Mine Shaft Systems

Dorr-Oliver & Vecor Equipment

The Standard of the Industry

2

Quality solutions
delivered

Mine shaft systems equipment

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Ore Skips 4-7
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Cages 8-9
Rebuilds/Refurbishes 10-11
FLSmidth offers you the
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Materials Handling Car/Cage 12-13
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Guide Rollers
Rope Sheaves


14-15
16-17
highest quality products
for your underground
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Measuring & Loading Stations 18-19
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Ross Chain Feeders
Mine Haulage


20-21
22-23
mining operation.
Contact us, we will help
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Mine Hoists 24-27
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Rope Attachments,
Arrestors & Catch Gear 28-29
find the best solution
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Crushers & Sizers 30-31 for your application.
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Customer Services 32-33
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Complete Solutions 34-35
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Complete mine shaft systems

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Ore skips

FLSmidth offers a
complete range of types and
sizes of Ore Skips from 1-45 m3
(40-1600 ft3). Our Skips,
regardless of size or style, are Bottom dump skip
designed for fast and clean Our Bottom Dump Skips are light and rugged for medium
dumping of ores, in all kinds of to large loads. They are well suited for large uncrushed
metallic and nonmetallic mines. muck and wet sticky fines.
Clean dumping due to the tilt-out action of the bucket
makes it particularly suited to handle sticky materials
Rolachute Skip
Fines spillage minimized by FLSmidths Dorr-Oliver
Capacity, 1200 cubic feet (34 cubic meters) piano-type bucket hinge and the Skip door that
protrudes into the dump chute
The Bottom Dump has the largest unobstructed
opening for discharge with no concern of bridging of
large uncrushed material
Simple & secure Dorr-Oliver locking and discharging
mechanism minimizes maintenance.
Discharge is activated by the dump rollers running in
scrolls, mounted in the headframe. (Optional cylinder
discharge in the headframe minimizes cycle time and
the required headframe height.)
 5

Since all Bottom Dump Skips Kimberley skip FLSmidths Arc-Gate Skips have
have a bail around the bucket, Lightest, Least Expensive been supplied to replace Front
they are good for shafts with less Best weight to payload ratio of Dump Skips for increased safety
than perfect guide alignment. any Skip and to eliminate the on-going
(Note: All types of FLSmidth Skips Very simple with minimal maintenance due to costly
can be supplied with a bail if so maintenance linkage mechanisms.
desired) FLSmidths quick-change Cleanest possible dumping due There is no requirement for heavy
design allows the bail to remain to overturning action and no air actuator cylinders or air piping
in the shaft while the bucket is possible discharge restrictions in mounted on the skip.
removed for liner replacement or the bucket. The cycle time, while relatively
exchanged with a Cage. Always the best choice for all short, can be reduced even further
Long lasting; some FLSmidth light small skip applications with to almost match the Rolachute by
weight aluminum Bottom Dump volumes less than 200 cubic using a headframe mounted
Skips have been in service in feet/5.7 cubic meters. cylinder actuator design.
hardrock mines for over 30 years. FLSmidth has been supplying Rugged construction results in
FLSmidths Bottom Dumps are Kimberley Skips for over 80 years. many Arc-Gate Skips having been
the workhorse of the Hardrock in service in hardrock mining for
Mining Industry. Arc-Gate skip over thirty years.
Lowest Maintenance, Rugged , Safest Best suited for dry, crushed
The FLSmidth Arc Gate is the material.
lowest maintenance skip on the
market today. This skip has only
one moving part, making it the
most simple and maintenance
free.
This Skip evolved from and These Arc-Gate skips have been in continuous
superseded the Front Dump Skip service since 1975. The only maintenance has
been regular lubrication and replacement of
by the elimination of the high
wear liners.
maintenance front mounted door
opening linkage.
The Arc Gate cannot open
accidentally, and when the door
is open, it does not protrude
outside of the compartment.
Contact with shaft steel is
impossible.

The standard Dorr-Oliver Aluminum Bottom

Dump skip is the workhorse of the hardrock
mining industry.
6

Ore skips
(cont.)

Rolachute skip Safety

Fastest Cycle, Low Maintenance All Skips are available with proven
The Rolachute door gives this Safety Mechanisms for either wood,
Skip the fastest cycle time of any steel, or rope guides.
Skip design. The absence of
scrolls in the headframe means Chairing
that it is not necessary to slow All Skips can be supplied with optional
down to a creep while entering Chairing Pads for use with Dorr-Oliver
the scrolls. shaft-mounted Skip Loading Chairs,
Simple Dump Rollers mounted in which eliminate excessive rope stretch
the headframe allow the door to when loading at great depth.
open with minimal vertical travel.
Low maintenance requirements; Material
no air-cylinders, actuators or All Skips can be constructed of Steel,
piping are required on the Skip. Aluminum, Stainless Steel or
Best suited for dry, crushed strategically placed combinations.
material. Advanced protective coatings &
insulation barriers are used to resist
Sala front-dump, galvanic and chemical corrosion.
incline, cage / skips
While not as common as the skips Liners
already listed, FLSmidth also makes All Skips have many Liner options
other types of Skips to match existing available including abrasion-resistant
or suit special conditions and steels, cast high manganese, or
situations. If it is a special application, rubber strategically placed in high
we have probably already supplied it impact and high wear areas, designed
or something similar to it before. Call for ease of replacement.
us to find the right Skip for your
requirements. Design
In some modern installations skips are All Skips are designed based on over
approaching high speeds of up to 80 years of experience supplying
3800 fpm (19 meters/sec), making thousands of Skips to every
balance and alignment critical design application, from Gold, Silver, Iron,
considerations and issues to which and Lead to Potash, Coal, Salt, and
we pay close attention. others. Documented experience,
methods and standards are coupled
Optimize your production by with the latest engineering design
maximizing payload to tare weight technology and FLSmidth Quality
ratios for improved operational Assurance Systems to produce
efficiency by installing the Skip type efficient, safe, long-lasting Skips.
and material of construction best
suited to your application, as
supported by our experience and vast
list of installations.
 7

