MODERN QUARRYING QUARTER 2 | 2026 Thriving in uncertainty Crushing targets, not safety standards In-house production ensures reliability 08 14 28
CALDAS AT
BUILT TO LAST
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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CONTENTS
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18
10
Collaboration is the cornerstone of local growth. PAGE 04
Balancing geology and production. PAGE 18
Thriving in uncertainty. PAGE 08
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IN-HOUSE EXCITER REPAIR EXTENDS SANDVIK SCREEN LIFE Keeping screens productive and reliable is vital to mineral processing. To support this, Sandvik Rock Processing operates a dedicated Exciter Repair and Refurbishment Facility that ensures the highest standards are applied to maximise screen uptime and performance.
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THE RISE OF MULTIFUNCTION MACHINES IN QUARRYING
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In an operating environment marked by rising input costs, tighter margins and increasing pressure to do more with less, quarry operators are rethinking their equipment strategy.
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QUARRYING UNDER PRESSURE
S outh Africa’s quarrying sector remains fundamental to the country’s infrastructure and industrial development, supplying the aggregates, sand and crushed stone required for roads, housing, water infrastructure, commercial construction and mining related projects. Yet despite the essential nature of these materials, the industry is operating in an increasingly challenging environment shaped by rising costs, logistics constraints, regulatory pressure and uncertain economic conditions. Among the sector’s most press- ing concerns is the rising cost of energy. Quarrying operations rely heavily on power intensive processes including crushing, screening, washing and conveying material. While load shedding has eased compared to the severe disruptions experienced in recent years, electricity tariffs continue to increase well above inflation, placing sustained pressure on operating margins. Escalating diesel prices are adding further strain, particularly for mobile equipment fleets and transport operations. Logistics remains another critical challenge. Aggregates are low
supplying concrete stone, road base and other construction inputs required for large scale energy infrastructure. At the same time, environmen- tal compliance requirements are becoming increasingly significant operational considerations. Quarry operators face growing pressure to demonstrate responsible envi- ronmental management around dust suppression, water use, noise control and site rehabilitation. While these measures are essential for sustainable resource development, compliance costs continue to rise, particularly for smaller and mid- sized operators. Illegal sand mining and unreg- ulated aggregate extraction also remain persistent concerns in sev- eral parts of South Africa. Beyond environmental damage, these activities create unfair competition for compliant producers that invest heavily in licensing, environmental management and labour standards. Capital investment decisions have meanwhile become more difficult in a high interest rate environment. Currency volatility and global supply chain pressures have increased the cost of imported equipment, spare parts and consumables, leading many operators to extend the life of existing plant rather than invest in new technologies. Skills shortages further com- pound operational pressures, with experienced artisans, plant operators, engineers and mainte- nance specialists remaining in high demand across both the mining and construction sectors. Despite these challenges, the long term outlook for South Africa’s quarrying industry remains closely tied to the country’s infrastruc- ture ambitions. Demand for quality aggregates will remain essential to economic development, urban expansion and industrial growth. The operators best positioned for future success will likely be those able to improve efficiency, embrace technological innovation and adapt to a more demanding operating environment.
margin, high volume products, making transport efficiency central to profitability. However, deteriorat- ing road infrastructure, congestion on key freight corridors and rising transport costs continue to erode margins across the sector. Ongoing rail constraints have increased dependence on road haulage, with transport now representing one of the largest components of delivered aggregate costs in many regions. The pace of infrastructure delivery also continues to influence market stability. Although govern- ment has repeatedly positioned infrastructure investment as a national priority, implementation delays, procurement bottlenecks and funding constraints have resulted in inconsistent demand patterns for construction materials producers. There are, however, encour- aging signs emerging across several sectors of the economy. Road rehabilitation programmes, renewable energy developments, water infrastructure upgrades and selected mining investments are beginning to stimulate renewed demand for aggregates and related materials. The expansion of wind and solar energy projects in partic- ular is expected to create sustained opportunities for quarry operators
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 Q1 2026: 4 582
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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MODERN QUARRYING QUARTER 2 | 2026
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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. By Shamiso Chideme (Head of Clients, Tshikululu Social Investments) and Richard Pfaff (Head of Social Impact, Tshikululu Social Investments) COLLABORATION IS THE CORNERSTONE OF LOCAL GROWTH
A mong 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. Not only is each of these an important area of exploration, but they are interconnected. Collaboration is fundamental to the achievement development is necessary for the sustainability of mining commu- nities and the wider economy. Conditions in many mining com- munities 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 insecurity, infrastruc- ture 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 mean- ingfully independent from the mining value chain. of inclusive local growth. Inclusive local economic 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 beneficia- tion, all form part of ensuring that mining drives domestic economic development. However, none of this can be accomplished in isolation. Reliance on discrete funding levers such as social and labour plan
(SLP) commitments, corporate social investment (CSI) and other socio-economic development (SED) funds creates a fragmented and short-term approach to solving complex, long-term problems. Fragmentation is not effective: collaboration between business, government, civil society and com- munities 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 coor- dinate resources. In our experi- ence as Tshikululu, we have found a strong appetite among social investors to move from compli- ance-driven, siloed interventions toward 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 collabora- tion 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 isolated program- matic investments. Instead, we are working together to find collabo- rative solutions that can work at scale. Collaboration is not easy, but it is
Shamiso Chideme - Head of Clients, Tshikululu Social Investments.
