ME Elecmetal delivers a reliable fastening solution designed to reduce operational deviations, strengthen asset reliability, and optimize KPIs for safety, availability, and productivity.
Customer Challenge
A major copper producer preparing for a large-scale expansion sought a comprehensive consulting proposal to reinforce the bolting and fastening elements of its SAG mill liners. The operation featured a SAG–ball mill grinding circuit, designed for high-throughput copper sulfide extraction, and required improved fastening reliability to ensure safety, availability, and consistent performance at higher production rates:
- SAG Mill (40×29 ft) – Equipped with a lifter/plate cylinder configuration in a three-ring layout (Feed / Central / Discharge).
- Ball Mill (27×49 ft) – Providing critical secondary grinding capacity to maximize metal recovery.
By targeting fastening reliability at the core of these mills, the customer aimed to minimize unplanned deviations and enhance long-term equipment integrity.
ME Elecmetal's Solution – Smart Bolting System
This challenge set the stage for the Smart Bolting System (SBS)—ME Elecmetal's market-leading solution engineered to eliminate fastening deviations and ensure consistent, verifiable performance. Unlike any other option in the market, SBS uniquely combines innovative fastening technology with premium-quality products, enhanced by tailored training and consulting to meet each customer's specific needs.
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Benefits
The benefits focus mainly on improving and optimizing key safety, reliability, availability, and productivity indicators of critical mining equipment. This is achieved by ensuring operation and adopting a predictive view of the performance of fastening systems for mill liners, campaign after campaign.
Reliability
Premium fastening components and digital monitoring ensured liner system integrity. Early deviation detection enabled timely corrective torque adjustments—preventing premature failures and maintaining optimal fastening strength.
Safety
Online tension monitoring reduced manual inspections, while targeted training improved relining safety and minimized human exposure during maintenance.
Maintainability
Comprehensive training, precise calibration, and consulting improved maintenance workflows—reducing human error and ensuring consistent torque/tension standards.
Availability
Enhanced fastening reliability directly increased mill availability, minimized unscheduled downtime, and supported long-term production goals.
Comprehensive SBS Proposal
ME Elecmetal delivered a comprehensive fastening proposal for SAG mill liners, fully aligned with the parameters of the Smart Bolting System (SBS). The solution was structured into three stages to ensure both operational excellence and long-term reliability:
1. Training & Preparation
- Hands-on training for the client's maintenance team on fastening elements.
- Definition of installation tensions and standardized procedures according to liner design.
- Calibration of torque wrenches to guarantee accuracy and consistency.
2. Maintenance & Implementation
- On-site technical support during maintenance activities.
- Verification that fastening procedures were applied correctly.
3. Online Monitoring
- Deployment of a secure web platform for real-time tension monitoring.
- Delivery of biweekly reports to track fastening conditions.
- Definition of a re-torque or re-tightening plan for sustained fastening integrity.
To further enhance reliability, ME Elecmetal conducted a liner-specific study to determine the optimal installation tension. The solution incorporated Ridgeback – Valley Forge bolts, offering a superior fit and secure seating within the liner bores. Additionally, tension sensors were installed to continuously monitor fastening performance throughout the campaign, verifying that the recommended installation tension of 170,000 lbf was consistently achieved and maintained.
Results
ME Elecmetal's Smart Bolting System delivered measurable improvements in fastening performance and asset reliability. By recording and monitoring installation tensions, the system enabled early detection of deviations during the installation process. This proactive approach allowed timely re-torque adjustments, preventing potential failures or breakages and ensuring consistent fastening integrity throughout the campaign.
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