Third edition of this important book containing extensive information about preventing, detecting, and fighting fires in your mine. Complete with exhaustive examples and detailed information.

This edition of The Best of Germany focuses on work being done by VDMA Mining member companies to give the best possible support to the global mining industry. German mining equipment manufacturers have taken great efforts to optimize operational safety of the machines. In cooperation with their worldwide customers, this leads to a unique level of safety, particularly for underground mining.. This also leads to substantial improvements in energy consumption, optimized endurance of machines and plants, and higher efficiency in total.

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This paper illustrates the crucial importance of developing a checklist culture to identify and eliminate human error throughout the mining operations lifecycle. It highlights the drivers for checklist development, training, coaching, and execution, as well as case studies from high reliability industries that depend on procedures-based cultures, where precision operations are mandatory. It concludes with a detailed look at how the combined expertise of Check-6 can help the mining industry deliver on its business objectives – ensure decision makers and crewmembers get the job done right, done safe the first time, every time.

Check-6’s Performance Coaching program dramatically reduces processing facility’s MSHA violations, increasing production while lowering cost per ton through enhanced leadership mentoring and hands-on workforce engagement.

Check-6’s Performance Coaching program greatly accelerates mining company’s efficiency by enhancing the collaborative relationship between production operations and mobile maintenance.

With the broadest line of mining equipment in the industry, Cat mining systems work harder, last longer and help move more material at a lower cost.

2012 USGS overview of the production of construction sand and gravel in 2012 along with information about foreign trade, transportation, recycling, and prices throughout the industry. Includes an look forward at the industry through 2013.

USGS statistical overview of crushed stone production in 2015.

USGS statistical overview of crushed stone production in 2015.

Originally presented at Haulage & Loading 2013. This white paper explores proximity detection in the open pit mine being used effectively as an operator assist strategy which improves digging production through enforcement of best practices, although it is normally thought of first as a safety tool, and second as a step toward full automation when combined with object avoidance.

This paper highlights an assortment of case studies and explains how arc flash hazards were identified, measured and mitigated at various industry facilities. Case studies will include: Compliance with IEEE 1584-2002 Guide for Performing Arc Flash Hazard Calculations along with regional workplace safety standards for a multi-site global cement manufacturer; Implementation of an Arcflash Reduction Maintenance System™ in an airlock section of a main switch room for a minerals processing plant upgrade; Investigation of an arc flash incident at a chemical processing facility; and a “Safety by Design” upgrade for the iron ore division of a global mining business. The paper will examine the plans and processes reviewed and considered, the strategy deployed to manage/reduce arc flash hazards, and then discuss lessons learned in the implementation of new systems to improve electrical workplace safety.

The authors describe the application of remote isolation systems in mining industry conveyance systems and offers case study details where these systems have been installed.

Common myths and documentation regarding circuit breakers utilizing Sulfur Hexafluoride (SF6) gas interrupters and switchgear using this gas for insulation. Regulatory, operational and total life-cycle costs associated with this technology and safety from the perspective of not just the electrical workplace but the impact of SF6 designs on the business and the impact on the planet.

This paper is a case study outlining the experience of a multisite cement producer and their experience in implementing an enterprise-wide electrical workplace safety program, including compliance with the National Fire Protection Association 70E-2012 standard.

Overview of arc-preventative motor control centers and how they enhance personal safety, protect equipment and support more reliable operations.

Working with Eaton can help you better manage costs, mitigate risk, protect people and equipment.

Lehigh Hanson implements an enterprise-wide arc flash compliance program

The mining industry is a competitive business with operators competing to uncover every advantage. Perhaps the biggest step forward could come from an unlikely source. Read about 10 things you may not have known about LED lighting in mining operations.

Blog post on pipe handling safety in the underground hard rock mining environment.

High pressure water as an ore flow solution: A mining innovation partnership between MacLean Engineering and Newcrest's Telfer mine in Western Australia delivers the world's first-ever sub level water cannon. http://www.macleanengineering.com/media-en/the-rig-report/180-wc3-water-cannon

Immersive Technologies has released further detailed verified results arising from their work with key mining customers. In partnership with mine management teams across Australia, North America, Latin America, Africa, Europe and Asia Immersive has delivered dozens of Continuous Improvement (CI) projects that have helped miners control costs, lift productivity and maintain safety standards. Verified in-pit gains over the last 12 month period include: US$1,100,000 haul truck fuel savings for a North American Mine 72% reduction in machine abuse events for a North American Mine US$500,000+ fuel savings at an Indonesian Mine US$770,000 tire life savings at an Indonesian Mine 68% reduction in haul truck down time for a Latin American Mine 4.9% spot time improvement at a Latin American Mine 31% reduction in equipment abuse events at an Australian Mine 5.1% excavator dig rate improvement at an Australian Mine 13% reduction in breakdown hours for excavators at a European Mine 72% reduction in breakdown hours for wheel loaders at a European Mine US$400,000+ Fuel savings in a Brazilian Mine 28% reduction in tire replacements saving US$1,500,000 in a Brazilian Mine 99% engine fire pass rate – global average after training

WorksiteVR™ has a relatively low cost of delivery with training environments that can be customized to deal with many worksite training challenges. • High learner retention and recall levels – Learning environment is highly focused, highly memorable and free from distractions. • Multiple learning style compatibility (seeing, hearing, doing) – To cater for various adult learning principles • Safe learning environments – No risk to personnel or property, educate learners in relation to hazards and their potential consequences. • Portability – Transported in a small suitcase sized package.

Cipta Kridatama Talent Development Manager, Gemilang Adi Perdana, said “with commodity prices going down, like many sites, we are looking at ways to cut costs and fuel consumption was identified as problem area. We were over budget by nearly 10,000 liters per month at one site and identified the contributors affecting fuel consumption. Operator skill level was the focus of the fuel efficiency efforts,” Perdana said. Fuel records for 30 haul truck operators were collected over a one month period and 18 of the 30 were over the budgeted liters per hour consumption. All operators were assessed using an Immersive Technologies, Advanced Equipment Simulator to establish a baseline, simulation based training then occurred followed by a reassessment. Once operators passed the reassessment they were put back in the field. After one month operators were assessed again to confirm retention of the new haul truck operating techniques.

Training for the Safest Operations: • Practice for a range of possible emergency situations in a safe environment • Increase confidence in reacting to emergencies • Significantly reduce your risk of LTIs and fatalities • Compliance Refresher Training

Drawpoint hang-ups represent significant impediments to getting the resource out of the ground in the safest, most expedient way, while oversize blocks of ore are tough for scoops to handle. So the business case for keeping the ore flowing is compelling. A MacLean blog post on addressing the gap between block caving animations and block caving real-life. www.macleanengineering.com

Everyday thousands of operators across the world begin their shift by assessing and responding to equipment issues before they begin operations but how can mine sites be sure pre-start inspections are properly completed and that safety, machine uptime and maintenance costs have not been compromised? A new interactive and virtual tool from Immersive Technologies has been launched to ensure effective and consistent training and assessment of operators on machine inspection routines. Early detection of equipment that is unsafe or worn saves on maintenance costs and reduces likelihood of injury, downtime or environmental damage. The new Pre-Start Inspection tool by the world leading mining simulation technology provider, Immersive Technologies, trains and assesses mining personnel on the correct identification and actions to be taken in relation to equipment issues. This tool allows operators to demonstrate competency when real world training is not possible and where mistakes are costly if undetected.

Whether it’s a low hang-up in a drawpoint, or oversize rock on the ground that’s too large for scoops to handle and too disruptive to get rid of with concussion blasting, it’s your secondary reduction rig that solves the problem and ensures that production isn’t held up. And when it’s not tasked with this mission, it can be put to use for ancillary drilling for mine services. www.macleanengineering.com

GEN-3 Feeds on MacLean Bolter: Ground support innovation delivers installation quality, safety, productivity & versatility http://www.macleanengineering.com/media-en/the-rig-report/179-gen-3-scissor-bolter-feeds

Oversized hang-ups present significant challenges to ore flow for mine operators. MacLean’s comprehensive suite of ore flow solutions starts with Water Cannons as a first line of attack to bring down hang-ups; it progresses to low, medium, and highreach Blockholer drills for persistent hang-ups and secondary breaking; then moves to the Mobile Rockbreaker for fragmenting the oversize at source without blasting. www.macleanengineering.com

An ideas instead of mining boom has a nice ring to it as a slogan, but what if mining booms and ideas booms are one in the same? http://www.macleanengineering.com/blog/getting-innovation-right

Frustrated by its drilling costs, a U.S. mine agreed to let Joy Global run tests comparing our Montabert HC110 to a leading competitor’s hydraulic drifter, to see if the Montabert drifter could help the mine reduce costs while improving safety and performance.

One of the biggest inefficiencies in the continuous mining process is waiting for a batch haulage unit to arrive and get into position. Any reduction in this wait time is time spent cutting and loading material. Understanding these delays is key to a successful mining operation, and is seldom obvious. A customer in the Midwestern United States recognized this inefficiency in its own operation, but could not achieve long-term results because whenever they focused and improved on one aspect of the process, the inefficiency seemed to take another form. The end result was no overall improvement.

Today’s mining market is a challenge, but Joy Global has the solutions to help mining operations reduce costs and increase productivity, while achieving or exceeding operating and financial goals. The company’s JoySmart Solutions are integrated offerings of its smart connected products and systems, advanced analytics and direct services, customized to solve the toughest mining challenges.

