dragline rigging - bradken · 12 13 rigging dump lock the dump block forms part of bradken’s...
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DRAGLINE RIGGING
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54 5
BRADKEN KNOWS THE MININGMARKET
OUR BUSINESSBradken is a global manufacturer of differentiated capital and consumable products to the mining, transport, general industrial and contract manufacturing markets with a sales and distribution network servicing customers around the world.
As a leading heavy engineering company we can manufacture fully machined cast iron and steel products from a
mass of 0.5 kg (1.1lbs) to 25 tonne (55,000 lbs). Bradken produces consumable wear products for all types of
earthmoving equipment to the global mining and quarrying industries. Our products include:
• Ground Engaging Tools (GET) and associated wear parts,
• Dragline rigging packages,
• A range of buckets to suit dragline, front-end loader, face shovel and hydraulic excavator equipment, and
• Undercarriage systems and componentry for hydraulic mining excavators and electric rope shovels.
Our experienced engineering team is able to adapt our range of Bradken designed products to address the
specific requirements and challenges presented by the diversity of the global mining market.
Bradken recognises that when it comes to dragline rigging, you’re only as strong as your weakest link. We manufacture an extensive range of dragline rigging components for a variety of applications and machines to provide customers with reliable and innovative solutions to suit their individual mine site needs.
With over 90 years’ experience
in the foundry business, the
accumulated wealth of knowledge
and depth of expertise in our
workforce enables us to offer our
customers a full service offering
with design, manufacturing,
maintenance and support services
ultimately providing improved
operational outcomes and safer
work practices.
With a worldwide network of
foundry and manufacturing
facilities and an established sales
and distribution network, our
geographical diversity allows us to
provide product, technical support
and advice, and exemplary service
to customers in the world’s major
mining and industrial regions.
EXPERIENCE DESIGN CAPACITY
Our range of Ground Engaging
Tools (GET), Buckets and
Rigging have been designed and
manufactured by our skilled and
experienced team to provide quality
and innovation that in turn provides
our customers with reductions
attributed to their Total Cost of
Ownership (TCO), whilst providing
improved safety features to reduce
the risk of injury at site.
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76 7
SWIVEL MOTION
Harmonise Upper Hoist system has been designed with freedom
of movement where it is needed most. The Integrated
Socket Equaliser ISE has horizontal swivel
movement for better operator control. The Tri-
Link has a vertical swivel motion to reduce
the load on the lower rigging, bucket and
chains during the dig cycle. Overall the co-
ordinated design is stronger, lighter, reduces
inherent stresses and offers the operator
more control.
Bradken’s Harmonise Rigging/Jewellery solution is a collection of innovative designs with a revolutionary
approach to the upper hoist rigging assembly. The new design features the Integrated Socket Equaliser (ISE),
an innovation that seamlessly replaces five components in the upper hoist assembly creating an elegant solution
that also reduces rigging height and weight.
This innovative (ISE) design has proven itself to be a “Fit and Forget” component that can last up to 12 months
without any maintenance or repair, which in turn reduces machine down time and lowers maintenance costs.
• Reduced number of change-outs due to longer lasting parts
• Reduced inventory due to less components in the upper rigging assemblies and only three pin types used
• All Bradken Lifting lugs permit latched hooks to be used for a safer installation
• Bradken have maintained the Strength Safety Factor while reducing the mass on a number of rigging
components by using intelligent design and superior materials
• No welding of cover plates required to contain Bradken APT pins, saving time by eliminating unnecessary
labour thereby reducing the risk of injury.
HIGHER SPOIL
The innovative Integrated Socket Equaliser (ISE) is unique to the Bradken Harmonise range. The ISE reduces
rigging height by more than a metre,the resulting gain in spoil height (dragline dependant) is also a large
advantage at spoil bound mine sites to reduce rehandle and walking time. A saving of 1 metre in spoil height
can gain your site an extra 4% pile volume.
REDUCED RISK EXPOSUREBradken is committed to providing reduced risk wherever possible:
Swivel/Miracle Hitch Hoist Package
ISE Swivel/Miracle Hitch Hoist Package
ISE Tri-Link Hoist Package
CENTRELINE WEDGE
Wedge removal can often require heavy hammering - a potential safety risk. Bradken has included the centreline
wedge concept in our sockets. They are safe, easy and quick to change in the field and are designed to utilise
the hydraulic wedge removal tool already in use at a number of sites.
