Ground Control 14 - Luyckx

GROUNDCONTROLThe magazine of Hitachi Construction Machinery (Europe) NVCONTENTSIssue 14 Autumn 2012 www.hcme.com04 NewsExplore Hitachi construction machinery from around the globe as well as all thelatest exhibition and new product news10 A world of experienceNew HCME President and CEO, Mr Moriaki Kadoya, reveals that this is hissecond appointment in The Netherlands12 Large-scale supportFind out what it takes to transport, assemble, operate and maintain theultra-large Hitachi EX8000-6 mining excavator2618 Zaxis-5 put to the testThe first Zaxis-5 excavators have been released into Europe and GroundControl asks the operators for their first impressions22 Urban legendsTwo British companies, the Carey Group and M O’Brien Plant Hire, are makingthe most of Hitachi clamshell telescopic excavators26 The drive for electric powerA fleet of EH3500ACII dump trucks operating on a trolley assist system ishelping to transform the Kansanshi mine in Zambia30 Focusing on customer solutionsNasta is celebrating its 30th year as the Norwegian Hitachi dealer with a newidentity and headquarters, and some recognition for its achievements22103034 Mobile lifting powerIntroducing Hitachi Sumitomo and the advantages of using crawler cranes ondifferent job sites in The Netherlands and BelgiumThe tourist trade in Eilat, Israel, is booming thanks to the support ofconstruction company, S Noufi and Sons34Ground Control is published twice a year and is circulated among 100,000 readers.Hitachi Construction Machinery (Europe) NV, Siciliëweg 5, 1045 AT Amsterdam, The NetherlandsTelephone: +31 -(0)20 44 76 700Fax: +31 -(0)20 33 44 045E-mail:magazine@hcme.comWebsite:www.hcme.comEditor:Hitachi Construction Machinery (Europe) NV: Ghislaine JonkerCo-ordination: Somacon, www.somacon.nlEditorial and design: Red International Communication, www.redinternational.co.ukPhotography:Glenn Blackburn, www.glennblackburn.co.ukTranslation:UvA Talen, www.uvatalen.nlPrinting:Roto Smeets GrafiServices, www.rsgrafiservices.nlCirculation:Vogelaar Verzenders BV, www.vogelaarverzenders.nl© Hitachi Construction Machinery (Europe) NV (HCME). All rights reserved. Reproduction in whole or in partis forbidden except with the written permission of HCME. While every effort is made to ensure the accuracyof information published in Ground Control, HCME is not responsible for inaccuracies or omissions. All viewsexpressed are not necessarily those of HCME. The manufacturer is not responsible for non-compliance toindustry-standard health and safety measures by third parties, nor for any damage or loss resulting fromanyone’s reliance on editorial and photography in Ground Control.1802 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 03

NEWSAnother first for HitachiZaxis-5 range unveiled at TKDHitachi launches ZW250-5wheel loaderFollowing the successful launch of its Zaxis-5 excavators,Hitachi has unveiled the first of its ZW-5 wheel loaders. The newZW250-5 has been designed to comply with EU regulations onemission standards and satisfy the requirements of Europeancustomers. It offers an exceptional level of comfort, excellentproductivity, advanced technology, and a range of features forenhanced sustainability, safety and easy maintenance.The cab is more spacious than the previous model and it hasgreater visibility thanks to a pillar-less windshield and large sunvisor. The 7.8-litre six-cylinder water-cooled turbo engine enablesa powerful digging performance, impressive travel speeds andexcellent fuel consumption.An example of its advanced technology is the quick powerswitch, which boosts the power when required by changing workmodes. One work mode is for regular operations, with the benefitof efficient fuel consumption; the other is for more demandingjobs and increases productivity.The sustainability of the ZW250-5 is highlighted by the mufflerfilter. It captures air pollutants, which are automatically burntthanks to an oxidation catalyst and exhaust temperature control.Easy maintenance features include the redesigned engine andradiator cover, which can be opened fully to provide quick accessfor daily inspection.Wilbert Blom, HCME International Sales, says, “We believethat the new ZW wheel loader not only meets our customers’expectations of high quality and reliability, but also providesa safe working environment, a comfortable cab with easy-to-usecontrols, and overall, a machine that responds quicklyand precisely.”The first Hitachi hybrid excavator has been presented to theEuropean market. Developed using decades of experience inhydraulic, battery-powered and electric excavator technologies,the ZH200 model was presented earlier this year at the Intermatexhibition.Better for the environment, easier for the operator and moreeconomical for the owner, the ZH200 hybrid heralds the startof a new generation of Hitachi excavators. It is equipped witha high-performance TRIAS HX system – a combination of ahybrid system with the energy-efficient TRIAS hydraulic system.This reduces fuel consumption and CO2 by 20 per cent (fuelconsumption is compared with the ZX210-3 in P-mode).The excavator’s user-friendly design incorporates a monitoringsystem, which highlights fuel usage on an average hourly anddaily basis. It also features low maintenance and highly durableelectrical components.Yusuke Kajita, General Manager of the Construction EquipmentDevelopment Centre at Hitachi Construction Machinery Co., Ltd.,says: “Technically advanced machines make Hitachi stand outfrom the crowd. Advanced technology is necessary to maintainour position in the market – not just for the hydraulics and engine,but also for electrical technology.“Hitachi is the biggest electrical products manufacturer in Japanand so we are very strong in this area. So, when fossil fuels are inshort supply and become more expensive, electrical technologywill be the key to the future and we will be in an excellent positionto capitalise on this.”Unique paint process forfactoryHitachi Construction Machinery (Europe) NV (HCME) hasimplemented a unique process to reduce chemical waste fromthe painting process at its factory in Amsterdam. Developed incooperation with Advantage Chemicals Ltd., the process willsave an estimated €60,000 per year on labour and energy costs,as well as disposal costs for waste water and sludge.The old painting process produced approximately 260 tonnesof waste per year. The paint would sink to the bottom of the poolof water beneath the paint facility. Twice a year, the pool had tobe cleaned, and the water and paint had to be removed, whichwas costly in terms of labour, energy, water and waste removal.HCME Production Engineering Manager Robin Huijsman, whois also Compliance Officer for Environmental Regulation, says,“Cleaning the pool was a difficult and dirty job. With the newsystem, we are able to remove the overspray paint and reuse thewater. The facility is cleaner and the filtering system that removespaint particles from the air functions better. Less solvents arereleased into the factory air and there is less dust.”The new process combines real-time CoAg (coagulation)systems with waste water treatment systems. Instead of sinking,the paint is suspended in the water and pumped to a wastetreatment tank. “Advantage Chemicals developed a chemicalthat makes the paint float. What is really innovative is that we onlyneed to run this process for four hours per month,” adds Robin.“The floating paint sludge is then skimmed off the top of thetank and is estimated at 30 tonnes per year. The new systemhas improved the overall carbon footprint of the HCME factoryin Amsterdam.”The biennial TKD (Technische Kontakt Dagen) event took place inWezep, The Netherlands in June. The three-day exhibition is one ofthe most important for the domestic market of Hitachi ConstructionMachinery (Europe) NV (HCME). It allows visitors to test driveconstruction machinery on display and make comparisons betweencompetitive products.HCME and its domestic dealer took the opportunity to present thenew Zaxis-5 excavators to the Dutch market. Several models wereon display, including the ZX250LC-5, ZX290LC-5, ZX350LC-5 andZX470LCH-5. The manufacturer also showcased the ZX250LC-5with a 15-metre super long front and a ZX470LCH-5 with a25-metre demolition front.Dutch owners and operators were drawn to the Hitachi standby two other special attractions: the new ZW250-5 wheel loaderand the ZH200 hybrid excavator. Both were on display in TheNetherlands for the first time. In addition, the ZX60USB-3 miniexcavator, ZX145W-3 wheeled excavator and the ZW150 wheelloader were available to test drive and proved extremely popularamong visitors.Director of Domestic Sales Pieter Weerts was pleased to see manyexisting Hitachi customers at this year’s TKD and delighted with theresponse to the stand: “The exhibition has been a huge successonce again, with 20,000 visitors. I think people were particularlyimpressed by the Hitachi stand because it was spacious, with lotsof machines to try out and one of the few to show larger machinesover 25 tonnes at work.”04 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 05

