Mining is a demanding industry that requires rugged, long-lasting equipment to extract and process minerals efficiently. At the heart of this industry is steel. This unsung hero of mining equipment fabrication is relied on for both equipment components and for key structures due to its incredible strength and corrosion-resistance – a must for safety and efficiency in the harshest environments.
For over 30 years, Carver Engineering has been at the forefront of designing, developing, and delivering standard and bespoke steel mining fabrications for clients around the world. Here are just a few examples of the mining equipment, components and steel structures that have passed through our in-house fabrication workshop over the decades and why steel remains the go-to choice for the mining sector.
How is steel used for mining equipment fabrication?
Stairs & handrails
Mining operations require the safe movement of personnel and heavy materials across multiple levels. Steel stairs and mezzanines are essential for ensuring secure access within mines. As with many industries, mining stairs and mezzanines must meet OSHA and IBC stair code. This includes having two separate escape routes and clear markings.
At Carver Engineering, all the stairs we design, fabricate and install adhere to industry standards, ensuring our clients can keep their teams, equipment and mined materials safe.
Conveyor systems
From the pit to processing, conveyor belts and pulley systems are used in every phase of mining, including to move heavy coal in and out a mine. These conveyor belts need to be able to withstand the harsh conditions prevalent in underground mining environments, as well as the wear-and-tear from transporting abrasive materials.
Steel is the perfect material to ensure optimum performance and lifespan of these systems. Not only can it make transporting mined materials easier, fabricated steel is resistant to the heavy impact of ripping and tearing during the initial mining production stages.
Frames & chassis
Mining equipment is subject to extremely high levels of stress and vibration. By creating reinforced frames and chassis, this helps the heavy mining machinery to operate more efficiently, and makes it safer for the operators.
Shaft assembly
While initial mine shafts may use wood or brick reinforcement, deep mines require stronger materials to withstand pressure. Steel provides the necessary reinforcement for shaft walls, support beams, elevators, lifts, and mine cages, ensuring structural stability and worker safety in underground operations.
Skips & buckets
At the very end of the mining process, the ores and minerals are loaded into skips or buckets for easy removal out of the mine. These are typically constructed from stainless steel, which gives them an extended lifespan and durability that’s key for this industry.
Equipment components
You’ll find wear-resistant fabricated steel components across many kinds of mining equipment, such as:
- Drilling bits
- Gear boxes
- Trucks
- Rigs
- Conveyors
- Core springs
- Tensioners
- Fasteners
- Bearing seals
Why is steel the preferred material for mining equipment fabrication?
Steel is the most commonly used material for mining applications for a reason. It’s hard-wearing, low-cost, lightweight and resistant to a lot of elements that would cause other materials to corrode. Plus, with modern fabrication techniques, including CAD (Computer-Aided Design) and plasma cutting, manufactured parts can be made with more precision and efficiency than ever before.
Protecting underground workers with metal mining fabrications
Mining is a notoriously hazardous workplace with a long history of accidents, and while the number of fatalities has decreased since the 20th century, care must still be taken. According to the International Labour Organisation (ILO), while mining only employs around 1% of the global workforce, it generates 8% of fatal accidents, which is why creating a safe underground environment is a priority.
Safety regulations are crucial, but the foundation of worker protection lies in the integrity of mining structures. Steel fabrications provide the necessary strength, flexibility and stability required to support underground operations and mitigate risks.
Steel mining equipment maintenance & refurbishment
Along with safety, effective preventative maintenance of metal fabrications ensures the longevity of your mining equipment and structures, minimises downtime, and can keep costs lower in the long run. Here are a few recommendations from our fabrication engineers on keeping your steel components in top shape:
1. Regular inspections and audits
Frequently inspecting your machinery and structures is key for ensuring compliance with safety standards. It also means you can spot minor faults before they become major issues.
2. Schedule preventative maintenance
Setting up routine maintenance can help you avoid unexpected breakdowns, which could ultimately result in costly downtime. Depending on the conditions your mining equipment fabrications face day-to-day, this could be a weekly check or something you carry on a monthly basis.
3. Consult the specialists
With hundreds of years of collective expertise under their belts, the engineers at Carver have got the know-how to support your steel fabrication refurbishment and repair. Spot something that needs fixing? Or you’ve got a question? Get in touch and we’ll be more than happy to advise.
Start your mining steel fabrication project with Carver
For durable, high-quality, and precision-engineered mining equipment, steel remains the material of choice
If you’re looking for an experienced mining equipment fabricator, Carver Engineering is ready to deliver reliability, durability and quality. Get in touch with the team for a quote on your mining fabrication project today, or check out our recent work here.