Joy offers a complete range of longwall equipment to suit the needs of mining operations worldwide. Globally recognized as the leading manufacturer of complete longwall systems, Joy provides its customers with a single, accountable source for shearers, roof supports, face conveyors, stageloaders, crushers and mobile belt tail pieces.

Through JoySmart Solutions, Joy Global helps solve its customers’ toughest challenges using data-driven intelligence, collaboration through partnership and experienced-based service execution. It is a solutions-based offering designed to help reduce costs and increase productivity for customers, while helping them achieve or exceed their operating and financial goals.

Joy Global Life Cycle Managment (LCM) solutions reduce mining costs by enabling us to partner with customers to optimize machine performance throughout the asset’s life cycle. Joy Global’s direct service teams work on-site and in local service centers to provide superior maintenance and repair services along with quality service products and consumables (SP&C) to meet the unique requirements of each mining environment. These teams work alongside mine personnel and recommend productivity-enhancing options and modernization's to help keep the asset available to achieve the lowest cost per ton throughout its life cycle.

Joy Global applies unparalleled experience, service capabilities, facilities and personnel for delivering “like-new” performance at a cost significantly less than purchasing a new machine. Partial rebuilds are designed to be flexible ensuring machine performance and minimizing downtime between major rebuilds. Machine rebuilds or exchanges can also be bundled per an agreed-upon schedule.

A few extra metres per day of advance can represent significant increases in the value of an ore body over a mine’s life, so rapid development isn’t just a buzzword, it’s now a business imperative. www.macleanengineering.com

With over 100,000 operator training sessions analyzed we know that less than 50% of experienced operators can recall the procedure to respond to an emergency machine failure. We can deliver over 90% pass rates through Immersive Technologies’ proven training solutions.

Steep declines in the price of coal have placed an emphasis on existing operators improving their productivity by improving cut sequences. Using an IM360 Advanced Equipment Simulator from Immersive Technologies an experienced operator trainer first observed the operators in the field and then operated the Continuous Miner to observe the unique conditions present at each of the mines. The trainer then developed a tailored curriculum within simulation, replicating coal tensile strength, rock bands, top height and other significant operational characteristics.

Making front suspension the standard, not the option: An increasing body of research is linking chronic Whole Body Vibration exposure to musculosketal disorders such as lower back pain, and these disorders are now the leading cause of chronic injury and absenteeism in the Canadian and US workforces. So for a mining industry facing prolonged pricing headwinds, keeping workers healthy and productive isn’t just the right thing to do, it’s also essential to surviving the downcycle to prosper on the other side.

Hexagon Mining is unique among technology providers in integrating solutions for planning, operations, and safety. President Hélio Samora discusses how the company is helping mines to prevail amid tough economic times.

Enrique Sánchez, Asesor Técnico Senior Grupo México, explains how the company has seen unprecedented levels of efficiency and control at its Toquepala mine in Peru by integrating fleet management with mine planning.

EVP Technology and Innovation, Glenn Wylde explains how Hexagon Mining is solving miners’ most complex problems - from autonomous mining to distributed computing - by adopting technology and innovating.

Mines in the Asia-Pacific region are not alone in seeking more from their operations: more productivity, increased safety and a healthier bottom line. Hexagon Mining is uniquely positioned to solve these challenges in the region, explains Hexagon Mining President Hélio Samora.

African Barrick Gold (ABG) needed help to address rising energy costs and tightening profit margins at its North Mara mine in Tanzania. North Mara is a high-grade open pit gold mine with a life-of-mine estimated at 10 years, and the potential to process 8,000 tonnes of ore per day.

In 2013, Mexico’s Cobre del Mayo (CDM) was attempting to solve common, yet complex issues at its open-pit copper mine in southern Sonora, 21 kilometers from the town of Alamos. CDM produces grade-A copper cathode, supplied as refractory, and vein-type ore for processing into concentrate. The mine is a copper porphyry system, structurally controlled by shear faulting with mineralization stockwork, disseminated and variable depth ranging oxidation.

The Pueblo Viejo gold mine in the Dominican Republic is a joint venture between Barrick Gold and Gold Corp., which hold 60% and 40% ownership respectively. The mine is operated by Barrick Gold and 2013 was the mine’s first full year of production.

Pan American Silver subsidiary, Minera Corner Bay, operates the Alamo Dorado open pit silver mine in Sonora, Mexico. Commercial production began on April 1, 2007. Production from Alamo Dorado generates most of its revenue from silver with the remainder from gold.

The successful introduction of battery power to hard rock mining isn’t going to be about the correct choice of battery chemistry alone, it will be about engineering a battery propulsion system that is fit-for-purpose with the mining application and duty cycle, and one with maximum flexibility to allow for the rapid pace of battery technology advances that will inevitably open up options for diesel-free mine planning and retrofitting. http://www.macleanengineering.com/media-en/blog

Increase Profit and Reduce Risk - We provide a managed solution including trainers, consultants and supervision at the level you require. Capabilities: Risk Management. Instructional Design and Curriculum Development, Training Center Design and Management, Training Needs and Performance Analysis, Staffing - all levels and all roles, part time or permanent, Continuous Improvement, Workforce Development Planning (for mines, regions and educational institutions)

What can drones do for you? If you are wondering how drones can be integrated into your operations, we invite you to read our Drone Mapping Considerations whitepaper. It discusses our experiences in research and development of drone systems and offers advice on integrating drones into your business.

The Kespry Drone System provides customers the tools needed during mine development to evaluate production potential and plan scheduling using PDF overlays, 3D Models, Contour Maps, Property Boundary Surveys, Geologic Borehole Locations - easily accessed and shared online with Kespry Cloud.

Reliability Centered Maintenance (RCM) is one of the most effective ways to improve the impact of preventive maintenance. While traditional preventive maintenance can avoid some premature failures, RCM adds advanced condition monitoring technologies to identify potential failures far more quickly and accurately while concurrently identifying root causes to eliminate or reduce their impact. A series of 6 phases examines the implementation of Reliability Centered Maintenance.

When mining maintenance requires improvement an evaluation is the essential first step of the improvement effort and a guarantee of its success. The evaluation avoids guessing at what needs to be improved, how and the priorities of corrective actions. The result is a realistic plan of action instead of confusion, frustration, disappointment and no improvement. Here’s how to get started.

Complete a free self-guided system review that provides you a customized report outlining simple, cost-effective ways to improve the operation of your dry chemical handling system.The System Health Check uses our expertise & data to help you take a proactive approach to identifying potential safety, reliability and process challenges before they become a problem.

Reliability Centered Maintenance identifies and applies maintenance responses to specific types of failures.

The diversity of mining operations, experiences of personnel and numerous other factors may preclude standardizing mining maintenance terminology. However, a clarification of maintenance actions and procedures can improve common understanding and communication among all who perform maintenance, support it or depend on its effectiveness. Toward those objectives the following Mining Maintenance Terminology definitions are offered for your consideration. Any feedback can be incorporated into a revised document for subsequent publication. Contact: [email protected].

My 'best effort' at listing maintenance terminology was posted a few days ago. So far lots of 'views' and 'downloads' but very little 'feed back.' Let's take a second look and make this a document that proves mining maintenance really knows what we are talking about. Your input will be incorporated into a revised document for subsequent publication.

Employing operational excellence to optimize underground haulage systems

Setting Maintenance Work Priorities - By setting maintenance work priorities, the relative importance of a single job in relationship to other jobs, operational needs, safety or equipment condition is established and a time period is assigned within which the work should be completed.

Joy Global debuts highly versatile P&H 77XD Blasthole Drill

Although many mines and processing plants have sophisticated maintenance cost information systems, cost control relies ultimately on management actions based on the information such systems generate. A systematic management approach to solving problems and implementing solutions is the key to effective maintenance cost control

Effective plant-specific computer-based training (CBT) used in a formal training program can make the difference between a successful start-up and a failure. Or, in the case of an existing plant, it can make a huge difference in the effectiveness of operating results—particularly if turnover of experienced personnel is a factor. Once the plant process design and control strategies have been established, equipment has been ordered, and the plant is either operating or under construction, the only major variable affecting success is the capability of plant operating personnel. It is essential that the myriad details concerning plant operation are documented in a comprehensive CBT system suitable for training the non-technical personnel who will operate the plant.

In this training module, Performance Associates International (PAI) covers the characteristics of a gyratory crusher that’s designed to be the first stage in the size reduction of run-of-mine ore. A gyratory crusher receives ore from a mine and crushes the ore between a gyrating main shaft and stationary liners called concaves. This module explains the gyratory crusher’s principle of operation and provides detailed descriptions of the major components and the role that each component plays in its operation. You'll learn how the drive system operates, the details of the dust sealing system, the importance of the various lubrication systems, and the two functions of the main shaft positioning system, or MPS. We’ll also explain the operation of the balance cylinders and how they’re designed to prevent oversize boulders from causing damage. We’ll also cover the apron feeder, which conveys the crushed ore from the crusher to a downstream discharge conveyor belt. The principle of operation and detailed descriptions of the components of the apron feeder—including the drive chains, pans, rollers, and an electric or hydraulic motor—are illustrated. This is one of many plant area modules that is covered in a typical PAI operations training module.

