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Sandvik Mining and Construction Sandvik Commando DC130Ri: Essen | Compact versatility with excellent references – both above and below ground

A total of five Sandvik drill rigs are used at Sächsische Sandsteinwerke. Two, a Commando DC302 and a Commando DC130Ri, are currently used for block extraction on different beds in the Lohmgrund quarry. (Photos: Sandvik)

he mobile Sandvik top hammer drill rig has carved out a career that its developers Tcould scarcely have dreamt of. Since its launch last year, the new Commando DC130Ri model from Sandvik has demonstrated its impressive versatility in a wide range of demanding applications both above and below ground. The ambitious home builder in Scandinavia is no different to anyone else when it comes to having a cellar. In solid rock this is no mean feat – and simply too expensive if you have to bring in large top hammer drill rigs to do the job. Almost three decades ago, resourceful development engineers came up with a solution to this cost-benefit conflict in the form of a mobile, lightweight and easy-to-handle drill rig called Commando, which proved to be extremely popular. Construction firms quickly began using it for foundation drilling, trenching, shaft drilling and roofbolting. The Commando has proven its strength in the secondary crushing of boulders in quarries, while in engineered stone applications its clean line drilling is synonymous with efficient Drilling operative Andreas Krause skilfully steers the four-wheel drive Commando DC130Ri block extraction. up the steep ramp to its working bed using the remote control. (Photos: Sandvik)

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Uwe Jahr (left) and Andreas Krause are unanimous in their positive assessment of the performance of the Sandvik drill rigs in their quarries. (Photos: Sandvik)

Uwe Jahr, Head of Extracting and Production, explains the reasons for the company‘s loyalty to the brand: „We tried out other brands, but none of them met the expectations that we had following our experiences with Sandvik equipment. Furthermore, Sandvik has stood by our side as a flexible partner even in times of economic uncertainty.“ This mutual solidarity has been of benefit to both parties. The most recent example of this is the new Commando DC130Ri.

Engineered stone for Princes and Kings The machine‘s optimised centre of gravity means it can reach even steep slopes without any problems. Drilling The restoration of the Frauenkirche in Dresden is just operative Andreas Krause skilfully and quickly steers the one of many prestige projects that fills the order books agile three-tonne machine up the steep ramp to its working of Sächsische Sandsteinwerke in , whose Elbe bed using the remote control. He then extends the front sandstone remains a popular engineered stone product. legs and drills a series of vertical blast holes. It takes just two to three minutes for him to sink a blast hole with water Deliveries for the Berlin City Palace are currently the flush and move on to the next one. Having already been main focus of the company‘s mining activities. The Lohmen familiar with the machine‘s predecessor, the Commando quarry and five other quarries between and DC125, getting to grips with the intelligent newcomer was Pirna supply different varieties of this much sought-after no problem to him. „Operation is slightly different, but natural stone. Sächsische Sandsteinwerke GmbH operates the quarries with expert knowledge of the quarrying Preparation for transport. Sandstone from is a much sought-after product. The Lohmgrund quarry is currently process and skilled craftsmanship in the mechanical supplying large quantities of material to Berlin. (Photos: Sandvik) and manual processing of the extracted raw blocks. The traditional construction material is quarried to meet specific requirements. For the City Palace project, coarse-grained sandstone from Lohmen is preferred along with the slightly softer stone from the quarry in Reinhardtsdorf. Sandvik drill rigs are the main players in the block extraction process. The operator‘s plant currently includes five of these rigs. Two of them – a Commando DC302 and a brand-new Commando DC130Ri – are currently being used on different beds in the Lohmen quarry The Commando DC130Ri delivers incredible off-road capability and versatility for vertical and horizontal line drilling.

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SSafety and contingency measures underground: Commando drill rigs play an important role at the potash mine in Teutschenthal. (Photos: Sandvik)

up the closed areas and widened them for subsequent backfilling. The new Commando DC130Ri top hammer drill rig quickly demonstrated its performance enhancements when used underground. Equipped with a highly energy- efficient hydraulic hammer, ergonomic controls and dust extraction, the new Commando is an impressive machine, even when breaking through occasional clay veins. The feed-percussion follow-up for the automatic adjustment of the drilling energy to varying rock conditions compared with basic rotary drilling during driving quickly paid for itself. The roll-over drill feed delivers flexibility in areas that are difficult to access. Another welcome feature is the much neater hosing and electrical wiring on the boom of the DC130Ri compared with its predecessor.

