughput. We call this ‘Dedicated by Design’.”

Thanks to their specialized geometries, 1000 horsepower, greater structural strength and proven technologies, the newly launched CH890 and CH895 are designed to increase performance in both secondary and tertiary/pebble crushing applications.

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The new mainshaft, made from a new high-strength material, is designed to withstand harsh mining requirements while the strength-optimized bottomshell design allows for greater loads. Simply stated, the heavy-duty structural design ensures durability and longevity in the most demanding conditions.

Further customer improvements, for increased safety and minimized downtime, include a relocated external dump valve and a new over pressure system to keep the lubrication oil clean, thereby increasing time between service.

Customers will also recognize the trusted cone crusher design from Sandvik with its hydraulically adjusted mainshaft and proven ASRi™ control system to facilitate online adjustment during full load and ensure peak performance at all times.

“The CH890 and CH895 crushers have been dedicated to specific applications while sharing the same platform for easy service and support which should facilitate efficient inventory management and parts forecasting”, adds Manfred Schaffer.

FOR MORE INFORMATION AND CONTACT:

Sanvik Mining and Construction Vice President Equipment, Surface Mining-

Gregg ScanlanTel.: +43 (0)316 - 90 26 26 503

eMail: [email protected] Internet: www.sandvik.com

Sandvik Sandvik is a global industrial group with advanced products and

world-leading positions in selected areas – tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2010 the Group had about 47,000 employees and representation in 130 countries, with annual sales of nearly SEK 83,000 M.

Sandvik Mining and Construction is a business area within the Sandvik Group and a leading global supplier of equipment, cemented-carbide tools, service and technical solutions for the excavation and sizing of rock and minerals in the mining and construction industries. Annual sales 2010 amounted to about SEK 35,200 M, with approximately 15,500 employees.


39Issue 03 | 2011



Wirtgen GmbH has meanwhile been acknowledged as the technology leader in surface mining worldwide: machines for the mining of rock by cutting have been developed for opencast mining since the end of the 1970s. Wirtgen is the sole manufacturer to have continuously pressed ahead with the development of surface mining equipment for mining rock by cutting, setting innovative standards in this technology. The biggest challenge consisted in introducing the surface mining technology as an alternative to conventional mining methods, such as drilling, blasting and crushing, and to demonstrate to customers the performance, economic efficiency and environmental friendliness of the method in most diverse applications. Wirtgen opened up a long-term market in this field, and has continued to expand it over the years.

The machine population currently comprises more than 350 machines in all parts of the world; in particular customers in Western and Eastern Europe, North Africa, the Middle East, Australia, India and North America enjoy the advantages offered by the surface miners.

Product portfolio: range of basic machines and cutting drums

With the 2200 SM, 2500 SM and new 4200 SM, Wirtgen offers its customers three tried and tested performance classes which can be equipped with a large variety of options and customized to specific project requirements. All models can be designed for loading the material into dump trucks or depositing it as a windrow behind the machine. Over two dozen drum designs with, for instance, different tool spacings are available for the machines as standard cutting drums while additional special designs are developed and built to meet specific application requirements.

Wirtgen group WIRTGEN SURFACE MINING TECHNOLOGIES: UNMATCHED PERFORMANCE RANGEIN 1980, WIRTGEN GMBH BUILT THE FIRST SURFACE MINER FOR THE MINING OF MINERALS IN OPENCAST

DEPOSITS. TODAy, WIRTGEN IS THE MARKET LEADER IN THIS SEGMENT, OFFERING A TECHNICALLy MATURE PRODUCT PORTFOLIO FOR OPENCAST MINING WHICH HAS BEEN TRIED AND TESTED IN OPERATIONS AROUND THE GLOBE. SURFACE MINERS FROM WIRTGEN OFFER CUTTING WIDTHS RANGING FROM 2.20 M TO 4.20 M AND CUTTING DEPTHS OF BETWEEN 20 CM AND 83 CM. WIRTGEN IS THE ONLy MANUFACTURER COVERING A SCOPE OF PERFORMANCE RANGING FROM 100 TONS TO 3,000 TONS PER HOUR. THIS MEASURE OF PRODUCTIVITy IS ATTRIBUTABLE TO THE MINERS’ EFFICIENT CUTTING TECHNOLOGy AND A WEALTH OF EXPERIENCE GAINED IN NEARLy THREE DECADES OF APPLICATIONS TECHNOLOGy.

Australia, iron ore: 20 high-production surface miners type 4200 SM and 2500 SM are mining iron ore in Western Australia. The deposit has been entirely organized for use of the surface mining technology right from the start.

Guinea, bauxite: The 2500 SM enables the selective and highly cost-efficient mining and processing of material in this mine as it dispenses with both blasting and primary crushing.

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The 2200 SM surface miner offers cutting widths ranging from 2.20 m to 3.80 m for most diverse rock hardnesses up to an unconfined compressive strength of 50 MPa. The front loader is used for the mining of, for example, gypsum, soft limestone or coal. A special, 3.80 m wide cutting drum assembly is available for this surface miner model which impresses with high production rates in particular when applied in soft rock, such as coal.

The 2500 SM rear loader is used for the selective mining of medium-hard to hard rock with unconfined compressive strengths of up to 80 MPa. It has a cutting width of 2.50 m and cutting depth of up to 60 cm. The machine can be supplied in reinforced design to enable rock of up to 120 MPa or higher to be mined in special earthwork and rock operations.

The new, enhanced design of the high-performance 4200 SM, the largest surface miner model, incorporates the findings and field experience gained with the 2500 SM and its predecessor model, the 3700 SM, on construction sites around the world. The 4200 SM has a working width of 4.20 m and is available in two different versions. The 4200 SM for soft rock is capable of cutting materials with unconfined compressive strengths of up to 50 MPa, such as coal, at cutting depths of up to 83 cm. The 4200 SM for hard rock is used as a high-end miner for the mining of medium-hard to hard rock with unconfined compressive strengths of up to 120 MPa, and is capable of cutting at depths of up to 60 cm. It is suitable not only for opencast mining but also for use in rock operations or trench construction.

Cutting technology: made to measure for any application

Wirtgen’s mining expertise is based mainly on the extensive know-how in applications technology. The effectiveness and strength of the solutions offered lie in particular in the field of cutting technology.

Each basic machine in the three performance classes offered by Wirtgen can be adapted to most diverse materials depending on the customers’ requirements or project-specific conditions. This applies in particular to the cutting drum, which is the core component of the surface miner technology. In addition to the mature range of standard cutting drum assemblies on offer, both the number of cutting tools and the tool spacing on the drum can be individually adapted to comply with the customer’s goals. The right cutting technology will then enable the material to be mined at the specified grain size, and the required cutting performance to be achieved.

Turkey, salt mining: Precise milling of a thin salt layer using a W 2000 modified to a “salt harvester”. Similar operations are carried out in Australia.

India, coal: Simplified mining of high-quality coal of small grain sizes using the 2200 SM. The special, 3.80 m wide cutting drum assembly ensures high production rates.

USA, gypsum: The 2200 SM is producing the specified grain sizes immediately during the gypsum mining operation, thus enabling the material to be mined and processed in a simplified operation at low cost.

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In addition to the standard drums available for the 2200 SM, 2500 SM and 4200 SM models, Wirtgen GmbH is capable of developing and building special cutting drums in an extremely short period of time, the entire technical specification of which is tailored to accurately fit the operation and project at hand.

The effective performance of the Wirtgen cutting technology covers rock hardnesses ranging from less than 10 MPa to up to 120 MPa or even higher in special applications. The surface miners are primarily used for mining limestone, coal, gypsum and iron ore, but special operations in salt mining, granite, bauxite, phosphate or oil shale are also part of the miners’ current scope of applications.

Wirtgen offers heavy-duty components for reduced wear and tear, easy maintenance and fast tool replacement also in the field of toolholder systems. A significant advantage of all the toolholder systems on offer is that the upper parts can be replaced on site quickly. In addition to the tried and tested HT6 and HT11 toolholder systems, the new heavy-duty HT14 toolholder system has been developed for use in the 2500 SM and 4200 SM models. The HT14 system is useful in applications where high hourly production rates are achieved, high annual mining capacities are realized, and hard, highly abrasive material needs to be mined. A special, battery-driven cutting tool extractor is available for this system, which considerably facilitates the replacement of tools and minimizes the time required to do so.

In addition to the choice of toolholder systems, Wirtgen GmbH offers a comprehensive range of mining tools comprising in excess of 50 cutting tool types optimized for wear and tear and suitable for most diverse applications and types of rock.

Applications technology: the Wirtgen Surface Mining ManualInternational experts at Wirtgen GmbH have pooled the

knowledge on everything to do with applications technology on more than 170 pages, visualized by means of instructive illustrations, photographs taken on job sites, and performance diagrams. The Mining Manual can be downloaded from Wirtgen GmbH’s website at www.wirtgen.com or ordered with the Mining Division at [email protected]. The manual describes the performance and process capabilities of the Wirtgen surface miners. It helps customers to choose the right machines for their intended applications or requirements.

Russia, limestone: Two 2500 SM surface miners are working simultaneously in a quarry, achieving high production rates. The material is directly loaded into trucks.

Estonia, oil shale: Selective mining of thin, horizontal seams of oil shale with the 2500 SM. Selective mining generally produces material of high quality.

Japan, granite: A customized 2500 SM is cutting precise foundations in hard granite in the vicinity of residential areas and railway lines without blasting and therefore without harming the environment by creating noise, dust and vibrations.


Wirtgen GmbH - Press RelationsReinhard-Wirtgen-Straße 2 53578 Windhagen | GermanyTel.: +49 (0)26 45 - 1 31-0 Fax: +49 (0)26 45 - 1 31 499eMail: [email protected] Internet: www.wirtgen.de

http://www.wirtgen.com

http://www.wirtgen-group.com

42Issue 03 | 2011



Brazil on the road to success with a Sandvik mobile trainSandvik QA450 triple deck screener, QH330 cone crusher and QJ340 jaw crusher

Sandvik Mining and Construction Sandviken | Sweden

Founder and Managing Director, Rogerio Baltt, spotted a niche in the market back in 1980 and started up his own transport company in the Itajaí valley region, Santa Catarina. This same entrepreneurial vision took him to acquire a quarry in 2005, in a period where the country was fast consolidating its position as one of the second biggest emerging world economies after China. The success of his business saw his fleet grow from a single used lorry, to more than thirty lorries as well as quarry and road construction equipment, helping to boost the economy of the southern region of Brazil along the way.

Among the main reasons for the acquisition of the three Sandvik machines are their productivity, mobility and design. The crushers and screener are track mounted and hydraulically driven, which allows them to work at the deposits along the BR-222 motorway. The units can be quickly relocated to a new area of the project as required, which makes them ideal not only for their flexibility but also for the cost efficiency of their quick set up. With the operator’s safety as priority, Sandvik units are designed and manufactured to all CE certification and safety standards ensuring ease of operation as well as peace of mind.

Sandvik proves once again to be a success in Brazil with the installation of a Sandvik train of mobile crushers and screens. In the city of Irauçuba, in the Ceará state close to the equator in the northeast of Brazil, the Sandvik qA450 triple deck screener, qH330 cone crusher and qJ340 jaw crusher are taking an active role in the renovation works on the BR-222 motorway, which joins the cities of Fortaleza and Sobral. Baltt Empreiteira Transportes e Terraplenagem Ltda. and the company CAMTER, which is hiring the equipment from Baltt, are pioneers of this crusher and screener set up in the biggest country in South America.

The material being processed is granite. The blasted 600 mm material is first processed by the Sandvik QJ340 jaw crusher. The high crushing speed of its 1250 x 750 jaw, together with its reverse crushing action function, permits a continuous flow of product into the second machine on the train: the Sandvik QH330 cone crusher. At a 28 mm CSS position, the material is further reduced from 100 to 25 mm. The material processed by the three foot Sandvik CH430 cone crusher fitted on the mobile unit, is of excellent shape and quality, thanks to the CSC (cubical shaped crushing) technique developed by Sandvik. Finally, the QA450 triple deck doublescreen, with a screening surface equivalent to a 20’ x 5’ area (6 x 1.5 m), produces -6, 6-12, 12-19 and +19 mm final products at a rate of 160 mtph (176 stph). The length and design of the four conveyors, allows a stockpiling capacity of over 5 metres and the possibility for it to be used in a recirculation mode with the QH330, with a potential to augment the quality of the final product even more.

43Issue 03 | 2011



Rogerio Baltt is clearly impressed with this latest Sandvik acquisition from the Santa Catarina dealer, Jok´s Equipamentos para Mineração Ltda: “we are extremely pleased with this new Sandvik purchase. The machines are well built, easy to set up and operate, which in this remote area, is invaluable”. With the back up of Sandvik’s cutting edge technology and first class global after sales support, this set up is destined to be a hit.


Sanvik Mining and Construction Marketing Communications,

Mobile Crushers and Screens Melissa Baker

Tel.: +44 (0)12 83 - 21 21 21eMail: [email protected]

Internet: www.sandvik.com

Sandvik Sandvik is a global industrial group with advanced

products and world-leading positions in selected areas – tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2010 the Group had about 47,000 employees and representation in 130 countries, with annual sales of nearly SEK 83,000 M.



44Issue 03 | 2011



ADVERTISEMENT

ContiTech Conveyor Belt Group | Phone +49 5551 [email protected]



http://www.contitech-online.com/tx

45Issue 03 | 2011



Bulk Materials Handling 2011 ”Systems - Components – Computer Simulations”

by Andre HankeF.E. Schulte Strathaus GmbH & Co. KG

Werl | Germany

Common problems with transfer points

Conveyor-belt cleaning: A 0.1mm thick layer that is not scraped from a 800mm wide belt running at a

speed of 1.5m/s and drops beneath the conveyor belt translates into a material loss of 3.5m3 in 8 hours.

This material:Must be removed•

Wears belt rollers and belt•

Can only be returned to the process to a limited extent •

Contributes to dust exposure and environmental pollution•

Dust exposure is a problem for belt conveyor operators more and more often.

Environmental burden•

Health protection at the workplace•

This is why optimal conveyor-belt cleaning is increasingly important.

Belt–saving operation:Damage caused to a conveyor belt by the wrong choice of belt cleaner:

The conveyor belt complete with installation is the biggest cost factor in belt conveyor installations.

Inflexible or stationary conveyor-belt cleaners can cause damage such as slashes but also accelerate cover wear by a factor of 2-3.

Sample calculation: Belt length 100m, belt width 800mm, €50/m (plus joint 1,000€) = €6,000

Normal service life e.g. 5 years => €1,200 per year• Wear factor 2-3 => €2,400€ to €3,600 per year •

Belt length 500m, belt width 1,400mm, €100/m (plus joint €2,000) = €52,000Normal service life e.g. 5 years => €10,400 per year• Wear factor 2-3 => €20,800 to €31,200 per year •

Fig. 1:Poorly cleaned conveyor belt

Fig. 2:Bulk material accumulating underneath a belt conveyor

Fig. 3:Damaged conveyor belt

Fig. 4:Conveyor belt with longitudinal grooves

46Issue 03 | 2011



Maintenance of conveyor-belt cleaners:Premature wear •

Complicated and time-consuming replacement of wear parts •

Plenty of training required for maintenance personnel •

Sealing of transfer points

Problem 1: Material drops from the sides of the conveyor belt and rolls backwards out of the transfer area.

Problem 2: Dust formation

Belt misalignmentBelt misalignment results from various factors:

Unbalanced material feed •

Slanted belt joints •

Changing weather conditions•

Poorly aligned belt conveyors•

Malfunction of belt rollers•

Especially with older installations belt misalignment can often not be economically remedied by removing the aforementioned factors. Misalignment causes sealing problems, makes material drop from the belt and results in premature wear of pulleys, belt and rollers.

Impact problemsLarge lumps of agglomerated material paired with the

height of fall may damage the conveyor belt.

Fig. 5:Insufficiently sealed transfer point

Fig. 6:Dust forms due to insufficient

sealing of the transfer point

Fig. 7:Belt misalignment problems in practice

Fig. 9:Transfer of large lumps of agglomerated material

Fig. 8:Misalignment problems in practice

47Issue 03 | 2011



Scraper Technology

Individual adjustment of all scraper segments to the conveyor belt:

Thanks to the special geometry of the insertion base each scraper blade can optimally adjust to the belt in the event of both wear and irregularities.

Polyurethane blade:Generally high wear volume•

Scraper blades wear faster in the centre than •at the side due to the higher load applied to the centre of the conveyor belt.