Far too often, natural resource companies start up new plants without a properly trained operations and maintenance team. The results can be disastrous for both safety and revenue. Obviously the ultimate objective is a plant that operates in a safe and profitable manner. In most cases, the pre-start-up safety training is satisfactory, resulting in few if any accidents during start-up and ongoing operations. However, many plants drop the ball when it comes to properly training operations and maintenance personnel. The payback on a properly executed training program far outweighs the cost. If you are going to budget for high-quality engineering, efficient procurement, and experienced and proven construction management (including commissioning), why leave training open to chance? Performance Associates International (PAI) developed an extensive operations and maintenance training program for Torex Gold’s El Limón-Guajes project in the state of Guerrero, Mexico. In 2015, PAI industry training specialists traveled to the project site to carry out the training for Torex Gold employees in anticipation of plant start-up and gold production. The venture was a “massive success,” according to Nelson Bodnarchuk, Director, Operational Systems. This video tells the story of that success, including generous feedback from the executive officers at Torex recognizing our role in the partnership.

Con demasiada frecuencia, las compañías de recursos naturales ponen en marcha plantas nuevas sin contar con un equipo de operaciones y mantenimiento debidamente capacitado. El resultado puede ser desastroso tanto en términos de seguridad como de ingresos. Obviamente el objetivo fundamental es una planta que funciona de forma segura y rentable. En la mayoría de los casos, la capacitación sobre seguridad que se da antes del arranque de la planta es satisfactoria, resultando en pocos accidentes (o ninguno) durante la puesta en marcha y operaciones subsecuentes. Sin embargo, muchas plantas son negligentes cuando se trata de la buena capacitación de su personal de operaciones y mantenimiento. Un programa de capacitación bien ejecutado compensa con creces los costos de ejecución del mismo. Si se va a presupuestar una ingeniería de alta calidad, un proceso de adquisición eficiente y una gestión de construcción experimentada y comprobada (incluyendo el comisionamiento), ¿por qué dejar a la suerte la capacitación? Performance Associates International (PAI) desarrolló un programa de capacitación por computadora comprensivo, el cual abarca operaciones y mantenimiento, para su planta de oro El Limón-Guajes en el estado de Guerrero, México. En el 2015, los especialistas de capacitación industrial de PAI viajaron al lugar del proyecto para entrenar a los empleados de Torex Gold en anticipación de la puesta de marcha de la planta y la producción de oro. El emprendimiento fue un “éxito masivo,” según Nelson Bodnarchuk, Director, Sistemas Operacionales. Este video cuenta la historia de ese éxito, incluyendo comentarios generosos de los oficiales ejecutivos de Torex, quienes reconocen nuestro papel en la colaboración.

Dry drilling on MacLean Small Section Bolter - In 2015, MacLean worked with Petra Diamonds’ Finsch mine in South Africa, the second largest diamond mine in the RSA, to develop a dry drilling option that was required for Finsch’s unique application / mine plan needs. www.macleanengineering.com

The availability of skilled mining workers is a common struggle in many countries throughout the world, impacting mining productivity, safety and ultimately profitability. Many countries are forecasting dire shortages in the coming years due to unskilled talent pools, an aging workforce and increased mining production. The development of training programs is a key focus for governments, mines and educational institutions. In support of this industry challenge, Immersive Technologies’ solutions have proven to be vital at numerous training centers around the world. In this case study one customer shows how the introduction of a simulation based training center accelerated operator learning and retention. Over the past five years this type of training center has been on the rise for Immersive Technologies. More case studies are available by emailing [email protected]

What are your operators really costing you? Operator skill and behavior directly affects site safety, tire life, bucket fill, machine availability, fuel usage, cycle times and machines repair & maintenance costs. Successfully managing each of these aspects can be the difference between a mine that is profitable and one that is not. Immersive Technologies can show you the financial gain of improving each of these through Operator Optimization on your mine. We’ve done it many times before. We’re yet to find a mine that has no opportunity for significant financial gain.

Simulation based operator training has been successfully applied to a range of diverse industries where high risk and high costs are everyday issues requiring smart solutions. Whether piloting a plane or launching a space shuttle, simulation training has been proven to dramatically reduce risk, cost, unscheduled maintenance, increase trainer effectiveness and efficiency while maximizing productivity. Within the often hazardous mining industry, simulation training has quickly gained recognition as a significant method of increasing site safety and profitability through improved operator skill and knowledge. Simulators provide operators a safe environment to learn and practice their skills while allowing the operator to practice for a range of possible emergency situations. Many of these situations are too dangerous, too difficult or too expensive to test in an actual mine. Operators can also be shown and assessed for the proper operating technique much more quickly and accurately than the traditional in machine approach. Focus on improving operator technique with Immersive Technologies’ simulators has delivered proven results including longer tire life, reduced spot time, reduced brake abuse, improvements in fuel use, reduction in engine overspeeds and more. Simulator training allows operators to be shown and assessed without the need to borrow machines from production. This allows new operators to practice many skills before being placed into a production circuit. Because operators are consistently shown and assessed on the proper operator techniques they have a better understanding and knowledge of the real machine. Following Immersive Technologies release of the world’s first mining dump truck simulator in 1998, their customer results, support network, machine range, global mining footprint, level of realism and OEM endorsements are without equal in the industry. Highlighting the benefits of simulation training, four leading Original Equipment Manufacturers, Caterpillar, Hitachi, Komatsu and Liebherr have chosen to exclusively sign technical information licensing agreements with Immersive Technologies, providing access to proprietary technical information necessary to accurately replicate the operation of their mining equipment. After significant supplier evaluation each major OEM has chosen to exclusively recommend Immersive Technologies' Advanced Equipment Simulators. This unprecedented support and commitment from the OEM's has helped to firmly entrench Immersive Technologies' Simulator technology as the industry leader. This provides customers the comfort of knowing they are investing wisely in a proven and accepted technology that is here to stay. As the world’s largest supplier of mining equipment simulators, Immersive Technologies’ has a customer base that includes many of the world’s leading mining operations, mining contractors, training schools and original equipment manufacturers. Widely recognized as the global industry standard, Immersive Technologies’ has extensive experience in delivering complete training solutions to the mining industry with measurable safety and business improvement outcomes. Immersive Technologies has worked closely with thousands of mining training professionals, managers, and executives to deliver comprehensive solutions that have been proven to improve safety and mine profitability.

483 MSHA reportable injuries involving jacklegs occurred at US mines between 2003 and 2012, according to a recent study published by NIOSH (Clark et al., 2016). And these are just the reportable injuries - if you consider the “Heinrich Safety Triangle”, this can be viewed as the tip of the iceberg. What are the options for mechanization?

MacLean Hard Rock Equipment R&D Report: The last 12 months at MacLean have seen the culmination of a two-year phase of intense product development activity, including fleet electrification; face bolting on the MacLean 975 Omnia Bolter; and, a new, ultra-versatile utility vehicle for high reach/heavy load applications - the MacLean LR3.

Columbia Steel manufacturers wear parts that go the distance in the world's most demanding industries. We work hard to make to make long-lasting castings that our customers have come to expect and demand. Tough Customers Welcome.

Columbia Steel manufactures long-lasting wear parts for the world's most demanding industrial equipment. We invite you to learn more about our company, its people, its products and unwavering guarantee.

Columbia Steel manufacturers wear parts that go the distance in the world's most demanding industries. We work hard to make to make long-lasting castings that our customers have come to expect and demand. Tough Customers Welcome.

Columbia Steel manufactures long-lasting wear parts for the world's most demanding industrial equipment. We invite you to learn more about our company, its people, its products and unwavering guarantee.

Tank Connection is a global leader in Dry Bulk Storage solutions and processes. Our bolted RTP storage silos are precision engineered, won't leak, feature a smoothwall tank interior, are manufactured with a powder coat system, and have unlimited options. Construction of our silos is at grade-level using a proprietary synchronized jacking process.

This multiple tank load-out terminal features 4 precision bolted RTP silos 27 feet in diameter and 85 feet tall. For lime storage, we lead the industry in turnkey storage systems for limestone, lime, hydrated lime, pebble lime and quicklime applications. When you are looking for a mineral storage tank system, you can't beat the quality and service provided by Tank Connection.

The Van der Graaf Brush Belt Cleaner offers a belt cleaning solution to remove residual materials from conveyor belts without the wear and tear of a conventional belt scraper. The compact, low profile design provides space savings, efficiency and reliability with virtually no maintenance. As a one component brush assembly, it can be easily installed behind the head pulley or inside the belt conveyor frame. This durable drum motor design is entirely sealed from the most challenging cleaning environments, providing a completely reliable, less complex solution.

The purpose of this experiment is to compare efficiency, losses and overall energy cost between a conveyor powered by the conventional motor/gearbox conveyor drive and a conveyor powered by the internally driven drum motor.

Pinetree Power, a subsidiary of GDF Suez Energy North America, in Fitchburg, MA, upgraded their conveyor drives to Van der Graaf Drum Motors. This upgrade allowed them to free up between 300 and 500 homes worth of electricity, increasing their revenue, while lowering operating and maintenance costs.

