Local mining manufacturing firm Proof Engineering’s zinc alloy couplers have been successfully field-tested at Sasol Mining’s Middelbult colliery, in Mpumalanga, since June last year.

The couplers, manufactured from its patented South Africa Future Value (ZAFV) material, are the result of a three-year research and development programme by the company to develop a replacement for the traditional copper or brass alloy plugs, sockets and couplers that facilitate the connection of electrical cables to mobile mining equipment.

“The problem with the copper or copper-based alloys normally used in the manufacture of electrical couplers is that, usually, components maintain an extremely high weight-to-value ratio and are a high theft risk. Coupler theft may also result in excessive downtime and subsequent lost production,” explains the company’s marketing and sales manager, Rikus Prinsloo.

The ZAFV-alloy coupler is 33% lighter than its brass equivalent and demonstrates material integrity while remaining completely malleable and retaining its machinability. The material may also have potential applications in components other than electrical couplers, such as switches, housings and flameproof glands.

“Owing to the fact that it is a unique patented alloy, material movement can be controlled between manufacturer, supplier and end-user,” says Prinsloo.

The product has been approved by Sasol, Exxaro, Xstrata and BHP Billiton, and the company is currently engaging with Sasol Commercial to service existing demand and amend the com- pany’s contract to include the use of the ZAFV-alloy components at all operations.

Further, the material is currently undergoing extensive testing at various accredited facilities in Australia, the UK and the US.

To subscribe to Mining Weekly's print magazine email subscriptions@creamermedia.co.za or buy now.