ISE centreline safety enhancement
Wedge centreline safety enhancement
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pins
APT (Advanced Processing Technology)
Dragline Rigging Pins are manufactured with
high hardness and high toughness which
has proven to last at least three times longer
than conventional rigging pins. This in turn
reduces your maintenance costs and machine
downtime.
Bradken has a range of DRP pins that can fit to
your current rigging package without the need
for modification. Talk to your local Bradken
representative about our current offering of
DRP pins or the opportunity to customise a
pin to suit your rigging requirements.
Take advantage of Bradken’s innovative APT
pins and make the change today.
SAFE INSTALLATION AND REMOVALBradken’s APT pins feature an industry accepted RUD lifting lug, which enables lifting hooks to fully close for
safer removal. Since employing this feature, Bradken has further developed the lifting lug concept following our
continuous improvement process. The latest variation of the pin now has a fully recessed lift point, reducing
the risk of the RUD lifting lug being removed in unforeseen circumstances, where the lug was not used in the
manner that it was designed.
Bradken’s Lifting lug is inset in the pin head, shielding it from damage of being knocked off.
Bradken’s lifting lug allows enough room for lifting hooks to close securely
Traditional Pin
APT Pin
Standard Pin
Heavy Duty Pin
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HAMMER FREE LOCKING SYSTEM
All Bradken rigging incorporates safe hammer free locking systems. Designed for installation using conventional
tools, Bradken retainer systems are fast and easy to operate.
The unique P-Lock system allows removal of the keeper from two directions, ensuring less handling of heavy
parts.
The T-Lock and B-Lock systems provide your mine site with hammer free locking pin options that are easy to
install and remove. B-Lock provides the added benefit of a fully covered locking head to minimise the risk of
damage.
REDUCTION IN YOUR TOTAL COST OF OWNERSHIP
With operating costs playing a key role in any mine site operations, Bradken has formulated a tool to
showcase the cost savings that our APT pins can provide. Your local Bradken representative will be able to
sit down with you and highlight these savings using our APT Cost Analysis Benefits tool.
Key OEM Pin Costs Bradken Pin Costs
350,000
300,000
250,000
200,000
150,000
100,000
50,000
(AU
D$
)
(MONTHS)
1 2 3 4 5 6 7 8 9 10 11 12
T-Lock locking system B-Lock system features a completely covered head to minimise risk
of breakages
P-Lock pin removes from both ends allowing for no hassles when rigging is positioned on the ground
P-LockB-LockT-Lock
PIN PLACEMENT
Bradken’s Harmonise pins have been designed to fit flush in rigging parts, reducing the risk of pin damage
and unscheduled down time.
LONG LIFE
Bradken has actively trialled APT pins against competitor offerings and has continually been able to exceed
the OEM part by more than three (3) times, in some instances, the part has lasted more than eight (8) times.
REDUCED INVENTORY
Bradken’s Harmonise Dragline Rigging products were designed simultaneously, which enabled Bradken to
consolidate pins and reduce inventory.
ISO View Side View
APT Pin
APT Pin
B-Lock
Hoist Link
Pin sits inset protecting it from damage
OEM BRADKEN
(WE
EK
S)
14
12
10
8
6
4
2
0
Key OEM Pin Bradken Pin
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RIGGING DUMP LOCK
The dump block forms part of Bradken’s Harmonise rigging system. This system has utilised the very latest
technology in engineering and has already demonstrated massive productivity gains over the current market
offerings.
INTERCHANGEABLE CAST CLEVIS
Bradken’s Dump Block features the option of a vertical or a horizontal cast clevis, which can be made to suit
any size dump rope between 50mm and 95mm. Bradken’s Harmonise Dump Block can be used with Bradken’s
Harmonise Rigging Package or your existing rigging.
Bradken Packages Competitor PackagesCast dump block clevis for strength
Plate dump block sides, reduces weight and costs
Dump block sides are manufactured separately to the clevis for easy removal
Competitor dump block sides and clevis combine into one castling, which increases weight and refur-bishment costs
Competitor clevis change out requires the clevis and side plate to be replaced
Option 2
Interchangeable Vertical Dump Block Clevis
Option 1
Interchangeable Horizontal dump block clevis
The Dump Block is known to wear faster than other parts of the Dump Block assembly. Bradken has developed a separate cast Dump Block Clevis to reduce maintenance costs and reduce downtime.