Drum Motors for Mining and Aggregate Applications Requiring High Power Conveyor Drives The rugged design of the Van der Graaf drum motor is ideal for the harsh and abrasive environmental conditions of the mining and aggregate handling industry. The drum motor encloses all moving parts within an oil bath that prevents dust and grit from wearing out key components. The benefit of this design eliminates the maintenance required on conventional exposed conveyor drives. • Engineered for Harsh Abrasive Environments • Lower Energy Costs • No Maintenance • Up to 300 HP

Van der Graaf is a leading designer and manufacturer of specially engineered drum motors. Built to endure the demands of the bulk handling industry – from ship loading, to power generation, to surface and underground mining. Van der Graaf products are manufactured and marketed worldwide through a respected international network of distributors. As the leading global supplier of conveyor belt drives, Van der Graaf has proven to be highly intuitive in projecting and reacting to changing market demands. The Extreme Duty Series offers a conveyor drive in which all components are housed internally. This advanced design eliminates the need for external features including the motor, gearbox, sprockets, chain, chain guard, and pillow block bearings, making it ideal for the harshest of environments. The Van der Graaf Extreme Duty Mining Series incorporates the benefits of a tried and tested drum motor with an increase in power and capacity. This durable design is entirely sealed from the most challenging work environments, providing a completely reliable, less complex, and virtually maintenance-free belt drive solution.

Syntron Material Handling - Link-Belt idlers

SMH provides quality Syntron Heavy-Duty Feeders for all your Material Handling needs

Syntron vibrators off an efficient, cost-effective means to maintain free flow of product from bin, hopper and chutes, with a direct and positive result on the bottom line.

Let SMH be your source for all Link-Belt and Syntron Aggregate Industry needs.

Syntron Material Handling Working with Hoppers

Let Syntron Material Handling be your source for all Syntron and Link-Belt replacement parts

The authors describe the application of remote isolation systems in mining industry conveyance systems and offers case study details where these systems have been installed.

This paper will explain some of the physiological aspects which give us our hearing capabilities. It will also describe how damage to the ear should be considered as part of an electrical safety program, as well as potential methods for reducing the hazard.

Customer success story on Deilmann Haniel explaining how Eaton increased safety and operational performance in a difficult climate.

FLEET ELECTRIFICATION THAT CONNECTS THE MINING CYCLE TO THE BATTERY CYCLE: The MacLean approach to battery propulsion is built on giving our customers access to best-in-class battery, electric motor, onboard charging, and vehicle analytics technology, and then successfully integrating these components into mobile underground equipment by leveraging our multi-discipline engineering expertise, hard rock mining knowledge, and custom manufacturing experience. In other words, you can’t just understand the battery cycle, you need to understand the mining cycle in which it will be used. This is how MacLean has developed battery power, engineered for life underground.

Consider the impact these five educational steps could have to help improve maintenance performance. Initially, clarify internal maintenance actions. Then specify help needed from other departments. Finally, secure the dedicated overall direction from mine management in a mine-wide coordinated maintenance effort

No Maintenance Program – Major Omission Attention Mine Managers – If maintenance does not have a program parallel to the one described in this article, don’t expect them to be able to deliver consistently reliable production equipment. Here is how to correct that situation. See an important notice at the end of the article.

The drivers pushing mining companies to seriously look at the EV transition encompass a broad range of benefits – reduced ventilation requirements (30-50% less) and associated energy costs, elimination of diesel fuel costs (tens of thousands of dollars per EV unit, per year), reduced maintenance costs (some 25% fewer parts on EV propulsion vs. diesel propulsion rigs), elimination of diesel fine particular matter in the underground environment, and last but definitely not least - less noise, vibration and heat for miners operating the equipment underground. So how do you quantify the operational savings?

A maintenance program that prescribes who does what, how when and why is the primary necessity for effective maintenance. Without it you are wasting your time. Here's the proof.

Maintenance Planning Essentials Please review the PowerPoint presentation to learn the essential, proven planning techniques that ensure the significant benefits of well-planned work are achieved. Note especially the illustrative diagrams, informative captions and the detailed instructor’s notes that ensure effective training.

The mining operation that understands who does what about performing or supporting maintenance, how, when and why can meet the objective of providing consistently reliable production equpment. A well informed workforce confident in all aspects of achieving effective maintenance guarantees this reality. The reality is the development, documentation, implementation and operation of a proven mine maintenance management program.

The utilization of professional training materials in the conduct of on-site maintenance management training has many advantages. Training can accommodate the availability of key personnel to avoid conflicts with operating schedules. As many personnel as necessary can be trained, singly or in logical organizational groups. Personnel from several departments can be trained together to clarify interdepartmental roles and actions. Presentations can be repeated for new personnel or those assigned new responsibilities. Individuals can train themselves. Training needs at remote mining locations are met avoiding expensive attendance fees and travel expenses to distant venues. Training solutions and recommendations are based on actual, realistic and proven situations unique and directly applicable to the mining industry.

Large enterprises are adopting drone technology at an incredible pace and the drone industry is adapting to meet their needs. As businesses around the globe implement drone programs they are pushing out the boundaries of what drones can do and what the drone industry delivers. Click here to learn how large enterprises are seeing a clear ROI using drone technology.

This video by PHOENIX Process Equipment shows the steps in dewatering slurry into a dry cake discharge with a Recessed Chamber and Membrane Filter Press.

PHOENIX provides process solutions to reduce slurry pond area with a rake-less Ultra High-Rate Thickener that provides mixing, flocculation and internal dilution followed by clarification and positive sludge collection and removal in a single tank. Complete elimination of slurry ponds can be obtained by adding a Belt Filter Press or Recessed Chamber Filter Press to dewater the thickened slurry.

Need a solution to reduce your slurry pond area? Clarifies the water while thickening the slurry from a wash plant to 40-45% solids to reduce the volume going to the slurry pond. For complete elimination of the slurry pond, a PHOENIX Belt Filter Press or Recessed Chamber Filter Press may be added to dewater the thickened slurry either initially or at a later date.

Browse the directory for Haulage & Loading 2017. This includes complete exhibitor list and contact information along with the technical program for the conference.

Capture, de-slime and dewater granular solids including construction aggregate, specialty sands, mine tailings, dredger slurry and more.

This paper outlines the experience of one global cement producer that embarked on site surveys and studies to achieve arc flash safety compliance at 13 cement plants in the U.S. and Canada.

The purpose of this paper is to review a case study of a successful energy project at the ArcelorMittal Burns Harbor facility involving the addition of five new adjustable frequency drives (AFDs) used to regulate flow of the high-volume water spray system for the runout table (ROT). The paper will outline 1) processes used in justifying new technology updates, 2) mill alignment with the serving electric utility to leverage energy credits, 3) equipment selection and installation and 4) metrics used to demonstrate the project delivered the desired payback.

The Elusive Qwest for World Class Maintenance - ‘Seat of the Pants’ Maintenance Isn’t Good Enough - A major deficiency of too many mining operations and the explanation of most maintenance problems is no program. As a result, maintenance personnel who are to carry it out or support it (like purchasing, warehousing and operations) are confused and uncertain about how to help. Mine managers are frustrated and impatient, expecting that maintenance should, by now, know what they are supposed to do and how. Too many assumptions have been made starting with the mine manager who should have said, "I want a logical, well-defined program about maintenance that fits our operating plan and I want all mine personnel to understand it, support it and make it work." To those mining operations and their maintenance departments who insist they know what to do, have them prove it with a well-documented program. Many can’t.

The cause for the large drop in fall-of-ground fatalities in Ontario, Canada since the 1960s can be attributed to a variety of factors including increased regulation, better engineering and ground support practices, and the buildup of a stronger culture of safety in mines.

The robots are coming: Taking the miner out of mining is the common theme these days as the pace of advance of artificial intelligence quickens, as big data goes from a buzz phrase to business-as-usual, and as the move through semi to full automation continues. Autonomous operation is on all the major mining companies’ innovation roadmaps. At some point down the road, that is where the bulk of the industry will end up. But we have lots of ground to cover and many years of advances to get through, before we get there in a broad sense. How to manage the transition years is the big question, for mining companies and manufacturers alike.

Eaton’s B-Line series metallic cable ladder systems are engineered to provide superior strength to weight ratio while providing the lowest total installed cost of any cable management system in the industry today. This is achieved through continuous innovation, market and customer based knowledge.

Too often training is done “for the sake of it” or only to fulfill a compliance requirement. In reality the biggest return on investment from training equipment operators is achieved by targeting actual performance variance identified through data including fleet management system data. Performance variance in production, machine abuse and safety costs an average mine millions of dollars per year.

Many level applications pose special problems for process level equipment and technologies. Whether the industrial site is a mine, power generation facility, or cement plant, these sites all require technologies that will withstand the tough environmental conditions as well as the harsh nature of the solids applications. These include heavy dust in the airspace, steep angles of repose, high temperatures, changing process conditions, corrosive media, abrasive solids materials, and more. In addition, so many different sizes and shapes of containment mean that many installations have to deal with obstructions like mechanical bracing for structural support

Many level applications pose special problems for process level equipment and technologies. Whether the industrial site is a mine, power generation facility, or cement plant, these sites all require technologies that will withstand the tough environmental conditions as well as the harsh nature of the solids applications. These include heavy dust in the airspace, steep angles of repose, high temperatures, changing process conditions, corrosive media, abrasive solids materials, and more. In addition, so many different sizes and shapes of containment mean that many installations have to deal with obstructions like mechanical bracing for structural support

The Aerodyne Vacu-Valve is an economical alternative to rotary valves. Its unique design allows it to provide an airlock with no moving parts on dust collectors that are operating with a slight vacuum. Material that is fine, free flowing and will not bridge drains from the Vacu-Valve sleeve, while maintaining an airlock.