Holes for blasting are placed at the removal hot-spots in each layer. The dust seal is positioned close to the wall and thus makes a clean job of air-flushed drilling. Blasting just a couple of hours of training were enough to master is then performed to widen voids or to access closed the machine.“ The drill operative appreciates his clever chambers. assistant, which features a roll-over system that delivers significant time savings when drilling horizontal holes. Blasting technician Alexander Ackermann skilfully manoeuvres both types of Commando – the 125 and the 130 – to the next deployment location on the quarry bed using the remote control. The older 125 models offer Too many voids in the wrong places – impressive reliability, while the new model ensures but not any more brand loyalty thanks to features for improved utility value and comfort. Yes, there may be a difference in operation The former potash mine in Teutschenthal in the Saalekreis district is currently operated as a stowage mine for non-mining mineral waste. Backfilling of the voids created in the course of room-and-pillar mining is important for safety reasons. The rock burst of September 1996, which led to the collapse of the entire eastern part of the potash mine, was a catastrophe that must not be repeated, and this has expedited the process of systematically backfilling these voids. The company charged with this task is GTS Grube Teutschenthal Sicherungs GmbH & Co. KG. To access the closed chambers and tunnels during the backfilling process, the operator called on the expertise of TS BAU GMBH. Armed with the required background knowledge and supported by three mobile Sandvik drill rigs – two Commando DC125 models and one of its successors, the DC130 – the experts opened

Use below ground: Holes for blasting are placed in each layer in order to be able to access and backfill closed chambers. (Photos: Sandvik)

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Commando DC130Ri: The better collective placement of the hydraulics and optimised location of the electrical cabinet have allowed the hosing and electrical wiring to be significantly reduced. (Photos: Sandvik)

also available to users in the three-tonne class. Experts from a wide range of application areas agree that the Commando DC130Ri represents a significant upgrade in utility value compared with its predecessor. Looking back at its original development goal, it is clear that the Commando has enjoyed a meteoric rise, and we haven‘t yet reached the end of Commando evolution 1.

– but the intelligent control systems make it easy for experts to bring the Commando DC130Ri with four-wheel FOR MORE INFORMATION AND CONTACT: drive undercarriage into position. The intelligent drilling control system provides assistance during drilling. The Sandvik Mining and Construction experienced blasting technician appreciates the ability to Central Europe GmbH change all drilling parameters during drilling if necessary, Sandra Pietsch not to mention the improved performance of the new Marketing Support Commando. Office Phone: +49 (0) 201 1785-352 Mobile: +49 (0) 173 9000457 TS-BAU site manager Jürgen Schrade has nothing but good things to say about his experiences with „his [email protected] Commando“. Other suitable underground drill rigs would home.sandvik have cost his company a lot more and offered a lot less flexibility. Thus he has three compact and versatile models for underground use, which are also suitable for many other applications once this job is finished. That is his Jürgen Schrade and Alexander Ackermann are impressed with the vision for the future. But first, there‘s plenty of work to do Commando range. They also praise the advice and service provided by the underground. Sandvik team in Germany, represented at the meeting by Drill Rig Sales Manager Olaf Gruner (from left to right). (Photos: Sandvik)

Positive feedback from a wide variety of users

In practice it is clear that Sandvik reliability comes not only from the products themselves, but also from the advice, sales and service provided by the German Sandvik drilling technology experts. While the qualities of the new Commando DC130Ri speak for themselves, this positive assessment has certainly helped the market launch of the improved all-rounder. Some of its state-of- the-art functions, such as intelligent engine control, have until now only been found on larger drill rigs, but are now

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Sandvik Mining and Construction Vogelsberger Basaltwerk GmbH & Co. KG: Essen | Germany Uncompromising secondary crushing