Skip / cage combinations

All Skips are available with integral man
cages, or with accommodation for
Trailer Cages. Our 3H Quick-Change
System allows for very quick installation
and removal of the Trailer Cage.

Guide rollers
All Skips can be fitted with a full
range of FLSmidth Guiding systems to
suit all applications and conditions
ranging from economical long lasting
Heavy-Ply, fixed rollers for slower
speed to High Speed Aircraft tires
with spring coil over gas-charged
Cylinder suspension. Several sizes and
types of tires including Pneumatic,
Solid Rubber, Foam-Filled, and solid
Polyurethane are available. The
wheels are mounted on Steel,
Aluminum, or Stainless hubs and
brackets with either fixed, serrated,
or eccentric axle adjustments.

Selection
Contact us and advise us of your
operating conditions and we will help
you pick the best Skip type, Material,
Guiding System, and Safety
Mechanism to economically suit your
application.

Solid modeling ensures all clearances

and interferences are considered at the
design stage.
8

Cages

Our cages range from very small

Two-Man Auxiliary Cages and
Trailer Cages to Multi-Deck Cages
handling 300 men or more, or
internal loads of trucks,
equipment, and material of 50
tons or more.

Guide Slippers service-able from inside the Cage, Safety Dogs and
FLSmidth installed Customers Hydraulic Chairing Device.
 9

Custom designed
(Top) BMR Cage
Varying conditions found at installations throughout the (Bottom) FLSmidths stainless steel cages.
world dictate that each cage is a custom design, tailored to
the clients specific requirements. All types, Service Cages,
Auxiliary and Trailer Cages, each with many options and
alternatives, such as various designs of cage floors, doors,
roofs, removable intermediate decks, and removable
counterweights are available.

Cages are usually designed with significant amounts of

aluminum to maximize payloads. However materials of
construction can include mild steel, stainless steel, and
strategically placed combinations of these materials,
depending on the application and service conditions.

Safety
For cages operating with single rope drum hoists, we
provide Safety Mechanisms for either wood, steel, or rope
shaft guides. The safety mechanism, which is activated by a
slack rope condition, brings the cage to a controlled safe
stop. cages are also designed to operate with a multi-rope
Koepe hoist. We also provide rope attachments and Safety
equipment such as Arrestor Frames for the head frame and
shaft sump. These devices are designed to create a predict-
able deceleration and bring the conveyance to a stop in the
event of a hoist problem.

Suspension
Traveling at high speeds, these large conveyances also
require proper suspension. We offer several types of
heavy-duty Guide Rollers and Suspension Systems to suit all
conditions.

Stainless steel cage

Shown to the right (top) is a BMR cage with 112 man
capacity. The cage shown to the right is stainless steel
construction with an aluminum roller door on the bottom
deck. The top deck is equipped with an aluminum guillo-
tine door. The Aluminum Roller Door can be supplied with
a spring or segmented counterweight.

Design
All cage designs are based on over 80 years of experience
of supplying thousands of cages. With that documented
experience, our methods and standards are coupled with
the latest technology engineering design methods and
Quality Assurance Systems to produce a Certified Safe and
long-lasting cage.
10

Rebuild / Refurbish
skips and cages

FLSmidth rebuilds and

refurbishes our own and other
manufacturers Skips and Cages
to a functionally new condition.

The solid model above was used to check clearances on the ultimate skip
rebuild; a front dump skip that had been manufactured by others and was
still relatively new was converted to an FLSmidth Dorr-Oliver Arc-Gate Skip
to eliminate the Front Dump maintenance issues. The bottom quarter of the
skip, which is the working section, was removed and replaced with this new
section.
 11

Conveyances often come back to us in a condition that

some people would consider to be at the end of their
(top) Skips in line for grit blast cleaning prior to inspection
useful life. The conveyances have suffered through
(bottom) A rotten piece that was removed by elective surgery and replaced
corrosive environments (salt brine and acidic shaft water) with new material. By not using patches the skip can be rebuilt many times,
and have withstood abrasion and impact from hard rock for many service campaigns.
and be scrapped or remanufactured.

The skip or cage is methodically re-built to a functionally

new condition, re-certified by a professional engineer and
returned to the mine to serve another complete tour of
duty. Many skips have been rebuilt and served additional
campaigns many times. Skips that have undergone a
regular preventative maintenance series of rebuilds, in the
end cost less because they serve more tours.

