MODERN QUARRYING Electra Mining Africa adds outdoor area Redefining screening media attachment systems 08 18 26
QUARTER 1 | 2026
The modular sand shift
FROM PAYLOAD TO PROFIT: THE DATA-DRIVEN SHIFT
From Rock to Road Astec is a Global Leader in innovative equipment and solutions for mining, quarrying, rock bearing and material handling, offering high-performance machinery designed for durability, efficiency and sustainability to meet evolving needs of mining and industrial operations worldwide.
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+27 11 820 7600
CONTENTS
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The modular sand shift. PAGE 27
Robust stakeholder partnerships at the heart of mining excellence. PAGE 42
Epiroc is launching the new generation PowerROC T45. PAGE 44
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REDEFINING SCREENING MEDIA ATTACHMENT SYSTEMS FOR FASTER, SAFER CHANGEOUT Hand and finger injuries remain one of the most common safety concerns in mining, often occurring during physically demanding main- tenance tasks. To help address this risk and remove potential safety hazards, Multotec has developed a range of hammer-less screening media attachment systems that significantly reduce the amount of hammer blows traditionally re- quired when installing or removing screen media.
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MOBILITY AS A STRATEGIC ADVANTAGE FOR MINES AND QUARRIES As mines, quarries and aggre- gate producers face rising costs, tighter margins, skills shortages and increasing pressure to improve safety and reduce their environmental impact, mobility is emerging as one of the most effective levers to improve oper- ational resilience.
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NEW GROWTH OPPORTUNITY FOR SA’S QUARRYING SECTOR
S outh Africa’s 2026 national budget marks a cautiously optimistic chapter in the country’s long- term economic journey. Finance Minister Enoch Godongwana’s budget speech delivered to Parliament emphasised fiscal stability, prudence and a renewed focus on investment-led growth, a foundation that bodes well for industries tied to infrastructure and construction, including the often overlooked quarrying sector. At its core, the 2026 budget reflects a turning point in South Africa’s public finances. After years of rising debt, the govern- ment projects that the debt-to- GDP ratio will peak and begin to decline, while government reve- nues continue to exceed non-in- terest expenditures, generating a growing primary budget surplus. This signals to investors and businesses alike that South Africa is committed to responsible fiscal management without resorting to punitive tax increases. For the quarrying industry - which supplies the raw materials
projects opens new avenues for private capital participation in infrastructure delivery. Quarry companies are well placed to benefit from this model - not only as suppliers of materials but as partners in integrated project value chains where local content and reliable supply are priorities. Another positive takeaway is the withdrawal of planned tax increases that had been pencilled into earlier drafts of the budget. By relieving businesses of higher tax burdens and adjusting per- sonal tax brackets for inflation, the government has signalled a more competitive tax environment for investment and consumption alike. While quarrying is not always at the forefront of fiscal policy dis- cussions, tax certainty and relief help improve industry cash flows, support reinvestment and contrib- ute to business confidence. Fiscal stability also enhances the broader economic backdrop in which quarrying operates. With improved revenue collections - in part supported by mineral price gains - South Africa is in a better position to fund growth-promoting policies while strengthening its credit outlook. It is true that the full impact of the budget will unfold over time, and challenges such as logistics bottlenecks and energy reliabil- ity remain unresolved in many regions. But the strategic align- ment of fiscal discipline, infra- structure investment and market confidence contained in Budget 2026 creates a more supportive climate for sectors anchored to physical development — among them, the essential quarrying industry. For an industry that sits at the intersection of economic growth and spatial transformation, the budget’s priorities offer a rare confluence of stability, demand and participation that could unlock new opportunities for sustainable expansion.
fundamental to roads, bridges, commercial developments and housing - this environment of fiscal steadiness and investment certainty is vital. Quarry operators thrive when demand for aggre- gates and industrial minerals is robust, and that demand is often linked to public investment in infrastructure and private sector construction activity. One of the most consequen- tial elements of the budget for quarrying is the government’s firm commitment to infrastructure expenditure. Over the medium term, public investment is set to exceed R1-trillion, spread across transport systems, logistics corridors, energy networks and municipal infrastructure projects. These are exactly the kinds of capital works that require signif- icant volumes of crushed stone, sand and other quarry products, creating sustained demand for quarrying activity and associated employment. Moreover, the budget’s empha- sis on public-private partnerships (PPPs) to help deliver major
EDITOR AND PUBLISHER Wilhelm du Plessis quarrying@crown.co.za ADVERTISING Erna Oosthuizen ernao@crown.co.za DESIGN Ano Shumba
CIRCULATION Karen Smith MANAGING DIRECTOR Karen Grant PRINTED BY: Tandym Print
PUBLISHED QUARTERLY BY: Crown Publications P O Box 140
Bedfordview, 2008 Tel: +27 11 622 4770 www.crown.co.za
TOTAL CIRCULATION Q4 2025: 4 299
The views expressed in this publication are not necessarily those of the editor or the publisher.
Wilhelm du Plessis – Editor quarrying@crown.co.za
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Copyright © 2025 Weir Minerals Europe Limited. All rights reserved.
