Mangaboy Promotes Safety First

Mangaboy Promotes Safety First

The development of safe lifting tools for Jaw Crusher liner and Cone Crusher liner handling and installation by Crushing Equipment Pty Ltd continues to attract attention. Introduction to Quarry and Mine sites in all States of Australia is well advanced and interest is now being expressed from overseas operators. Promoted using the trade name MANGASAFE with the dominant Mangaboy leading the way, the change from traditional long standing and now outdated lifting techniques becomes the norm for Crushing Equipment Pty Ltd customers. 

The introduction of the lifting tools began in 2009 and continues with great support from end users. Development began with the initial trials being carried out by the Conundrum Holdings Stawell Quarry, their Quarry Manager Brian Calovic, Crushing Equipment Pty Ltd parent company Cast Products – Amsted Foundry Solutions and key project personnel Tom Bruce, Lew Dilkes and Trevor Box. 

The traditional handling, installation, removal and reversing of crusher liners from the introduction of rock crushers pre 1900 was predominately carried out using weld on lifting lugs and to a lesser extent cast on lifting hooks or lifting holes. The cast on components often did not cover all handling requirements and in the main do not cover today’s standards for lifting requirements. Examples below.

A committee comprising Quarry Operators, Maintenance Tradespersons and Representatives from Crushing Equipment Pty Ltd carried out extensive investigation from 2008. The many existing lifting arrangements were reviewed along with the training and procedures for weld on lifting lugs. Although welding procedures were developed and welder training was supported for all operators the outcome was not the answer. The most highly trained welder cannot predict the suitability of the cast manganese steel liner in its many metallic forms. The days when crusher maintenance persons knew they had to ‘stand back’ while lifting jaw or cone crusher liners with weld on lifting lugs may have been lost along the way. The occasional mishap with a liner dropping onto the ground or equipment rarely gets reported. There have been death, injuries and plant damage during the past ten years that do not need to be revisited in this report. Further work was required.

Introduction of Mangasafe

Crushing Equipment Pty Ltd had the crusher end user support and the expertise within their own company group to take on the challenge to introduce a lifting tool to cover both Jaw Crusher and Cone Crusher liners. The lifting tool had to meet the following criteria: 

  • The lifting tool shall be designed to eliminate the requirement for weld on lifting lugs for handling, installation and removal.
  • The lifting tool shall be designed to support the crusher liner during the entire process of installation or removal. This includes eliminating the possibility for the liner to become disconnected from the lifting device during times of slack chains. This also included eliminating the requirement for the removal of the lifting tool prior to the liner being secured to the crusher eg., bolts fitted etc.
  • The lifting tool shall be designed to bend or distort before failure if overloaded. 
  • The lifting tool shall be designed with a Working Load Limit greater than the load for each lifting eye 
  • The lifting tool will not include bolts or threads.
  • The lifting tool shall be tested and certified to AS3776. Test reports to be available for all end users. Ongoing inspection and testing to be included with other on-site lifting tackle annual inspections. 
  • The lifting tool to be positioned on the crusher liner to allow clearance for feed chutes and securing arrangements.
  • It shall be designed to accommodate both the top and bottom of a split jaw liner and include liner rotation where required. 
  • The design shall allow the liner to be lifted at the correct angle to minimize manual handling of the liner into position.

Jaw Liner Lifting Tool 

The Jaw Liner Lifting Tool CE011, comprises two Lifting Eyes (WLL 4.0 Tonne each) and a stabilizer bar. It is light, easy to use and manufactured, tested and approval for liners up to 4,000kg. The jaw liner cast lifting holes are strategically located to angle the jaw liner against the crusher jaw liner backing plate without the use of additional mechanical aids (Fig 1)

Lifting a Jaw Liner includes the following steps:

  • The Jaw Liner Lifting Tool is used to lift the liner from the storage position (floor, pallet or other open container) to the crusher or from within the crusher during jaw liner change or reversal. 
  • Both Lifting Eyes are inserted into the elongated lifting holes and rotated 90º in the recess cast into the fitting face of the jaw liner (Fig 2).