Richard Pfaff - Head of Social Impact, Tshikululu Social Investments.
necessary. Effective collaboration, especially when targeting issues on a scale as big as local economic development, relies on good gover- nance 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.
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MODERN QUARRYING QUARTER 2 | 2026
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LETISHA VAN DEN BERG MAKES IQSA HISTORY
In a landmark moment for South Africa’s quarrying and surface mining sector, Letisha van den Berg has been elected as the first female chairperson of the Institute of Quarrying South Africa. Her appointment signals not only a shift in leadership, but a broader transformation within an industry traditionally dominated by men. Wilhelm du Plessis spoke to her at the IQSA conference in Durban.
V an den Berg, who also serves as Director of ASPASA, steps into the role with a clear and pragmatic vision: to elevate the IQSA to international standards while strengthening skills development across the sector. She has emphasised the importance of aligning South Africa with global best practices, particularly in formalising qualifications for surface mining professionals and building a stronger, more recognised professional pipeline. Her predecessor, Jeremy Hunter-Smith, steered the IQSA through the difficult Covid-19 pandemic period and leaves the organisation in a strong position to move forward. At the core of her leadership agenda is a focus on people. Van den Berg has repeatedly highlighted the urgent need to address skills shortages - not only in traditional trades, but also in emerging areas such as digital technologies, automation and data-driven operations. She believes the Institute must play a leading role in creating awareness at school level, opening pathways into mining careers, and support- ing alternative qualification routes such as Recognition of Prior Learning (RPL). Her dual leadership roles at IQSA and ASPASA position her uniquely to bridge the gap between individual professional development and industry-wide growth. “IQSA represents the indi- vidual, while ASPASA represents the company,” she notes - an interplay she sees as essential for building a sustainable talent
From left: ASPASA Chairman, Collin Ramukhubathi; outgoing IQSA Chairman Jeremy Hunter- Smith and the new Chairperson, Letisha van den Berg.
pipeline that feeds directly into the needs of the sector. Van den Berg is equally candid about the challenges facing the industry. These include regulatory complexity, illegal mining, and the slow pace of permitting processes. Rather than simply criticising government, she advocates for col- laborative, solution-driven engage- ment - such as adopting risk-based approaches to streamline approv- als without compromising environ- mental standards. Transformation is another key theme. While she acknowledges the growing presence of women in mining, Van den Berg broadens the conversation to include youth participation and opportunities for people with disabilities. For her, meaningful inclusion means diver- sifying decision-making spaces and expanding access across all levels of the industry.
Looking ahead, she sees sig- nificant opportunity in infrastruc- ture development - provided that government unlocks supply chains and enables industry participation. At the same time, she is a strong proponent of ESG principles, par- ticularly the practical use of data to
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phased approach - encour- aging the adoption of more accessible, entry-level technologies that can still deliver meaningful safety and productivity gains. This, coupled with targeted skills development, will ensure that both workers and operators are equipped to adapt to a rapidly evolving landscape. Ultimately, Van den Berg’s leadership marks a new chapter for the IQSA - one defined by inclusivity, skills development, and stron- ger industry alignment. Her appointment is not just symbolic; it reflects a sector evolving to meet the demands of a more complex, technologically advanced and socially conscious future. l
shared resources more efficiently. Such an approach, she argues, will not only reduce costs for operators but also create more consistent standards across the country. She is also mindful of the role technology will play in shaping the future of quarrying. While advanced systems such as high-level automation and collision avoidance are often costly, Van den Berg advocates for a
improve efficiency, reduce costs, and drive sustainability initiatives such as recycling and the circular economy. Beyond policy and strategy, Van den Berg is also focused on strengthening the visibility and relevance of the Institute itself. She has pointed to the need for stron- ger regional engagement through hubs that can deliver training, mentorship and
ASPASA supports small surface mines in overall compliance and lobbying with the various legislators and specification developers.