In the world of construction, the quality of materials directly determines the strength, durability and long term performance of any structure. Among these materials, aggregates - whether used in concrete, asphalt or base layers - play an essential role. Ensuring that aggregates are correctly sized and properly graded is not just a technicality - it is a vital factor in achieving structural integrity, performance consistency and compliance with design specifications. QUALITY AGGREGATES ARE THE FOUNDATION OF STRONG, DURABLE CONSTRUCTION
“A ggregate grading is about more than just particle size,” Amit Dawneerangen, Construction Materials Executive: Sales & Product Technical at leading construction materials supplier, AfriSam explains. “It determines how the material compacts, how concrete mixes perform and how well load bearing structures can handle stress over time.” When aggregates are incor- rectly sized or poorly graded voids can occur within the mix, reduc- ing density and compromising strength. This often leads to issues such as cracking, shrinkage and water ingress - all of which can shorten the lifespan of roads, buildings or infrastructure. Conversely, well-graded aggregates create dense cohesive mixtures that enhance workability, reduce cement or binder demand, and ensure more uniform compac- tion and stability. Beyond physical performance, consistent aggregate quality ensures that engineers and contractors can meet design standards and regulatory specifi- cations. Projects designed around specific grading envelopes depend on accurate and repeatable aggregate properties to perform as intended. However, achieving this level of precision requires technical expertise, process control and rigorous testing which is why working with a reputable quarry or construction materials supplier is critical. Trusted suppliers operate under strict quality management systems, implement regular laboratory testing and maintain
Amit Dawneerangen, Construction Materials Executive: Sales & Product Technical at Afrisam.
AfriSam carries out multiple process control tests as an integral part of its daily production operations to maintain consistent product quality.
Both coarse and fine aggregates used in concrete must comply with the requirements of SANS 1083.
calibrated crushing, screening and blending processes to ensure product consistency. “Partnering with an established, credible supplier provides confidence that every load delivered meets specification,” Dawneerangen adds. “It also means access to reliable technical advice and traceability - from the source rock right through to the final product.” Reputable suppliers invest heavily in quality assurance infrastructure, from advanced testing laboratories to on-site quality control technicians. Their focus extends beyond supply - they actively collaborate with engi- neers and contractors to ensure that the correct material is selected for each layer or mix design, reducing the risk of costly rework and ensuring long term performance. In a market where quality, compliance and sustainability are non-ne- gotiable, correct aggregate sizing and grading are the cornerstones of successful construction. “Working with a trusted technically capable supplier is therefore not just a purchasing decision - it is a quality assur- ance choice that safeguards the integrity and longevity of every project,” Dawneerangen concludes.
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MODERN QUARRYING QUARTER 1 | 2026
JD - 800E SOOSAN Surface drill rig Drilling Diameter ø65~102mm Drifter 22hp / 17kw Air Flushing 5.5 m 3 / min Drill Steel T38, T45
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In South Africa’s safety-critical industries, a single breathalyser reading can carry serious consequences - from removing a worker from a site to defending a dismissal at the CCMA. Yet workplace alcohol testing operates in an environment with limited formal regulation, leaving employers exposed when results are challenged. ALCO-SAFE EARNS SANAS ACCREDITATION FOR BREATHALYSER CALIBRATION
A gainst this backdrop, ALCO-Safe has reached a significant industry milestone, becoming the first privately owned laboratory in South Africa to achieve accreditation by the South African National Accreditation System (SANAS) for breathalyser calibration, and the only privately owned provider accredited to manage the full lifecycle of handheld breathalysers, from sales and servicing to calibration, under a single accredited framework. This accreditation by SANAS marks a major shift, formally recognising the technical compe- tence of ALCO-Safe’s calibration laboratory and confirming that its breathalyser calibration and verification processes meet strict national and international stan- dards for accuracy, consistency and traceability. Turning uncertainty into defensible certainty In the absence of a prescribed national standard for workplace breathalyser testing, employers are often required to justify the credibility of their testing equip- ment after the fact, particularly during CCMA or Labour Court proceedings. “Without an independent benchmark, employers can find themselves trying to prove the accuracy of their instruments every time a result is challenged,” explains Rhys Evans, Managing Director at ALCO-Safe. “SANAS accreditation removes that uncertainty by confirming that our calibration procedures, documen- tation and accuracy calculations have already been independently
assessed and approved.” The accreditation process
required ALCO-Safe to demon- strate not only the precision of its calibration instruments, but also the strength of its quality systems. Detailed procedures, traceable records and repeatable methods ensure calibration results remain consistent, regardless of which technician performs the work. Protecting safety programmes and labour outcomes For organisations operating in mining, construction, transport, and manufacturing, the risks asso- ciated with inaccurate alcohol testing extend beyond compliance. Questionable results can undermine zero-tolerance policies, expose employers to costly disputes and weaken overall safety cultures. “The real risk of using non-accred- ited calibration services is not just technical, it’s operational and legal,” Evans notes. “If a breathalyser result cannot be defended, employ- ers may be forced to reinstate employees or settle cases, even when safety was genuinely at risk.” SANAS accreditation strength- ens the legal defensibility of test results, giving employers confi- dence that alcohol testing out- comes will stand up to scrutiny when challenged. Making audits simpler and compliance stronger The benefits of SANAS accreditation extend into day-to-day operations, particularly during audits and safety reviews. In heavily regulated sectors, employers are frequently required to demonstrate that their testing equipment meets rec- ognised standards. “When customers are audited, they can point directly to the
Rhys Evans, Managing Director at ALCO-Safe.
