Rocktec partnered with Crushing & Mining Equipment Pty Ltd to deliver a high-performance apron feeder system for Fortescue Metals Group at the Cloud Break Mine in Pilbara, Australia. Designed for rugged reliability, the system forms a critical part of the mine’s ROM ore handling infrastructure and supports continuous, high-volume operations.
Project Overview: 17m Heavy-Duty Apron Feeders for FMG
- Client: Crushing & Mining Equipment Pty Ltd
- End User: Fortescue Metals Group Ltd
- Location: Pilbara, Western Australia
- Industry: Mining – ROM Ore Handling
- Scope: Design and build of four 17m apron feeders
- Completion: Cloud Break Mine (Year not specified)
The Challenge: Handling Heavy Loads in Harsh Conditions
Fortescue Metals Group needed a robust apron feeder system capable of withstanding severe material weight, high impact forces, and constant abrasion. Moreover, the feeders had to deliver a reliable 2500 tph feed rate while maintaining structural integrity in extreme environmental conditions. Therefore, minimising maintenance requirements and maximising uptime were essential goals from the start.
Rocktec’s Solution: Built Tough for the Pilbara
To meet these demands, Rocktec designed four apron feeders, each measuring 17 metres in length and 1200mm in width. The systems prioritised durability, consistent output, and reduced wear. Key features included:
- D4 chain with roller running gear to absorb shock and improve lifespan
- Overlapping steel pans bolted to crawler tractor chain for continuous flow
- Segmented sprockets for efficient power transfer and easier maintenance
- 75kW installed power per unit to support the 2500 tph feed rate
- Heavy-duty spherical roller bearings for stability at both head and tail ends
- Steel support rollers that reduced friction and extended equipment life
- Central impact bars to prevent deformation during extreme load surges
As a result, Rocktec delivered a heavy-duty solution that performs with exceptional reliability in demanding mine conditions.
Implementation Process: Designed, Built, and Delivered
- Engineering: Rocktec’s design team collaborated closely with the client to meet technical and environmental specs.
- Fabrication: The feeders were manufactured at Rocktec’s facility in New Zealand using premium wear-resistant materials.
- Assembly: Technicians completed full in-house testing and assembly before dispatch. As a result, quality and consistency were ensured.
- Delivery: Each feeder was shipped to Pilbara as a near-complete unit, which significantly reduced installation time on-site.
Results and Benefits
- Reliable Capacity: Each apron feeder system consistently delivers 2500 tph with minimal downtime.
- Proven Durability: Built for high-impact environments with reinforced pans and chain systems.
- Quick Installation: Preassembled delivery enabled faster commissioning and earlier productivity.
- Reduced Maintenance: Durable components and impact protection result in fewer service disruptions.
Conclusion: Engineered for Extreme Conditions
This project highlights Rocktec’s ability to deliver high-output, heavy-duty apron feeder systems for some of the harshest mining environments. Thanks to smart engineering, robust materials, and tight quality control, Fortescue Metals Group gained a feeding system that continues to perform reliably under extreme operational pressure.
Want to Learn More?
To explore the latest advancements in bulk materials handling, visit the Australian Bulk Handling Review.
If you’re developing a high-capacity ore feed system or require a custom-engineered mining solution, contact Rocktec to discuss your project.