The same personnel that build FLSmidths new Dorr-Oliver

Skips and Cages perform the rebuild and implement the
same methods and quality criteria. FLSmidth quality
standards, systems and procedures, and an engineering
rebuild package specific for each skip or cage are used. The
engineering package consists of to-do lists including
critical items that require NDT ultrasonic testing, magnetic
particle and liquid penetrant inspection, original detail and
modification drawings, quality assurance check lists,
painting and special client requests for modifications.

Ready to return to work, and functionally the same as

a new skip.(See light blue skip to the left) Typically, the
equipment has been blast cleaned, straightened, any
damage repaired, or corroded sections replaced, cracked
welds repaired, any areas where problems have occurred
were redesigned and made stronger, worn guide slippers
replaced, all bearings, seals and bushings replaced, safety
spring replaced, all safety device pins, shackles, shafts and
dogs and drawbars were NDT tested and replaced as
necessary, hinge pins and liners replaced. It was painted
with two coats of High Build Epoxy and given a new load
certificate and OEM warranty. Ready for another campaign
equal in length to the previous one.

Why not just use a local shop?

An FLSmidth rebuild is not just putting on a patch and
replacing liners. The integrity of the rebuilt conveyance is
assured and it can be trusted to s afely and efficiently
perform like new.
Grit blast cleaned
Completely dismantled & inspected
NDT tested, repair or replace
Replace bearings, bushings and wear items
Re-Design problem areas, stronger
Ensure integrity & straightness of structure
Ensure smooth operation of mechanical
Painted & Certified with new OEM Warranty
12

Material handling
cars/cages

Material handling car

Material Handling Cars are available to transport material
of any specified length, for slinging inside cages or
Counterweights. Designs for track or trackless operations.

Fully enclosed with expanded metal for trash removal from

underground. Floor can be either live to transport packaged
timber or pipe or may have a flat floor.

Zimmerman materials cage

The Zimmerman Timber Cage has proven itself as a time &
labor saving mine conveyance, especially in installations
where hoisting capacity is limited. It requires only a few
minutes to swing the cage in or out of the shaft using the
shaft hoist and permanently fixed slings.

We will design to suit any compartment or guide size and

Cages are available for either track or trackless operations.
 13

Materials Handling Car slung inside Coun-

terweight

Zimmerman Material Handling Cage with

flat floor and enclosed with expanded
metal for trash removal.
Zimmerman Material Handling Cage
with live Roller Floor for Timber or Pipe
Handling.
14

Guide rollers

Guide roller selection is specific

to conditions at each shaft.
Correct application helps
maintain guide alignment and
minimize maintenance.

Left, urethane tires are well suited

to shafts with high loads, steel
guides and moderate speeds.
 15

Minimize shaft maintenance and

extend equipment life
Set of solid rubber tires on aluminum hubs with urethane compression
FLSmidth has developed over many years a complete range suspension. The suspension unit consists of a swing arm with urethane
of Guide Rollers to suit every condition and application. compression springs. The suspension maintains pressure against the
guides. Light and heavy-duty suspensions are available.
FLSmidths Dorr-Oliver Guide Rollers operate on timber or
hollow structural steel shaft guides at speeds as high as 40
miles per hour. With an improperly designed or miss-applied
Guide Roller any slight misalignment of the guides can cause
the conveyance to impact the guides at as much as 2  Gs.
These impacts eventually cause further misalignment of the
guides and the problem compounds until the guides must
be re-aligned. The use of FLSmidths Dorr-Oliver Guide
Rollers results in reduced shaft maintenance and roller
adjustment and prolonged roller life.

Sizes
Range from 9 to 16-1/2 diameter.

Tires
Include Heavy Duty Pneumatic-tube, Solid Rubber, Foam
Filled, Solid Polyurethane and the Pneumatic Aircraft tire.

Materials
Options for the Hub and Brackets include pressed steel,
aluminum and stainless steel.

Mountings
Include Fixed Bracket, Compression Suspension and the
Coil Over Shock Absorber.

Set of solid rubber tires on cast aluminum rims. Coarse adjustment via ec-
centric axle or serrated plates is available. Fine adjustment via the threaded
suspension rod.
16

Rope sheaves

The success of our Sheaves

is due to high quality
manufacturing and design
practices. The Dorr-Oliver
sheave is widely recognized
as the best available.

Solid modeling and finite element analysis are standard design

procedures and the designs exceed all applicable codes. Raw materials
and the final product are subjected to extensive non-destructive testing.
 17

Head & deflection sheaves

FLSmidths Dorr-Oliver Head Sheaves and Deflection Sheaves
are available in a variety of all types with sizes ranging from
3 ft. diameter to 25 ft. diameter or larger as required.

All sheaves are designed to withstand a load equal to the

rope breaking strength.

Our Sheaves can be designed with split type or

segmented construction for ease of handling and
installation in limited space.

Alternative designs include unlined, steel-lined, and

polyurethane-lined to satisfy all applications and conditions.