Our membership consists of 38 mining houses with approximately 115 quarries across South Africa.
Our members do not mine critical minerals, but we extract essential minerals to ensure you have a comfortable livelihood.
Our member mines fall under the other commodity classification of the Department of Mineral Petroleum Resources – the minerals that looks after your basic everyday needs : • Clean water thanks to lime • Roads and water pipes with thanks to the various aggregates mined • The house you live in from foundation to roof top thanks to: o Aggregates for roads, readymix, rail and décor products o Cement o Bricks o Dimension stone granite o Clay for the roof tiles and decor o Paint from lime o Your fire-resistant braai/pizza oven from andalusite mining o Steel work thanks to iron ore and manganese mining • Your fresh breath is thanks to fluorspar mining • Your clean clothing from washing detergent containing silica sand • Cat litter sand thanks to attapulgite clay • And this does not even cover all the non-metallic other products our member produce
Your voice when it matters most
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The Institute of Quarrying Southern Africa (IQSA), in conjunction with ASPASA, successfully hosted its 55 th AGM Conference & Exhibition on 16 and 17 April 2026 in Durban, bringing together quarrying, mining and construction materials professionals from across Southern Africa and around the world. THRIVING IN UNCERTAINTY
U nder the theme Malaysia, New Zealand and Hong Kong, creating a valuable platform for knowledge sharing and industry collaboration. The two-day programme featured keynote presentations, technical case studies, panel discussions and industry updates covering a broad range of topics, including operational excellence, crushing and screening, haul road maintenance, diesel rebates, illegal mining, legal liability, blasting technology and proj- ect sponsorship. International speakers from the Institute of Quarrying UK and Australia shared global perspectives, while Thriving in Uncertainty , the event welcomed international delegates from the UK, Australia, local experts addressed the challenges and opportunities facing the South African quarry- ing sector. The conference also showcased the latest products, technologies
International speakers from the Institute of Quarrying UK and Australia shared global perspectives, while local experts addressed the challenges and opportunities facing the South African quarrying sector.
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MODERN QUARRYING Quarter 2 | 2026
and services through a vibrant exhibition, providing delegates with opportunities to engage directly with suppliers and solution provid- ers. Networking events, including the industry awards dinner, cele- brated excellence within the sector and reinforced the industry’s com- mitment to safety, sustainability and innovation. As market conditions, regula- tory requirements and operational challenges continue to evolve, the conference highlighted the importance of adaptability, techni- cal excellence and collaboration in ensuring the long-term success of the quarrying industry. l
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CALDAS AT 30: BUILT TO LAST
Thirty years is a milestone that naturally encourages reflection. For Caldas Engineering, however, it is less a celebration of the company itself and more an opportunity to acknowledge the people and industries that have allowed the business to grow and evolve over three decades. “No company reaches 30 years without the support of its customers, employees, suppliers and industry partners,” says Michael Da Camara, COO of Caldas Engineering. “The trust that customers have placed in us over the years is something we never take for granted.” F ounded in 1996, Caldas began with a clear objective: to provide reliable crusher wear parts and support to operators looking for a trusted alternative in the market. Although proudly South African, the business initially focused on exporting wear parts to customers around the world. As relationships developed and the company’s reputation grew, South African operators began looking for the same support, responsiveness and technical expertise that international customers had come to expect. What followed was not the execution of a carefully crafted growth strategy, but rather a business evolving in response to customer needs. “What started as a predominantly export-focused business gradu- ally evolved into one serving customers throughout Southern Africa while continuing to support operations around the world,” explains Da Camara. “That growth was never really driven by a plan to become bigger. It was driven by customers placing their trust in us and giving
us the opportunity to support their operations.” Over the years, Caldas expanded its manufacturing capabilities, broadened its product range, and invested heavily in technical expertise and quality systems. Yet despite these developments, the com- pany’s philosophy has remained remark- ably consistent. “We’ve always believed that our role is to help customers succeed. The products are important, but they are ultimately a means to an end. What really matters is whether we are helping customers improve productivity, reduce downtime and operate more efficiently.” That philosophy has become increas- ingly important as the quarrying and crushing industries have evolved. Thirty years ago, many operators were focused primarily on securing reliable supply. Today, they face a far more complex operating environment. Rising costs, increasing pressure on productivity, sustainability requirements and height- ened competition mean customers are constantly looking for ways to do more with the resources they have available.
