BHT: Jan 2010

BULK HANDLING TODAY Jan 2010

Jan 2010
Featured on the cover:

Contents
Rema Tip Top
Cover Story 29 Terminal with a Difference
Tel: (011) 813-2222 5 Reducing Risks
Email: juan.slabbert@re- 33 Market Forum
matiptop.co.za Earthmoving
7 Service is Key Endorsing Bodies
9 Beating the Crunch • CMA (Conveyor Manufacturers
Association)
Lifting Equipment • HCASA (Hydraulic Conveying
11 Be Legal, be Safe Association of SA)
15 How to Select a Crane
• LEEASA (Lifting Equipment Engineering
Trucking Association of South Africa)
19 Future in Their Hands • RFA (Road Freight Association)
Copyright Beltcon • SAIMechE (SA Institution of Mechanical

All rights reserved. No edi- 21 Conveyor Idlers Engineering)
torial matter published in • SAIMH (SA Institute of Materials Handling)
“Bulk Handling Today” may Harbours & Ports
be reproduced in any form 25 Open Top Containers in Materials
or language without written Handling
permission of the publishers.
While every effort is made to
ensure accurate reproduction,
the editor, authors, publishers
and their employees or agents
shall not be responsible or in
any way liable for any errors,
omissions or inaccuracies
in the publication, whether
arising from negligence or
otherwise or for any conse-
quences arising therefrom.
The inclusion or exclusion of
any product does not mean
that the publisher or editorial
board advocates or rejects its
use either generally or in any
particular field or fields.
The monthly circulation Proprietor and Publisher: Advertising Sales:

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

CONVEYOR MANUFACTURERS ASSOCIATION
Happy New Year!

The focus of the whole world will be on South Africa for the CMA Members List as at January 2010
World Cup and other sporting events this year, so what a
marvellous opportunity to showcase all that is new in ad- All members subscribe to the CMA Code of Ethics
vancing technology in our industry! Last January, I urged Member Company
that each and every opportunity that offers itself is grabbed ABB Industry
with two hands and used to maximum advantage – so what Afripp Projects
has been achieved during 2009? Actom
F
Atlanta Manufacturing
irst of all, industry has gained another Bateman Engineered Technologies
Bauer a Division of Hudaco Transmission
40 graduates of the Diploma in the
BMG (Bearing Man Group)
Design and Operation of Belt Convey- Bearings International
ors, thanks to the efforts of Graham Belt Reco RSA
Shortt and the rest of the CMA Qualifications Bonfiglioli Power Transmissions
organising team, and of course, thanks to Bosworth A Division of Hudaco Trading
the candidates own hard work in achieving Brelko Conveyor Products
a successful result in the examination. CKIT Conveyor Engineers
Continental Crushing & Conveying
The CMA Belting and Belt Splicing Working Conveyor Watch
Group completed its task when SABS published CMG Electric Motors South Africa
three new national standards in belt splicing: CPM Engineering
CT Systems
SANS 484 parts 1 and 2, SANS 485 and
David Brown Gear Industries
SANS 486 were all issued in 2009. With Delras Engineering
these standards now in place, belt splicing DRA Mineral Projects
Simon Curry construction companies are able to apply for Dunlop Belting Products
the SABS mark of accreditation and splice Dymot Engineering Company
construction training may be regulated. This ELB Engineering Services
is the next step in which the CMA intends to make Facet Engineering
Fenner Conveyor Belting (South Africa)
a big impact in 2010.
Flexible Steel Lacing SA
This is the next step in which the CMA intends to make Hansen Transmissions SA
Hosch - Fördertechnik (SA)
a big impact in 2010
M & J Engineering
Martin Engineering
In 2009, the CMA Handbook Working Group made Melco Conveyor Equipment
great strides in gathering material for the CMA Moret Mining
Handbook and when assigning tasks to everyone MS Conveyor Pulleys SA
involved, made a firm resolution that 2010 is to be Nepean Conveyors
the year in which it is to be published. The Hand- OE Bearings
book is being written specifically for South African Osborn Engineered Products SA
Read Swartman & Voigt
conditions – another first for our industry!
Rema Tip Top South Africa
Events Renold Crofts
The Calendar of CMA events in 2010 are as fol- Roymec
RSV ENCO Consulting
lows:
Sandvik Materials Handling SA
Members Meetings: 3 February, 14 April, 9 June, Schaeffler South Africa
13 October, all on Wednesdays at Bryanston Secrivest
Country Club. Senet
Annual Golf Day: Wednesday 17 February at Benoni SET Agencies
Country Club. SEW Eurodrive
Annual Dinner: Wednesday 19 May at Bryanston Shaft Engineering
Shaw Almex Africa
Country Club. Siemens Southern Africa
Please check the website www.cmasa.co.za regularly SKF South Africa
for information on CMA activities. Technique Avant Garde
ThyssenKrupp Materials Handling
All that remains is for me to wish each and every Transmission Components
one of you a happy, healthy, successful and pros- Unitek Engineers
perous New Year. Veyance Technologies Africa
Voith Turbo
Simon Curry Zest Electric Motors
Chairman
COVER STORY
Reducing Risks
The concept of Total Cost of Ownership can be traced as far back as Napoleon’s time when engineers began to
pay close attention to issues like the effectiveness of cannons, how easily they were moved and repaired, and
how long they lasted in active service. In modern times, TCO (total cost of ownership) analysis was popularised
by the IT industry to determine the financial impact of deploying information technology products over their
lifecycle.
develop something specifically for service

around the conveyor belt, rubber and
corrosion industries of South Africa.”
Services
“Over the past eight months, our TCO
service model has been implemented at
a local coal mine and it’s been a huge
success,” adds Dries van Coller, General
Manager Rema Tip Top South Africa.
“We physically established a presence on
site and our personnel took full control
of the conveyor operations in terms of
maintenance, repairs and continuous
improvements.
Part and Parcel
“Over the past four months, our staff has
become part and parcel of the mine’s
daily activities on a full-time basis to
look after all conveyor operations. In
an alliance relationship, Dunlop Belt-
Managing Director Rema Tip Top South Africa, Thorsten Wach (left) and (right) Dries van ing South Africa was part of the initial
Coller, General Manager Rema Tip Top South Africa set-up, but since acquiring Dunlop, the
T
full service offering now comes from
oday there are a number of methodolo- Rema Tip Top.
gies and software packages to apply TCO
“We now supply the belting, splice it and install it
calculations to the business plan of vari-
together with our wide range of conveyor products
ous industry sectors. However, it basically
that make up a conveyor system,” explains Dries.
comes down to determining the additional costs
“When it comes to equipment we don’t manufacture
that must be added to the initial purchase price
ourselves, such as conveyor mechanicals, a number
of an item in order to calculate the total cost of
of equipment partners supply us so we can offer
ownership.
a full service. In terms of maintenance, however,
The end-user wins all the way because nobody we service all the equipment around the conveyor
understands a conveyor systems and all the equipment systems ourselves.”
around it better than us Products
Rema manufactures a wide range of product in-
South Africa cluding rubber linings, coatings, wear protection,
Rema Tip Top is an international company that corrosion protection, bonding systems, belt cleaning
has practiced TCO principles for many years across systems and vulcanising products. “Having such
the world and they’re now rolling out a model in a wide range of products which now includes all
South Africa specifically developed for the con- belting products and associated services, the end-
veyor industry. “Bulk Handling Today” speaks to user wins all the way because nobody understands
Managing Director Rema Tip Top South Africa, a conveyor systems and all the equipment around
Thorsten Wach. “Although Rema Tip Top has it better than us,” says Thorsten. “Also, we have
been doing this in Europe for many years, it is a worldwide resources to tap into within the group
relatively new development for the local conveyor to solve any eventuality that may arise around a
market,” he says. conveyor system.”
“We tapped into many TCO models applicable to Rema Tip Top’s dedicated TCO model can be
a diverse cross-section of industry to adapt and tailored to any of the various service applications,

COVER STORY
be it corrosion protection, wear protection,

conveyor maintenance, conveyor servicing or
a combination of these. Dries elaborates,
“We follow the same business model
and simply adapt it to each client’s
specific requirements. However, the
unique programme is very flexible,
so we can tweak it to make each
installation site specific, even within
the same company.”
Data
Web-based software is used to
control and communicate with
the conveyor systems in order to
build up a database of informa-
tion on activities and actions on
the site. Says Dries, “This allows
us full tracking in terms of asset
management for each individual site.
What makes our offering unique is
the way in which we have adapted the
programme for conveyor belt service and
corrosion protection applications.”
“For example, the database contains a list of
each and every idler, bearing, belt, scraper and
other component on the conveyor system,” adds
Thorsten. “It will not only maintain a full history
of every component replacement and the services
carried out, but the system also plays a crucial
role in warning and planning for future services
and component replacements.”
Unlike mining staff, we’re always in

touch with new conveyor technology as
it develops which is a major advantage
Advantages
The advantages for the conveyor owner are numer-
ous, the main one being a significant reduction
in costly unexpected breakdowns due to poor or
neglected maintenance. “Having service staff on
site reduces the chances of an unexpected belt tear,
for example, because they have the experience to
notice fatigue in other components that may lead
to a belt failure,” says Thorsten in conclusion.
“Unlike mining staff, we’re always in touch with
new conveyor technology as it develops which is a
major advantage for the owner. We constantly bring
new technology, standards and freshly-trained staff
right onto his doorstep as part of our service. Not
only do the customers benefit but we also help to
set standards and maintain quality service levels
in the conveyor industry in general.”
Juan Slabbert, Tel: (011) 813-2222, Email: juan.slabbert@
rematiptop.co.za