NEWSRegis Moulin, the founder and CEO of Moulin TPGlobal e-Service – an essential toolDeveloped to protect the investment made by customers in Hitachiconstruction machinery, the Support Chain after-sales programmecontributes to efficient fleet management, minimal downtime andreduced running costs.One of the links in the chain is Global e-Service, an onlineapplication that allows customers to monitor their machinesremotely. It is available as standard for Zaxis excavators and ZWwheel loaders, and is optional for large EX mining excavators andEH mining dump trucks. The machines send operational data ona daily basis via GPRS or satellite to a main server managed byHitachi. The data is then processed and made available to view in aclear, accessible way on the Global e-Service website.Customers and dealers can visit the website at any time toview a variety of information. This includes operational data,such as working hours, pressures, temperatures and payloads,as well as fuel levels and consumption figures, CO2 emissiondata, recommended service and inspection intervals, maintenancehistory and the geographical location of each individual model.Fuel consumptionThe fuel consumption figures are particularly useful for Frenchcustomer Moulin TP, a company that specialises in public works(groundworks, utilities, foundations, road construction), quarrying,waste management, recycling and forestry. It currently has twoHitachi excavators, a ZX520-3 and ZX350-3 used for public works,and a ZX500 excavator and ZW310 wheel loader working in theTrevas granite quarry. All were supplied by its local official Hitachidealer, Teramat.Regis Moulin, the founder and CEO, says, “I use Global e-Serviceto verify the fuel consumption, and number of hours a machine hasoperated. This helps me to easily ensure optimal performance ofmy Hitachi machines.”As well as daily fuel consumption, the Global e-Service facilityalso shows the estimated lifetime consumption of that machineGlobal e-Service helps Moulin TP to manage its fleetand can calculate an average over a self-defined period. This isparticularly useful at a time when fuel prices are rising steadily.From an environmental perspective, Global e-Service can alsohighlight the CO2 emissions of an individual Hitachi machine, as wellas indicate hours of idling. This kind of information is increasinglyimportant as local legislations are placing further restrictions onexcessive emissions.Maintenance schedulingCustomers like Moulin TP also use the Global e-Service website tostore details of completed and forthcoming maintenance services,to assist with the planning of each machine’s utilisation andordering spare parts. “As well as accessing daily information, I alsolook up statistical information from when the machine has been inoperation,” says Regis.Any maintenance work carried out by Teramat, the official Hitachidealer, is entered on the machine’s computer and recorded onGlobal e-Service the following day. Regis can therefore downloadlists of daily inspections, and periodical or preventive maintenancefor each of his machines, saving valuable time in planning andstoring this information for the fleet.Location tracking and monitoringWorking across varied industry solutions and in different locationsat any one time makes planning essential for the successfuloperation of companies like Moulin TP. The Global e-Servicewebsite displays the locations of each individual machine usingeither Google Maps or GIS (Geographical Information System). Thelatter also allows customers to trace multiple machines by specificsearch criteria, and track and display movements of machines overa period of time.The Global e-Service is therefore an essential tool, ensuringHitachi equipment performs at the highest level, and making lifeeasier for fleet managers and machine owners all around the world.A special landmark for HCMEThis year marks the 40th anniversary of Hitachi ConstructionMachinery (Europe) NV (HCME). Established in Oosterhout in 1972,the company moved its manufacturing, sales and marketingheadquarters to Amsterdam in 2002. This location now includes afactory for the construction of medium excavators, assembly ofwheel loaders, and a Training and Demonstration Centre. Miniexcavators and special application equipment are manufacturedin Oosterhout, which is also the location for the EuropeanDistribution Centre.During the past four decades, HCME has established a strongnetwork of dealers and liaison offices throughout Europe, Africa,the CIS and the Middle East. The company mission to ‘think global,act local’ has been reflected by its focus on customer needs andsupported by the Hitachi brand values associated with innovationand technology.HCME has witnessed a steady growth in demand for Hitachiconstruction machinery across all territories over the years. Since2002, for example, the total market share for excavators up to sixtonnes has doubled; and the total market share for wheel loadershas tripled.New President and CEO, Mr Moriaki Kadoya, is delighted to jointhe company as it celebrates such an important milestone. “We willbe celebrating HCME’s 40th anniversary at different events with ourcolleagues, dealers and customers,” he says.“We can feel proud of our long history in The Netherlands andEurope. However, we wouldn’t have enjoyed such successwithout our customers – so it’s a big thanks to them from all of usfor their support.“We are delighted with how our business has continued to thriveand Hitachi is here to stay in Europe. Our ongoing commitment toour customers is to improve our business activities so that we cancontinue to help them to be profitable.”Mr Kadoya outside HCME’s Amsterdam headquartersSuper Wide DH-1 and DH-2 oilfor maximum performance.LED working light.Superior illumination!Watch Rubber StrapComplete package toservice your machine.Contact your local dealerfor more information.InformationHitachi Performance Parts06 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 07

NEWSRelentless ZW250 cuts fuelcostsHitachi holds the key for UKrental marketMoviter Service Manager Luis Bertão (centre) with the operatorsHitachi tackles climatechangeThe Japanese Government has donated four medium Hitachiexcavators to the Republic of Cape Verde. The four ZX210H-3Gswere delivered to the Ministry of Environment, Rural Developmentand Marine Resources in December 2011. They will help thecountry to recover from natural disasters such as hurricanes,volcanic eruptions, droughts and floods.The machines began operation in January 2012 on fourislands: Praia, São Nicolau, Santo Antão and São Vicente. TheZX210H-3Gs were chosen from a variety of models becausethey offer an ideal size/performance ratio. The official PortugueseHitachi dealer, Moviter, provided training for the operators, andwill continue to support the machines with periodic service andmaintenance checks.“The people of Cape Verde are very happy with the performanceof the products,” says Moviter Service Manager Luis Bertão.“They are also satisfied with the support and training they havereceived from Moviter.”This is the first time that Hitachi excavators have beendelivered to the Republic of Cape Verde as part of an OfficialDevelopment Assistance programme run by the JapaneseGovernment. The programme aims to improve the capabilitiesof countries worldwide to cope with natural disasters caused byclimate change.As well as construction equipment, the Japanese Governmenthas donated trucks, mobile workshops, ambulances andgenerators, for example, to countries in Africa, the Middle East,Asia, South and Central America. As part of the programme,Hitachi products will also be delivered to Ghana, Benin, BurkinaFaso, Burundi, Gambia, Kenya, Malawi, Mauritania, Senegal,Togo and Uganda.Swedish-owned Södra Cell is one of the world’s leadingmanufacturers of paper pulp. One of its facilities is Södra CellFolla, a pulp mill located in Verran, central Norway. It producespulp for manufacturing milk cartons, tissue and printing paper.Three years ago, when it needed a new wheel loader, four leadingbrands were tested. Nasta, the official Hitachi dealer in Norway,offered the ZW250 together with a full service contract.After three years of operation, the machine has 15,500 workinghours and 86,000km on the clock. With the ZW250, the companyhas managed to reduce fuel consumption by up to 25 per cent,compared with the wheel loader it replaced. Fitted with a 15m 3bucket, the Hitachi wheel loader transports wood pellets andsawdust around the mill in three shifts per day, seven days aweek, and travels up to 180km in 24 hours.Kjell Sørensen, who is responsible for wheel loader sales atNasta, says: “The most important benefit of the ZW250 wheelloader for this customer is the 20 to 25 per cent reduction infuel consumption. Another advantage is the optional limited slipdifferential, which delivers effective driving force to both wheelsfor greater traction on snow-covered roads.”Tore Andreas Norum, supervisor and operator at Södra CellFolla, adds: “We are delighted with the performance of the ZW250– it is a powerful, fast machine, and it never stops. After threeyears and 15,500 hours, it works like new!”Ground-breaking investmentin IsraelSix Hitachi EH3500ACII rigid dump trucks have been deliveredto a phosphate mine in Israel. The order by Rotem Amfert NegevLtd represented the largest sale of mobile plant equipment in thecountry’s history.The multinational company manufactures phosphoric acids,fertilisers, specialty chemicals and phosphate salts. It required thenew models to update its fleet of Euclid trucks. They are used toremove overburden, and haul the phosphate to storage areas,crusher and processing plant at the Mishor Rotem Mine, near theNegev Desert.The handover ceremony in April was attended by representativesfrom the customer and its parent company, ICL. Senior managementfrom Hitachi Construction Machinery (Europe) NV (HCME) andHitachi Construction Machinery Co., Ltd. (HCM), also joined the keypersonnel from CMD, the official Hitachi dealer in Israel.Kiyomitsu Yamanaka, Special Advisor for HCM, said: “SinceHCM gained ownership of Euclid in 2001, it has introduced newAC drive technologies, as seen in the EH3500ACII. These and otherinnovations will enable Hitachi to become further established as aworld leader in the design and production of large mining trucks.”HCME Manager of Heavy Equipment Sales Malcolm Edwardssays, “Rotem chose Hitachi because it could offer its own electronicsfor the truck’s electronic drive system – it is a one-stop shop. Theyalso saw the successful operation of the EH3500ACII trucks workingat the Talvivaara nickel mine in Finland in temperatures of -32°C.Additionally, they have a good working relationship with CMD andare happy with the support they receive.”HCME and CMD provided training for 90 operators, who will keepthe trucks moving 24/7. “The trucks are scheduled to complete 6,400working hours a year, doing three shifts per day,” adds Malcolm.A customer of HM Plant, the official UK Hitachi dealer, hasinvested in 68 new Zaxis excavators this year. Keyway, basedin Gloucester, ordered a range of models, from the ZX17U-2to the ZX210LC-3. The company was established in 1966 andspecialises in operated and self-drive plant hire.The founder’s two sons, Eamonn and Brian McGurk, andgrandsons, Eamonn Jr and Patrick, are now responsible for thecompany and are supported by several other family members,including Brian’s sons, Ryan and Gearard. “Keyway specialisesin long-term hires and offers customers excellent rates and abespoke service,” says Eamonn. “We can be working on 50 to100 job sites a day, with anything from one machine to a hugefleet operation.”The company has been buying Hitachi machines for morethan 17 years and the decision to invest in the new models wasbased on several factors. “Hitachi is recognised in the industryas a top brand, the advanced technology is unsurpassed, andthey’re reliable, durable and easy to operate,” adds Eamonn.The cost of ownership and resale value are additional benefits,explains Brian: “We replace our machinery after three years andat the end of their life cycle with Keyway, Hitachi models sustainthe best values on the market.”“The reliable support we receive from HM Plant is alsoimportant,” says Eamonn. “They have continued to raise theirgame over the years and offer us an improved level of service.”HM Plant Operations Director Andy Baker (left)and Keyway’s Eamonn McGurk08 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 09