SANAS certificate of the laboratory that supplies and calibrates their breathalysers,” Evans says. “That single document carries significant weight and removes the need for lengthy technical explanations or repeated verification requests.” The certification also reduces administrative burden by stream- lining audit processes and mini- mising delays linked to calibration challenges. Setting a new benchmark for workplace alcohol testing With this accreditation, ALCO-Safe has strengthened its position as a leader in breathalyser distribution, maintenance, and calibration in South Africa. “This accreditation is about more than compliance,” Evans con- cludes. “It’s about trust, trust in the numbers, trust in the process and trust that employers are making decisions based on results that are accurate, fair and defensible.” By achieving SANAS accred- itation, ALCO-Safe has not only reinforced its own standards but helped raise expectations for work- place alcohol testing across South Africa’s safety-critical industries.
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MODERN QUARRYING QUARTER 1 | 2026
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South Africa’s mining, power, electrical, automation, industrial, transport, and manufacturing sectors are the engine of the nation’s economy. Together, they drive growth, create jobs, and turn raw materials into value-added products that fuel trade and exports. ELECTRA MINING AFRICA ADDS NEW OUTSIDE EXHIBIT AREA
E lectra Mining Africa brings all these industries together in one dynamic trade show, offering a platform for buyers, sellers, and decision- makers to connect, explore innovations, and forge partnerships. With in-person networking and cutting-edge exhibitor content, Electra Mining Africa is where industry collaboration meets business growth. The biennial show is set to unveil several exciting additions in 2026, among them, a new outside exhibit area located in the Arena at the Expo Centre. According to Montgomery Group Africa port- folio director Charlene Hefer, the introduction of the new Orange Zone comes in direct response to exhibitor demand. “The new Orange Zone provides the additional space needed to accommodate more companies that want to showcase their equip- ment and innovations outside,” says Hefer. ”There will be more original-equipment manufacturers than at previous shows and this level of representation will be of benefit to visitors interested in this particular sector as they are able to view, compare and evalu- ate the offerings all in one place. The Orange Zone complements the existing Red, Blue, Green, and
Yellow Zones, creating an even more dynamic outdoor showcase.” Exhibitors located in the outside exhibit areas will span the full mining and industrial equipment value chain - from global and local OEMs to leading component and service providers. Major OEMs such as South African heavy equipment manufacturer Bell Equipment, global mining and construction machinery OEM Komatsu, mining equipment and tools OEM Sandvik, drilling, global construction and mining OEM Sany, mining machin- ery OEM Eickhoff, specialist man- ufacturer/supplier OEM All Terrain Mining & Tunnelling Machinery, and
Montgomery Group Africa portfolio director, Charlene Hefer.
Shantui (represented by Everstar Industries) will be at the show with complete machinery and technology solutions driving productivity and innovation. Complementing them
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demonstrating strong industry sup- port for the show and confirming its proven track record as a driver of leads and sales. Taking place in Nasrec, Johannesburg between 7-11 September 2026, Electra Mining Africa is a 6-in-1 Trade Show, incorporating Electra Mining Africa, Automation Expo, Elenex Africa, PowerEx, Transport Expo and the Local Southern African Manufacturing Expo. It is the largest show of its kind in Southern Africa, and one of the largest mining and industrial shows globally. “We are really excited about Electra Mining Africa 2026,” says Hefer. “The 2024 event was the big- gest ever show since the inaugural edition in 1972, hosting 950 exhibi- tors across 6 exhibition halls and 4 outside exhibit areas, with almost 40 000 visitors attending. Now, with the addition of the Orange Zone, a new SAIMechE Career and Skills Hub, and other exciting initiatives, Electra Mining Africa 2026 is set to be even bigger”. l
manufacture through to digital inte- gration, distribution, maintenance, and operational excellence. “The presence of these indus- try leaders will attract high-level buyers, engineers, and deci- sion-makers seeking reliable, high-performance solutions, while also fostering partnerships, local manufacturing, and skills develop- ment,” notes Hefer. With just under eight months to go until Electra Mining Africa 2026, the exhibition is already 98% sold,
are distributors, technology partners, and component and service suppli- ers such as Barloworld, Egelquip, GHM Machinery, Drilling Mining and Construction, Kappa Engineering, Alpin, and nVolve Solutions, which provide equipment support, auto- mation technologies, parts, sys- tems, and engineering services that enhance OEM performance and operational reliability. Together, this diverse mix ensures a comprehen- sive showcase of the mining and industrial ecosystem—from original
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COLLABORATION AT THE CORE OF MINING GROWTH
The Investing in African Mining Indaba 2026 brought together key players to engage on the subjects most relevant to the future of the mining industry in Africa. Among other critical areas of discussion – from energy security to modernising the industry to Africa’s strategic positioning – two key themes carried through the conversations: the need to prioritise inclusive local growth for sustainable economic development, and the role of collaboration in unlocking capital and ensuring shared benefit. By Shamiso Chideme (Head of Clients, Tshikululu Social Investments) and Richard Pfaff (Head of Social Impact, Tshikululu Social Investments)