Plant premises with decision-makers: VBW is investing step-by-step in modernising its processing while retaining the existing process. (Photos: Sandvik) here is no hiding their enthusiasm when the “decision makers” at Vogelsberger TBasaltwerk GmbH & Co. KG, VBW, describe their latest addition. The optimally designed Sandvik CS550 installed at the plant in February is a powerful and reliable high- throughput unit that delivers precision and quality at the secondary crushing stage. The Büdingen-Rinderbügen quarry in Wetteraukreis, Bauens - The birthplace of construction“. The basalt grit Germany, has been supplying the basalt that is is used by VBW to produce construction materials to meet characteristic of the Vogelsberg landscape since 1963. the requirements of several customers in the region. The basalt is currently quarried and reduced to gravel, chippings and fine flint, as well as crushed sand, by Vogelsberger Basaltwerk GmbH & Co. KG, VBW, part of the Dressler Verwaltungsgesellschaft mbH group of companies. The group, now managed by second generation members Fritz Dressler and Klaus Dressler, is regarded as one of the leading names in construction planning, civil engineering, road construction and development. The group has also secured added value in materials production through its raw materials subsidiary VBW, under the slogan „Der Ursprung des

The process starts with the filling of the primary crusher and concludes with the production of high-quality gravel, chippings and crushed sand. (Photos: Sandvik)

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Timely alternative: an optimal secondary crusher solution was found for the plant when the CS550 was launched on the market. The powerful cone crusher is ideal for applications in the 700 to 750 t/h range. In addition to flexibility and sheer tonnage, the model offers advanced automation features and ease of maintenance for maximum productivity and uptime. (Photos: Sandvik)

of familiar components from the proven CH crushers and operates at higher pressure levels compared to traditional CS-crushers, has low-maintenance and many safety features and is less sensitive to material feed variations, for example, a secondary crusher from the CH series. The reliable and powerful secondary crusher with its high reduction ratio comes with a completely redesigned crusher chamber, which essentially guarantees the enhanced quality demanded at the secondary crushing stage. To meet Bernd Krempel joined Dressler as co-director at the the demands of the customers, the C (coarse) crushing beginning of 2016. One of his most important tasks, together chamber is designed for intake of materials with a feed with operations manager Dieter Pracht and foreman Heiko size of up to 350 mm, while the EC (extra coarse) crushing Schlögel, is continuous optimization of the basalt plant chamber can handle up to 430 mm. process. The first step of the modernization programme was to replace the secondary stage crusher – a 1650 cone German customers were given the first opportunity crusher that had been in operation since 1984 – with the to inspect the new crusher at close hand at an event in aim of improving capacity and product quality. Always September 2016, when Bernd Krempel and Dieter Pracht satisfied with the service and support from Sandvik, VBW’s where able to closely monitor the assembly and disassembly decision makers favoured replacing the crusher with a of the CS550 that was on show. Already impressed by the Sandvik CH-series Hydrocone, even though they knew well thought-out design, which gave an indication of the this decision would also impact operation of their primary potential productivity and simplified maintenance and crusher. However, at just the right time for VBW, Sandvik servicing, any final doubts they might have had were announced the new CS550 that was even more ideal for quickly dispelled when making process simulations with their requirements.

Generous intake of crushed material of up to 350 mm in feed size. (Photos: Sandvik) A perfect fit

Just to recommend, never mind purchase, a brand new innovation requires a deep, mutual trust. With no lack in trust between the consultancy partner, stationary crusher specialist Hubertus Kirschbaum from Sandvik Mining and Rock Technology’s sales team in Essen and those involved at VBW, the advice was spot on. Results of quarry testing in Sweden of the pre- series models of the brand new Sandvik CS550 spoke for themselves. This latest, innovative cone crusher from the 500- series not only complements the two existing Sandvik CH550 and CH540 models, it’s also an ideal alternative for the popular CH660. The Sandvik CS550 uses a range

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Hubertus Kirschbaum explains the modern crusher control system. It optimises operation and adapts the crusher optimally to suit different operating conditions. (Photos: Sandvik)

downstream CS550 manages with just 80 to 130 of its 330 kW.“ A major change compared to the previous situation, since the old crusher always required the 250 kW that was provided. Why is this possible? Because the modern IE3 motor only draws as much energy as it needs. Depending on the feed material, as well as the defined throw and the closed side setting, the crusher can handle up to 700 tonnes per hour.

