Free State fleet
Bloem Contract Fleet
Kit handoff between two contract sites in one week.
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Fleet swap on the Bloemfontein contract sites
In the Free State, two mobile crushing and screening fleets were due for a kit handover in a single working week. One site was wrapping up a high-volume contract at the edge of the Karoo, while the incoming team had to be up and running at the new pit just outside town. The plant made use of jaw crushers with older manganese profiles, a cone with a shallow chamber, and a VS impactor that had run through its last set of tips. With variable feed and heavy fines from the previous campaign, there was clear uneven wear on jaw plates and concaves. Both sites needed reliable turnaround so that production losses were kept to a minimum.
Supplying wear parts and managing the changeover
We organised a pre-packed consignment for the bakkie run between the two plants. The kit included replacement jaw plates in OEM profile for the 1100 by 700 mm unit, fresh cone mantles and concaves with a mid-range closed side setting profile, and a set of martensitic blow bars with ceramic inserts for the impactor. Screen mesh was swapped out for modular polyurethane panels, given the high sand content and frequent Eskom power cuts, aiming for less downtime on maintenance. All supplied parts were marked with batch codes for traceability and came with lifting lugs. Our team assisted with safe changeout in the yard, using correct lockout procedure and torqueing liner bolts with a calibrated wrench, as per the OEM manual. The toggles were inspected and replaced where wear was excessive, acting as a fuse against tramp metal events.
- Pre-packed wear kit by crusher model
- Batch-coded parts for tracking
- Safe changeout with lockout and correct bolt torque
- Upgrade to polyurethane screen media
- On-site advice for feed distribution and choke feeding
Ongoing best practice and lessons for next time
After the kit change, the plant team maintained daily wear checks, kept records of liner life and made sure feed was evenly distributed to maximise chamber performance. Screen tension was closely monitored and tramp magnets checked before every shift. The team followed up with us on wear profiling, sending photos for future campaign planning. In hindsight, we would coordinate more closely with the transport contractor to avoid delays when moving heavy liner sets across provincial borders. For future swaps, a better handover checklist and advance notice on backing compound requirements would provide a smoother transition between sites.
- Daily liner and screen inspection
- Regular feed and chamber profiling
- Feedback loop for campaign planning
- Better logistics coordination recommended
- Advance check on consumables before next move
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