EARTHMOVING
Service is Key
Earthmoving equipment hire and the purchasing of notably hydraulic hammers. Then in 2006, they
second-hand machines has picked up. In most instances, a secured the sole dealership for Southern Africa for
good second-hand machine can save on capital and still get the Komac brand of hydraulic hammers and attach-
the job done. ments. Komac, based in Korea, is a manufacturer
of hydraulic breakers and attachments.
“
Bulk Handling Today” speaks to Vaughan Ellis, Vaughan explains, “We’re particularly proud that
owner of Maximum Plant and Equipment. By we are a featured supplier of quality plant and ma-
way of background, Vaughan explains that chinery to many blue chip South African organisa-
Maximum started operations in 1997 with tions in the earthmoving, mining and construction
the sales and marketing of quality used equipment. industry. Our team of qualified staff attends to any
In 2005, they branched into the plant hire market mechanical or servicing queries that customers
specialising in excavators and attachments, most may require. We are small enough to care, yet big
enough to deliver. And our service ethos is
apparent throughout the company.
Much potential
“We offer a full range of tracked excavators
from 5 tonne through to 50 tonne with
trenching buckets, ripper buckets, general
purpose buckets and hammers. Backhoe
loaders come with trenching buckets, stan-
dard buckets and hammers. We believe that
our rates, service, delivery and back up are
second to none in the market which is why
our clients return time and time again.
There are some challenges, for
example, getting finance for the
machines
“On the attachment side we have been very
successful in the scrap metal and timber
industries with our brackets and grabs. Al-
though we are still small in this field, there is
a lot of potential in this market and because
we have a quality product, we are sure to
grow,” says Vaughan optimistically.
More lenient
We ask him if second-hand equipment sales
have picked up in the current economic
climate? “There is a marked increase in the
rental side and the purchasing of second-
hand machines. However, there are some
challenges, for example, getting finance for
the machines,” he says.
“This has been one of the biggest problems
but it appears that the banks are getting
a bit more lenient. To assist, we have put
together quite a few hire to purchase con-
tracts for customers.”
Having said that, the company has expe-
rienced five years of growth even in these
times. “Because we are so niche, especially
in the attachment market but also because
we have diversified, the economy has actu-
ally been quite kind to us. I do think that

EARTHMOVING
2010 is going to be a lot better that 2009 which He goes on to says that they are still doing well
is something to look forward to,” Vaughan adds. mainly because they have a few blue chip clients
who have supported them through the year.
I believe this is where the men separate from the boys. “We have clients like Rumdel Cape, Quarry Cats
On the second-hand equipment side we tend to stick to (Group 5) and Fraser Alexander Bulk Mech. Another
what we know of our big clients is Protech Khuthele who has
placed a lot of business our way.”
Vaughan is a big believer in back up and
service. “I believe this is where the men
separate from the boys. On the second-
hand equipment side we tend to stick to
what we know and only sell machines that
we know we can service. All the machines
have warranties.”
For the future
Vaughan concludes by saying that they have
plans for expanding their rental fleet “We
would like to gain a bigger market share on
the attachment side and, otherwise, keep
on doing what we have been doing so far.
If it ain’t broke, don’t fix it!”
Vaughan Ellis, Owner, Maximum Plant and Equip-
ment, Tel: (011) 464-0930/1, Fax: 086-504-7119,
Email: info@maximumplant.co.za, Website: www.
maximumplant.co.za

EARTHMOVING
Beating the Crunch

Ending the year on a high note is not
something that most earthmoving com-
panies can lay claim to. Although 2009
has been hard for everyone, it looks like
things are starting to change.
aftermarket business, ensuring

a stable base going forward.
Extremely conservative lending
criteria by banks has adversely
impacted on equipment sales but
this has buoyed our spares sales
as clients extend the service life of
their machines,” he explains.
Customer support
Morné ascribes the company’s
W
success to its strong culture of
e speak to Morné Booij-Liewes, ‘support first and sale second’.
Communications Officer for Babcock “You must ensure your clients receive the highest
Equipment. level of technical and aftermarket support, and
He explains that the past year has only when this is achieved do we earn the right to
been a tough one but one with several highlights sell them equipment.”
including the local launch of the Volvo Road A hands-on team of skilled and experienced prod-
Machinery line as well as the delivery of the first uct specialists and technicians provide a 24 hour
L350F wheeled loaders, the biggest in the Volvo product support and technical information service.
product range. “We also have comprehensively equipped workshops
“The current market conditions are the toughest we throughout our branch network. Our product support
have yet seen, but in spite of many of our competitors services includes technical training, application
suffering record losses, Babcock Equipment has, analysis, operator training and warranty support.
for the trading year to date, remained in positive A centralised warehouse provides a personalised
figures. With the large population of Volvo machines, parts service and availability at first pick’s in
we have been able to harvest greater volumes of excess of 90%. We also run a very successful in-
house apprentice diesel earthmoving technician
programme and currently have 54 apprentices
Extremely conservative lending criteria by banks has
undergoing training,” says Morné.“
adversely impacted on equipment sales
Leading brands
“The company represents some of the lead-
ing brands in the industry including Volvo
Construction Equipment, Winget and Ponsse.
Babcock Equipment has sold more than
5000 Volvo CE units since being awarded
the exclusive Volvo CE distributorship for
South Africa, Namibia, Botswana, Zambia,
Swaziland, Lesotho, and most recently, Mo-
zambique. The company has also, during
the almost 10 years it has represented the
Volvo CE brand, been recognised as Top
Dealer for the International Region on three
occasions in addition to winning several
awards for sales success and after-market
service excellence.
Says Morné, “However we have definitely
been affected by the economy. The contin-

EARTHMOVING
implemented at the company, inventory

reductions and the adjustment of costs to
current demand.”
Measured in units, the total world market
for heavy, compact and road machinery
equipment decreased by 42% in the third
quarter of 2009 compared with the same
period last year. In Europe the market was
down by 54%, the North American market
decreased by 50% and Asia declined by
11%. Other international markets decreased
by 61%.
The rapid flow of stimulus funding into its
construction industry meant that China was
one of the few bright spots in the industry dur-
ing the period, increasing by 45% compared
with 2008. In fact Asia accounted for over
a third of Volvo Construction Equipment’s
net sales during Q3 – putting it on a par
with Europe.
Positive signs
“Tough market conditions continue in the
sector, but there are some positive signs
indicating that the decline in demand may
have bottomed out and that we are now
beginning a gradual recovery,” says Olof
Persson, President & CEO of Volvo Construc-
tion Equipment.
“But we are not relying on a substantial
recovery and will therefore continue to
Measured in units, the total world market for heavy, improve efficiency and adjust our costs to
compact and road machinery equipment decreased by current demand. I am confident of improving our
42% market position globally as we are well positioned
for the new emission regulations that will soon
ued weakness in the world market for construction
come into force, with new products and services
equipment was reflected in Volvo Construction
at the absolute forefront.”
Equipment’s third quarter 2009 financial results,”
he adds. The outlook for the full year is expected to see
both the European and North American markets to
Declining sales have reduced by 50% during 2009 compared with
“Net sales declined by 38% during the period. How-
2008, while the rest of the world is forecast to see
ever, the operating loss was considerably below
a reduction in demand of between 40-50%.
the SEK 1,259 M experienced in the second
quarter of 2009. This Company structure
improvement Morné gives us a bit of background on the
is the re- company and says that Babcock Equipment
sult of effi- is one of five divisions of Babcock Brands
ciency mea- which, in turn, is a division of Babcock Africa,
sures being a wholly-owned subsidiary of the Babcock
International Group, a London Stock Ex-
change listed FTSE 200 Company.
“Founded in 1947, Babcock Equipment
has generally shown steady growth,
largely due to its acquisition of leading
brand names.” he adds.
Morne Booij-Liewes, Communications
Officer, Babcock Equipment, Tel: (011)
230-7300, Fax: (011) 397-6614, morne.
booijliewes@babcock.co.za
10 BULK HANDLING TODAY Jan 2010