InterviewWhat is HCM’s current perception of the European market?HCM is proud that HCME has a long and successful history. Europeis a tough, competitive market, especially with the cost of importinggoods from Japan due to the current strength of the yen. There is awide range of requirements, even between the different applicationsin each country.So, it is important to evaluate our business model with the aimof increasing productivity and profitability. The plan is to increasethe proportion of parts sourced from local suppliers in Europe. Thiswill help to reduce our production costs and exposure to currencyfluctuations.A WORLDOF EXPERIENCEMr Moriaki Kadoya took up his post as the new President and CEO of Hitachi ConstructionMachinery (Europe) NV (HCME) in Amsterdam at the beginning of May. In addition, hisappointment as regional CEO for Europe, Russia, CIS, Middle East, and North, West andCentral Africa is a true reflection of the vast experience he has gained from his previousroles within Hitachi Construction Machinery Co., Ltd. (HCM)Mr Kadoya is no stranger to The Netherlands, having previouslyworked as HCME’s Sales and Marketing General Managerfrom 1992 to 1998. However, his varied career with HCM startedin 1981 after graduating in Economics from Keio University in hisnative Japan.For the first five years, Mr Kadoya worked in the Overseas SalesDepartment, where he gained responsibility for Africa and thenEurope. He moved to the Overseas Cooperation Department in1986, where his experience broadened with the initiation of the Fiat(Europe) and John Deere (USA) joint ventures, as well as setting upoverseas subsidiaries.After returning from his assignment at HCME, Mr Kadoya took onmanagerial roles in the Finance Department and Corporate PlanningOffice up to 2002. The former gave him a firm grasp of the principlesof accountancy, while the latter offered an invaluable insight into thecompany as a whole.His first posts as General Manager were two-year stints in theSupply Chain Management Office – an extension of his previous rolein Corporate Planning – and the Sales Administration Departmentto coordinate HCM’s sales and production processes. Finally,Mr Kadoya returned to sales and marketing for six years in theAmericas Department, where he managed the strategic relationshipbetween Hitachi and John Deere.This firm grounding and international experience will standMr Kadoya in good stead for his new role with HCME. In anexclusive interview, Ground Control asks him about his past career,current priorities and future developments after a busy openingperiod at HCM’s European subsidiary.What do you see as the major developments in the constructionindustry during your career?For the first 20 years, there were no emerging markets in the globalconstruction industry. North America, Japan and Europe accountedfor 70 to 80 per cent of worldwide demand. Now, the Chinese marketis very important and the Korean manufacturers are competitive.Mining has also become a significant industry solution. So, thewhole landscape of the construction industry has changed and the“emerging” territories now account for around 70 per cent of themarket. This is remarkable.Which part of your career have you enjoyed the most?I have experience of strategic planning, finance and sales, butI believe that our business should be based on marketing, becauseit’s all about customers. Sometimes people think that marketingis all about analysis, but the “smell” of the customer ismore important.What is the key to HCM’s marketing approach?Hitachi has to experience the “smell” of the customers by invitingthem to the factory and visiting them on job sites. This is veryimportant and not the sort of marketing activity that is foundin textbooks. Our success in Europe is based on the internationalsales team and Hitachi dealers visiting customers with engineersfrom Japan to research what is required. By listening to theserequests, the number of modifications that have to be made tothe standard machine in each market are minimised and we cancontinuously search for areas of improvement.What do you like most about the Hitachi brand – and why?Hitachi is extremely focused on engineering. So, our engineers arealways interested in listening to the owners and operators of themachines, and the problems they want to solve. This is the key toour brand proposition.What is the current feeling among the dealer network?I have already visited some of the dealers in western Europe undermy HCME role, and found them to be open and honest. Theyall shared some positive comments and constructive criticismswith me.Some of HCME’s dealers have a long history with Hitachi and someare strong family-run businesses. They help to form important corevalues within our company, which are passed on from generationto generation. Hitachi may not be family owned, but that sense of afamily spirit is very important to us.Which countries do you see as emerging nations within yourjurisdiction?The most potential seems to be coming from the Russian and Turkishmarkets. HCME’s European Distribution Centre at Oosterhout is alsodoing well and benefiting from the growth of the mining and generalconstruction sectors in these countries, and the other nations withinthe CIS. In addition, there is much potential in North and West Africa.Why do you feel you are so well suited to your new position?My previous experience in The Netherlands is an obvious advantage,when I worked within the Dutch dealer with responsibility to sellexcavators and wheel loaders. I found this to be an interesting andchallenging role. Prior to that, I had the pleasure of conductingbusiness in Europe. My career has also included mid-termcorporate planning, overseas development projects and turnaroundprogrammes for HCM subsidiaries.What is HCME’s long-term strategy?We have a very diversified business and product range, but are stillheavily focused on excavators. So, we would like to place moreemphasis on the growth of mini excavators and wheel loaders, tobring them closer to the hydraulic excavator business.I would also like to prioritise the Support Chain after-salesprogramme. More machines will stay in Europe for longer – asemerging countries will not accept our advanced specificationmachines – and so we have to take care of them. This incorporatesthe parts requirements for these models, so that they can work evenmore reliably under the toughest of conditions.What is your message to Hitachi customers in Europe?I would like to thank all of our customers for their support and loyalty.Without them, we would not have enjoyed such a long history. HCMis extremely proud of the success of its business in Europe.HCME is celebrating its 40th anniversary in 2012 and we’re hereto stay, so that we can work together with our expanding customerbase. We aim to improve our range of products and services in linewith our customers’ expectations – and that is our commitmentto them.10 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 11

