Wirtgen Group Profile

The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating the traditional brands, WIRTGEN, VÖGELE, HAMM, KLEEMANN and BENNINGHOVEN. As a technological leader, the company offers its customers mobile machine solutions for road construction and road rehabilitation, as well as for mining and processing minerals.

VIEW COMPANY WEBSITE

Press Downloads

MOBILE SCREENING PLANT SET FOR LAUNCH IN SA

[Johannesburg, 24 May 2017]: Wirtgen SA, local subsidiary of the Wirtgen Group, global leader in mobile machine solutions for road construction and rehabilitation as well as mining and mineral processing, will soon be launching the much anticipated Kleemann Mobiscreen MS 703 EVO to the South African market.

Developed and designed in Germany, the Kleemann MS 703 EVO is a triple deck mobile classification screen that precisely screens out almost all types of coarse natural stone, residual construction materials and iron particulates of up to 150 mm up to four fractions. Finding application in both the mining and construction sectors, this screening plant screens out material after the initial crushing process and offers superior performance, fuel efficiency and intuitive handling.

Measuring in at 1.520 m x 4.440 m with a 75 kW engine and with a feed capacity of 350 t/h, the MS 703 EVO comes with either diesel-hydraulic or diesel-electric drive as well as a large number of screening media to achieve a variety of final grain sizes and to take different feed material. Thanks to a generously proportioned screen casing, material is well-distributed across the screen surface and its built-in peripheral platform means the screening plant is easily accessible for maintenance and screen media changing.

The plant boasts a large feed hopper which can readily accept feeding by means of a wheel loader, an excavator or directly from a crushing plant. Both folding and vibration gates are optionally available. The plant also has a special space-saving transport position, so that the most compact dimensions can be achieved should the plant be required to move to a new site; this is complemented by quick set-up times and fast screen media change capability.

Classifying screens

The Mobiscreen series from Kleemann comes with classifying screens that are renowned for their inherent flexibility, which contributes to optimal functioning and resultant output values. Suitable for a host of applications, the MS 703 EVO’s adaptability is made possible by the variety of available screen casing sizes as well as the ease and speed with which it can be transported.

Screening media on a classifying screen plant are put to the test on a daily basis and are manufactured from a special wear-resistant spring wire steel or round wire to withstand the workload and to produce consistently accurate results. Double bracing at intersections makes high mesh stability – and therefore uniform screening – a possibility, which is also influenced by grain shape, moisture content as well as the loaded volume.

Various mesh shapes and dimensions are available, including square, rectangular and harp, depending on the required application:

Square mesh screen surfaces are the most commonly used and are predominantly used in applications where a cubic shape is required. Different wire qualities and thicknesses are available: the thicker the wire, the longer service life it will have; the thinner the wire, the higher production it will ensure. Rectangular mesh screen surfaces are for screening cubic grain sizes and are often used to sort natural gravel at high throughput. The Harp screening media are used for screening damp material and difficult screening products. They boast a self-cleaning mechanism through the natural vibration of the longitudinal wires and should be inserted at the lower deck of the screen. The harp screen surface is available in different versions, including W-harp, S-harp, and Varia harp.

With fast set-up time, operator-friendly design and cost-saving features, the Mobiscreen MS 703 EVO is backed not only by Kleemann’s exacting standards, but by fully qualified service technicians available 24 hours a day as well as all recommended spares available at Wirtgen SA’s Pomona offices. Set to be launched in South Africa on 9 June 2017, the local market can expect to learn more about this dynamic new screening plant by means of road shows, demonstrations and site visits co-ordinated by Wirtgen SA.

[ENDS]

About Wirtgen SA

Wirtgen SA is the local partner for the Wirtgen Group’s sales and service offering in South Africa. Wirtgen Group offers a broad range of services tailored to individual requirements for all areas of road construction as well as the mining and processing of pay minerals. With passion and know-how, our experienced team ensures your success every single day.

More than just a machine supplier, for Wirtgen Group, the delivery of a machine marks the beginning of a long-standing service partnership. Our team of service experts is always on hand to answer any questions concerning the machine and its operation. Short response times and fast solutions are guaranteed by our experienced service specialists. In addition, we remain in close contact with the Wirtgen Group’s headquarters to ensure comprehensive support whenever it is needed.

The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating the traditional brands, Wirtgen, Vögele, Hamm, Kleemann and Benninghoven. As a technological leader, the company offers its customers mobile machine solutions for road construction and rehabilitation as well as for mining and processing minerals.

Wirtgen SA contact:

Lantie van der Merwe
Sales Executive – Kleemann
Tel: +27 (0) 11 452 1838
Cell: +27 (0) 82 306 1707
Email: lantie.vandermerwe@wirtgen-group.com
Web: www.wirtgen-group.com/southafrica/en/

Media contact:

Boitumelo Mogano
MoonDawn Media & Communications
Cell: +27 (0)76 733 2615
Email: boitumelo@moondawnmedia.co.za
Web: www.moondawnmedia.co.za



THREE DECADES OF EXPERIENCE MAKES HAMM THE WORLD LEADER IN OSCILLATION COMPACTION

Over 30 years ago, HAMM became the first roller manufacturer to offer an oscillation drum for tandem rollers, and these rollers have become an integral part of its product offering. In the past five years alone, the specialists for compaction technology have delivered more than 3,000 machines with this innovative technology. Today, one in four of the tandem rollers made by HAMM is equipped with an oscillation drum. With more than 30 models to choose from, HAMM has by far the widest offering of oscillation rollers in the world. And only HAMM builds oscillation tandem rollers in the compact class, as well as soil compactors with oscillation compaction capability.