LIFTING EQUIPMENT
Be Legal, be Safe…
Any company that lifts goods on its prem-
ises should have a safe lifting programme
in place, not only to comply with the ba-
sic legal requirements, but also to ensure
control over the safety of the working
environment of their people. In addition
to lifting, lowering and stacking goods
properly, expensive lifting equipment and
tackle will last that much longer if well
taken care of.
“One of the most neglected aspects concerning lift-

ing equipment is storage,” adds Piet. “It is a legal
requirement that equipment be stored properly when
not in use. Lastly, companies must comply with the
procedures, codes of practice and quality standards
around lifting equipment. Safety is obviously the
first concern but it is equally important to comply
with the legal aspects concerning record keeping,
a highly neglected aspect of lifting equipment.”
Tackle inspectors
A misconception in the lifting industry, spread by
certain service providers who want to make easy
money, is that a company’s LTI (lifting tackle
inspector) has to be a registered LMI (lifting ma-
chinery inspector). “The LTI does not have to be a
registered ECSA LMI,” stresses Piet. “This is clearly
stated in GNR 257, published in the Government
Gazette on 7 March, 2008. Lifting tackle has to
be inspected properly at intervals not exceeding
three months by an LTI and these inspections can
be done in-house or contracted out.
100% overload
“Lifting tackle does not have to be proof load tested
annually or at any given interval and only needs
to be inspected visually. The practice of proof load
Piet Otto of Phakamisa
testing used lifting tackle, which has been in use for
P
some time now, is not a legal requirement and not
iet Otto of Phakamisa Safety Consultants, a recommended by lifting tackle manufacturers.
company that specialises in safety, training,
“The reason is straightforward,” Piet elaborates.
plant audits, registers and codes of practice
“Why apply a test load to lifting tackle if it is obvi-
for the lifting industry, speaks to “Bulk
ously damaged, worn or shows any defect during
Handling Today.” “Firstly you have to select the
a visual inspection? Rather just scrap it. On the
correct lifting equipment and then use it correctly,”
other hand, why apply a load test to lifting tackle
he says to outline what a safe lifting programme
if it does not show any sign of damage, abuse or
entails. “The records of lifting equipment on your
deterioration, rather use it. A proof load test is in
premises must always be up to date. They should
effect a 100% overload and, in fact, repetition can
not only contain copies of the certificates from
severely damage the lifting tackle or weaken it as
your suppliers, but also records of the inspections
a result of the overload applied thus reducing the
carried out on the equipment.
working life of the sling.”
A misconception in the lifting industry, spread by certain
Registers
service providers who want to make easy money, is that A while back Piet realised that keeping proper
a company’s LTI has to be a registered LMI records is a serious shortcoming in industry in
BULK HANDLING TODAY Jan 2010 11

LIFTING EQUIPMENT
general. Existing registers were outdated while

some companies simply found a book somewhere
to do the job. Piet set out to compile a new register
that makes it easier for companies to comply with
legal requirements in terms of both the OHS-Act as
well as the Mine Health and Safety Act. “Although
we are now bringing out the fourth edition of the
register, it’s still a fairly new thing to the industry,”
he says. “Those who are using the register swear
by it and order new replacement registers as stock
items every year.”
One of the most neglected aspects
concerning lifting equipment is storage
The register is a 108 page guide to lifting equipment
inspections, contains product information, columns
to record inventory, repairs, examinations as well
as detailed inspection checklists for 30 items of
12 different types of lifting equipment, including
harnesses, over a 12-month period. There is enough
space in the register to note who the lifting tackle
inspector of the company is, outline a lifting opera-
tions plan, list legal requirements and standards
as well as general safety requirements.
Personalised
Lifting equipment definitions are listed while there’s
information on lifting tackle types, inspection meth-
Lifting tackle

LIFTING EQUIPMENT
formance, or at least a Certificate of

Conformance,” he says. “A Certifi-
cate of Test and Conformance must
display the actual test load applied,
as well as the standard to which the
product conforms. This certificate
must also include the date of test,
manufacturer’s details, relevant sling
or component markings or serial
numbers and other information as
required by the standards to which
the item is manufactured.
Existing registers were outdated while some

companies simply found a book somewhere
to do the job
“The Certificate of Conformance,

on the other hand, simply specifies
that an item was manufactured in
compliance with a specific quality
standard,” says Piet in conclusion.
Tracing the item
“This certificate is normally issued
after batch testing only and not
individual load testing of compo-
nents as is the case with shackles,
eye bolts, wire ropes and webbing
slings. Furthermore, all components
used on a sling, such as hooks and
connectors, must be marked with
clearly recognisable and traceable
brand names or other markings that
The register can trace the item back to the original
supplier or manufacturer.”
ods and criteria and an inventory list. Piet has even
gone as far as including an incident report form Piet Otto, Phakamisa, Tel: (011) 462-9620, Email: potto@
and there’s a special section to record repairs to icon.co.za
chain blocks and lever hoists. It’s rounded off with
sections for examination and test
reports, check lists for inspections
and a notes section for summaries
and conclusions.
“For those who want it, we now can
now also put the company name and
logo on the cover of the register,”
says Piet. “Keeping the register is
the responsibility of the lifting tackle
inspector (LTI) appointed from the
company whose life is made much
easier every three months when he
has to update the register in which
to record inspections.”
Certificates
Piet stresses the importance of
buying lifting tackle from reputable
suppliers who can meet all the
documentation requirements. “All
lifting tackle should be supplied
with a Certificate of Test and Con-

LIFTING EQUIPMENT
How to Select a Crane

The selection of an overhead or gantry crane is not as straightforward as it may first appear mainly due to
each crane being built differently because no two buildings are alike. To add to the complexity, the duty cycle
of the crane has to be determined accurately, not only to comply with regulations, but also to ensure that the
crane is manufactured to last its full lifecycle.
T
o learn more about the art of manufacturing
overhead cranes, “Bulk Handling Today”
speaks to Frikkie Henning, Service Manager
at East Rand Cranes. “It is crucial to first
ascertain the duty cycle of a crane before you decide
on building a light, medium or heavy duty crane,”
he says. “It is also important to consider future
expansion of the business so that you don’t run
out of capacity when the duty cycle of the crane
increases due to heavier lifting more frequently.
A common mistake is to underestimate the forecast
which means that clients run out of capacity very
quickly
“If, for example, you’re using the crane all day long
to lift three tonnes and only lift ten tonnes once in
a while, then a light duty crane will suffice because
you’re not working at full load all the time,” Frikkie
explains. “However, if this crane starts working at Frikkie Henning, Service Manager at East Rand
Cranes
Final assembly of a gantry crane

LIFTING EQUIPMENT
For a long crane life, it is essential to service a crane of overloading, but because it is working hard
frequently more frequently and the duty cycle chosen was
incorrectly calculated.”
full load all the time, the customer should have
chosen a medium duty class from the beginning Building a crane
otherwise the crane simply won’t last, not because East Rand Cranes manufactures crane systems
either to supplied specifications
or they are designed to spec ac-
cording to the customers forecast
of the crane’s duties. “A common
mistake is to underestimate the
forecast which means that clients
run out capacity very quickly,”
Frikkie says. “Even if specifica-
tions are supplied, we will always
advise the customers to make sure
his or her forecasting is realistic
in terms of what he expects the
crane to do now as well as in
the future.
“The situation where the light
duty crane starts doing the work
of a medium duty crane before
long should be prevented from the
outset,” says Frikkie. “However, if
medium duty work is introduced
over a long period of time, it is
possible to upgrade the hoist and
A hoist in the workshop
the crane to a certain degree,
but it can be costly because all
the components including the gearbox on a crane
are designed to a specific duty cycle. On very
rare occasions you can mix the components and
use a 2M duty gearbox with a 1M duty motor, for
example.”
Structures
It is also important to assess the support structures
that the crane will be mounted on because one ten
tonne crane may weigh much more than another
and therefore the structures have to be inspected
beforehand as well. “Up to 3M duty the crane
design is pretty standard, but when it reaches the
4M duty class cranes, the crane itself becomes
much bulkier,” says Frikkie.
“For example, if you put a ten tonne 2M duty crane
and a 4M duty ten tonne crane next to each other
you’ll clearly see that the 4M class is of a much
bulkier construction than the other in spite of hav-
ing the same capacity. The girder and components
are built specifically to withstand the high stresses
associated with heavy duty craning. The class of
crane therefore determines the type of support
structures necessary for the rails.”
The workshop
Frikkie takes us through their workshop where
cranes of various sizes are in different stages
of completion. Hoists, motors, electrical control
panels and reels of steel rope are being fitted into
place on small and large girders with huge Demag
overhead cranes, for which East Rand Cranes are

LIFTING EQUIPMENT
the agents in South Africa. neglected, especially when times are tough like
Behind welding screens, the flare of arc welding now. But as we maintain service records for our
lights the place sporadically as we ask Frikkie about customers, it’s one less thing for them to worry
the actual construction procedures. “A completed about because we’ll call them up to advise when
crane has many of its sections hidden behind other a service or a load test is due.”
components and therefore we have very specific Linton Moodley, East Rand Cranes, Tel: (011) 817-3423,
holding points during construction,” he explains. Email: linton.moodley@eastrandcranes.co.za
“Our quality control procedure requires the inspec-
tion of all welds to check whether penetration is
correct, whether the stag-
ger is correct and so on.
Before any weld is covered
with something else, it
has to be inspected and
signed off by our internal
inspector.
We have very
specific holding
points during
construction
“This is standard proce-

dure, but if required, as
in the case of refurbishing
old cranes, we also carry
out non destructive testing
which is verified by an
independent third party
NDT inspector.”
New Workshop/
Stores
East Rand Cranes has The control system for a crane
recently built a new work-
shop and stores. The new
workshop will be utilised for
the fabrication and assem-
bly line for the fabrication
of crane box girders and
gantry’s. The workshop
will be fitted with 4 over-
head gantry cranes and 6
jib cranes as part of the
fabrication and assembly
line. The new spares store
holds R4 million of stock
for various overhead crane
spares/components.
Service
Another of East Rand
Crane’s services is to in-
spect and service cranes for
clients with a mandatory
annual load test on their
cranes and structures. “For
a long crane life, it is es-
sential to service a crane
frequently. Unfortunately,
this is an area that is often
A large crane system ready for delivery

