The magazine of Hitachi Construction Machinery (Europe) NV ...ultra-large Hitachi EX8000-6 mining...

GROUNDCONTROLIssue 14 Autumn 2012 www.hcme.com

The magazine of Hitachi Construction Machinery (Europe) NV

Coal mining in MozambiqueBelow-ground construction in the UK First Zaxis-5 excavators working in Europe

THE MINING GIANTS

www.hcme.com

Hitachi Construction Machinery (Europe) NV02

Ground Control is published twice a year and is circulated among 100,000 readers. Hitachi Construction Machinery (Europe) NV, Siciliëweg 5, 1045 AT Amsterdam, The Netherlands Telephone: +31 -(0)20 44 76 700Fax: +31 -(0)20 33 44 045E-mail: [email protected]: www.hcme.comEditor: Hitachi Construction Machinery (Europe) NV: Ghislaine JonkerCo-ordination: Somacon, www.somacon.nlEditorial and design: Red International Communication, www.redinternational.co.ukPhotography: Glenn Blackburn, www.glennblackburn.co.ukTranslation: UvA Talen, www.uvatalen.nlPrinting: Roto Smeets GrafiServices, www.rsgrafiservices.nlCirculation: Vogelaar Verzenders BV, www.vogelaarverzenders.nl

© Hitachi Construction Machinery (Europe) NV (HCME). All rights reserved. Reproduction in whole or in part is forbidden except with the written permission of HCME. While every effort is made to ensure the accuracy of information published in Ground Control, HCME is not responsible for inaccuracies or omissions. All views expressed are not necessarily those of HCME. The manufacturer is not responsible for non-compliance to industry-standard health and safety measures by third parties, nor for any damage or loss resulting from anyone’s reliance on editorial and photography in Ground Control.

The magazine of Hitachi Construction Machinery (Europe) NV CONTENTSIssue 14 Autumn 2012 www.hcme.com

GROUNDCONTROL

04 NewsExplore Hitachi construction machinery from around the globe as well as all the

latest exhibition and new product news

10 A world of experienceNew HCME President and CEO, Mr Moriaki Kadoya, reveals that this is his

second appointment in The Netherlands

12 Large-scale supportFind out what it takes to transport, assemble, operate and maintain the

ultra-large Hitachi EX8000-6 mining excavator

18 Zaxis-5 put to the testThe first Zaxis-5 excavators have been released into Europe and Ground

Control asks the operators for their first impressions

22 Urban legendsTwo British companies, the Carey Group and M O’Brien Plant Hire, are making

the most of Hitachi clamshell telescopic excavators

26 The drive for electric powerA fleet of EH3500ACII dump trucks operating on a trolley assist system is

helping to transform the Kansanshi mine in Zambia

30 Focusing on customer solutionsNasta is celebrating its 30th year as the Norwegian Hitachi dealer with a new

identity and headquarters, and some recognition for its achievements

34 Mobile lifting powerIntroducing Hitachi Sumitomo and the advantages of using crawler cranes on

different job sites in The Netherlands and Belgium

The tourist trade in Eilat, Israel, is booming thanks to the support of

construction company, S Noufi and Sons

[email protected]

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NEWS

04 Hitachi Construction Machinery (Europe) NV

Another first for HitachiThe first Hitachi hybrid excavator has been presented to the European market. Developed using decades of experience in hydraulic, battery-powered and electric excavator technologies, the ZH200 model was presented earlier this year at the Intermat exhibition.

Better for the environment, easier for the operator and more economical for the owner, the ZH200 hybrid heralds the start of a new generation of Hitachi excavators. It is equipped with a high-performance TRIAS HX system – a combination of a hybrid system with the energy-efficient TRIAS hydraulic system. This reduces fuel consumption and CO2 by 20 per cent (fuel consumption is compared with the ZX210-3 in P-mode).

The excavator’s user-friendly design incorporates a monitoring system, which highlights fuel usage on an average hourly and daily basis. It also features low maintenance and highly durable electrical components.

Yusuke Kajita, General Manager of the Construction Equipment Development Centre at Hitachi Construction Machinery Co., Ltd., says: “Technically advanced machines make Hitachi stand out from the crowd. Advanced technology is necessary to maintain our position in the market – not just for the hydraulics and engine, but also for electrical technology.

“Hitachi is the biggest electrical products manufacturer in Japan and so we are very strong in this area. So, when fossil fuels are in short supply and become more expensive, electrical technology will be the key to the future and we will be in an excellent position to capitalise on this.”

Hitachi launches ZW250-5 wheel loaderFollowing the successful launch of its Zaxis-5 excavators, Hitachi has unveiled the first of its ZW-5 wheel loaders. The new ZW250-5 has been designed to comply with EU regulations on emission standards and satisfy the requirements of European customers. It offers an exceptional level of comfort, excellent productivity, advanced technology, and a range of features for enhanced sustainability, safety and easy maintenance.

The cab is more spacious than the previous model and it has greater visibility thanks to a pillar-less windshield and large sun visor. The 7.8-litre six-cylinder water-cooled turbo engine enables a powerful digging performance, impressive travel speeds and excellent fuel consumption.

An example of its advanced technology is the quick power switch, which boosts the power when required by changing work modes. One work mode is for regular operations, with the benefit of efficient fuel consumption; the other is for more demanding jobs and increases productivity.

The sustainability of the ZW250-5 is highlighted by the muffler filter. It captures air pollutants, which are automatically burnt thanks to an oxidation catalyst and exhaust temperature control. Easy maintenance features include the redesigned engine and radiator cover, which can be opened fully to provide quick access for daily inspection.

Wilbert Blom, HCME International Sales, says, “We believe that the new ZW wheel loader not only meets our customers’ expectations of high quality and reliability, but also provides a safe working environment, a comfortable cab with easy-to-use controls, and overall, a machine that responds quickly and precisely.”

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Unique paint process for factoryHitachi Construction Machinery (Europe) NV (HCME) has implemented a unique process to reduce chemical waste from the painting process at its factory in Amsterdam. Developed in cooperation with Advantage Chemicals Ltd., the process will save an estimated €60,000 per year on labour and energy costs, as well as disposal costs for waste water and sludge.

The old painting process produced approximately 260 tonnes of waste per year. The paint would sink to the bottom of the pool of water beneath the paint facility. Twice a year, the pool had to be cleaned, and the water and paint had to be removed, which was costly in terms of labour, energy, water and waste removal.

HCME Production Engineering Manager Robin Huijsman, who is also Compliance Officer for Environmental Regulation, says, “Cleaning the pool was a difficult and dirty job. With the new system, we are able to remove the overspray paint and reuse the water. The facility is cleaner and the filtering system that removes paint particles from the air functions better. Less solvents are released into the factory air and there is less dust.”

The new process combines real-time CoAg (coagulation) systems with waste water treatment systems. Instead of sinking, the paint is suspended in the water and pumped to a waste treatment tank. “Advantage Chemicals developed a chemical that makes the paint float. What is really innovative is that we only need to run this process for four hours per month,” adds Robin.

“The floating paint sludge is then skimmed off the top of the tank and is estimated at 30 tonnes per year. The new system has improved the overall carbon footprint of the HCME factory in Amsterdam.”

Zaxis-5 range unveiled at TKDThe biennial TKD (Technische Kontakt Dagen) event took place in Wezep, The Netherlands in June. The three-day exhibition is one of the most important for the domestic market of Hitachi Construction Machinery (Europe) NV (HCME). It allows visitors to test drive construction machinery on display and make comparisons between competitive products.

HCME and its domestic dealer took the opportunity to present the new Zaxis-5 excavators to the Dutch market. Several models were on display, including the ZX250LC-5, ZX290LC-5, ZX350LC-5 and ZX470LCH-5. The manufacturer also showcased the ZX250LC-5 with a 15-metre super long front and a ZX470LCH-5 with a 25-metre demolition front.

Dutch owners and operators were drawn to the Hitachi stand by two other special attractions: the new ZW250-5 wheel loader and the ZH200 hybrid excavator. Both were on display in The Netherlands for the first time. In addition, the ZX60USB-3 mini excavator, ZX145W-3 wheeled excavator and the ZW150 wheel loader were available to test drive and proved extremely popular among visitors.

Director of Domestic Sales Pieter Weerts was pleased to see many existing Hitachi customers at this year’s TKD and delighted with the response to the stand: “The exhibition has been a huge success once again, with 20,000 visitors. I think people were particularly impressed by the Hitachi stand because it was spacious, with lots of machines to try out and one of the few to show larger machines over 25 tonnes at work.”