Successful pioneers

In the 1980s, HAMM pioneered the development of oscillation compaction and was long the only supplier in the market. Customers were quick to appreciate the benefits of this technology. In the meantime, oscillation has proved itself and become successfully established in the market.

Fast, cost-effective and high-quality

The reason for this success is simple: oscillation rollers make for fast, cost-effective and high-quality dynamic compaction. In particular, tandem rollers with one oscillation drum and one vibrating drum achieve at least the same degree of compaction as double vibrating drum rollers, but with fewer passes. Another benefit is the extremely low vibration provided by oscillation, making dynamic compaction on bridge overlays, of thin layers, and in sensitive areas — such as near hospitals, city centers, rail tracks, or industrial plants — possible for the first time. The scope of applications is enormous.

Compaction at every construction phase

Another bonus is that oscillation rollers can start dynamic compaction directly behind the paver (→ breakdown phase). They can then also deal with the main compaction (→ intermediate phase). And even with lower asphalt temperatures at the end of compaction (→ finish phase), oscillation ensures an increase in compaction without crushing the aggregate. Overall, when using oscillation rollers, the time available for compaction is significantly greater than with vibratory rollers.

Experience shows

When building oscillation drums, HAMM – unlike its competitors, which have all entered the market with this technology in recent years only – can draw on decades of experience. And it is precisely this experience that makes the difference, as Richard Evans, vice president, HAMM, explains: “You can copy technical solutions, but you can’t copy experience.”

Thanks to its wealth of experience, HAMM possesses extensive know-how in application technology. This knowledge is not confined to a few specialists in the factory, but extends to the subsidiaries all around the world. Due to the large number of oscillation rollers on the market, spare parts availability is also very high. In addition, the service engineers all over the world are thoroughly familiar with the technology and trained with regard to oscillation.

Comprehensive portfolio for asphalt paving and earthwork

The HAMM portfolio encompasses tandem rollers for asphalt paving ranging from 2.5 t to 15 t. When it comes to the pivot-steered rollers in the DV+ series, a popular choice for demanding road building projects, the share of oscillation rollers is particularly high: in 2016, around 40 percent of all DV+ series rollers were delivered with oscillation drums.

The oscillation rollers for the compact class from 2.5 to 4.5 t also experience great market demand. Hardly surprising, because HAMM is the world’s only manufacturer in this market segment. This also applies for earthwork. Customers worldwide seeking a solution for compactors with the facility to choose between oscillation and vibration find that only HAMM has the answer in the form of its VIO drums.

The oscillation principle

But what exactly happens in an oscillation drum, and how does oscillation differ from vibration? With vibration, a single unbalanced shaft generates the upward and downward movement of the drum, causing it to strike the ground at a rapid rate. In oscillation drums, on the other hand, two unbalanced shafts rotate synchronously, driven by a toothed belt. The unbalances are offset by 180° relative to one another. As a result, the drum performs a rapidly alternating forward/backward rotary movement.

Due to this movement, the drum directs the compaction force into the substrate tangentially to the front and rear in the form of shear forces. Here, unlike with vibrating drums, the compaction force acts continuously on the substrate because the drum is in contact with the ground at all times. This is why oscillation rollers compact dynamically as well as statically with their intrinsic weight the whole time.

Maximum wear resistance

HAMM’s experience of more than 30 years is also reflected in the way in which the technology is incorporated in the design. An example of this is the drum shell. On oscillation drums, it is inevitably subject to greater stresses, due to the constant ground contact, than is the case with vibrating drums.

Thanks to ongoing product and material development, the operating life of HAMM oscillation drums is today nearly the same as that of vibrating drums. This is made possible by using highly wear-resistant fine grain steel for the drum shell. Its material thickness is more than 150% greater than that of comparable competitors’ machines.

In addition, an integral reinforcing ring ensures that the drum is extremely hard-wearing. This is why HAMM confidently provides a remarkable warranty against wear of at least 4,000 operating hours. With this warranty, the manufacturer surpasses any other serious offer on the market by a wide margin.

Quality thanks to chamfered drums

To ensure that the drums leave no impressions in the still soft asphalt, especially in curves, HAMM gives all drum edges a slight chamfer. Impressions of this nature have to be re-rolled afterwards, wasting time. Otherwise, they remain visible in the asphalt and compromise quality. Both issues are avoided from the outset thanks to HAMM’s design solution. This chamfer also can be found on all of HAMM’s vibrating drums.

Low-maintenance operation

A glance at the exciter system drive inside the oscillation drum also shows that it is based on a great deal of experience. HAMM has continuously optimized the position of the unbalanced weights in the oscillation drum to enable the resulting forces to be utilized as effectively as possible.

At the same time, HAMM’s oscillation drums are designed to require very little maintenance. The toothed belt, the core element of the drive, has been perfectly attuned to the overall system: its operating life corresponds to that of the entire drum. Checking the belt tension after 2000 operating hours is all that is recommended.

Use for all layers

Oscillation rollers can be used to compact all earthwork and road building layers. They come into their own in earthwork, where re-loosening of the upper layers has to be effectively prevented, such as in garden and landscaping work. Another important application is the compaction of soils in vibration-sensitive areas, for example above gas, water and other pipework.

In asphalt paving, base courses, binder courses and surface courses can be reliably compacted with oscillation rollers. They perform especially well in the compaction of generally hard-to-compact asphalts such as SMA or in the case of polymer-modified material mixes. This is because, in contrast to vibration compaction, the effective direction of the vibrations during oscillation promotes the desired redistribution of long-chain binding agents.

Other applications include work on thin layers (surface courses, thin overlays), in vibration-sensitive areas (bridges, confined urban spaces, buildings or parking decks) and wherever the mix cools quickly (thin layers, windy or cold environments). Also of particular importance is joint compaction where the hot asphalt is to be compacted without damaging the adjoining cold asphalt.