We’ve always believed that our role is to help customers succeed. The products are important, but they are ultimately a means to an end. What really matters is whether we are helping customers improve productivity, reduce downtime and operate more efficiently.
MODERN QUARRYING Quarter 2 | 2026 10
An industry transformed The quarrying and aggregates sector of 2026 bears little resemblance to that of the mid-1990s. Increasing pressure to maxi- mise productivity, reduce operating costs and improve sustainability has fundamen- tally changed customer expectations. Today’s operators are more data-driven and performance-focused than ever before. They expect suppliers to understand their operations and contribute meaningfully to plant efficiency and profitability. “The industry today looks very different to what it did 30 years ago,” says Rui Caldas, founder of the business in 1996. “Customers are looking for partners who understand their operations and can contribute to performance improvements, not simply sell a product.” For Caldas, adapting to these chang- ing expectations has required continuous investment in product development, technical expertise and customer support capabilities. Listening to customers has become a defining aspect of the company’s business philosophy. “The common thread throughout the last 30 years has been listening. Our customers have largely shaped the evolution of our business.”
SNAPSHOT
Founded in 1996, Caldas began with a clear objective: to provide reliable crusher wear parts and support to operators looking for a trusted alternative in the market.
Over the years, Caldas expanded its manufacturing capabilities, broadened its product range, and invested heavily in technical expertise and quality systems.
Increasing pressure to maximise productivity, reduce operating costs and improve sustainability has fundamentally changed customer expectations.
As Caldas looks towards the future, the company sees its 30 th anniversary not as a destination, but as a foundation for continued growth and improvement.
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blies, process equipment, modular crushing plants and screening solutions alongside its traditional wear parts and spares business. The transition was a natural one “For many years our role was helping customers keep their equipment running. Increasingly, customers began asking us to help them solve bigger operational challenges. Expanding into equipment solutions was simply the next step in supporting those customers.” This evolution reflects a broader belief within the company that success comes from understanding the customer’s entire operation rather than focusing on individual components. Whether supplying a wear part that delivers longer service life, a critical spare that prevents unplanned downtime or a complete crushing solution that enables a customer to enter a new market, the objective remains the same: creat- ing value for the customer. The company’s expansion into modular crushing solutions is a particularly good example of this philosophy in action. Across Southern Africa, many operators are looking for practical, cost-effective ways to expand production, improve flexibility and enter new markets. Modular and mobile solutions provide opportunities to achieve these goals while reducing implementation times and capital risk. “Customers are looking for equipment that is reliable, efficient and supported locally. They want solutions that help them grow their businesses with confidence. We see that as an opportunity to continue supporting customers in new ways. Customers will always remain at the heart of our offering,” says Caldas. Quality that performs in the field While products and technologies continue to evolve, one area that remains unchanged is Caldas’ commit- ment to quality. The company has invested signifi- cantly in manufacturing oversight, quality assurance systems, material development and operational feed-
Founded in 1996 and headed up by Rui Caldas, the company maintains an expert team with warehouse facilities in Johannesburg, Kwa-Zulu Natal as well as a soundly managed distribution network.
More than a parts supplier For years, Caldas built its reputation around crusher wear parts and mechanical spares. Those products remain central to the business and continue to play a critical role in helping customers maximise plant availability and productivity. However, customer requirements have expanded, and so too has the com- pany’s offering. Today, Caldas supplies crusher assem-
MODERN QUARRYING Quarter 2 | 2026 12
the greatest measure of success.” The company is equally proud of the employees who have contrib- uted to that success over the years. We have been fortunate to have dedicated people who genuinely care about our customers and our business. Many have devoted a significant part of their careers to Caldas, and their contribution cannot be overstated. The future As Caldas looks toward the future, the company sees its 30 th anniver- sary not as a destination, but as a foundation for continued growth and improvement. The next decade will see further investment in people, engineering expertise, equipment solutions and tech- nologies that help customers improve operational performance. Yet despite these developments, the company’s guiding philosophy remains unchanged. “Our vision is simple: continue earning the trust of our customers every day.” For a business that has spent three decades adapting to the needs of the industries it serves, that philosophy may well prove to be its greatest strength. After all, the story of Caldas Engineering has never really been about products. It has always been about people, partnerships and a commitment to helping customers succeed. l
solutions to suit specific customer requirements has become one of the company’s greatest strengths. Looking back, Da Camara believes one of the company’s most significant achievements is not measured by turnover, market share or product range, but by the relationships it has built. Perhaps the milestone we are most proud of is the number of cus- tomers who have remained with us for decades. In an industry built on trust, long-term relationships are
back processes. Decades of field experience have provided valuable insights into how products perform under real operating conditions. Every application teaches us something. The greatest classroom we have ever had is the field. The feedback we receive from custom- ers continually helps us improve. The importance of flexibility The same principle applies to flexibility. No two operations are identical, and the ability to adapt
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There are few aggregate operations in South Africa that combine production scale, technical sophistication and operational discipline as successfully as AfriSam’s Peninsula Quarry. Situated approximately 25 km north of Cape Town in the Tygerberg Hills, the quarry has earned a reputation as one of the busiest and best-run aggregate operations in the country, supplying large volumes of material into the Western Cape’s asphalt, ready-mix, building and civil construction sectors. Wilhelm du Plessis visited the site and experienced this premium quarry in operation. CRUSHING TARGETS, NOT SAFETY STANDARDS
Safety, operational discipline and continuous optimisation remain central to the way AfriSam manages every aspect of Peninsula Quarry’s operations.