The CS550 is currently set to operate in low output mode, due to the primary crusher limitation. Operators select the Sandvik‘s Plant Designer program, featuring data from smallest possible throw of 24 mm to suit the situation at their own basalt. The crusher was commissioned, and hand. Even at this level, the plant is achieving a 20 percent installed in February 2017 as a replacement for VBW‘s outdated predecessor (1650 crusher). Successful team: Hubertus Kirschbaum, Managing Director Bernd Krempel, Deputy Operations Manager Heiko Schlögel and Operations Manager Dieter Pracht (from left to right) underline their effective development collaboration. They have remained in regular contact even since the new CS550 secondary Putting theory into practice crusher was commissioned, thus faithfully extending their cooperation. (Photos: Sandvik) The eminent suitability of the CS550 as a viable alternative to the CH-series for secondary stage crushing at VBW quickly became clear. The large C-chamber intake to match the jaw crusher in the primary stage quickly „swallows“ the crushed material of 250 to 350 mm in feed size, and thus offers the possibility to produce large volumes of the final grain fractions even at the secondary stage, while ensuring a high reduction ratio and an excellent shape of the end product. Between 250 and 300 tonnes of material per hour can be processed, with seemingly no effort, to the target particle size of 0/56 mm, with the proportion of the preferred particle size of < 32 mm being around 80 percent. The wide range of additional settings, together with additional, larger throws of 24/28/32, 32/36/40 and 40/44/48 mm provides excellent processing flexibility if this should be needed. The reduction of fine material that is required is a strikingly positive feature compared to the old crusher. The Sandvik CS550 also clearly meets VBW’s requirements in terms of oversized particles (>32/X).

„It‘s quite the guzzler!“, says Managing Director Bernd Krempel happily after just a few weeks’ operation, which he describes as being the first successful step in their modernization step, which will undoubtedly be followed by more: „There is still more potential. We are pushing our primary crusher to its performance limits and the

Issue 03 | 2017 www.advanced-mining.com 47 TRANSFER OF TECHNOLOGY increase in production following the upgrade. However, setting of the primary crusher – with a negative impact on this will only work if all of the plant components keep pace. the throughput of the overall process. This means that – at This is not a problem for the downstream vertical shaft least in terms of capacity – a similar production increase crusher that is used for producing fine grit, since it is now in operation with the same target particle size would not supplied with the perfect secondary material from which have been possible.“ to produce the required 5/8 fraction. Rough final grain fractions of up to 32 mm can be removed directly after the secondary crusher thanks to their outstanding quality and classified in accordance to the required spectra. Automation, control and ease of access

Overall, the new secondary crushing stage therefore Of course, the Sandvik CS550 comes as standard with allows a more efficient process with a significant a modern crusher control system. It uses Sandvik‘s latest reduction in the recirculating load, while at the same time automation and control system and is state-of-the-art in relieving the tertiary stage of some of its load. This allows terms of automation and machine/process control of the the operators more time to quality assure the product. This crusher, supplying a wealth of valuable data. It optimizes was an essential element of the modernization plan. operation in correlation to throughput and reduction ratio and adapts the crusher to suit different operating The question now is whether this would have been conditions, thereby ensuring that an optimum level of possible to the same extent if they were using a CH-series consumption is always achieved in terms of energy cone crusher, as had originally been planned. „More efficiency. The Hydroset system regulates the positioning than likely not“, explains Hubertus Kirschbaum: „Our of the main shaft and at the same time offers overload Sandvik CH660 has certainly successfully demonstrated protection to permit the passage of uncrushable items. its outstanding qualities many times when it comes to processing. In this case, however, the feed size would have needed to be reduced to 250 to 280 mm. This could only have been achieved by adjusting the closed side

Animation of CS550 in the quarry. (Photos: Sandvik)