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1514 15
COMPATIBLE WITH BECKETED ROPES
One of the unique features of Bradken’s Harmonise Dump Block is the ability to use it on a number of machines at
your mine site operations. The 48” Dump Block encompasses the most common dragline machines (see packages
page for machine classes) and is designed to be used with becketed ropes, ensuring there is no additional
downtime attributed to changing dump ropes during planned/unplanned maintenance breaks. The Dump Block is
also designed to suit rope sizes of 51mm (2”), 76mm (3”) and 83mm (3 1/4”).
ENGINEERED TO LAST THE DISTANCE
The Dump Block features 20% larger bearings compared to OEM offerings, enabling the bearing life to double
that of the competition. Finite Element Analysis (FEA) has been used to effectively reduce the weight by making
sure that there is no wasted mass in the dump block while at the same time optimising the material for maximum
strength.
CHAIN
Bradken’s Harmonise Chain combines innovative design with
world class manufacturing and inspection techniques to
provide reliability, safety and reduced operating costs.
Available in a range of chain lengths and sizes to suit
Hoist, Drag and Dump Chain configurations.
Clearance for rope ferrule
Flexible design allows for the use of standard rope
and becketed rope
Clearance for rope ferrule
36
30
24
18
12
6
Competitor Small Bearings
Competitor BearingsBradken Small Bearings
Bradken Bearings
Bearing Conparison Indentical Test Conditions
(Mon
ths)
OPTIMISED MATERIAL DISTRIBUTION
Bradken’s product development team optimised the crotch/bight contact between
all Harmonise links by increasing the surface area to improve sliding contact. This allows for
a more uniform wear, which in turn decreases the contact pressure and maximises chain life.
Hard Facing options to suit site specific conditions.
Competitor LinkUneven wear of crotch/bight
Bradken LinkEven wear of crotch/bight
Advanced geometry to evenly distribute contact pressure under load
Section View of a Intermediate Link
Competitor LinkBradken Link
Increased crotch/bight thickness increases strength and provides more
wear material
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INCREASED WEAR MATERIAL WHERE IT MATTERS
Bradken chain was designed using dynamic simulation analysis and Finite Element Analysis (FEA) in order
to provide increased wear material where needed whilst keeping the rigging weight to a minimum. The chain
features a greater section thickness in high-wear crotch/bight areas, particularly in the step-up and stud-end
links. The chain is cast in Bradken Intellectual Property (IP) alloys, with options suitable for abrasive and high
impact sites.
BRADKEN 3” DUMP CHAIN VS 2.5” DUMP CHAIN
Bradken’s dump chain provides unparalleled benefits to other like products currently being offered in the
market.
Bradken’s larger heavy duty 3” dump chain has been designed with additional wear material in high wear areas
while maintaining a similar weight to a standard 2.5” assembly.
The 3” chain assembly requires fewer links to achieve comparable lengths to the 2.5” assembly, which means
it can be installed without requiring modifications to the dump rope as there is no adverse effect on the bucket
carry angle.
The Bradken 3” dump chain offers improved wear life resulting in less downtime and reduced maintenance
costs.
MECHANICAL REPAIR LINKS - HAMMER FREE
The Harmonise range features a hammer free Mechanical Repair link to suit a wide range of chain sizes
and OEM equivalents. The mechanical repair link reduces unscheduled downtime caused by chain
failures
Competitor Link Competitor LinkBradken Link Bradken Link
Wear Material distributed towards high wear areas at the
ends of the link
Increased material on tie bar for added strength
Increased crotch/bight thickness in common
high wear areas
3410mm
3345mm
2.5”
3”
Mechanical Link
Temporary solution to reduce unscheduled downtime
Hammer free system for improved safety
• Made from superior cast alloy
• Standard dump or becketed socket options
• Centreline socket system allows for easy wedge
removal with a hydraulic ram
• Hammer free locking system(s)
• Optimised fit with other Bradken linkages
• Significant mass reduction compared to