TRUCKING
Future in Their Hands

A trucking and transport company has to be built from the Financial health
ground up. Getting your drivers involved and empowering FHS Accountancy and Management Services has
them, helps to grow the business exponentially. been appointed to assist the drivers with their
finances ensuring their financial affairs are in or-
W
der, submitting statutory returns, controlling high
e speak to John Sprenger, Owner- cost areas, and administering arrangements with
Driver manager for Cargo Carriers insurance companies, financial institutions and
about their successful driver-owner other third parties.
programme.
Cargo Carriers assists the drivers by providing fuel
Due to the ongoing success of the Cargo Carriers’ and maintenance services, properly maintained
Swaziland Empowerment scheme, which includes trailers, infrastructure, systems, experience and
five Cargo Carriers Swaziland Truck drivers operating back-up.
as owner drivers, a further 11 existing Swaziland
drivers have been appointed as owner drivers. Working together
On the education front, the candidates receive inten-
The success of the programme depends on the owner sive training through Cargo Carriers’ four-day train-
drivers rendering the outsourced transport work to the ing programme. Two days are spent on contractual
satisfaction of Cargo Carriers and service provider issues, operating parameters,
accounting matters and budgeting principles, and
is conducted by John Sprenger. The remaining two
The aim of the programme is to empower drivers
days cover entrepreneurship, business management,
who would otherwise never have an opportunity
problem solving, and business communications
to become successful entrepreneurs. The most
and is conducted by LCC Capital.
important aspect of the owner-driver programme is
the identification and training of suitable candidates The first task for each of the drivers is to employ
and the experience they receive. a co-worker and two shared workers per branch to
ensure that they can provide a double shift, 24/7
Successful entrepreneurs operation for the 8,5 month crop season. The
The new owner-driver programme commenced at the owner-drivers must, therefore, strike a balance
start of the new 2009 Swaziland cane crop season. between both control and supervision measures.
Five of the 11 drivers are based at the Swaziland
Simunye branch, while the remaining six are based “The success of the programme depends on the
at the Swaziland Big Bend branch. owner drivers rendering the outsourced transport
work to the satisfaction of Cargo Carriers and its
“In terms of the service agreement with each of customers. Customer service cannot be compro-
the 11 new owner drivers, certain portions of two mised at any stage. It is vitally important that the
of the Cargo Carriers Swaziland contracts are out- drivers ensure that the correct product, of the right
sourced to the drivers. These include the hauling quality, is timeously delivered to the customers as
of infield cane from fields to the loading zone or per the daily delivery schedule,” adds John.
field edge, and the hauling of cane from the fields
to the mill,” explains John. Grassroots level
“This programme is all about a con-
tinuing partnership; where the drivers
are empowered to determine their own
success and the direction of their own
future. This is not boardroom empower-
ment, instead it is aimed at a grassroots
level because that is where true success
lies!” concludes John.
Elmarie Ollewagen, Business Development &
Communications Manager, Cargo Carriers,
Tel: (011) 485-8700, Fax: (011) 485-8781,
E-mail: elmarie@cargocarriers.co.za

BELTCON
Conveyor Idlers
Conveyor idlers are generally considered a consumable element of the conveyor. Their unit value is relatively
low when compared to the price of a pulley, plummer blocks or the conveyor belting. However, there are many
idlers within a conveyor system. Consider a typical in-plant conveyor, say 250 m long – typically this would
comprise 5 pulleys, 250 trough idlers and 80 return idlers, further broken down into 750 trough rolls and 80
return rolls (160 if V return idlers are used).
C
onsidering the possibility of damage re- required duty.
sulting from a failed idler roll (increased
An investigation of existing idler standards showed
friction, increased belt cover wear, pos-
that the idler load rating was specified in CEMA.
sibility of fire due to increased friction
This allowed the designer to specify a specific idler
and the possible catastrophic damage to the most
category to suit the required duty in accordance with
costly piece of equipment, the belt) it is clear that
the CEMA classification. One small problem was
a careful selection of the idler for a specific duty
that the CEMA standard was not readily available in
is required.
the old highly sanctioned South African market.
Selection The idler committee was again called together,
The failure of an idler roll is dependant on a mul- this time to update the standard to incorporate a
titude of factors including the initial specification method to allow for the selection of idlers to suit
based on the selection of the roll to suit specific specific duties. The committee decided to amend
design criteria, the inherent product quality and the standard by creating a Part 3 which would in-
the accuracy with which its components are manu- clude the performance criteria and testing methods
factured and assembled. previously incorporated in Part 1 as well as a duty
The committee decided to amend the standard by based selection method.
creating a Part 3 The development of Part 3 has been a continuing
project since 2004 and it is hoped that it will be
This paper reviews the development of SABS/SANS concluded in 2009.
1313, identifies in basic format the loads applicable
to idlers and defines the criteria used to select The basis for idler design
the idlers based on the identified maximum load Prior to discussing the creation of SANS 1313 Part
conditions. It then relates this to available selec- 3 it is worthwhile to review the factors affecting
tion standards and introduces the latest revisions idler design as well as idler selection criteria.
to SANS 1313, undertaken to ensure that the Idler loading
standard retains its relevance and high regard in The total load on an idler is established from the
the idler industry. following factors:
The available idler standards are: SANS 1313 • Burden or material load
PART 1, PART 2, PART 3 – 2009? • Mass of the belt
The first variation one notices is the change in • Self mass of the rollers
nomenclature from SABS (South African Bureau of • Secondary loads such as misalignment loads
Standards) to SANS (South African National Stan- (tension), loads due to dynamic effects (speed
dards), this being due to a realignment and creation and material dependant) , loads due to belt
of different business units within the SABS. geometry (curves)
Noticeable is the inclusion of a Part 3. The foregoing are well defined in most conveyor
The existing specifications and particularly SABS idler catalogues and in CEMA.
1313 Part 1 incorporated only a ‘series’ in differ- Selection criteria
entiating between idlers of different load carrying Once the total load on the idler has been calculated
capacity. Part 2 followed the part 1 format, but for the idler may be specified and selected on the basis
different styles of idlers (eg. fixed and linked sus- of the following criteria:
pended idlers). The idler series basically specifies
the diameter of the shaft at its ends (implying that • Roller diameter in terms of belt speed
this equates to the bearing inner diameter). • Roller bearing types and size
• Shaft diameter
Calculating the load on the idler and hence the • Idler base materials
most highly loaded roll carrying capacity within
the idler set was left up to the conveyor system Selection criteria for idler rolls
designer. The designer would typically select the Once the total load on the idler has been calculated
roll shaft diameter and bearing type to suit the the load applicable to individual loads can be cal-

BELTCON
culated by applying a Burden Factor (Burden Factor vantages of the use of taper roller bearings, in that
is the proportion carried by the most highly loaded under conditions of heavy load the significantly
roll) to the total load to obtain the individual roller higher load rating (when compared to a deep groove
loads. Typical burden factors on 3 roll trough idlers bearing) is reduced exponentially by the effect of
is 0.7, i.e. 70% of the total load is carried on the misalignment of the bearing components.
centre roll. The Burden Factor is dependant on the
Selection criteria for idler bases
idler type, trough angle, the material characteristics
Having calculated the total load on the idler, the
and the belt fill ratio.
main load carrying member of the idler base (typi-
The committee believes that it took the process further cally a rolled steel angle section) is selected on the
by including the shaft deflection criterion within the load basis of the following typical criteria:
rating • Maximum bending stress – dependant on type of
construction – typically 100MPa – 165MPa.
Having calculated the load on the most highly
• Maximum deflection at centre of 1/360 of
loaded roll, the roll is selected on the basis of
the mounting centres but limited to 5mm
three criteria
maximum
• Bearing life
• Shaft deflection
SANS 1313 ratings
The CEMA procedure gave the committee an indi-
• Shaft bending stress
cation of the way forward.
The bearing life and shaft deflection criteria are
The committee believes that it took the process
somewhat interdependent in that the formula for
further by including the shaft deflection criterion
calculating bearing life is only applicable in cases
within the load rating.
where the alignment between the inner and outer
cages (equivalent to the generically termed ‘shaft The process followed is as follows:
deflection’) remains within pre-defined limits. The bearing life criterion was selected as 40,000h
to match the requirements of SANS 1313.
Typical values for these selection criteria
are: The maximum load to achieve the 40,000h bearing
• Bearing life (as calculated using the L10 formula) life was calculated for different types of bearings
between 30,000 hours and 60,000 hours. based on the individual bearing Dynamic Load
• Shaft deflection dependant on bearing type. Rating at a roll rotating speed of 750rpm (the limit
Typical values for deep groove ball bearings set by SANS 1313).
are between 6-15 minutes of arc, highly de- The maximum load to limit the deflection to that
pendant on the type of cage material used. specified by the bearing manufacturer (dependant
Typical values for taper roller bearings are on bearing type and with due cognisance given to
between 2-6 minutes of arc dependant on the manufacturing tolerances) was then calculated.
geometry of the rolling elements. This was applied to all the roll lengths defined in
• Shaft bending stress of 110 MPa. SANS 1313 using a generic roll seal to determine
The values quoted for shaft deflection are the the ‘overhang’ dimension.
maximum allowable bearing value onto which it The lower of these two values (life and deflection
is practical to allow the idler manufacturer some dependant) was then selected as being the roll
leeway for manufacturing inaccuracies – hence rating for a specific roll face length.
typically the limits for deep groove ball bearings
Using the standardized sealing system and the
are set at between 5-10 minutes, again dependant
abridged data shown in the tables below a series of
largely on the bearing cage construction.
tables giving the maximum load carrying capacity
The foregoing illustrates one of the major disad- of a specific roll were created.
Bearing details Note that the life crite-
Bearing reference: 420204 420205 6205 6206 6305 6306 6307 6308 rion is based purely on
Static load rating: 5 11 7.8 11.2 11.6 16 19 24 kN a maximum roll rotating
Dynamic load rating: 10.4 12.7 14 19.5 22.5 28.1 33.2 41 kN speed and thus the need
Revs per minute: 750 750 750 750 750 750 750 750 RPM to replicate the tables for
Required bearing life: 40000 40000 40000 40000 40000 40000 40000 40000 hrs
different roll diameters is
Maximum bearing load in N: 855 1044 1151 1603 1850 2310 2729 3370 N
not required.
Maximum bearing load in kg: 87 106 117 163 189 235 278 344 kg The tables to be presented
Table 1: Data Used for Life Criterion in SANS 1313 Part 3 will
include:
Bearing ref: 420204 420205 6205 6305 6206 6306 6307 6308
Allowable bearing deflection to DIN: 14.0 14.0 15.0 15.0 15.0 15.0 15.0 15.0 min• 3 roll Trough
Basic allowance for manufacturing inaccuracies 6 6 6 6 6 6 6 6 min and Impact
Allowable deflection for calculation purposes: 8.0 8.0 9.0 9.0 9.0 9.0 9.0 9.0 min• 5 roll Trough
and Impact
Table 2: Data Used For Deflection Criterion