D espite the scale of the operation and the relentless demand placed on the site, Peninsula Quarry’s defining characteristic is not simply its output. According to Works Manager Chris Kruger, the operation is built around a no-compromise philosophy when it comes to safety, environmental management and process optimisation. “At Peninsula Quarry, production is important, but it can never come at the expense of safety or oper- ational discipline,” says Kruger. “Everything we do is measured against those standards.” These principles are deeply integrated into the quarry’s daily opera- tions and influence everything from mine planning and traffic management through to crusher perfor- mance and water usage. For visitors to the quarry, the first impression is one of scale and organisa- tion. The large open pit descends in wide, carefully
engineered benches, while below, an extensive net- work of crushers, screens, conveyors and stockpiles operates in synchronised fashion to maintain produc- tion flow. However, behind the visible infrastructure lies an operation driven by meticulous planning, disci- plined execution and continuous optimisation. A quarry with a long history Peninsula Quarry has been operating since 1963, fol- lowing prospecting work carried out during the early 1960s on the farms Roozenboom, Welbeloond and Mont Blanc. Geological investigations identified significant deposits of hornfelsic quartzite and greywacke asso- ciated with the Malmesbury geological system. The quarry extracts what are referred to on site as “blue rock” and “brown rock”, both of which are well suited for aggregate applications due to their hardness and durability.
MODERN QUARRYING Quarter 2 | 2026 14
Mining currently progresses in a south- erly direction across 11 production benches, with the southern end of the pit reaching depths of approximately 110 m. Bench heights range between 10 m and 13 m, while some bench lengths extend up to 400 m. One of the operation’s key design advantages is the long-bench layout, which allows both blue and brown rock to be mined simultaneously from the same bench. “The bench layout gives us the flexibility to manage material flow far more efficiently,” he explains. “It allows us to optimise blend- ing while minimising unnecessary move- ment of equipment.” Large-scale production capability Peninsula Quarry’s installed crushing and screening infrastructure is designed to produce approximately 1,2 million tonnes of aggregate annually, placing it among the country’s highest-volume hard-rock aggre- gate quarries. The operation runs multiple crushing circuits configured to maximise throughput while maintaining product quality and operational flexibility. Primary Plant A consists of a 38/48 Osborn jaw crusher fed by apron feeder and supported by a Sandvik H6800 cone crusher. Material is delivered to the plant by 35 t articulated dump trucks operat- ing at feed rates of approximately 450 t/h. Primary Plant B incorporates a 30/42 Osborn jaw crusher with vibrating grizzly feeder, together with a Sandvik CH440 cone crusher and a VSI crusher. Operating at feed rates of roughly 250 t/h to 275 t/h, this circuit produces a wide range of products including G1 to G7 layer-work materials, 20 mm concrete stone and road stone products. The inclusion of the VSI crusher is par- ticularly important for improving particle shape in concrete aggregate applications, where cubical stone plays a major role in achieving quality concrete performance. Further downstream, the tertiary plant includes multiple screens, Sandvik H4800 and H3800 cone crushers and a Barmac VSI crusher to produce aggregate fractions ranging from 7 mm through to 53 mm con- crete stone. Additional infrastructure includes a sand plant, washing plant and an onsite AfriSam ready-mix facility, all of which contrib- ute towards improving product value and reducing waste. Kruger notes that there are already plans under consideration to increase produc- tion capacity even further in response to
Peninsula Quarry’s integrated approach to mining, crushing and material handling supports consistent production performance across its extensive aggregate operations.