Developed to protect the investment made by customers in Hitachi construction machinery, the Support Chain after-sales programme contributes to efficient fleet management, minimal downtime and reduced running costs.

One of the links in the chain is Global e-Service, an online application that allows customers to monitor their machines remotely. It is available as standard for Zaxis excavators and ZW wheel loaders, and is optional for large EX mining excavators and EH mining dump trucks. The machines send operational data on a daily basis via GPRS or satellite to a main server managed by Hitachi. The data is then processed and made available to view in a clear, accessible way on the Global e-Service website.

Customers and dealers can visit the website at any time to view a variety of information. This includes operational data, such as working hours, pressures, temperatures and payloads, as well as fuel levels and consumption figures, CO2 emission data, recommended service and inspection intervals, maintenance history and the geographical location of each individual model.

Fuel consumptionThe fuel consumption figures are particularly useful for French customer Moulin TP, a company that specialises in public works (groundworks, utilities, foundations, road construction), quarrying, waste management, recycling and forestry. It currently has two Hitachi excavators, a ZX520-3 and ZX350-3 used for public works, and a ZX500 excavator and ZW310 wheel loader working in the Trevas granite quarry. All were supplied by its local official Hitachi dealer, Teramat.

Regis Moulin, the founder and CEO, says, “I use Global e-Service to verify the fuel consumption, and number of hours a machine has operated. This helps me to easily ensure optimal performance of my Hitachi machines.”

As well as daily fuel consumption, the Global e-Service facility also shows the estimated lifetime consumption of that machine


NEWS

and can calculate an average over a self-defined period. This is particularly useful at a time when fuel prices are rising steadily.

From an environmental perspective, Global e-Service can also highlight the CO2 emissions of an individual Hitachi machine, as well as indicate hours of idling. This kind of information is increasingly important as local legislations are placing further restrictions on excessive emissions.

Maintenance schedulingCustomers like Moulin TP also use the Global e-Service website to store details of completed and forthcoming maintenance services, to assist with the planning of each machine’s utilisation and ordering spare parts. “As well as accessing daily information, I also look up statistical information from when the machine has been in operation,” says Regis.

Any maintenance work carried out by Teramat, the official Hitachi dealer, is entered on the machine’s computer and recorded on Global e-Service the following day. Regis can therefore download lists of daily inspections, and periodical or preventive maintenance for each of his machines, saving valuable time in planning and storing this information for the fleet.

Location tracking and monitoringWorking across varied industry solutions and in different locations at any one time makes planning essential for the successful operation of companies like Moulin TP. The Global e-Service website displays the locations of each individual machine using either Google Maps or GIS (Geographical Information System). The latter also allows customers to trace multiple machines by specific search criteria, and track and display movements of machines over a period of time.

The Global e-Service is therefore an essential tool, ensuring Hitachi equipment performs at the highest level, and making life easier for fleet managers and machine owners all around the world.

Regis Moulin, the founder and CEO of Moulin TP Global e-Service helps Moulin TP to manage its fleet

Global e-Service – an essential tool

A special landmark for HCMEThis year marks the 40th anniversary of Hitachi Construction Machinery (Europe) NV (HCME). Established in Oosterhout in 1972, the company moved its manufacturing, sales and marketing headquarters to Amsterdam in 2002. This location now includes a factory for the construction of medium excavators, assembly of wheel loaders, and a Training and Demonstration Centre. Mini excavators and special application equipment are manufactured in Oosterhout, which is also the location for the European Distribution Centre.

During the past four decades, HCME has established a strong network of dealers and liaison offices throughout Europe, Africa, the CIS and the Middle East. The company mission to ‘think global, act local’ has been reflected by its focus on customer needs and supported by the Hitachi brand values associated with innovation and technology.

HCME has witnessed a steady growth in demand for Hitachi construction machinery across all territories over the years. Since 2002, for example, the total market share for excavators up to six tonnes has doubled; and the total market share for wheel loaders has tripled.

New President and CEO, Mr Moriaki Kadoya, is delighted to join the company as it celebrates such an important milestone. “We will be celebrating HCME’s 40th anniversary at different events with our colleagues, dealers and customers,” he says.

“We can feel proud of our long history in The Netherlands and Europe. However, we wouldn’t have enjoyed such success without our customers – so it’s a big thanks to them from all of us for their support.

“We are delighted with how our business has continued to thrive and Hitachi is here to stay in Europe. Our ongoing commitment to our customers is to improve our business activities so that we can continue to help them to be profitable.”

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Mr Kadoya outside HCME’s Amsterdam headquarters

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NEWS Relentless ZW250 cuts fuel costsSwedish-owned Södra Cell is one of the world’s leading manufacturers of paper pulp. One of its facilities is Södra Cell Folla, a pulp mill located in Verran, central Norway. It produces pulp for manufacturing milk cartons, tissue and printing paper. Three years ago, when it needed a new wheel loader, four leading brands were tested. Nasta, the official Hitachi dealer in Norway, offered the ZW250 together with a full service contract.

After three years of operation, the machine has 15,500 working hours and 86,000km on the clock. With the ZW250, the company has managed to reduce fuel consumption by up to 25 per cent, compared with the wheel loader it replaced. Fitted with a 15m3 bucket, the Hitachi wheel loader transports wood pellets and sawdust around the mill in three shifts per day, seven days a week, and travels up to 180km in 24 hours.

Kjell Sørensen, who is responsible for wheel loader sales at Nasta, says: “The most important benefit of the ZW250 wheel loader for this customer is the 20 to 25 per cent reduction in fuel consumption. Another advantage is the optional limited slip differential, which delivers effective driving force to both wheels for greater traction on snow-covered roads.”

Tore Andreas Norum, supervisor and operator at Södra Cell Folla, adds: “We are delighted with the performance of the ZW250 – it is a powerful, fast machine, and it never stops. After three years and 15,500 hours, it works like new!”

Hitachi tackles climate changeThe Japanese Government has donated four medium Hitachi excavators to the Republic of Cape Verde. The four ZX210H-3Gs were delivered to the Ministry of Environment, Rural Development and Marine Resources in December 2011. They will help the country to recover from natural disasters such as hurricanes, volcanic eruptions, droughts and floods.

The machines began operation in January 2012 on four islands: Praia, São Nicolau, Santo Antão and São Vicente. The ZX210H-3Gs were chosen from a variety of models because they offer an ideal size/performance ratio. The official Portuguese Hitachi dealer, Moviter, provided training for the operators, and will continue to support the machines with periodic service and maintenance checks.

“The people of Cape Verde are very happy with the performance of the products,” says Moviter Service Manager Luis Bertão. “They are also satisfied with the support and training they have received from Moviter.”

This is the first time that Hitachi excavators have been delivered to the Republic of Cape Verde as part of an Official Development Assistance programme run by the Japanese Government. The programme aims to improve the capabilities of countries worldwide to cope with natural disasters caused by climate change.

As well as construction equipment, the Japanese Government has donated trucks, mobile workshops, ambulances and generators, for example, to countries in Africa, the Middle East, Asia, South and Central America. As part of the programme, Hitachi products will also be delivered to Ghana, Benin, Burkina Faso, Burundi, Gambia, Kenya, Malawi, Mauritania, Senegal, Togo and Uganda.

Moviter Service Manager Luis Bertão (centre) with the operators

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Ground-breaking investment in IsraelSix Hitachi EH3500ACII rigid dump trucks have been delivered to a phosphate mine in Israel. The order by Rotem Amfert Negev Ltd represented the largest sale of mobile plant equipment in the country’s history.

The multinational company manufactures phosphoric acids, fertilisers, specialty chemicals and phosphate salts. It required the new models to update its fleet of Euclid trucks. They are used to remove overburden, and haul the phosphate to storage areas, crusher and processing plant at the Mishor Rotem Mine, near the Negev Desert.

The handover ceremony in April was attended by representatives from the customer and its parent company, ICL. Senior management from Hitachi Construction Machinery (Europe) NV (HCME) and Hitachi Construction Machinery Co., Ltd. (HCM), also joined the key personnel from CMD, the official Hitachi dealer in Israel.

Kiyomitsu Yamanaka, Special Advisor for HCM, said: “Since HCM gained ownership of Euclid in 2001, it has introduced new AC drive technologies, as seen in the EH3500ACII. These and other innovations will enable Hitachi to become further established as a world leader in the design and production of large mining trucks.”