Benefits of oscillation

Oscillation offers a wide range of benefits, enhancing efficiency, quality, productivity and profitability. Here are the most important ones:

Benefit 1: High compaction power – great efficiency.
Oscillation rollers compact very quickly. Or to put it differently: their compaction power is very high. The reason for this is the superimposition of dynamic shear forces with the permanent load from the roller’s own weight. As a result, considerably fewer passes are needed, especially on large areas.

Benefit 2: Easy operation. HAMM makes use of the laws of physics to generate vibrations in such a way that the oscillation roller is extremely easy to operate. Simply switch the machine on, and there’s nothing more for the operator to do. The appropriate amplitude is set automatically according to the rigidity of the material to be compacted. This happens so quickly that compaction is always adjusted perfectly, even with varying substrates. In this way, HAMM has eliminated the risk of operating errors due to incorrect settings.

Benefit 3: Smooth, skid-resistant surfaces. Oscillation rollers produce surfaces with excellent longitudinal evenness, resulting from the drum remaining in contact with the ground at all times. Surface rippling, on the other hand, does not occur, not even at high working speeds. Asphalt compaction with oscillation also provides good initial skid resistance, because the oscillating movement of the drum rubs off asphalt from the top surface of the pavement.

Benefit 4: Low vibration emissions. Oscillation drums do not lift off the ground while compacting. In comparison to vibrating drums, with oscillation drums only around 15 percent of the vibration is directed into the substrate around the roller. This means that oscillation rollers can also be used without problems for dynamic compaction near vibration-sensitive buildings or installations. Because the rollers are also much quieter, they help to protect the environment. Another benefit provided by low-vibration compaction is that it reduces component wear and is also perceptibly less tiring for the roller drivers.

Benefit 5: Material-friendly compaction. With vibration compaction, once a certain level of rigidity has been achieved, there is a risk of destroying the material structure or crushing the aggregate. This is not the case with oscillation: it ensures that the aggregate particles are redistributed undamaged. In this way, oscillation avoids detrimental aggregate crushing and over-compaction. Moreover, oscillation compaction produces watertight, long-lasting joints without damaging the cold asphalt.

Benefit 6: Wider temperature window. Oscillation widens the temperature window in which compaction is possible because even at lower temperatures, it can be used to compact without damage. For this reason, oscillation is particularly suited to the compaction of thin layers or on fast-cooling surfaces such as on bridges. Moreover, this characteristic increases flexibility during the construction process.

Customers worldwide are moving to oscillation

As the examples show, dynamic Dynamic compaction with oscillation has many intrinsic benefits and increases road construction quality. This is common knowledge among construction authorities and private customers alike.

That’s why it’s no surprise that both pavement owning agencies and contractors alike increasingly specify the use of oscillation rollers for compaction when quality, performance and durability are paramount.

Very recent examples include the construction of the Formula 1 motor racing circuit in Baku (Azerbaijan), where medium and heavyweight tandem rollers were used, and refurbishment work in the city of Vienna (Austria), for which the use of compact rollers with oscillation was specified.

Last but not least, oscillation has also proved its worth in large projects. Here, the rapid increase in compaction ensures an optimized process that can be carried out with fewer rollers.

Further information is available from:

HAMM AG
Gottfried Beer, Stephanie Mayer
Hammstraße 1
95643 Tirschenreuth
Germany
Telephone: +49 (0) 9631 801-95 / 98
Fax: +49 (0) 9631 801-43
E-mail: gbeer@hamm.eu, smayer@hamm.eu
Web: www.hamm.eu

WIRGEN SOUTH AFRICA

Waylon Kukard
Sales Manager
Wirtgen South Africa
Cell: 0829291449
E-mail: waylon.kukard@wirtgen-group.com
Web: http://www.wirtgen-group.com/southafrica/en/

Media contact:

Boitumelo Mogano
MoonDawn Media & Communications
Cell: +27 (0)76 733 2615
Email: boitumelo@moondawnmedia.co.za
Web: www.moondawnmedia.co.za







Premium pays superior dividends

Over its 17-year existence, Road Milling and Sweeping has carved itself a niche rental business to become the largest privately-owned operator of milling machines in South Africa. With a clear understanding that the success of a business of this nature largely depends on machine uptime, the company has vested its trust in premium Wirtgen milling machines over the years, a decision that is continually paying dividends.

From humble beginnings back in 1999 with a single Wirtgen 1000C milling machine, Road Milling and Sweeping (RMS) today owns a strong 21-unit fleet of milling machines, making it the single biggest privately-owned operator of such specialised gear in South Africa. Founded by Cecil Aling and a business partner at the time, today the family-owned business is being steered by two of Cecil & Glynn Aling’s three daughters, Leigh Cameron and Lesley Kafka, who share their father’s passion for anything mechanical, but with a premium taste, of course. RMS has stuck with the Wirtgen brand for its milling equipment needs over the years, purely driven by the understanding that premium calls for premium capital outlay, but the returns, in the long run, are massive.

Road Milling’s core business is the rental of milling machines for rehabilitation of asphalt and concrete roads. The company operates on a national basis and has recently successfully completed cross-border contracts. “We work all over South Africa in terms of the milling work we do. In the past year, we have done quite a lot of cross border work,” says Lesley Kafka, general manager of RMS. “We still have got ongoing work in Lesotho that will pick up in 2017. We have also worked in Namibia, Botswana, Swaziland and Malawi.”

Kafka foresees increased cross-border work moving forward as most of the South African civil contractors spread their wings into the rest of Africa for greener pastures. This is considering that most of the cross-border contracts RMS has are with local South African companies doing work outside the country. According to Kafka, 98% of the company’s cross-border work is through the South African contracting fraternity working elsewhere in Africa.