Job siteThe EX8000-6 excavating overburden with its huge43m 3 bucket (note the EX5500-6 in the background)LARGE-SCALESUPPORTThe EX8000-6 is the largest excavator made by Hitachi. There have been recordedsightings in North America and Australasia, but none in Europe or Africa – until now.Ground Control goes to Mozambique in search of not one, but two of the giganticmining machines at Vale’s Moatize siteSince Mozambique became independent from Portugal in 1975,it has been troubled by conflict, economic fragility and famine.Sixteen years of civil war ended in 1992 and since then the countryhas made significant progress in terms of economic development andpolitical stability. The national infrastructure still suffers from colonialneglect, a lack of investment and the devastation caused by floodingin 2000-01.However, foreign investors are now showing interest in the country’swealth of natural resources and a large new mining project isattracting much attention from around the world. Vale’s Moatizecoal mine will be the flagship site in the Tete province, lying 17kmnortheast of the city of Tete (which is on the Zambezi River) and 80kmeast of the Malawi border.This region holds one of the world’s largest untapped carbonreserves, particularly for coking coal, which is used to make steel.High demand for steel worldwide has accelerated the development ofcoking coal mines in various regions, such as Russia, China, USA andAustralia, but this is the only one in Africa. Mozambique’s location onthe east coast of Africa is also strategically placed to feed the Indianand Chinese markets.However, all export growth plans would have to overcome the woefulstate of the country’s infrastructure. The Government is planning toestablish a framework for how future projects are planned and who willbenefit, to ensure all those expected to come online will get access toports and rail links.Coal producers are also looking at building a new terminal at Chinde,north of Beira, which would have the capacity to handle 18-26milliontonnes per year. The port’s construction is planned to coincide with thestart of production at Rio Tinto’s new project in 2015, after it becameVale’s neighbour by acquiring Riversdale Mining in Tete for $4billion.This is just one example of the growing competition for Vale fromother mining companies in Africa. The Brazilian company led the wayin 2006 with a concession to build and operate the mine at Moatize toexport coal via rail to Beira. Operations began in 2008, including theupgrading of 670km of railway at a cost of $375million, and it startedproduction in 2011.Vale is the second largest metals and mining company, and one of thelargest publicly traded companies in the world. It is the largest producerof iron ore and the second largest producer of nickel. In addition tothermal and coking coal, it also produces manganese, ferroalloys,copper, cobalt, platinum group metals and fertiliser nutrients.Vale is seeking to become a major global company in the coal sector.It has announced plans to invest $15-20billion in Africa between 2010and 2015. This includes a $6billion expansion of Moatize to doubleoutput to 22million tonnes per year. First production from the expandedmine is forecast for the second half of 2014.The expansion will include $4.4billion dedicated to the building ofa new coal terminal at the northern port of Nacala and a 912km-railline connected to Moatize. The deep-water port is seen as moreadequate to handle Panamax vessels (those that can travel throughthe Panama Canal) than the shallower one at Beira. The railway andport will initially have a capacity of 18million tonnes to meet Vale’srising demand for exports.Gildiney Sales, Vale’s Mining Manager at Moatize, explains theimportance of the project, “Vale has coal mines in other countries, butMoatize is the first time that we have developed one from scratch.This mine is extremely important as we aim to become the world’s topmining company in the area of steelmaking resources.”12 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 13

Job siteThe Moatize coal reserve is 954million tonnes and its life expectancy is35 years. There are over 1,100 Vale employees and 600 subcontractorspresent on the site. They work across three shifts and in four teams,with one of these on standby. The overall proportion of Mozambicans is84 per cent, despite the scarcity of skilled human resources.“The civil war ended 20 years ago and the 20- and 30-somethingslack sufficient education and work experience,” says Mamoru Sawabe,President of Hitachi Construction Machinery (Mozambique), Ltd., thefirst local subsidiary established by a Japanese company in the country.“In these circumstances, it is no easy task to maintain a high operatingrate, while hiring and training local workers. Fortunately, Hitachi hassome Japanese Brazilian staff, who have come from HCM’s head officein Tokyo and are helping to support the local workers and developtheir skills.”The mining method is an open pit through sequential layers usingexcavators, wheel loaders and rigid dump trucks, in which theproduction and rehabilitation process runs simultaneously. With vastquantities of overburden to be removed and dumped in designatedpiles, and layers of coal to be collected and transported to the primarycrusher, Vale has invested heavily in its mining equipment.The line-up includes two EX8000-6s (with 43m 3 coal buckets) andthree EX5500-6s (34m 3 ) – the largest two excavators manufacturedby Hitachi. The machines are subjected to one of Africa’s harshestenvironments, where temperatures exceed 50°C, and they come witha bespoke after-sales support package to meet Vale’s requirements.One of the EX8000-6s had already been operational for three monthswhen Ground Control visited Moatize in May 2012. However, the secondmachine was being assembled by a team of specialist sub-contractors,overseen by Hitachi Construction Machinery Southern Africa Co., Ltd.’sNational Product Specialist, Dave Thomas.Dave has worked in the industry for almost 30 years and already spentsix months at this mine to manage the installation of the EX5500-6s andEX8000-6s. “Each of the disassembled EX8000-6s was transportedon 29 trucks from the port at Durban in South Africa to the site on arigorous two-week journey,” he explains.“The first one took eight men – one rigger and seven fitters – only 19days to prepare, due to the urgency required by Vale to get the machineworking on the site. When the EX8000-6 is ready for action, it takes us1.5 days to walk it down to the pit!”The decision regarding which mining excavator to purchase is onethat Vale takes very seriously. It not only compares different machinesfor productivity, but also for the level of technology that contributes tothe safety of the operators and support offered by the manufacturer inremote areas such as Tete.“We have a dedicated department in Brazil that is responsible foracquiring new machinery,” says Mário Carpegiane, Vale’s MaintenanceSupervisor at Moatize. “They know the level of equipment required tostart operations at the mine and have knowledge of the availability andsupport for other equipment that we are using around the world. Hitachihas a good reputation and is renowned for continuously developing itsmining equipment.”After one year of production, Mário had nothing but positive feedbackabout the first two EX5500-6s. The availability was excellent and thequality of service and support had exceeded expectations. On thisbasis, it was decided that Vale would continue to operate Hitachiexcavators at Moatize, so another EX5500-6 and two EX8000-6s wereordered to assist with the expansion of production.The EX8000-6 offers a quiet working environmentThe EX8000-6s and EX5500-6s are subjected to one of Africa’s harshest environments, where temperatures exceed 50°C14 Hitachi Construction Machinery (Europe) NV GROUND CONTROL15

Job site“If a part weighs over 200kg for example, then it is not possibleto use air freight. That means that it would take seven days to reachMoatize over land due to the paperwork required and otherproblems, such as those encountered at border crossings. So, wehave to determine how many parts are required for each machineand keep a good stock of the key items on site.”Training is not only required for looking after the huge Hitachimining machines, but also for operating them. This is a long andcomplicated process, and the best trainees graduate with a highlevel of concentration and knowledge of the stringent safetyprocedures in place.The man responsible for training at Moatize is Leonam Cancela.He’s been an operator with Vale for a decade and has beentraining new recruits for the past three years. Having operated anEX2500 in Brazil and the EX5500-6 and EX8000-6 since arriving inMozambique, he is certainly well qualified for the role.“It takes six months to fully train an operator from novice status,although it depends on his natural ability of course,” Leonam says.“The training includes an induction on Vale, health and safety issues,the importance of the environment and technical procedures. Theymust understand how everything works, because this can be ofinvaluable assistance to the support crew.”Arlindo Sitoe is one of the fortunate few who have made it to theunrivalled status of EX8000-6 operator. The 24-year-old Mozambicancompleted his training programme with some distinction andalready had one year’s experience operating the EX5500-6 beforeprogressing on to the EX8000-6.“It gives me a lot of pleasure to work with the EX8000-6 and I amstill very excited when I go to work every day,” enthuses Arlindo.“I’ve had invaluable training from Vale and Hitachi, and I was luckyto be selected as one of the best operators to work on these hugemachines.“I find that the EX8000-6 is very fast and of course comfortable,especially with the air conditioning in these conditions. It’s verystable, incredibly powerful and strong. The best feature for me isthat it offers a quiet working environment, which is so importantwhen loading dump trucks in the pit.”Recent investments in mining and infrastructure for huge projectssuch as Vale’s Moatize coal mine have had a positive effect onMozambique’s economy. Although it will take many years of sustainedgrowth to complete its recovery process, the country has theopportunity to dig deep into its natural resources with large-scalesupport from companies such as Hitachi.To see a movie of the EX8000-6 giantexcavator working in Mozambique, please visitwww.youtube.com/user/HitachiConstruction.To receive a digital version of Ground Controlwith new movies, please register online atwww.igroundcontrol.com/subscribe/englishA rare species: the EX8000 world map123Muskeg River oil sands mine,Alberta, Canada (four)Horizon oil sands mine,Alberta, Canada (two)Jackpine oil sands mine,Alberta, CanadaThe first EX8000-6 was assembled in 19 daysThe installation team on the second EX8000-6543231456Brule coal mine,British Colombia, CanadaWolverine zinc mine,Yukon, CanadaMoatize coal mine,Tete, Mozambique (two)The EX8000-6 is such a rare piece of equipment that there is evenmore emphasis placed on the dedicated support of Hitachi to helpmeet production targets than with any other machine. “The high levelof on-site support is an extremely important aspect of operatingHitachi excavators,” adds Mário. “The conditions in Mozambique areso tough that the maintenance and service are crucial to our operation.“Hitachi supplies the parts and service for the excavators. AsMozambique doesn’t have a good infrastructure or people with therequired experience and expertise, this places even more emphasison the relationship with the manufacturer. If we didn’t have a goodsystem in place with Hitachi, then it would be very difficult to maintainour production levels.“The availability of both models has been excellent as a result of thissupport. The interface with the Hitachi team is second to none andwe enjoy a good level of communication. Also, if you compare Hitachimodels with other excavators, the design and layout are good, whichis especially useful for replacing parts and general maintenance.”Mr Sales echoes these comments: “We are also using Hitachimachines in Brazil and therefore know about their high quality. Thesupport service for this mine is also particularly good. We can obtainparts and components within a short time frame, and we are verysatisfied. The operating rate exceeds the guaranteed level of 89 percent, and thanks to this, the whole project is going well.”Hitachi Construction Machinery (Mozambique), Ltd.’s MaintenanceSupervisor Sergio Campos manages the support team of 20personnel at Moatize. He has worked in the mining industry for morethan a decade and with Hitachi for the past two years. The key roles ofsupervisor, technician and electrician are covered across the four shiftsto cover mainly preventative and corrective maintenance procedures.“It’s a huge challenge because the machines are of course workingnon-stop,” says Sergio. “We therefore have to inspect the machineson a daily basis at every available opportunity, such as when there isa shift changeover.“The extreme heat at Moatize can cause some issues, for instancewith the air conditioning. Overall, the working conditions dictate thatthe radiator and cooler need to be kept as clean as possible. The coaldust particles are very small and can get everywhere.“I’ve worked in other countries and the main issues in Mozambiqueare with logistics and personnel. So, we need to make sure that weprepare well, plan ahead and prioritise our training procedures.678910Jellinbah coal mine,Queensland, AustraliaCallide coal mine,Queensland, AustraliaLiddell coal mine,New South Wales, AustraliaBulga coal mine,New South Wales, Australia7 89 1016 Hitachi Construction Machinery (Europe) NV GROUND CONTROL17