N ot only is each of these an important area of exploration, but they are interconnected. Collaboration is fundamental to the achievement of inclusive local growth. Inclusive local economic devel- opment is necessary for the sus- tainability of mining communities and the wider economy. Conditions in many mining communities make it clear that efforts to develop
local economies and create positive social impact are falling short: unemployment remains a dominant community pressure point, and energy and water inse- curity, infrastructure backlogs and weak spatial planning are ongoing constraints. Jobs are not being created at the levels needed for the growth of local economies that are meaningfully independent from the mining value chain. The Indaba recognised that transformative approaches are needed to achieve change. Community participation and provincial investment promotion, together with an enhanced under- standing of domestic beneficiation, all form part of ensuring that mining drives domestic economic development. However, none of this can be accomplished in isola- tion. Reliance on discrete funding levers such as social and labour plan (SLP) commitments, corpo- rate social investment (CSI) and other socio-economic develop- ment (SED) funds creates a frag- mented and short-term approach to solving complex, long-term problems. Fragmentation is not effective: collaboration between business, government, civil soci- ety and communities is the only way to create change. Collaboration has become a buzzword in social investment, but we need to move beyond talking about it and work together to coordinate resources. In our experience as Tshikululu, we have found a strong appetite among social investors to move from compliance-driven, siloed interventions towards a deliberate,
collaborative approach. We are already seeing exam- ples of collaborative efforts with specific emphasis on investing in inclusive local growth. The Indaba highlighted the Impact Finance Network (IFN), through which Anglo American and its partners, Impact Capital Africa and Edge Growth, are identifying innovative, impactful businesses in the region and bringing together a net- work of investors seeking social investment opportunities. Taking a regional approach, Tshikululu has begun the internal process of working in partnership to define a long-term, structured collab- oration model across mining houses with operations in the same district. These companies and their host communities share deep, systemic challenges that cannot be solved through iso- lated programmatic investments. Instead, we are working together to find collaborative solutions that can work at scale. Collaboration is not easy, but it is necessary. Effective collabo- ration, especially when targeting issues on a scale as big as local economic development, relies on good governance and clear strategy. It requires all parties to align on shared outcomes, even while different pots of funding and diverse activities are deployed to achieve them. Inclusive local economic devel- opment is a strategic imperative for South Africa, and especially for the mining industry. Everyone has a role to play, and collaborating stra- tegically to achieve shared goals is the only way to succeed. l
Shamiso Chideme (Head of Clients, Tshikululu Social Investments).
Richard Pfaff (Head of Social Impact, Tshikululu Social Investments).
MODERN QUARRYING QUARTER 1 | 2026 10
The mining and quarrying sector across South Africa and the broader African continent is undergoing a decisive transformation. Market consolidation, stricter compliance requirements, and relentless pressure to maximise throughput while minimising waste and downtime are redefining operational priorities. In this environment, intelligent connected systems that provide real-time visibility and actionable insight are no longer optional - they are fundamental to sustainable performance. Loadrite, an international brand of smart scales for heavy equipment, is at the forefront of this shift, with a comprehensive, locally supported approach through Loadtech Loadcells that makes it possible to weigh in real time, optimise loading operations, and access live data from anywhere on the continent. FROM PAYLOAD TO PROFIT: THE DATA- DRIVEN SHIFT
Loadrite’s L5000 smart scale and other Loadrite configurations bring precise weight measurement directly into the operator’s view.
A frica remains a critical global supplier of base metals, precious minerals, and bulk commodities. In South Africa, gold, manganese, chrome, platinum group metals, coal, and aggregates continue to anchor both domestic economic activity and export markets. Yet operators face mounting pressure to reduce non-productive downtime, eliminate overloading penalties, and maintain reliability in harsh operating conditions. Digital transformation is accelerating across the sector. Industry 4.0 principles - connected equipment, predictive maintenance, remote diagnostics, and cloud-based analytics - are becoming competitive differentiators. The ability to collect, consolidate, and interpret oper- ational data across multiple sites and fleets is reshaping how mines and quarries are managed. What was once manual, reactive oversight
is evolving into proactive, data-driven optimisation. This shift creates opportunity. Operations that can measure accurately,
MODERN QUARRYING QUARTER 1 | 2026 12
SNAPSHOT
Loadrite, an international brand of smart scales for heavy equipment, is at the forefront of this shift, with a comprehensive, locally supported approach through Loadtech Loadcells.
Loadrite, complemented by InsightHQ and delivered through Loadtech’s in-house capabilities, offers a complete, locally supported solution.
Loadrite’s integrated ecosystem provides a practical, scalable path to weather the volatility of mining and quarrying markets while laying the foundation for a truly connected, intelligent, and data-driven mining operations landscape.
One of Loadrite’s differentiators in the South African and African market is the commitment to all-in-house parts, installations, training, and technical support through Loadtech.
respond quickly, and analyse performance systematically gain measurable advantages in cost control, compliance, and output consistency.