Therefore there must be sufficient power to press the •blades in the centre to the belt surface

But the external blades that are still longer must not be-•pressed to the surface too hard (belt damage)

Secondary scraper:Desired flexibility is achieved by a polyurethane footing/•base

Towing operation to ensure perfect adjustment and •make way for obstacles

Blade insert rotates 360° •

Overlapping carbide blades:Clean consistently over the entire scraping •width

Avoid belt wear and blade base wear bet-•ween the blade inserts

Scraper replacement without tools:Plug-in mechanism to connect blade with •blade base

No screws or pins needed •

Quick change•

No problem caused by soiling•

Fig. 10, 11, 12:Primary scraper, secondary (main scraper), internal belt scraper

Fig. 13 and 14:Examples of head scrapers that

“auto-compensate” for wear

Fig. 15:Flexible scraper blade for

optimal adjustment

Fig. 16:Degrees of freedom of flexible secondary scraper blades

Fig. 17:Degrees of freedom of flexible

secondary scraper blades

Fig. 18 and 19:Carbide scrapers with overlapping blade inserts

Fig. 20:Blade replacement without tools

48Issue 03 | 2011



“Smart” tensioning devicesPre-tensioning dial •

Automatic locking gear for easy, single-handed tensioning and •releasing

Steel leg springs for operation irrespective of temperature and ageing•

Long suspension travel – in combination with the force stored in the •blade – reduces re-tensioning to a minimum

Fig. 21:Torsion-tensioning device for use at the discharge pulley

Fig. 22:Modular design

Modular designOriented towards the specific given bulk materials handling problem •

For a wide variety of bulk materials, footprints, surrounding conditions •

Investment possibility •

Composing the optimal system from components•

Compatibility of parts•

Dimensioning of components:Components can be adapted to:

Belt speed•

Type of bulk materials (e.g. abrasiveness, stickiness, moisture content)•

Frame width, belt width•

Spatial conditions•

Required service life•

Primary scraper at the pulley:Required for substantial material build-up as pre-scraper used •in conjunction with a secondary scraper

Suitable for sticky and caking materials•

Secondary scraper at the pulley:As a single carbide scraper at the pulley•

Suitable for extremely abrasive materials•

Fig. 23:Dimensioning of components

Fig. 24:Carbide scraper at the pulley

49Issue 03 | 2011



Secondary scraper in the road (between pulleys):Used as a secondary scraper in conjunction with a pre-scraper •for strong build-ups

Used as a single scraper for medium build-ups•

Suitable for extremely abrasive materials •

Optimal, finest cleaning •

Secondary (high-precision) scraper for use in the road with automatic swivel unit:

Movement results from the belt direction of movement •and the friction between blade and belt

No need for pneumatic, hydraulic or electric drives•

Installation position: between 6 o’clock pulley position •to a suitable point in the road

Carbide blade with polyurethane footing – speeds up to •approx. 6 m/s

Belt widths up to approx. 2m•

Belt Tracking

Belt misalignment causes the following problems:Damage to conveyor belt •

Material loss•

Soiling of the surroundings •

Wear of conveyor rollers•

Cut-off by off-track governor•

Types of tracking systems: slack side tracking, 1-piece45° bearing •

Diamond profile rubber•

Designed for belt installation with one conveying direction •

Internally arranged, completely protected bearing•

Instant response•

Low maintenance •

Types of tracking systems: slack side tracking system, 3-piece

Conical side rollers •

Diamond-profile, wear-resistant rubber lining •

Pivot bearing in an oil bath, sealed dust-proof •

For belt installations with one or two conveying directions •

Heavy-duty dimensioning•

Instant response •

Low-maintenance •

Fig. 25:High-precision carbide scraper for use in the road

Fig. 26:High-precision scraper in the road with automatic swivel unit

Fig. 27:Tight side tracking systems

Fig. 28:1-piece slack side tracking

Fig. 29:Reversible slack side

tracking system

50Issue 03 | 2011



ATypes of tracking systems: tight side tracking system, 3-piece

Conical side rollers •

Diamond-profile, wear-resistant rubber lining •

Pivot bearing in an oil bath, sealed dust-proof •

Designed for belt installations with one or two conveying •directions

Heavy-duty dimensioning•

Gradually adjustable to the trough design of the belt installation •

Instant response•

Low-maintenance•

Benefits of the presented belt tracking systems:

Instant alignment effect •

No need for lateral guide rollers•

Prevents belt damage and premature component •wear

Prevents material loss and soiling •

Minimisation of maintenance costs•

No installation down-time caused by off-track •governor

Fig. 30:Reversible tight side steering system

Fig. 31:Tight side tracking systems

Sealing of transfer pointsKey here is individual pressure adjustment

to compensate for unbalanced wear and height differences. The sealing rubber must have a lower Shore hardness than the conveyor belt.

Benefits of segmented sealing systems:Individual adjustment to the conveyor belt •

Segments can be individually reset •

Only worn blocks need to be replaced •

High wear volume •

Optimal sealing•

Resource-saving design •

Fig. 32:Optimally sealed transfer point

Fig. 33:Optimally sealed

transfer point

51Issue 03 | 2011



Impact damping

Impact damping stations for material-saving bulk feed:

Improved guidance for the belt•

Belt-saving operation due to optimal setting •

Additionally belt-saving material feed •

HDPE rail with low friction value •

Vulcanised connection between HDPE and rubber •damper

Impact damping stations for improved sealing in conjunction with chute sealing systems:

Form-fit and friction-locked connection between the •impact components and the steel structure

Angle is adjusted to the trough design of the conveyor •belt

Bayonet fixing for impact strip •

Modular design •

Fig. 34:Complete impact table and selection aid for impact systems

Fig. 35:Complete impact table and

selection aid for impact systems

Fig. 36:Sealing support due to optimal belt guidance

Fig. 37:Impact table set-up

Andre Hanke

Contact:F.E. Schulte Strathaus GmbH & Co. KG

Runtestraße 42 59457 Werl

Tel.: +49 (0)29 22 - 97 75-0 | Fax: +49 (0)29 22 - 97 75-75| [email protected] | www.schulte-strathaus.de |

choice of correct impact elements:

heig

ht o

f im

pact

(m)

max. size of medium (kg)

http://www.schulte-strathaus.de

52Issue 03 | 2011



Conveying Technology: BEUMER HIGH CAPACITY BELT BUCKET ELEVATORSQuality and tradition

Quality and tradition BEUMER has established a leading market position for the supply of bucket elevators and has done pioneer work in the field of high capacity bucket elevators. With the development of high quality, patented steel cable belts, their endless connection methods and the appropriate bucket mountings, the conditions were created for today‘s generation of high capacity belt bucket elevators with heights above 150 m, which are capable of handling material flows of 1,700 m3/h and over.

Chain bucket elevators as well as belt bucket elevators have proven their reliability in thousands of applications during operations under the most difficult and even extreme conditions. For difficult and specific requirements, special bucket elevators are available.

Der Standort im dänischen Aarhus. Jetzt auch mit einem Büro für die Geschäftsbereiche Fördern und Verladen, Palettieren und Verpacken.

BEUMER Maschinenfabrik GmbH & Co. KG Beckum | Germany

Bucket elevatorsBucket elevators for the mechanical, vertical

transportion of materials have become a crucial link in the production process in many industrial sectors. Actual industrial requirements have led to the development of high capacity bucket elevators with belts or chains as traction elements, which have allowed BEUMER to decisively influence the technology of the designs which are in operation today. This is proven by the large number of industrial installations as well as the implementation of specialized applications for extreme requirements.

The BEUMER technology has paved the way for the largest bucket elevators in the world.

Thousands of supplied installations as well as a large number of satisfied customers give evidence of belt and chain bucket elevators being an economical and reliable conveying method.

High capacity belt bucket elevators

The specific conditions of the individual applications are decisive for the type of the traction element to be used. Belt bucket elevators are mainly used for the transport of high capacity flows of powdery and fine products at long center distances. High capacity belt bucket elevators are a reliable conveying means that ensures a high degree of availability and a long service life.

53Issue 03 | 2011



BEUMER technology – the reliable solution of your transport duties

BEUMER high capacity belt bucket elevators with steel-reinforced belts as traction elements are especially suited for the transport of fine materials.

In many industrial sectors, BEUMER high capacity bucket elevators are used for the vertical transport of bulk materials.

Thanks to the low energy consumption of mechanical conveyors, which is many times lower than that of pneumatic conveyors, high capacity belt bucket elevators are in operation all over the world. Examples of this would be in feeding silos, as well as preheaters for kilns in the cement industry.

The users of the BEUMER technology benefit from low operating costs, a high reliability and a long service life of their machines, thus strengthening their competitive position.

Conveying capacities of more than 1,700 m3/h and center distances over 150 m are possible

If a belt is used as the traction carrier and the bucket spacing is optimized, conveying speeds can be achieved which permit transport volumes of more than 1,700 m3/h.

Bucket widths ranging between 160 mm and 2,000 mm are available to achieve the required transport volumes up to the maximum.

Conveying heights over 150 mThe belts are reinforced with steel wires, which are

arranged in a special way, so that center distances in excess of 150 m are possible. Depending on the combination of conveying rate and bucket filling level, belts are available with appropriate strengths that can be used, taking into account the required safety factors.

Long service lifeThe special connection between the

bucket and belt reduces the wear of the belt to a minimum, thus avoiding the tearing out of the bucket during operation thereby ensuring a long service life and profitable operation of the machine.

Maximum reliability of operation

The proven machine components of the BEUMER bucket elevator technology are the basis of a high reliability and a trouble-free operation.

54Issue 03 | 2011



The bucket elevator headBesides the housing construction, the bucket

elevator head consists of the following functional groups: the drive pulley, the drive unit, the material discharge with discharge plate and the dedusting connection.

The power transmission at the drive pulley takes place through friction between the pulley and the belt. By the use of rubber lagging (segmented), the friction factor between belt and pulley can be increased. The belt tracking is automatically controlled by the crowned face of the drive pulley. For capacities as low as 15 kW, the drive unit is furnished with a hydrodynamic coupling to reduce starting power consumption and as an overload protection and an inching drive.

An adjustable discharge plate in the discharge area minimizes the carryover and fallback of material. For inspection and maintenance works, appropriate service doors are located in suitable places in the bucket elevator housing.

A platform can be arranged all around the bucket elevator head as an option, in order to permit the access to all machine parts.

The bucket elevator bootIn the bucket elevator boot, the material is fed via the

inlet chute directly into the buckets. Material missing the target is scooped out of the bucket elevator boot. The gravity type parallel tensioning device ensures perfect belt tracking and acts as a guide between belt and return pulley. The tension pulley is designed as a bar drum. Trickling material is removed by a double cone, which is arranged in the bar drum. In this way, circulating material cannot be caught between the belt and the pulley and belt damage is avoided.

The bucket mountingDepending on the material size, two different

types of bucket connections are used for BEUMER high capacity belt bucket elevators, i.e. the mounting with split segments (pictures 1a and 1b) and the rubber-batten mounting (picture 2). If the buckets are connected with bucket screw mountings, they

Bucket elevator head

Bucket elevator boot

55Issue 03 | 2011



are frequently torn out and for this reason, this type of connection is not used. The material size is a criterion for the selection of the mounting type. The segment mounting is used for sizes of up to 25 mm. For sizes ranging between 25 and 60 mm, the rubber-batten mounting developed by BEUMER is used (for temperatures of up to 70 °C).

The segments form a closed strip on the bucket back side, so that all forces acting on the belt are equally distributed to the steel wires embedded in the belt, thus making it impossible for the buckets to be torn out of the belt. An intermediate rubber plate in the bucket mounting area provides the wear protection of the belt.

The segments on the back side of the belt are inserted with the belt and the rubber plate into the shaped plate of the bucket back wall, so that the belt is perfectly configured to the diameter of the drive pulley.

For high belt traction forces, the contact side of the belt is provided with recesses. These recesses, in connection with a profiled rubber plate between belt and bucket, ensure that the belt is guided without deflections in the bucket mounting area. In this way, tension peaks leading to additional strains on the traction carriers are avoided.

Pic. 1a Pic. 1b Pic. 2

56Issue 03 | 2011



The technical features of the traction carrier

The steel wire belts used for BEUMER high capacity belt bucket elevators, have some special features that give them special advantages. Thanks to its low weight in proportion to its breaking strength, the belt as traction carrier has a key function in the realization of center distances greater than 150 m.

The arrangement of the steel wires embedded in the belt with cablefree

zones in the bucket bolting areas is a crucial feature.The special steel wire arrangement in the belt makes it possible that the buckets are connected to the belt without inflicting any damage or separation of the steel wires. Textile fabric layers on both sides of the steel wires, along with the continuous segments of the bucket mountings, give the belt an extremely good diagonal stiffness.

All belts are provided with temperature-resistant top layers. For smaller scale requirements, such as smaller center distances and material temperatures below 80 °C, the use of textile belts is applicable.

The BEUMER high capacity belt bucket elevator technology

The BEUMER high capacity belt bucket elevator technology is based on experiences with the supply and installation of more than 2,000 bucket elevators that are in operation all over the world. The use of a solid and proven technology in connection with safety and monitoring devices and high quality materials, make the BEUMER high capacity belt bucket elevator a highly reliable system for customers in all sectors of industry.

The continuous BEUMER research and development program ensures their ability to meet and handle any future demands arising in the market.

If requested by the customer, the BEUMER service offers service contracts for the bucket elevator, in order to ensure a preventative maintenance program and troublefree continuous operation.

The reliable technology of the BEUMER high capacity bucket elevator will meet your demands.

BEUMER Maschinenfabrik GmbH & Co. KGOelder Str. 40

59269 Beckum | GermanyTel.: +49(0) 25 21 - 24 0

Fax: +49(0) 25 21 - 24 280E-Mail: [email protected]

Internet: www.BEUMER.com


BEUMER GroupThe BEUMER Group is an international leader in the

manufacture of intralogistics for conveying, loading, palletising, packaging, sortation and distribution technology. Together with Crisplant a/s the BEUMER Group employs about 2,300 people and achieves an annual turnover of about 375 million EUR. With its subsidiaries and sales agencies, the BEUMER Group is present in many industries the world over. For more information visit: www.BEUMER.com.

demonstration model

http://www.BEUMER.com

http://www.beumer.com

57Issue 03 | 2011

NEWS & REPORTS


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WWW.ADVANCED-MINING.COM

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If crusher technology by Metso looks after anything, then it’s your purse: the Barmac vertical impact crusher protects the rotor which controls the process in an autogenous layer of feed material in crushing. The mobile Lokotrack LT1415 protects the nerves, as its large intake opening prevents bridging.As a primary crusher, the LT140 saves time – in conjunction with the flexible Lokolink conveyor system it makes such progress in opencast quarrying that you can save a large proportion of your dumpers.Talk to us about the possibilities of staying successful even in difficult times.

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Best results lead to the breakthrough

Your contact person:Karl-Heinz HesslerTel.: ++49 (0)621 72700-611Mobile: ++49 (0)177 [email protected]




58Issue 03 | 2011

NEWS & REPORTS


ATLAS COPCO PRESENTS A NEW CAB FOR THE PIT VIPER 270 SERIES

Garland, TX – Atlas Copco Drilling Solutions presents a new cab for the Pit Viper 270 series, configured as a Pit Viper 271 or Pit Viper 275, to go along with the latest Rig Control System (RCS)

automation technology that comes as an optional feature on the blasthole drill rig.

AtlAs CopCo Drilling solutions

Increasing productivity through a safe, ergonomical design

The cab is larger than the previous model and offers a number of ergonomic and safety features to increase productivity. Greater visibility is offered with larger windows, an excavator style chair that sits on an elevated platform and a more robust set of windshield wipers.

Ease of maintenance is a key component of the cab with integrated lights in the cab’s profile that prevent the need of climbing onto the cab to service. The air conditioning unit is located under the cab and the A/C compressor, evaporator and condenser are all hydraulically driven. The A/C has been designed to maximize airflow on the driller to provide a comfortable working environment in the summer and winter months.

Enhanced working environment for the driller

The cab is better insulated to ensure that the cab stays much cooler than the previous model and fitted floor mats, integrated into the cabin, assist with keeping the cab clean by keeping out unwanted dust particles. With the improved pressurization, door sealing and insulation

http://www.atlascopco.com

59Issue 03 | 2011

NEWS & REPORTS


Atlas Copco Drilling Solutions is a part of the Atlas Copco group and belongs to the Construction and Mining Technique (CMT) business area. The divisional headquarters and main production plant is located in Garland, Texas, USA.

Atlas Copco Drilling Solutions Product Line Manager, Mining Blasthole Drills

Dustin PennTel.: +1 (972) - 496 - 74 00

eMail: [email protected] Internet: www.atlascopco.com

of the new cab for the PV-270 series, the outside sound of drilling is greatly attenuated by decreasing the decibel level to less than 70 dBa inside the cab. There are also a number of integrated radio slots installed in the cab to house the needed components required for a mine site, such as work orders and drill plans.

There are also three buddy seats that flip-up to provide extra storage and they can be replaced with other options, such as a refrigerator, locker and/or microwave. You can also upgrade one of the buddy seats to a trainee seat that comes with a backrest and seatbelt assembly. This way driller’s in training will learn how to operate the RCS technology in a safe, ergonomic working environment.


http://www.atlascopco.com

60Issue 03 | 2011

NEWS & REPORTS


At POWTECH 2011 the HAVER & BOECKER Group will provide information on

the broad product range of both the Wire Weaving and Machinery divisions, and on the subsidiary companies BEHN + BATES and HAVER ENGINEERING MEIßEN.

HAver & BoeCker DrAHtWeBerei unD MAsCHinenfABrik

POWTECH 2011The main focus of the Wire Weaving division this year is

particle analysis and related products for classifying bulk products in the size range of 10µ to 400 mm according to official norms. Together with W.S. Tyler in the USA, HAVER & BOECKER is a leading manufacturer of products for particle size and shape analysis and sets the standards of success when it comes to precision. Furthermore industrial woven screens, pre-tensioned screen decks, ultrasonic screening systems, filter elements, wire woven components and laminates will be presented.

With the recent development of the ADAMS® 2000, the Machinery Division will provide information about the HAVER ADAMS PROCESS® technology. Also optimised screening machines of the NIAGARA M-CLASS will be presented. These machines enable a wide range of cut sizes in the least possible amount of space.

