The need to ‘reduce, reuse and recycle’ is now widely accepted, but equipment rebuilds can also reduce fuel consumption, total cost of ownership (TCO), downtime and accidents, in addition to the mine’s carbon footprint, original-equipment manufacturer (OEM) Sandvik Mining South Africa rebuilds and upgrades portfolio manager Francois Nell stated in a press release last month.

He explained that “even the industry’s wealthiest players” are keen to keep their machines out of the scrapyard, and stressed that Sandvik is able to completely refurbish almost any of its older machines to the latest specifications, at a significant discount to what customers would pay for an equivalent new model.

“From any of our 70 workshop facilities around the world, Sandvik’s certified technicians are able to provide a rebuild service to precisely match the customer’s needs and budget,” said Nell.

“While it’s true that a lot of our business traditionally comes from markets where there is an emphasis on keeping equipment running for as long as possible, it’s important to remember that our solutions aren’t just for those machines that are nearing the end of their life.”

He noted that rebuilds can be most effective when they are undertaken as midlife services that ensure greater reliability in the long-term, while immediately helping to boost performance, increase safety and slash TCO.

Further, he suggested that the growing recognition of the value these services offer explains why major players are “jumping on the rebuild bandwagon, rather than automatically trading up”.

Nell commented that, two decades ago, the OEM industry rarely promoted rebuilds and customers were more likely to react as and when necessary, rather than implementing a predictive maintenance and rebuild strategy.

“With rebuild workshops becoming busier and increased lead times for components large and small, much more forward planning is required nowadays. This also ensures that customers can select the least disruptive time for the work to be carried out, minimising unplanned shutdowns.”

Moreover, Nell stated that Sandvik’s rebuild offering ranges in complexity from the base Custom Rebuilds, through Life Extension, up to Reborn and Reborn+ scopes.

“We begin with a thorough assessment, to decide what components are required to meet the brief. This allows us to order the parts in advance, so that work can begin as soon as we receive the machine. The whole process typically takes six to seven months, although two to three months isn’t unheard of, when the need is urgent.”

He stresses that the aforementioned time lines are based on the assumption that the inter vention would be carried out at a Sandvik facility, enabling the company to use the “highest levels of standard operational pro cedures, tools and cleanliness”.

Nell added that, by rebuilding to a set of fixed standards, Sandvik can offer the cus tomer an ‘as new’ or standard warranty depending on the scope, which could not be guaranteed if the work was done at the customer’s site. Some equipment, however, may be irretrievably situated below ground, in which case exceptions can be made.

Tearing Down to Build it Back up

More than 1 000 measurements, diagnostics and check points are analysed before the restoration begins. After the machine has been fully stripped down, Sandvik’s engineers carry out nondestructive testing to determine the extent of any metal fatigue and ensure that a rebuild is indeed viable. Once it’s been approved and repainted, it is effectively a full ‘nut and bolt’ restoration, using only genuine parts.

Often using preassembled kits to speed up turnaround time, all major components will usually be replaced. Older machines will frequently be rebuilt to new generation specifications, such as the latest engine technologies where appropriate, or upgrades in terms of hardware and software – most notably the inclusion of Sandvik’s Knowledge Box technology or the latest safety features.

Testing for functionality follows, before the machines are once again put back into service. A further benefit of this approach is that, unlike when a ten-year-old machine is replaced with a new model, there is no need to retrain the operator. “They can simply get in and immediately begin providing the same (if not higher) levels of productivity as they previously did – albeit in greater comfort and safety.”

Although the majority of underground equipment is rebuilt once, owing to structural fatigue, machines such as rotary surface drillscan quite easily have their components replaced two or three times, operating well over 100 000 machine hours before they are scrapped.

“With rebooted machines typically offering at least 90% of the life span of new equipment, the economic advantages to mine owners are clear – and we haven’t even touched on the environmental benefits that result from the huge reduction in energy consumption enabled by this reduce-and-reuse philosophy,” Nell commented.

Upgraded Toro Loader Added to Range

A new low-profile unit joined Sandvik’s Toro family; the Toro LH208L loader. In an April release, the OEM noted that the new loader is tailor-made to operate efficiently in conditions where working height is extremely limited, with an equipment height of just 1.6 m but high payload capacity of 7.7 t.

The main market for Toro LH208L loader is Southern Africa.

The Toro LH208L loader is a “strong and reliable workhorse” for low-profile, hard-rock mining, specifically designed for the “toughest of conditions”. With its robust reinforced structure, compact size, high payload capacity and components that are designed to perform in the mine environment, the loader is designed to meet productivity targets in applications where working height is extremely limited.

The Toro LH208L loader’s frames are reinforced to resist ground and roof impacts, with the welded steel box structures used in the frame and boom providing strong resistance to shock loads.

It is fitted with a roll-over-protection- and falling-object-protective-structure-certified canopy. The canopy door includes a door lock and latch mechanism, with an interlock switch that automatically applies the brakes and inactivates boom, bucket and steering when the door is opened.

To improve overall safety underground, a proximity detection system interface option is also available.

The Toro LH208L loader offers options that are specifically designed to improve productivity, such as the Sandvik integrated weighing system and traction control, both of which are already available for a number of other Sandvik loaders.

Sandvik Mining South Africa is a sponsor and exhibitor for the Investing in African Mining Indaba, which will be held at the Cape Town International Convention Centre from May 9 to 12.

Sandvik Mining and Rock Solutions