Tag Archives: foundations

Martin Engineering goes virtual with conveyor training

Bulk handling, Careers in mining, Mining equipment, Mining maintenance, Mining services, , , , , , ,

With in-person training curtailed for the foreseeable future due to COVID-19 restrictions, Martin Engineering says it has developed an extensive array of tools to continue its tradition of educating those who maintain, manage and design conveyors for industrial operations.

The result is a wide range of globally-available options to help improve safety and efficiency, reduce maintenance expenditures and extend equipment life, ultimately contributing to greater profitability, it says.

“The pandemic has impacted our ability to teach traditional classes at customer sites,” PE Todd Swinderman, CEO Emeritus of Martin Engineering and an industry veteran with more than 40 years of hands-on experience, said. “But it doesn’t reduce the need for conveyor operators and facility managers to obtain the benefits and continuing education credits those sessions provide.”

In response to the restrictions that the virus has placed on face-to-face learning, Martin has created a series of interactive online modules based on the same non-commercial curriculum it has produced over the years. Designed to keep attendees engaged and organised into 90-120 minute segments, the virtual classes cover topics such as best practices for safety, fugitive material control and belt tracking. Upon completion, attendees are eligible to receive either Professional Development Unit (PDU) or Continuing Education Unit (CEU) credits.

“The Foundations™ online seminars deliver non-commercial, topic-specific problem-solving information that can be put to immediate use,” Swinderman said. “There’s no sales pitch, and even the most remote locations can take advantage,” he added.

Customer Development Manager, Jerad Heitzler, an instructor of Martin’s safety workshops since 2010, said: “Conveyors are one of the best productivity-enhancing tools available, but conveyor injuries cost employers millions of dollars annually. Because of the size of their material cargoes, the speed of their operation, and the amount of energy they consume and contain, conveyors have been shown to be a leading cause of industrial accidents, including serious injuries and fatalities. But injuries are preventable with the right training, preparation and safety precautions.”

According to Heitzler, the company’s preferred platform is Zoom, but its expert trainers also have experience with Google Meet, Microsoft Teams and Webex.

“Our platform has been built to increase attendee engagement as much as possible,” Heitzler added. “Many trainers don’t use the available platform features effectively, because they were thrust into online training as a result of the pandemic. But we’ve worked hard at using engagement features to increase learner participation, with options such as a raise hand button, chat, Q and A, screen sharing, white boards, private breakout rooms and polling.”

Heitzler said the Martin team has taught around 2,000 attendees using video conferencing since the onset of the virus.

“We’ve presented these modules to learners in coal handling plants, cement manufacturing, aggregate production and pulp and paper mills,” he said. “We’ve also provided training for industry consultants, service providers and engineering firms who design conveyors and plants.”

Swinderman estimates the firm has trained more than 50,000 miners, operators, maintenance staff and management personnel around the world.

There are two standard tracks: one for maintenance and operations personnel that stresses safe work practices and solutions to common conveyor problems, and one designed for technical and management personnel that emphasises the design and operation of conveyors for safety and productivity. In addition, Martin trainers and engineers can custom design programs not only for customers using conveyors but for those needing training on the application of industrial vibration, air cannons and silo cleaning.

“Both methods of training are highly interactive, effective and non-commercial, focusing on delivering timely information that can be put to immediate use,” Swinderman concluded.

Belzona reinforces crusher foundations at Brazil copper mine

Base metals, Equipment maintenance, Mineral processing, Mining equipment, Mining maintenance, Mining services, , , , , , , , ,

Belzona has used its own concrete repair and rebuild composite to keep a primary crusher operational at a copper mine in Brazil.

A common cause of wear in the mining industry can be vibration. This can cause eventual fatigue, resulting in cracks and a loss of material in operational equipment. It can also lead to premature failures in areas such as concrete foundations and their anchoring systems.

“Generally speaking, concrete can be considered too brittle and weak to absorb such constant impact and vibration transferred from the equipment,” Belzona said. “Once the concrete has failed, anchor bolts in the foundations can loosen, further aggravating the effects of the vibration on the foundation.”

A copper mine in Marabá, Brazil, found this to be the case with its primary crusher, according to the company, with the base of the primary crusher needing to be rebuilt due to weakening caused by vibration. The 3,000 t/h primary crusher weighs 336 t, is 9.5 m high and 5.6 m wide, contributing further to the amount of stress being put on the foundations, Belzona said.

“Being one of the biggest copper crushers in South America, and with copper being traded at around $6,000/t, every hour of shutdown can result in a loss of almost $20 million,” the company said.

A solution was required that could rebuild the foundation and bases of the primary crusher, while being able to withstand high dynamic and impact loads without shattering and breaking, according to Belzona. “Excellent mechanical properties and a fast curing time were also critical in ensuring the primary crusher would return back to service in as little time as possible.”

The solution used was Belzona 4111 (Magma Quartz), a high-performance concrete repair and rebuild composite.

Using an impact hammer drill, the first two layers of concrete were removed to reach the steel reinforcement structure.

“Particularly with concrete repairs, surface preparation is critical in its success,” Belzona said. ”The substrate needs to be free from contamination, free from excess moisture and any loose material needs to be removed.”

The area was cleaned and degreased with solvent and compressed air was used to remove the entire repair area of loose debris and dust. A conditioner was then applied to ensure an optimum bond between the substrate and repair materials.

The perimeter of the repair area was initially built up, later acting as a mould for a slurry mix of Belzona 4111. The material was able to level evenly to recreate a foundation at the base of the primary crusher, according to Belzona.

“The implemented solution offered resistance to high vibrations and dynamic loads due to its high mechanical strength. The system adhered to both metal and old concrete allowing for a homogeneous load distribution, without weak spots during the anchoring/grouting procedure and service,” the company said.

The assembly of the machine to the structure commenced in as little as four to six hours after application, according to Belzona, with a full return to service possible in some 16 hours.

“The fast turnaround time allowed the copper mine to continue its processes without a majorly disruptive or costly downtime,” the company concluded.

Specialising in erosion, corrosion and chemical protection, Belzona calls itself a world leader in the design and manufacture of repair composite materials and protective coatings for machinery, equipment, buildings and structures.