BEHN + BATESBEHN + BATES will present innovative and future-

oriented machines with its turbine-type packers for valve bags ranging in weight from 10 to 50 kg. These machines include metal detectors in the filling canals.

HAVER ENGINEERING MEIßEN (HEM)Process engineering solutions and innovative services

are offered by HAVER ENGINERING MEIßEN (HEM). This independent engineering company, which is an affiliated institute of the Technical University Bergakademie

HAVER & BOECKER AT THE POWTECH 2011

With the new ADAMS® 2000, the Machinery Division will offer information on the HAVER ADAMS PROCESS® technology, which allows environmentally gentle filling of powder-type products into weather-tight PE bags.

Freiberg bundles the expertise of the entire HAVER Group. The in-depth expertise of the Group can be applied when processing orders and conducting work for clients.

HAVER & BOECKER DRAHTWEBEREI UND MASCHINENFABRIK

Carl-Haver-Platz 3 D-59302 Oelde

Tel.: +49 (2522) - 30 0 Fax: +49 (2522) - 30 403

eMail: [email protected] Internet: www.haverboecker.com


HAVER & BOECKER OHG Andrea Stahnke,Communication ManagerTel.: +49 (2522) - 30 820 Fax: +49 (2522) - 30 720eMail: [email protected] Internet: www.haverboecker.com

http://www.haverboecker.com

http://www.haverboecker.com

61Issue 03 | 2011

NEWS & REPORTS


For nearly six months, a heavy Case crawler excavator of the CX700B ME type has been used by the company Backes Bau- und Transporte GmbH, from Auw. The task has been

extraction in the Dockweiler pit located in the centre of the volcanic Eifel region, providing a mobile crushing plant with basalt and lava, for use in its own use in road construction.

CAse ConstruCtion equipMent

Case crawler excavator CX700BWhen a crawler extractor, weighing approx 70t with

463 hp capacity, was designed specifically for heavy earthwork, then works in extraction operations, the application profile of the machine is clearly defined.

Huge tear-out forces of 224kN, extremely fast loading and a modern engine and hydraulic management meet all the requirements for enormous handling performance.

However, things in the Dockweiler pit are somewhat different. A decisive factor for the acquisition of the power pack from the Case CX family was not its special performance in large-scale extraction, but rather the successful combination of very powerful hydraulics, robust construction and extremely sensitive steering. These special requirements for the crawler excavator result from the particular operational situations in the basalt and lava pit in Eselberg, which is relatively close to the local borders of Dockweiler, and has guidelines for nature and landscape conservation.

Senior manager Peter Backes explains: “We took over the Dockweiler pit about 3 years ago. Until then, relatively unregulated, more haphazard extraction took place here. Then we began to examine the deposits in order, then we removed the abandoned contaminated sites and introduced sustainable management.

First of all, it was necessary to provide our road construction operations with the required installation materials and aggregates. We never forgot our goal to promote extraction, which is as sound and sustainable as possible, with minimum impact on the local residents. The biggest problem in extraction is, of course the

A GENTLE GIANT - CX700B ME CX700B SHOWS SENSITIVITY IN EXTRACTION IN THE VOLCANIC EIFEL REGION

detonations which are necessary in order to access the material. And this is where our new CX700B comes into play, by using the machine we can significantly reduce the number of necessary detonations and their depth.

Today we go with boreholes which are only 4-5m deep. This means that the impact of the firing processes is considerably reduced. The excavator has such high tear-out forces that it can clear lighter covering material

62Issue 03 | 2011

NEWS & REPORTS


on its own, for the most part. It can also easily break out material on the standing wall with the pressure of the scoop tip, and can even crush it if the structure of the rock has been sufficiently loosened by the detonation. This makes it much easier to follow the workable layers in a targeted way, without unnecessarily digging up the countryside.”

Excavator operator Helmut Wölwer is completely satisfied with his ‘Piter II’, as the CX700B was named after the head of the company. “We don’t need to talk about engine power here. It’s simply there when you need it. The steering is precise and comfortable to operate, and you can set the scoop precisely to the centimetre.

The levers have a direct response which means that I can arrange the biggest blocks so that I can lift them securely and load them onto the dumper.” These pieces of rock, mentioned by Helmut Wölwer, are basalt and lava blocks directly broken out of the wall, with an irregular form and a weight easily reaching 5 to 6 tons and more.

This is no particular challenge for the heavy excavator with its lifting capacity of over 30 tons and a wide undercarriage, but in order to avoid expensive repairs to the crushing plant, which is designed for processing sizes up to a ton, larger blocks are separated and crushed by a second excavator with a hydraulic hammer. The material is then loaded onto an articulated dumper and transported to the crusher.

“When working with heavy loads directly at the wall, it is good to have the solid ROPS/FOPS protection. After all, a rock can slide down from above at any time, or one of the bulky blocks can slip out of the scoop, if I really swing the upper carriage, so obstacles must be avoided by lifting. It is great to have a cabin where you can feel completely secure. You also have plenty of space, with particularly easy access, and handholds and steps for safety”.

In total, the company Backes Bau- und Transporte GmbH operates five lava and basalt quarries, with a total area of over 100 hectares. The material obtained is used for self-supply, and is brought to the respective construction sites on their own trucks, and installed there. Peter Backes estimates the annual output as approximately 200,000 tons. The planning objective for the Dockweiler pit has a very long-term nature, with management of 50 - 100 years.

Long-term planning and sustainable economic activities are then also important features of the Backes group, as sales consultant Ewald Hehn from Tecklenborg Baumaschinen in Koblenz describes his client: “Although Backes group now employs over 300 people in the construction sector alone, and since its founding in 1946, has grown to a modern organisation with very different business divisions, in the areas of civil engineering, construction of roads and passages, transportation, building material and recycling. It is still a typical family business with strong regional connections, with the second and third generations now working there. There is therefore a natural interest in maintaining the economic basis for future generations.

Nothing is wasted or needlessly thrown away here in the Eifel region. We are careful with what we have, so that our children and grandchildren can also benefit from it.

The new CX700B fits into this concept brilliantly. It is powerful, reliable, and easy to operate despite its complex control systems, and very easy to maintain.

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The crucial factor in the purchasing decision was the positive experience which we had gathered at Backes with a CX225SR excavator and a large wheel loader of the 921E type.

Working closely with the Case factory branch in Groß-Gerau, we were able to organise the delivery of the new CX700B at the end of last year.”

Senior manager Peter Backes emphasises this statement: “We maintain a machinery inventory of around 60 excavators, 5 bulldozers and 60 wheel loaders. We rely on high quality devices which are generally newly purchased and replaced after the appropriate period of time. With the Case excavator, we knew that we were getting a reliable, powerful machine. This has also been confirmed in recent months. Aside from some adjustments to the pressure pipe fittings and optimisation of the hydraulic setting, which were carried out very quickly and professionally by customer services, there were no problems.

The machine was delivered by the low-loader in an operational state, and since then has worked extremely profitably, and is also very economical and clean for an excavator of this tonnage. Of course, a very welcome side effect of using this heavy machine is that the number of very expensive and damaging detonations could be reduced. Overall, this confirms our decision, and shows that our direction in Dockweiler is correct, and fits in with our company concept.”

CASE Construction Equipment Ilona Rautenberg

Tel.: +49 (0)71 31 - 64 49 154 Fax: +49 (0)71 31 - 64 49 181

eMail: [email protected] Internet: www.casece.com


Case Construction Equipment Inc. Case Construction Equipment sells and supports a full line of construction equipment around the world, including the No. 1 loader/backhoes, articulated trucks, crawler and wheeled excavators (including compact), telescopic handlers, motor graders, wheel loaders (including compact), vibratory compaction rollers, crawler dozers, skid steers, compact track loaders, tractor loaders and rough-terrain forklifts. Through Case dealers, customers have access to a true professional partner - with world-class equipment and aftermarket support, industry-leading warranties and flexible financing. More information is available at www.casece.com.Case is a division of CNH Global N.V., whose stock is listed at the New York Stock Exchange (NYSE:CNH), which is a majority-owned subsidiary of Fiat Industrial S.p.A. (FI.MI). More information about CNH can be found online at www.cnh.com

TLC PR for ALARCON & HARRIS Lynn CampbellTel.: +44 (0)151 - 227 49 57 eMail: [email protected]

http://www.casece.com

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Belgium based Keestrack Group, together with their German distributor Oppermann & Fuss GmbH, present their latest developments of track mobile crushing and screening

equipment.

keestrACk - MoBile CrusHing AnD sCreening equipMent

Latest mobile crushing & screening equipment

At display are the Galion cone crusher, a novelty, as well as the re-designed Argo jaw crusher and the new Novum scalping screen with the removable middle fraction conveyor.

KEESTRACK’s track mobile cone crusher, the GALION, features:

High quality crushing unit with a capacity of approx. •200t/h

A quick release system allowing the feed hopper to •be interchanged with a pre-screen unit

Available with a secondary 2-deck screenbox of •4500 x 1500 mm in closed circuit.

KEESTRACK SHOWS THE LATEST MOBILE CRUSHING & SCREENING EQUIPMENT

OMTRACK SPA , a member of the Keestrack Group shows the long time proven but re-designed and modernized ARGO at the Keestrack booth. This jaw crusher is equipped with the by OMTRACK patented Non-Stop System (NSS) to ensure a continuous process while protecting the crusher from un-crushable feeds.

The new ARGO (1000 x 600 mm) features:

True transport weight below 30mt•

Hydraulic height adjustable magnet separator•

Longer output conveyor to load direct on a screen •without a ramp

Improved cubical material output shape•

Improved performance•

Stage 3A, John Deere engine•

New in Keestrack’s range of track mobile screening machines is the Diesel- electrical powered 4 split Explorer 1800.

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Diesel electric drive unit with 60kVa genset•

Switchable to external power source •

Variable speed adjustments by frequency •inverters

IFM control unit inter-connectable to inline •production equipment

Keestrack Group together with Oppermann & Fuss GmbH are inviting to the upcoming Steinexpo where you’ll be updated on the complete Keestrack product range of track mobile crushing and screening equipment.

Keestrack - Mobile Crushing and Screening EquipmentTaunusweg 2

3740 Bilzen | BelgiumTel.: +32 (0)89 51 - 58 51 Fax: +32 (0)89 51 - 58 50

eMail: [email protected] Internet: www.keestrack.com


Keestrack - Mobile Crushing and Screening Equipment Herr Marcel KerkhoffeMail: [email protected] Internet: www.keestrack.com

http://www.keestrack.com

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Sandvik Mining and Construction enjoy record breaking show

In order to take advantage of such an excellent show as Steinexpo, Sandvik invested in an extensive 3,000m2 stand to demonstrate their capabilities to the quarrying industry. The impressive display of product lines and operational competancies also gave a tantalising insight for customers of the total solutions nature of Sandvik’s customer focused portfolio. Amongst the many items that headlined Sandvik’s display included:

Stationary crushing & screening: CH430, CV217, CJ412 •

Aftermarket capabilities: Rotor 73LP, Flexi feed, WR Modu-•lar Screening Media, and a new version of the WT7000

Drill rigs & tools: DI550, DP1100i both equipped with the re-•spective tools,

Breakers: BR2155, BR3288, BR333, BR555, •BR777 and BR999.

Mobile crushing & screening: QI440 with •screening unit and wear protection, QJ241

This was not all as other exhibits included Sandvik’s training simulation technology, HX410 dust suppression system, and a display of conveying components. Additionally, and one of the major attractions of Steinexpo, was the

SANDVIK MINING AND CONSTRUCTIONENJOY RECORD BREAKING SHOW AT

STEINEXPO 2011

sAnDvik Mining AnD ConstruCtion

SANDVIK MINING AND CONSTRUCTION TOOK THE OPPORTUNITy OF THE PREMIER EUROPEAN WORKING qUARRy SHOW, STEINEXPO, TO SHOWCASE NEW MEMBERS OF ITS PRODUCT RANGES, SOME OLD FAVORITES, AND THE LATEST DEVELOPMENTS IN SANDVIK’S AFTERMARKET CAPABILITIES.

live action demonstration of equipment. Sandvik used their 2,000m2 demonstration area to show for the first time in Central Europe the QE440 scalper / screen and many other recently launched products, as well as other members of their product range including.

The new jaw crusher QJ341 feeding into the new QH440 •and handing the material to the QA450 Screen

The the new crusher QI240 feeding into the new screen •QA331


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And last but not least the new breaker model BR4099 was showed when boulding the big stones.

This sample of Sandvik machinery shows that the Sandvik product offering now provides solutions for virtually any application, and encompasses such diverse businesses areas as surface rock quarrying, excavation, demolition, recycling, civil engineering and tunneling. The range of products developed to service these industries includes rock tools, drilling rigs, breakers, tunneling equipment, crushing and screening machinery, bulk-materials handling systems - in fact machinery to deal with virtually every possible requirement.

The demonstrations were hosted by local TV personality Astrid Houben and Sandvik’s Distributor Support Manager, Michael Brookshaw. They provided a running commentary of the demonstrations, as well as acting as masters of ceremonies for the entire Sandvik show. Visitors to the stand were delighted to be interviewed by Astrid, who not provided some glamour for the occasion, but proved to be helpful for visitors in providing an insightful commentary of events throughout.

State of the art machinery from the Sandvik product range were not the only highlights for customers at Steinexpo, as

Sandvik’s recent Aftermarket developments were given due emphasis. Customers were presented with opportunities to discuss their parts and service requirements at first hand, as well able to learn just how Sandvik can provide that little more value added benefit. This proved to be particularly beneficial as many customers were pleased to see just how Sandvik supports them throughout the life time of ownership of their Sandvik equipment.

Steinexpo 2011 proved to be a record breaking show as Germany and Europe emerge from their recent economic problems. Sandvik Mining and Construction used Steinexpo to show that they are well positioned to benefit from any upturn, as well as welcoming many customers new, old and yet to be.


Sanvik Mining and Construction Central Europe GmbH

Daniela Meinzinger, Marketing and Communication

Hafenstrasse 280 45356 Essen | Germany

Tel.: +49 (0)201 - 17 85 304Fax: +49 (0)201 - 17 85 800

eMail: [email protected]: www.sandvik.com


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ECONOMY AND ENVIRONMENT SHAKING HANDS WITH SANDVIK DPI DRILL RIG’S LOW FUEL CONSUMPTION

EVERYONE WINS!


SANDVIK DPI IS A FAMILy OF INTELLIGENT SURFACE TOP HAMMER DRILL RIGS LAUNCHED IN 2008 AND DESIGNED FROM THE OUTSET FOR MAXIMUM ENVIRONMENTAL PERFORMANCE. THE FUNCTIONS OF DPI DRILL RIGS ARE OPTIMIzED By MEANS OF A CAREFULLy DESIGNED INTELLIGENT CONTROL SySTEM, AND THE RIGS CONSUME AROUND 15% LESS FUEL THAN EARLIER SIMILAR RIGS.

Sandvik Dpi-Drill RigDuring the three years that the Sandvik DPi family of

drill rigs has been on the market it has earned praise.Customer feedback says that these rigs outperform

the previous generation both in productivity and fuel economy. Operators are very happy with the excellent working conditions provided by the rig, and the intelligent control system makes their work easier.

Lower fuel consumption – a key targetEnergy-efficiency was one of the main features

defined in the new DPi series development project. “We set three key environmental targets: one

was lower fuel consumption and the other two minimizing noise and dust emissions. We developed a new way of measuring fuel consumption which also incorporates the productivity aspect. While the previous measurement unit for fuel consumption was litres per hour, we now count litres per drilled meter,” explains Tapani Sormunen, Engineering Manager, New Products, Surface Drills.

Pekka Kesseli, Global Product Line Manager, Surface

Drills, says that Sandvik’s long-term experience with this type of drill rig is clearly visible in DPi’s technical

solutions: “The business environment keeps changing constantly. The DPi project had to address issues such as increasing energy costs, diminishing fossil fuel resources and higher requirements for environmental performance. Judging by the praise we have garnered, the product seems to respond to these challenges very well“

One can say that: As a result of the efforts, the DPi series rigs consume 15% less fuel than their counterparts. This means a considerable drop in CO2 emissions; in typical Construction applications with 2 500 engine hours annually, the drop is 35 tons. In surface mining applications, with 6 700 engine hours, the difference is as high as 90 tons.

Intelligent solutions behind it allLow fuel consumption was reached by a combination

of multiple factors. One of the key factors is intelligent compressor control: “The system automatically increases the compressor pressure level only when necessary, such as during drill hole flushing. The control system independently guarantees the necessary pressure level,” says Mr. Sormunen.

Optimized RPM control of the diesel engine is another

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fuel saver. The RPM setting is now 1800 instead of the previous 2100. The intelligent drill rig control system will set the engine RPM as required for transferring the rig or for drilling, for example. The operator does not have to pay attention to that. A lower RPM also decreases noise and extends the service life of the engine.

A third fuel-economy solution relates to the electric load-sensing system of the rig hydraulics, a feature first adopted in the DPi rig family. The electric load-sensing system sets the pump to just the right pressure level for each operating condition. It causes fewer power losses than the previous system and therefore also consumes less fuel. Yet another novelty in the DPi is a new cooling fan with an alternating RPM adapting to the cooling requirements. The device must be able to perform in varying climatic conditions. In winter the fans can rotate slower while hot weather requires higher RPMs. In addition to fuel consumption, the adaptable cooling fan system also lowers the noise level.

Being equipped with TIER4 engines for cleaner exhaust emissions, the Sandvik DPi series rigs also meet the strict environmental regulations of Europe and North America.