Sometimes a turning point can only be seen clearly in hindsight. Such is the case for the mine of the future as we begin 2018, coming out of a 2017 where major mining companies continued to demonstrate capital spending austerity and focus on debt reduction. All the while, there were growing signals that digitalization, electrification and automation were all gaining momentum, even though actual examples of minesite implementations could as of yet, still be counted on one hand. MacLean took the opportunity that industry downturn presented over the past several years to focus intensely on three key product development ventures – first and foremost, the battery electrification of our entire fleet, which will be complete by the end of 2018; second, the successful introduction of face bolting as a feature on our 975 Omnia bolter; and, third, the launch of the latest addition to our utility vehicle product line – the LR3 Boom Lift for heavy load and high reach applications. The past year was one where for the first time we had a fleet of battery electric vehicles working underground, allowing us the ability to validate our performance and total cost of ownership (TCO) models with real-world data, while at the same time continuing to build out our EV offer across the product lines. Looking forward, as we work hard to fully electrify our fleet of ground support, ore flow/secondary reduction, and utility vehicles, we’re keenly aware that electrification is but one step in the ongoing mechanization of underground mining, a transition to the mine of the future that will be increasingly efficient through digitalization and automation that will increase production and reduce costs.

Drone technology and aerial intelligence data enables companies to complete more accurate inventory management and maximize revenue. Download this report to learn more about drone technology for your organization.

The GPC Dust Collector is an efficient way to handle your dust collecting needs. The GPC dust collector’s small size makes it easy to solve dust collecting problems for plants and workshops with limited floor space or overhead clearance, making it an ideal solution for your dust collecting problems.

Evaluate your current dust collection system for operational efficiency. Explore these five crucial areas and assess the effectiveness of your: Pickup points, Duct work, Dust Collector, Cyclone, and Exhaust fan. Pinpoint how these major areas may affect your dust collection.

Drone technology is proving to be the most valuable tool available for industrial use cases. Companies using Kespry drone solutions are realizing better inventory management and data reliability, which increases profitability.

Do the rotary valves under your dust collectors cause maintenance headaches? Are they clogging? Are you having to drop everything and assign extra labor to fix them? Aerodyne™’s Vacu-Valve ® is the solution! Have a look at this infographic and to learn how the Vacu-valve solves these issues and improves the discharge efficiency of your baghouse, filters and cyclones.

The costs of replacement bags, machine downtime and wages accumulate quickly. Our infographic shows how placing a cyclone dust collector in front of a baghouse can lower expenses by extending filter life and reducing maintenance. See the components of an efficient, low-maintenance system. Download this infographic now to get more information about: 1) Components of a low-maintenance system. 2) 5 reasons to use a cyclone before a baghouse. 3) Animation of a counter-cyclonic dust collector.

How Much is Your Baghouse or Cartridge Collector Costing You? This whitepaper highlights: 1) The Top 5 Reasons to use a cyclone as a pre-filter for baghouses or cartridge collectors. 2) How pre-filters help to extend bag or filter life, and improving removal efficiencies.

These are just some of the questions that should be addressed when considering a material handling valve for your application. What type of material is being handled? How much should be spent? What kind of power source can be supplied? This white paper offers an easy how-to-guide for selecting the right material handling valve for your specific application.

This video from the Dust Efficiency Clinic discusses five warning signs that your dust collection system needs a pre-filter. Pre-filtering may reduce operating and maintenance costs by extending bag or filter life and improving removal efficiencies.

At Firmatek, we do a lot of inventory measurements for our clients. Often times, we know plant managers aren't thrilled about getting their inventory measurements because of problems they've experienced with past vendors. However, we serve as a trusted advisor for our clients and make the inventory process as easy as possible from start to finish. With our share of success, we see our share of issues. In this study, we discuss the top issues we see with inventory measurement and how we work to mitigate these issues.

These are just some of the questions that should be addressed when considering a material handling valve for your application. What type of material is being handled? How much should be spent? What kind of power source can be supplied? This white paper offers an easy how-to-guide for selecting the right material handling valve for your specific application. Simply fill out the form and you will have immediate access to the guide.

Firmatek conducted a study comparing 3 types of equipment across 29 piles ranging in size on a site where we have significant historical data. In this analysis, we look at how two types of drones compare to Lidar.

Learn why long-time Firmatek client, Brox Industries, chose to move to Firmatek's Drone Solutions program.

Is your dust collection system working at peak efficiency? A quick, do-it-yourself examination may identify symptoms that your system needs a check-up. Enjoy this video from The Dust Efficiency Clinic at Aerodyne. You'll be able to identify five signs that may diagnose a sluggish system so that you can return your system to full efficiency.

Drones have exploded in popularity thanks to their versatility and the growing accessibility of the devices. Flown carelessly, drones can be dangerous. While drones work to keep employees safe and out of dangerous environments, it's important to be aware of the regulations enforced by the Federal Aviation Administration. Check out our Drone Regulation Guide published in Occupations Health & Safety to review a couple of important considerations in maintaining safe and legal flying practices.

In order to control inventory in a typical aggregate operation, the producer must understand the whole process, from production through sales. Inadequate control in any one of these areas leads to inventory uncertainty and makes it more difficult to make decisions based on a strong understanding of the operation. In this report, we cover the basics of aggregate inventory management and suggest best practices.

A true service provider is called upon to bring all of their tools, knowledge, and expertise in times of crisis. We provide our clients with confidence in their data, and go above and beyond to serve them and work with them to solve critical problems. One of our clients was facing a serious problem when an underground tunnel was in grave danger of collapsing or causing a major flood. Read our case study to find out how we used the right tool for the job and found a solution to their problem.

Drone technology is still relatively new, but the adoption of drones is revolutionizing the way we work in countless industries. The aggregate industry rarely leaps at the latest and greatest technologies, preferring to stick with known commodities, but those who incorporate drones will discover that they have the potential to create a far safer and more efficient job site. First published in Cement Americas Spring Edition 2018, this article discusses 3 steps to follow to incorporate drone usage into your workflow.

This guide describes our recommended best practices for setting, maintaining, and capturing Ground Control Points suitable for creating 3D maps using drones. We've included tips for GCP placement, as well as how to properly maintain your GCPs to ensure you are establishing an accurate position of data.

The amount you pay for your measurement is not your only cost when it comes to inventory. In the industry, we talk about what it costs to measure your inventory, but rarely do we discuss the cost of not measuring your inventory. Cutting costs by rarely measuring inventory could actually be costing your business more money. We invite you to download our article on the costs associated with not measuring your inventory for more information.

Firmatek has been measuring stockpiles and helping the Aggregate Mining Industry manage its inventory for almost 30 years. The industry has used a variety of different technology over the years. From wheel and tape, to drone solutions, Aggregate Mining companies have continued to develop innovative solutions for measuring inventory. With each evolution in the technology, there have been improvements in everything from accuracy, to safety, to management systems. Let’s take a look back at how we got to where we are today.

Data is everything, but gathering it can be a challenge. There are several factors that go into choosing the right technology for your site. LIDAR and drone technology are both effective data collection methods, so how do you know which method is the best tool for the job? For aggregate producers, there are a few key questions you should ask when deciding which technology is best for a particular job. Download our article to learn more about the 4 questions you should keep in mind when choosing between LiDAR, drone technology, or both.

Fresh ideas aren't just welcomed, they are needed. Sustainable mining practices have been a concern for years and they are now more important than ever. As demand for resources continues to grow, mining companies are focused on figuring out how to deliver raw materials as efficiently and sustainably as possible — and the driving force behind this effort is technology. Download our article for more information on the 3 Ways to Continue Mining's Journey Toward Sustainability.

Firmatek's strategic Drone Program addresses the complex needs of clients and delivers the same precise measurements and data analytics that our customers have come to know and trust. Our drone solutions are simple, fast, and accurate. Simply fly the drone on your site, and upload the data to our client portal for processing. Firmatek doesn't stop there, we make sure you understand what the data is saying so you can be confident in the decisions you make for your operation. We invite you to watch our Drone Program video for more information. Get started with Firmatek Drone Solutions today!

Manual mapping methods are expensive, time consuming, and dangerous. Firmatek is breaking that paradigm using drones to simplify the mapping process. We use drones to collect mapping data from our client's sites and integrate technology into our service offering. Download our article to learn how.

A lot can happen in a month or quarter on your site, making it difficult to prepare for your month end inventories. Firmatek’s Drone Solution allows you to fly your sites and then upload the data to our team for processing. This gives you the flexibility you need to capture data when you need it. With this in mind, we've developed three tips to remember when preparing for your month end inventories. Download our article to learn more!

Technology is adding unparalleled value to the mining and aggregate industries. Executives and plant managers are able to access more information than ever before, allowing them to make better, more informed business decisions. However, technology adoption in mining could frighten many employees in the industry for various reasons. To help ease their fears, we've developed 4 things to keep in mind. Download our article to learn more!