Sticking to core business

Over the years, RMS has stuck to its core niche business of renting out milling machines, but with a few other value adds such as lowbed trucking services, road sweeping, tippers and water carts. The company now owns its own three lowbed trucks used mostly for transporting its rented milling machines to sites, but these can also be outsourced to any other customers in need of lowbed trucking. However, Kafka says sticking to the milling business only is a difficult decision from a strategic point of view. “We ask ourselves whether we need to stick to our niche or diversify the business,” says Kafka.

“Diversification has got its own pros and cons. Sometimes you become too thinly spread. Ours is a capital intensive business, so to diversify you need to invest huge amounts of capital into equipment. Diversifying is also a bit challenging in the sense that all of our people are focused on milling, our operators know how to mill and are not versed with any other work,” reasons Kafka.

But, Cameron financial manager believes that if ever the decision to expand the product portfolio is made, the immediate possible and closest option would be recyclers. She believes that recycling is aligned to what the company does and will allow it to continue dealing with the very same customer base.
RMS reports increased demand for its milling machines in the past 12-18 months. “We believe we had a fantastic year in 2016 in terms of being able to keep our machines on hire,” says Kafka. Demand is mostly driven by smaller civil engineering contractors. This is in direct contrast to some five years ago where the company would mostly deal with the bigger civil contractors.

Understandably so, this trend is because of the way civil projects are being packaged in South Africa at this stage. Projects are being packaged into smaller lots to allow smaller and upcoming contractors to have a share of the government infrastructure spend. Most of these smaller contractors lack the financial muscle to invest in their own specialised gear such as milling machines, hence the increased demand for RMS’s services.

Success drivers

For a rental business of this nature, machine uptime is a key success driver. For that reason, RMS, from its inception, has always purchased Wirtgen milling machines only. All its 21 milling machines are Wirtgen machines. Kafka explains the reasons behind the loyalty to the brand. “We started out with a Wirtgen and created a strong bond at the time,” she says, adding that the relationship has been further strengthened over the years.

RMS has also built a strong technical competence on Wirtgen machines with its own mechanical workshop equipped with strong technical capability to service these machines in-house. Led by Errol Edwards, workshop manager at RMS, the technical knowhow on Wirtgen machines goes beyond service and maintenance to include complete rebuilds of the machines in-house.

Another reason of sticking to Wirtgen, is the fact that these German-made milling machines have a good reputation among RMS’s customer base. “Wirtgen machines are popular products among our customers, in terms of their quality of work and productivity,” says Kafka.

The quality of the build and durability is another key driver for sticking it out with this range of machines. This is reinforced by the fact that the first Wirtgen 1000C which kicked off the business back in 1999 is still in operation today, and works beyond expectations.

Meanwhile, a good product is as good as its service, and aftermarket support from Wirtgen South Africa has kept this relationship intact over the years. Waylon Kukard, Wirtgen sales manager, who has become more than just a business partner, is always at hand to respond to RMS’s needs, be it technical queries, parts issues or even advice, especially at a time when the company is grappling with the idea of diversifying its product range. “We have become friends along the way. We work closely together on RMS’s plans for the future,” says Kukard.

Strong maintenance regime

Prior to the purchase of its new machine in July 2016, the previous machine RMS bought was back in 2013. According to Cameron, that speaks volumes about the quality of the build of the machines, but more importantly the strict service and maintenance regime. “Due to our strong focus on maintenance, even our first machine is still running perfectly beyond our customers’ expectations,” she says.

The longevity of this gear is also buoyed by the fact that these machines are rented out with an operator. Every operator sticks to their own machine, which, over the years, has become their daily office. “Our operators are very territorial about their machines and they look after them,” says Kafka.

A strict service and maintenance regime is followed, according to Edwards. Services, including oils, hubs, gear boxes and engine oil, are done at every 250-hour intervals. These intervals are maintained even when machines are out on sites. These services are undertaken on sites 95% of the time. Major services, such as drums and hydraulics, are done once a year, especially during the December downtime period when most machines return to the workshop.

Wirtgen undertakes services for all machines under warranty. All services are then done in-house when machines are off warranty. Continuous training of the 25 operators is also a key focus for the company, says Brian Manganyi, operations manager at RMS. It is this thorough training regime that has seen Manganyi himself raising through the ranks over the years when he started as a security guard, before he became a foreman, a supervisor and currently the operations manager.

Looking ahead, Kafka and Cameron convinced that the business will continue on a good course in 2017. “Our vision is to continually strive for excellence to further build our reputation. We always go an extra mile for our customers, delivering more than they expect.” This goes beyond the equipment to the people, constantly focusing on the people who make it happen on the ground. “Being a smaller, family-owned business, allows you to have that desire to always go out of your way for customer service.”

For further information

please contact:
Wirtgen SA contact:
Calvin Fennell
Business Development Manager
Tel: 011 452 1838
Cell: 072 721 3951
Email: Calvin.Fennell@wirtgen-group.com
Web: http://www.wirtgen-group.com/southafrica

Media contact:

Bridgette Macheke
MoonDawn Media & Communications
Cell: +27 (0)73 400 1549
Email: bridgette@moondawnmedia.co.za
Web: www.moondawnmedia.co.za







WIRTGEN 2200SM SURFACE MINER PROVES ITS METTLE IN SA DEMO AND TRIALS

[Johannesburg, 21 February 2017]: Wirtgen SA, local subsidiary of the Wirtgen Group, global leader in mobile machine solutions for road construction and rehabilitation, as well as mining and mineral processing, recently put its 2200SM surface miner to the test by conducting a series of demonstrations and trials under local conditions.