FLSmidth Sheaves typically outlast the mineshaft that they

were installed in because they are built to last, FLSmidths
Dorr-Oliver Sheaves are often recycled and reused in a new
shaft. We have replaced sheaves that were manufactured by
others that had not lasted even to the life of the first shaft.

Compensating sheaves
The Blair arrangement uses two sheaves side by side, for
two connections to the skip or cage. This provides deep
hoisting capability with two ropes, thus eliminating the
requirement for a safety mechanism and wooden guides.
Economical rope guides can instead be used. Our
Compensating Sheaves ensure hoist rope tensions and
lengths are equally maintained via our supply of load cells
and hydraulic power package.
Largest Sheave in North America 21.5 ft ~ 6.6 m diameter

Sinking sheaves
Standard sizes of 36, 48, 60 and 72 inch point diameter,
complete with shaft and bearing assemblies. Customer
specific sizes also available.
18

Measuring &
loading stations

FLSmidth Skip Loading Systems

will move your ore and/or waste
from your ore passes or storage-
surge bins to your skip and
control your hoisting plant
automatically and unattended.
 19

The heart of the Loading System is

the proven load-sensing device
between the measuring capsule and
its supporting structure, which
controls the feeders or conveyors and
the gates or transfer hoppers on two
compartment systems.

The arrival of the empty skip at the

loading position discharges the
appropriate measuring capsule,
initiates the hoisting plant and
re-cycles the feeding and conveying
function. Multiple level and manual
operation are available on all loading
systems.

FLSmidth can supply the system to FLSmdiths Dorr-Oliver Loading

feed the Loading Station as a Loading Stations are custom designed to suit
System Package. Items like the each situation. Designs include swing
conveyor, vibratory pan or Ross Chain out directional chutes and air
Feeders and the belt magnet are operated transfer hoppers/cars to
included. The cylinders, conveyor, direct the ore to the proper
feeders, measuring boxes and skips measuring capsule from a single
can all be interlocked with proximity conveyor.
switches and hoist controls via PLC.
The entire loading and hoisting The images to the right were part of
system can be fully automated. a skip loading station supplied in
These photographs show a Measuring
2005. Also included were two
Flask with an ARC GATE door discharge
The illustration on the left shows a guillotine gate feed chutes, abrasion chute that is particularly well suited in
typical but basic two-compartment resistant liners, support structure, limited space and where very accurate flow
loading station with each access platforms, pneumatic cylinders control is required.

compartment fed by a separate & controls. Hydraulic cylinders and

conveyor and the Wedged Lock optional power packs are also
splash-proof doors that are available.
particularly well suited for sticky muck
and rapid discharge applications.
Modern high speed hoisting systems
must be kept in motion as much of
the time as possible. Therefore you
cannot afford to have a skip waiting
for a slow loading arrangement.
Many types of arrangements are
available and almost any arrangement
and capacity has already been
supplied.
20

Ross chain feeders

Handle heavy granular materials

with ease & efficiency.

In the circle in the photo to the right is a man checking the chain
at installation. It is difficult for the uninitiated to understand how
completely the Ross Chain Curtain curbs the most violent rush of
material into a quiet steady flow.
 21

Application
Ross Chain Feeders are handling every
known granular material on five
continents. They have proven their
efficiency in handling the heaviest
rock and ore feeds to primary
crushers, bin storage feeds to
secondary crushers, and as hopper,
bin and chute control feeds to
conveyors and skips.

The Yielding Top Control Principle of

operation ensures remarkably long
life to the equipment and minimum
power consumption. It guards the
outlets of 2000-ton vertical ore
pockets and in other installations; curtain, which lies on the material.
35-ton loads are being dumped The feeder rotates moving the
straight at the feeder. material into a steady single-ply
stream and feeds it down a chute at a
Pivot chute controlled rate. Ross Feeders are
For precise control of feed, the Ross available in a large range of Drive and
Pivot Chute Lip is a valuable addition. Chain sizes to handle a full range of
No other change in the feeder is size from large uncrushed rock to
required. Raising or lowering the lip crushed granular materials.
changes the tonnage flow over a
range as great as 3.5 to 1 on small or Variable speed drive
crushed material or 1.5 to 1 on very The flow range can be further
large rock. increased several times by including a
variable speed drive on the Feeder.
Operation This makes it ideal for feeding
The Ross Chain Feeder is much more crushers, pulverizers, dryers, Kilns,
effective than a stationary chain mixers, conveyors and screens. Drive
curtain. The Feeder provides the options include variable frequency AC
restraining effect of an endless drives and Hydraulic drives.