HCME Manager of Heavy Equipment Sales Malcolm Edwards says, “Rotem chose Hitachi because it could offer its own electronics for the truck’s electronic drive system – it is a one-stop shop. They also saw the successful operation of the EH3500ACII trucks working at the Talvivaara nickel mine in Finland in temperatures of -32°C. Additionally, they have a good working relationship with CMD and are happy with the support they receive.”

HCME and CMD provided training for 90 operators, who will keep the trucks moving 24/7. “The trucks are scheduled to complete 6,400 working hours a year, doing three shifts per day,” adds Malcolm.

Hitachi holds the key for UK rental marketA customer of HM Plant, the official UK Hitachi dealer, has invested in 68 new Zaxis excavators this year. Keyway, based in Gloucester, ordered a range of models, from the ZX17U-2 to the ZX210LC-3. The company was established in 1966 and specialises in operated and self-drive plant hire.

The founder’s two sons, Eamonn and Brian McGurk, and grandsons, Eamonn Jr and Patrick, are now responsible for the company and are supported by several other family members, including Brian’s sons, Ryan and Gearard. “Keyway specialises in long-term hires and offers customers excellent rates and a bespoke service,” says Eamonn. “We can be working on 50 to 100 job sites a day, with anything from one machine to a huge fleet operation.”

The company has been buying Hitachi machines for more than 17 years and the decision to invest in the new models was based on several factors. “Hitachi is recognised in the industry as a top brand, the advanced technology is unsurpassed, and they’re reliable, durable and easy to operate,” adds Eamonn.

The cost of ownership and resale value are additional benefits, explains Brian: “We replace our machinery after three years and at the end of their life cycle with Keyway, Hitachi models sustain the best values on the market.”

“The reliable support we receive from HM Plant is also important,” says Eamonn. “They have continued to raise their game over the years and offer us an improved level of service.”

HM Plant Operations Director Andy Baker (left) and Keyway’s Eamonn McGurk


Interview

A WORLD OF EXPERIENCEMr Moriaki Kadoya took up his post as the new President and CEO of Hitachi Construction Machinery (Europe) NV (HCME) in Amsterdam at the beginning of May. In addition, his appointment as regional CEO for Europe, Russia, CIS, Middle East, and North, West and Central Africa is a true reflection of the vast experience he has gained from his previous roles within Hitachi Construction Machinery Co., Ltd. (HCM)

Mr Kadoya is no stranger to The Netherlands, having previously worked as HCME’s Sales and Marketing General Manager from 1992 to 1998. However, his varied career with HCM started in 1981 after graduating in Economics from Keio University in his native Japan.

For the first five years, Mr Kadoya worked in the Overseas Sales Department, where he gained responsibility for Africa and then Europe. He moved to the Overseas Cooperation Department in 1986, where his experience broadened with the initiation of the Fiat (Europe) and John Deere (USA) joint ventures, as well as setting up overseas subsidiaries.

After returning from his assignment at HCME, Mr Kadoya took on managerial roles in the Finance Department and Corporate Planning Office up to 2002. The former gave him a firm grasp of the principles of accountancy, while the latter offered an invaluable insight into the company as a whole.

His first posts as General Manager were two-year stints in the Supply Chain Management Office – an extension of his previous role in Corporate Planning – and the Sales Administration Department to coordinate HCM’s sales and production processes. Finally, Mr Kadoya returned to sales and marketing for six years in the

Americas Department, where he managed the strategic relationship between Hitachi and John Deere.

This firm grounding and international experience will stand Mr Kadoya in good stead for his new role with HCME. In an exclusive interview, Ground Control asks him about his past career, current priorities and future developments after a busy opening period at HCM’s European subsidiary.

What do you see as the major developments in the construction industry during your career?For the first 20 years, there were no emerging markets in the global construction industry. North America, Japan and Europe accounted for 70 to 80 per cent of worldwide demand. Now, the Chinese market is very important and the Korean manufacturers are competitive. Mining has also become a significant industry solution. So, the whole landscape of the construction industry has changed and the “emerging” territories now account for around 70 per cent of the market. This is remarkable.

Which part of your career have you enjoyed the most?I have experience of strategic planning, finance and sales, but

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I believe that our business should be based on marketing, because it’s all about customers. Sometimes people think that marketing is all about analysis, but the “smell” of the customer is more important.

What is the key to HCM’s marketing approach?Hitachi has to experience the “smell” of the customers by inviting them to the factory and visiting them on job sites. This is very important and not the sort of marketing activity that is found in textbooks. Our success in Europe is based on the international sales team and Hitachi dealers visiting customers with engineers from Japan to research what is required. By listening to these requests, the number of modifications that have to be made to the standard machine in each market are minimised and we can continuously search for areas of improvement.

What do you like most about the Hitachi brand – and why?Hitachi is extremely focused on engineering. So, our engineers are always interested in listening to the owners and operators of the machines, and the problems they want to solve. This is the key to our brand proposition.

What is HCM’s current perception of the European market?HCM is proud that HCME has a long and successful history. Europe is a tough, competitive market, especially with the cost of importing goods from Japan due to the current strength of the yen. There is a wide range of requirements, even between the different applications in each country.

So, it is important to evaluate our business model with the aim of increasing productivity and profitability. The plan is to increase the proportion of parts sourced from local suppliers in Europe. This will help to reduce our production costs and exposure to currency fluctuations.

What is the current feeling among the dealer network?I have already visited some of the dealers in western Europe under my HCME role, and found them to be open and honest. They all shared some positive comments and constructive criticisms with me.

Some of HCME’s dealers have a long history with Hitachi and some are strong family-run businesses. They help to form important core values within our company, which are passed on from generation to generation. Hitachi may not be family owned, but that sense of a family spirit is very important to us.

Which countries do you see as emerging nations within your jurisdiction?The most potential seems to be coming from the Russian and Turkish markets. HCME’s European Distribution Centre at Oosterhout is also doing well and benefiting from the growth of the mining and general construction sectors in these countries, and the other nations within the CIS. In addition, there is much potential in North and West Africa.

Why do you feel you are so well suited to your new position?My previous experience in The Netherlands is an obvious advantage, when I worked within the Dutch dealer with responsibility to sell excavators and wheel loaders. I found this to be an interesting and challenging role. Prior to that, I had the pleasure of conducting business in Europe. My career has also included mid-term corporate planning, overseas development projects and turnaround programmes for HCM subsidiaries.

What is HCME’s long-term strategy?We have a very diversified business and product range, but are still heavily focused on excavators. So, we would like to place more emphasis on the growth of mini excavators and wheel loaders, to bring them closer to the hydraulic excavator business.

I would also like to prioritise the Support Chain after-sales programme. More machines will stay in Europe for longer – as emerging countries will not accept our advanced specification machines – and so we have to take care of them. This incorporates the parts requirements for these models, so that they can work even more reliably under the toughest of conditions.

What is your message to Hitachi customers in Europe?I would like to thank all of our customers for their support and loyalty. Without them, we would not have enjoyed such a long history. HCM is extremely proud of the success of its business in Europe.

HCME is celebrating its 40th anniversary in 2012 and we’re here to stay, so that we can work together with our expanding customer base. We aim to improve our range of products and services in line with our customers’ expectations – and that is our commitment to them.


Job site

LARGE-SCALE SUPPORT The EX8000-6 is the largest excavator made by Hitachi. There have been recorded sightings in North America and Australasia, but none in Europe or Africa – until now. Ground Control goes to Mozambique in search of not one, but two of the gigantic mining machines at Vale’s Moatize site

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Since Mozambique became independent from Portugal in 1975, it has been troubled by conflict, economic fragility and famine. Sixteen years of civil war ended in 1992 and since then the country has made significant progress in terms of economic development and political stability. The national infrastructure still suffers from colonial neglect, a lack of investment and the devastation caused by flooding in 2000-01.

However, foreign investors are now showing interest in the country’s wealth of natural resources and a large new mining project is attracting much attention from around the world. Vale’s Moatize coal mine will be the flagship site in the Tete province, lying 17km northeast of the city of Tete (which is on the Zambezi River) and 80km east of the Malawi border.

This region holds one of the world’s largest untapped carbon reserves, particularly for coking coal, which is used to make steel. High demand for steel worldwide has accelerated the development of coking coal mines in various regions, such as Russia, China, USA and Australia, but this is the only one in Africa. Mozambique’s location on the east coast of Africa is also strategically placed to feed the Indian and Chinese markets.