  • The Stabiliser Bar is fitted through the holes in both Lifting Eyes and locked into place with two clip pins (Fig 1). 
  • Lifting chains, including closed hooks attached to equal length chains, are attached to both Lifting Eyes. 
  • To remove jaw liners from the crusher it is important to ensure they are free of any obstructions and all retaining bolts are removed before lifting commences. To remove the jaw liner from the crusher seating face it is important to ensure the two chains are evenly loaded and the combined load does not exceed the combined working load limit of the Jaw Liner Lifting Tool Lifting Eyes or the working load limit of the chain sling.
  • The Jaw Liner Lifting Tool is removed once the jaw liner is placed on the floor or container, or securely bolted to the crusher backing plate. the lifting holes may be filled with expanding foam to minimize the amount of crushing residue entering the lifting hole cavity.
Jaw liner lifted with angle towards fitting face

Lifting Eye rotated into recess

Cone liner lifting Tool

The Cone Liner Lifting Tool CE014 comprises two Lifting Eyes (WLL 4.0 Tonne each) complete with locking slides (Fig 3 & 4). Elongated holes are cast into the cone liner to accommodate the two Lifting Eyes. The Lifting Eyes are strategically located in the cone liner to ensure a vertical lift without the use of additional mechanical aids (Fig 4)

Lifting Eyes with with 
Locking Slides for CE014
Lifting Eyes secured with
Locking Slide in place

Lifting a cone liner includes the following steps:

  • The Cone Liner Lifting Tool is used to lift the liner from the storage position (floor, pallet or other open container) to the crusher or from within the crusher during liner changes. 
  • Both Lifting Eyes are inserted into the elongated lifting holes in the cone liner and rotated 90º (Fig 5).
  • The locking Slides are moved forward into the lifting holes and locked into place with two Lynch Pins (Fig 4). 
  • Lifting chains, including closed hooks attached to equal length chains, are attached to both Lifting Eyes. 
  • The Cone Liner Lifting Tool CE014 is removed from the cone liner once the liner is placed on the floor, in a container, or securely fitted to the crusher. 
  • At the completion of the cone liner installation the lifting holes may be filled with expanding foam to minimize the amount of crushing residue entering the lifting hole cavity.
FIG 5

Safe Operating Instructions:

The lifting tools are supplied with instruction booklets for all those involved with their use. It is important to incorporate these instructions for the Jaw Liner Lifting Tool and Cone Liner Lifting Tool into site specific Operating Procedures and Work instructions. A Crushing Equipment Pty Ltd Representative is available to assist with these documents if required. A number of relevant points to be observed include:

  • Before lifting a jaw or cone liner the cast in lifting holes must be inspected to ensure any excess wear or damage does not exceed the requirements included in the instruction booklets.
  • Removing jaw or cone liners from the crusher presents issues due to manganese expansion onto side walls, locking onto seating faces or locking bolts not removed. It is important to ensure the liner is free of any obstructions and all locking devices are removed. To remove the cone or jaw liner from the crusher seating face it is important to ensure the two chains are evenly loaded and the combined load does not exceed the combined working load limit of the Lifting Tool lifting eyes. Cranes with load measuring devices to protect all equipment from possible overload must be given preference for this task. 

Crushing Equipment Pty Ltd has the design and manufacturing facilities to custom make liners for the quarry industry. This includes cast in lifting holes for the lifting tools strategically placed to meet individual customer requirements. The total package, initially introduced to address the current safety issue identified by the Committee, has lead to significant cost savings due to the reduced time and crane hire required for liner changes.

LOCATIONS

Melbourne

6 Dib Court
Tullamarine Vic 3043
ph: (03) 9338 0200
fx: (03) 9338 0680
e: vic.admin@crushingequip.com.au

Perth

88 Barberry Way
Bibra Lake, WA 6163
ph: (08) 9434 5552
fx: (08) 9434 5515
e: wa.admin@crushingequip.com.au

Brisbane

Unit 2 23-31 Meaking road
Meadowbrook QL 4131
ph: 07 3801 8153
fx: 07 33820098
e: qld.admin@crushingequip.com.au