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applied across thousands of cycles, translate into lower cost per tonne and greater profitability. Real-time feed- back also reduces rehandling and enhances operator confidence, contributing to smoother shift performance. Beyond the cab, InsightHQ serves as the cloud-based data centre and analytics hub of the ecosystem. It con- solidates data from connected machines across multi- ple sites into a secure, centralised platform. Managers gain access to dashboards displaying payload metrics, machine utilisation, calibration events, and perfor- mance trends - whether on site or working remotely. A unified data environment replaces fragmented report- ing with a single source of truth. Live monitoring enables supervisors to respond immediately to anomalies. Alerts can be configured for out-of-range weights, calibration drift, or other devi- ations, allowing corrective action before minor issues become costly disruptions. Integration across mixed fleets ensures that loaders, excavators, forklifts, and reach stackers feed into the same analytical frame- work, supporting consistent performance benchmark- ing across operations. The benefits extend beyond efficiency. Accurate weighing reduces exposure to overloading fines and strengthens contractual compliance. Digital audit trails simplify inspections and reporting, reinforcing gover- nance and accountability. Precise measurement also enhances safety by preventing hazardous overload con- ditions and reducing the need for manual verification. Over time, the accumulation of accurate data estab- lishes measurable baselines for uptime, fleet utilisation, and payload consistency. Recurring patterns - such as calibration drift after certain usage thresholds or operator-related variability - can be identified early. Preventative maintenance and targeted retraining reduce unplanned downtime and extend equipment life. In this way, data evolves from a reporting tool into a strategic asset. The Loadrite L5000 smart scale exemplifies this technological progression. Recognised in South Africa
Turning weight into intelligence Loadrite, an international brand of smart scales for heavy equipment, is positioned at the forefront of this transformation. Supported locally by Loadtech Loadcells, the company delivers a connected eco- system that converts payload data into measurable operational value. At machine level, the Loadrite L5000 smart scale and related configurations provide precise payload measurement directly in the operator’s line of sight. For front-end loaders, excavators, forklifts, and reach stackers, real-time weight feedback eliminates guess- work. Operators can achieve target loads faster, reduce spillage, and avoid under- or overloading. The result is improved truck cycle efficiency, lower fuel consumption, and reduced material loss. In high-volume operations, marginal improvements compound quickly. Small gains in loading accuracy,
MODERN QUARRYING QUARTER 1 | 2026 14
integration and embedding data- driven practices across more sites. Enhanced interoperability with plant management systems, ERP plat- forms, and maintenance software will enable end-to-end operational visibility. Hardware development continues to prioritise resilience, ensuring systems withstand dust, heat, vibration, and variable power conditions common across African climates. Expanded training programmes will strengthen skills development at operator and supervisory levels, while collaborative partnerships with mining houses and infrastruc- ture projects will demonstrate measurable improvements in load accuracy, safety performance, and cost efficiency at scale. The broader impact of this shift is both operational and strategic. Precision in payload measurement compounds over thousands of cycles, reducing waste and equip- ment wear. Real-time visibility across fleets enables management to move from reactive trouble- shooting to proactive optimisation. Standardised metrics reduce vari- ability, improve forecasting accu- racy, and support smarter capital allocation. For operators on the ground, immediate feedback reduces rework and supports consistent productivity. For site managers and executives, consolidated dash- boards provide clear oversight across locations. Procurement and maintenance leaders can justify investment decisions using quanti- fiable performance indicators such as uptime, payload accuracy, and maintenance trends. Ultimately, mining and quar- rying operations in South Africa and across Africa are progressing toward greater digital maturity. Converting operational data into actionable intelligence strengthens safety, efficiency, and profitabil- ity in an increasingly competi- tive global market. Through the integration of real-time smart scales, cloud-based analytics, and comprehensive local support, the transition from payload to profit becomes not just a strategy, but a measurable reality. l
The Loadrite ecosystem is designed to connect with a broad range of equipment. Whether a mine runs a mixed fleet of loaders, excavators, forklifts, or reach stackers, the data from each device feeds into the same InsightHQ environment.