Special featureRobert Hahn, ZX670LCH-5, Schön + Hippelein, Germany, excavatingoverburden in the Calcitwerk Heidenheim quarry“The loading cycle is fast even when emptyingthe bucket”ZAXIS-5 PUTTO THE TESTThe new Zaxis-5 range was launched to critical acclaim at the Intermatexhibition in April. Since then, these medium and large excavators havebeen distributed all over Europe by Hitachi Construction Machinery (Europe)NV (HCME). So, who better to ask for their initial impressions of thesenew machines than the first operators in Europe to put the latest Hitachitechnology to the test“I’ve been operating excavators for 20 years and have spentthe last two of these working with Schön + Hippelein. This hasincluded recent experience of a ZX470LCH-3 and ZX670LCH-3,which I found to be well suited to quarrying.“The ZX670LCH-5 is powerful and offers excellent handlingcapabilities for loading rocks on to EH750 dump trucks. The cabis spacious, there is more than enough legroom and the seat iscomfortable. The control panel is similar to that of a car – it isso easy to understand the functionality and operate the monitor.“Productivity is so important in a quarry and that’s why I thinkthe speed of the swing mechanism is the best thing about theZX670LCH-5. It only takes four passes to fill one of the trucksand the loading cycle is fast, even when emptying the bucket.”“All of this makes life much easier forthe operator”“Our demolition company owns two ZX350LCN-3s, with a thirdone due to be delivered soon. I have operated excavators foraround 25 years and currently run KS Engineering with mybusiness partner Tobias Kuhn. In today’s competitive market,Hitachi products represent excellent value for money, especiallyin terms of reliability and minimal downtime.“The ZX350LC-5 is the replacement for our existing model andits superior power and handling characteristics are what wewould expect from Hitachi. The cab is really comfortable, theinterior is very modern and the technology is similar to what youwould find in a car.Manfred Schöllhorn, ZX350LC-5, KS Engineering, Germany,demolishing a former US military base in Augsburg“The most impressive feature is the ergonomic design of thecontrol panel and LCD monitor. It is so easy to operate the airconditioning, rear-view camera and other functions. All of thismakes life much easier for the operator.”18 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 19

Special feature“The changes between the old and new Zaxisexcavators are all positive”“I’ve been an excavator operator for 30 years and have worked withtwo other Hitachi models before experiencing the new ZX250LC-5:a ZX160W and ZX210-3. I’ve always been impressed by thesehigh-quality machines – they’re very stable and reliable.“I feel like I’ve got three arms when I’m at the controls”“With more than 25 years as an operator, and the past 17 yearsworking with Hitachi products, my experience of Zaxis excavatorshas been very positive. The reliability is excellent and Hitachiexcavators just keep going to deliver high levels of productivity andminimal downtime.“My initial impressions are that the changes between the old andnew Zaxis excavators are all positive. The hydraulics are especiallygood and I’m also very happy with the swing torque and theenhanced performance of the engine.“The new ZX870LCH-5 is more luxurious than the previous model,with increased legroom and overall comfort. The colour monitorprovides more access to useful information and the ergonomiccontrol panel is much easier to use.Frans Maenhout, ZX870LCH-5, Jan de Nul, Belgium, offloading rocksinto the Albert Canal between Antwerp and LiègeAndres Sœtre, ZX250LC-5, Trafikk & Anlegg AS, Norway,earthmoving on the E18 road between Sandefjord and Tønsberg“In my opinion, the whole package counts when you’re operatingan excavator, but with long days on job sites such as this, thencomfort comes first. The ZX250LC-5 doesn’t disappoint: the seatis comfortable; the controls are within easy reach; and there’s lessnoise and more legroom in the cab.”“The best feature of this machine is that it is very precise. When youmove the joystick, the excavator does exactly what you want it todo. This is invaluable on projects such as this and I feel like I’ve gotthree arms when I’m at the controls.”To see a movie of the new Zaxis-5 rangeworking on various job sites, please visitwww.youtube.com/user/HitachiConstruction.To receive a digital version of Ground Controlwith new movies, please register online atwww.igroundcontrol.com/subscribe/english20 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 21

Industry solutionsURBAN LEGENDSTwo of the first Hitachi clamshell telescopic excavators to work in the UK were selected for excavationon complex projects in central London. Completing the work safely and on schedule, they had a deepand positive impact on owners, operators and contractorsThe demand for special application machines, such as theHitachi ZX225USRLC-3 and ZX350LC-3 fitted with clamshelltelescopic arms, is rising in cities across Europe. To cater for theneeds of growing populations in urban areas, where space toexpand is a rare commodity, construction projects below groundlevel are increasingly common.Two ongoing projects in central London highlight the successfulapplication of these machines, which were supplied by the officialUK Hitachi dealer, HM Plant. The safety, productivity and reliabilityof the excavators were fundamental for both sites: the constructionof the World Conservation and Exhibition Centre; and Crossrail, anew railway for London and the south east of England.Safe and reliableWork on the World Conservation and Exhibition Centre involvedexcavation of several basement levels belonging to the neighbouringBritish Museum between autumn 2011 and summer 2012. TheCarey Group was responsible for completing the excavation toenable the construction of five storeys below ground level. Theywill house scientific research facilities, storage and study roomswhen the Centre opens in 2014.The Carey Group was established in 1969 by Chairman JohnCarey and his brothers, Pat and Tom. It specialises in demolition,civil engineering, concrete structures, building and environmentalsolutions, and works on projects throughout the UK and Ireland.More than 70 of its employees were working on the WorldConservation and Exhibition Centre project.The company invested in the Hitachi ZX225USRLC-3 followinga visit to Düsseldorf in October 2011 to see a similar modelworking on an underground car park. HM Plant OperationsDirector David Hearne organised the trip with the help of Kiesel,the official German Hitachi dealer.“Pat Carey and Sean O’Donnell were so impressed with itsperformance that they immediately ordered the excavator forthis job,” said Mr Hearne. “They were particularly impressed bythe compact size of the machine, which makes it suitable forworking at pavement level on busy, urban sites and within smallhoardings.”The sliding cab is an important feature for job sites suchas the World Conservation and Exhibition Centre. “The cab ispositioned 700mm further forward than on a conventional Hitachiexcavator,” explains Mr Hearne, “and it has the capacity to slideThe ZX225USRLC-3 with clamshell telescopic arm removes material from depths of 21m below ground level22 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 23