BELTCON
• 2 Roll V and Flat Return It will continue to ensure that the South African
• Separate tables for 3 and 5 roll link suspended idler manufacturing sector retains its good stand-
(garland) idlers. This is necessary to account ing amongst the worldwide materials handling
for the larger dim. Normally encountered with fraternity.
this type of roller. This paper has been condensed due to space constraints.
Two typical tables, for 3 roll Trough and Impact and The author is Adriano Frittella. This paper was first
for 2 roll Vee and Flat return are included below. presented at Beltcon 15 held in Johannesburg on Sep-
tember 2 and 3, 2009 and copyright is vested with the
Utilising CEMA without taking note of IMHC. Enquiries can be made through the website; www.
shaft deflection can lead to significantly beltcon.org.za
reduced roller life
Discussion
It is noted that the examples are merely 3 Roll troughing and impact
a direct comparison of tabulated values Belt width: Gauge: Allowable load on the centre roller in kg *
not reflecting the full design process, 400 180 174 213 235 377 327 471 556 687
however they give a clear indication 450 200 174 213 235 377 327 471 556 687
of the basic difference in approach 500 210 174 213 235 377 327 471 556 687
proposed by the two codes. 600 250 174 213 235 377 327 471 556 687
It is clear from the above that the major 750 300 174 213 235 377 327 471 556 687
difference between CEMA and SANS 900 350 164 213 235 370 327 471 556 687
1313 is the non-adherence in the CEMA 1050 400 139 213 235 312 327 471 556 687
code to the shaft deflection criterion. 1200 460 119 213 235 263 327 471 556 687
This becomes increasingly significant 1350 510 105 213 235 232 327 440 556 687
as the roll length increases. 1500 570 93 213 221 204 327 385 556 687
1650 620 85 207 201 185 327 349 556 687
Utilising CEMA without taking note of 1800 670 78 190 184 169 327 319 553 687
shaft deflection can lead to significantly 2000 750 69 168 163 149 315 281 486 687
reduced roller life. 2100 775 66 162 157 144 304 270 468 687
When considering SANS 1313 a note 2200 810 63 154 149 137 289 257 445 687
to the tables stipulates that ‘shafts are 2400 880 58 141 136 125 264 234 405 637
plain and not stepped’ i.e. the shaft Allowable load on 1019 2243 1590 2365 2283 3262 3874 4893
diameter is the same throughout its centre roller
length. Bearing ref: 420204 420205 6205 6305 6206 6306 6307 6308
Series: 20 25 25 25 30 30 35 40
There is clearly an economical case for The above loads do not include the rotating mass of the roll.
reducing the shaft diameter at its ends The rotating mass of the roll should be subtracted from the above roller load.
(depending on loading) and utilising * shafts are plain and not stepped
a bearing of smaller diameter. This Table 3: Roll Selection - 3 Roll Trough and Impact
may however create problems when
specifying replacement parts as the 2 Roll vee & flat return
user can only readily see the shaft Belt width: Gauge: Allowable load on one roller in kg *
end and will use this as the selection 600 310 174 213 235 377 327 471 556 687
dimension. 750 410 135 213 235 303 327 471 556 687
900 485 112 213 235 247 327 468 556 687
Conclusion 1050 570 93 213 221 204 327 385 556 687
In conclusion, the idler committee of 1200 645 81 198 192 177 327 333 556 687
the CMA is constantly reviewing the 1350 730 71 173 168 154 324 289 501 687
idler standard SANS 1313 with the 1500 810 63 154 149 137 289 257 445 687
aim of maintaining it as the premier 1650 895 57 139 134 123 259 230 397 625
worldwide specification. 1800 975 52 127 122 112 236 209 361 567
The soon to be issued revised specifica- 2000 1085 46 113 109 99 210 186 321 504
tion comprising three sections 2100 1156 43 106 102 93 196 174 300 470
2200 1195 42 102 98 90 190 168 289 453
• Part 1 – defining the dimensional
requirements of all rolls and of 2400 1308 38 93 89 81 172 152 262 410
‘foot mounted’ idlers Allowable load on 1019 2243 1590 2365 2283 3262 3874 4893
centre roller
• Part 2 - defining the specific require- Bearing ref: 420204 420205 6205 6305 6206 6306 6307 6308
ments for under-slung idlers Series: 20 25 25 25 30 30 35 40
• Part 3 – defining the performance The above loads do not include the rotating mass of the roll.
requirements and load ratings of The rotating mass of the roll should be subtracted from the above roller load.
idlers * shafts are plain and not stepped
Table 4: Roll Selection - 2 Roll Vee and Flat Return

Are You
Doing
Your
Bit?
Green This prestigious award recognises

people, projects and products
Supply
that have gone above and be-
yond the call of duty to enhance
the
environment in which they oper-
Chain
ate.
The inaugural awards in 2009
Awards
enjoyed a wonderful response
from the supply chain community
and everything is on track to make
this year’s event one of the indus-
try’s most prestigious accolades.
Come and see who walks away

with the coveted trophies and
enter your product or project for
this year’s event.
Entries for next year’s event open

in February and the awards cer-
emony is being planned for 26 Au-
gust 2010.
Contact: Catherine Larkin on

Tel: (011) 789-7327/787-9127,
Cell: 083 300 0331, Fax: (011) 787-7865
Email: cvlarkin@ciltsa.org.za
24
30 BULK HANDLING
Supply TODAY
Chain Today Jan 2010
Jan 2010
HARBOURS & PORTS
Open Top Containers in

Materials Handling
Containerisation has revolutionised cargo shipping since its introduction in the 1950’s. Today approximately
90% of non-bulk cargo worldwide is transported in containers, with 11.3 units handled every second in ports
around the world. Low cost and
easy access to handling equip-
ment has helped to extend the use
of containers to enter new fields.
Among these new applications is
the transport, storage and han-
dling of bulk materials.
D
uring the 1980’s, the South
African company Rocon intro-
duced the concept of loading
ships using a standard GP
container with a tipping device. Unfor-
tunately information with regards to this
pioneering development is scarce and
it is unknown if any Rocon devices are
still in operation at present.
The uniqueness of this handling
solution may necessitate some
explanation
The an open-top container system 20 years later the concept re-emerged

when Bulk Connections, a bulk materials
terminal in Durban South Africa, sought
ways to optimise their port operations.
After a developmental phase, the first
container tippler was commissioned in
2003. Based on this earlier installation,
ThyssenKrupp Materials Handling has
further developed the concept culminat-
ing in a second generation container
tippler.
Operation
The uniqueness of this handling solu-
tion may necessitate some explanation
concerning the operation of such a
system.
The tippler is a device suspended on ropes
which may use diverse types of lifting
equipment as platform. Bulk Connections
employed a standard container crane
for this purpose. The parent machine
serves to maneuver the tippler and at-
tached container from the quayside to
Due to the universality of the system components and operation, it lends itself for use in a position above the ship’s hold.
diverse fields of application

