ME Elecmetal delivers a reliable fastening solution designed to reduce operational deviations, strengthen asset reliability, and optimize KPIs for safety, availability, and productivity.
A major copper producer preparing for a large-scale expansion sought a comprehensive consulting proposal to reinforce the bolting and fastening elements of its SAG mill liners. The operation featured a SAG–ball mill grinding circuit, designed for high-throughput copper sulfide extraction, required improved fastening reliability to ensure safety, availability, and consistent performance at higher production rates:
SAG Mill (40×29 ft) – Equipped with a lifter/plate cylinder configuration in a three-ring layout (Feed / Central / Discharge).
Ball Mill (27×49 ft) – Providing critical secondary grinding capacity to maximize metal recovery.
By targeting fastening reliability at the core of these mills, the customer aimed to minimize unplanned deviations and enhance long-term equipment integrity.
This challenge set the stage for the Smart Bolting System (SBS)—ME Elecmetal’s market-leading solution engineered to eliminate fastening deviations and ensure consistent, verifiable performance. Unlike any other option in the market, SBS uniquely combines innovative fastening technology with premium-quality products, enhanced by tailored training and consulting to meet each customer’s specific needs.
ME Elecmetal delivered a comprehensive fastening proposal for SAG mill liners, fully aligned with the parameters of the Smart Bolting System (SBS). The solution was structured into three stages to ensure both operational excellence and long-term reliability:
Hands-on training for the client’s maintenance team on fastening elements.
Definition of installation tensions and standardized procedures according to liner design.
Calibration of torque wrenches to guarantee accuracy and consistency.
On-site technical support during maintenance activities.
Verification that fastening procedures were applied correctly.
Deployment of a secure web platform for real-time tension monitoring.
Delivery of biweekly reports to track fastening conditions.
Definition of a re-torque or re-tightening plan for sustained fastening integrity.
To further enhance reliability, ME Elecmetal conducted a liner-specific study to determine the optimal installation tension. The solution incorporated Ridgeback – ValleyForge bolts, offering a superior fit and secure seating within the liner bores.
Additionally, tension sensors were installed to continuously monitor fastening performance throughout the campaign, verifying that the recommended installation tension of 170,000 lbf was consistently achieved and maintained.
The proposed solution integrates specialized training, precision torque wrench calibration, the implementation of online tension sensors, and the supply of high-performance fastening elements—all designed to ensure safer installations and greater long-term reliability.
ME Elecmetal’s Smart Bolting System delivered measurable improvements in fastening performance and asset reliability. By recording and monitoring installation tensions, the system enabled early detection of deviations during the installation process. This proactive approach allowed timely re-torque adjustments, preventing potential failures or breakages and ensuring consistent fastening integrity throughout the campaign.