Technology has made business operations more seamless, but in order to understand exactly what customers need, you have to spend time with them and get to know their business. It’s more than a sales pitch — we like to partner with our customers to create the best technology solution. Despite the constant stream of technological advancements we enjoy, the human element isn’t going out of style. If your company is looking to stand out from the crowd, incorporating the human element into your company-wide strategy will help you reach your full industry potential. Download our article for strategies on how to maintain a personal touch in your tech company. 

Training is a make or break customer satisfaction opportunity. If not executed well, it can actually chase your clients away. It's our job to make sure our clients are prepared and equipped to capture great data. With this in mind, building a strong training program has been a key focus this year at Firmatek. Our Chief Drone Officer, Andrew Maximow, identifies 3 key take-aways that he believes make training programs great. Download his article to learn more.

Each individual will require more than 3 million pounds of minerals, metals and fuel during his or her lifetime, meaning companies must optimize to meet increased demand. Big data can help achieve that goal, but only if it's used correctly. Because data is being collected more frequently, it's more important than ever for everyone to understand the basics of data collection, analysis, and delivery. The best way to do this is by forming an accurate  picture of the end-to-end process. Download our published article to learn more. 

In an industry where technology is constantly evolving, you can’t just listen to what everyone is saying. When there’s a new drone or app introduced every few weeks, how can you keep up and separate the truth from the hype? In our latest blog, Chief Drone Officer Andrew Maximow debunks 3 popular myths about drones in the commercial & industrial space. Download his full article here!

Turner Mining Group continues to embrace new technology to increase efficiency and keep their employees safe. Drones have had a big impact on both of these factors. From billing reconciliation to safety, adopting Firmatek’s Drone Solutions across Turner Mining's nationwide organization has helped them improve efficiencies in a number of areas. Download our case study to learn how drone solutions can help improve your operations.

Every job site demands unique attention. That’s why every Bridgestone and Firestone Off-the- Road tire must meet our standard of engineering and innovation. Our UGHR line-up provides the cut resistance and durability required for underground mining, while delivering a high level of stability and traction to meet the varying heat- severity requirements of our customers.

Transform your site data into business intelligence. Conducting inventory measurements on a monthly basis gives you key insights about your operation. The measurement itself is just data, but when you turn the data into insights, you're building your level of business intelligence. This allows you to manage and improve your overall operation. Download our article to learn more about the 3 Reasons to Conduct Monthly Inventories and how you can improve your operation.

Let's face it: Pipeline planning and upkeep require a huge investment of capital. Technology is taking pipeline construction and maintenance to another level. Ignoring the benefits of tech is no longer an option. If you want to keep up with the competition and improve safety, efficiency, and profits, you have to jump on board and make the most of what's available. Download our resource to learn more.

Are you a DIY-er? Or do you prefer hiring a full-service provider? The choice between the two comes down to what you value most: time, cost, or the experience you want to have. At Firmatek, we believe that clients deserve a tailored solution and we work with them to determine which option on the spectrum of full service to partial DIY makes sense for them. We work with clients to uncover what value choices are right for them. Download our article to find out where your business falls on the DIY spectrum. p.p1 {margin: 0.0px 0.0px 0.0px 0.0px; font: 12.0px Lato}

Moving from using traditional surveying techniques to using drones for aerial data capture can increase productivity as much as 200%.  You can deliver the data you have always produced for your customers quicker and take on new projects that were too complex or hazardous before.With Firmatek’s Data Analysis and Reporting Platform, you can quickly fly a site and process the data in hours, providing a fast, cost-effective way to perform surveys. Our platform turns your drone captured aerial imagery into high precision 2D maps and 3D models, reducing expensive and time-consuming field work, while expediting the output of reporting and analytics, while providing you with survey-grade accuracy, custom reporting and reliable analytics designed for surveying and mapping.

Once upon a time, decision makers in the aggregates industry had to rely on guesswork to figure out whether they could meet a client need. Fast-forward to today, and drone technology has taken much of the guesswork out of the equation. Plus, mines are safer because data collectors are spending less time in the field.As drone tech continues to improve, there will be fewer and fewer reasons for decision makers not to incorporate drones. In the aggregates industry, it's imperative that executives begin to prepare even their most tech-challenged employees for a drone-filled future. Download our article, published in Rock Products, to learn about four tips that can help you get started. 

At Firmatek, we love technology. Who wouldn't want to have cool drones, lasers, and software? But cool tech isn't what makes our clients' operations more successful. It's the insights we provide from the information tech gathers. We often see clients start with the "what" when they need to be looking at the "why." Why do you want to use technology? How will it help your business? We use tech to give you more than just another data point or inventory volume. We give you insights that help you increase your business intelligence. Download our resource to learn more about business intelligence.

We consistently tell our clients one thing: you can't manage it if you can't measure it. The increased demand for data analysis and use of drones for 3D mapping has prompted more questions around additional case uses for drones. And in 2019, we see this trend continuing. As the "early majority" adopters in the commercial/enterprise drone industry climb up the "slope of enlightenment", there is a need for different ways to measure its growth beyond the number Part 107 license and drones being deployed. For us the key to growth is in the demand for data analytics. This demand, in turn, will further drive the supply of drones and Part 107 pilots. How does Firmatek plan to facilitate demand and drive growth in the drone industry? Download our resource from Chief Drone Officer, Andrew Maximow, to learn more.

Tsubaki SMART TOOTH offers users the ability to identify and schedule drive system maintenance before critical component failure occurs. Strategic placement of our patented Wear Indicator pins on one or more sprocket teeth provides visual indication that a sprocket is still within the allowable wear tolerance, or that it needs to be replaced. When factoring in the cost of critical drive systemcomponents, implementation of Tsubaki Wear Indicator technology makes sense for applications that are driven by capital equipment, or where non-scheduled downtime is simply not acceptable.

Stockpile measurements are an integral part of running a successful aggregates business. Operating efficiency and profits depend on stockpile measurements, yet many aggregates operations are guilty of making numerous common mistakes. Stockpile measurements aren’t 100 percent perfect, but you should focus on making accuracy one of your top priorities. With a more refined picture of your stockpiles, you can base decisions on sound data instead of deceptive estimates, improving efficiency and boosting profit margins. To solve some of the most common measurement problems, there are a few strategies to keep in mind. Download our resource to learn more! 

StrataConnect WirelessMonitor. Control. Track. Alert.Completely wireless and battery-powered components to build and expand your network, for permanent or temporary needs.

Proximity detection and collision avoidance is one of the most vital of today’s technologies for keeping workers safe around heavy machinery. The ever-enhancing Strata HazardAvert® is designed to be used in both underground and surface mining operations and the system promotes safer work practices through increased safety awareness and modified worker behavior. It works to prevented accidents and collisions which in-turn improves overall productivity and efficiency.

Proximity detection in mining is one of the most vital of today’s technologies for keeping workers safe around heavy machinery.  Strata HazardAvert® for coal mines is specifically designed for the underground coal environment and is MSHA approved to be used mine-wide on both production and haulage equipment. The system promotes safer work practices through increased safety awareness and modified worker behavior. It works to prevented accidents and collisions which in-turn improves overall productivity and efficiency.

We frequently get asked about the drones or UAVs that we use. What is the best drone? Why do you use such-and-such vendor? Utilizing the best technology available helps ensure that we can equip our clients with the business intelligence that they need to improve their operations. A one-size-fits-all solution in our industry isn’t practical, so we work with our clients to determine the best tool for precise and efficient data collection. Check out part one of Andrew Maximow's article series, Guide to Drone, to learn more about how we choose the right tool for the job. hashtag

Geospatial mapping is becoming a game-changer in the quality of the construction process. The construction industry is continually evolving, trying to find the best ways to maximize their profits and ensure efficiency. Cutting-edge drone technology has been a key influence working towards goals of better documentation; project management and inspections; and designing, planning, and estimating. Download our resource to learn more about the advantages of utilizing geospatial mapping data in your operation.

Does Firmatek hire drone pilots? The short answer is no. Providing key insights is our WHY. Collecting data, whether with drones or other tools, is just the tip of the iceberg of WHAT we do. Because of this, when we hire we look for skill sets beyond Part 107. We hire people who speak our client's language— mining, geology, construction, energy, and civil engineering. Andrew Maximow provides an in-depth explanation on our blog. Check it out here!

While drones are widely used for collecting amazing photos and videos, technology is evolving rapidly to collect and analyze more data. Industries that deploy drone tech discover new possibilities. Firmatek is helping clients in several industries get started with data, build use-cases, and deliver insights via more quantitative and qualitative data analytics. In the first blog of our Guide to Drone Series, we discussed the criteria we use to select drone/UAV platforms. In this article, we take a closer look at specific use-cases and the types of data they provide. Download our resource to learn more.

Many people look to implement drones into their operation and only go as far as to think about the data they are receiving. At Firmatek, we enable our clients by giving them more than just a number. We believe in using the right tool for the right job, so we work with our clients to provide a solution that works for them. Sometimes that means we do everything from collecting the data to analyzing it and providing analysis and results. Other times, we put a drone in the hands of our clients and they collect the data and we do the analysis; often, we do a combination of both. Our clients take the analysis we provide and use it to elevate their business intelligence and improve their efficiencies. That's why Turner Mining Group chooses our drone solutions. Download our resource to learn more about our Q&A with Turner Mining Group at the AEC Next conference this week.