Showcasing the 2200SM to various local mining companies, Wirtgen SA undertook to demonstrate to a discerning audience the capabilities of the machine in supporting and enhancing profitable mining operations in South Africa. Mike Newby, Mineral Technologies at Wirtgen SA, comments, “We wanted to show industry leaders how easily and effectively the 2200SM mines coal and selectively mines material by separating thin seams so as to minimise contamination. The machine also cuts, crushes and directly loads the coal ore in a single operation.”

“This means that delivering a final, sellable product without the need to drill, blast, load, and primary crush is possible,” says Newby, adding, “Along with drastically reduced washing costs and processes, product yields are significantly increased, making for a machine with attractive operational costs and production rate capabilities.

Tried and tested

Wirtgen SA’s 2200SM demonstrations began at two different sites in Mpumalanga, where the machine’s flawless performance proved its worth in open cast coal mines. 96% of the mined material was <53 mm and fines content (that is <1 mm size product) was less than 14% without the need for drilling, blasting and primary crushing – well within expected result parameters. Both sites were prepared by cleaning out a blocks measuring about 50 m x 100 m directly on the coal seam, after which the 2200SM took centre stage, cutting and crushing the coal and loading it directly onto the mines’ 40 ton articulated dump trucks for hauling to the final stockpile. Instantaneous production rates reach over 800 t/h in most cases and after taking into account the final effective production rates after a shift, including standard production stoppages and delays, the average production rate was more than 400 t/h. “The machine was also put to the test in sandstone interburden and with great results,” notes Newby. “This means that thin seams of coal, waste and interburden can be effectively mined selectively, easily separating the product from the waste,” he says. Wirtgen SA’s final demonstration of the 2200SM took place at another open cast coal mine in Delmas with the primary objective to improve the yield at the production plant. “The 2200SM surface miner mined highly selectively, separating coal from waste and ensuring that good, clean coal was sent to the plant with minimal contamination and no crushing required,” remarks Newby. “Once again, the machine proved its worth in this context and mine management expressed its satisfaction with the machine’s performance, committing to implement the 2200SM in future projects.” Wirtgen SA’s demonstrations and trials of its 2200SM proved highly successful and illustrated how viable an alternative this machine is to open cast mining methods. “These machines offer real capital cost savings at initial mine set-ups, improve operational yields, mine selectively, are safe and easy to operate, eliminate the need for drilling, blasting, loading, hauling and primary crushing, and significantly reduce the costs of washing,” says Newby, concluding, “Wirtgen has proven its worth the world over and we’re proud to now have the nod from an astute South African market as well.”

About Wirtgen surface miners

Wirtgen surface miners offer cutting widths ranging from 2.20 m to 4.20 m and cutting depths of between 20 cm and 83 cm and the company is the only manufacturer covering a scope of performance ranging up to 3000 t/h in coal mining with direct loading by conveyor belt.

Four models make up the product range:

• The 2200SM (with a cutting width of 2.2 m and a depth of up to 30 cm);
• The 2200/3.8 SM (with a cutting width of 3.8 m and a depth of 30cm);
• The 2500SM (with a cutting width of 2.5 m and a depth up to 65cm);
• And the big 4200SM, which cuts 4.2 m wide, up to 83 cm deep and can deliver up to 3000 t/h in coal.

Wirtgen currently has over 500 surface miners in operation around the globe, with more than 130 specifically mining coal in Mozambique, the USA, India, Australia, Europe, China, and more. Other applications include bauxite, limestone, iron ore, gypsum, salt, phosphate, oil sands, kimberlite, mudstone and even granite.

[ENDS]

About Wirtgen SA

Wirtgen SA is the local partner for the Wirtgen Group’s sales and service offering in South Africa. Wirtgen Group offers a broad range of services tailored to individual requirements for all areas of road construction as well as the mining and processing of pay minerals. With passion and know-how, our experienced team ensures your success every single day.

More than just a machine supplier, for Wirtgen Group, the delivery of a machine marks the beginning of a long-standing service partnership. Our team of service experts is always on hand to answer any questions concerning the machine and its operation. Short response times and fast solutions are guaranteed by our experienced service specialists. In addition, we remain in close contact with the Wirtgen Group’s headquarters to ensure comprehensive support whenever it is needed.

The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating the traditional brands, Wirtgen, Vögele, Hamm, Kleemann and Benninghoven. As a technological leader, the company offers its customers mobile machine solutions for road construction and rehabilitation as well as for mining and processing minerals.

Wirtgen SA contact:

Mike Newby
Mineral Technologies
Tel: +27 (0) 11 452 1838
Cell: +27 (0) 82 788 8184
Email: mike.newby@wirtgen-group.com
Web: www.wirtgen-group.com/southafrica/en/about-us/wirtgen-south-africa/

Media contact:

Bridgette Macheke
MoonDawn Media & Communications
Cell: +27 (0)73 400 1549
Email: bridgette@moondawnmedia.co.za
Web: www.moondawnmedia.co.za







Media Advisory
Approved

SURFACE COURSE REHABILITATION: COMPACT MILLING MACHINE IS A CLASS OF ITS OWN

VORO, a milling contractor based in Kassel, Germany, brought the versatility of the W 100 CFi Wirtgen compact milling machine into play when rehabilitating the surface course of a federal highway.

The B3 extends over a distance of 755 km from Buxtehude in the north of Germany through to the Swiss border in the south. The job involved milling areas of damaged asphalt on one side of the highway in the vicinity of the municipality of Jesberg in the federal state of Hesse. As the project progressed, a free flow of traffic had to be maintained on the opposite lane. A total of 1,200 m² asphalt surface course had to be removed to a depth of 4 cm. The entire milled area was divided into 13 individual sections, each 3.50 m wide and located at intervals of 50 to 100 m.