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Service partnership paves the way

As already mentioned, VBW and Sandvik were once increase in throughput capacity, even with the remaining again in contact when it came to the new secondary limitations in terms of the overall concept. The higher crusher in terms of the replacement investment, not reduction ratio in the secondary stage means more final least because of their longstanding service partnership. product to bypass tertiary crushing and less recirculation However, service of the future will not look the same as results in reduced wear and less downtime. These it did in the past - the new digital possibilities will change advantages are warmly welcomed by VBW, who see the face of the collaboration. However, the partnership themselves as being in a partnership-based development itself will continue to endure, because solutions like this collaboration with Sandvik to further develop this incredibly that are designed to make everyday working life more strong newcomer. convenient are highly valued by those in the business. The ease of maintenance and servicing of all Sandvik 500-serie crushers delivers this trump card. For example, backing compound is no longer used when installing the Sandvik-Group crushing chamber, making them much easier to replace when needed - particularly since a Sandlock lifting device Sandvik is a high-tech and global engineering group is available to make replacement of the cone and crushing offering products and services that enhance customer mantle significantly easier and safer. Inspection openings productivity, profitability and safety. We hold world-leading positions in selected areas – tools and tooling systems for in the lower section, manufactured from polyurethane, metal cutting; equipment and tools, service and technical simplify access to trouble spots and an offline filter system solutions for the mining and construction industries; products ensures permanent lubricant filtration. The quality of in advanced stainless steels and special alloys as well the lubricating oil can thus be consistently maintained as products for industrial heating. In 2016, the Group had “as new” for years, despite the difficult environmental approximately 43,000 employees and sales of 82 billion SEK in conditions. This in turn reduces wear on the main machine more than 150 countries within continuing operations. components and saves costly oil changes every year. The user-friendly operating concept of the motor is enhanced Sandvik Mining and Rock Technology by a hydraulically-operated pivoting motor base, which simplifies re-tensioning of the belts and it also keeps it at a Sandvik Mining and Rock Technology is a business area constant tension. within the Sandvik Group and a global leading supplier of equipment and tools, service and technical solutions for the mining and construction industries. Application areas include rock drilling, rock cutting, crushing and screening, loading and hauling, tunneling, quarrying and breaking and Well equipped to meet demand demolition. In 2016, sales were approximately 31 billion SEK with about 14,000 employees in continuing operations. Dressler’s rock and stone division has taken an important step for the future by investing in the Sandvik CS550 secondary crusher for VBW and, since February, is therefore in a much better position to meet increased demand, demonstrated by an impressive 20 percent FOR MORE INFORMATION AND CONTACT:

Sandvik Mining and Construction Central Europe GmbH Sandra Pietsch Marketing Support Technical data CS550 Office Phone: +49 (0) 201 1785-352 Mobile: +49 (0) 173 9000457 Max. throughput capacity 700 t/h [email protected] Max. feed size F100=432 mm; CSS 200 mm home.sandvik Configurations of crushing mantle EC and C Configurations of crushing cone A, B and S Motor output 330 kW Side setting 24 – 48 mm Weight 24,600 kg

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Sandvik Mining and Construction NEW SANDVIK WX6500 SCREENING MEDIA: Essen | Germany NCC INDUSTRY IMPRESSED BY THE LIFETIME AND ACCURACY OF NEW SANDVIK WX6500 SCREENING MEDIA

CC Industry in Södra Sandby, Sweden has experienced dramatic results with new NSandvik WX6500 screening media. After nearly a year, the company’s first test panels are still in place and performing reliable fine screening.