for its rugged design and precision, it integrates seamlessly with existing hydraulic systems while maintaining consistent accuracy even on uneven terrain through advanced angle sensing. An intuitive, evolving user interface with larger displays and clear target-weight guidance shortens the learn- ing curve and supports rapid adoption. A dedicated day/night display mode enhances visibility in underground or low-light conditions, reducing visual fatigue. As connectivity improves across the continent, InsightHQ enables increas- ingly robust remote diagnostics and system optimisation. Software updates, data field synchronisation, and performance monitoring can be coordinated between site teams and cloud-based systems, ensuring rapid response and continuous improvement. Local support and the road ahead Technology’s value is realised only when supported by dependable service infrastructure. In South Africa and across Africa, Loadrite’s partnership with Loadtech Loadcells ensures installations, calibration, system inte- gration, and ongoing maintenance remain locally managed. Experienced technicians familiar with regional operating conditions provide commis- sioning and technical support, while a structured supply chain ensures critical components are readily available - an essential factor in remote or demanding environments. Training is a central pillar of the model. Operators and maintenance per- sonnel receive structured onboarding that extends beyond system operation to data interpretation and performance optimisation. When teams under- stand both the technology and its analytical value, adoption deepens and return on investment accelerates. Looking toward 2026 and beyond, the strategic focus centres on expanding
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MODERN QUARRYING QUARTER 1 | 2026
As mines, quarries and aggregate producers face rising costs, tighter margins, skills shortages and increasing pressure to improve safety and reduce their environmental impact, mobility is emerging as one of the most effective levers to improve operational resilience. MOBILITY AS A STRATEGIC ADVANTAGE FOR MINES AND QUARRIES
boasts resale value and can be eas- ily relocated to new projects, holding higher residual value.” Saunders states that when it comes to operational flexibility and efficiency, mobile equipment delivers. “Because mobile plants, crushers and screens can be moved to the material, they are ideal for operators managing multiple, smaller or remote sites. They offer rapid deployment. Mobile plants typically offer significantly faster setup times than stationary alter- natives - a matter of minutes and hours upon arrival of the units on site, rather than weeks and months, enabling quicker, immediate revenue generation. Safety and environmental benefits “By reducing haul truck traffic on-site, mobile equipment directly lowers the risk of accidents. It also benefits the environment. Since the transport requirements are lower, carbon emissions, noise and dust are reduced. It is also simpler to add, remove, or upgrade mobile units to change the process or
A ccording to leading global manufacturer Astec Industries, equipment like the Astec GT205 mobile screen, GT125 mobile jaw crusher, the newly introduced FT2650 mobile jaw crusher, FT200 OC track cone crusher and GT165 scalper are increasingly sought after by astute operations recognising the benefits they offer in terms of flexibility, lower operation costs and improved safety compared to traditional, fixed installations.
Astec Industries product sales manager Philip Saunders expands on the advantages: “By allowing material to be processed directly at the extraction point, mobile units eliminate the need for extensive haulage, significantly reducing fuel consumption, labour and mainte- nance expenses. Mobile equipment typically has a lower upfront cost compared to building a fixed, sta- tionary crushing plant. Productivity is increased and overall operational efficiency boosted by eliminating the downtime associated with waiting for haul trucks. Mobile equipment
MODERN QUARRYING QUARTER 1 | 2026 16
stroke processes more material than competitive models, increasing production and reducing operating costs. A simple manual folding head section on the discharge conveyor reduces the footprint of the machine, reducing shipping costs. Astec has also recently introduced the larger FT2650 mobile jaw plant into its local South African offering, expanding its tracked jaw range for higher-capacity applications. The FT2650 incorporates a 50” × 26” (1 270 mm × 660 mm) Vanguard jaw crusher. Designed for contractors and producers requiring greater primary throughput, the FT2650 integrates hydraulic CSS adjustment, a robust tracked chassis and real- time monitoring systems to support consistent high-volume production in demanding quarry and mining environments. The Astec FT200 OC track cone crusher incorporates a Kodiak K200+ cone with a high-efficiency roller bearing design, delivering improved mechanical efficiency and reduced operating costs. The unit features remote closed-side setting adjustment, interchange- able chamber configurations and a low-impact tramp relief system that protects the crusher from overload events. A variable-speed hydraulic drive and automated feed regulation support consistent product quality and throughput, while precision balancing and protected internal counterweights enhance long-term reliability. The rugged, exceptionally por- table Astec GT165 scalping screen offers ideal gradation control for recycled, crushed stone, demolition and topsoil applications. This track- mounted screen was designed as a tool for overburden, to scalp ahead or behind a primary crusher, as well as screen a wide array of materi- als, from aggregates to recycle to organic materials. “While mobile equipment is gener- ally ideal for short-to-medium-term projects or to augment large, long- term, fixed operations, its portability, lower labour requirements and abil- ity to keep up with an advancing site make it a critical tool for modern, efficient and profitable operations,” Saunders concludes. l
The three-deck mobile unit is fitted with a 5 x 20 screen and a Caterpillar C4.4 129 HP Tier III diesel engine. The screen’s gradation control allows for reclaiming fines in both wet and dry applications. Plant capacity is rated at up to 600 tph, depending on application and material conditions. With some units achieving in excess of 800TPH with modifications and upgrades for special applications. Mobile jaw is equally effective for aggregate and recycling applications Astec’s mobile jaw plants are engi- neered for maximum jaw crushing mobility and production efficiency. Featuring heavy-duty Vanguard and Pioneer-series jaw technol- ogy, these plants are designed to deliver up to 25% more capacity than comparable competitive mod- els, depending on application and configuration. Astec’s GT125 mobile jaw crusher is equally effective in aggregate and recycling applications. This crusher is making its mark around the world, in applications that include produc- ing and recycling aggregate. The GT125’s large, dynamically balanced, heavy-duty flywheels produce up to 33 percent more inertia than com- petitive models, leading to a reduced cost per ton over the lifetime of the machine. The crusher’s large, 32mm
increase capacity compared to modifying a stationary plant.” Astec mobile incline screen plants have an array of features for maximum screening efficiency and production. “They are engineered to provide higher production capaci- ties and more efficient sizing than comparable screens,” Saunders explains. “Our mobile plants combine heavy-duty screens with indus- try-leading conveyor heights. A large range of media provides flexibility for a variety of applications.” The GT205 is a 5’ x 20’, track- mounted plant featuring a conven- tional screen on the top deck and a high-frequency screen on the bottom deck. The unique combination of high frequency and conventional screens in one self-contained unit puts more energy into the screening process, creating a powerful machine capable of increasing capacity by up to 50 percent on the bottom deck. The GT205’s large screen box enables the production of high volumes of material when produc- ing straightforward products such as G5. But, with the three-deck four-product conveyor setup, there is an element of finesse avail- able when coupled with the height and angle adjustable screen box, Saunders explains. “This function- ality allows the quarry to maximise high quality low yield products such as 7 and 10mm surfacing stone.”