Steady steps forwardSandvik’s development work will not end here. Today’s

challenges include the development of drill tubes. The goal is to extend the traditional range of drill rods to include drill tubes that can improve the flushing flow of drilling air and influence compressor optimization, meaning further savings in fuel consumption. It is clear that protecting the environment will be an increasingly important aspect in the design of new products.

The Sandvik DPi series consists of four models: DP800i Hole range: 76 – 127 mm•

DP900i Hole range: 89 – 127 mm•





Satu Ramö, Marketing and Communications

ManagerTel.: +49 (0)358 - 40 537 40 20



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ADVANCED NAVIGATION SYSTEM FOR SURFACE DRILLING

SANDVIK TIM3D: ON TOP OF ACCURACY AND EFFICIENCY !


SANDVIK IS LAUNCHING A NEW 3D NAVIGATION SySTEM FOR SURFACE DRILLING. THE SySTEM, TIM3D, USES SATELLITE NAVIGATION TO GUIDE THE STARTING POINT AND THE CORRECT COURSE OF DRILLING IN ACCORDANCE WITH THE DRILLING PLAN. IT SIGNIFICANTLy IMPROVES DRILLING ACCURACy AND EFFICIENCy IN qUARRyING, CONSTRUCTION AND OPEN PIT MINING APPLICATIONS.

Sandvik TIM3DSandvik TIM3D is a drill rig navigation system

that brings drilling rigs into the realm of 3D machine automation. It is an operator aid consisting of three essential operations: Rig navigation, feed alignment and drilling.

The TIM3D navigation system improves hole quality and hole position accuracy, translating into better fragmentation and decreased amount of boulders and fines. This results in increased efficiency further in the production process, both in crushing and loading and hauling. The system also removes the need for surveying and any hole marks, and thereby also the risk for marking errors, significantly speeding up drilling. Thanks to a modern and clear user interface, the system is easy to use.

Based on a multisatellite RTK GNSS navigation, TIM3D is compatible with GPS and GLONASS satellite systems. The navigation uses drilling plans made either with standard office programs or with the system itself. The plan is imported to the rig with a USB memory in IREDES standard format, containing the target coordinates in three dimensions.Local base station, or VRS correction, keeps navigation accuracy within 10 centimetres.

TIM3D makes the drilling process easier for the operator. The system compares the position of the drill bit with the planned hole position and guides the operator to the correct starting point of the chosen

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hole. During drilling, the operator can follow the penetration rate and hole depth, distance to target, number of required holes and current feed alignment. Furthermore, drilling stops automatically at the target depth. The system also shows the status of the holes with color codes.

TIM3D allows the operator to deviate from the drill plan if needed, for example due to an infeasible planned starting point. Despite the modification, the hole bottom remains as planned: TIM3D system automatically calculates a new course based on the actual starting point of the hole.

The drilling data – the actual parameters - are stored in the system memory, from where it can be imported to various programs, such as blasting simulation. The data includes a quality report, position and depth of the drilled holes, drilling time, and start and end points.

The TIM3D navigation system is available for Sandvik DPi and DX series surface top hammer drill rigs.

Sandvik Sandvik is a global industrial group with

advanced products and world-leading positions in selected areas – tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2010 the Group had about 47,000 employees and representation in 130 countries, with annual sales of nearly SEK 83,000 M.




Satu Ramö, Marketing and Communications Manager

Tel.: +49 (0)358 - 40 537 40 20eMail: [email protected]



72Ausgabe 03 | 2011

NEUHEITEN & REPORTAGEN


www.advanced-mining.comWWW.ADVANCED-MINING.COM

ADVERTISEMENT



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FOR INCREASED PRODUCTIVITY AND REDUCTION


Sandvik Flexifeed crushing mantle The Flexifeed crushing mantle for cone crushers

is a Sandvik patented design consisting of a variable intake in its upper circumference. A key development is that while the feed opening is decreased in parts of the intake, its production capability is maintained. This is accomplished as the mantle, and thereby the pockets, rotate during crushing, thus facilitating the passage of top size material through the chamber.

The major benefits include: • Extended life time - the liner‘s lifetime is

extended by 20-50% depending on the application, due to optimized utilization.

• Increased material reduction - material reduction is increased by approximately 5%.

• Improved productivity – output levels are maintained throughout the mantle’s lifetime.

• Top size capability - is maintained and enhanced

The Flexifeed mantle is available for the Sandvik CH440 CH430 and CH660 cone crushers.



Satu Ramö, Marketing and Communications Manager

Tel.: +49 (0)358 - 40 537 40 20eMail: [email protected]



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SANDVIKS CRUSHER MANGANESE KNOW-HOW ENSURES MAXIMUM PRODUCTIVITY FOR CUSTOMERS


Sandvik has been in the business of producing the finest and most complete range of crushing chambers for more than one hundred years, with in-house foundry technology since 1916. Sandvik has helped enhance customer productivity and safety by using the highest quality of materials and levels of expertise. Sandvik adheres to a simple motto to ensure quality: The customers’ perception forms the basis for our work.

Why is quality paramount when it comes to productivity? Experience has shown that wear parts of inadequate quality are often associated with such discrepancies as incorrect profile shapes, dimensions and ovality, all of which have rather expensive implications. These include diminished capacity and reduction, incorrect product graduation, increased circulating load and damage to bearings, bushings and other components.

Sandvik believes that productivity is the pivotal factor in any decision regarding the purchase of a crusher. This productivity is measured in terms of tons of end-product material produced. Many get sidetracked by secondary issues, such as hours worked, manganese content or tons through the crusher, and there is no denying that these are all important features. However, they only play a part in a bigger process, since it is the end-product produced that defines the actual return on investment for capital employed in the purchase of equipment, parts and services. Without this, no revenues can be generated.

Sandvik crusher products include cones, jaws, primary gyratories, impactors and the corresponding wear parts comprising concaves, mantles, jaw plates and impact bars, all produced to the highest standards of manufacturing. The extensive and complete range has been developed through a close working relationship with customers, established through services provided, training and continuous dialog.

Confirmation of this process of continuous development through customer input is the recently launched Sandvik Flexifeed mantle. The new patented mantle features an extension at the intake. This means that more crushing takes place in the upper section of the chamber, while large stones can still be crushed where there is no extension. This translates into extended liner life and a higher reduction ratio through maximal utilization of the crushing chamber.

The focus on customer productivity and quality goes hand in hand with efforts to improve the environment, health and safety in the manufacturing and operational process. Sandvik foundries utilize recovered manganese and, where possible, a vacuum mold process without chemical binders. In addition, the sand used in the molding process is recycled.

The Sandvik crusher manganese product range provides an excellent example of how maximum customer productivity can be achieved through the highest standards of engineering and manufacturing, while being produced with the utmost respect for the environment.


Sanvik Mining and Construction Satu Ramö,

Marketing and Communications ManagerTel.: +49 (0)358 - 40 537 40 20


Sanvik Mining and Construction Jesper Persson, Global Market and Offering manager Crushing and ScreeningTel.: +46 (0)40 - 40 90 35eMail: [email protected]: www.sandvik.com


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FOCUSES ON AGGREGATE PRODUCER PROFITABILITY


Sandvik WR screening media At the very heart of the WR screening media is an

anti-blinding system; this allows the media to screen even the most difficult of materials, very accurately and at high rates of production. The basis for this is a patent-pending production technique, and pioneering design, that gives an open production area far greater than that found in traditional modular media. This is achieved through the use of cross-mounted flexible screen panels a revolutionary wave like cascade effect is generated in the material bed which improves stratification, allowing undersize material to find a more rapid path to the screening surface.

In order to optimize screening accuracy, the WR modular screening media utilizes a fiber reinforced rubber screen membrane, which enables thinner panels with closer aperture spacing that maximizes the open screening area. Furthermore, by elevating the screen panels from the longitudinal support bars, the screen panels may be fully perforated from side liner to side liner. This absence of blind fields in the directional flow of material ensures maximum material separation, and minimizes the amount of undersized particles “carried-over” to the end product.

qUARRIES, SAND PITS, AND OTHER AGGREGATES SUPPLIERS ARE FACING MOUNTING PRESSURES TO PRODUCE THE VERy HIGHEST qUALITy AGGREGATES, AND IN RESPONSE TO THIS THE PATENT-PENDING WR MODULAR SCREENING MEDIA FROM SANDVIK MINING AND CONSTRUCTION HAS BEEN DEVELOPED FOR USE ON SCREENS WITH LONGITUDINAL PROFILES. THIS ENABLES AGGREGATE PRODUCERS ENHANCED HIGH PRODUCTION CAPACITy, TOGETHER WITH THE HIGHEST LEVELS OF SCREENING ACCURACy. EASy TO INSTALL, WITH NO REqUIREMENT FOR ANy SCREEN MODIFICATION ENSURES THAT DOWN TIME IS MINIMIzED, THEREBy PROVIDING AGGREGATE PRODUCERS WITH HIGH PRODUCTION CAPACITy, ACCURATELy SIzED MATERIAL AND INCREASED OPERATIONAL EFFICIENCy LEADING TO INCREASED PROFITABILITy.

Use of the WR screening media ensures that operational downtime is minimized as the long lasting rubber and polyurethane materials used to make WR screen panels extend service intervals. Additionally the WR screen panels possess a built-in cross beam protection lip which, together with support bar rubber capping, protects the adapter system against wear. User friendly flexible use is ensured as replacing the screen panels, when the need arises, may be easily accomplished as the wedge locking them into place may be quickly removed and reinstalled. This keeps change over time to a minimum, and as the absence of steel reinforcement makes the WR system light, which reduces the stress on the screen and bearings, there is a further reduction in the risk of unplanned production stops.

The Key benefits of the WR screening media may be summarized as:

Optimized screening accuracy•

higher capacity•

Minimized downtime •

No screen modifications needed•

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The new WR system is set to increase aggregate producer profitability as it will enable high quality aggregates to be produced at high production rates, and at the same time increase operational efficiencies. It has been developed to fit most screens on the market currently equipped with modular media on longitudinal profiles, and as it is made of rubber, or different grades of polyurethane, the screen panels are delivered cut to length in order to fit any screen width on the market. Highly productive, accurate, tough wearing, easily replaced, and environmentally focused, the WR screening media from Sandvik is set to become a key tool in the aggregate producers armory.

Sandvik Sandvik is a global industrial group with advanced products and world-leading positions in selected areas – tools

for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2010 the Group had about 47,000 employees and representation in 130 countries, with annual sales of nearly SEK 83,000 M.



Sanvik Mining and Construction Satu Ramö,

Marketing and Communications ManagerTel.: +49 (0)358 - 40 537 40 20


Sanvik Mining and Construction Henrik Rudolf Product Line Manager Screening media, Wear protection and Screening mediaTel.: +46 (0)40 - 40 93 58eMail: [email protected]: www.sandvik.com


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Since Waldemar Rataj began working at Cementownia Warta in 1987, much has changed at the site in Dzialoszyn. Originally built by the Russians in 1963 and state-owned until the 1980s, its first cement facility has now closed and a new production line has been introduced at its second facility, known as Warta 2.

“Everything has changed during my career,” says Waldemar, the Quarry Manager. “For example, the number of employees here has fallen from 2,500 to 800; yet production has risen from one million tonnes to two and a half million.”

The amount of limestone required from its 200-hectare quarry – one of the largest in Poland – has doubled to meet today’s daily production target of 3,000 tonnes of cement. This has been achieved by upgrading and modernising the company’s equipment, including investment in its first Hitachi excavator.

WHEN POLISH CEMENT PLANT CEMENTOWNIA WARTA BEGAN INCREASING PRODUCTION, A LARGER EXCAVATOR WAS REqUIRED TO WORK IN ITS LIMESTONE qUARRy. ALTHOUGH THE HITACHI BRAND IS RELATIVELy NEW TO THIS SECTOR IN POLAND, THE OFFICIAL DEALER, TONA, CONVINCED THE COMPANy THAT THE EX1200-6 WAS THE BEST MACHINE FOR THIS DEMANDING JOB.

Before the EX1200-6 arrived in July 2010, the company extracted limestone by blasting once a day and using smaller, electric excavators to load the material on to dump trucks. But the larger EX1200-6, fitted with a 6.5m³ bucket, has greater capacity to extract the material without the need for blasting.

“Without blasting, it’s less expensive and much better for areas such as this with underground water,” explains Technical Director Marek Górnik. “It also means additional profit for our company.” Due to its proximity to the River Warta, the company has a large water pumping system to transport water back to the river. The EX1200-6 is therefore also required to excavate from water and depths of up to 11m. “It’s important that it can do this – we don’t want to use additional equipment,” says Waldemar.

HITACHI AT POLISH CEMENT PLANT CEMENTOWNIA WARTA

MAXIMISING POTENTIAL

HitACHi ConstruCtion MACHinery Co The Hitachi EX1200-6 has a greater capacity than the

company’s electric excavators to extract the limestone

HITACHI EX1200-6 THE BEST MACHINE FOR DEMANDING JOB

MAXIMISING POTENTIAL

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“The large bucket capacity has maximised the efficiency of the loading process,” he adds. “It can also be moved easily to a variety of locations around the quarry, which makes it more versatile than our electric excavators. The EX1200-6 does the same work as four electric excavators, and it only needs one operator.”

The limestone extracted by the EX1200-6 is transported to crushers, then stored before blending. Once it has been turned into a powdered material, it goes into the kiln to produce cement. This is a 24-hour process that operates all year round.

The limestone is a high-quality raw material, because it contains around 55 per cent calcium oxide. It enables Warta to produce high-quality cement, which is used for bridges, motorway surfaces and airport runways, particularly for the military.

The company’s investment in the EX1200-6 is part of an ongoing modernisation process, which will include the installation of a conveyor belt within three to four years. “We are working to get a licence from the Government to do this, which shouldn’t be difficult,” says Marek. “It will be more cost-effective than using trucks to transport materials over a longer distance.”

Cementownia Warta will also invest in analysis equipment to make sure the limestone is of the same consistency and quality before blending. “We will test the materials after extraction from different parts of the quarry,” he explains.

The successful introduction of the first Hitachi excavator to Cementownia Warta can be accredited to the efforts of Tona Sales Managers Daniel Gola and Kamil Kubica, and has greater implications for the Polish dealer. Cementownia Warta has seven other excavators, 40 Belaz dump trucks and has opened an additional limestone quarry. And it is estimated that Warta 2 will be operational for a further 100 years.

Left to right: Tona Sales Manager Kamil Kubica, Cementownia Warta Technical Director Marek Górnik, Production Director Krzysztof Garns and Quarry Manager Waldemar Rataj

Hitachi Construction Machinery Hitachi Construction Machinery Co., Ltd. (HCM) and

its consolidated subsidiaries (the HCM Group) use extensive experience and advanced technological capabilities to develop and manufacture a wide range of leading-edge construction machinery.


Hitachi Construction Machinery (Europe) NVSicilieweg 5 1045 AT Amsterdam | NetherlandsTel.: +31 (0)20 44 - 76 700 Fax: +31 (0)20 33 - 44 045eMail: [email protected] Internet: www.hcme.com

Hitachi Construction Machinery Co., Ltd.Internet: www.hitachi-c-m.com

http://www.hcme.com

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The Hitachi wheel loader range was extended last year with the European launch of three larger models: the ZW330, ZW370 and ZW550. Designed by Hitachi Construction Machinery Co., Ltd., with co-operation from Kawasaki Heavy Industries Ltd., the new wheel loaders are ideal for working in demanding environments such as quarries.

This is due in part to their powerful and economical engines, and the use of Torque Proportional Differential, which is particularly beneficial for work on uneven terrain. In addition, the ZW370 and ZW550 have improved torque control and superior traction control, which adjusts the engine speed automatically to suit individual working conditions.

To see how the ZW370 and ZW550 performed in operation, Ground Control visited marble producer Furrer and aggregates company Gruppo Mezzanotte in Italy. Both

THE LARGER ADDITIONS TO THE HITACHI WHEEL LOADER RANGE HAVE BEEN WELL RECEIVED THROUGHOUT EUROPE AND ARE ALLOWING THE BRAND TO EXPAND ITS PRESENCE IN THE qUARRyING SECTOR. CUSTOMERS FURRER AND GRUPPO MEzzANOTTE GIVE THEIR IMPRESSIONS OF THE FIRST zW370 AND zW550 TO BE DELIVERED IN ITALy.

HITACHI WHEEL LOADER RANGE HAVE BEEN WELL RECEIVED THROUGHOUT EUROPE POWERFUL PERFORMERS!

HitACHi ConstruCtion MACHinery Co

The ZW370 has proved its versatility at the Casal Selce quarry owned by Gruppo Mezzanotte

customers were already familiar with the Hitachi brand of excavators and were keen to discover whether the new wheel loaders would offer similar advantages of enhanced efficiency, increased productivity and reduced running costs for their businesses.

The ZW370 was delivered by SCAI, the official Italian Hitachi dealer, to an aggregates quarry owned by Gruppo Mezzanotte in May 2010. Four companies operate at the site in Casal Selce outside Rome and all are owned by the group. It was founded in 1978 with three employees, including owner Maurizio Mezzanotte and son-in-law Pino Mangione. Today, the group employs 130 people at three quarries in the surrounding area of Rome.

The 20-hectare quarry at Casal Selce has three crushers and produces 9,000 tonnes of aggregates per day in the following grades: 0-6mm; 6-18mm; 18-30mm; and

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30 to 100mm. Up to 95 per cent is used for concrete, the remainder is used for the production of asphalt.