competitors
• Optimised fit with mating anchor links, dump
links and dump equaliser
• Added wear material in high wear areas
• Made from superior cast alloy
• Hard Facing Options available
• APT pins allow for reduced inventory and
operating costs
• Selection hammer free of locking systems
• Fits existing bucket hitches
• Increased wear material where needed
Pin Size Rope Size
CLASS 1, 2 ,3
4.25”
HARD FACING OPTIONS AVAILABLE
Pin Size
DUMP SOCKET
DUMP SHACKLE/HITCH LINK
CLASS 1, 2 ,3
5”
80mm to 83mm31/8” to 31/4”
4.25”5”
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1918 19
CLASS 2
6” 4.25”
80 to 89mm31/8” to 31/2”6” NO LUG
6” 4.25”
CLASS 3
7” 4.25”
92 to 102mm3 5/8” to 4”
7” 5”
7” NO LUG
6” 4.25”
7” 4.25”
CLASS 4
9” 5”
119 to 127mm4 3/8” to 5”
9” NO LUG
9” NO LUG
DRAG SOCKET
• Made from superior cast alloy
• Centreline socket system allows for easy
wedge removal with a hydraulic ram
• Optimal force flow design, distributing
pressure evenly on rope
• Optimised fit with other Bradken linkages
• Increased wear material where needed
DRAG SHACKLE /HITCH LINK
• Added wear material in high wear areas
• Made from superior cast alloy
• Surface crotch fit with Pear Links
• APT pins allow for reduced inventory and costs
• Selection of locking systems
• Fits existing bucket hitches
• Increased wear material where needed
HARD FACING OPTIONS-AVAILABLE IN ALL SIZES
CLASS 1
6” 80-98mm31/8” to 31/2”
CLASS 2
8”92 to 102mm
3 5/8” to 4”
CLASS 3
8”9”
110 to 127mm4 3/8” to 5”
• Made from superior cast alloy
• Male and female hoist sockets
• Centreline socket system allows for easy wedge
removal with a hydraulic ram
• Hammer free locking system(s)
• Optimised fit with other Bradken linkages
• Added wear material in high wear areas
• Made from superior cast alloy
• Optimised to fit 3”,3.5”,4” and 4.5” hoist chain
• APT pins allow for reduced inventory and
operating costs
• Selection of hammer free locking systems
• Increased wear material where needed
Pins PinsLug Pins Rope Size Rope Size
SPREADER BAR
• Made from superior cast alloy
• Cast ends
• Incorporates safe hammer free locking
system(s) and APT Pins
• Reversible – Connecting pins can be
inserted from either side
• Available in a range of different lengths
• Increased wear material where needed
Class 2
Class 2 & 3
Class 4
HOIST SOCKET
Y-LINK
CLASS 2
6”
CLASS 3
7”
CLASS 4
9”
Pin Size
CLASS 2
6”
CLASS 3
8”
CLASS 4
8”9”
Pins
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CLASS 2 & 3 HOIST PACKAGES CLASS 4 HOIST PACKAGES
PACKAGE OPTIONS PACKAGE OPTIONS
NAMING CONVENTIONS NAMING CONVENTIONS
Rigging Locking Pin
Spreader Bar Class 2
Chain Size Number of Links Hard Facing
Hoist Chain End Link Type
(optional)
Lower Spreader Bar
Class 2
Length (6.0m)
Upper Hoist Cluster Class 2
Upper Hoist Cluster Class 4
Spreader Bar Class 4
Lower Spreader Bar
Class 4
Length (7.0m)
Rigging Lock Length
Lock Type Profile
Rigging Locking Pin
Spreader Bar Class 2
Chain Size Number of Links Hard Facing
Hoist Chain End Link Type
(optional)
Lower Spreader Bar
Class 2
Length (6.0m)
Upper Hoist Cluster Class 2
Upper Hoist Cluster Class 4
Spreader Bar Class 4
Lower Spreader Bar
Class 4
Length (7.0m)
Rigging Lock Length
Lock Type Profile
Rigging Locking Pin
Spreader Bar Class 2
Chain Size Number of Links Hard Facing
Hoist Chain End Link Type
(optional)
Lower Spreader Bar
Class 2
Length (6.0m)
Upper Hoist Cluster Class 2
Upper Hoist Cluster Class 4
Spreader Bar Class 4
Lower Spreader Bar
Class 4
Length (7.0m)
Rigging Lock Length
Lock Type Profile
TT TT T
H H
D D
BB BB B
PP PP P
SS SSSS SS
(T -Lock) (T -Lock)(T -Lock) (T -Lock) (T -Lock)
Intermediate Link Intermediate LinkIntermediate Link Intermediate Link
(B -Lock) (B -Lock)(B -Lock) (B -Lock) (B -Lock)
Stud-End Link Stud-End LinkStud-End Link Stud-End Link
(P -Lock) (P -Lock)(P -Lock) (P -Lock) (P -Lock)
H2UH83S
30HC 40HC30HC 40HC
30HC09 40HC0930HC09 40HC09
2UH83ST
Optional Locks Optional Locks Optional Locks
Lower Hoist Package Lower Hoist PackageUpper Hoist Package Upper Hoist Package
Harmonise Harmonise
Dragline Dragline
Connecting Ring & Spool Connecting Ring & Spool
Y-Link Y-Link
Optional Parts Optional PartsY-Link
Y-Link
Optional Part
Optional Part
SS SSSS SS
Only three different sized pins are used in the entire
rigging package.