However, all export growth plans would have to overcome the woeful state of the country’s infrastructure. The Government is planning to establish a framework for how future projects are planned and who will benefit, to ensure all those expected to come online will get access to ports and rail links.

Coal producers are also looking at building a new terminal at Chinde, north of Beira, which would have the capacity to handle 18-26million tonnes per year. The port’s construction is planned to coincide with the start of production at Rio Tinto’s new project in 2015, after it became Vale’s neighbour by acquiring Riversdale Mining in Tete for $4billion.

This is just one example of the growing competition for Vale from other mining companies in Africa. The Brazilian company led the way in 2006 with a concession to build and operate the mine at Moatize to export coal via rail to Beira. Operations began in 2008, including the upgrading of 670km of railway at a cost of $375million, and it started production in 2011.

Vale is the second largest metals and mining company, and one of the largest publicly traded companies in the world. It is the largest producer of iron ore and the second largest producer of nickel. In addition to thermal and coking coal, it also produces manganese, ferroalloys, copper, cobalt, platinum group metals and fertiliser nutrients.

Vale is seeking to become a major global company in the coal sector. It has announced plans to invest $15-20billion in Africa between 2010 and 2015. This includes a $6billion expansion of Moatize to double output to 22million tonnes per year. First production from the expanded mine is forecast for the second half of 2014.

The expansion will include $4.4billion dedicated to the building of a new coal terminal at the northern port of Nacala and a 912km-rail line connected to Moatize. The deep-water port is seen as more adequate to handle Panamax vessels (those that can travel through the Panama Canal) than the shallower one at Beira. The railway and port will initially have a capacity of 18million tonnes to meet Vale’s rising demand for exports.

Gildiney Sales, Vale’s Mining Manager at Moatize, explains the importance of the project, “Vale has coal mines in other countries, but Moatize is the first time that we have developed one from scratch. This mine is extremely important as we aim to become the world’s top mining company in the area of steelmaking resources.”

The EX8000-6 excavating overburden with its huge 43m3 bucket (note the EX5500-6 in the background)

The Moatize coal reserve is 954million tonnes and its life expectancy is 35 years. There are over 1,100 Vale employees and 600 subcontractors present on the site. They work across three shifts and in four teams, with one of these on standby. The overall proportion of Mozambicans is 84 per cent, despite the scarcity of skilled human resources.

“The civil war ended 20 years ago and the 20- and 30-somethings lack sufficient education and work experience,” says Mamoru Sawabe, President of Hitachi Construction Machinery (Mozambique), Ltd., the first local subsidiary established by a Japanese company in the country.

“In these circumstances, it is no easy task to maintain a high operating rate, while hiring and training local workers. Fortunately, Hitachi has some Japanese Brazilian staff, who have come from HCM’s head office in Tokyo and are helping to support the local workers and develop their skills.”

The mining method is an open pit through sequential layers using excavators, wheel loaders and rigid dump trucks, in which the production and rehabilitation process runs simultaneously. With vast quantities of overburden to be removed and dumped in designated piles, and layers of coal to be collected and transported to the primary crusher, Vale has invested heavily in its mining equipment.

The line-up includes two EX8000-6s (with 43m3 coal buckets) and three EX5500-6s (34m3) – the largest two excavators manufactured by Hitachi. The machines are subjected to one of Africa’s harshest environments, where temperatures exceed 50°C, and they come with a bespoke after-sales support package to meet Vale’s requirements.

One of the EX8000-6s had already been operational for three months when Ground Control visited Moatize in May 2012. However, the second machine was being assembled by a team of specialist sub-contractors, overseen by Hitachi Construction Machinery Southern Africa Co., Ltd.’s National Product Specialist, Dave Thomas.

Dave has worked in the industry for almost 30 years and already spent six months at this mine to manage the installation of the EX5500-6s and EX8000-6s. “Each of the disassembled EX8000-6s was transported on 29 trucks from the port at Durban in South Africa to the site on a rigorous two-week journey,” he explains.

“The first one took eight men – one rigger and seven fitters – only 19 days to prepare, due to the urgency required by Vale to get the machine working on the site. When the EX8000-6 is ready for action, it takes us 1.5 days to walk it down to the pit!”

The decision regarding which mining excavator to purchase is one that Vale takes very seriously. It not only compares different machines for productivity, but also for the level of technology that contributes to the safety of the operators and support offered by the manufacturer in remote areas such as Tete.

“We have a dedicated department in Brazil that is responsible for acquiring new machinery,” says Mário Carpegiane, Vale’s Maintenance Supervisor at Moatize. “They know the level of equipment required to start operations at the mine and have knowledge of the availability and support for other equipment that we are using around the world. Hitachi has a good reputation and is renowned for continuously developing its mining equipment.”

After one year of production, Mário had nothing but positive feedback about the first two EX5500-6s. The availability was excellent and the quality of service and support had exceeded expectations. On this basis, it was decided that Vale would continue to operate Hitachi excavators at Moatize, so another EX5500-6 and two EX8000-6s were ordered to assist with the expansion of production.


Job site

The EX8000-6 offers a quiet working environment

15GROUND CONTROL

The EX8000-6s and EX5500-6s are subjected to one of Africa’s harshest environments, where temperatures exceed 50°C


Job site

The EX8000-6 is such a rare piece of equipment that there is even more emphasis placed on the dedicated support of Hitachi to help meet production targets than with any other machine. “The high level of on-site support is an extremely important aspect of operating Hitachi excavators,” adds Mário. “The conditions in Mozambique are so tough that the maintenance and service are crucial to our operation.

“Hitachi supplies the parts and service for the excavators. As Mozambique doesn’t have a good infrastructure or people with the required experience and expertise, this places even more emphasis on the relationship with the manufacturer. If we didn’t have a good system in place with Hitachi, then it would be very difficult to maintain our production levels.

“The availability of both models has been excellent as a result of this support. The interface with the Hitachi team is second to none and we enjoy a good level of communication. Also, if you compare Hitachi models with other excavators, the design and layout are good, which is especially useful for replacing parts and general maintenance.”

Mr Sales echoes these comments: “We are also using Hitachi machines in Brazil and therefore know about their high quality. The support service for this mine is also particularly good. We can obtain

parts and components within a short time frame, and we are very satisfied. The operating rate exceeds the guaranteed level of 89 per cent, and thanks to this, the whole project is going well.”

Hitachi Construction Machinery (Mozambique), Ltd.’s Maintenance Supervisor Sergio Campos manages the support team of 20 personnel at Moatize. He has worked in the mining industry for more than a decade and with Hitachi for the past two years. The key roles of supervisor, technician and electrician are covered across the four shifts to cover mainly preventative and corrective maintenance procedures.

“It’s a huge challenge because the machines are of course working non-stop,” says Sergio. “We therefore have to inspect the machines on a daily basis at every available opportunity, such as when there is a shift changeover.

“The extreme heat at Moatize can cause some issues, for instance with the air conditioning. Overall, the working conditions dictate that the radiator and cooler need to be kept as clean as possible. The coal dust particles are very small and can get everywhere.

“I’ve worked in other countries and the main issues in Mozambique are with logistics and personnel. So, we need to make sure that we prepare well, plan ahead and prioritise our training procedures.

The first EX8000-6 was assembled in 19 days The installation team on the second EX8000-6

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Horizon oil sands mine,Alberta, Canada (two)

Muskeg River oil sands mine, Alberta, Canada (four)

Jellinbah coal mine,Queensland, Australia

Jackpine oil sands mine,Alberta, Canada

Callide coal mine,Queensland, Australia

Bulga coal mine,New South Wales, Australia

Wolverine zinc mine,Yukon, Canada

Liddell coal mine,New South Wales, Australia

Brule coal mine,British Colombia, Canada

Moatize coal mine,Tete, Mozambique (two)

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already had one year’s experience operating the EX5500-6 before progressing on to the EX8000-6.

“It gives me a lot of pleasure to work with the EX8000-6 and I am still very excited when I go to work every day,” enthuses Arlindo. “I’ve had invaluable training from Vale and Hitachi, and I was lucky to be selected as one of the best operators to work on these huge machines.

“I find that the EX8000-6 is very fast and of course comfortable, especially with the air conditioning in these conditions. It’s very stable, incredibly powerful and strong. The best feature for me is that it offers a quiet working environment, which is so important when loading dump trucks in the pit.”