HARBOURS & PORTS
A container, filled with material, is

transported to the quayside where the
tippler is lowered onto it and attached
by engaging the standard twistlocks.
Once attached, the container is lifted and
maneuvered towards the ship. At this
stage the clamping beams are activated
and clamping is completed by the time
the tippler reaches its position above
the cargo hold. Tipping commences
with the inner frame rotating through
180° and discharging the cargo into
the ship’s hold.
Some impact damage was
found on the clamping beams
which probably stems from
rough operational practices
Containers are used as the primary medium for storage, transport and handling of bulk Once the material is discharged the in-
materials within a handling system of this type ner frame, together with the container,
returns to its original orientation and the
whole unit travels back to the quay. The
unit is lowered to the rail platform where
the twistlocks are disengaged and the
system is ready for the next cycle. The
operating cycle is therefore similar to the
handling of standard containers.
Container tippler (prototype) – 1st
generation
Bulk Connections Terminal in Durban
was the user of the first unit which was
delivered in 2003. As it was a novel
concept, the entire system was closely
monitored for the duration of the first
year of operation. During this period the
system handled 580 000 tons of sized
coal. The average load per cycle was
25 tons and a loading rate of 18-20
tips per hour was maintained. A daily
output of 10 000 tons of the sized coal
was achieved.
The introduction of the system proceeded
Tipping the load

HARBOURS & PORTS
without any major technical problems. Some minor has come under the spotlight. The entire clamping
modifications were required to resolve teething is- philosophy was reviewed and an improved clamp-
sues, mainly the introduction of guards to protect ing concept was developed. This necessitated
the electrical and hydraulic equipment that was changes to the shape and guiding installation of
liable to be damaged during the operation of the the clamping beam, which have subsequently been
unit. When the first unit was recently overhauled, introduced. The new clamping method will reduce
no trace of fatigue cracking was recorded. Some the chances of impact when lowering the tipping
impact damage was found on the clamping beams device onto the container.
which probably stems from rough operational
practices. Technical parameters of the 2nd generation of the tippler:
- container type 20” open top or 20” GP (top removed)
Container tippler - 2nd generation
The experience gained from monitoring the opera- - capacity 35.0 ton (excl. container mass),
tion of the first unit was employed to improve the - typical cycle time 120-150 seconds,
design of the second generation device. The main - clamping time 4 seconds,
objective of the design review was a mass reduc- - tilting time 15-19 seconds,
tion. Originally the mass of the tipping unit was
- twistlock lock/ unlock 1 second,
approximately 21 ton. As a result, the combined
weight of the tippler, container and payload in some - twistlocks ISO universal,
cases exceeded the loads normally encountered - weight 12.0 tons excl. head block,
in container terminals. This limited the use of - material handled no limitation.
the device, as standard cranes required structural
modifications.
Containers
A FEM based optimisation process, combined Containers are used as the primary medium for
with the benefits of an improved control system, storage, transport and handling of bulk materials
has helped to lower the mass of the design to within a handling system of this type. The selection
12 tons. This is close to the mass of a standard and design of these units is therefore an important
single–lift telescopic spreader, which is the basis aspect from a systems perspective. It should be
on which most of the container handling equip- noted that such containers are only used on land
ment is rated. within the confines of the handling terminal and
Further attention was given to reducing power are therefore not subject to marine standards in
consumption. Torque requirements for various pay- terms of strength and rigidity.
loads throughout the tipping range were simulated The use of an open-top container system provides a
to find the optimal geometry of rotation. Installed terminal operator with great flexibility
power and the size of the tilting cylinders could
thereby be optimised. When the original unit was commissioned, Bulk
Due to the impact damage which was observed Connections decided to opt for modified secondhand
on the clamping beams, the clamping procedure containers to minimise the cost. The modifications
included the re-
moval of the upper
wall of the contain-
ers and welding
the doors closed.
It was found that
these secondhand
containers had a
service life of ap-
proximately 5 000
cycles.
Four new contain-
ers were also built
and operated in
parallel with the
older units. These
units exhibited no
trace of fatigue
damage after 12
months of opera-
tion. Data collected
during this period

HARBOURS & PORTS
gives an indication of the most economical container to be handled. Container terminals are no longer
selection for specific operational philosophies, cycle restricted to the handling of containerised cargo
times and duration of operation and storage. The but are also able to deal with bulk materials. The
capital invested for different container types can be process of stacking containers for bulk materials
weighed against each other considering the number is not significantly different from stacking general
of units in circulation and the lifespan of each. purpose dry containers. Handling of containers
carrying bulk materials can therefore be done using
Great flexibility
standard container infrastructure.
The use of an open-top container system provides a
terminal operator with great flexibility. There are no The material can also be stored in the containers,
restrictions to the quantity and variety of materials depending on the requirements of the port opera-
tor. The need for capital outlay associated with
Due to the universality of the system components and conventional stockyards, stockyard equipment and
operation, it lends itself for use in diverse fields of rail tipplers is therefore eliminated.
application Diverse fields
Due to the universality of the system
components and operation, it lends
itself for use in diverse fields of ap-
plication. For example, ThyssenKrupp
is investigating the use of a derivative
system for supplying coal to power
stations during emergencies. A com-
plete handling system can be set up
in a few months based on standard
container handling equipment such
as reach stackers, straddle carri-
ers, container cranes and overhead
cranes.
Such machines are also readily
available on the secondhand market.
Because the entire system is based
largely on the “off the shelf” equip-
ment, it can be financed for long or
short term operation on an equipment
lease basis.
More information can be found on Thys-
senKrupp, Website:www.thyssenkrupp-
materialshandling.co.za

HARBOURS & PORTS
When
you talk about a bulk
coal terminal in KZN, most people as-
Terminal with
a Difference
sume you’re talking about the coal
handling operation in Richards Bay. In
the meantime, the port of Durban has
a very active ‘boutique’ bulk terminal
tucked away on the Bluff where dry
bulk is handled with kid gloves.
“Our main prod-
uct line now is
sized coal, steam
I
or unsized coal,
ain Geldart, managing director of Bulk Connec- copper concen-
tions, a Bidvest company that owns this bulk trates, manganese
operation in Durban’s port speaks to “Bulk and metallurgical
Handling Today”.“During a privatisation initia- coke, but we also
tive in the late eighties, we took over this operation do other commod-
purely as a coal handling terminal but over the ities in smaller
years the facility has been diversified to include a quantities,” adds
variety of dry bulk products,” he says. Iain. “We used
to do grain un-
Soft handling literally entails handling the product very til the facility in
carefully so that it’s not broken down to smaller sized Durban port at
chunks Maiden Whar f
was upgraded
with ship loaders
and unloaders spe-
cifically to handle Iain Geldart, managing director, Bulk
grain through this Connections
port.”
Unique equipment
Although Bulk Connections leases the 4-berth site
from the National Port Authority, all the equipment,
developed specially for the ‘soft’ handling of bulk
commodities, belongs to them. “The ship loaders,
for example, are quite unique in that we converted
the old type 30 tonne container cranes to 50 tonne
capacity specifically for our purposes,” Iain says.
“A thorough finite element analysis on these old
cranes showed that by simply strengthening the
front legs, they could be modernised with new
motors, gearboxes and brakes. We also converted
the drive system from DC to AC to accommodate
variable speed drive control.”
Sized coal
Soft handling literally entails handling the prod-
uct very carefully so that it’s not broken down to
smaller sized chunks which would happen if it were
dropped from a certain height. This is crucial as
sized coal, for instance, ends up as unsized coal
which is an inferior grade.
“The handling process basically consists of loading
the product from stockpile or other storage with a
front-end loader into an open top container which
is hauled by a special harbour-type tractor to the
ship loader,” explains Iain. “The ship loader picks
Bottom discharging coal the container off the high capacity trailer, over

HARBOURS & PORTS
the hatch of the ship and then through doors at The system
the bottom of the container which open up to let In their search for the best solution in soft handling
the product out softly. After trying various other worldwide, Bulk Connections sourced various
methods, we’ve found that this unique container bits and pieces of equipment from around the
design lets the product out gently.” globe and had this unique design engineered and
manufactured locally coming in lighter than the
In the morning it may be loading coal at one of our three
previous system they used. “The system works
loading berths and by the afternoon it could very well be exceptionally well for sized coal, but it’s also very
off-loading metallurgical coke good for concentrates because concentrates tend
to stick to the vertical sides of chutes
and transfer points, blocking everything
up,” adds Iain.
“With our container system, however, the
whole load simply slumps out, resulting
in exceptionally good load rates with
all the materials we handle. Another
difficult material to handle in bulk is
manganese ore, which is very lumpy
and highly abrasive. The bottom-open-
ing container system is very efficient in
that we’re loading an average of 24 000
tonnes of manganese a day compared
with a dedicated manganese loading
system that averages 12 to 15 000
tonnes a day.
Grab
“It’s a hybrid system in that the same
crane is simply fitted with a 25 cubic
An aerial view of the terminal in Durban port
metre grab mechanism in the place of
Loading 14 000 tonnes a day

