BMT Duracluster

DuraCluster | modification & repair scheme for draglines

Improved design modification and repair scheme for draglines with tubular boom designs dramatically improve fatigue performance, extend life, minimise downtime, and significantly lower costs.

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Chris Batten - Environment

Regional Sales Director, Asia Pacific

Chris Batten - Environment

Regional Sales Director, Asia Pacific

Perth, Australia

+61 8 6163 4900 (981)

Extending life, reducing cost

We have used our extensive knowledge of the mining industry, stress monitoring, materials and equipment engineering to develop DuraCluster, extend the life and reduce repair costs of operational draglines.

With DuraCluster offering the highest levels of lifecycle support and optimization of removal capacity at the lowest cost per tonne, our dragline design scheme is one of the industry’s most sustainable mining solutions.

The improved design modification and repair scheme dramatically improves the fatigue performance on existing draglines with tubular boom designs. 

Longer life, less downtime, significantly lower cost:  how can DuraCluster improve your operations?

The problem

The draglines, so essential to many mining operations, experience stresses at joints that can result in endemic fatigue and cracking.  Repair costs become unsustainable, with a boom replacement costing $20 million and three months’ downtime.  These issues led us to create DuraCluster, dramatically improving performance on existing tubular-boom draglines.

Cracking at cluster joints creates these three significant, unsustainable costs:

Cost of crack detection

Visual inspection is difficult due to the complex geometry | The crack must propagate through the chord wall before detection is possible | Substantial crack growth is required before you can find it, which significantly increases the risk of a catastrophic failure

Cost of repair

Poor access for achieving a quality repair to the chord | Coping adds time and cost | Cranage, scaffolding adds to cost | Cutting and replacing windows in lacings increases the potential for failure in the lacing

Cost of replacement and downtime

A single boom replacement can cost an estimated $20 million | Replacement requires a three-month machine outage | Boom replacements expose operators to a potentially high-risk task with significant financial consequences

The DuraCluster Solution

Very easy installation - +/- 1 week per cluster

Cost savings - up to $18M can be made on a major boom repair

Multiple clusters can be modified simultaneously

Significant reduction of stress concentrations

Improved load paths

Dramatically extend the fatigue life of tubular boom and mast structures (Est. 15-20x)

Excellent access for welding ensures all damaged welds are repaired

Reduced maintenance and inspection workloads moving forward

Easier inspection and NDT on the upgraded cluster design

The Procedure