REBUILDS costs 50 % to 60 % of the value of new equipment ,” he says . He explains that the decision on the rebuild is taken jointly with the client , according to their needs . In the case of CSN ’ s trucks , he points out that several technical and financial studies were carried out , including TCO , which demonstrated the product ’ s viability . “ The study phase also included visits by the client ’ s board of directors to Vespasiano , which attested to our ability to perform the service . Finally , the creation of a financing line for this service with Cat Financial was decisive for the conclusion of the deal .”
The rebuild process aims to return the equipment to a condition analogous to the new one . For this , the equipment needs to go through a robust reform process , where it is completely disassembled . The chassis goes through a general inspection process , crack recovery , joint machining , measurements and stress relief before reassembly begins . “ This is the most critical step in the process and all the know-how from Sotreq and Caterpillar is applied to guarantee the structural longevity of the equipment . The Power Train and the other components are completely renovated in our Contagem CRC , following all the program ’ s criteria . In addition , items such as radiators , tanks , valve groups and cabin are repaired . At the end of the scope , more than 15,000 parts were replaced , including all hydraulic lines , electrical harnesses and sensors ,” explains Amaral .
The refurbishment of the trucks lasted 120 days at the Sotreq facilities , an even more attractive period in relation to the delivery cycle of new equipment . The six rebuilt 793Ds were delivered between July and August 2020 . Amaral points out that the strategy of carrying out a Caterpillar Certified Rebuild ( CCR ) in mining equipment allows the client to maximise the life of their asset for another lifecycle . This is because the equipment with a high hour meter loses performance and has a high operating cost , requiring a greater maintenance effort to continue operating at acceptable efficiency standards .
“ Post-rebuild equipment returns to the similar hourly cost and performance of new equipment , reducing the asset ’ s TCO . Another benefit of the program is the reduction of HC on the site and the optimisation of other resources necessary to carry out major interventions , contributing to the maintenance routine of the equipment in operation on the site .” Sotreq offers several options for equipment rebuilds . In addition to the CCR carried out on CSN equipment , the Mining Machinery Reform Workshop has the option of CPT ( Certified Power Train Rebuild ) and a Rebuild in Material Time . “ In this last option , the customer has total flexibility to define the scope of the partial rebuild within their financial needs , with the support of our technicians who bring information from inspections and essential tests to identify the critical points of the equipment to be prioritised ,” concludes Amaral .
The overhaul specialists
When it comes to big rebuild contracts over long time periods , and supply of innovative in-house technologies , the market also has specialists who can step in and provide these services – one of the best examples being H-E Parts , which is headquartered in Atlanta , Georgia in the US but has locations in all the big mining hubs and ultimately is part of Hitachi Construction Machinery headquartered in Japan .
H-E Parts has recently been awarded a two year rebuild contract with Minera Las Bambas SA , MMG Ltd ’ s major Peruvian copper mine . The contract was awarded to H-E Parts for the rebuild of front wheel groups on their Caterpillar 797F haul trucks . The mine is located between the districts of Challhuahuacho , Tambobamba and Coyllurqui , province of Cotabambas , and the district of Progreso , province of Grau , in the Apurímac Region , at an altitude between 3,800 and 4,600 m above sea level , approximately 75 km southwest of the city of Cusco .
The contract will be fully managed by the H-E Parts Mining Solutions division based in Peru . The contract includes the initial inspection , disassembly , front wheel group repair including the control fit procedure for bearing adjustment in the wheel , assembly , delivery , and commissioning . This contract will allow H-E Parts to utilise proprietary technology to ensure the lowest total cost of ownership is achieved , through extended component life , ease of maintenance and superior performance .
H-E Parts says it is able to offer a flexible , cost effective solution that tailors all services and repairs to fit the customer ’ s specific needs , while remaining within the customer ’ s budget . It says its unit cost per hour is lower than leading competitors and OEMs . “ We are excited and eager to increase their current PCR with our technology and to be partners with Las Bambas in the permanent task of being more efficient every day ,” says Cesar Jonquet , General Manager , Peru . H-E Parts believes that this partnership , combined with
workshop support and in-house engineering , will provide a flexible , cost effective , long-term solution for Las Bambas .
Earlier in 2021 , H-E Parts was awarded a multiyear , major equipment overhaul contract with Codelco . The contract was for the rebuild of 23 Komatsu 930E haul trucks , and will be conducted through Rajo Inca , Codelco ’ s Salvador Division . The contract will be fully managed by the H-E Parts Mining Solutions division based in Antofagasta , Chile . The contract includes the initial inspection , disassembly , major component repair including proprietary Birrana™ enhancements , assembly , delivery , and commissioning .
This contract will allow H-E Parts to utilise proprietary Birrana™ technology it says “ to ensure the lowest total cost of ownership is achieved , through extended component life , ease of maintenance , and superior performance .” Incorporated in the scope of work are major drivetrain componentry , such as front and rear wheel groups , suspensions , and differentials . Additionally , H-E Parts offers a range of complementary products such as the Birrana™ Brake Wear Gauges , BEST Plug , and Colleted Pin , which address inherent environmental and safety concerns .
Traditional repair options in the Chilean mining market are costly . Conversely H-E Parts says it is
H-E Parts has recently been awarded a two year rebuild contract with Minera Las Bambas SA , MMG Ltd ’ s major Peruvian copper mine for the rebuild of front wheel groups on their Caterpillar 797F haul trucks
FEBRUARY 2022 | International Mining 71