Industry solutionsa further 1,300mm forward, allowing for an additional two metresof visibility through the glass floor.”Between January and June 2012, the Carey Group usedthe Hitachi ZX225USRLC-3 fitted with a 21-metre clamshelltelescopic arm to remove material from below ground at the site.Equipped with a 0.8m 3 bucket, it loaded an average of 45 trucksa day. The trucks transported the material, known as ‘Londonblue clay’, to Margate in Kent, approximately 110km south eastof the city, where it was used to reinstate a landfill site.Carey Group Assistant Project Manager David Kyari explainedthe importance of the machine’s productivity: “It takesapproximately 12 minutes to fill each truck; eight seconds for thearm to extend and ten seconds for it to retract. It’s important forthe process to be as fast and smooth as possible, as the trucksare not allowed to queue on the street adjacent to the site, dueto parking restrictions and emissions regulations.”Without the Hitachi ZX225USRLC-3, the process would beslower and less safe. “We would have to use skips, conveyorbelts and a crane to lift the skips to remove the material, whichwould then have to be stockpiled on site,” says Mr Kyari. “Withthis machine, we can do both the excavating and loading, and itis up to three times quicker than the traditional method.”“The use of tower cranes and skips would mean more movingparts to the process,” adds Mr Hearne, “which has implicationsfor safety risks on such a busy site. Enhanced safety is one ofthe most important benefits of this excavator to the Carey Group,because it is always a top priority for the company.”The safe and smooth operation of the Hitachi excavator wasalso extremely quiet. This is another important considerationfor inner-city projects because of its close proximity to offices,residences and the British Museum, which has remained openthroughout the construction work.Powerful and productiveA short distance across London, two more clamshell telescopicZaxis excavators were working on Crossrail, the largestUsing the ZX350LC-3 was three times quicker than using skips and cranes at the Crossrail siteFrom left, Daniel and Michael O’Brien (M O’Brien Plant Hire) withHM Plant Operations Director David Hearne and Costain WorksManager Martyn Redsellengineering project in Europe. It involves the construction ofa new railway across the city, which will connect 37 stationsincluding Heathrow Airport and Maidenhead in the west withCanary Wharf, Shenfield and Abbey Wood in the east.One of the project’s 20 job sites is the construction of theeastern ticket hall of the Bond Street Crossrail station at HanoverSquare. Costain Skanska Joint Venture (CSJV) contracted theZX350LC-3 and later the ZX350LC-5 from M O’Brien Plant Hire.They were required to carry out excavation work on two shafts,five storeys below ground, leading down to the level of the newtrain platforms. This work was necessary to prepare for the arrivalof tunnel boring machines in late 2012.Between March and June 2012, the ZX350LC-3 – fitted witha 25-metre arm and 1.2m 2 bucket – worked 24-hour shifts,seven days a week, removing material from the first shaft. Itloaded a six-tonne dumper, which transported the materialsto an on-site stockpile. A Hitachi ZX225USLC-3 then loadedthe materials on to trucks for transportation off site.Completing the work on schedule was extremely importantto CSJV and it conducted a test to compare the performanceof the Hitachi clamshell telescopic excavator against the useof skips. Costain Works Manager Martyn Redsell explains:“The excavator was three times quicker than using an 8m 3 skip.The skips removed 13m 3 per hour compared to 39m 3 per hourremoved by the Hitachi. By mid-May, we were four days ahead ofschedule.”Operator Tony O’Sullivan, who works for M O’Brien Plant Hire,was also impressed by the performance of the Hitachi ZX350LC-3.“I was initially surprised at how stable it was, how far it couldreach and how much material it could bring up,” he said. “I foundit easy to operate, it has smooth hydraulics and it’s comfortable,too. Compared to other brands of machinery I’ve worked with,Hitachi is Mr Reliable.”For Tony’s employer, Michael O’Brien, the Hitachi clamshelltelescopic excavators have other advantages. “The benefitsinclude increased safety and flexibility in terms of where we canwork. They give our company greater versatility; we can reachmore customers with these machines.” The new ZX350LC-5model, delivered in July 2012, has the additional advantages ofenhanced hydraulics and the stage IIIB low-emission engine.The family-run firm, based in St Albans, Hertfordshire, wasestablished by Michael and his wife, Annamarie, in 1991 withone machine. Today, it has a 100-strong fleet of Hitachi constructionmachinery, ranging from the ZX29U-3 mini to ZX470-3 largeexcavators. “We have found Hitachi excavators to be powerful,robust and reliable,” says Michael. “The most important benefitsfor my company are the good service we receive from HM Plantand the machines’ strong residual value.”The future of M O’Brien Plant Hire lies in providing a diverse andspecialist range of equipment to meet the increasingly complexand challenging requirements of today’s construction projects.The demand for Hitachi telescopic clamshell excavators looks setto grow in accordance with this trend, and HM Plant sees greatpotential in this product category. “These machines are becomingthe standard way to do this kind of work now,” says Mr Hearne.Following their work in London, the ZX225USRLC-3 andZX350LC-5 belonging to the Carey Group and M O’Brien PlantHire respectively were scheduled to start on other projectsaround the UK. As more construction companies see them inaction, awareness of their capabilities will undoubtedly increaseand extend their appeal for underground construction projectseven further.To see a movie of the ZX225USRLC-3 workingbelow the ground in London, please visitwww.youtube.com/user/HitachiConstruction.To receive a digital version of Ground Controlwith new movies, please register online atwww.igroundcontrol.com/subscribe/english24 Hitachi Construction Machinery (Europe) NV GROUND CONTROL25

Technical focusTHE DRIVE FORELECTRIC POWERGround Control visits one of the largest copper mines in the world to investigate the benefits of the newtrolley assist system for Hitachi dump trucks. The massive Zambian project includes the installation of anew fleet of electric EH3500ACII models as part of a four-year expansion programme for the Kansanshi mineThe new EH3500ACII powers up the 750m test track at the Kansanshi copper mineGlobal investment in mining increased by 40 per cent in 2011,which was in line with the growing demand for preciousmetals, such as copper and iron ore. There is a high concentrationof such natural resources in the southern part of Africa and copperproduction is growing at a particularly high rate.Various economic and political circumstances have curbed pastinvestment in Africa. A good example is the long and expensiveroute to the nearest port from the landlocked nation of Zambia.However, the soaring prices of mineral resources – caused byhigh demand in China and other emerging countries – are helpingthe African market to gain momentum. Hitachi mining machines aresupporting this development and are at the forefront of new andexisting operations.First Quantum Minerals Ltd. (FQM) is an established miningcompany currently operating three mines worldwide to producecopper, nickel, gold and sulphuric acid. The company’s operationsinclude the Kansanshi copper and gold mine in Zambia, whichis located approximately 10km north of the town of Solwezi and180km to the northwest of the Copperbelt town of Chingola.Kansanshi is Africa’s largest copper mine – and the eighthlargest in the world – with 1,635 employees (at the end of 2011)and an estimated lifespan of at least 11 years. It operates 24/7in a three-shift pattern. Eighty per cent of the mine is owned byKansanshi Mining PLC (a FQM subsidiary) and the remaining 20 percent belongs to a subsidiary of ZCCM Investments Holdings, 85 percent of which is owned by the Zambian Government.Mining is carried out in two open pits, which are known as Mainand Northwest. FQM uses conventional open pit mining methodsand employs hydraulic excavators and a fleet of rigid dump trucks.The line-up of large excavators includes a wide range of Hitachimining equipment, including: two EX1200-5s (with over 38,000 and42,000 working hours respectively); four EX1900-5s (27-40,000);one EX1900-6 (over 14,000); and three EX2500-6s (7-20,000).However, the fleet of 11 EH3500ACII trucks is the most recent26 Hitachi Construction Machinery (Europe) NV GROUND CONTROL27