The quarry’s five largest customers each have approximately 40 concrete production plants. Trucks arrive from 6am to 5pm but work continues at the quarry until 8pm to prepare stockpiles for the first delivery the following day.

To ensure that each of its machines is being used efficiently, the company gives each operator a key fob to operate the fuel pumps on site. “Gruppo Mezzanotte can then see how much fuel is being used by each machine, and whether the operator is using it efficiently,” says SCAI Engineer Christian Costantini.

The ZW370 is the latest addition to the group’s Hitachi fleet, which includes two ZW310 wheel loaders, and one ZX870-3, three ZX470-3 and two ZX60USB-3 excavators. The group also has nine articulated dump trucks.

With a five cubic-metre bucket capacity, the ZW370 loads the dump trucks with sand from a conveyor belt and it is then transported to on-site stockpiles. The wheel loader also loads smaller trucks, which transport the sand to customers located within a 30km radius.

“The company tested the ZW370 and ordered one due to its versatility – especially considering factors such as the travel speed, productivity and fuel consumption,” says SCAI Rome Salesman Gianni Capuano.

Gianni is hopeful that there may be potential for further investment in large Hitachi wheel loaders by Gruppo Mezzanotte. Work can continue at this site for a further 20 years and the company may expand the quarry by 100 hectares.

Within the next few years, another aggregates production plant approximately 100km away from Casal Selce will close. “This means that Gruppo Mezzanotte will be the only company producing these kinds of aggregates in the Rome area,” explains Gianni.

Italy’s first ZW550 was delivered in April 2010 to FB Cave, a subsidiary of Furrer, which operates a mountain-top marble quarry in Betogli near Carrara. The region is renowned for producing the finest white marble used for high-quality construction projects, as well as in the pharmaceutical and food industries. Approximately one million tonnes of marble are produced in Massa Carrara each year, which equates to one per cent of global marble production.

One tonne of marble costs approximately €2,000. Gino Mazzi, owner of Furrer, says, “When this quarry opened in 1850, helicoidal wire and sand were used to extract the marble, which was a time-consuming and inaccurate process. The equipment we have today, including Hitachi excavators and wheel loaders, allows us to be more precise and take greater care when we extract the marble. In that way, we can add value to what Mother Nature has given us.

“Annual marble production at this site reaches up to 20,000 tonnes, which represents a third of the company’s total production,” explains Mr Mazzi. “The rest is calcium bicarbonate, a by-product used in the pharmaceutical industry, for paint, plaster and paper.”

Quarry Manager Antonio Di Biagio, Group Manager of Gruppo Mezzanotte Pino Mangione and SCAI Salesman Gianni Capuano

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The quarry has three Hitachi machines, including an EX800H excavator – one of the first to be delivered by SCAI. Following their positive experience with this machine, they decided to invest in a new ZX520LCH-3 and the ZW550. “The customer invested in the new Hitachi wheel loader because they were satisfied with the advanced technology,” says SCAI Massa Carrara Branch Manager Alfredo Italiani.

Alfredo remembers the delivery of the new wheel loader to the site, which is approximately 850m above sea level. “We had to drive the wheel loader in reverse up the steep, winding road, which has no asphalt. Part of the road goes through a tunnel, which was once used as a train line to transport the marble. It took four hours!”

The ZW550 is used in all parts of the extraction process. It removes small rocks placed beneath large blocks of marble that are extracted by the EX800H. It can also be used with a fork attachment to transport the blocks around the site and load trucks for transporting the marble to Furrer’s factory in nearby Avenza. From there, it is cut into slabs and distributed to customers throughout the country.

Operator Miki Venturini’s initial impressions of the new Hitachi wheel loader were positive. “It’s a high-quality machine that is ideal for this quarry. This job site requires wheel loaders with excellent stability and that are capable of carrying heavy loads. Traction is also very important. “The ZW550’s tyres are specific to the work that is done here and the machine has other important features suitable for working in a marble quarry. It can

manoeuvre around the site quickly and easily, and can carry loads of up to 40 tonnes.” Both Furrer and Gruppo Mezzanotte are satisfied with the performance of the new Hitachi large wheel loaders, and SCAI is optimistic about their potential. “There are approximately 2,800 quarries in the Mediterranean region, so this represents a promising market for the ZW330, ZW370 and ZW550,” says SCAI Salesman Antonio Bauleo.

HCM’s co-operation with Kawasaki has been a positive step and will help to further develop the Hitachi range of wheel loaders. “The Kawasaki brand is renowned for reliability in Italy,” says Christian Costantini. “And our customers recognise that Hitachi excavators are the best on the market, which is another positive association.

Now the first large ZW wheel loaders to be put to the test in Italy are gaining their own reputation for enhanced efficiency, increased productivity and reduced running costs.”


Hitachi Construction Machinery (Europe) NVSicilieweg 5 1045 AT Amsterdam | NetherlandsTel.: +31 (0)20 44 - 76 700 Fax: +31 (0)20 33 - 44 045eMail: [email protected] Internet: www.hcme.com

Hitachi Construction Machinery Co., Ltd.Internet: www.hitachi-c-m.com

The ZW550 transports marble blocks weighing up to 40 tonnes at the mountain-top marble quarry near Carrara

http://www.hcme.com

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Komatsu is the first OEM in the construction equipment industry to offer its customers a Complimentary Maintenance Program, as part of Komatsu CARE. The complimentary program includes all 500-hour factory-scheduled maintenance intervals on Tier 4 Interim Komatsu construction equipment for the first 3 years or 2,000 hours (whichever occurs first), and is available at all distributors in the U.S. and Canada.

The Komatsu CARE Complimentary Maintenance Program includes:

Komatsu Genuine Fluids •

Komatsu Genuine Fluid Filters •

Service work performed by a Komatsu Factory Certified •Technician

Multi-point inspections performed by a factory •certified technician

Komatsu Oil & Wear Analysis (KOWA) •

Komatsu Genuine SuperCoolant •

ROLLING MEADOWS, IL, AUGUST 23, 2011 — KOMATSU AMERICA CORP. TODAy INTRODUCES KOMATSU CARE™, A SERVICE AND ADVANCED PRODUCT SUPPORT SOLUTION THAT COMES STANDARD WITH ALL CONSTRUCTION SIzE TIER 4 INTERIM MACHINES. KOMATSU CARE CAN LOWER THE COST OF OWNERSHIP WHETHER IT IS RENTED, LEASED OR PURCHASED.

koMAtsu AMeriCA Corp

KOMATSU AMERICA LAUNCHESKOMATSU CARE™

First in Industry to Offer Complimentary Maintenance Program

“With the introduction of Komatsu CARE, Komatsu is the first in our industry to offer a comprehensive complimentary maintenance program,” said Dave Grzelak, CEO, Komatsu America Corp. “Complimentary maintenance programs have been very successful, particularly within the luxury auto industry, because they have increased residual values on lease returns, increased the price of used vehicle sales, and increased the longevity of component life. With Komatsu CARE we think we can replicate that success within the construction industry for those who buy and lease Komatsu machines.”

The Komatsu CARE Complimentary Maintenance Program ensures that proper maintenance is performed with OEM parts by factory certified technicians. The program also increases uptime and efficiency, and provides detailed machine maintenance records that can—in turn—bring higher resale value. Komatsu CARE is transferable to new owners, upon resale, within the United States and Canada.

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“We’ve introduced Komatsu CARE at this time to ease the cost of buying or leasing a Tier 4 machine,” Grzelak continued. “Komatsu CARE is yet another example of the value-added tools and services that go along with owning a piece of Komatsu equipment. This is the kind of program that Komatsu and our distributors offer to continually improve our customers‘ experience.”

Komatsu America Corp. is a U.S. subsidiary of Komatsu Ltd., the world’s second largest manufacturer and supplier of construction, mining and compact construction equipment. Komatsu America also serves

forklift and forestry markets. Through its distributor network, Komatsu offers a state-of-the-art parts and service program to support the equipment. Komatsu has been providing high-quality reliable products for nearly a century.

For Komatsu CARE program details, please visit the website at www.komatsuamerica.com/komatsu-care for more information.


Komatsu America Corp.One Continental Towers

1701 W. Golf Road Rolling Meadows, IL. 60008 | USA

Tel.: +1 (847) 437 - 5800 Internet: www.komatsuamerica.com

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Stroyservice, ZAO became the owner of mine No.12 in Kiselevsk town (Kuzbass) recently, which is the oldest one in Kuzbass and will soon turn 95 years old. More than 70 million tons of valuable coal lies in it. For its mining Stroyservice has procured Komatsu mining machinery fleet consisting of one PC2000-8 excavator with 200 tons operating weight which will be increased to five units by the end of year and two HD785-7 dump trucks with carrying capacity of 91 tons which will be also increased to ten units. Those machines were supplied through Sumitec International, Ltd., the local Komatsu distributor in Kuzbass, who will also provide services to them. Taking notice that Komatsu machinery coming to the line is original premiere not only in mine scales, but also for all Stroyservice company. Miners of „Twelfth“ haven’t worked on such machineries yet.

Heavy machines have come from Japan with sub-assembled. Operators took part in machinery assembling by themselves, so that they now know the machine structures very well.

Alexey Jakobchuk, operator: «It is comfortable, silence in a cabin, calmness, a lot of interesting. There is an air-conditioner, a heater».

koMAtsu Cis, llC

STROYSERVICE BEGAN LARGE – SCALED MODERNIZATION AT KISELEVSK MINE USING

KOMATSU MINING FLEET „12th“ was included into a group of enterprises

Stroyservice in 2009. The oldest mine in Kuzbass was predicted as dangerous and unprofitable, however the new owner has made modernization in which mine got a second life as a result.

Yury Kurtobashev, a general director of «Mines No.12» Company Stroyservice: «The development investment program designed to mine till 2035 and provides for the replacement of domestic machinery which has worked for more than 40 years, the technology leaders of mining machinery fleet».

As a joke, miners called this area a «Japanese team». Komatsu excavators, bulldozers and dump trucks will work in one fleet. It will not only increase mine productivity significantly but also make repair and maintenance work much easier.


Komatsu CIS, LLCMoscow | Russia

eMail: [email protected]: www.komatsu.ru

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Metso CorporAtion

New IC1000 automation system: MAXIMIZES JAW CRUSHER EFFICIENCY

The Nordberg C series jaw crusher is proven to be a reliable, highly productive, easy-to-maintain machine and is the backbone of thousands of quarries and mines around the world.

The IC1000, the new-generation Nordberg C series jaw crusher automation system, can take jaw crusher performance to the next level. It ensures optimum operating parameters so that the full potential of the jaw crusher and the whole primary crushing station is utilized. And while optimizing the capacity, the IC1000 simultaneously monitors and protects the crusher for safety and long life.

Metso is a unique solution provider for construction and mining customers around the world. We offer equipment, process technology and automation from a single source.

A complete Nordberg C Series jaw crusher set up with an IC1000 automation unit

The IC1000 is designed to be as easy and simple to use as possible. It has a built-in help screen and trouble-shooting options. The operator interface of the IC1000 offers full control for the crusher and automatic feeding control, which improves process efficiency. The IC1000 can control several different feeding equipment alternatives.

With the IC1000 controls, the C jaw crusher is always fed in the ideal amount and at the optimal feed rate in order to maximize production and end product quality.


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Based on Metso DNA automation

The IC1000 runs on the Metso DNA automation platform. Metso’s extensive automation knowledge comes from delivering 4,500 Metso DNA automation systems to different industries worldwide.

The IC1000 collects trend data from key parameters of the crusher and process for later performance and utilization analysis and process optimization. It is easy to connect to the upper plant level automation system, which can be either a Metso DNA plant automation extension or a third party’s control system.

The Nordberg IC1000 automation system offers a variety of control modes for various production requirements. The operation features include: crusher setting monitoring and control, crusher power draw monitoring, controls for the feed arrangement and many other features.

Nordberg C Series - Metso‘s new C120 presented on steinexpo 2011

Inside view of the new C120

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Several safety and maintenance related options, such as bearing temperature monitoring for main shaft bearings and jack shaft bearings, are available.

The Nordberg IC1000 can be ideally configured to meet the specific requirements on site. A limited number of functions can be configured and taken into use if requested for whatever reason or, alternatively, several functions can be taken into use by selecting from a wide range of the functionalities available.


Metso Corporation Marko Salonen

Tel.: +35 (0)8 40 515 9853

eMail: [email protected]: www.metso.com

The main display of an IC1000 automation unit


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ADVE

RTIS

EMEN

T

BROAD SERVICE SPECTRUM The BBM Group is active in a variety of future-orientated business areas:Our core business comprises mining, structural, underground and civil engineering as well as assembly. In addition, as an innovative company we have also embarked on the development and marketing of new IT technologies. Our services at a glance:

WE BUILD THE FUTURE Every project needs a vision – and the resources to transform it into reality. BBM combines both: Top quality demands throug-hout all of our activities in a wide range of areas, excellent corporate knowhow and expert knowledge of the skilled trades and technology. This results in excellent products and services, for which we are renowned and valued right across Europe. BBM is a reliable and in-demand part-ner, greatly trusted by its clients and cooperative partners. This high performance level and consistent orientation towards the demands of our customers makes us exceptional. We accept challenges and create added value: As a dynamic company that will continue to grow in the future and tap into new markets across Europe. BBM brings projects to a successful conclusion – take our word for it and profit from our rich wealth of experience.

DIVERSE ACTIVITIES ACROSS EUROPE The proprietor-managed BBM Group has enjoyed success on the market since 1990 and is active in a wide range of business areas. Networked with internationally renowned cooperative partners, we support demanding projects throughout Europe. In doing so we apply the skills of around 1,000 highly qualified employees, who work with competence and commitment to ensure the seamless fulfilment of our orders. It is with maximum flexibility that we set benchmarks in quality and reliability. Thanks to rapid decision-making and the central steering of all activities, we offer integrated solutions from a single source and generate tailored solutions – in all business sectors.

OPEN CAST MININGExcellent raw materials for successful construction projects Our quarries produce first-class rock for structural and civil engineering. Our stone fractions, high quality fine flints and ar-chitectural stone are used primarily in road construction and concrete production, and also in the chemical industry. BBM is also increasing in demand as a contract mining supplier for raw materials extraction.

MININGTop quality services based on experience BBM is an outstanding supplier of specialist under-ground mining services, in particular in Germany. Working on behalf of large mining compa-nies, we assume responsibility of complete lots or provide personnel for all forms of mining and assembly work. Our teams are available for flexible application right across Europe. Our own workshop maintains our fleet of machines. BBM has also succeeded in making a name for itself as a contract mining supplier in the underground mining sector.

CONTACT:Operta-BBM

Dieter-aus-dem-Siepen-Platz 1D-45468 Mülheim an der Ruhr

PHONE +49 (0) 208 459 59-0FAX +49 (0) 208 459 59-59

EMAIL [email protected]

WWW.OPERTA-BBM.DE


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BEUMER and CRISPLANT in the UK now BEUMER GROUP UK:

ALL UNDER ONE ROOF Beckum, August 2011. – As part of the integration of Crisplant Ltd. into the Beumer Group, the company in the UK is now operating under the name BEUMER Group UK Limited.

BeuMer group gMBH & Co. kg

Since the beginning of 2010, the intralogistics specialist had been represented in the UK by its subsidiary BEUMER UK with two product ranges: conveying and loading, and palletizing and packaging. Customers in the field of sorting and distribution equipment had previously been served locally by Crisplant Ltd. As a result of the merger, BEUMER customers in all three business segments now have a common point of contact.

The staff of BEUMER Group UK, which in the meantime numbers more than 20, can still be reached at the usual place in Leicestershire for all matters concerning BEUMER and Crisplant products and services on 01530 26 70 91.

The headquarters of BEUMER Group UK in Leicestershire. Address: Wilson House, 207 Leicester Road, Ibstock, Leicestershire, LE67HP

BEUMER GroupThe BEUMER Group is an international leader in the manufacture of intralogistics for conveying, loading, palletising,

packaging, sortation and distribution technology. Together with Crisplant a/s the BEUMER Group employs about 2,300 people and achieves an annual turnover of about 375 million EUR. With its subsidiaries and sales agencies, the BEUMER Group is present in many industries the world over. For more information visit: www.BEUMER.com.

BEUMER Maschinenfabrik GmbH & Co. KGOelder Str. 40 59269 Beckum | Germany Internet: www.BEUMER.com

Pressekontakt:Regina SchnathmannTel.: +49 (0)25 21 - 24 381eMail: [email protected] Verena BreuerTel.: +49 (0)25 21 - 24 317eMail: [email protected]




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BEUMER Group expands its operations: STRONGER PRESENCE IN THE INDIAN MARKET!

The BEUMER Group has taken over the company Enexco Teknologies India Limited, thus expanding its operations in India. The purchase agreement was signed by both parties on September 20, 2011. With this action BEUMER has enhanced its market presence in the cement industry, one of the world’s most important growth markets.

BeuMer group gMBH & Co. kg

“We are very pleased to have taken this step in a market like India, which is so important,” said Dr. Christoph Beumer, Chairman of the Board. “The expansion of the BEUMER Group will have positive effects for our location in Germany as well. By building up our strength in India we look forward to a considerable enlargement of our business volume, with positive consequences for the parent company.”

Enexco Teknologies India Limited is located in Gurgaon, near New Dehli. It currently has 600 employees. With the addition of Enexco’s employees, the workforce of the BEUMER Group will increase to more than 3,000 worldwide.

