Johannesburg - South Africa - In what has been one of the largest global product conversions in the mining industry, AEL Mining Services announced that it has achieved close on 75% shock tube conversion success in the Narrow Reef sector to date.

AEL started the customer transformation process from capped fuse and igniter cord to shock tube blast initiation systems in the Narrow Reef mining sector during 2006. Since then, annual growth of shock tube volumes has been significant, with expectations of completing the process by 2010.

Shock tube initiating systems, although available and successfully implemented in mines since the 1980s, were only recently adopted across the industry as the production and conversion costs became viable, and local manufacturing capacities were expanded.

Latest Statistics

AEL's latest conversion statistics bear witness to the magnitude of the conversion project. According to AEL SA's Business Director, Liesel de Villiers, over 2,500 people have received formal training since conversions began in 2006, and this excludes post implementation support and individual coaching on the face.

"All our Narrow Reef customers are in the process of converting to shock tube, the main drivers being safety and improved blasting results", says de Villiers.

"The conversion process over the last couple of years has been an enormous challenge due to the large number of initiators involved. AEL developed a new generation of world class "super" shock tube products and is in the process of automating production facilities to a level unparalleled in the explosives industry worldwide.

"We are currently supplying assemblies produced at our existing plant, as well as at our new automated factory. The plan is to gradually increase the new plant capacity and phase out our manual plant by 2012."

Managing Change

Along with the challenges of producing world class shock tube products in tandem at the manual and automated plants, the largest challenge for AEL has been the management of the conversion process against a backdrop of 50 years of capped fuse usage.

De Villiers comments, "We developed a robust conversion methodology, which comprises a nine step training process that engages all users on the ground, including supervisory levels, and involves both surface and underground training over a period of three to four days. The most important step to ensure successful conversion is to engage users at all levels, and support management as they take ownership."

AEL adopted a phased training approach, which includes three major stages:- training of middle management; train-the-trainer at the customer's facilities; and training of the production crew.

"To demonstrate shock tube technology", says de Villiers, "we came up with an innovative concept and converted an articulated truck into a Mobile Training Unit and fitted life-size models which replicate a stope, gully and development end to show users how to connect shock tube for different applications. "

Benefits of Shock Tube

The benefits of AEL's shock tube technology include enhanced safety features during production, storage and application.

De Villiers adds, "Many of our customers documented numerous benefits of shock tube during 2008, which not only contributed to increased safety but to cost savings. These included the reduction of the number of misfires, increased advance per blast, improved hanging wall conditions, a more uniform fragmentation profile, shorter blasting times and increased production."

Dilokong Excels at Conversion

An example of a successful conversion recently took place at Dilokong Chrome Mine, a wholly owned subsidiary of ASA Metals, situated 30km from Burgersfort en route to Polokwane.

AEL has supplied Dilokong Chrome Mine with capped fuse initiating systems and explosives for many years . The capped fuse conversion project commenced in April 2008 and was completed within a couple of months.

Buks van Rensburg, Mine Manager at Dilokong comments, "We approached the conversion project with total commitment, and ensured that we were fully prepared for the process. This involved engaging our mine personnel at every level, from management through to production to ensure that we had buy-in from all staff members.

"We took into account that our staff have worked with capped fuse for many years and that there would be a certain degree of resistance to change, but we managed to communicate effectively the over-riding benefits of safety, ease of use and cost savings.

"AEL assisted us in the process and spent a week on site training over 120 staff," adds van Rensburg. "The process went very smoothly and once our staff realised how easy and safe shock tube is to connect, they were persuaded."

Moving Forward

As AEL's automated plant reaches its final phases of implementation, the group has the capacity to ramp up production to match demand and supply of shock tube assemblies.

"By partnering with our customers and planning the process together, we can ensure that there is always sufficient supply of world class quality products that contribute towards increasing productivity, delivering zero blast delays, lowering blasting costs, improving fragmentation, and increasing safety", concludes de Villiers.

Editorial Contacts

Contact Trish at P and P Communications on +27 11 447 3511 or +27 83 378 2903