For any aggregate extraction operation to be carried out effectively, it is critical that every stage in the process runs with maximum efficiency and reliability.

There have been rapid technological advances in areas such as materials science and mechanical and electrical design and engineering, and this has seen dramatic improvements in the efficiency and lifespan of process equipment, as well as in ease of access to key parts to allow quick and easy maintenance and repairs.

However, equipment design is only part of the story, and the highly demanding applications performed by quarrying equipment will mean that the system will always be subject to wear and tear – so it is equally important that the correct repair and maintenance strategies are in place.

Historically, the vast majority of process maintenance within quarries has been carried out on a purely reactive basis, but there are a number of disadvantages to this approach. First and foremost among these is that it effectively means accepting that failures in the system will inevitably happen during the lifespan of the project.

It is important not to underestimate the significant impact that the failure of even a simple piece of equipment can have on the bottom line. Many modern processes run end to end, with flow rates at every stage carefully calculated to ensure that material flows through the system without either excessive build-ups or the need to frequently stop and start equipment to control throughput.

In such carefully balanced processes, a failure at any stage will therefore halt the entire process and have a direct impact on bottom-line production. The duration of the resulting period of downtime can vary significantly depending on whether it is immediately apparent what has caused the problem, how long it takes for qualified personnel to reach the site, the scale of the repairs required and the availability of replacement parts.

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