Technical focusOne of the existing EH3500ACIIs dumping overburden at the vast Zambian siteHugo Truter, Hitachi Construction Machinery (Zambia), Ltd.’sAssembly Coordinatoraddition to the Hitachi stable at Kansanshi, with 2,000 to 6,000working hours between them.John Coleshaw, FQM’s Project Manager, started working atKansanshi in 2010 and so wasn’t involved with the order for thelarge Hitachi excavators. “The EX1200s, EX1900s and EX2500swere already here when I arrived,” he confirms. “These machinesare quite old now, with some having accumulated more than 40,000hours. They have given good service and we can’t fault them.“Hitachi offered the only solution for electric-drive 180-tonnetrucks when we were in the market for these products two yearsago. The EH3500ACII is a good machine and our operators arehappy with their working environment. A main benefit of thesemodels is the automatic retarding control to regulate the downhillspeed, which is excellent for safety and preserves the lifetime ofthe product.”Born in the Copperbelt, Collins Banda has been an operatorwith FQM for three years and has driven one of the EH3500ACIIsfor over 12 months. His wife is also an operator, although she’snow more involved in training new recruits to master the miningmachinery at Kansanshi.“I’ve always dreamt of operating such a big truck and theEH3500ACII is the best machine in my opinion,” says Collins. “It’sso comfortable, even over the roughest ground, and I find that I’mnot as tired as I used to be at the end of my shift. The quality of theair conditioning, seat and suspension contribute to this feeling. Itdrives well on the haul roads, and is so powerful and fast enoughto maintain a high level of productivity.”A number of projects are planned to expand annual copperproduction capacity from the 230,000 tonnes achieved in 2011 toa target of 400,000 tonnes by 2015. The $370million expansionprogramme will be implemented in three phases.Phase one comprises of the expansion of the treatment capacityof the oxide circuit by 20% to 7.2million tonnes throughput perannum. The $200million phase two is planned to increase the oxidetreatment capacity to 15million tonnes per annum.Phase three is planned to comprise of the construction of anew sulphide concentrator with a planned annual throughput of16million tonnes of ore, with the capability of expansion to 25milliontonnes.New additions to the mining fleet will also play a key role in theexpansion programme and some equipment has already beenprocured, including 23 new EH3500ACIIs. These purpose-builttrucks are being supplied as part of a trolley assist package. Thiscommenced in March 2012 with the installation of a 750m testtrack, including an overhead line and a new dump truck for trials byHitachi engineers.The Assembly Coordinator for the Hitachi machines at Kansanshiis Hugo Truter of Hitachi Construction Machinery (Zambia), Ltd.(HCMZ). He has much experience of the rigours of mining in Africa,having worked with Hitachi Construction Machinery SouthernAfrica Co., Ltd. (HCSA) in a coal mine in the Northern Provenceof South Africa since 2002. Four years later, he moved to theLumwana copper mine in Zambia, firstly as the Truck AssemblyCoordinator for the delivery of 28 EH4500 trucks and then as aSiemens technician.In 2009, he started working for what is now HCMZ’s branch atKitwe. “I was initially employed as the Site Manager, before takingon the role of After-sales Development Manager,” says Hugo. “I’vebeen involved with the assembly of the existing EH3500ACIIs, aswell as the future development and assembly of the new truckswhen they are delivered.“The trials with the new truck on the trolley line have been goingwell. The line was supplied by Siemens to test the substationsand to see if it can take three trucks at the same time. It will bemaintained by FQM with an additional 2km running from the baseof the existing line to the bottom of the Main pit.”The design of electric dump trucks has become a more simplifiedprocess since the turn of the century. Technological innovation hasopened the door for the powerful AC drive to replace the traditionalDC drive.Dump trucks with trolley assist require initial investment forincidental facilities, such as power sources and overhead powerlines, but their power to climb slopes and acceleration are excellent.Fuel consumption is also about ten per cent lower than that ofHitachi engine-driven counterparts.The new trucks were scheduled to arrive from mid-July thisyear and be ready for full operation with the new trolley line byMarch 2013. After arriving disassembled from Hitachi ConstructionMachinery Co., Ltd. in Japan, they were partially assembled inSouth Africa so that they could still be transported by road.The journey from Johannesburg to the mine takes around 14days, partly due to the maximum travel speed of 80km/h and thequality of the roads, which means that the trucks have to zigzagthrough each country. It takes three trucks to move each partiallyassembled EH3500ACII: one to carry the frame; one with the loadbody; and one with the tyres.“The advantages of using the trolley line are reduced runningcosts – due to less fuel consumption – and the increased lifeexpectancy of the equipment,” explains Hugo. “There is also ashortage of quality fuel in Africa and the new trucks will help to savediesel for other applications.“The electric trucks excel in environmental performance, in termsof achieving low emissions and noise levels. They also have a lowerrisk of breakdown, because they don’t need a transmission andother such complex components. Their construction is more basicand they require fewer parts, which in turn means lower costs, lessmaintenance and consequently minimum downtime.“These Hitachi EH3500ACIIs were selected for Kansanshi,because the whole truck is owned and designed by Hitachi.The customer wanted a reliable system that can be used asone complete unit. All the other trucks in the market have beendesigned and built by the manufacturer, with the drive systemsupplied by a third party.”The technologically advanced trolley assist system thereforeallows a mining company such as FQM to increase its profits.Needless to say, the reduction in running costs is a major factor indetermining a mining company’s evaluation of a manufacturer andHitachi has already shown that it is ahead of the competition inthis respect.To see a movie of the EH3500ACII rigiddump trucks working in Zambia, please visitwww.youtube.com/user/HitachiConstruction.To receive a digital version of Ground Controlwith new movies, please register online atwww.igroundcontrol.com/subscribe/english28 Hitachi Construction Machinery (Europe) NV GROUND CONTROL29

DealerFOCUSINGON CUSTOMERSOLUTIONSNasta celebrates its 30th anniversary this year as the Hitachi Construction Machinery(Europe) NV (HCME) dealer in Norway. Rather than reflecting too much on pastachievements, the company is moving forward with a clear vision and enthusiasm forthe new range of Zaxis excavators and ZW wheel loadersA ZX250LC-5 on test at a road construction siteNasta’s Managing Director and CEO, Tom Johansen (left) and Sales Manager Henrik AnholtNasta employees help to ensure that customers reach their goalsNasta was the new name given to the company formerly known asNanset Standard at the beginning of last year. The fresh corporateidentity coincided with the move to an impressive 38,000m 2 €10millionsite near Larvik in the county of Vestfold, 100km southwest of Oslo.“We decided to move and change the company name at the sametime,” explains Nasta Managing Director and CEO Tom Johansen.“Our goal was to modernise the identity: Nanset was the place wherethe company originated and we had moved away from that area;and Standard Oil was rebranded in 1977, and we had stopped sellingthe product.“So, the name change seemed a logical step after leaving the formerlocation and product behind. After the creative process, we decidedto combine the two old words and create Nasta from the first two andthree letters of Nanset and Standard respectively.”The company has every right to be proud of its past after beingfounded by Søren Røed in 1929. His eldest son, Asbjørn, assumedresponsibility in 1962 and he remained as Managing Director until Tomtook over in 1999, having joined the organisation three years previously.Asbjørn and his brother, Finn, are still joint owners of Nasta.Just before the Second World War, the company secured thedistribution rights for Austin cars and later entered the constructionmarket in 1955 with International Harvester. In 1964, it added Toyotacars to its portfolio and this relationship lasted until 2005, when the carbusiness was sold to concentrate on the construction industry.This connection with Japanese technology was reinforced when itbecame a Hitachi dealer in 1982. “When selling Hitachi products, weused to say that the brand was the Toyota of the excavator world,”says Tom. “This was especially effective with customers who were moreacquainted with Toyota and we were able to capitalise on the link toreliability.”Nasta currently has 111 employees and the company’s absenteeismrate was only 2% in 2011 – well below the national average of 5.4%. Itwas also ranked second in the 2011 Vestfold Company of the Year polland voted third most popular company in Larvik by the local businesscommunity.“Nasta’s main commercial aim is to be an efficient link betweenproductivity and the job itself,” says Tom. “We should also make asignificant contribution to ensure that our customers reach their goals.Our employees help to achieve this by enjoying their role of deliveringquality products and services, which in turn provide Nasta with acompetitive advantage.“Our core values are to be resolute and adapt to changing conditionswithin the market by looking for and securing new commercialopportunities. This means that everyone is empowered to make theirown decisions, especially when consulting with customers. We believethat this is one of the main factors behind our low staff turnover andabsenteeism rates.”Nasta’s new base is unique in the Norwegian market – due to its sizeand range of in-house services – and provides Hitachi with the idealplatform from which to promote its corporate strapline of “Reliablesolutions”. The construction machinery sector in Norway peaked in2007 at 3,639 units, but this figure dropped by 55% in 2009 in the30 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 31