Maneuverable and versatile but as productive as its big brothers
“We decided to use a type W 100 CFi Wirtgen compact milling machine for this job, as it achieves a high area output with low fuel consumption and, with its compact design and maneuverability, can be easily transported from one job site to the next,” explained Alexander Emde, Operations Manager of VORO Straßenfräsdienst GmbH.

In the Wirtgen Compact Class, customers can choose from no less than eight models with standard milling widths ranging from 1.0 m to 1.5 m and milling depths of up to 330 mm. Combined with the Flexible Cutter System, milling widths of 8 cm to 1.5 m are possible. The entire machine range – encompassing the W 100 CF / W 100 CFi, W 120 CF / W 120 CFi, W 130 CF / W 130 CFi and W 150 CF / W 150 CFi – delivers on performance and economic efficiency. It covers classic small milling machine applications such as partial road repairs as well as the removal of entire road pavements – a task which is normally the preserve of large milling machines. Wirtgen compact milling machines are therefore not only extremely versatile. In combining the advantages of the large and small milling machine classes, implementing a uniform operating concept and, in particular, incorporating pioneering control technologies, the Wirtgen compact class is now one thing above all: The next step in the development of cold milling.

Effective operation and increased performance

The Wirtgen W 100 CFi is equipped with a powerful, 257-kW diesel engine and, despite its high capacity, meets the stringent requirements of the exhaust emissions standards EU Stage 4 / US Tier 4 Final. The drive unit is designed for a maximum milling depth of 33 cm. The mechanical milling drum drive transmits the engine torque to the milling drum with a high degree of efficiency.

“Wirtgen’s Generation X point-attack cutting tools cut through the 4-cm surface course with ease and produced very smooth and excellent milling results,” reported Sigbert Werner, milling machine operator with VORO. “The noise insulation on the machine is also very good. The engine runs very quietly at full load,” commented Werner.

In addition, the driving dynamics package supports a travel speed of up to 7.5 km/h, enabling the machine to move swiftly to the next surface to be milled. As the entire job site extended over a 1.2-km stretch, this was essential to ensure a fast milling procedure.

New control technology sets standards

The new operating concept with a multifunctional armrest and fully integrated LEVEL PRO PLUS leveling system guarantees optimum milling results. After all, it leaves the operator free to focus almost entirely on the milling work itself. “After a brief induction on the brand new control system, the machines are a great deal easier to use than ever before,” commented Sigbert Werner, describing his experiences with the new operating concept. One highlight is the ergonomic multifunctional armrest. This is used to show all important information – including the compilation and visualization of job data – in color on the operating display. Four “favorites” buttons integrated into the armrest can, for example, be programmed with any of 20 different functions. In addition to the steering wheel, the operator also has access to an extremely sensitive, fingertip steering function in the multifunctional armrest.

The large number of added and automated functions make life easier for the operator and also save time. For example, the automatic button-activated folding in of the compact milling machine’s right rear crawler track also speeded up the milling work on the B 3. The track can be folded in without lowering the milling drum or manually loosening a bolt. In addition to the “basic position”, the new “outside” position – in which the right rear crawler track is located within the cutting diameter of the drum, enabling the machine to be easily positioned along the right-hand milled cut – and the “folded in” position are possible. The first milled cut on the B3 ran alongside a safety barrier. For this reason, Werner moved the crawler track into the “folded-in” position to be able to mill along the outer edge of the roadway with the zero-clearance side. To prevent the side plate from sinking into the surface when working on loose substrate – for example gravel or on the adjacent grass verge as in Jesberg – it has an active floating position. It ensures that the side plate is lifted at specific intervals.

To support the leveling and milling process, the milling machine operator Werner was also able to use an automatic lowering function when positioning the W 100 CFi in the milled cut. When the milling drum unit reaches the surface to be milled, the lowering speed is adjusted automatically so that the milling drum slowly penetrates the material down to the set depth. In addition, the height of the crawler units can be adjusted in steps of 1 mm or 5 mm using the new millimeter height function to precisely set the milling depth. The most frequently used height settings can be stored in three height-adjustment memories and called up quickly at any time.

Optimum visibility concept for safe working on confined construction sites

As traffic continued to flow on the opposite side of the highway during the rehabilitation project and the job called for frequent machine relocations, the Wirtgen compact milling machine was the ideal candidate for these job sites. The sophisticated visibility concept enables the operator to maneuver with millimeter accuracy. The chassis of the W 100 CFi is distinctly narrower and affords the operator a better view to the front. In addition, the operator’s stand can be hydraulically displaced 200 mm beyond the edge, thus providing a perfect view ahead of the milling drum assembly and onto the front right-hand crawler track. Thanks to the camera system, the left-hand milled edge or material discharge is always clearly visible to the machine operator on the high-resolution display. “The dust extraction device on the discharge conveyor also makes work very pleasant,” Werner adds.

Best quality at top speed

The milling work was completed within a few hours. Alexander Emde was satisfied with the results: “The W 100 CFi not only created a very smooth milled surface over the entire area, but also worked with minimum wear.” It was possible to pave the new surface course immediately after the milling work had been completed. This job was done by a Vögele road paver.

Image captions:

W100CFi_00955
Working on the job site while traffic is flowing in the opposite direction is no problem for the Wirtgen W 100 CFi. The considerably narrower chassis that also provides the driver with an optimum view of the milled edge is an additional advantage here.

W100CFi_00958
With its compact dimensions and low weight, the Wirtgen W 100 CFi can be transported easily and without requiring additional permits. This is ideal for working on several sites on one day.

W100CFi_00966
The ergonomic multifunctional armrest of the Wirtgen W 100 CFi features four “favorites” buttons that can be programmed with any of 20 functions as well as a color operating display. All important information is shown on a small screen – for instance the compilation and visualization of job data.