Recent investments in mining and infrastructure for huge projects such as Vale’s Moatize coal mine have had a positive effect on Mozambique’s economy. Although it will take many years of sustained growth to complete its recovery process, the country has the opportunity to dig deep into its natural resources with large-scale support from companies such as Hitachi.

“If a part weighs over 200kg for example, then it is not possible to use air freight. That means that it would take seven days to reach Moatize over land due to the paperwork required and other problems, such as those encountered at border crossings. So, we have to determine how many parts are required for each machine and keep a good stock of the key items on site.”

Training is not only required for looking after the huge Hitachi mining machines, but also for operating them. This is a long and complicated process, and the best trainees graduate with a high level of concentration and knowledge of the stringent safety procedures in place.

The man responsible for training at Moatize is Leonam Cancela. He’s been an operator with Vale for a decade and has been training new recruits for the past three years. Having operated an EX2500 in Brazil and the EX5500-6 and EX8000-6 since arriving in Mozambique, he is certainly well qualified for the role.

“It takes six months to fully train an operator from novice status, although it depends on his natural ability of course,” Leonam says. “The training includes an induction on Vale, health and safety issues, the importance of the environment and technical procedures. They must understand how everything works, because this can be of invaluable assistance to the support crew.”

Arlindo Sitoe is one of the fortunate few who have made it to the unrivalled status of EX8000-6 operator. The 24-year-old Mozambican completed his training programme with some distinction and

17GROUND CONTROL

To see a movie of the EX8000-6 giant excavator working in Mozambique, please visit www.youtube.com/user/HitachiConstruction. To receive a digital version of Ground Control with new movies, please register online at www.igroundcontrol.com/subscribe/english

A rare species: the EX8000 world map

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“All of this makes life much easier forthe operator”

“Our demolition company owns two ZX350LCN-3s, with a thirdone due to be delivered soon. I have operated excavators foraround 25 years and currently run KS Engineering with mybusiness partner Tobias Kuhn. In today’s competitive market,Hitachi products represent excellent value for money, especiallyin terms of reliability and minimal downtime.

“The ZX350LC-5 is the replacement for our existing model andits superior power and handling characteristics are what wewould expect from Hitachi. The cab is really comfortable, theinterior is very modern and the technology is similar to what youwould find in a car.

“The most impressive feature is the ergonomic design of thecontrol panel and LCD monitor. It is so easy to operate the airconditioning, rear-view camera and other functions. All of thismakes life much easier for the operator.”

Manfred Schöllhorn, ZX350LC-5, KS Engineering, Germany, demolishing a former US military base in Augsburg

ZAXIS-5 PUTTO THE TESTThe new Zaxis-5 range was launched to critical acclaim at the Intermat exhibition in April. Since then, these medium and large excavators have been distributed all over Europe by Hitachi Construction Machinery (Europe) NV (HCME). So, who better to ask for their initial impressions of these new machines than the first operators in Europe to put the latest Hitachi technology to the test


Special feature

“The loading cycle is fast even when emptying the bucket”

“I’ve been operating excavators for 20 years and have spentthe last two of these working with Schön + Hippelein. This hasincluded recent experience of a ZX470LCH-3 and ZX670LCH-3,which I found to be well suited to quarrying.

“The ZX670LCH-5 is powerful and offers excellent handlingcapabilities for loading rocks on to EH750 dump trucks. The cabis spacious, there is more than enough legroom and the seat iscomfortable. The control panel is similar to that of a car – it isso easy to understand the functionality and operate the monitor.

“Productivity is so important in a quarry and that’s why I thinkthe speed of the swing mechanism is the best thing about theZX670LCH-5. It only takes four passes to fill one of the trucksand the loading cycle is fast, even when emptying the bucket.”

Robert Hahn, ZX670LCH-5, Schön + Hippelein, Germany, excavating overburden in the Calcitwerk Heidenheim quarry

19GROUND CONTROL


“The changes between the old and new Zaxis excavators are all positive”

“I’ve been an excavator operator for 30 years and have worked with two other Hitachi models before experiencing the new ZX250LC-5: a ZX160W and ZX210-3. I’ve always been impressed by these high-quality machines – they’re very stable and reliable.

“My initial impressions are that the changes between the old and new Zaxis excavators are all positive. The hydraulics are especially good and I’m also very happy with the swing torque and the enhanced performance of the engine.

“In my opinion, the whole package counts when you’re operating an excavator, but with long days on job sites such as this, then comfort comes first. The ZX250LC-5 doesn’t disappoint: the seat is comfortable; the controls are within easy reach; and there’s less noise and more legroom in the cab.”

Special feature

Andres Sœtre, ZX250LC-5, Trafikk & Anlegg AS, Norway, earthmoving on the E18 road between Sandefjord and Tønsberg

21GROUND CONTROL

“I feel like I’ve got three arms when I’m at the controls”

“With more than 25 years as an operator, and the past 17 years working with Hitachi products, my experience of Zaxis excavators has been very positive. The reliability is excellent and Hitachi excavators just keep going to deliver high levels of productivity and minimal downtime.

“The new ZX870LCH-5 is more luxurious than the previous model, with increased legroom and overall comfort. The colour monitor provides more access to useful information and the ergonomic control panel is much easier to use. “The best feature of this machine is that it is very precise. When you move the joystick, the excavator does exactly what you want it to do. This is invaluable on projects such as this and I feel like I’ve got three arms when I’m at the controls.”

Frans Maenhout, ZX870LCH-5, Jan de Nul, Belgium, offloading rocks into the Albert Canal between Antwerp and Liège

To see a movie of the new Zaxis-5 range working on various job sites, please visit www.youtube.com/user/HitachiConstruction. To receive a digital version of Ground Control with new movies, please register online at www.igroundcontrol.com/subscribe/english


The demand for special application machines, such as the Hitachi ZX225USRLC-3 and ZX350LC-3 fitted with clamshell telescopic arms, is rising in cities across Europe. To cater for the needs of growing populations in urban areas, where space to expand is a rare commodity, construction projects below ground level are increasingly common.

Two ongoing projects in central London highlight the successful application of these machines, which were supplied by the official UK Hitachi dealer, HM Plant. The safety, productivity and reliability of the excavators were fundamental for both sites: the construction of the World Conservation and Exhibition Centre; and Crossrail, a new railway for London and the south east of England.

Safe and reliableWork on the World Conservation and Exhibition Centre involved excavation of several basement levels belonging to the neighbouring British Museum between autumn 2011 and summer 2012. The Carey Group was responsible for completing the excavation to enable the construction of five storeys below ground level. They will house scientific research facilities, storage and study rooms when the Centre opens in 2014.

The Carey Group was established in 1969 by Chairman John Carey and his brothers, Pat and Tom. It specialises in demolition, civil engineering, concrete structures, building and environmental solutions, and works on projects throughout the UK and Ireland. More than 70 of its employees were working on the World Conservation and Exhibition Centre project.

The company invested in the Hitachi ZX225USRLC-3 following a visit to Düsseldorf in October 2011 to see a similar model working on an underground car park. HM Plant Operations Director David Hearne organised the trip with the help of Kiesel, the official German Hitachi dealer.

“Pat Carey and Sean O’Donnell were so impressed with its performance that they immediately ordered the excavator for this job,” said Mr Hearne. “They were particularly impressed by the compact size of the machine, which makes it suitable for working at pavement level on busy, urban sites and within small hoardings.”

The sliding cab is an important feature for job sites such as the World Conservation and Exhibition Centre. “The cab is positioned 700mm further forward than on a conventional Hitachi excavator,” explains Mr Hearne, “and it has the capacity to slide

URBAN LEGENDSTwo of the first Hitachi clamshell telescopic excavators to work in the UK were selected for excavation on complex projects in central London. Completing the work safely and on schedule, they had a deep and positive impact on owners, operators and contractors

Industry solutions

The ZX225USRLC-3 with clamshell telescopic arm removes material from depths of 21m below ground level

engineering project in Europe. It involves the construction of a new railway across the city, which will connect 37 stations including Heathrow Airport and Maidenhead in the west with Canary Wharf, Shenfield and Abbey Wood in the east.