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ACE is engineered for unparalleled security and features a robust dual locking mechanism that ensures maximum reliability.
Hand and finger injuries remain one of the most common safety concerns in mining, often occurring during physically demanding maintenance tasks. To help address this risk and remove potential safety hazards, Multotec has developed a range of hammer-less screening media attachment systems that significantly reduce the amount of hammer blows traditionally required when installing or removing screen media. REDEFINING SCREENING MEDIA ATTACHMENT SYSTEMS FOR FASTER, SAFER CHANGEOUT
D esigned for faster, easier changeouts while lowering the number of hammer blows needed, these systems not only make the process quicker and easier for maintenance, but also significantly improve operator safety, reducing the risk of injuries, fatigue and unplanned downtime in demanding mining environments. “Safety is at the heart of every innovative solution we design,” says Denzyl Macauley, Screening Support Manager at Multotec. “By reducing hammer use during panel changeouts, we are directly addressing one of
Denzyl Macauley, Screening Support Manager at Multotec.
Jean Laurens, Screening Support Engineer at Multotec.
MODERN QUARRYING QUARTER 1 | 2026 18
to fasten modular screen panels to support frames on mineral processing equipment such as trommels and vibratory screens. Each panel typically requires multiple hammer blows per pin, as well as additional tools such as screwdrivers and crowbars. The removal process is also two-step, which increases both time and risk. These tasks are often carried out in confined and ergonomically challenging spaces. For maintenance personnel, this creates multiple safety hazards: from hand and finger injuries caused by missed hammer blows, to pinch points when holding pins in place during hammering, to repetitive strain from repeated, forceful exertion. In some cases, hot work such as flame cutting is required, which introduces additional burn and spark risks. In today’s mining industry, where safety is non-negotiable, such risks not only endanger personnel but also contribute to unplanned stoppages and productivity losses from extended installation times. Invest in both safety and productivity simultaneously As an alternative to this, Multotec’s hammer-less attachment systems for screen media simplify static and vibrating screen media changeouts, making them faster, safer and more efficient. Instead of repeated hammering, panels can be clipped or snapped into place using just a few light hammer blows, or simple hand leverage. This minimises the force required, reduces the number of moving parts compared to conventional systems, and lowers overall maintenance effort and cost. “By simplifying the process and reducing hammer blows, our latest attachment systems make screen panel changeouts faster, easier, and safer,” explains Jean Laurens, Screening Support Engineer at Multotec. “That means fewer injuries, greater efficiency and less disruption to production,” adds Laurens. Furthermore, Multotec offers several latest-generation hammer-less systems for use on modular runner-type screens that accommodate interlocking, standardised screen panels. These systems can also be retrofitted to any existing screen decks or applications currently in operation. The ERX system, designed for extremely heavy-duty applications, secures modular interlocking polyurethane or rubber panels using fixed clamping strips and a top locking strip. This eliminates the need for multiple bolts and nuts and removes hot
SNAPSHOT
Safety is at the heart of every innovative solution we design.
Multotec’s hammer-less attachment systems for screen media simplify static and vibrating screen media changeouts.
ACE is engineered for unparalleled security, and features a robust dual locking mechanism that ensures maximum reliability.
The result is a safer working environment, faster maintenance, greater plant availability and improved productivity, fully aligned with the mining industry’s growing emphasis on both safety and operational efficiency.
mining’s most common safety hazards and helping to reduce the number of hand injuries on site,” Macauley adds. Conventional attachment systems require repeated hammer blows
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Designed for faster easier changeouts while lowering the number of hammer blows needed.
removal, ACE requires no screwdrivers or pry bars. Multotec’s engineered, battery- powered tool makes panel removal simple, fast, and safe, which is the smarter way to get the job done. Together, these advanced attachment systems demonstrate Multotec’s focus on putting personnel safety first while streamlining changeouts. By reducing hammering and simplifying installation, they lower the risk of hand injuries and pinch points, cut down on repetitive strain and decrease operator fatigue, improving alertness and morale. The result is a safer working environment, faster maintenance, greater plant availability and improved productivity, fully aligned with the mining industry’s growing emphasis on both safety and operational efficiency. Available through Multotec’s global branch network, these attachment systems reflect the company’s strong commitment to innovation and safety. They give mines a practical, proven way to reduce injuries, improve worker conditions and achieve higher productivity during routine maintenance. l
By simplifying the process and reducing hammer blows, our latest attachment systems make screen panel changeouts faster, easier, and safer.