(Top) Standard Ross Chain Feeder

(Bottom) Ross Chain Feeder with Pivot
Chute Lip
22

Mine Haulage

Mine cars for all your

underground mining needs

Arc-Flow bottom dump cars requirements. Standard proven components and methods
FLSmidths Dorr-Oliver Arc-Flow Cars are available in of construction are combined with FLSmidthss long
capacities from 70ft3 to 350ft3 and for track gauges for 30 experience in underground haulage and mine operations to
up to standard rail gauge of 4 8-1/2. When arranged with produce the best mine car value available in North America.
overlapping ends for continuous loading and ramp
dumping, the Arc-Flow car train becomes an ideal Gable bottom cars
application for semi or fully automatic haulage systems. Muck that has proven impossible to discharge from
conventional mine cars can be handled efficiently in
Granby cars FLSmidths Dorr-Oliver Double Door Gable Bottom mine cars.
FLSmidth has manufactured over 2500 Granby Type Mine
Cars ranging from 40 to 300 cubic foot capacity. Most of Tipple cars
these cars are still in operation today handling the bulk of FLSmidths Dorr-Oliver Tipple Cars are available in capacities
the Canadian underground mining production, waste from 100ft3 up and designs can range from simple tub-like
haulage, and in some cases, backfill. FLSmidths Granby construction to literal battleships.
Cars are practically all custom designed to fit our customers
 23

Grangesberg cars
FLSmidths Grangesberg cars with
overlapping ends and remote
locomotive control at the loading
chutes have proven to be very
efficient one man high capacity
haulage system. The locomotive and
cars are carried over the dump station
by a series of rollers engaging a track
on both sides of the locomotive and
the car bodies. The bottoms of the
cars drop away on the contoured
single dump rail permitting
unrestricted material discharge.

Rock dump cars

FLSmidths Dorr-Oliver Rock Dump have tremendous possibilities for
Cars are the best known type of mine handling ore, waste, back fill or other
car in the world. FLSmidth has material underground, and almost
manufactured well over 3,000 Rock any free flowing material in surface
Dump Cars in capacities ranging from processing plants. Potential is limited
10 to 60ft3 and these have included only by the working space available.
all possible conditions of track gauge
and cage sizes, etc. The Rock Dump Man coaches
Car is still very popular for As underground workings spread out,
development and production haulage the time required to place men in the
underground. working areas becomes a major
problem. FLSmidth has manufactured
Scraper trains and supplied a considerable quantity
Some development drives and of man coaches with capacities
tunnel projects are well suited for ranging from four to forty men for
the application of Scraper and various mines across the world. All
Slusher Trains. FLSmidth has designs provide maximum protection
supplied several Slusher Train and as much comfort as possible with
Installations for development work, wood slat seats, rubber cushioned
all of which have completed their wheels and couplers, and optional, Shuttle cars
designed projects and since then sprayed on lining for sound proofing. Drifting and development work
converted to regular haulage. always presents the problem of
Zimmerman timber cage cars getting the loaded car away from the
Double door bottom dump cars FLSmidths Zimmerman Timber Cage face and an empty car in its place.
FLSmidths Double Door Bottom Cars are enclosed with expanded FLSmidths Dorr-Oliver Shuttle Car is
Dump Cars are high capacity main metal for trash removal from an accepted and proven method of
haulage cars designed for continuous underground operations. Zimmerman passing cars up to the face in most
bottom dumping and continuous Timber Cage Cars are available to mines.
loading. This type of car is well suited handle the materials from 8 to 22 ft.
for high production haulage of long and to suit any compartment or Service cars
primary crushed muck. guide size with special designs for Transporting supplies and equipment
slinging inside cages or for trackless both on surface and underground is
Self-Propelled transfer cars mining operations. always a costly and difficult
FLSmidth has designed and procedure. FLSmidth has not
manufactured a number of air and Transfer cars neglected this phase of haulage and
electrically driven transfer cars for Head Frame Transfer Cars are have designs available for almost any
both underground and surface another specialty of FLSmidth. type of Service Car. If you have a
applications. These can be operated Designs are available to direct the service car problem, call us to find out
manually from the unit, or remotely flow of ore or waste in as many as how we can help you.
from a control station. Transfer cars four different directions.
24

Vecor mine hoists

6.0 m 4-Rope Koepe Hoist - Lonmin K4. We also design and supply hoists for specialized applications
FLSmidth has a proven history in the design, such as stage hoists for shaft sinking operations.
manufacture and supply of robust, reliable Vecor Mine
Hoists. Our office based in Johannesburg, South Africa is FLSmidth has supplied hoists with drum diameters ranging
the center of excellence for hoisting technology within the from less than 1.0 meter to greater than 6.0 meters. The
FLSmidth. majority of these hoists have been of the double drum
configuration with dual clutched drums and diameters
FLSmidth has a hoist reference list that exceeds 500 greater than 5.0 meters.
installations worldwide over a period spanning more than
100 years. Design & braking systems
The FLSmidth design team has pioneered and perfected
We have extensive experience in the supply of hoists in the many hoisting configurations particularly in the field of
three principle categories, namely: deep level hoisting. FLSmidth has designed, manufactured
Friction/Koepe Hoists and supplied more BMR hoists than any other hoist
Drum Hoists (Single and Double Drum) supplier. We are also the first company to successfully
Blair Multi-Rope (BMR) Hoists supply a hoist operating over a single winding depth in
excess of 3000 meters.
 25

The hoist design process makes extensive use of our (Top) FEA model for hoist drum
in-house finite element analysis (FEA) facilities. Modern (Bottom) Disc braking arrangement
software allows for all geometric details to be modelled
and fully analyzed, ensuring reputed robust and reliable
designs. Our designs have been proven over many years in
the field, with performance being backed by field strain
gauge testing.