In an industry that’s flooded with new and improved tools and software systems, we help our clients by providing key insights and custom solutions. Serving our industry to the best of our ability requires us to act as trusted advisors. We start by suggesting the right tool for the job. In part three of our Guide to Drone series, Steele Olsen, Geospatial Field Technician, highlights some specific UAV platforms that are currently in-use at Firmatek and discusses why they fit well within our clients’ operations. Download our resource to learn more about the tools we use and why!

In many mine and plant operations, safety is looked upon as an extra layer of special attention placed above the operations management layer. But safety awareness must be built into the detailed operations and maintenance training on the equipment as well as on the process itself.  

Performance Associates (PAI) delivered a jaw crusher introductory maintenance manual and animation to Northern Star Resources, Ltd.—Kanowna Belle Project in Western Australia on June 7, 2019. The animation provides a narrative description of the jaw crusher’s location in the process, its function, components, and maintenance requirements. With this delivery, PAI successfully met Northern Star Resources’ need for an animation that could introduce new maintenance personnel to the Kanowna Belle jaw crusher in a dynamic visual context. The narrated animation replaced the standard text and graphics in the description section of the equipment maintenance computer-based training (CBT) module. The descriptive text was adapted to a narrative form. Multimedia specialists used engineering drawings and photographs to create models of the equipment and animate the modeled images to illustrate the key concepts and components in concert with the narration.

As many industries are adopting drone technology across their entire organizations, it is important to learn from our collective successes, mistakes, and key findings. Regardless of your industry, there are many similarities in implementing a drone program across your organization.Building an Enterprise Drone Program requires first seeking to understand why you want it, what success looks like, and how you want to build it. Building a successful Enterprise Drone Program is a large task. But when done well, the impact on your business can be significant. You will gain the business intelligence that you need to make your operations more efficient.Download our white paper to learn more about successfully building and implementing your enterprise drone program.

Excellence in Mining, Process Plant, Maintenance, and Safety Training  Performance Associates International, Inc. (PAI) is the world leader in online and on-site training for the mining industry. We provide organizations with a single source for assessments, skills training, continuing education, safety training and compliance mandates, and more. Our first-class content guides your staff to gain the critical knowledge they need to work safely and efficiently today.  Our proven, leading-edge industrial training programs improve performance in existing operations and ensure success during the start-up of new operations. Our training programs have saved companies millions in personnel accident prevention, production loss, and equipment damage. We partner with our customers and consult collaboratively to provide the analysis and content development to meet your needs.  Services PAI Offers  Plant Operator Training Our three-tier concept for effective plant operator training starts with fundamental knowledge and progresses to plant-specific concepts that are reinforced through detailed animations and interactive simulations.  Maintenance Training We custom build state-of-the-art maintenance training programs using exploded graphics, explanatory text, detailed procedures, and management systems.  Mobile Equipment Operator Training Our first-class training program focuses on operator controls and indicators, safety, and performance optimization. It also includes operating, emergency, and troubleshooting procedures. Commissioning and Start-Up We can identify, track, and control the thousands of activities that must occur for the successful commissioning and start-up of a process plant. There is no shortcut to a successful start-up. Testing and Tracking Systems We can help manage and track the performance of employees to improve the overall performance of the mine and plant industrial training programs. Our testing and tracking systems provide invaluable assistance in safety and operational compliance.  Introductory and Safety Training Off-the-shelf introductory and safety training packages are an excellent source for mine and plant industrial training courses. They provide fundamental knowledge and basic training concepts. Now offering online courses! E-Learning, Animations, and Simulations Our interactive e-learning keeps trainees focused and engaged. Our experienced in-house multimedia team develops state-of-the-art graphics, virtual and mixed reality training, stunning 3D animations, and technically engineered simulations of real-world scenarios. Other Services We also provide many services relevant to planning, analyzing, and evaluating process plants, including: ·         Operations readiness plan. ·         Planning studies. ·         Quality management. ·         Systems implementation. ·         Statistical process control. ·         Reliability-based asset management. ·         Productive capacity studies. ·         Surveys and needs analyses. ·         Economic life analysis. ·         Process control strategies and methods. ·         Debottlenecking and process optimization. ·         Spare parts inventory and analysis. ·         Feasibility studies. ·         Consulting assistance. Consulting * Gap Analysis * Content Development * LMS * On-Site * Train-the-Trainer * E-Learning * Process Plant Optimization * Training * Safety * Mine Training * Plant Operator Training * Maintenance * Mobile Equipment * Competencies * Commissioning  

Three dimensional animations integrated into a process plant computer-based training (CBT) program can greatly enhance trainee understanding of process equipment. This introductory maintenance manual and animation provides a narrative description of a jaw crusher’s location in the process, its function, components, and maintenance requirements. The animation introduces maintenance personnel to the jaw crusher in a dynamic visual context. The narrated animation replaced the standard text and graphics in the description section of the equipment maintenance (CBT) module. The descriptive text was adapted to a narrative form. Multimedia specialists used engineering drawings and photographs to create models of the equipment and animate the modeled images to illustrate the key concepts and components in concert with the narration.

During the final stages of metallurgical plant construction there is tremendous pressure to commence production. More often than not, there will have been budget overruns and schedule delays. Corporate management and investors are naturally anxious to generate cash flow. This pressure may evolve into a fast-track culture regarding the commissioning and start-up.  www.perfnet.com 

During the final stages of metallurgical plant construction there is tremendous pressure to commence production. More often than not, there will have been budget overruns and schedule delays. Corporate management and investors are naturally anxious to generate cash flow. This pressure may evolve into a fast-track culture regarding the commissioning and start-up. www.perfnet.com 

Mapping is one of the least understood applications for drones. Maps are very useful for many industries, but if your customers require accurate measurements, additional controls are needed beyond simple photo processing. As drone-based photogrammetry becomes widely accepted, it is important to note best practices that help ensure quality, trusted insights for your clients. In Andrew Maximow's latest article, he covers what is needed in a drone mapping system to produce and collect accurate, quality data. Check it out here.

Developing a profitable mining venture is no small matter. It requires enormous initial investments in research, construction, and equipment. But a mineral processing plant does not run itself. Even with the best equipment and good ore quality, optimal results are dependent upon keeping the process running smoothly, avoiding process upsets, maintaining process variables in the desired range, and minimizing breakdowns and downtime. A highly trained workforce is an essential element in a successful, and profitable, start-up. The knowledge and abilities of plant operators and maintenance personnel can make or break an operation. Trained operators know what to look for during preoperational and routine inspections, allowing maintenance tasks to be planned and unexpected costly breakdowns avoided. Trained operators know what variables exist at different stages in the process and how to make appropriate adjustments in real time. Trained maintenance personnel are well acquainted with the plant equipment, and maintenance planners can schedule work and maintain a spare parts inventory to minimize downtime. Additionally, new operations that train their workforce just prior to plant commissioning can utilize their operators in the commissioning process. Having been trained and gained field experience through plant commissioning, operators are ready to hit the ground running once feed is introduced. A faster ramp-up means more earnings, more quickly. The cost of developing a proper training program is a small percentage of the overall engineering, procurement, and construction budget but it constitutes a large percentage of the gains realized from a successful start-up and ramp-up to full production. Performance Associates International (PAI) has designed and presented custom training programs for operators and maintenance personnel in metallurgical plants around the world for over 35 years. We are proud to have been part of the successful start-ups at Lundin Mining’s Eagle Mine, Vale’s Voisey’s Bay project, and Torex Gold’s El Limon-Guajes project. Click Download to view the actual vs. projected start-up results from these three metallurgical plants that made use of PAI’s custom-built training programs and on-site training.

Telsmith provides a full range of integrated processing equipment to the aggregate, mining, industrial, and recycling industries with cone crushers, jaw crushers, vibrating equipment, portable plants, track plants, as well as full-scale modular processing facilities. 

In the past, we’ve discussed techniques and best practices necessary for precision mapping projects requiring a high degree of absolute accuracy. Not all clients require that level of accuracy, so different tools and techniques are used to create the deliverables. A one-size-fits-all solution in our industry isn’t practical, so we research and work with our clients to determine the best tool and software available for precise and efficient data collection and processing. In this article, Andrew Maximow compares the traditional way of processing photos along with two faster and more efficient methods that save time, processing steps, and resources. Learn more on the blog!

With reference to greenfield plant projects, using process simulators similar to the designed plant Human-Machine Interface (HMI) or Distributed Control System (DCS) has become common practice. These simulators represent a “virtual plant” based on process modeling of the circuit chemistry and thermodynamics, and on the physical nature of the plant, including equipment, valves, piping, etc. The virtual plant allows trainees to troubleshoot problems, optimize process variables, react to alarms, etc., all based on the process simulation model. Performance Associates’ experience is that this complex simulator training is valuable, but only after more in-depth training on the process and control logic. To truly optimize a process plant, prior to simulator training, the control room operators must have detailed knowledge of the following:  Process objective of each process system, comprising a group of unit operations.  Process objective of each unit operation.  Process chemistry and the variables affecting it.  Important characteristics of each unit operation, the variables affecting it, and the impact on downstream unit operations.  Plant control loops, interlocks, and alarms.  Safety issues related to the process and control schemes.  Operating procedures for start-up and shutdown under various scenarios, as well as important operator tasks. Additionally, trainees must be intimately familiar with the applicable fundamental scientific concepts, such as pressure, temperature, heat exchangers, electricity, PID control logic, combustion, etc. With this fundamental and plant-specific foundation, the process simulator can be fully exploited for training.

