Case Study: Transforming Underground Mining: Safer, Faster Axle Bolting with HYTORC

A multinational mining company faced a critical challenge in their Zimbabwe, Africa operations involving how to safely and efficiently handle the axle bolts on underground mining machines. Their existing methods, relying on unwieldly manual wrenches and impact guns, were not only slow but also came with significant safety risks.

The customer had concerns regarding the application of torque on the axle bolts of their front-line underground haul trucks, the method used was with manual clicker wrenches and the consistency was irregular. HYTORC was asked to look and evaluate the scenario and recommended a bespoke reaction fixture in conjunction with our electric torque guns. The fixture allowed reaction to occur without interfering with bearing journals and seal landings. – John Fairhurst, Corporate Account Manager: Africa

The Axle Bolting Challenge: Safety, Speed, and Precision

The company’s goal was to find a solution that would eliminate the inherent dangers of their traditional axle bolting procedures while also boosting efficiency. The technical requirements were specific and demanding and required an innovative approach to an everyday, yet critical, maintenance task.

• Handling 11/4" multi-spline bolts with 2,500 Newton-meters of torque.
• Crucially, the solution needed to apply this high torque without impacting sensitive bearing journals.
• Adding to the complexity, the desired system had to operate without the need for hydraulic or pneumatic hoses, ensuring greater maneuverability and safety in confined mining spaces.

The HYTORC Solution: Tailored Power Meets Precision

HYTORC stepped in with a specialized bolting system custom-designed to meet the company’s unique needs. The solution focused on integrating advanced tooling with bespoke components for optimal performance:

• Enhanced Safety: By replacing dangerous impact guns and labor-intensive manual wrenches, HYTORC helped significantly reduced the hazards associated with axle bolting. This meant a safer working environment for maintenance crews.
• Increased Efficiency: The impact on productivity was immediate and substantial. What once took 65-75 minutes for axle bolt fitment was slashed to just 35 minutes! This dramatic time saving directly translates to reduced machine downtime and increased operational production for the company’s vital underground fleet.
• Precise Torque Application: The HYTORC system consistently applied the exact 2500Nm torque required for the 1 1/4" multi-spline bolts, ensuring secure and reliable connections without over-tightening or under-tightening.
• Custom Design for Optimal Performance: A specially engineered Arched Track Pad and fixture were developed. This custom solution ensured perfect clearance and optimal interaction with the unique geometry of the axle bolts and bearing journals, preventing damage to critical components.
• Streamlined Loosening: The system also included an electric torque tool specifically configured for efficient "run down" after the initial loosening of the bolts, further streamlining the entire process.

A Blueprint for Regional Adoption

The success of this tailored HYTORC solution in Zimbabwe has set a new standard for the company’s operations. Based on the proven safety enhancements and remarkable efficiency gains, the company plans to implement this improved bolting system across its broader Southern African operations.

This partnership between this organization and HYTORC demonstrates how targeted, innovative bolting solutions can significantly impact safety, precision, and productivity in even the most challenging industrial environments, paving the way for more efficient and safer underground mining.