Drum design is a crucial component for all hoists. Drums

are exposed to heavy loads of a cyclical nature and are
therefore designed in accordance with recognised
international standards for fatigue design.

Various drive configurations can be offered including

geared, direct drive with overhung motors and Integral.
Motors can be AC Induction, AC Synchronous or DC and
would be supplied through a preferred supplier.

For the purposes of cost competitiveness, FLSmidth

employs concepts of designed for manufacture and
make use of their global network for material and
component sourcing in order to provide hoists of the finest
quality with unparalleled levels of reliability and production
availability.

FLSmidth is able to offer fully customised designs to suit

individual client needs and requirements. These customised
designs make use of commonly used standard components
such as bearings and clutches.

FLSmidth as an international leader in hoisting technology,

has developed hydraulic systems for Escort and Closed-
Loop brake control. The developments in Closed Loop
control were stimulated by the need to reduce dynamic
rope loads under emergency braking conditions.

The resultant reduction in peak rope loads has facilitated

deep shaft hoisting. Sophisticated hydraulic systems are
employed to ensure rapid speed of response and repeatable
control accuracy.

Disc braking systems are the preferred arrangement for

current hoists. The design of the brake path or brake disc
ensures minimum deflection under rope loading and high
stability under thermal loading.
26

Vecor mine hoists

(cont.)

(left) Koepe Hoist - Lonmin K4 Friction & drum hoists operating loads due to the required
(right) 6.0 m Double Drum Hoist - Friction hoists, commonly referred to use of tail, or balancing ropes. For
Impala 14#.
as Koepe hoists, provide an adequate rope life, the static load
economical solution to many hoisting range should be limited to
applications. These hoists typically approximately 12 % of the rope
have lower capital costs when breaking strength. Regular rope
compared to drum hoists due to maintenance and replacement is
characteristic lighter, single-drum essential on these hoists.
constructions and lower installed
power requirements. Koepe hoists are not normally favored
Koepe drums are subjected to high for depths of wind greater than 1800
cyclic fatigue loads, typically reversed m. However, for depths within the
during every drum revolution. Design 1800 m range, very large payloads can
is of necessity for infinite fatigue life. be handled by increasing the number
of head ropes. Koepe hoists frequently
The head ropes of a Koepe hoist are find application as service hoists for
subjected to cyclic variations in men and materials using a cage and
 27

counterweight arrangement. These

are often configured for use with push
button cage control.

Drum hoists, both single drum and

double drum, are the most frequently
used type of hoisting system. With
multi-layer coiling the double drum
hoist is frequently used for lengths of
wind to 2500 metres, but can be
used for lengths of wind greater than
3000 metres.

Although normally winding in The BMR system significantly

balance, the range of brake torque increases the hoisting capacity of a
required during emergency braking drum hoist. Hoists with end loads of
requires some form of brake control 32 tonnes at depths of 2500 meters
system to provide acceptable are common. The Moab Khotsong
retardation levels under all winding BMR winder, supplied by FLSmidth to
conditions. The control of emergency Anglogold Vaal River Operations,
braking retardation for single drum was the first hoist to operate to a
hoists is particularly problematic due depth of 3150 m in a single wind
to the high out of balance loads and with an end-load of 23 tonnes.
great variation in the natural rates of
retardation for different hoisting The most frequently encountered
conditions. FLSmidth has extensive problem with a BMR hoisting system
experience in the design of suitable is that of Fleet angle control because
brake control systems. of the wide drums inherent in BMR
hoists.
Blair multi-rope hoist
The conventional double drum hoist A number of solutions are employed:
underwent a major development in
1957 when Robert Blair introduced Arranging the drums in tandem
the concept of combining the load and mechanically coupling
carrying capacity of multiple ropes in through gears.
the friction hoist system with the Arranging the drums in tandem,
simplicity and flexibility of drum or side by side, but inclined at an
hoists. Each drum of a BMR hoist is angle, and coupling electrically.
divided into two (or more) In-line arrangement of drums
compartments with a single rope per where the shaft system allows for
compartment - each rope on the conveyances at large centre 5.1mBMR Hoist with Hookes JointCou-
drum being attached to the same distances, for example using the pling - South Deep

conveyance. Systems are incorporated outer compartments of a shaft.

to ensure load sharing between ropes Arranging the drums inclined to
and protection against miscoiling. each other, but mechanically
coupled through a Hookes Joint.
28

Rope attachments,
catch gears,
and arrestors
Fine adjustment hydraulic Thimble type cappel
linkage Thimble Cappels are used in single
Fine adjustment Linkage is primarily and multi-hoist applications.
used in friction hoisting setups. The
linkage allows fine adjustment so all Solid thimble & clamps
ropes in a muti-rope arrangement are Solid Thimble and U-Bold Clamps are
equally tensioned and therefore used with either Round Strand Hoist
working together which in turn or Balance Rope connections.
greatly extends rope life.
Dorr-Oliver catch gear
Sockets Pawl configuration custom
Sockets are used on a variety of designed to suit load case and
applications including Hoist, Balance, space constraints
Guide and Sinking Ropes. (single or multiple pawl columns,
The Socket attachment offers a safe, double sided designs for tight
economical connection and can be clearances between
installed with either the quick and compartments).
efficient Wirelock Resin or Zinc. Pawl box with guides and guide
shoes mounted to support post
and base.
With special Threaded STT and STJ Hydraulic buffers to reduce
Type Sockets, a wide range of Jaw or impact loading on components
Tang ends can be made to suit most and headframe structure.
required connections without a Link Manual or hydraulic pawl
Plate. Our standard SJ (non-threaded) retraction for maintenance checks.
Sockets normally require an Adapter
Link Plate, adding both cost and bulk
but are preferred in some
installations.