W100CFi_00993
With the increased steering angle of the front axle, the Wirtgen W 100 CFi can describe very small turning circles. What’s more, the hydraulically operated folding discharge conveyor can be swiftly folded up, making this machine an excellent choice for tie-in milling jobs in confined conditions.

W100CFi_00949
The operator’s stand, which can be hydraulically displaced 200 mm beyond the edge, provides a perfect view ahead of the milling drum assembly and onto the front right-hand crawler track.

W100CFi_00473
The diesel engine of the Wirtgen W 100 CFi is equipped with both an oxidation catalytic converter and an SCR catalytic converter for effective exhaust gas treatment and meets the stringent requirements of the highest current exhaust emissions category EU Stage 4/ US Tier 4f.

For further information please contact:
Wirtgen SA contact:

Calvin Fennell
Business Development Manager
Tel: 011 452 1838
Cell: 072 721 3951
Email: Calvin.Fennell@wirtgen-group.com
Web: http://www.wirtgen-group.com/southafrica

Media contact:

Bridgette Macheke
MoonDawn Media & Communications
Cell: +27 (0)73 400 1549
Email: bridgette@moondawnmedia.co.za
Web: www.moondawnmedia.co.za













Media Advisory
Approved

WIRTGEN SURFACE MINING: MAXIMISING COAL RECOVERY BY MINIMISING CONTAMINATION AND FINES CONTENT.

[Johannesburg, 29 July 2016]: The Wirtgen Group, global leader in mobile machine solutions for road construction and rehabilitation, as well as mining and mineral processing, has recently conducted several large-scale field tests on material degradation. Findings confirm that Wirtgen surface miners offer significant advantages in the reduction of contamination experienced in normal open cast mining methods.

In the coal mining industry, the breakage of coal occurs throughout production, from extraction at the face to end use. While some of this breakage is intentional, such as during extraction and crushing, breakage occurring during transportation, stockpiling, sizing or washing is not desired. Generally speaking, breakage behaviour depends heavily on geology, but mining technology of today offers the option to reduce the amount of fines generated during production to maximize coal recovery for optimised operation as well as minimizing contamination of mined coal to increase yields.

Most coal mines measure the particle size distribution (PSD) of their plant feed to obtain information about the suitability of the feed for their processes, especially with regards to fines content. However, few mines know precisely where these fines come from and even fewer measure the fines content at the face to compare it with the plant feed data and to optimise the connecting processes.

According to Calvin Fennell, Wirtgen SA Business Development Manager, “There are a number of challenges associated with failing to optimise this connecting process. The cost of washing coal fines is higher because of the intensive processes used and the product losses that occur, all resulting in a lower rate of recovery. With increased losses, more tailings must be suitably disposed of and coal that does not meet the customer’s size requirements cannot be sold. Furthermore, coal mines have the tendency to retain moisture, which can cause problems in the downstream process.”

“On the other hand, optimising fines content and reducing contamination of the run-of-mine (ROM) coal offers numerous savings and benefits, such as a lower level of respirable and airborne dust, increasing workplace safety, reducing the risk of coal dust explosions and improving yields,” comments Fennell.

In an effort to serve its customers better, Wirtgen recently conducted a number of large-scale field tests on material degradation. The company found that its surface miners offer significant advantages when it comes to minimizing contamination by selectively mining coal seams to separate the ore from the waste.

Wirtgen surface miners

A Wirtgen surface miner is a crawler-mounted mining machine with a rotating cutting drum for rock penetration mounted at the centre of gravity, a configuration that ensures that the full weight of the miner machine can be transformed into rock penetration force. The cutting drum transfers the material onto a conveyor belt from which it is directly loaded onto a dump truck.

The machine mines layer by layer down to the required depth and the cutting depth can vary according to seam thickness. “Even thin seams of just 10 cm thick can be mined and precisely separated from the layers above and below. This level of precision makes for a cost-effective and more environmentally sensitive approach to mining of mineral deposits without any drilling or blasting,” Fennell notes.

PSD field tests

In its many field tests over the years on PSD and material degradation, coal and sedimentary ore from eight different pits were analysed to obtain their PSD. Close to 8000 tons of material was screened to compare the material produced by surface miners versus conventional mining methods.

In one coal mine, Wirtgen surface miners operated alongside dozers that employed the conventional rip-and-stack method and in view of the coal prices at the time, the mine was optimising every step of the operation. This included optimising the process for target size material, enabling most of the material to be processed in the cheaper coarse circuit of the processing plant. Reducing crushing costs was also an objective.

“Once again, the test proved the suitability of the Wirtgen surface miner for this type of operation,” says Fennell, explaining, “The machine delivered coal with a lower fines level and more target size material than the conventional dozer rip-and-stack method. In fact, out of the 1500 t/h of coal delivered from the dozer to the processing plant, 225 t/h were fines smaller than 2 mm, but with the surface miner, this figure is closer to 185 t/h. This means that 22% less coal had to be washed in the fines circuit and could be washed in the cheaper coarse circuit. In terms of fines smaller than 1 mm, by using the Wirtgen surface miner, the plant could process 33% less fine material.”

The Wirtgen surface miner delivers more than 70% target size coal (2-40 mm), while the dozer ranges at less than 58%. Savings are also enjoyed in the crushing stage, where only 17% of the material from the surface miner has to be crushed, as opposed to more than 26% when processing dozer coal, resulting in more fines that have to be processed.

In another trial location with sedimentary ore deposit mined using surface miners as well as the conventional drill-and-blast method, the surface miner was able to continually feed material with a < 1 mm fines level as low as 15% to the processing plant. The normal plant feed (includes material of drill-and-blast and surface miner operation) contained 25% and more fines < 1 mm.