AfriSam’s Peninsula Quarry demonstrates how world-class aggregate production can successfully coexist with strong environmental performance, maintenance discipline and uncompromising safety standards.
SNAPSHOT
Mining currently progresses in a southerly direction across 11 production benches, with the southern end of the pit reaching depths of approximately 110 m.
Peninsula Quarry’s installed crushing and screening infrastructure is designed to produce approximately 1,2 million tonnes of aggregate annually, placing it among the country’s highest-volume hard-rock aggregate quarries.
Additional infrastructure includes a sand plant, washing plant and an onsite AfriSam ready-mix facility, all of which contribute towards improving product value and reducing waste.
Process simulation software, including AggFlow, is used to model production circuits and evaluate potential improvements before modifications are implemented in the plant.
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MODERN QUARRYING Quarter 2 | 2026
Peninsula Quarry’s carefully engineered bench layout supports efficient extraction of both blue rock and brown rock materials from the same production areas.
2,8 m. These blasting parameters have been refined over time to achieve optimal fragmentation for both primary crushing cir- cuits. Oversized material can create bottlenecks throughout the processing chain, increasing wear on crushers and reducing overall efficiency. Maintaining consistent fragmentation therefore plays a major role in controlling operating costs and sustaining production levels. Kruger emphasised that Peninsula Quarry evaluates the entire production process as an integrated system rather than a series of separate activities. “What happens at the blast face ulti- mately affects every part of the plant downstream,” he says. “If fragmentation is consistent, the entire process becomes more effi- cient and more predictable.” Technology driving productivity Technology and data-driven oper-
growing market demand. “The demand for quality aggregate in the Western Cape remains strong,” he says. “We are evaluating addi- tional modular plant solutions that will allow us to expand production capacity in a flexible and efficient manner as demand increases.” Optimisation begins at the blast face According to Kruger, efficient pro- duction at Peninsula Quarry starts long before material reaches the crushing plant. “Drill-and-blast design is regarded as one of the most important aspects of the operation because fragmentation quality directly influences down- stream crusher performance, wear rates, fuel consumption and plant throughput,” he says. The quarry uses 115 mm blast holes with burden and spacing parameters of approximately 3,9 m x 4,3 m and stemming lengths of
ational management play a major role in maintaining Peninsula Quarry’s efficiencies. The opera- tion continuously measures plant availability, throughput, payload performance and equipment turnaround times. Load-and-haul activities, drilling and blasting and product delivery are outsourced, but contractor performance is closely managed through ser- vice-level agreements and ongoing monitoring. One of the more interesting operational controls is the quar- ry’s strict fleet-age policy. Mining and dispatch equipment are generally not permitted to exceed 15 000 operating hours, ensuring high reliability levels while reduc- ing downtime and maintenance risks. Within the plant itself, optimi- sation efforts focus heavily on crusher closed-side settings (CSS), choke feeding conditions and screen media selection. Even relatively small changes in CSS can affect product grading, recirculating loads and throughput efficiency, making precise control essential for stable production. The quarry has also introduced split-bearing arrangements in key plant areas to reduce main- tenance downtime. Unlike con- ventional bearings, split bearings simplify replacement procedures and minimise the amount of
Drill-and-blast design is regarded as one of the most important aspects of the operation because fragmentation quality directly influences downstream crusher performance, wear rates, fuel consumption and plant throughput.
MODERN QUARRYING Quarter 2 | 2026 16
environmental performance at the Institute of Quarrying. Environmental management integrated into operations Environmental management at Peninsula Quarry is treated as a core operational function rather than a compliance exercise. The operation conducts continuous monitoring of dust fallout, water quality and boundary noise lev- els through formal monitoring programmes. Stormwater man- agement infrastructure across the quarry includes diversion channels, catchment systems, settling dams and runoff control structures designed to minimise environmental impact both within and beyond the mining area. Water efficiency has become an increas- ingly important focus area, particu- larly following the severe Western Cape drought of 2017. During that period, Peninsula Quarry reduced municipal water consumption by approximately 85% by switching its ready-mix operations to the use of quarry pit water. Fuel, electric- ity and water consumption are all closely monitored as part of AfriSam’s broader sustainability reporting structures. Setting the benchmark What ultimately distinguishes Peninsula Quarry is the consis- tency with which every part of the operation is managed. The quarry’s ability to maintain exceptionally high production volumes while simultaneously focusing on safety, environmental stewardship, main- tenance discipline and technical optimisation reflects a level of operational maturity developed over decades. For Kruger and his team, success is not measured only in tonnes produced, but in the ability to achieve those volumes safely, efficiently and responsibly. In an industry where production pres- sure often challenges operational discipline, AfriSam’s Peninsula Quarry continues to demonstrate that world-class aggregate production and uncompromising operational standards can suc- cessfully coexist. l
Wilhelm du Plessis, Editor of Modern Quarrying (left) and Works Manager, Chris Kruger.