All Sockets are designed with a

minimum of 10:1 Factor of Safety,
Proof Load Tested to 2 times Safe
Working Load, Ultrasonically and Wet
Magnetic Particle Inspected. All meet
or exceed National Coal Board
Standards. Sockets are customer
(Bottom) Ultra Heavy Duty Catch Gear for
designed to suit customer needs.
North Americas Largest Ore Skips. Shown
is part of a set designed for an impact
loading of 1,400,000 lbs.
 29

Swivel & swivel hooks base unit to facilitate rotation of the

Swivels are used to provide rotation, Guide Ropes, thereby evenly
primarily in Balance or Sinking Stage distributing wear over the rope
Ropes, to alleviate torque surface.
buildup, which is damaging to ropes.
A variety of styles are available ranging Guide rope tensioning
in capacities from 1 to 100 tons. Where shaft Guide Rope systems are
used in lieu of rigid type guides,
Glands several attachment assemblies are
Glands are used for the maneuvering, available. Arrangements are offered
lifting and suspension of Round with bottom weight tensioning (most
Strand or Locked Coil Ropes. common), bottom spring
tensioning or top spring tensioning.
The Gland design is similar to that of
a Wedge Cappel, utilizing The upper attachment includes a
interlocking wedges inside the two Spherically Seated Gland, while the
part gland body. bottom end can be fitted with a
socket or glands. The socket or gland
All Glands are manufactured from is then connected to a Triangular Link
high quality steel, Proof load tested to Plate which facilitates load transfer (Above) Spherically Seated Glands and
2 times safe working load, for rope changes. Manoevering & Suspension Gland

ultrasonically and wet magnetic

Balance (tail) ropes
particle inspected. With bottom weight tensioning,
34x7 & 34x17
cheeseweights are mounted on a rod
Plastic Enhanced
Maneuvering & suspension and platform thereby keeping
Special Small Loop Construction
glands guideropes tensioned. As mentioned,
This type of gland is commonly used rather than cheeseweights, spring
Guide ropes
for manoeuvring ropes into position tensioning can be employed at either
Half Locked Coil
or anchoring permanently where top or bottom.
rotation is not required.
Drum hoisting ropes
Tension Weights (Cheeseweights)
FLSmidths capabilities range from
Spherically seated glands The dimensions of the cast iron
simple single drum to deep shaft
The Spherically Seated Gland can be tension weights are generally
installations.
used similar to the non-spherical type determined by the shaft layout
High Performance Non-Rotating
but in addition, has a spherical brass and position of the guide and
Flattened Strand
rubbing ropes.

Lead cheeseweights can be used

when height restraints become
an issue.

Friction (Koepe)
hoisting ropes
FLSmidth offers solutions for tower
and ground mounted Friction (Koepe)
Hoists which have a long standing
reputation for providing ropes for
deep shaft and difficult friction hoist
installations.

Hoist (head) ropes

(Bottom Left) Standard Thimble Cappel,
High Performance Non-Rotating
shown with thimble removal tool
(Bottom Right) Hydraulic Linkage
Full Locked Coil
Round Strand
Flattened Strand
30

Crushers & sizers

Over 100 years of experience

and reliability in Crushing and
Grinding equipment and service.

FLSmidth has over a century of Crushing products

experience in crushing and is known Gyratory Crushers
as a world-class supplier of crushing Cone Crushers
equipment for the mining, cement Low Speed Sizers
and aggregate industries. This Roll Crushers
expertise is supported by more than Jaw Crushers
1,700 installed crushers, feeder- Feeder-Breakers
breakers and sizers. Hammermills
Vertical Shaft Impactors
All of our crushing and sizing Plants & Systems
equipment is available for surface or Crusher Gears
underground installation, for
stationary or mobile applications, and
for climatic conditions that range
from tropical to arctic.
 31

Mine shaft systems

sales staff
David Strong
Mining Technical Sales
david.strong@flsmidth.com

Ron Ostertag
Mining Sales Manager
ron.ostertag@flsmidth.com

Jim Brownlee
Mining Product Manager
jim.brownlee@flsmidth.com
32

Customer services

FLSmidth provides the service

and maintenance to keep your
application safe and operational.
 33

FLSmidth is your one source for spare

parts, services, maintenance and
operational services. Our customer
services group provides a wide range
of services from installation,
troubleshooting, mechanical analysis,
recertification and commissioning of
FLS equipment. Customers are our
most important assets. Indeed,
everyone promises it, we deliver it.