Only three different sized pins are used in the entire
rigging package.
Only three different sized pins are used in the entire
rigging package.
Only three different sized pins are used in the entire
rigging package.
Only three different sized pins are used in the entire
rigging package.
Traditional Pin108mm (4.25’’)
Traditional Pin108mm (4.25’’)
Traditional Pin152mm (6’’)
APT Pin108mm,127mm,152mm
(4.25”, 5”,6”)
APT Pin108mm,127mm,152mm
(4.25”,5”,6”)
APT Pin 108mm (4.25’’)
APT Pin 152mm (6’’) Standardisation Standardisation Standardisation Standardisation Standardisation
Spreader Bar Spreader Bar
LSB2 - LSB2 -
50 64
77 84
LH: UH:
LH: UH:
Lower Hoist Upper Hoist
Lower Hoist Upper Hoist
H: Harmonise D: Dragline Replacement
H: Harmonise D: Dragline Replacement
S: Swivel LinkT: Tri-Link
S: Swivel LinkT: Tri-Link
SS: Stud end, Stud endPP: Pear link, Pear link
SS: Stud end, Stud endPP: Pear link, Pear link
Rigging Cluster: Rigging Cluster:
Link Type: Link Type:
End Link Type: End Link Type:
Locking Pin: Locking Pin: T: T-LockB: B-LockP: P-Lock
T: T-LockB: B-LockP: P-Lock
Assembly: Assembly:
07
15
07
15
07
15
07
15
Rigging Locking Pin
Spreader Bar Class 2
Chain Size Number of Links Hard Facing
Hoist Chain End Link Type
(optional)
Lower Spreader Bar
Class 2
Length (6.0m)
Upper Hoist Cluster Class 2
Upper Hoist Cluster Class 4
Spreader Bar Class 4
Lower Spreader Bar
Class 4
Length (7.0m)
Rigging Lock Length
Lock Type Profile
Rigging Locking Pin
Spreader Bar Class 2
Chain Size Number of Links Hard Facing
Hoist Chain End Link Type
(optional)
Lower Spreader Bar
Class 2
Length (6.0m)
Upper Hoist Cluster Class 2
Upper Hoist Cluster Class 4
Spreader Bar Class 4
Lower Spreader Bar
Class 4
Length (7.0m)
Rigging Lock Length
Lock Type Profile
4UH127TT
H4UH127T
Upper Hoist ClusterUpper Hoist Cluster
Rigging Locking Pin
Spreader Bar Class 2
Chain Size Number of Links Hard Facing
Hoist Chain End Link Type
(optional)
Lower Spreader Bar
Class 2
Length (6.0m)
Upper Hoist Cluster Class 2
Upper Hoist Cluster Class 4
Spreader Bar Class 4
Lower Spreader Bar
Class 4
Length (7.0m)
Rigging Lock Length
Lock Type Profile
4
APT Pin127mm,152mm,228mm
(5”, 6”, 9”)
APT Pin 279.4mm (11”)
UPPER HOIST CLUSTER CLASS 2 UPPER HOIST CLUSTER CLASS 2
HOIST CHAIN HOIST CHAINSPREADER BAR SPREADER BAR
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Australia
China
Europe
North America
South America
Africa
© 2017 - Bradken®
20 McIntosh Drive, Mayfield West, NSW 2304 Australia T +61 2 4926 8200 F +61 2 4926 8201E [email protected]
PACIFIC20 McIntosh Drive, Mayfield West, NSW 2304 Australia T +61 2 4926 8200 F +61 2 4926 8201E [email protected]
AMERICASSuite 647, 12200 NW Ambassador DriveKansas City MO 64163 USAT +1 816 270 0700F +1 816 270 0799E [email protected]
AFRICAUnit G1 The Palisades 39 Kelly RoadJet Park South AfricaT +27 11 390 0100F +27 86 615 0876E [email protected]
ASIANo.120, XuHai Road SouthEconomic Development ZoneXuzhou P.R. China 221131 T + 86 516 8355 3958F + 86 516 8355 3959E [email protected]
Regional Head Offices
Global Corporate Centre
Visit bradken.com for your local representative.
Ref: 3 BKM SP MKT Dragline Rigging - July 2016