Peninsula Quarry continuously monitors plant performance, throughput and equipment efficiency to support reliable, data-driven production management.
dismantling required during maintenance shutdowns. Process simulation software, including AggFlow, is used to model production circuits and evaluate potential improvements before modi- fications are implemented in the plant. Additional technologies include high-efficiency electric motors and extensive camera installations on both earthmoving equipment and plant infrastructure to improve visibility, operational monitoring and safety performance. Safety remains the overriding priority Despite Peninsula Quarry’s enormous production demands, safety remains the operation’s central priority. Kruger describes the quarry’s safety culture as uncompromising, particularly given the constant interaction between heavy mining equipment, contractors, plant personnel and dis- patch traffic. The operation has implemented extensive traffic management sys- tems incorporating segregated pedestrian walkways, designated vehicle routes, controlled access points and clearly defined speed management measures. Behavioural safety initiatives form an equally important part of the quarry’s approach. Toolbox talks, safety campaigns, safety coach- ing programmes and management visibility initiatives are used continu- ously to reinforce safe working practices and identify unsafe behaviour before incidents occur. “A quarry environment is inherently high-risk, so there can never be complacency,” says Kruger. “Safety awareness has to remain constant, whether you are in the pit, the plant or the dispatch area.” The quar- ry’s commitment to operational discipline extends beyond safety alone. Peninsula Quarry has achieved 100% compliance against its EMP audit requirements and received the ASPASA Environmental Award for best
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Situated near Malmesbury in the Western Cape, AfriSam’s Rheebok Quarry has established itself as one of the region’s key aggregate suppliers, producing high-quality crushed granite for major road-building and infrastructure projects throughout the province. Under the leadership of Acting Quarry Manager Luca Clayton, the operation has evolved into a technically focused quarry that combines high production volumes with carefully controlled mining and processing methodologies designed specifically around the challenges of an exceptionally competent granite resource. Wilhelm du Plessis visited this quarry. BALANCING GEOLOGY AND PRODUCTION
production aspects of quarrying operations. High-demand operation supporting regional infrastructure Rheebok Quarry traditionally produces between 250 000 t and 300 000 t of aggregate annually which includes stone, crusher sand, base, sub-base, roadstone and ballast. However, the accelera- tion of infrastructure activity in the Western Cape - particularly around the Malmesbury bypass and N7 upgrades - resulted in unprec- edented demand during 2025. According to Clayton, the quarry exceeded 700 000 t of sales during the year, forcing the operation to move onto continuous 24-hour production schedules over four- day operating cycles in order to satisfy customer requirements. The operation supplies mate- rial into municipal infrastruc- ture projects as well as major
C layton, who has spent close to three decades within the business, brings extensive operational experience to the role. Having
progressed from assistant roles through maintenance, electrical work, production supervision and operational management, he possesses a strong understanding of both the mechanical and
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Extremely competent granite creates fragmentation challenges The defining technical characteris- tic of Rheebok Quarry is the nature of its granite deposit. While the rock produces excellent aggregate products, it is extremely compe- tent and resistant to fragmentation during blasting. This creates one of the quar- ry’s most significant operational constraints. Even with carefully designed blast patterns and initiation systems, the granite frequently produces oversized boulders that cannot be handled efficiently by the primary crushing circuit without additional secondary breaking. As a result, secondary rock breaking has become a permanent and essential component of the operation rather than an occasional support activity. Rheebok currently operates two hydraulic peckers dedicated to reducing oversized material after blasting. These machines work continuously on blasted rock piles, breaking large boulders into sizes suitable for loading and primary crushing. The presence of the two peckers is not simply a convenience but a production necessity. Without them, excessive oversize material would soon create bottlenecks in the load- and-haul cycle, restrict crusher feed consistency and significantly reduce plant throughput. “The fragmentation is the big- gest challenge,” explains Clayton. “Because of the type of granite, the blasts generate large boulders and the peckers therefore become criti- cal to the operation.” Balancing blast performance and environmental control Blasting at Rheebok requires par- ticularly careful engineering due to both the geology and the quarry’s proximity to surrounding infra- structure and communities. The operation cannot simply increase powder factors aggres- sively in an attempt to improve frag- mentation because vibration control remains a critical consideration. Blast designs therefore need to strike a balance between sufficient
SNAPSHOT
Rheebok Quarry traditionally produces between 250 000 t and 300 000 t of aggregate annually which includes stone, crusher sand, base, sub-base, roadstone and ballast.