The BEUMER Group significantly expanded its capabilities in automatic sortation and distribution technology in 2009, when she acquired Crisplant in Denmark. In 2010 it strengthened its position as a supplier of conveying and loading equipment by taking over an internationally important manufacturer of pipe conveyors. Thus the BEUMER Group’s decision to expand its cement operations in one of the world’s major growth markets is a logical continuation of its overall strategy.

The BEUMER Group has taken over Enexco Teknologies India Limited, thus expanding its operations in India.

BEUMER Maschinenfabrik GmbH & Co. KGOelder Str. 40 59269 Beckum | Germany Internet: www.BEUMER.com

Press contact:Regina SchnathmannTel.: +49 (0)25 21 - 24 381eMail: [email protected] Verena BreuerTel.: +49 (0)25 21 - 24 317eMail: [email protected]


A view of the Indian company’s production facilities


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New Doosan DA40 articulated dumpIncorporating over 40 years of expertise in the

ADT market and using quality components from world-class suppliers such as Scania, ZF, NAF, Parker and Rexroth, the new Doosan ADTs are optimised for extreme off-road performance. The exceptionally flexible and agile undercarriage, which is designed to ensure that all 6 wheels are in permanent contact with the ground, means that Doosan trucks can operate on very rough and soft terrain on construction sites such as road projects and mass excavation hauling as well as in mining and quarrying applications.

The new articulated dump trucks complement Doosan’s wide range of excavators and wheel loaders, allowing Doosan to offer a one-stop solution for equipment to excavate, load and transport all types of materials. All Doosan ADT and heavy equipment products are supported by flexible financing packages from Doosan Financial solutions, offering ‘tailor-made’ solutions for purchasing Doosan products.

Like all Doosan heavy equipment, the new range of ADTs is supported by a regional sales and service operation with strategically located parts depots to service a worldwide network of Doosan dealers. All the depots have fully trained Doosan service and parts specialists to support our dealers and to ensure the customer experiences maximum uptime from their machine.

DOOSAN INFRACORE CONSTRUCTION EqUIPMENT HAS LAUNCHED THE NEW DA40 ARTICULATED DUMP TRUCK (ADT), THE FIRST IN A NEW FAMILy OF DOOSAN ADTS OFFERING INCREASED ENGINE POWER AND TORqUE, HIGHER PAyLOADS, LOWER FUEL CONSUMPTION, ENHANCED OPERATOR COMFORT AND FASTER TRAVEL SPEEDS.

DoosAn infrACore ConstruCtion equipMent

NEW DOOSAN DA40 ARTICULATED DUMP TRUCK OFFERS SIGNIFICANTLY IMPROVED PERFORMANCE

The new DA40: Power, Performance, Productivity and Fuel Efficiency

Powered by the 6-cylinder Scania DC13 Stage IIIB compliant diesel engine with a gross power output of 368 kW (500 HP) at 2100 rpm, the new DA40 offers a 10% increase in engine power compared to the previous MT41 model. With

http://www.doosaninfracore.com

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a 22% increase in gross torque to 2373 Nm (1750 lb ft) at 1300 rpm, the torque available in the DA40 is ‘best in class’ in the ADT market.

The increased engine power is combined with SCR technology to lower fuel consumption. Also contributing to the overall 8% reduction in fuel consumption (under standard working conditions) is the new ZF transmission offering 8 forward and 4 reverse speeds. The new transmission improves the transfer of power from the engine to the wheels for outstanding traction. To withstand the increased power, the driveline dimensions and cooling capacity of the truck have been increased.

The DA40 combines ‘best-in-class’ fuel consumption with a higher top speed of 58 km/h (36 mph). The DA40 also has an increased body capacity of 24.4 m³, and the payload has been boosted to 40 metric tonne without tailgate, an increase of more than 15% over the payload of the MT41. The higher speeds and payloads will allow the customer to increase profits from their mining, quarrying or earthmoving operations.

6-wheel traction and outstanding rough and soft terrain capabilities

The DA40 has permanent 6-wheel drive for equal power distribution while the free-swinging rear tandem bogie and the special articulation system offer excellent driving performance in difficult terrain. The sloping body design enhances the stability of the truck thanks to its low centre of gravity and allows fast and

easy tipping, even in the most demanding conditions. The combination of the unique tandem bogie and the sloping rear frame results in ‘best in class’ rough and soft terrain capabilities and avoids the need for electronic aids such as traction control.

To handle the increased payload as well as provide a smoother ride for the operator, the DA40 has a completely new hydro-gas front suspension. This independent front suspension (there is no rigid axle) is a unique feature of the Doosan ADT which allows for free movement on one side, without movement on the opposite side, providing maximum ground contact and shock absorption.

The articulation hinge is positioned behind the turning ring to provide equal weight distribution even during maximum turning and ensure maximum contact between the front wheels and the ground for optimum traction.

Thanks to the high engine power and torque, the improved ground clearance and the efficient powertrain, the DA40 delivers ‘best-in-class’ rim pull in extreme hauling conditions. Like all Doosan ADTs, the

DA40 features a powerful engine brake and hydraulic transmission retarder as standard.

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The wet brakes offer a long service life and sealed protection from the environment and, with oil-cooled multiple disc brakes on all the wheels, the safety of the operator is never compromised.

Operator comfort and convenienceThe DA40 has a completely new cab providing more

space and improved visibility for the operator, ‘best in class’ noise levels and a fully automatic climate control system. For easier operation, Doosan has introduced new electronic systems and simplified fingertip controls with a digital display of all desired machine functions.

The fully automatic 8 gear transmission and smooth Tiptronic gear-shifting (both automatic and manual gear functions are available) allow the operator to concentrate on working conditions.

For routine maintenance and service, the cab can be tilted backwards to provide easy access to components. Easier service access and longer service intervals result in lower operating costs. A fully automatic central greasing system and rear view camera are standard.

About Doosan Infracore Construction Equipment Doosan Infracore Construction Equipment is an industry leader in the engineering, manufacturing, and marketing of compact and heavy construction equipment, attachments, air compressors, lighting systems, generators and articulated dump trucks. We represent world-renowned brands, including Doosan, Bobcat, Montabert, Geith, Doosan Moxy and Doosan Portable Power. Our vision is to be a global top 4 leader in the construction equipment industry by becoming a primary partner to our dealers and customers. Our Compact and Heavy construction equipment teams work together to maximise synergies within our business to ensure we can offer a full line of dependable, innovative products that provide exceptional value to our customers with an unmatched ownership experience. From small building sites to the construction of the Channel Tunnel, Doosan construction equipment has been used in countless projects all over the world to help our customers do their jobs more efficiently and effectively. With a network of more than 3,500 dealers worldwide, we have what it takes to help you do your work better, faster, and with greater productivity. The Construction Equipment division is a member of Doosan Infracore, a company of Doosan Group. Visit us at www.doosaninfracore.com and www.doosan.com.

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Performance, productivity and fuel efficiency

Driven by the 5-cylinder Scania DC9 Stage IIIB compliant diesel engine with a gross power output of 276 kW (375 HP), the DA30 offers an 8% increase in engine power compared to the MT31. In combination with the greater engine power, the DA30 also has 30% more gross torque (1873 Nm at 1300 rpm), to produce the powerful rim pull required to work in extreme hauling conditions.

The increased engine power is combined with SCR technology for ‘best-in-class’ fuel consumption with a higher top speed of 58 km/h (34 mph). Contributing to the overall 8% reduction in fuel consumption (under standard working conditions) is the new ZF transmission offering 8 forward and 4 reverse speeds. The fully automatic transmission with smooth Tiptronic gear-

BUILDING ON THE SUCCESS OF THE POPULAR MT31 MODEL WHICH IT REPLACES, THE NEW DOOSAN DA30 ARTICULATED DUMP TRUCK (ADT), WHICH HAS A PAyLOAD OF 28 METRIC TONNE, OFFERS MANy NEW FEATURES TO MEET CUSTOMER DEMANDS FOR INCREASED POWER AND PERFORMANCE, EASIER OPERATION, INCREASED FUEL EFFICIENCy, ENHANCED DRIVER COMFORT AND FASTER TRAVEL SPEEDS.

DoosAn infrACore ConstruCtion equipMent

NEW DOOSAN DA30 ARTICULATED DUMP TRUCK

shifting (both automatic and manual gear functions are available) allows the operator to concentrate on working conditions and improves the transfer of power from the engine to the wheels.

As well as permanent 6-wheel drive, the DA30 also has a free-swinging rear tandem bogie designed to ensure that all 6 wheels are in continuous contact with the ground, enabling the truck to operate on very rough and soft terrain.

The articulation hinge is positioned behind the turning ring to provide equal weight distribution even during maximum turning and ensure full contact between the tyres and the road surface.

The sloping rear frame enhances the stability of the truck thanks to its low centre of gravity and allows fast and easy tipping, even in the most demanding conditions.

Like its predecessor, the DA30 features an independent front suspension (there is no rigid axle), a unique feature of the Doosan range, which allows for free movement on one side, without movement on the opposite side, giving maximum ground contact and shock absorption.


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Like all Doosan ADTs, the DA30 features a powerful engine brake and hydraulic transmission retarder as standard. The air-cooled multiple disc brakes on all wheels offer long service life and sealed protection from the environment.

Quality and reliabilityIncorporating over 40 years of expertise in the ADT

market and using quality components from world-class suppliers such as Scania, ZF, NAF, Parker and Rexroth, the new DA30 is part of a new generation of ADTs from Doosan optimised for extreme off-road performance.

Operator comfort and convenienceThe DA30 has a new cab providing more space and

improved visibility for the operator, ‘best in class’ noise

levels and a fully automatic climate control system. For easier operation, Doosan has introduced new electronic systems and simplified fingertip controls with a digital display of all desired machine functions.

Maintenance and serviceFor routine maintenance and service work, the cab

can be tilted backwards to provide easy access to components. A fully automatic central greasing system and rear view camera are standard equipment.

One-stop shop solutionThe new articulated dump trucks complement

Doosan’s wide range of excavators and wheel loaders, allowing Doosan to offer a one-stop shop solution for equipment to excavate, load and transport all types of materials. All Doosan ADT and heavy equipment

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products are supported by flexible financing packages from Doosan Financial solutions, offering ‘tailor-made’ solutions for purchasing Doosan products.

The new range of ADTs is supported by a regional sales and service operation with strategically located parts depots to service a worldwide network of Doosan dealers. All the depots have fully trained Doosan service and parts specialists to support the dealer and ensure the customer experiences maximum uptime from their machine.

About Doosan Infracore Construction Equipment Doosan Infracore Construction Equipment is an industry leader in the engineering, manufacturing, and marketing of compact and heavy construction equipment, attachments, air compressors, lighting systems, generators and articulated dump trucks. We represent world-renowned brands, including Doosan, Bobcat, Montabert, Geith, Doosan Moxy and Doosan Portable Power. Our vision is to be a global top 4 leader in the construction equipment industry by becoming a primary partner to our dealers and customers. Our Compact and Heavy construction equipment teams work together to maximise synergies within our business to ensure we can offer a full line of dependable, innovative products that provide exceptional value to our customers with an unmatched ownership experience. From small building sites to the construction of the Channel Tunnel, Doosan construction equipment has been used in countless projects all over the world to help our customers do their jobs more efficiently and effectively. With a network of more than 3,500 dealers worldwide, we have what it takes to help you do your work better, faster, and with greater productivity. The Construction Equipment division is a member of Doosan Infracore, a company of Doosan Group. Visit us at www.doosaninfracore.com and www.doosan.com.

Doosan Infracore Germany GmbH. (Machine Tools)Hans-Boeckler-Strasse 27-29

40764 Langenfeld-Fuhrkamp | Germany Internet: www.doosaninfracore.com



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VOLVO TRUCKS’ FLAGSHIP CELEBRATES WITH 750 HPTHE VOLVO FH16 IS NOW AVAILABLE WITH 750 HP AND 3550

NM TO HANDLE THE HEAVIEST AND MOST DEMANDING TRANSPORT ASSIGNMENTS. IT WILL REACH THE MARKET JUST IN TIME TO CELEBRATE THE 16-LITRE ENGINE’S 25TH ANNIVERSARy.

1987 saw the introduction of the Volvo F16 with Volvo‘s first-ever 16-litre engine, producing 470 hp. Since then, market needs have driven the development towards

increasingly powerful trucks.

„With the Volvo FH16 750 we can offer our customers a truck with absolute top performance, good fuel efficiency and extremely low emissions. It‘s an uncompromising combination for the heaviest and most demanding of transport operations,“ says Staffan Jufors, President and CEO of Volvo Trucks.

Performance, fuel efficiency and environment

The new engine is based on the same technology as Volvo Trucks‘ current 16-litre 700 hp diesel engine - an in-line six with overhead camshaft, four valves per cylinder and unit injectors. It has been optimised for higher power and torque but fuel consumption is unchanged. The 750

volvo truCks

engine is available in two versions, one for Euro 5 and the other for EEV (Enhanced Environmentally-friendly Vehicle), giving even lower particle emissions and less smoke.

The Volvo I-Shift automated gearchanging system is fitted as standard and has been modified to handle the engine‘s high torque. The rear axle range encompasses axles for gross combination weights of up to 250 tonnes. For fast long-haul duties, the recently introduced RS1360 solo axle is a fuel-efficient alternative.

Driveability and productivityThe new 750 engine produces 2800 Nm of torque

at 900 revs/minute, after which the torque curve rises sharply and reaches its peak level of 3550 Nm at 1050 revs/minute, then levels out to 1400 revs/minute. This makes it possible to maintain a high speed on even the toughest uphill climbs.

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„The more power you have at your disposal at low revs when starting to haul a heavy load, the less strain on the engine and the more fuel-efficient your progress. This in turn results in superb drivability,“ says Hayder Wokil, product manager at Volvo Trucks.

The Volvo FH16 750 is intended both for truly heavy transport duties and for assignments that demand high average speed running on hilly or very hilly roads.

„For most FH16 customers, the focus is on transporting as many tonnes as possible in the shortest possible time. However, many customers also need to quickly transport highvalue goods and fresh products across long distances with varying topography and deliver just-in-time,“ explains Wokil.

Heavier transport - more powerful trucks

There has long been a trend towards increasingly heavy transport and thus also a greater need for more powerful trucks. Since the introduction of the Volvo F16 in 1987 and the first-generation 16-litre engine producing 470 hp, power levels have risen step by step in pace with market and customer needs. In 1993 power rose to 520 hp. Ten years later an all-new engine arrived, producing 610 hp. In 2009 Volvo was the first manufacturer to reach 700 hp, and now it is time for the next step - the Volvo FH16 750 hp.

Production of the first Volvo FH16 trucks for the European market with the higher power output will get under way in the beginning of 2012. In addition to the 750 hp version, Volvo‘s 16-litre engine is available with power outputs of 540, 600 and 700 hp.

Volvo Trucks Central Europe GmbH Nigel Hanwell, Press Officer, Volvo Trucks

Tel.: +44 (0)19 26 - 41 42 10Fax: +44 (0)19 26 - 41 43 86

Mobile: +44 (0)78 31 - 81 70 83eMail: [email protected]: www.volvotrucks.com


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CATERPILLAR INTRODUCES 3516C-HD TIER 4 INTERIM CERTIFIED DIESEL GENERATOR SET

“This is the first diesel generator set producing more than 2MW that has been certified by the EPA,” said Robert Koval, global distribution director of Caterpillar Electric Power Division. “Tier 4 Interim certified generator sets are required for high-hour applications, such as rock crushers, peaking plants and remote installations. Our emergency standby customers will also realize benefits with this genset, particularly in areas with especially stringent local standards. The lower emissions from the Tier 4 Interim generator set should eliminate or minimize the amount of additional aftertreatment needed to comply with local emissions regulations.”

The 3516C-HD is the latest addition to Caterpillar’s line of Tier 4 Interim certified generator sets. Ranging from 455 kW to 2500 kW, Caterpillar offers the widest range of Tier 4 Interim certified generator sets in the industry.

To provide customers with the most economical and efficient emissions solutions, Caterpillar continues to develop generator sets engineered to deliver flexibility,

CAterpillAr inC.

Cat® 3516C-HD Diesel Generator Set

PEORIA, IL – Caterpillar Inc. announces today the availability of the new Cat® 3516C-HD diesel generator set, certified to meet United States EPA Tier 4 Interim standards. This 60 Hz package is rated at 2500 ekW for standby power, 2250 ekW at prime power and 2050 ekW at continuous power, offering highly efficient fuel consumption rates, compact footprint and lower emissions for prime power, peak shaving, standby and mission critical applications.

NEW UNIT EXTENDS INDUSTRy LEADING LINEUP OF TIER 4 INTERIM CERTIFIED GENERATOR SETS RANGING FROM 455 KW TO 2500 KW.

expandability, reliability and cost-effectiveness, while at the same time addressing the emission reduction levels required by EPA regulations. The 3516C-HD Tier 4 Interim certified generator set is optimized for use with the Cat clean emissions module (CEM). This aftertreatment system features a diesel oxidation catalyst (DOC) combined with a selective catalytic reduction (SCR) module and an air-assisted urea injection system.

This diesel generator set also features integrated electronics for monitoring, protection and closed loop NOx control, an ADEM™ A4 controller, Air-to-Air After Cooler cooling system, MEUI fuel system and state-of-the-art Cat EMCP 4 control panel. This simple-to-use control panel delivers a more intuitive, user-friendly interface and navigation, and is scalable to meet a wide range of customer power requirements.