With reference to greenfield plant projects, using process simulators similar to the designed plant Human-Machine Interface (HMI) or Distributed Control System (DCS) has become common practice. These simulators represent a “virtual plant” based on process modeling of the circuit chemistry and thermodynamics, and on the physical nature of the plant, including equipment, valves, piping, etc. The virtual plant allows trainees to troubleshoot problems, optimize process variables, react to alarms, etc., all based on the process simulation model.  Performance Associates’ experience is that this complex simulator training is valuable, but only after more in-depth training on the process and control logic. To truly optimize a process plant, prior to simulator training, the control room operators must have detailed knowledge of the following:Process objective of each process system, comprising a group of unit operations.Process objective of each unit operation.Process chemistry and the variables affecting it.Important characteristics of each unit operation, the variables affecting it, and the impact on downstream unit operations.Plant control loops, interlocks, and alarms.Safety issues related to the process and control schemes.Operating procedures for start-up and shutdown under various scenarios, as well as important operator tasks.Additionally, trainees must be intimately familiar with the applicable fundamental scientific concepts, such as pressure, temperature, heat exchangers, electricity, PID control logic, combustion, etc. With this fundamental and plant-specific foundation, the process simulator can be fully exploited for training. 

We were recently asked to inspect a large indoor construction site with a roof height of approx 100 feet. The project will eventually be one of the largest indoor mall and family entertainment complexes in the world. The site has experienced a rocky journey with construction that started nearly 20 years ago. The roof height poses a challenge for new owners and contractors. The only solution in knowing whether proper work has been done over the years? Indoor drone inspection. In this article, Andrew Maximow discusses this project and three significant challenges to deploying drones indoors. Learn more on the blog!

The geology report, feasibility study, and mine plan look great. Why do so many mining project start-ups fail to perform? Most mining companies put a great deal of emphasis on the nature of the reserve, the mine plan, the extraction process to be used, and the process plant design—obviously all very important. Even when large, highly regarded engineering, procurement, and construction firms develop the project, operating results are very often disappointing. In this paper, we explore the role of Operations Readiness on the financial impact of mining project start-ups. A relatively small investment in operations readiness produces a huge financial return. Many investment firms, as well as mining company senior executives, fail to consider this important factor in operating success.

Drone adoption is thriving in several industries and the aggregates and mining industry that Firmatek serves is no exception. Although drone tech is relatively new, drones are revolutionizing the way we work. However, with all of the operational benefits that drones bring to the table, there are a few concerns that contribute to lack of adoption. We tackle three common concerns in our latest article by Henzé (hen-zay) Gustave. Check it out here!

Founded in 1983, Performance Associates International (PAI) is the worldwide leader in mine and plant industrial training. Our custom training modules and on-site training have improved start-up success and operations for clients on nearly every continent. We invite you to experience one of our e-learning training modules. Here you will see a video demonstration of a sample principle of operation from an e-learning module. A principle of operation describes in detail how a piece of equipment or a process works. In this sample, you will learn about Jameson Cell flotation technology and how its design allows for more efficient mineral separation in a much smaller tank than traditional column and mechanical flotation cells. We describe in detail the key components of the Jameson Cell and the operating principles. At the end of the module, a test will help assess what you learned. In a full training program, test results can be recorded and tracked in an LMS. A principle of operation like this would be only one of many included with a full plant operations training program. Note: This is a sample and does not contain the Jameson Cell training module in its entirety. If you would like to try out this e-learning module, please contact Kenneth Slack at [email protected] or +1-520-544-2220.

How can the overall performance of your plant be determined? Most plants calculate availability, or the percent of the time the plant or a particular circuit is operating, as well as overall production and recovery. But, is this information enough? Does it provide sufficient fine-grained information on where improvements can be made? This paper suggests five quantitative factors applied to a plant or to individual parts of a plant that identify the productivity of the plant—in other words, its productivity profile.

In this interactive PDF, we talk about common training myths and our responses.

Using existing leaky feeder coaxial cable, along with Strata’s high-quality bidirectional line amplifiers, DigitalBRIDGE Plus+ delivers power, Ethernet data and a full spectrum of VHF radio frequencies all over a single cable network.

StrataConnect DigitalBRIDGE™ is a point-to-multipoint Power-over-Ethernet (PoE) network for underground applications. It delivers both power and high-speed Ethernet data over a single coaxial cable to any location where digital end-point devices are desired. DigitalBRIDGE™ provides data speeds and capabilities comparable to fiber and can be used for a wide variety of applications such as, voice communications, Wi-Fi access, video, telemetry, tracking, tele-remoting and more.

How can the overall performance of your plant be determined? Most plants calculate availability, or the percent of the time the plant or a particular circuit is operating, as well as overall production and recovery. But, is this information enough? Does it provide sufficient fine-grained information on where improvements can be made? This paper suggests five quantitative factors applied to a plant or to individual parts of a plant that identify the productivity of the plant—in other words, its productivity profile.

See how secondary check valves in discharge piping up a highwall work to prevent water hammer and alleviate stress on the pump to help you avoid ugly repair bills and downtime. For more information on secondary check valves or any of your pump rental needs, contact Xylem Rental Solutions.

Ensure that your plant has a good inventory of spare parts on hand by learning how to collect the data necessary to build your own spare parts inventory model.

Increase efficiency, improve safety, and reduce downtime with the VDG Drum Motor. Customers and OEMs share their experiences upgrading their belt conveyors with our one-component drum motor.  The innovative VDG Drum Motor has all drive components including motor and gear reducer enclosed inside the drum for a safer, more efficient, and space optimized belt conveyor drive solution. Reducing energy expenses by 30% per drive, all components of the VDG Drum Motor are designed for 80,000 hours of continuous operation before maintenance, minimizing downtime, reducing maintenance costs, and increasing production.  All VDG Drum Motors are engineered and manufactured in-house in USA and Canada, using cutting-edge production technology and automation, ensuring quality, fast delivery, and after sales support.

Haver & Boecker Niagara introduces a new electronic guide that expands its dedicated suite of tools to complement its PROcheck approach.

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Large conveyor capital expenditures in sectors like mining, power plants, and ports must take safety and sustainability into account, but this isn't done as effectively or as regularly as it should be to make sure the investments make financial sense.A fundamental economic assessment is necessary for businesses thinking about installing an overland conveying system to examine the expense, but it's not usually simple to carry out.

Having developed tailer-made system solutions for mining for almost 90 years, BEUMER’s acquisition of FAM GmbH, Magdeburg supplements the company’s know-how and global position, giving customers the combined experience of the leader in the bulk materials technology market and aptitude of a time-tested conveying system manufacturer.

With the acquisition of one of the leading companies for air supported belt conveyors, The Hendrik Group Inc., the BEUMER Group is expanding its portfolio in the field of bulk material transport. In particular, the handling of alternative fuels (AFR) and raw materials confirms BEUMER's commitment towards sustainability and is at the same time fully complementary to the current technologies offering ensuring an even broader customer benefit. The technology also generates additional potential in the field of bulk material handling of sensitive materials when it comes to preventing hazardous substances from being released into the environment. 

A bag of cement has a long journey behind it before it arrives at the building site. Between being quarried, processed, and supplied as the finished product, the material passes through many different stages. At each of these stages, special systems are in place to ensure the process is smooth, economical, and environmentally friendly: systems from BEUMER Group. Systems you can rely on – whether the job involves conveying, loading, or packaging cement.

Mining companies and their suppliers are constantly looking for new ways to increase safety, productivity, efficiency, and cost-effectiveness. Nowadays they are putting more emphasis on climate-friendly and eco-friendly processes, zero-emission technologies, and optimal allocation of resources. Automation and digitalization are also playing a bigger role at all levels.

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BEUMER was founded in Beckum, Germany, in 1935 as a manufacturing company for conveyor equipment, and its first order came from the cement and lime industry in Westphalia. Since then, products and solutions have been manufactured worldwide for the cement industry. Today, BEUMER Group is an experienced, internationally active operator in the cement industry and has the right solution ready for any challenge in conveyor, loading, silo, filling, palletising or packaging technology. Download the brochure to learn more.

In the area of opencast mining technology, FAM offers an impressive selection of various machines and systems, such as bucket wheel reclaimers for the extraction of mineral resources like lignite, hard coal, overburden, marl, etc. Opencast mining is a mining technique of extracting minerals from the near-surface layer of the earth, these raw materials can be then used for further processing, for example, in the production of metals or building materials. Our product portfolio ranges from mining equipment (e.g., excavators) to crushers, belt conveyors and subsequent stacking technology.

Learn how BEUMER helped modernize and increase the performance of the plant between the longitudinal stockyard and the ship loading system for ASEAN Bintulu Fertilizer.

Does the market demand higher throughput? No problem: The BEUMER paletpac® high-performance palletiser could be your answer. Our palletisers and palletising systems can stack exceptionally high quantities of robust, bagged products onto pallets and then move them carefully, safely and economically. Take the opportunity to increase your production with an automated palletising process. 

Vibrating screens work hard to keep your product in spec. But, like all equipment, they require proactive maintenance, wear part replacement and periodic upgrades to more efficient technology to maintain reliability and productivity. Read more for daily, weekly and monthly inspection tips.