REBUILDS
structural repairs, and replacement or rebuilding of major components. This tiered approach allows mining operators to select solutions aligned with their expectations in terms of cost, lead time, quality, and service life.
From its early initiatives in the 1980s to its current dual focus on new equipment and remanufacturing, Aramine’ s trajectory illustrates how experience and adaptability continue to shape the evolution of mining equipment practices.
In terms of the general process, once the machine is completely dismantled piece by piece, as far as possible, Aramine prioritises repairing the major components such as the chassis and axle, which helps limit the carbon impact for these heavy parts. Conversely, many parts are replaced with new ones, for example all the pumps, electronic components( dashboard, etc), as well as all the fasteners.
Two copies and one soft copy of the spare parts catalogue are provided according to the technical features of the machine with all sections clearly detailed. Catalogues are composed of OEM part numbers and correspond 100 % to the machine. Each catalogue is dedicated for one specific serial number. Catalogues are sent separately to the project manager at the arrival of the machine at site for startup.
At start up, the Aramine service team perform an inspection and test list in presence of the customers( training, maintenance, operations, how to repair and main operations). A start up certificate is delivered at the end of the training.
Epiroc’ s Midlife range of options
IM spoke to Maria Tutumlu, Epiroc Global Product Line Manager for Circular Services, about its rebuild offering for the mining sector. In her role she is responsible for everything related to rebuilds and upgrades on machines including all the component repairs as well as training and safety solutions.
The main focus in terms of rebuilds is its rebuild program, Midlife services, which has three levels.“ First we have Midlife Basic, where you do the midlife rebuild on the machine and just restore it as when it was bought. The machine is inspected and the main components replaced with the same specifications, extending the machines productive lifetime. This still always includes sandblasting and making sure the frames are fully functional with non-destructive testing. We have to make sure that they won’ t crack, because usually it’ s the frames that are the most vulnerable part of the machine, and then you replace components based on if they need to be new or if they can be repaired to keep the cost down for the customer, but also to have circularity in mind.”
Epiroc’ s collaboration with Byrnecut is embodied in the Zero Hour Rebuild Program
Then there is Midlife Plus, where the machine is upgraded to the latest technical specifications, plus all available options covering productivity, reliability and operator comfort.“ This version means you can add options that you didn’ t have when you bought the machine so it allows you to get the latest and greatest basically, especially for areas like axles and engines. For example, the latest RCS software upgrades from RCS3 to RCS5 or RCS4 to RCS5. So you end up with a machine very similar to a current new machine.”
Finally, there is Midlife Tech + where the machine is upgraded with all the latest technology options to increase productivity and safety. This can include starting an automation journey by connecting the machine and monitoring machine data. Having the latest RCS version brings the ability to proceed with these more advanced capabilities and options that come with that in terms of real time monitoring and the ability to apply semi or full automation.
The circular and sustainable aspect of rebuilds is very important, and reflects the fact that the rebuilds largely do not resort to using new steel, manufacturing or shipping, but ultimately impart a renewed lease of life to essential assets.
In addition, for customers- either mining companies or contractors that want to carry out rebuilds themselves and have the facilities to do that- Epiroc also offers midlife kits. And for those who don’ t want to do a full midlife rebuild or restore the machine fully, it can also supply modules.
When do the discussions about a rebuild start? Tutumlu:“ It’ s already discussed when they first buy the machine, especially with the big customers who from the outset are thinking about the TCO and the total lifecycle of the machine. Extending machine life has become more and more popular in recent years, because customers want to get as much as possible out of their assets without needing to buy a new one. I would go as far to say that if you cannot show them that we are capable of extending the life of the machine and then also showcase the benefits of it, you would not even be considered anymore in today’ s market in big tenders.”
She adds:“ We have cases where midlife rebuilds are contracted from the beginning, then we have cases where it’ s part of a service agreement cost, then others where they just buy new but want to be secure in the knowledge that they can do a rebuild when they want to.”
In terms of general midlife popularity over time, Tutumlu said it depends largely on the customer and what kind of technology level they are on plus their budget and also their thinking on technology. She added“ And we are getting better at it – in some cases we’ re doing more rebuilds on the same machine than we used to do before. Customers are also pushing machines to get more hours out of them before even starting a rebuild or changing a big module like a tower on a big Pit Viper drill. In a way this is all possible because of the knowledge we have built up over the years especially on how far you can safely and efficiently push major components.”
But Tutumlu also emphasised that add new machine sales and the aftermarket business including rebuilds go hand in hand.“ One is not cannibalising the other, I would say they really complementing each other because customers want to extend the life of their asset and really maximise its value. But if we can do that by collaborating and partnering with them, it also makes them feel more secure when it does come to buying new machines. They may buy a few new units but also opt to rebuild their oldest machines and in today’ s market even look at doing battery conversions at the same time”. Which machines are rebuilt the most often?“ I would say trucks and loaders are
82 International Mining | FEBRUARY 2026