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Available with a full range of factory designed and tested attachments, the 3516C-HD offers flexible packaging options for easy installation and optimal performance, while minimizing impact on generator set space requirements and maintenance hours. Cat Tier 4 generator sets are capable of integrating into larger power systems that could include UPS, Switchgear and ATS products. To support this new line of generator sets, Cat Dealers and technicians will be factory trained in emissions technology installation and service.

Caterpillar is a leader in the power generation marketplace with power systems engineered to deliver unmatched durability, reliability and value. The company offers worldwide product support, with parts and service available globally through the Cat authorized service and dealer network. In addition, dealer service technicians are trained to service every aspect of Cat equipment.

For technical or dealer information, visit www.catelectricpowerinfo.com/pr. For additional information on emissions regulations and our emissions reduction technology, visit www.cat.com/power-generation/generator-sets/emissions. To interact with other power generation professionals in our online community, register at www.catelectricpowerinfo.com/connect.

Cat® 3516C-HD Diesel Generator Set

CaterpillarFor more than 80 years, Caterpillar Inc. has been making progress possible and driving positive and sustainable change on every continent. With 2010 sales and revenues of $42.6 billion, Caterpillar is a technology leader and the world’s leading manufacturer of construction and mining equipment, clean diesel and natural gas engines and industrial gas turbines. More information is available at www.cat.com.

Press Inquiries Caterpiller Inc. Jennie Tylec

Tel.: +1 (0) 309 - 578 34 71eMail: [email protected]

Internet: www.cat.com


Press Inquiries Gelia Bob Chase Tel.: +1 (0) 716 - 629 32 30eMail: [email protected]

http://www.cat.com

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REFINED DESIGN FOR THE CAT® D11T AND D11T CARRYDOZER DELIVERS FUEL-EFFICIENT PRODUCTIVITY, RUGGED DURABILITY AND OPERATOR-SAFETY ADVANCES

Engine technology and coolingThe C32 engine with ACERT™ technology is configured

to meet U.S. EPA Tier 4 Final emissions standards for those geographical areas requiring a high degree of emissions control. For lesser regulated areas, the engine will be configured to meet U.S. EPA Tier-2-equivalent emissions standards.

CAterpillAr inC.

The D11T and D11T CD’s 850-net horsepower (634 kW) Cat C32 engine can work fuel efficiently anywhere in the world, and with blades ranging in capacity to 57 cubic yards (43.6 m3) and operating weights to 248,456 pounds (112 698 kg), the D11T/CD can work productively in the toughest of materials

THE CAT® D11, SINCE 1986, HAS SET THE STANDARD FOR MACHINE PRODUCTIVITy, DURABILITy, RELIABILITy, SAFETy AND OPERATOR CONVENIENCE IN HIGH-PRODUCTION DOzING APPLICATIONS. THE NEW D11T AND D11T CD ELEVATE THAT STANDARD WITH DESIGN REFINEMENTS THAT INCLUDE ENHANCED AUTO SHIFT, DyNAMIC INCLINATION MONITOR, AUTOMATIC CLIMATE CONTROL AND AVAILABLE AUTOMATED RIPPER CONTROL. THE D11T AND D11T CD’S 850-NET HORSEPOWER (634 KW) CAT C32 ENGINE CAN WORK FUEL EFFICIENTLy ANyWHERE IN THE WORLD, AND WITH BLADES RANGING IN CAPACITy UP TO 57 CUBIC yARDS (43.6 M3) AND OPERATING WEIGHTS UP TO 248,456 POUNDS (112 698 KG), THE D11T AND D11T CD CAN WORK PRODUCTIVELy IN THE TOUGHEST OF MATERIALS.

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The Tier 4 Final configuration employs the Cat NOx Reduction System, which captures and cools a small volume of exhaust gas, then returns it to the combustion chambers to lower temperatures and retard formation of nitrogen oxides (NOx). A Diesel Oxidation Catalyst uses oxidation, a chemical process, to condition exhaust gases to meet emission standards.

A new cooling package uses a two-part radiator with aluminum bar-plate cores that contribute to durability, efficient heat transfer and corrosion resistance. The new oil-to-air hydraulic-oil cooler uses similar construction, and a hydraulically variable demand fan uses less power, reduces fuel consumption and lowers sound levels.

Drive train and undercarriageNew for the D11T and D11T CD is the Enhanced

Auto Shift (EAS) system, designed to conserve fuel by automatically selecting the optimal reverse gear

and engine speed, based on load and desired ground speed. When the EAS mode is not activated, an Auto Downshift feature automatically change gears down to most efficiently handle loads.

Operator environment and safetyThe D11T and D11T CD‘s spacious, well-appointed

cab features single-joystick blade control, finger tip steering, automatic climate control and Cat Comfort Series seats that are now are available with a heated and ventilated option.

A new Dynamic Inclination Monitor provides a readout of tractor pitch angle and side-to-side slope angle, and Automated Blade Assist Control uses preset blade-pitch positions to simplify positioning. An optional Autocarry system automatically controls the blade during the carry segment.

The new D11T and D11T CD feature design refinements that include Enhanced Auto Shift, Dynamic Inclination Monitor, automatic climate control and available automated ripper control

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A new operator-presence system locks out the power train and hydraulic system to avoid unintentional machine movement when the operator is entering or leaving the cab, which can be done via an optional hydraulically actuated access ladder that deploys and stores in seconds.

An optional sound-suppression package reduces average spectator sound power levels for both the operator and the surrounding environment benefit.

Serviceability The D11T and D11T CD features an „OK-

to-Start“ system that electronically checks critical fluid levels. Routine maintenance is facilitated by easily accessed filters, an optional automatic lubrication system, high speed oil change for engine and powertrain systems, and ecology drains for capturing fluids for proper disposal or recycling. A fast-fill fueling system incorporates a positive shutoff to prevent spills.

For more information about the D11T and D11T Carrydozers, customers should visit https://mining.cat.com/D11T or contact their local Cat dealer.

D11T and D11T Carrydozers

Net power (SAE J1349) 850 hp (634 kW)Operating Weight (D11T) 229,848 lb. (104 257 kg)Operating Weight (D11T CD) 248,456 lb. (112 698 kg)Track on ground 175 in. (4 444 mm)Track gauge 114 in. (2 896)Displacement 1959 in. (32.1 L)

Press Inquiries,Cat Trade Press Media RepresentativesSharon Holling eMail: [email protected] SantoreMail: [email protected] eMail: [email protected] Internet: www.cat.com


Machine Specifications

CaterpillarFor more than 80 years, Caterpillar Inc. has been making progress possible and driving positive and sustainable change on every continent. With 2010 sales and revenues of $42.6 billion, Caterpillar is a technology leader and the world’s leading manufacturer of construction and mining equipment, clean diesel and natural gas engines and industrial gas turbines. More information is available at www.cat.com.

http://www.cat.com

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CATERPILLAR/JEWELL ALLIANCE DEVELOPS NEW ULTRA-HIGH-DEMOLITION EXCAVATORS

The Caterpillar OEM Solutions Group selected Jewel Attachments LLC from a number of potential partners, based on proven capability and dealer/customer acceptance. Jewell is the market leader for high-reach excavator conversions in North America, and the company‘s products embody an industry-leading design that incorporates features most requested by users surveyed in Caterpillar‘s Voice of the Customer research. The alliance with Jewell provides demolition customers with a range of machines that meets environmental and safety standards and flexible machine configurations.

The new UHD models— APEX 50, APEX 70 and APEX 100—will use a Caterpillar manufactured carrier (upper structure, lower structure and undercarriage) combined with Jewell UHD fronts, cab-guarding package and Demolition Control System (DCS). The APEX 70 is now available, to be followed by the APEX 100 and APEX 50 in the first and third quarters of 2012, respectively. Caterpillar will continue to offer the demolition customer all other product families available in the current Cat product range through its existing dealer network.

Innovative, heavy-duty designThe upper-frame design for the new UHD machines

incorporates a 30-degree tilting cab and uses heavy reinforcing plates at critical stress points. The heavy-duty boom structures, using high-strength-steel plates that are plasma cut with 30-degree bevels for weld fill, are fabricated „in position,“ then line-bored for perfect fit.

High-carbon, hardened steel pins and bushing are used throughout the front structure, and plumbing is a combination of DOM (Drawn Over Mandrel) seamless

CAterpillAr inC.

CATERPILLAR HAS ADDED A NEW DIMENSION TO ITS ULTRA HIGH DEMOLITION (UHD) EXCAVATOR BUSINESS By LEVERAGING THE EXPERTISE OF JEWELL ATTACHMENTS LLC, WHICH WILL DESIGN AND MANUFACTURE A NEW RANGE OF UHD EXCAVATORS, BRANDED APEX, TO BE SOLD EXCLUSIVELy THROUGH NORTH AMERICAN CAT® DEALERS. JEWELL, IN BUSINESS SINCE 1985, HAS EXTENSIVE MANUFACTURING FACILITIES AND A REPUTATION FOR BUILDING HIGH-qUALITy MACHINES WITH VERTICAL-REACH CAPABILITIES FROM 75 TO 182 FEET.

tubing and high-pressure (5,000-6,000-psi) hoses. Boom structures provide positive protection for hydraulic cylinders, and an available dust-suppression system features dual adjustable nozzles, hydraulic pump and plumbing that conforms to standard fire-fighting components.

The full FOPS (Falling Objects Protective Structure), which is mechanically secured to the hydraulically tilting cab platform, uses thick-wall tubing and vertical bars to wrap the top, front and rear of the cab enclosure, but the protective structures are designed to allow unimpaired visibility. Glass in the cab is made of tempered inner and outer panels that are heat-vulcanized over a multi-layer polycarbonate core. Cab features include a programmable touch-screen-computer interface that allows pre-setting work parameters, an automatic climate-control system and an available attachment-observation system featuring two high-resolution cameras.

Safety, structures, transportMachine working range is limited by the DCS

computer to maintain a safe operating envelope. The DCS boom-monitoring system constantly determines boom position and keeps boom travel within safe parameters when raising, lowering or using work tools. If the boom approaches pre-established boundaries, the operator is advised via an audible warning system, and if operation continues, the system allows only boom movement that will restore the safety margin. In addition, the DCS modulates hydraulic-function speed to mitigate dynamic forces, thus contributing to a stable working platform.

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The new APEX models also are equipped with pilot-assisted load-lock valves for the boom-hoist, mid-stick and working-stick cylinders, and the machines use locking anti-burst valves with a pilot-assist cartridge. These safety features are used in conjunction with a remote pilot source to provide failure protection, load control and load-holding capability.

Front structures for the APEX 70 include the three-piece 84-foot (maximum vertical pin height) boom with a maximum tool-weight capacity of 9,600 pounds; the three-piece 98-foot (maximum vertical pin height boom) with a maximum tool-weight capacity of 6,700 pounds; a straight main boom; and custom booms as customer requirements dictate. In addition, boom extensions and multiple working sticks are available.

To facilitate transport, boom configurations are designed to be within transport-height regulations when fully crowded. Also available are custom boom trailers that allow correct pin height for „walk-up“ connection at the transport joint. Also, cradles can be customized to accept extensions and additional sticks.

Among the work tools available for the new APEX UHD models are multi-processors, rotating shears and hydraulic breakers—all available in a range of sizes and configurations to match customer applications.

The new UHD models— APEX 50, APEX 70 and APEX 100—will use a Caterpillar manufactured carrier (upper structure, lower structure and undercarriage) combined with Jewell UHD fronts, cab-guarding package and Demolition Control System (DCS).

APEX 70 Specifications

Operating Weight w/o Tool:84-ft. boom 132,974 lb.98-ft. boom 133,424 lb.

Max. Vertical Pin Height:84-ft. boom 84'98-ft. boom 98'

Max. Horizontal Pin Reach:84-ft. boom 51' 2"98-ft. boom 58' 10"

Specifications

Press Inquiries,Cat Trade Press Media RepresentativesSharon Holling eMail: [email protected] SantoreMail: [email protected] eMail: [email protected] Internet: www.cat.com


http://www.cat.com

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CDe gloBAl ltD

CDE GLOBAL - IMPROVED SAND QUALITY FOR REDDAL SAND, NORWAY

A new sand washing plant for Reddal Sand has resulted in a significant improvement in the quality of the sand being produced at their site in

the South of Norway.

Reddal Sand is located in Grimstad, Aust-Agder and has supplied a variety of construction materials to major projects in the area since 1989. These include materials for use in the manufacture of roofing tiles, concrete, road construction and various types of groundworks including sports fields, playgrounds and golf courses.

Morten and Jan Tore Pedersen of Reddal Sand began looking for suitable wash plants as they believed they could recover more material than was currently the case from the sand and gravel reserve. A particular area of concern was the top 3 to 4 metres of the deposit which contained a high level of fines and clay contamination that was compromising the final quality of their sand product.

After looking into a number of potential suppliers they chose the Evowash sand washing plant from Northern Ireland company, CDE Global

“We chose CDE equipment as a result of the experience they were able to demonstrate in the provision of equipment for similar applications in many countries” says Morten Pedersen. “An additional factor in their favour was the flexibility they showed in terms of being able to customise the plant to the specific nature of the material we are processing.”

The new sand washing plant includes the Evowash 71 and Evowash 151 supplied by Ankerløkken Equipment who represents CDE in Norway. “The Evowash allows us to maximise the production of quality sand” says Morten Pedersen. “The new installation has ensured that we are able to offer a higher quality sand product to our customers, which sets us apart from other suppliers in the area.”

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Reddal Sand are supplying material to a diverse range of customers including roof tile manufacturer Skarpnes as well as Skarpnes Rør (concrete pipes), Ribe Betong (concrete), Digernes Betong (concrete) and Betong Sør (concrete). The company also supplied all the aggregates used on the construction of the new E18 road between Grimstad and Kristiansand through Ølen Betong (concrete).

Samples taken of material from the site suggest it to be one of the best reserves of natural sand and gravel in the South of Norway. The current processing licence is

initially for a 20 year period with an option to extend for several more years. Current production capacity at the site following the addition of the two Evowash sand washing plants is 200,000 tonnes per year.

Reddal Sand is a member of PGL – the Norwegian Federation of crushed rock and sand and gravel suppliers and all the concrete aggregates produced meet the relevant Norwegian quality standards in co-operation with the Control Council for Concrete Products.


CDE Global LtdMarketing & Sales Support Manager

Peter CravenTel.: +44 (0)28 8676 7900 Fax: +44 (0)28 8676 1414

eMail: [email protected] Internet: www.cdeglobal.com

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CDe AsiA

CDE ASIA - INTRODUCE MOBILE WASHING TO IRON ORE PROCESSORSMany of the leading players in the iron ore market in India recently attended an event in

Jabalpur highlighting the new washing technology available from CDE Asia.

As well as welcoming customers from Jabalpur and Katni regions there were also representatives from Mumbai, Delhi, Gujarat and Raipur in attendance to hear about the developments made with CDE washing technology specifically for application in the processing of iron ore. The event was also attended by members of several regulatory bodies including the Pollution Control Board and the Indian Board OF Mines.

CDE Asia has been providing iron ore washing systems in India since 2005 and includes many of the major steel producers in India among their customers. Commenting on the event in Jabalpur Managing Director, Manish Bhartia said “The efficiency gains being enjoyed by steel companies as a result of the introduction of our iron ore washing

technology has ensured there is significant interest in any new technology we can offer. The event in Jabalpur was a response to this growing interest and the recent addition of mobile washing to our product portfolio.”

Visitors to the CDE Asia technology launch were introduced to the M2500 mobile washing plant and presented with a project case study detailing its recent application in iron ore washing. This presentation from CDE Asia President, Dr Arabinda Bandyopadhyay focused on the potential increases in Fe value that can be realised following the introduction of the M2500. Dr Bandyo’s presentation also included a detailed analysis of many CDE iron ore washing projects in India detailing the efficiency gains being enjoyed by existing customers.

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The event program also included a presentation from SREI Equipment Finance detailing the various financing schemes available to operators in India considering the purchase of a CDE Asia iron ore washing plant. “There are many options available to operators considering the introduction of our washing technology” says Chiranjib Banerjee, Deputy General Manager Sales with CDE Asia. “Our involvement with SREI Equipment Finance ensures we have the flexibility to cope with the differing requirements of a broad range of potential customers.”

The event in Jabalpur is the first in a series of events planned by CDE in India over the next few months with final preparations being made for conferences in Barbil and Goa. “We are very pleased with the interest in our technology launch events fromexisting customers, potential clients and the major regulatory authorities in India” explains Dipankar Chakraborty, Corporate Communications Manager with CDE Asia. “There are significant opportunities for us to increase our market coverage in India as a result of the efficiencies we can bring to iron ore processing and steel manufacturing operations.”

Further details on the events program over the coming months will be published at www.cdeasia.com

CDE Asia Headquarters8th Floor, Park Plaza,

71 Park Street, Kolkata 700 016 | IndiaTel.: +91 (0)33 3028 208

Fax: +91 (0)33 3028 2082eMail: [email protected] Internet: www.cdeglobal.com


http://www.cdeglobal.com

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CDe gloBAl ltD..

CDE - TARGET WASHING EQUIPMENT MARKET IN AUSTRIA CDE have announced the appointment of a new country

manager for Austria as the company seeks to expand its coverage throughout Europe. Stefan Hunger joins CDE bringing with him significant experience in the construction materials markets in Europe, North Africa and Latin America.