One of the project’s 20 job sites is the construction of the eastern ticket hall of the Bond Street Crossrail station at Hanover Square. Costain Skanska Joint Venture (CSJV) contracted the ZX350LC-3 and later the ZX350LC-5 from M O’Brien Plant Hire. They were required to carry out excavation work on two shafts, five storeys below ground, leading down to the level of the new train platforms. This work was necessary to prepare for the arrival of tunnel boring machines in late 2012.

Between March and June 2012, the ZX350LC-3 – fitted with a 25-metre arm and 1.2m2 bucket – worked 24-hour shifts, seven days a week, removing material from the first shaft. It loaded a six-tonne dumper, which transported the materials to an on-site stockpile. A Hitachi ZX225USLC-3 then loaded the materials on to trucks for transportation off site.

Completing the work on schedule was extremely important to CSJV and it conducted a test to compare the performance of the Hitachi clamshell telescopic excavator against the use of skips. Costain Works Manager Martyn Redsell explains: “The excavator was three times quicker than using an 8m3 skip.


From left, Daniel and Michael O’Brien (M O’Brien Plant Hire) with HM Plant Operations Director David Hearne and Costain Works Manager Martyn Redsell

a further 1,300mm forward, allowing for an additional two metres of visibility through the glass floor.”

Between January and June 2012, the Carey Group used the Hitachi ZX225USRLC-3 fitted with a 21-metre clamshell telescopic arm to remove material from below ground at the site. Equipped with a 0.8m3 bucket, it loaded an average of 45 trucks a day. The trucks transported the material, known as ‘London blue clay’, to Margate in Kent, approximately 110km south east of the city, where it was used to reinstate a landfill site.

Carey Group Assistant Project Manager David Kyari explained the importance of the machine’s productivity: “It takes approximately 12 minutes to fill each truck; eight seconds for the arm to extend and ten seconds for it to retract. It’s important for the process to be as fast and smooth as possible, as the trucks are not allowed to queue on the street adjacent to the site, due to parking restrictions and emissions regulations.”

Without the Hitachi ZX225USRLC-3, the process would be slower and less safe. “We would have to use skips, conveyor belts and a crane to lift the skips to remove the material, which would then have to be stockpiled on site,” says Mr Kyari. “With this machine, we can do both the excavating and loading, and it is up to three times quicker than the traditional method.”

“The use of tower cranes and skips would mean more moving parts to the process,” adds Mr Hearne, “which has implications for safety risks on such a busy site. Enhanced safety is one of the most important benefits of this excavator to the Carey Group, because it is always a top priority for the company.”

The safe and smooth operation of the Hitachi excavator was also extremely quiet. This is another important consideration for inner-city projects because of its close proximity to offices, residences and the British Museum, which has remained open throughout the construction work.

Powerful and productiveA short distance across London, two more clamshell telescopic Zaxis excavators were working on Crossrail, the largest

Industry solutions

The skips removed 13m3 per hour compared to 39m3 per hour removed by the Hitachi. By mid-May, we were four days ahead of schedule.”

Operator Tony O’Sullivan, who works for M O’Brien Plant Hire, was also impressed by the performance of the Hitachi ZX350LC-3. “I was initially surprised at how stable it was, how far it could reach and how much material it could bring up,” he said. “I found it easy to operate, it has smooth hydraulics and it’s comfortable, too. Compared to other brands of machinery I’ve worked with, Hitachi is Mr Reliable.”

For Tony’s employer, Michael O’Brien, the Hitachi clamshell telescopic excavators have other advantages. “The benefits include increased safety and flexibility in terms of where we can work. They give our company greater versatility; we can reach more customers with these machines.” The new ZX350LC-5 model, delivered in July 2012, has the additional advantages of enhanced hydraulics and the stage IIIB low-emission engine.

The family-run firm, based in St Albans, Hertfordshire, was established by Michael and his wife, Annamarie, in 1991 with one machine. Today, it has a 100-strong fleet of Hitachi construction machinery, ranging from the ZX29U-3 mini to ZX470-3 large excavators. “We have found Hitachi excavators to be powerful, robust and reliable,” says Michael. “The most important benefits

for my company are the good service we receive from HM Plant and the machines’ strong residual value.”

The future of M O’Brien Plant Hire lies in providing a diverse and specialist range of equipment to meet the increasingly complex and challenging requirements of today’s construction projects. The demand for Hitachi telescopic clamshell excavators looks set to grow in accordance with this trend, and HM Plant sees great potential in this product category. “These machines are becoming the standard way to do this kind of work now,” says Mr Hearne.

Following their work in London, the ZX225USRLC-3 and ZX350LC-5 belonging to the Carey Group and M O’Brien Plant Hire respectively were scheduled to start on other projects around the UK. As more construction companies see them in action, awareness of their capabilities will undoubtedly increase and extend their appeal for underground construction projects even further.

25GROUND CONTROL

To see a movie of the ZX225USRLC-3 working below the ground in London, please visit www.youtube.com/user/HitachiConstruction. To receive a digital version of Ground Control with new movies, please register online at www.igroundcontrol.com/subscribe/english

Using the ZX350LC-3 was three times quicker than using skips and cranes at the Crossrail site


The new EH3500ACII powers up the 750m test track at the Kansanshi copper mine


Technical focus

THE DRIVE FORELECTRIC POWERGround Control visits one of the largest copper mines in the world to investigate the benefits of the new trolley assist system for Hitachi dump trucks. The massive Zambian project includes the installation of a new fleet of electric EH3500ACII models as part of a four-year expansion programme for the Kansanshi mine

Global investment in mining increased by 40 per cent in 2011, which was in line with the growing demand for precious metals, such as copper and iron ore. There is a high concentration of such natural resources in the southern part of Africa and copper production is growing at a particularly high rate.

Various economic and political circumstances have curbed past investment in Africa. A good example is the long and expensive route to the nearest port from the landlocked nation of Zambia.

However, the soaring prices of mineral resources – caused by high demand in China and other emerging countries – are helping the African market to gain momentum. Hitachi mining machines are supporting this development and are at the forefront of new and existing operations.

First Quantum Minerals Ltd. (FQM) is an established mining company currently operating three mines worldwide to produce copper, nickel, gold and sulphuric acid. The company’s operations include the Kansanshi copper and gold mine in Zambia, which is located approximately 10km north of the town of Solwezi and 180km to the northwest of the Copperbelt town of Chingola.

Kansanshi is Africa’s largest copper mine – and the eighth

largest in the world – with 1,635 employees (at the end of 2011) and an estimated lifespan of at least 11 years. It operates 24/7 in a three-shift pattern. Eighty per cent of the mine is owned by Kansanshi Mining PLC (a FQM subsidiary) and the remaining 20 per cent belongs to a subsidiary of ZCCM Investments Holdings, 85 per cent of which is owned by the Zambian Government.

Mining is carried out in two open pits, which are known as Main and Northwest. FQM uses conventional open pit mining methods and employs hydraulic excavators and a fleet of rigid dump trucks.

The line-up of large excavators includes a wide range of Hitachi mining equipment, including: two EX1200-5s (with over 38,000 and 42,000 working hours respectively); four EX1900-5s (27-40,000); one EX1900-6 (over 14,000); and three EX2500-6s (7-20,000). However, the fleet of 11 EH3500ACII trucks is the most recent addition to the Hitachi stable at Kansanshi, with 2,000 to 6,000 working hours between them.

John Coleshaw, FQM’s Project Manager, started working at Kansanshi in 2010 and so wasn’t involved with the order for the large Hitachi excavators. “The EX1200s, EX1900s and EX2500s

27GROUND CONTROL


Technical focus

were already here when I arrived,” he confirms. “These machines are quite old now, with some having accumulated more than 40,000 hours. They have given good service and we can’t fault them.

“Hitachi offered the only solution for electric-drive 180-tonne trucks when we were in the market for these products two years ago. The EH3500ACII is a good machine and our operators are happy with their working environment. A main benefit of these models is the automatic retarding control to regulate the downhill speed, which is excellent for safety and preserves the lifetime of the product.”

Born in the Copperbelt, Collins Banda has been an operator with FQM for three years and has driven one of the EH3500ACIIs for over 12 months. His wife is also an operator, although she’s now more involved in training new recruits to master the mining machinery at Kansanshi.

“I’ve always dreamt of operating such a big truck and the EH3500ACII is the best machine in my opinion,” says Collins. “It’s so comfortable, even over the roughest ground, and I find that I’m not as tired as I used to be at the end of my shift. The quality of the air conditioning, seat and suspension contribute to this feeling. It drives well on the haul roads, and is so powerful and fast enough to maintain a high level of productivity.”