Impact of rehandling

Rehandling contributes significantly to material degradation occurring during the mining process. Simulating this process, Wirtgen conducted a study to establish the amount of material degradation that occurs during rehandling.

For simulation purposes, 80 tons of material was loaded by a wheel loader and run through a screening plant several times. With every throughput, the amount of fine material increased significantly and during five test cycles in coal, the amount of material < 4 mm increased from 19% to 26%, representing an increase of 34%. A similar result was found with sedimentary ore in that the fine fraction increased by 24% during five test cycles. “None of the steps in the simulation (loading, transport to the screen deck, sizing on the screen deck itself) involved the high material stress levels that would be induced, for example, by a dozer moving on stockpiled material,” comments Fennell. “Nevertheless, significant material degradation was measured during the simulation, leaving one to assume that the material degradation that takes place during stockpiling results in an even higher increase of the fine fractions,” he adds. Keeping in mind that even this level of ‘soft’ rehandling causes significant material degradation, it is important to minimise the number of rehandling steps, each of which contribute to processing costs. "This is where Wirtgen surface miners offer a two-fold advantage: Material mined with a surface miner has not been blasted, but cut out of the ground by the rotating cutting drum, which means that the level of fines is already low; and as the material is loaded for transport, rehandling is kept to a minimum, contributing further to a low level of fines. With a view of the complete mining operation, it is clear that a surface miner simplifies mining operations and reduces the number of process steps tremendously, resulting in immediate cost savings,” Fennell says. The Wirtgen surface mining concept is no longer an unknown in the southern African mining sector. Surface mining has proven to be a viable alternative in South African open-cast mines, most especially in coal mines, where these machines really prove their worth. “Wirtgen SA is engaged in extensive talks with various mining companies about solutions for their greenfields and existing mines,” remarks, Fennell, concluding, “Wirtgen surface miners are set to revolutionise the open-cast mining industry in southern Africa, as it has done across the world, by addressing the need for safer, more environmentally friendly, effective and efficient mining by improving yields.” [ENDS]

About Wirtgen SA

Wirtgen SA is the local partner for the Wirtgen Group’s sales and service offering in South Africa. Wirtgen Group offers a broad range of services tailored to individual requirements for all areas of road construction as well as the mining and processing of pay minerals. With passion and know-how, our experienced team ensures your success every single day.

More than just a machine supplier, for Wirtgen Group, the delivery of a machine marks the beginning of a long-standing service partnership. Our team of service experts is always on hand to answer any questions concerning the machine and its operation. Short response times and fast solutions are guaranteed by our experienced service specialists. In addition, we remain in close contact with the Wirtgen Group’s headquarters to ensure comprehensive support whenever it is needed.

The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating the traditional brands, Wirtgen, Vögele, Hamm, Kleemann and Benninghoven. As a technological leader, the company offers its customers mobile machine solutions for road construction and rehabilitation as well as for mining and processing minerals.

Wirtgen SA contact:

Calvin Fennell
Business Development Manager
Tel: 011 452 1838
Cell: 072 721 3951
Email: Calvin.Fennell@wirtgen-group.com
Web: http://www.wirtgen-group.com/southafrica/en/about-us/wirtgen-south-africa/

Media contact:

Bridgette Macheke
MoonDawn Media & Communications
Cell: +27 (0)73 400 1549
Email: bridgette@moondawnmedia.co.za
Web: www.moondawnmedia.co.za



Latest News

Mobile screening plant set for launch in SA

0

[Johannesburg, 24 May 2017]: Wirtgen SA, local subsidiary of the Wirtgen Group, global leader in mobile machine solutions for road construction and rehabilitation as well as mining and mineral processing, will soon be launching the much anticipated Kleemann Mobiscreen MS 703 EVO to the South African market.   (more…)

Three Decades of Experience Makes HAMM the World Leader in Oscillation Compaction

0

Over 30 years ago, HAMM became the first roller manufacturer to offer an oscillation drum for tandem rollers, and these rollers have become an integral part of its product offering. In the past five years alone, the specialists for compaction technology have delivered more than 3,000 machines with this innovative technology. Today, one in four of the tandem rollers made by HAMM is equipped with an oscillation drum. With more than 30 models to choose from, HAMM has by far the widest offering of oscillation rollers in the world. And only HAMM builds oscillation tandem rollers in the compact class, as well as soil compactors with oscillation compaction capability.  (more…)

Premium pays superior dividends

0

Over its 17-year existence, Road Milling and Sweeping has carved itself a niche rental business to become the largest privately-owned operator of milling machines in South Africa. With a clear understanding that the success of a business of this nature largely depends on machine uptime, the company has vested its trust in premium Wirtgen milling machines over the years, a decision that is continually paying dividends. (more…)

Wirtgen 2200SM surface miner proves its mettle in SA demo and trials

0

[Johannesburg, 21 February 2017]: Wirtgen SA, local subsidiary of the Wirtgen Group, global leader in mobile machine solutions for road construction and rehabilitation, as well as mining and mineral processing, recently put its 2200SM surface miner to the test by conducting a series of demonstrations and trials under local conditions.    (more…)

Surface course rehabilitation: Compact milling machine is a class of its own

0

VORO, a milling contractor based in Kassel, Germany, brought the versatility of the W 100 CFi Wirtgen compact milling machine into play when rehabilitating the surface course of a federal highway.

 (more…)

Wirtgen Surface Mining: Maximising coal recovery by minimising contamination and fines content

0

[Johannesburg, 29 July 2016]: The Wirtgen Group, global leader in mobile machine solutions for road construction and rehabilitation, as well as mining and mineral processing, has recently conducted several large-scale field tests on material degradation. Findings confirm that Wirtgen surface miners offer significant advantages in the reduction of contamination experienced in normal open cast mining methods.  (more…)