Rheebok currently operates two hydraulic peckers dedicated to reducing oversized material after blasting.
Blasting at Rheebok requires particularly careful engineering due to both the geology and the quarry’s proximity to surrounding infrastructure and communities.
Drone-assisted survey technology has become increasingly important in this process. Rheebok uses drone mapping and photogrammetry software to conduct volumetric surveys, monitor pit progression and improve stockpile management accuracy.
indicate that the quarry retains a minimum life-of-mine estimate of approximately 30 years, with the possibility of significantly extend- ing this as additional reserves are opened and future mining areas are developed.
SANRAL-linked road developments. The abrasive granite produced at Rheebok is particularly well suited to road construction applications because of its durability, hardness and resistance to wear. Recent reserve evaluations
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MODERN QUARRYING Quarter 2 | 2026
Carefully engineered mining and processing methodologies allow Rheebok Quarry to efficiently manage an exceptionally competent granite resource.
energy distribution for acceptable fragmentation and controlled ground vibration levels that remain within regulatory and operational limits. Electronic initiation systems and carefully sequenced blast timing are used to optimise energy release and improve fragmentation consistency where possible. Even with refined blasting practices, the granite’s natural competency still results in substantial secondary breaking requirements. The quarry’s drill-and-blast contractor works closely with site management to continuously refine blast designs based on observed fragmentation performance, bench conditions and downstream plant requirements. Pit development and mining strategy Current mining activities focus heavily on opening new working areas and exposing additional reserves for future extraction. According to Clayton, one of the operation’s ongoing challenges is maintaining sufficient open working faces while simultaneously managing the large volumes of oversize blasted material generated during mining. Bench development requires con- tinuous stripping, scaling and selec- tive loading practices. In many areas,
Secondary rock breaking plays a critical role at Rheebok Quarry to manage oversized blasted material and maintain efficient plant throughput.
Rheebok Quarry supplies high quality crushed granite into major road-building and infrastructure projects across the Western Cape.
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and screening plant. Wear rates on liners, crusher components and screen media are naturally higher than at operations processing softer rock types, requir- ing ongoing maintenance attention and disciplined shutdown planning. Clayton says that recent plant upgrades have focused on main- taining throughput reliability while improving maintenance efficiency. The quarry recently replaced sec- tions of its wash plant and continues evaluating additional crushing circuit improvements aimed at increasing throughput and product flexibility. Feed consistency remains partic- ularly important because irregular feed sizes from oversized blasted rock can destabilise crusher perfor- mance and reduce plant efficiency. The peckers therefore play a major role not only in reducing oversize but also in maintaining more consistent crusher feed gradation. Production growth supported by operational discipline While Rheebok has experienced significant production growth, Clayton emphasises that opera- tional discipline and safety man- agement remain non-negotiable priorities. Daily toolbox talks, production meetings, shift handovers and continuous supervisory engagement form part of the quarry’s operational culture. Camera systems installed on equipment and within operational areas have also improved operator awareness and machine monitoring, contributing to both production effi- ciency and safety management. As Rheebok Quarry continues expanding its mining areas and refining its production systems, the operation remains a strong exam- ple of how technical adaptation and disciplined quarry management can overcome difficult geological conditions. At Rheebok, productivity is not achieved through easy mining conditions, but through engineering solutions that allow a highly compe- tent granite resource to be mined, processed and supplied efficiently into one of South Africa’s busiest construction markets. l
Integrated camera technology at Rheebok Quarry assists with monitoring operational areas, enhancing both safety management and production visibility.
Strong operational discipline, continuous supervisory engagement and a safety-focused culture underpin daily activities at Rheebok Quarry.
oversized granite blocks must first be reduced by peckers before material can even be removed from the active mining zone. The operation is also strategically pushing back selected pit sections in order to create improved access to deeper reserves and establish more efficient long-term mining layouts. These pushbacks are important not only for reserve access but also for improving operational flexibility and reducing congestion in active mining areas. Drone-assisted survey technology has become increasingly important in this process. Rheebok uses drone mapping and photogrammetry software to conduct volumetric surveys, monitor pit progression and improve stockpile management accuracy. Compared with conventional survey techniques, drone technology has sig- nificantly reduced the time required for volume calculations and mine planning updates while improving data accuracy. Crushing circuit under pressure The granite’s abrasive nature places continuous pressure on the crushing
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