A number of projects are planned to expand annual copper production capacity from the 230,000 tonnes achieved in 2011 to a target of 400,000 tonnes by 2015. The $370million expansion programme will be implemented in three phases.

Phase one comprises of the expansion of the treatment capacity of the oxide circuit by 20% to 7.2million tonnes throughput per annum. The $200million phase two is planned to increase the oxide treatment capacity to 15million tonnes per annum.

Phase three is planned to comprise of the construction of a new sulphide concentrator with a planned annual throughput of 16million tonnes of ore, with the capability of expansion to 25million tonnes.

New additions to the mining fleet will also play a key role in the expansion programme and some equipment has already been procured, including 23 new EH3500ACIIs. These purpose-built trucks are being supplied as part of a trolley assist package. This commenced in March 2012 with the installation of a 750m test track, including an overhead line and a new dump truck for trials by Hitachi engineers.

The Assembly Coordinator for the Hitachi machines at Kansanshi is Hugo Truter of Hitachi Construction Machinery (Zambia), Ltd. (HCMZ). He has much experience of the rigours of mining in Africa, having worked with Hitachi Construction

Hugo Truter, Hitachi Construction Machinery (Zambia), Ltd.’s Assembly Coordinator

29GROUND CONTROL

To see a movie of the EH3500ACII rigid dump trucks working in Zambia, please visit www.youtube.com/user/HitachiConstruction. To receive a digital version of Ground Control with new movies, please register online at www.igroundcontrol.com/subscribe/english

Machinery Southern Africa Co., Ltd. (HCSA) in a coal mine in the Northern Provence of South Africa since 2002. Four years later, he moved to the Lumwana copper mine in Zambia, firstly as the Truck Assembly Coordinator for the delivery of 28 EH4500 trucks and then as a Siemens technician.

In 2009, he started working for what is now HCMZ’s branch at Kitwe. “I was initially employed as the Site Manager, before taking on the role of After-sales Development Manager,” says Hugo. “I’ve been involved with the assembly of the existing EH3500ACIIs, as well as the future development and assembly of the new trucks when they are delivered.

“The trials with the new truck on the trolley line have been going well. The line was supplied by Siemens to test the substations and to see if it can take three trucks at the same time. It will be maintained by FQM with an additional 2km running from the base of the existing line to the bottom of the Main pit.”

The design of electric dump trucks has become a more simplified process since the turn of the century. Technological innovation has opened the door for the powerful AC drive to replace the traditional DC drive.

Dump trucks with trolley assist require initial investment for incidental facilities, such as power sources and overhead power lines, but their power to climb slopes and acceleration are excellent. Fuel consumption is also about ten per cent lower than that of Hitachi engine-driven counterparts.

The new trucks were scheduled to arrive from mid-July this year and be ready for full operation with the new trolley line by March 2013. After arriving disassembled from Hitachi Construction Machinery Co., Ltd. in Japan, they were partially assembled in South Africa so that they could still be transported by road.

The journey from Johannesburg to the mine takes around 14 days, partly due to the maximum travel speed of 80km/h and the quality of the roads, which means that the trucks have to zigzag through each country. It takes three trucks to move each partially assembled EH3500ACII: one to carry the frame; one with the load

body; and one with the tyres.“The advantages of using the trolley line are reduced running

costs – due to less fuel consumption – and the increased life expectancy of the equipment,” explains Hugo. “There is also a shortage of quality fuel in Africa and the new trucks will help to save diesel for other applications.

“The electric trucks excel in environmental performance, in terms of achieving low emissions and noise levels. They also have a lower risk of breakdown, because they don’t need a transmission and other such complex components. Their construction is more basic and they require fewer parts, which in turn means lower costs, less maintenance and consequently minimum downtime.

“These Hitachi EH3500ACIIs were selected for Kansanshi, because the whole truck is owned and designed by Hitachi. The customer wanted a reliable system that can be used as one complete unit. All the other trucks in the market have been designed and built by the manufacturer, with the drive system supplied by a third party.”

The technologically advanced trolley assist system therefore allows a mining company such as FQM to increase its profits. Needless to say, the reduction in running costs is a major factor in determining a mining company’s evaluation of a manufacturer and Hitachi has already shown that it is ahead of the competition in this respect.

One of the existing EH3500ACIIs dumping overburden at the vast Zambian site


FOCUSINGON CUSTOMERSOLUTIONSNasta celebrates its 30th anniversary this year as the Hitachi Construction Machinery (Europe) NV (HCME) dealer in Norway. Rather than reflecting too much on past achievements, the company is moving forward with a clear vision and enthusiasm for the new range of Zaxis excavators and ZW wheel loaders

Nasta employees help to ensure that customers reach their goals

Nasta’s Managing Director and CEO, Tom Johansen (left) and Sales Manager Henrik Anholt

Dealer

Nasta was the new name given to the company formerly known as Nanset Standard at the beginning of last year. The fresh corporate identity coincided with the move to an impressive 38,000m2 €10million site near Larvik in the county of Vestfold, 100km southwest of Oslo.

“We decided to move and change the company name at the same time,” explains Nasta Managing Director and CEO Tom Johansen. “Our goal was to modernise the identity: Nanset was the place where the company originated and we had moved away from that area; and Standard Oil was rebranded in 1977, and we had stopped selling the product.

“So, the name change seemed a logical step after leaving the former location and product behind. After the creative process, we decided to combine the two old words and create Nasta from the first two and three letters of Nanset and Standard respectively.”

The company has every right to be proud of its past after being

founded by Søren Røed in 1929. His eldest son, Asbjørn, assumed responsibility in 1962 and he remained as Managing Director until Tom took over in 1999, having joined the organisation three years previously. Asbjørn and his brother, Finn, are still joint owners of Nasta.

Just before the Second World War, the company secured the distribution rights for Austin cars and later entered the construction market in 1955 with International Harvester. In 1964, it added Toyota cars to its portfolio and this relationship lasted until 2005, when the car business was sold to concentrate on the construction industry.

This connection with Japanese technology was reinforced when it became a Hitachi dealer in 1982. “When selling Hitachi products, we used to say that the brand was the Toyota of the excavator world,” says Tom. “This was especially effective with customers who were more acquainted with Toyota and we were able to capitalise on the link to reliability.”

Nasta currently has 111 employees and the company’s absenteeism rate was only 2% in 2011 – well below the national average of 5.4%. It was also ranked second in the 2011 Vestfold Company of the Year poll and voted third most popular company in Larvik by the local business community.

“Nasta’s main commercial aim is to be an efficient link between productivity and the job itself,” says Tom. “We should also make a significant contribution to ensure that our customers reach their goals. Our employees help to achieve this by enjoying their role of delivering quality products and services, which in turn provide Nasta with a competitive advantage.

“Our core values are to be resolute and adapt to changing conditions within the market by looking for and securing new commercial opportunities. This means that everyone is empowered to make their own decisions, especially when consulting with customers. We believe that this is one of the main factors behind our low staff turnover and absenteeism rates.”

Nasta’s new base is unique in the Norwegian market – due to its size and range of in-house services – and provides Hitachi with the ideal platform from which to promote its corporate strapline of “Reliable solutions”. The construction machinery sector in Norway peaked in 2007 at 3,639 units, but this figure dropped by 55% in 2009 in the aftermath of the recession. However, Nasta was able to ride the storm by gaining a 25% market share in the same year.

In 2011, it sold 400 new machines – an increase of 50 units from the previous year – to record a turnover of €77million. Around

A ZX250LC-5 on test at a road construction site


Dealer

20% of this figure comes from special application machines and the largest ever excavator delivered by Nasta was an EX2500-6 installed on a pontoon in February 2011. Other examples of the dealer’s specially adapted equipment include a ZX225USLC-3 for railway applications and a ZX190W-3 for tunnels.

“If a customer needs something special, then we want Nasta to be considered as a viable option,” says Sales Manager Henrik Anholt. “We pride ourselves on focusing on customer solutions. Our facilities here are second to none with spacious service, special application, welding, refurbishment, paint and washing areas. This wide range of services makes it more interesting for technicians and presents them with invaluable experience and fresh challenges. This will also help to develop their skills.”

As well as expanding into a new head office, Nasta has developed its service network. There are five other branches – with office, workshop, parts and stockyard facilities – in Lillestrøm (Tuen), Bergen (Espeland), Stjørdal, Kristiansand and Vestnes, and a total of 36 mobile service units providing national coverage.