Commenting on his appointment Stefan said “Through the work already done throughout Europe the potential for application of CDE washing equipment has been proven. There are many opportunities in Austria to bring increased efficiencies to construction materials producers and the CDE range is suited to the specific requirements of the market in Austria.”

Over the last five years CDE has undertaken significant product development work across the full range and now offer a modular washing equipment portfolio which includes Prograde screens, Evowash sand washing plants, Aquacycle thickeners, the M2500 mobile washing plant and Rotomax logwashers.

“CDE built a reputation as washing experts based on the delivery of major turnkey washing plants through their global office network in Northern Ireland, the Middle East, Eastern Europe and India” explains Stefan. “As we sought to expand our global coverage our product range was developed to facilitate selling through a distribution network where the requirement existed for individual plant items that could be introduced to existing operations to enhance efficiency and add value to the final products.”

The move to modularity has brought success in recent years throughout Europe and over the last eighteen months the speed of development has been enhanced with the introduction of the M2500 mobile washing plant. The M2500 was launched to the global market at the Bauma Munich exhibition in 2010 and has allowed CDE to develop business in a number of new territories including France, Germany, Turkey, Poland, India and Australia as well as the company’s home markets in Ireland and the UK.

“The key success of the M2500 is the integration of the sand washing element onto a compact, portable chassis” says Stefan. “Operators are for the first time able to enjoy a compact mobile washing plant incorporating feeding, screening, sand washing and stockpiling.”

According to Stefan the versatility of the M2500 has also been a major contributor to its success having been applied on the washing of a wide variety of materials including sand and gravel, crushed rock, construction and demolition waste recycling, scalpings and iron ore washing.

“The ability to add value to such wide range of materials through the introduction of the M2500 means that there are many opportunities to build on the success enjoyed to date” explains Stefan. “I am confident of enjoying further success in Austria with the CDE range as it meets the requirements of the market in that it is a development of the existing washing equipment offering and it satisfies the demand from operators for mobile processing systems.”

With the increased specification of CDE washing equipment has come a parallel increase in the frequency of water treatment and recycling being included. The

M2500 AggMax and AquaCycle in England

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Aquacycle thickener has enjoyed increased popularity as a result of its capability to deliver recycling of 90% of the water used on a washing plant. A combination of increasing environmental legislation and a growing awareness of the costs of maintaining large settling ponds has led to this increase according to Stefan. “Some form of water treatment and recycling is now included on around 80% of our washing projects and the combination of choice is the M2500 and Aquacycle thickener as a result of the small plant footprint, quick installation time and the ability to move the plant to another processing site as and when required.”

As CDE seek to develop the market in Austria under the management of Stefan Hunger they are adopting

the model that has seem them establish a presence in other European countries such as Poland, France and Germany.

“The model we have for the development of individual markets is tried and tested and is centred on establishing the right partnerships with companies who have a track record in the delivery of crushing and screening projects” says Stefan. “I will also be meeting directly with operators in Austria over the coming months to highlight the benefits that a CDE washing plant can bring.”

Further information on the range of equipment available from CDE can be found on their web site at www.cdeglobal.com .


CDE Global LtdMarketing & Sales Support Manager

Peter CravenTel.: +44 (0)28 8676 7900 Fax: +44 (0)28 8676 1414

eMail: [email protected] Internet: www.cdeglobal.com

M2500 in Poland M2500 and AquaCycle in Poland

http://www.cdeglobal.com

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WIRTGEN GROUP Wirtgen Vögele Hamm KleemannA future grown out of tradition: 50 years of Wirtgen – From pioneer to corporate group with four strong brands

The name Wirtgen stands for an unrivalled success story. In 1961, at the age of just 18 years, Reinhard Wirtgen founded a haulage company for transporting construction materials. A keen entrepreneur, he pursued his vision with tremendous pioneering spirit and boldness. His one-man company has grown to become today‘s Wirtgen Group, a renowned global company with over 5,000 employees. A company moulded by family tradition and strong local responsibility.

Wirtgen group

Today as in the past, the Wirtgen Group owes its strength to the four core brands and their unique experience: Wirtgen, Vögele, Hamm and Kleemann. In each of the specialist brands, the companies‘ employees have decisively contributed to the development and advancement of processes and machines in their respective core areas at each moment in time. And that includes cost-efficiency and environmental compatibility.

In all areas of the road construction business, the Wirtgen Group stands out through innovative solutions, recognized processes and a full range of modern products meeting the highest demands. Be it for building new roads or repairing existing roads, asphalt or concrete roads, narrow cycle paths or heavy-duty runways at airports throughout the world. It is these characteristics which have made the Wirtgen Group market leader for mobile

road construction equipment. However, the Wirtgen Group also offers innovative and practical technology tailored to the most extreme conditions for mining deposits and processing mineral raw materials – technology that combines high reliability with low operating costs.

In addition to a workshop service that covers everything from A to Z and rapid availability of replacement parts, the Wirtgen Group also operates a worldwide marketing and service network providing customer-centric solutions. Right there where they are needed:

Close to our customers!

Wirtgen Group: Press and Public RelationsFranz-Sales Mantel, Michaela Adams

eMail: [email protected]

http://www.wirtgen-group.com

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Cost-efficient milling technology: always ahead of the times.

In the early 1970s, Wirtgen pioneered the removal of defective asphalt pavements with its first hot milling machine which allowed existing roads to be rehabilitated much more economically. The next quantum leap followed with the development of cold milling machines. Today, Wirtgen leads the world market with modern, cost-efficient and eco-friendly milling technology to the benefit of traffic infrastructure worldwide.

The most modern pavers ever built.The history of asphalt pavers goes back a long time

and Vögele played a major part in the development of their technical and technological innovations, from the first paver with hydraulic drive through innovative high compaction technology in screeds to a uniform, easily learned operating concept for the entire product range. Today, Vögele offers a complete range of modern machines for all paving jobs.

A pioneer makes history: Always a roller length ahead.

When the steam engine was its height, Hans Hamm designed and built the world‘s first motor-driven road roller back in 1911, laying the foundation for Hamm rollers‘ legendary reputation throughout the world today for all demanding soil and road compaction jobs. What‘s more, these rollers have repeatedly won awards for their innovative and user-friendly design.

Irresistible appeal, both yesterday and today.

Kleemann began to build the first mobile crushing and screening plants back in the 1920s. With decades of competence in the construction of stationary plants, Kleemann also holds a pole position in the market for mobile plants. Right up to the present day, they feature sophisticated details which are always designed with the overall process in mind.

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When a new machine is developed from scratch, the moment of truth – the market launch – always strikes sooner or later, and no matter how well or how diligently the preparations and testing work may have been, this is a time when various questions arise. How will the machine be received by the customers? Will it truly live up to the promise it showed during its development and prototype testing? Will the machine be a market success? One year after the market launch, all of these questions can be answered with a clear „yes“.

NEW KLEEMANN MOBIREX EVO PLANTS - A GLOBAL SUCCESS STORY

kleeMAnn gMBH

A GOOD YEAR AFTER THE MARKET LAUNCH OF THE NEW GENERATION OF MOBILE IMPACT CRUSHERS, THE PLANTS HAVE SINCE BEEN USED FOR THE MOST DIVERSE APPLICATIONS THE WORLD OVER.

The right technical concept pays offIn terms of performance and fuel consumption, both the

MR 110 and the MR 130 have demonstrated what is possible in their size class when the right concept is applied. The new material flow concept, which ensures that there is no restriction to the flow of the material, successfully prevents the blockages, reduces wear and increases the performance of the entire plant. Factors contributing to this include proven Kleemann components as well as further

Kleemann Mobirex MR 110 Z EVO recycling rubble in China

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developed components, such as the active double-deck pre-screen, the vibrating discharge chute as well as the all new crusher with its new innovative inlet geometry and new rotor ledges technology. The fully automatic hydraulic gap setting system of the crushing jaw, which is unique in the market, also substantially improves not only the quality of the final product but also the availability of the plant in combination with the effective overload protection system.

Successful the world overAn MR 110 Z EVO plant has recently been proving

its worth in the field of recycling in Xuchang in the Province of Henan, China, crushing demolition material. The feed material has an average size of 0 - 900 mm, in some cases even 1,000 mm, and is crushed to a size of 0 - 32 mm. The material is then recycled for use in the manufacture of various products, such as cement and bricks, or is used as a subgrade material in road construction. Performance tests showed feed capacities of as much as 350 t/h. According to David Zhao of Wirtgen Group sales and service company Wirtgen China, the customer already had experience with other makes, but only the Kleemann plant can fulfil its demands in terms of reliability and performance.

Another example is in Sydney, Australia, where an MR 130 ZS EVO is also being used for recycling. Diverse materials are being processed here, demonstrating the great versatility of the plant: asphalt, bricks, tiles, concrete and demolition material with dimensions of up to 700 mm are crushed to various sizes from 0 - 40 mm. These materials are being recycled and used for road construction, as well as in gabions and decorative applications. The decisive factors for the customer were the high average performance of more than 300 t/h, the robust design and machine features such as the active pre-screen and the diesel-electric drive system with direct crusher drive.

The new plants are also demonstrating their capabilities when it comes to natural stone, for example in a limestone application in Switzerland. Or in France, where an MR 110 Z EVO processes up to 3,000 tonnes of bauxite in an 8-hour shift. According to Michael Schwarz, Area Sales Manager at Kleemann GmbH, the customer is particularly impressed by the hourly capacity and low diesel consumption.

MR 130 ZS EVO processing asphalt in Australia

MR 130 ZS EVO crushing natural stone in Switzerland

MR 130 ZS EVO crushing natural stone in Switzerland

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Conclusion: market launch more than successful

These are just a few examples of many successful projects around the world. Time and again, the plants are impressing Kleemann customers with their tremendous performance, their low fuel consumption and wear and,

not least, the broad range of applications they can handle. And so, the questions posed at the start of this article can be answered not only with a clear „yes“, but with a resounding „Yes, and how!“.

Kleemann GmbH Mark Hezinger

Manfred-Wörner-Str. 160 73037 Göppingen | Germany

Tel.: +49(0) 71 61 - 20 62 09 Fax: +49(0) 71 61 - 20 61 00

eMail: [email protected] Internet: www.kleemann.info


MR 110 Z EVO crushing bauxite in France

MR 110 Z EVO crushing bauxite in France

Kleemann Mobirex MR 110 Z EVO processing slag in Spain

Kleemann GmbHKleemann GmbH is a member company of the Wirtgen Group, an expanding and international group of companies doing business in the construction equipment industry. This Group boasts the four well-known brand names, Wirtgen, Vögele, Hamm and Kleemann. Its parent plant is located in Germany and other production facilities exist in the Brazil, India and China. Customer service is provided on a global level through its 55 sales and service offices.

http://www.kleemann.info

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EVENTS


THE AMS-EVENT CALENDER2011

October 201104 - 07 Oct Surface Mining in XXI century Krasnoyarsk, Russia www.russianmining.com

05 - 07 Oct MiningWorld Uzbekistan 2011 - 6th International Exhibition for the Mining & Processing of Metals & Minerals Tashkent, Uzbekistan www.ite-uzbekistan.uz

06 - 07 Oct Bergbau- und Steine- und Erden-Tag 2011 Amberg/Oberpfalz, Germany www.abbm-bayern.de

09 - 12 Oct Mineral Processing 2011 Lake Tahoe, NV, USA www.minprocshow.com

11 - 13 Oct POWTECH 2011 Nürnberg, Germany www.powtech.de

12 - 14 Oct MPES 2011 - 20th International Symposium on Mine Planning and Equipment Selection Almaty, Kazakhstan www.mpes2011.cmrp.kz

13 - 14 Oct Jahresversammlung der GDMB Goslar, Germany www.gdmb.de

13 - 14 Oct gemeinsame Vortragsveranstaltung "Neue Rohstoffprojekte in Deutschland" Goslar, Germany www.gdmb.de

16 - 18 Oct 31st Coaltrans World Coal Conference Madrid Madrid, Spain www.coaltrans.com

17 - 18 Oct Latin Exploration 2011- 3rd International Conference on Exploration in Latin America Buenos Aires, Argentina www.argentinamining.com

17 - 19 Oct Rock Mass Classification For Mine Design Spokane, WA, USA www.edumine.com

19 - 20 Oct Tanzania - Mining Energy Conference & Exhibition Arusha, Tanzania www.tanzaniaminingenergy.com

26 - 28 Oct Mining 2011 Resources Convention Brisbane, Australia www.verticalevents.com.au/mining2011

26 - 29 Oct XXIX Convención Internacional de Minería 2011 Acapulco, Mexico www.tcexpo.com.mx

28 - 31 Oct China Coal & Mining Expo Peking Peking, China www.chinaminingcoal.com

November 201106 - 08 Nov China Mining 2011 Tianjin, China www.chinamining.org

07 Nov Steinkohlentag: Steinkohle 2011 - Energie für neue Wege Essen, Germany www.gvst.de

08 - 09 Nov 8. Hochschul-Kupfer-Symposium Hanover, Germany www.kupferinstitut.de/symposium

08 - 10 Nov Next Generation Mining Summit - Africa South Africa www.ngminingsummit.com

09 - 10 Nov Tagung "Aufbereitung und Recycling" Freiberg, Germany www.uvr-fia.de

15 - 16 Nov 8th Annual Exploration & Mining Investment Conference 2011 Stockholm, Sweden www.rmg.se

15 - 17 Nov Geothermiekongress 2011 Bochum, Germany www.geothermie.de

16 - 18 Nov 10th International Symposium on Tunnel Construction and Underground Structures Ljubljana, Slovenia www.ita-slovenia.si

21 - 24 Nov The BiG 5 - International Building & Construction Show Dubai, UAE www.thebig5.ae

21 - 24 Nov SITP Algier Algier, Algeria www.salontp.com

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GEOLOGICAL INVESTIGATIONExploration

Survey & Mapping•

Mineral exploration program•

Geological investigation•

Geochemical investigation•

Geological and structural analysis•

Microscopic investigation and mineralogical analysis •

Geological ModellingData collection and review of projects•

Database validation and verification•

Exploration and data management•

3D geological, structural and mineralization interpretation •and modeling

Statistic and geostatistic analysis•

Geostatistical resource estimation•

Resource classification, reporting andreconciliations•

MINE DESIGN & MINE OPTIMIZATIONMine Planning

Design and optimization of pit layout •

Mine development planning•

Scheduling •

Design of mine dumps•

Optimum location of surface facilities•

Field of activityFEASIBILITY STUDIES•

ExPLORATION•

GEOLOGICAL MODELLING•

GEOSTATISTICAL RESOURCE ESTIMATION•

RESOURCE CLASSIFICATION•

MINE DESIGN•

MINE OPTIMIzATION•

EQUIPMENT SELECTION•

DRILLING & BLASTING•

SLOPE STABILITY & MONITORING•

ASSESSMENT OF GEOTECHNICAL RISK•

HYDROLOGICAL INVESTIGATION•

HEALTH & SAFETY IN MINING •

MINING TECHNOLOGY CONSULTING

COMPANY-PRESENTATION

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Equipment Selection & ModellingLoading and haulage•

Transport route optimization•

Optimization of primary crusher location (Mobile / semi-•mobile / stationary crusher)

Economic evaluation•

Slope Stability & MonitoringGeotechnical investigation•

Groundwater investigation•

Slope stability assessment•

Slope design•

Implementation of geotechnical instrumentation•

Slope monitoring•

Assessment and management of geotechnical risks•

Drilling & BlastingPlanning of drilling and blasting•

Blast vibration control•

Control of borehole deviation•

Economic evaluation•

Compact coursesFor the international mining industry on mining methods and technology:

Seminars, conferences, courses, lectures and workshops•

Albrecht-von-Groddeck-Str. 3D-38678 Clausthal-Zellerfeld

Tel.: +49(0) 53 23 - 98 39 33Fax: +49(0) 53 23 - 96 29 90 8

MINING TECHNOLOGY CONSULTINGProfessor Dr.-Ing. habil. H. Tudeshki

www.mtc-tudeshki.com


COMPANY-PRESENTATION

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EVENT NOTE

Issue 03 | 2011

IMPRINT

121www.advanced-mining.com

PUBLISHING COMPANyAMS Online GmbHDiepenbenden 2952066 Aachen | GermanyeMail: [email protected]: www.advanced-mining.comSt.-Nr.: 201/5943/4085VST | USt.-ID: DE 262 490 739

EXECUTIVE MANAGERDipl.-Umweltwiss. Christian Thometzek

PUBLISHERProf. Dr.-Ing. habil. Hossein H. TudeshkiUniversity Professor for Surface Mining and International MiningeMail: [email protected]

EDITORIAL TEAMProf. Dr.-Ing. habil. Hossein H. TudeshkiDr. Monire BassirDipl.-Umweltwiss. Christian ThometzekeMail: [email protected]

DESIGN & LAyOUTDipl.-Umweltwiss. Christian ThometzekeMail: [email protected]

BANK CONNECTIONBank: Sparkasse Aachen, BLZ 390 500 00Account-No.: 1070125826SWIFT: AACSDE33IBAN: DE 27390500001070125826

GRAPHICAL DESIGNGraumann Design AachenDipl.-Des. Kerstin GraumannAugustastr. 40 - 4252070 Aachen | GermanyTel.: +49 (0) 241 - 54 28 58Fax: +49 (0) 241 - 401 78 28eMail: [email protected]: www.graumann-design.de

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AMS-Online Issue 03/2011

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