HARBOURS & PORTS
the container to turn the crane

into an off-loader,” explains Iain.
“In the morning it may be loading
coal at one of our three loading
berths and by the afternoon, it
could very well be off-loading
metallurgical coke from a ship
in the next berth.
“On a typical day, we could be
handling three ships simultane-
ously where one is loading man-
ganese with a conveyor system,
the second one is at work loading
coal while a third could be off-
loading coke.”
Planning
Although space at the facility is
limited in terms of stockpiling,
careful logistics planning of the
trains coming in to be loaded or
off-loaded, goes some way to al-
leviating the situation. “According
to a weekly business plan, we
liaise closely with Transnet and
The modified container crane used for bulk handling
the mines on train movements
so that they can come in and
off-load straight away,” explains
Iain. “Trains are off-loaded by
several automated wagon off-load-
ers which are similar to tipplers,
but at ten wagons an hour it is a
slow, much gentler off-load than
the typical wagon tippler that just
dumps the product into a pit.”
It would turn sized coal

into much less valued
steam coal by the time it
got to the ship
The product is then stacked in

a stockpile yard where some
blending can be done if required.
“Most clients export around
40 000 tonnes at a time, so we
make space accordingly plus about
10%,” explains Iain. “One of the
reasons we had to find a unique
handling solution is because the
stockyards are almost a kilometre Front-end loaders filling the containers
away from the berths. It is, there-
fore, very difficult to transport the product with a ity is concerned, but also to extend the range of
conveyor system that has many transfer points. It products we handle to include the export of other
would turn sized coal into much less valued steam materials such as woodchip pellets as fuel.”
coal by the time it got to the ship.” Iain Geldart, managing director, Bulk Connections, Tel:
(031) 466-1960, Fax: (031) 466-1935, Email: iaing@
Expansion bulk.co.za
Bulk Connections has come far in the last few
years but they are not resting on their laurels. Iain
says in conclusion, “We’re already working on an
expansion programme, not only as far as capac-

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32 BULK HANDLING TODAY Jan 2010 Advanced Materials Today September 2007 39
Market Forum
An iron garden
Alpha Sand and Klip continue to service local
demand for sand and stone for a variety of
construction projects in and around Polok-
wane. This 36-year old business operates a
mixed fleet, but owner Jannie van Warveren
has thirteen Volvo trucks in his fleet.
“I’m married to machinery and I live in an
iron garden,” are some of the first words said
by Jannie as we sit across his boardroom
table in his family run business in Annadale,
Polokwane. His wife Cathy and his two sons
Niekie and Jannie work alongside him.
“Vehicles are my life,” he adds as he ex-
plains how he has been in the transport
business since 1973. He started his fleet
with a 1954 Albion which is still working
as a water bowser on the current site he is
processing for river sand and stone.
Jannie first operated Volvo’s in the 70’s and
was very pleased to hear of their return to
the market in 1994. “I went to find out what
was available and I was even more of a fan
when I began to experience the very high
service standards offered by Volvo that just
had no equal at the time.
“We are still happy with Volvo now and the
service we get locally and I hope before I
retire, I will be able to buy a Volvo 660hp
unit. I already have the low-bed trailer in Jannie’s 25 Volvo trucks transport sand,
my yard,” he adds with a laugh. stone and concrete products to the
construction and mining industries
Volvo (Southern Africa) (Pty) Ltd, Tel: (011) 842-
5000, Fax: (011) 842-5037, www.volvo.co.za
and even remanufacture some bearing components.

The bearing was refurbished within one month at 50% of the
cost of new bearings and following installation and commis-
sioning, SKF issued a vibration certificate to the customer.
Refurbishing bearings Martin reports that the screw conveyors are operating trouble-
Bearing and rotating technology specialist, SKF South Africa, free and that the customer has expressed satisfaction with
who has been managing the account of a local coastal steel both SKF products and service.
giant since 1998, was approached by the steel plant to Samantha Joubert, SKF South Africa (Pty) Ltd, Tel: (011) 821-3500,
refurbish a set of six screw conveyor bearings. Fax: (011) 821-3501, Email: samantha.joubert@skf.com, www.skf.
The screw conveyors on the plant force coke, coal and directly co.za
reduced iron (DRI) down a shaft into the melter gassifier.
SKF South Africa suggested that rather than replacing the
screw bearings annually, as was current practice, the steel
plant should consider refurbishment as an option to reduce
costs. Inspection of bearings at the plant by SKF service
technicians revealed that refurbishment presented the perfect
solution for these large size screw conveyor bearings, saving Duff feeders
cost and money for the customer. BMG’s materials handling product portfolio includes duff
SKF Saldanha sales manager, Martin Roode says that the steel feeders which accommodate the removal of dry or wet mate-
plant representatives were most impressed when they visited rial from underneath belt scrapers down to collection points.
SKF’s Remanufacturing Centre in Witfield, Johannesburg. “Our These duff feeders also allow access for easy maintenance
facility utilises SKF specific, custom-designed machines and of conveyor rollers and belt scrapers.
equipment modeled on the SKF Steyr (Austria) benchmark Duff feeders convey light duff and wet or dry dribble, oper-
facility to refurbish damaged bearings, restore old bearings ating efficiently for extended periods before maintenance is

Market Forum
equipment, like pumps.”
The low friction co-efficient of OST liners, prevents
the build-up of duff and dribble and ensures smooth
conveying. These liners are available in HDPE 6 or
Tivar 80.
These duff/dribble feeders are equipped with vibrator
motors with an IP 65 index protection rating. Grease
nipples are mounted inside the motor covers to protect
the motor from dust and also ensures that no unau-
thorised person has access to the system.
Gavin Pelser, BMG, Email: gavinp@bmgworld.net, Web:
www.bmgworld.net
necessary. The feeders, which fit into confined spaces, can

operate fully loaded or empty.
“An important benefit of this system is no labour is required at Good demand
the transfer points because of the effective conveying of duff Condra has reported a good order intake for its hoist range,
or any other spillage that may occur between the conveyor with an encouraging increase in the number of enquiries.
belt and transfer chute,” says Gavin Pelser, director, BMG. While management admits that the company order book is
“Conventional equipment requires costly manual labour and slightly down on last year, it predicts a return to more normal
static chute systems need regular cleaning. Another disad- order levels during the course of 2010.
vantage of traditional systems is that fine duff and dribble Condra’s line of hoists comprises two main ranges: the veteran
require the spraying of water, which necessitates additional K-Series and the newer Titan range, the latter divided into

Market Forum
Bormann commented that the company has made
a natural progression towards employing
women. “It has been the outlook
of SEW Eurodrive to employ
people according to their
skills and natural ability
not focusing on race and
sex. Women have a natural
attention to detail, something
which is of extreme importance
in engineering, and probably in
any business.”
; Ti ta n co m pa ct
Ti ta n SH ho ist Engineering is a largely male-
ho ist dominated arena. SEW Euro-
the Titan Short Headroom
drive South Africa has made a
(SH) and Titan Compact
point of employing females in management positions. “We
sub-ranges.
sometimes find our clients are taken aback by the fact that
Titan-SH hoists are designed to make it is woman on the other end of the line, but it has had a
maximum use of expensive factory positive effect in the industry. SEW Eurodrive is known as
space – headroom as well as floor. an unconventional engineering company and our marketing
Based on the proven K‑Series, this has been rated top in the industry. In fact we recently won
newer design has reduced the size the Frost and Sullivan Award for Market Leadership in our
of many K-Series components to take category” adds Ute.
height out of the final crane assembly.
Hoist profile is some 20% less than the
K‑Series.
When carried through to the crane, the
reduced height can deliver huge savings
during factory construction by lowering
the entire roof. Alternatively, the extra lift
height delivers an ability to take on projects
that other factories cannot.
The Titan-SH series has a maximum capacity of 16 tons, and
incorporates refinements such as automatic rope tensioning,
smoother travel, a built-in load limiter, standardised direct
drive and universal carriage.
Condra (Pty) Ltd, Josef Kleiner, Tel: (011) 021-3712, Fax: 086 669-
2372, E-mail: condra@mweb.co.za
Top award
SEW Eurodrive South Africa was announced as the winner
of the Top Gender Empowered Company award in the Min-
ing, Engineering and Construction sector during a glamorous
Ute Bormann, GM Sales and Marketing receiving the award on behalf
awards ceremony held in Johannesburg on 18 November of SEW Eurodrive, from Connie Nkosi - Non Executive Chairman:
2009. First Technology, Gauteng; Chief Executive Officer: Lidonga Invest-
The awards form part of the Top Woman in Business and ment Holdings (Pty) Ltd
Government Awards which is held annually. This award goes
The company has appointed women in senior positions such
to the company that demonstrates the most success in tack-
as General Manager: Sales and Marketing, General Manager:
ling and improving gender empowerment in their respective
Operations, National Marketing Manager, Financial Manager,
sector. Important factors are measurable and accountable
National Stock Controller, Exports Co-Ordinator, Head of
leadership that is committed to developing women in the
Internal Sales and as a Non Executive Director.
company and the per capita expenditure on training, educa-
tion and development of women. SEW-Eurodrive Pty Ltd, Rene Rose, Tel: (011) 248-7000, Fax: (011)
248-7289, Email: rrose@sew.co.za, www.sew.co.za
Accepting the award on behalf of the company, Ms Ute