Cost-effective, Ergonomic (ACE) fixing solution requires zero hammer blows, eliminating the risk of impact injuries during screen panel changeouts. The ACE panels lock in place with just hand pressure so there is no impact risk and no pinch points. By reducing physical effort, it lowers the risk of strain or injury, creating a safer, more ergonomic work environment. Once in place, ACE is engineered mechanism that ensures maximum reliability. When paired with the top locking strip, it becomes virtually fail-proof, staying securely in place even where other fastening solutions have failed. This exceptional resilience makes the system the most reliable solution on the market. When the time comes for for unparalleled security and features a robust dual locking
work such as grinding or cutting during changeouts. The Y-LOK system is specifically tailored for Multotec trommel screens, where modular polyurethane or rubber screen panels attach via a snap-on mechanism along a Y-shaped groove rail system, enabling quick and secure installation with minimal hammering. For general screen attachment needs, the CCX and HALO systems provide versatile clip-in and snap-on solutions suitable for applications ranging from sizing and dewatering to media recovery. These systems reduce reliance on tools, allowing single-person changeouts to be done by hand, while being compatible with all screen media materials. Derived from the ERX series, Multotec’s Adaptable,
MODERN QUARRYING QUARTER 1 | 2026 20
Weir hosted a number of customers at its Alrode operation, welcoming them to the new Screens Heavy Bay facility to showcase its enhanced screen manufacturing capabilities.
South Africa has cemented its position as a global centre for the production of Weir’s cutting edge ENDURON® Elite banana screens. Backed by major infrastructure investment at Weir’s Alrode facility in Gauteng, this site is now the first in the world dedicated solely to manufacturing this advanced new range. SA TAKES THE LEAD AS GLOBAL HOME OF WEIR’S ENDURON ® ELITE SCREENS T he Alrode expansion adds a further 1 600 m² of dedicated production space under roof, equipped and regional supply chain - enabled us to manufacture the first two ENDURON ® Elite screens even before completion of the expansion,” says Van Vuuren. “We already had the specialised expertise and equipment in place, including a laser facility capable of cutting the massive 12 m by 5 m side plates. In parallel, we ran a targeted supplier development programme to further strengthen and empower our local supply partners.” The outcomes of this process were rigorously assessed and
with two 63 ton gantry cranes operating at a clearance height of 18,5 metres, according to Alandré van Vuuren, Integrated Supply Chain Director at Weir. This strategic upgrade was driven by a landmark £53-million contract awarded to Weir by Barrick’s Reko Diq copper-gold project in Pakistan, which includes the supply of fine grinding, separation, and tailings solutions. “The advanced technological capability and rigorous quality assurance at our Alrode plant - together with our robust local
The advanced technological capability and rigorous quality assurance at our Alrode plant - together with our robust local and regional supply chain - enabled us to manufacture the first two ENDURON ® Elite screens even before completion of the expansion.
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The new heavy bay screen manufacturing facility at Weir Alrode is now producing the ENDURON Elite double deck banana screens for the Reko Diq order.
Alandré van Vuuren, Integrated Supply Chain Director at Weir.
audited by both an independent third party and Weir’s own technical team, clearing the way for the expansion which commenced in early 2025. Construction has required substantial earthworks and piling, with excavations reaching two storeys below ground to accommodate the concrete and steel structure of a 1 000 ton plinth. This specialised plinth is engineered to absorb the intense vibration forces generated by the exciters during product testing. The expansion has created two dedicated assembly stations for the high capacity double deck ENDURON ® Elite screens – each weighing nearly 50 tonnes, with deck dimensions of up to 4,3 m wide by 8,5 m long. “This expansion marks a significant boost to South Africa’s manufacturing capacity,” he says. “Facilities with heavy engineering capability and crane clearance at these heights are rare in the country, yet they are essential to support the ambitious manufacturing plans we are rolling out at Alrode.” The upgraded facility enables the safe and efficient assembly of large screen components such as the subframe, screen body, screen deck and exciters, with completed units reaching heights of over 15 metres, Van Vuuren notes. The new production bays will have the capacity to manufacture at least two ENDURON® Elite screens per month - without disrupting Alrode’s ongoing output of small, medium and large screens across the broader ENDURON® range. “Our production for the first half of 2026
The recent expansion at Weir Alrode, which included the addition of a heavy bay screen manufacturing facility, has added a further 1 600 m² of dedicated production space under roof.
SNAPSHOT
The Alrode expansion adds a further 1 600 m² of dedicated production space under roof, equipped with two 63 ton gantry cranes operating at a clearance height of 18,5 metres.
The expansion has created two dedicated assembly stations for the high capacity double deck ENDURON ® Elite screens – each weighing nearly 50 tonnes, with deck dimensions of up to 4,3 m wide by 8,5 m long.
Weir is advancing the development of its Alrode plant in line with its strong sustainability commitments, with the expanded facility serving as one of the company’s pilot sites for water- based paint application.
While most of the ENDURON® Elite screens produced at Alrode will be destined for export, nearly all components and materials are sourced locally.
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