REBUILDS
In 2025, Sandvik commissioned an AutoStore robotic storage grid in its Eindhoven warehouse. At 700 square metres, with 14 robots and 28,000 bins, the building is designed to increase picking efficiency and reduce manual lifting, reaching and long walking distances. This improves both safety and fulfilment speed for parts orders. For mines, faster, safer fulfilment removes a hidden source of downtime risk.
Beyond supply, Sandvik rebuild and repair services are backed by more than 60 workshops worldwide with over 5,500 skilled service personnel supporting diesel, electric and BEV fleets. This local‐plus‐global presence is the difference between‘ rebuilt’ and‘ reliably rebuilt,’ with technicians trained on current maintenance requirements, best‐practice techniques and consistent quality standards.
Sandvik also has a variety of telemetry, remote monitoring, fleet utilisation and productivity systems all within My Sandvik Insight and Productivity subscriptions. They prevent minor faults from becoming issues and provide dashboards for machine health and safety alerts, among many other options.
An often overlooked driver of lifecycle cost is bucket wear. Sandvik offers Shark™ GET, which are engineered for abrasive underground environments to protect bucket lips and geometry.“ And the results speak for themselves: up to three times longer bucket life, up to 45 % cost reduction over total bucket life and maintained one‐pass loading that reduces cycle times and protects driveline components and tires. Pairing a rebuilt loader with a Shark™ GET bucket increases your return on investment with longer intervals, fewer rebuilds and higher productivity.”
Buckets themselves are OEM‐optimised for breakout forces and centre‐of‐gravity, design choices that improve machine stability and extend component life. When rebuilds include these buckets and GET optimisations, sites reduce maintenance hours and variability in payload performance, while guaranteeing equipment’ s safety.
Extending fleet life should never extend risk. Eclipse ® Fire Suppression( FS) systems by Sandvik are fluorine‐free, engineered for loss‐of‐pressure with fail‐to-safe activation and designed to discharge foam for 40-70 seconds cooling superheated surfaces.“ This prevents risk of re-ignition unlike dry chemical alternatives. Eclipse ® FS can be installed on any mobile equipment brand and integrates automated detection and engine shut‐down as standard features. For mines extending first‐life assets into second life, standardising Eclipse ® FS across fleets raises the safety baseline while simplifying service and compliance.”
Big yellow rebuilds – the Caterpillar approach
IM also spoke to Caterpillar to get some insight into the depth of its rebuild offering and its general strategy in this part of the market. The aim of an equipment rebuild is to restore machinery to a like-new condition, both mechanically and structurally, while extending service life at a lower cost compared to purchasing new equipment.
Caterpillar says its dealers are uniquely positioned to help customers achieve maximum extended life.“ Customers can expect a detailed inspection and assessment process to identify the scope of work required for the rebuild. This includes evaluating machine condition, checking for structural issues and reviewing operational performance. Based on this diagnosis, a rebuild plan is created and shared with the customer, including estimated timelines, parts needed and cost. Transparency, communication and technical accuracy are key from the very beginning of the process.”
It adds that equipment rebuilds are instrumental in extending fleet life. Performed by Cat dealers in specialised workshops or component rebuild centres, the Caterpillar rebuild process follows a very structured approach which includes inspection & assessment- a full diagnostic review to determine rebuild viability and scope. This is followed by disassembly where machines are stripped of core components or down to the frame. Component inspection sees critical systems undergo rigorous testing then worn parts are replaced or restored to OEM specifications. Equipment is then rebuilt to OEM specifications in controlled dealer environments before functional and safety checks ensure readiness for return to service. Final setup includes performance monitoring and optional operator training.
Caterpillar:“ This process supports operational continuity, cost control and sustainability goals, making rebuilds a viable option compared to purchasing a new machine. By restoring the machine to like new condition, rebuilds deliver equipment with the latest technology updates and engineering enhancements. The rebuilt machine is capable of delivering the equivalent operating hours, reliability, productivity and safety of a new machine.”
But are rebuilds only for equipment reaching the end of its life, or is there value to rebuilding machines mid-service?“ Rebuilds are not limited to equipment at the end of its life. In fact, there is significant value in rebuilding machines during mid-life as part of a preventive maintenance strategy. Mid-life rebuilds help avoid unexpected failures, reduce downtime, and optimise long-term operating costs. Cat dealers can help with a repair-before-failure strategy with the help of predictive health insights such as Cat ® Product Link™ and Cat ® MineStar™ Health.”
It says by rebuilding major components or systems before they fail, customers can achieve higher part reuse during rebuild, increased equipment availability, extended asset life, and improved safety & productivity. Additionally, rebuilding at midlife is more cost-effective than waiting for a critical breakdown, which results in higher repair costs and longer lead times due to unplanned outages.
Cat argues that rebuilding equipment also goes beyond improving sustainability. While extending the life of assets and reducing waste are certainly benefits, the broader advantages often make rebuilds a good decision. Rebuilt components can perform like-new at a lower cost. Fuel efficiency, machine availability and reduced wear on other systems can all lead to operating cost savings. It also means a lower TCO as a well-executed rebuild can restore greater than 90 % of the machine’ s original performance for 60 %-85 % or less of the cost of new equipment, depending on the rebuild option. This improves asset value over its lifecycle.
Planned rebuilds also help avoid unexpected failures and breakdowns. When planned accordingly and by practicing a repair-before-failure strategy, rebuilds minimise production disruptions and give maintenance teams more control over fleet availability.
Worn parts and outdated systems can lead to risks.“ Rebuilds ensure critical components and systems are within OEM specifications. Safety enhancements and upgrades incorporated during machine rebuilds improve operator and site safety.”
Cat Reman and dealer subcomponents and major components can be incorporated into a machine rebuild, further reducing the need for raw materials. This lowers carbon emissions associated with manufacturing new machines and contributes to circular economy practices.
There is also the possibility of technology integration.“ Cat ® MineStar™ Health products and services enable customers to collect and transmit equipment data, monitor critical machine parameters, obtain realtime alerts, analyse operational trends and patterns, predict failures and receive repair recommendations, assisting with proactive maintenance services and predictive equipment analysis.”
Cat adds that its dealers are uniquely equipped to help customers maximise equipment life and productivity by implementing a repair-before-failure approach. Advanced Condition Monitoring, powered by connected technologies such
86 International Mining | FEBRUARY 2026