Market Forum
Physical and mental stamina Richards Bay to power stations around the country.
Eskom recently gave its heavy-duty road transport division, According to Dennis Child, Rotran general manager, Multi-axle
Rotran, the go-ahead to purchase six Western Star road-train Division, “The transformers weigh 150-tons each and two
truck tractors to move new imported power transformers from truck tractors are needed
to move a single unit.
After extensive research,
we opted for the Western
Star 6900XD. It is an 8x6
truck tractor pushing out
600 horse-power, giving
it the edge over European
rivals.”
The six new Western Star
truck tractors were sold to
Rotran by local Western
Star distributor, Liebherr-
Africa, which also spe-
cialises in the supply and
support of heavy earthmov-
ing equipment.
“The trucks will move the
transformers using an im-
ported Nicolas abnormal-
load, multi-axle draw-bar
trailer,” explains Dennis.
“These low-bed trailers
are 15-metres long with
12 independent-steer axle
lines. The total tare mass of the two truck tractors and the
trailer is 121- tons. As dedicated transformer transporters,
each laden rig will have a gross-vehicle-mass (GVM) of
271 tons.”
With trip distances varying between a few hundred kilometres
up to as much as 2 640 km and governed by a speed limit
of 20 km/h, piloting one of these rigs is a highly specialised
task, requiring both physical and mental stamina.
“The Western Star 6900XD is the perfect vehicle for the job
in terms of power, safety and comfort,” says Duncan Prince,
product manager, Western Star (a division of Mercedes-Benz
South Africa). “The Cummins ISX engine powers a fully-
automatic six-speed Allison RDS 4000 transmission and is
equipped with both an engine brake and a hydraulic retarder.
This allows the rig to safely maintain a constant speed of
20 km/h, uphill and downhill, without the driver having to
change gears or apply the service brake.”
Shirle Greig, Tel: (012) 677-1904, Fax: (012) 677-1714, Email: shirle.
greig@daimler.com
Box-container tipper
An all-new box-container tipper from Flexicon forms a dust-
tight seal between the container and the equipment, tips the
container, and discharges bulk material through a chute at

Market Forum
with chute for the passage of non-free-
flowing bulk solids that may otherwise
bridge across smaller openings, and allows
control of the material discharge.
The tipper is available constructed of
stainless steel to food, dairy, pharmaceuti-
cal or industrial standards, and of mild
steel with durable industrial coatings.
It is available with optional receiving
hoppers configured with the company’s
mechanical or pneumatic conveyors to
transport discharged material to any
plant location.
The company also manufactures drum
tippers, drum fillers, bulk bag discharg-
ers, bulk bag conditioners, bulk bag fill-
ers, bag dump stations, weigh batching
and blending systems, and engineered
plant-wide bulk handling systems with
automated controls.
Flexicon Africa (Pty) Ltd, Tel: (041) 453-1871,
sales@flexicon.co.za, www.flexicon.co.za
Celebration
Tip-Tite Box-Container Tipper from Flexicon forms a gasketted, dust-tight connection be- GIBB, one of Africa’s largest multi-dis-
tween the container and the equipment, tips the container to either 45, 60, or 90 degrees ciplined engineering and science con-
past horizontal, and discharges bulk material through a chute at controlled rates sulting companies celebrates the 11th
controlled rates. Trademarked Tip-Tite, the tipper accommo- anniversary of its Rail Division this year,
dates boxes including truncated corner boxes, from 915 mm and is right on track when it comes to handling the boom in
to 1 220 mm on a side,
and 990 mm to 1 117
mm overall height.
The container platform is
raised by a single hydraulic
cylinder, creating a dust-
tight seal between the top
edge of a box (or rim of a
drum) and the underside of
the containment hood. Twin
hydraulic cylinders then
pivot the platform-hood
assembly, with container
intact, to either 45, 60
or 90 degrees beyond
horizontal, including a mo-
tion-dampening feature at
the termination of container
rotation.
An optional, gasketted, top
discharge gate actuated by
twin pneumatic cylinders,
provides a large opening

Market Forum
the rail transportation infrastructure in South Africa
GIBB recently completed a R53 million railway siding project Subscription
for South African Coal Mine Holdings (SACMH) in a scant
seven months from inception to completion. The scope of the Please fax us if you wish to subscribe to “Bulk Handling Today” at
project was the design and construction monitoring of the R400,00 (incl postage and VAT) per year; R945,00 per year for Af-
new Umlabu siding, situated approximately 3km from the
rica/Overseas. We will post you an invoice on receipt of your fax.
Umlabu coal mine in Breyten, near Ermelo, Mpumalanga;
as well as the earthworks, perway, electrical and signaling PROMECH PUBLISHING Fax No: (011) 781-1403
systems and an in-motion weighbridge. After an initial fea-
sibility study in 2007, and the submission of GIBB’s design Email: editorial@promech.co.za
and tender documents in mid-April 2008, construction began
on 19 May and the official handover of the project was 31 From:.........................................................................................
October 2008, with the first test-run being successfully
implemented on 11 November 2008. (insert your name)
The earthworks for the construction of the loading area,
including 3 000m2 of tar road and 250m of drainage struc- Title: ..........................................................................................
tures, required a staggering 180 000 cubic metres of soil and
took four months and 81 000 accident-free work hours to Company: .................................................................................
complete. A total of 2.44km of railway line was constructed,
including the installation of two turnouts on the mainline of Address: ..................................................................................
Transnet Freight Rail (TFR), which can be operated remotely
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commodate the 24-hour-a-day productivity levels.
To save costs on installing additional cables, each of the 66 ......................................................................Code: ..................
luminairs mounted onto the 49 masts installed were fitted
with a photocell to switch off the lights in the daytime, and Telephone: ( ) ....................................................................
the innovative, imported signal remote-system will boost
worker safety levels as trains can now enter and exit the Fax: ( ) .................................................................................
siding from the mainline without drivers having to disembark
to change direction of the turnouts. Email:........................................................................................
Additionally, the design of the in-motion weighbridge al-
lows it to weigh wagons moving at a speed of up to 8km
per hour, enabling the cross-referencing of shipping and
haulage costs. Index to Advertisers
Says Johann Rauch, director of Gibb Rail Division, The siding Afzelia 14
was designed by GIBB to accommodate anticipated future Almex 20
expansion, which includes the installation of a rapid-loader,
AST Inside Front Cover
which will enable a 60-ton wagon to be loaded within 90
seconds while moving, translating to a 100-wagon train Barpro 6
being loaded in less than three hours compared with the Brelko 13
current six; and the electrification of the 22km railway line
Dymot 26
between Ermelo and Umlabu in order to reduce diesel-lo-
comotive haulage costs.” East Rand Cranes Inside Back Cover
Gibb, Tel: (011) 519-4600, Fax: (011) 807-5670, www.gibb.co.za EMS 18
Engineer Placements 38
EPNS 12
Feel at Home 36
Engineer Placements Green Supply Chain Awards 24

Innov-X 8
When the business world lights up again, and the
clarion call for skills is heard once more, will you be on KMG 34
our database for us to contact you? Linde 16
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BULK HANDLING TODAY Jan 2010 

 BULK HANDLING TODAY Jan 2010

Featured on the cover:

Copyright Beltcon • SAIMechE (SA Institution of Mechanical

The monthly circulation Proprietor and Publisher: Advertising Sales:

BULK HANDLING TODAY Jan 2010 

Happy New Year!

develop something specifically for service

BULK HANDLING TODAY Jan 2010 

be it corrosion protection, wear protection,

Unlike mining staff, we’re always in

 BULK HANDLING TODAY Jan 2010

BULK HANDLING TODAY Jan 2010 

 BULK HANDLING TODAY Jan 2010

Beating the Crunch

aftermarket business, ensuring

BULK HANDLING TODAY Jan 2010 

implemented at the company, inventory

10 BULK HANDLING TODAY Jan 2010

“One of the most neglected aspects concerning lift-

BULK HANDLING TODAY Jan 2010 11

general. Existing registers were outdated while

12 BULK HANDLING TODAY Jan 2010

formance, or at least a Certificate of

Existing registers were outdated while some

“The Certificate of Conformance,

BULK HANDLING TODAY Jan 2010 13

How to Select a Crane

Final assembly of a gantry crane

BULK HANDLING TODAY Jan 2010 15

16 BULK HANDLING TODAY Jan 2010

“This is standard proce-

BULK HANDLING TODAY Jan 2010 17

Future in Their Hands

BULK HANDLING TODAY Jan 2010 19

BULK HANDLING TODAY Jan 2010 21

22 BULK HANDLING TODAY Jan 2010

Table 4: Roll Selection - 2 Roll Vee and Flat Return

BULK HANDLING TODAY Jan 2010 23

Green This prestigious award recognises

The inaugural awards in 2009

Come and see who walks away

Entries for next year’s event open

Contact: Catherine Larkin on

Open Top Containers in

The an open-top container system 20 years later the concept re-emerged

BULK HANDLING TODAY Jan 2010 25

A container, filled with material, is

26 BULK HANDLING TODAY Jan 2010

BULK HANDLING TODAY Jan 2010 27

28 BULK HANDLING TODAY Jan 2010

BULK HANDLING TODAY Jan 2010 29

Loading 14 000 tonnes a day

30 BULK HANDLING TODAY Jan 2010

the container to turn the crane

It would turn sized coal

The product is then stacked in

BULK HANDLING TODAY Jan 2010 31

CARING FOR DISADVANTAGED ANIMALS SINCE 1958

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