NCC Industry’s Stone Materials division has long chosen rubber screening media over wire mesh. The choice EASY TO INSTALL BUT SURPRISINGLY is crucial in Södra Sandby, where abrasive quartzite STRONG NCC produces excessive wear on metal components. Yet despite its preference, the company has struggled to find a Industry agreed to try Sandvik WX6500 on a long-term rubber solution for fine screening. Mogårdshammar FH C 2172/3 screen, which would receive a feed size of up to 32 mm from a Svedala H6800 crusher. A turning point came when Elna Hovén, Product Five panels with 26 mm holes were delivered as rolls and Manager Screening Media at Sandvik, approached NCC installed on the upper deck in summer 2016. Industry about a full-scale test of Sandvik WX6500. “The outer dimensions of this screen are big, but it’s a Specifically designed for fine screening in the 2–32 mm very tight fit inside,” says Klinte. “The WX6500 was thin range, the new rubber media was presented as a light, and very easy to roll out, which makes a difference when thin, and yet highly durable alternative. there’s little space between the decks.”

“When I first saw Sandvik WX6500, I really wondered about the thinness of it,” says NCC Industry Supervisor Magnus Klinte. “With the aggressive raw material we have, I thought it would wear out directly.”

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Klinte also notes that the panels could be installed with a much higher tension than other rubber media, producing a drumskin-like fit that benefits the screening result. “The wear, they can be removed and reinstalled at the far end, material is thin, but you can get a lot rougher with it,” he where they take less of a beating. explains. “Media in standard materials with the same thickness can’t be installed with the same amount of “If you remove a wire mesh panel, you won’t be able tension.” to reuse it. It’s sharp, nasty, and complicated to get off in one piece—and even if you could it would be a struggle to get it tight again,” Klinte explains. “WX6500 is light, flexible and absolutely perfect to reuse on the screen.” ALMOST ONE YEAR WITHOUT MEDIA CHANGES “The Sandvik WX6500 was thin and very easy to roll out, which makes a difference when there’s little space The real revelation, however, came the first time the between the decks.” test installation was inspected. “There was so little wear,” says Klinte, “that you could still see the structural markings “We do both weekly and monthly checks of the finished from the manufacturing process.” product for our CE declaration, and Sandvik WX6500 does a perfect job.” Now, nearly one year later, around 285,000 metric tons have been fed to the Sandvik WX6500 panels. This far exceeds the 30,000 metric tons that would have been LESS BLINDING, PEGGING, AND NOISE achievable with wire mesh. Nonetheless, the media is in excellent shape. “It’s still going strong,” Klinte remarks. Product lifetime, of course, is only valuable if the media “I’m surprised every time I look into the screen.” achieves results. NCC Industry has found that Sandvik WX6500 provides highly accurate sizing, ensuring a Combined with the ease of installation, this durability finished product with the desired maximum dimension of means further ways to extend the media life. When the 32 mm. panels at the feed end of the deck eventually begin to

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FOR MORE INFORMATION AND CONTACT:

Sandvik Mining and Construction Central Europe GmbH Sandra Pietsch Marketing Support Office Phone: +49 (0) 201 1785-352 “The material is so thin that it really doesn’t plug, so we Mobile: +49 (0) 173 9000457 have no problems with the blinding and pegging that you [email protected] get with thicker media,” Klinte says. “We do both weekly home.sandvik and monthly checks of the finished product for our CE declaration, and WX6500 does a perfect job.”

The problem-free sizing makes the media popular with operators, who also experience 50 percent less noise compared to wire mesh. “Our plant is indoors to contain the silica dust,” Klinte says, “so any improvement in noise levels makes a big difference.”

THE WAY FORWARD FOR FINE SCREENING

As a former service technician, Klinte likes the balance of performance and ease of use offered by Sandvik WX6500. “I’m happy about the lifetime, but I also like the fact that it’s so worker-friendly and easy to change,” he says. “For anyone running wire mesh, this is going to be a big change.”

These factors together mean long-term economy, which is why Klinte is convinced that NCC Industry will continue using Sandvik WX6500 after the test batch retires. “Downtime is expensive, and reprocessing if the media breaks down is very expensive,” he says. “With this media, I think Sandvik has found the right way forward.

SANDVIK WX6500 SCREENING MEDIA • Screening duty: Intermediate and final • Max feed size: 20-70 (0,8-2,7”) • Separation: 2-32 (0,1-1,25”) • Application: Dry • Dewatering: No • Deck design: Cambered • Panel type: Tensioned • Material: Rubber • Aperture: Punched • Fastening: Cross- or lenght tensioned

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