We work closely with our customers

from project inception to help best
incorportate most current designs for
safety, production and ease of
maitainence services required to engineer, procure Rope attachments and
and rebuild to OEM quality and rope handling equipment:
Rebuilds standards while updating to the Sockets, Hoist, Balance and Guide
FLSmidth can rebuild your exisiting current design standards and Rope. Hoist Rope thimble Cappels,
mining equipment with quality and incorporating any upgrades required Solid Thimble & Clamps, Fine
reliable OEM parts providing the by the customer, a cut above the Adjusting Hydraulic Linkage, Swivels,
competition. Glands, Sinking Attachments,
Chaseblocks, Buckets, Load Cells,
Original OEM spares; Cheeseweights
Hoists, Drum, Koepe, BMR ,
Tensioning Reels Consulting, recertification,
Sheaves, Head, Deflection. BMR design and modification
Compensating, Sinking, Double services, mine hoisting
Down seminars;
Skips,Bottom Dump, Kimberly, Rope Installation, Hoisting System
Rola Chute, Arc Gate, Front Design, Socketing Seminars, Rigging
Dump, Incline Seminars, Mine Hoisting Seminars,
Cages, Single/Double/Triple Deck, Maintenance Procedures, Testing/
Two Guide and Four Guide. Recertification, Attachments
Counter Weights/Frame & Pipe Inspections, Attachment
Types Recertification, All Rope Installation,
Guide Rollers Removal, Maintenance & Service
Haulage Equipment, Mine Cars, Needs, Rentals and Site Services
Arc-Flow Bottom Dump. Granby,
Grangesberg Additional products;
Ross Chain Feeders Rope installation and removal
After many hours of operation equipment Gates and Chutes equipment, Tensioners, Reel Winders,
needs to be rebuilt/upgraded to maintain Measuring and Loading Stations Lubricators, Socketing Stands,
safety. Our rebuild shops ensure the highest Tuggers/Winches, Reeving Sheaves,
quality and safest rebuilds available.
Goosenecks, Reeving sheaves, Rope
Unwinders, Rope Transporters,
Grooving Tools, Rope Cleaners.
34

One Source,
many solutions

In addition to underground
mining solutions FLSmidth brings
together the experience and
reliability of global leading
brands and services to provide
complete systems and solutions
for your application.

As a One Source supplier, FLSmidth integrates testing,

detailed design engineering, global procurement, expert
process control, and localized services to deliver a complete
flowsheet of products and process support for the minerals
processing industries.
 35

FLSmidth is your One Source for the

worlds largest installed base of original
equipment, enhanced products,
technologies, and services unmatched in
the mining and minerals processing
industries. FLSmidth offers a broad range
of equipment and processes including:
testing, design, engineering, crushing,
grinding, classifying, flotation, thickening
and clarifying, vacuum and pressure
filtration, pyroprocessing, material
handling, slurry handling, automation,
along with OEM quality replacement parts,
modernization services and other after-sale
services.
Product brands: FLSmidth KREBS - hydrocyclone
To successfully compete in todays
separation and severe-duty slurry
challenging world economy, companies ABON - feeding, sizing, crushing
pumping solutions since 1952.
often require innovative solutions to make and screening equipment since the
Krebs also supplies Technequip
their plant operating systems function at 1920s.
Valves.
peak efficiency. Utilizing the latest in Buffalo - feeding and crushing
FLSmidth Material Handling
equipment technology, resources, and equipment for mining and general
Brands Koch, MVT, RAHCO, and
materials, we deliver the optimum design, industries since 1975.
equipment, and process support needed. Conveyor Engineering combine to
Dawson Metallurgical Laboratories
When you select FLSmidth as your partner, design, manufacture, and service
metallurgical testing for ore
you also bring this solid foundation and bulk handling systems including
amenability, process development,
over a century of experienced support to mobile conveyors, radial stackers,
flowsheet layout and plant design
your business. portable conveyors, fixed/overland
since the 1930s.
conveyors, and at-the-face mining
Dorr-Oliver and EIMCO - over 100
conveyors, as well as supplying
years of technical innovation in
coke oven plant technology, rolling
liquid/solid separation solutions
mill systems, and steel construction
and underground mining including
for hydraulic engineering.
product offerings from WEMCO
Mller - design, engineering,
and Shriver.
procurement, erection, and
Fuller-Traylor/FFE - dating back to
commissioning of pneumatic
1903, Fuller-Traylor mills, crushers
conveying systems and silos
and pumps have a reputation for
equipped with pneumatic facilities.
ruggedness and reliability.
VECOR - mine hoist technology.
Raptor Cone Crushers - These
FLSmidth Automation - automation
well-designed, robust and durable
and quality control systems and
FLSmidth offers engineering, field services and machines offer outstanding
process control systems needed to keep your plant total electrifications projects
productivity.
running smoothly and efficiently.
Mine Shaft Systems Vecor Technology Center
FLSmidth Ltd. FLSmidth (Pty) Ltd
174 West St. South PO Box 5073 Weltevreden
Orillia, Ontario L3V 6L4 Park 1715 Roodepoort
CANADA Gauteng SOUTH AFRICA
Toll Free: 1-888-878-4726 Tel: +27 (0)10 210 4000
Rev. 9/6/2014 al-us

Email: mining@flsmidth.com Fax: +27 (0)10 210 4050

Copyright 2010 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or
warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. www.flsmidth.com