“Nasta places a huge emphasis on after-sales, so that we could survive off the revenue from this sector of the business, even if we don’t sell a single excavator,” adds Henrik. “That’s very important, because we don’t know when to expect the next drop in the market. Our aim is to reach a level of 60% of new machines being supplied with a service contract in 2012.

“Almost half of after-sales revenue comes from Hitachi Parts and these are of course included within the service contracts.

Nasta places a huge emphasis on after-sales

The wide range of services provides technicians with invaluable experience

To see a movie of the ZX250LC-5 working on the roads in Norway, please visit www.youtube.com/user/HitachiConstruction. To receive a digital version of Ground Control with new movies, please register online at www.igroundcontrol.com/subscribe/english

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Our proactive approach to maintenance enhances the life of the machine, with less downtime. This in turn leads to our goal of complete customer satisfaction.”

Nasta divides the country into the different territories for sales and service. The sales regions are segmented according to the postal system, which is based on the main routes for transportation. This makes it easier for the salesmen to manage their time and visit each customer on a regular basis.

While general construction is the most popular industry sector, there are signs that there will be increased demand from the rental and quarrying sectors. The Norwegian Government is also making a significant investment in infrastructure through the National Transport Plan 2010-2019.

This initiative includes: 350km of national roads being upgraded; 230km of national roads being converted to four lanes; 500km of new footpaths and cycle paths; and 144km of new railway track, 116km of which will be two-way.

“There are many projects in the pipeline or that have already started,” explains Henrik. “So, we are optimistic about continued growth in the market over the next three years at least and we expect there to be an increase of 10-15% in 2012.”

The demands of the construction industry are also shaped by the country’s characteristics. Norway has the lowest population density in Europe after Iceland, so there is a need for versatile equipment that can cater for more than one application. In addition, the harsh climatic conditions, poor soil quality and difficult terrain lead to tough working conditions for machinery and the requirement for them to be durable.

Two events dominated Nasta’s activities this year: Vei og Anlegg (Road and Construction Site) 2012, Norway’s largest construction exhibition, which had an appropriate theme of “tough machines and future solutions” to match the Hitachi dealer’s current promotional requirements; and a three-way cooperation with the local Scania

and Volkswagen distributors, in which each party invited key customers to test an impressive fleet of automotive and commercial vehicles, and construction machinery.

The exhibition, held every three years in May, was the perfect launch pad to promote Nasta’s modern corporate identity, as well as the innovative new range of Zaxis-5 excavators and ZW wheel loaders. Some customers had the opportunity to test a ZX250LC-5 medium excavator in advance of the show, and the reaction was extremely positive.

“We have assessed the feedback of the operators, who have completed a questionnaire after trying out the new Zaxis-5 machine,” says Henrik. “This has been hugely positive and we have also used the ZX250LC-5 for sales and technical training.”

When asked to summarise the future prospects of the Norwegian market, Tom concludes: “Nasta has always had a close working relationship with Hitachi. We are very happy with the level of support, which has helped us to maintain a leading position for the crawler excavators.

“Our partnership with HCME means that we are seen as one of the major players in Norway. The reputation enjoyed by the Hitachi product range and Nasta’s improved organisational structure mean that we are in an excellent position. We are aiming to capitalise on the positive outlook and increase our market share, especially in other product groups.”

Some of the Nasta team outside their impressive head office near Larvik



HCM launched the world’s first fully hydraulic crawler crane – the KH150 – in 1971, with the KH series being superseded by the CX series in 1994. SHI was founded in 1963 and began to sell mechanical truck cranes a year later, before introducing hydraulic truck cranes in 1970.

The two companies’ crane departments merged to form HSC in October 2002. HCM and SHI each have a 50% share in the joint venture, which specialises in the manufacture, sales and support of Hitachi Sumitomo crawler cranes and auxiliary equipment.

The current model line-up consists of the SCX series, which was unveiled in 2003 with the launch of the SCX900-2 and SCX1200-2. Since then, the range has expanded to include 12 products – from the SCX400T to the 6000SLX – covering lifting capacities of between 40 and 550 tonnes.

“Hitachi is one of the main manufacturers that sell both crawler cranes and construction machinery,” says Martin Visser of Hitachi

Construction Machinery (Europe) NV (HCME) International Sales. “Historically, SHI’s expertise has extended to large cranes, while HCM has been focused on smaller models of up to 100 tonnes of lifting capacity.

“Hitachi has also had dealer representation in The Netherlands since 1972 so it has a high level of knowledge and experience in the European market. The launch of the Hitachi Sumitomo SCX series coincided with the opening of the HCME factory in Amsterdam in October 2002 and so HSC has been able to integrate with the dealer network for construction machinery.”

HSC’s strongest markets are Belgium, The Netherlands and UK, and most sales are generated from large rental companies. The prospect for future growth comes from the erection of windmills in the renewable energy market and general construction requirements within the power generation industry.

“Hitachi Sumitomo has an excellent reputation for quality,

Industry solutions

MOBILE LIFTING POWERHitachi Construction Machinery Co., Ltd. (HCM) and Sumitomo Heavy Industries, Ltd. (SHI) have had long and successful histories in the crane market. They have become even stronger since they joined forces to create Hitachi Sumitomo Heavy Industries Construction Crane Co., Ltd. (HSC) and manufacture a range of crawler cranes that have proved invaluable to owners and operators alike

A Heerema barge waiting to be loaded by a Hitachi Sumitomo crane

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power and reliability,” adds Martin. “These models have a long life expectancy of more than 20 years and it is not unusual to come across an old KH machine with 25 to 30 years’ service! Operators also find that the latest SCX range offers a comfortable working environment and user-friendly control panel.”

Hitachi Sumitomo crawler cranes offer excellent mobility over soft surfaces and can be used across a broad range of applications, ranging from civil engineering to port cargo handling projects. A typical example of a company benefiting from these products is Heerema Fabrication Group, which has five Hitachi Sumitomo cranes operating at its Vlissingen-Oost yard in the south west of The Netherlands.

Heerema specialises in the engineering and manufacturing of large and complex structures for the offshore oil and gas and energy-related industries. This 200,000m2 strategically located coastal site allows the company to have access to 720m of quayside, with 450m of this available for large load-outs.

The first of Heerema’s Hitachi Sumitomo cranes was delivered ten years ago and it currently has two SC2000s, one SCX2500 and two SCX2800-2s. They are used to: aid the construction process by lifting large components into place for oil platform jackets; and to load heavy assembled equipment on to barges.

Crane operators need to undergo a training programme and receive a special licence before they can begin work. There is no substitute for experience though and 66-year-old Hans Bezenber has been an operator for 35 years, the last three of which have been spent with Heerema.

“Hitachi Sumitomo cranes are exceptional machines,” enthuses Hans. “I have worked with other brands in the past, but the comfort and flexibility of the SCX series is second to none. They are easy to manoeuvre with the joysticks, and are fast and precise thanks to the hydraulics. The tilting cab is also beneficial.

“I’m very happy with the overall package offered by Hitachi Sumitomo. They provide a strong and stable base from which to perform everyday tasks, and are extremely mobile on the sandy and often damp conditions at this site. It’s also possible to lift at the same time as the machine is moving, which means that it finishes jobs much faster than an alternative machine.”

Another Hitachi Sumitomo crane operator, Guido Olivier, has 19 years’ experience of operating cranes. He has worked with Hye, a leading Belgian waterworks company that specialises in coastline and canal construction projects, for the past 17 years. Guido is operating Hye’s SCX2800-2 on a pontoon as part of a project to widen a marina at the port of Zeebrugge.

“I’ve been working with this machine since it was delivered new

two years ago and I’m very happy with how easy it is to use,” he explains. “The tilting cab has been integrated well into the design of the crane and is extremely comfortable. The main advantage for me is that I’m not so tired at the end of an eight-hour working day.”

The comfort of the cab is a recurring theme among operators, while the reliability of Hitachi Sumitomo cranes is the number one benefit according to owners and rental customers across Europe. The growing popularity of these powerful machines is the result of successful collaboration between HCM and SHI, and has proved mutually beneficial for both companies.

The Hye SCX2800-2 on the marina at Zeebrugge

Heerema operator Hans Bezenber Martin Visser, HCME International Sales

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The magazine of Hitachi Construction Machinery (Europe) NV ...ultra-large Hitachi EX8000-6 mining...

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