DealerNasta places a huge emphasis on after-salesSome of the Nasta team outside their impressive head office near Larvikaftermath of the recession. However, Nasta was able to ride the stormby gaining a 25% market share in the same year.In 2011, it sold 400 new machines – an increase of 50 units from theprevious year – to record a turnover of €77million. Around 20% of thisfigure comes from special application machines and the largest everexcavator delivered by Nasta was an EX2500-6 installed on a pontoonin February 2011. Other examples of the dealer’s specially adaptedequipment include a ZX225USLC-3 for railway applications and aZX190W-3 for tunnels.“If a customer needs something special, then we want Nasta to beconsidered as a viable option,” says Sales Manager Henrik Anholt.“We pride ourselves on focusing on customer solutions. Our facilitieshere are second to none with spacious service, special application,The wide range of services provides technicians with invaluable experiencewelding, refurbishment, paint and washing areas. This wide range ofservices makes it more interesting for technicians and presents themwith invaluable experience and fresh challenges. This will also help todevelop their skills.”As well as expanding into a new head office, Nasta has developed itsservice network. There are five other branches – with office, workshop,parts and stockyard facilities – in Lillestrøm (Tuen), Bergen (Espeland),Stjørdal, Kristiansand and Vestnes, and a total of 36 mobile service unitsproviding national coverage.“Nasta places a huge emphasis on after-sales, so that we couldsurvive off the revenue from this sector of the business, even if we don’tsell a single excavator,” adds Henrik. “That’s very important, becausewe don’t know when to expect the next drop in the market. Our aim isto reach a level of 60% of new machines being supplied with a servicecontract in 2012.“Almost half of after-sales revenue comes from Hitachi Parts andthese are of course included within the service contracts. Our proactiveapproach to maintenance enhances the life of the machine, withless downtime. This in turn leads to our goal of complete customersatisfaction.”Nasta divides the country into the different territories for sales andservice. The sales regions are segmented according to the postalsystem, which is based on the main routes for transportation. Thismakes it easier for the salesmen to manage their time and visit eachcustomer on a regular basis.While general construction is the most popular industry sector,there are signs that there will be increased demand from the rentaland quarrying sectors. The Norwegian Government is also making asignificant investment in infrastructure through the National TransportPlan 2010-2019.This initiative includes: 350km of national roads being upgraded;230km of national roads being converted to four lanes; 500km of newfootpaths and cycle paths; and 144km of new railway track, 116km ofwhich will be two-way.“There are many projects in the pipeline or that have already started,”explains Henrik. “So, we are optimistic about continued growth in themarket over the next three years at least and we expect there to be anincrease of 10-15% in 2012.”The demands of the construction industry are also shaped by thecountry’s characteristics. Norway has the lowest population density inEurope after Iceland, so there is a need for versatile equipment thatcan cater for more than one application. In addition, the harsh climaticconditions, poor soil quality and difficult terrain lead to tough workingconditions for machinery and the requirement for them to be durable.Two events dominated Nasta’s activities this year: Vei og Anlegg(Road and Construction Site) 2012, Norway’s largest constructionexhibition, which had an appropriate theme of “tough machines andfuture solutions” to match the Hitachi dealer’s current promotionalrequirements; and a three-way cooperation with the local Scania andVolkswagen distributors, in which each party invited key customers totest an impressive fleet of automotive and commercial vehicles, andconstruction machinery.The exhibition, held every three years in May, was the perfectlaunch pad to promote Nasta’s modern corporate identity, as wellas the innovative new range of Zaxis-5 excavators and ZW wheelloaders. Some customers had the opportunity to test a ZX250LC-5medium excavator in advance of the show, and the reaction wasextremely positive.“We have assessed the feedback of the operators, who havecompleted a questionnaire after trying out the new Zaxis-5 machine,”says Henrik. “This has been hugely positive and we have also used theZX250LC-5 for sales and technical training.”When asked to summarise the future prospects of the Norwegianmarket, Tom concludes: “Nasta has always had a close workingrelationship with Hitachi. We are very happy with the level of support,which has helped us to maintain a leading position for the crawlerexcavators.“Our partnership with HCME means that we are seen as one of themajor players in Norway. The reputation enjoyed by the Hitachi productrange and Nasta’s improved organisational structure mean that we are inan excellent position. We are aiming to capitalise on the positive outlookand increase our market share, especially in other product groups.”To see a movie of the ZX250LC-5 workingon the roads in Norway, please visitwww.youtube.com/user/HitachiConstruction.To receive a digital version of Ground Controlwith new movies, please register online atwww.igroundcontrol.com/subscribe/english32 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 33

Industry solutionsMOBILE LIFTINGPOWERHitachi Construction Machinery Co., Ltd. (HCM) and Sumitomo Heavy Industries, Ltd. (SHI) havehad long and successful histories in the crane market. They have become even stronger sincethey joined forces to create Hitachi Sumitomo Heavy Industries Construction Crane Co., Ltd.(HSC) and manufacture a range of crawler cranes that have proved invaluable to owners andoperators alikeHeerema operator Hans BezenberMartin Visser, HCME International SalesA Heerema barge waiting to be loaded by a Hitachi Sumitomo craneHCM launched the world’s first fully hydraulic crawler crane –the KH150 – in 1971, with the KH series being superseded bythe CX series in 1994. SHI was founded in 1963 and began to sellmechanical truck cranes a year later, before introducing hydraulictruck cranes in 1970.The two companies’ crane departments merged to form HSC inOctober 2002. HCM and SHI each have a 50% share in the jointventure, which specialises in the manufacture, sales and support ofHitachi Sumitomo crawler cranes and auxiliary equipment.The current model line-up consists of the SCX series, which wasunveiled in 2003 with the launch of the SCX900-2 and SCX1200-2.Since then, the range has expanded to include 12 products –from the SCX400T to the 6000SLX – covering lifting capacities ofbetween 40 and 550 tonnes.“Hitachi is one of the main manufacturers that sell both crawlercranes and construction machinery,” says Martin Visser of HitachiConstruction Machinery (Europe) NV (HCME) International Sales.“Historically, SHI’s expertise has extended to large cranes, whileHCM has been focused on smaller models of up to 100 tonnes oflifting capacity.“Hitachi has also had dealer representation in The Netherlandssince 1972 so it has a high level of knowledge and experience in theEuropean market. The launch of the Hitachi Sumitomo SCX seriescoincided with the opening of the HCME factory in Amsterdamin October 2002 and so HSC has been able to integrate with thedealer network for construction machinery.”HSC’s strongest markets are Belgium, The Netherlands andUK, and most sales are generated from large rental companies.The prospect for future growth comes from the erection ofwindmills in the renewable energy market and general constructionrequirements within the power generation industry.“Hitachi Sumitomo has an excellent reputation for quality,power and reliability,” adds Martin. “These models have a long lifeexpectancy of more than 20 years and it is not unusual to comeacross an old KH machine with 25 to 30 years’ service! Operatorsalso find that the latest SCX range offers a comfortable workingenvironment and user-friendly control panel.”Hitachi Sumitomo crawler cranes offer excellent mobility oversoft surfaces and can be used across a broad range of applications,ranging from civil engineering to port cargo handling projects. Atypical example of a company benefiting from these products isHeerema Fabrication Group, which has five Hitachi Sumitomocranes operating at its Vlissingen-Oost yard in the south west ofThe Netherlands.Heerema specialises in the engineering and manufacturing oflarge and complex structures for the offshore oil and gas andenergy-related industries. This 200,000m 2 strategically locatedcoastal site allows the company to have access to 720m ofquayside, with 450m of this available for large load-outs.The first of Heerema’s Hitachi Sumitomo cranes was deliveredten years ago and it currently has two SC2000s, one SCX2500 andtwo SCX2800-2s. They are used to: aid the construction processby lifting large components into place for oil platform jackets; andto load heavy assembled equipment on to barges.Crane operators need to undergo a training programme andreceive a special licence before they can begin work. There is nosubstitute for experience though and 66-year-old Hans Bezenberhas been an operator for 35 years, the last three of which have beenspent with Heerema.“Hitachi Sumitomo cranes are exceptional machines,” enthusesHans. “I have worked with other brands in the past, but the comfortand flexibility of the SCX series is second to none. They are easyto manoeuvre with the joysticks, and are fast and precise thanks tothe hydraulics. The tilting cab is also beneficial.“I’m very happy with the overall package offered by HitachiSumitomo. They provide a strong and stable base from which toperform everyday tasks, and are extremely mobile on the sandyand often damp conditions at this site. It’s also possible to lift at thesame time as the machine is moving, which means that it finishesjobs much faster than an alternative machine.”Another Hitachi Sumitomo crane operator, Guido Olivier, has 19years’ experience of operating cranes. He has worked with Hye, aleading Belgian waterworks company that specialises in coastlineand canal construction projects, for the past 17 years. Guido isoperating Hye’s SCX2800-2 on a pontoon as part of a project towiden a marina at the port of Zeebrugge.“I’ve been working with this machine since it was delivered newtwo years ago and I’m very happy with how easy it is to use,” heexplains. “The tilting cab has been integrated well into the designof the crane and is extremely comfortable. The main advantage forme is that I’m not so tired at the end of an eight-hour working day.”The comfort of the cab is a recurring theme among operators,while the reliability of Hitachi Sumitomo cranes is the number onebenefit according to owners and rental customers across Europe.The growing popularity of these powerful machines is the result ofsuccessful collaboration between HCM and SHI, and has provedmutually beneficial for both companies.The Hye SCX2800-2 on the marina at Zeebrugge34 Hitachi Construction Machinery (Europe) NVGROUND CONTROL 35

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