It’s a vibrant global market for conveyors serving customers in aggregates and other building materials handling industries.
Telestack has supplied two mobile shiploading systems to DEME, one of the world’s leading marine engineering and offshore energy companies, as part of the Coastal Virginia Offshore Wind (CVOW) project, a landmark initiative in the US’ renewable energy sector.
As the largest offshore wind project in the US, CVOW represents a pivotal step toward clean energy and reducing carbon emissions, with Telestack’s innovative shiploading equipment playing a vital part in its success.
CVOW, developed by Dominion Energy, is designed to deliver 2.6 gigawatts (GW) of renewable energy, enough to power approximately 660,000 homes at peak output. The project involves the construction of 176 wind turbines, three offshore sub-stations, and undersea cables, with onshore infrastructure to channel renewable energy to the grid.
Telestack’s two mobile shiploading systems have integrated into the material handling element of the project, helping to ensure the efficient loading of large-grade armour rock into flexible fall pipe vessels (FFPV).
The company’s shiploading equipment is operating in Bayside, Canada, where it has supplied two AP 1500 D3 wheel-mounted apron steel feeders and two TB52 (170-foot) radial telescopic shiploaders for loading rock material onto DEME’s specialised rock installation vessels at a high loading rate.
The Telestack system included a range of technical features and benefits that were vital for the long-term handling of these rock grades. The AP 1500 feeders included a heavy-duty steel apron chain, complete with high-grade cast steel flights and bearings, for large rock applications. The feeder allows wheeled loaders to be fed from over three sides, providing ultimate flexibility and increased tonnage. The integrated variable speed drive on the feeder is designed to ensure a controlled flow of material to the TB52 Shiploader, key for the large rock. The feeder features a wheel-mounted design, allowing the operator to move the unit via tow hitch around the quayside as required, aiding the system’s mobility.
The feeder then discharges into the TB52 Radial Telescopic, which also features a number of innovative features, designed to meet the challenges of handling these material grades effectively. The 52m telescopic boom conveyor can load the largest FFPVs, including the DEME’s Yellowstone, which is currently the largest FFPV in the world with a 37,000-tonne capacity and free-board/draft height of more than 14m.
The design of the radial and telescopic features enables the operator to place the material easily within the rock hold. At flows the same time, minimising the work required for the vessel’s excavator to move the material within the hold, ultimately increasing the tonnage rate of the entire operation.
The TB52s are tracked, mounted units, which allows them to move off the site when not required, easing their use on multi-cargo berths and jetties. The machines include heavy-duty rollers, belting and skirting, complete with anti-roll-back features to handle large rocks.
The rollers are spaced 600mm apart to minimise the ‘bounce’ of the material when the units stop in operation. This material is further controlled by the variable speed drive on the shiploaders, which works in conjunction with the feeder to ensure full operational control in all scenarios.
This contract has helped to demonstrate Telestack as among the leaders in mobile bulk material handling, largely due to its experience and ability to design and manufacture products that meet the specific demands of such an instrumental project.
The company’s shiploading solutions are engineered for high throughput, operational efficiency and flexibility achieved through mobility.
“Telestack has a huge portfolio of international projects that demonstrate our expertise,” Telestack international sales manager Carl Donnelly said.
“Our team is experienced in high-profile projects and values the pre-engineering stage, which allows the solution to develop through true collaboration, listening to the needs of the operation and leveraging decades of experience.
“This process isn’t just one meeting – it takes time, patience and partnerships, which we pride ourselves on.”
Designed for the toughest applications, Telestack’s heavy-duty equipment is engineered to handle the most demanding materials with durability and efficiency. Built with reinforced structures and mine-spec componentry, its shiploading solutions help to ensure performance regardless of the application.
The high-capacity loading ability of the Telestack solutions enables the rapid transfer of rock materials, minimising turnaround times for the FFPV. They also assist in delivering to vessels accurately and in compliance with environmental regulations.
Mobile shiploading can significantly enhance the operational performance and productivity of a port by offering greater flexibility, efficiency and cost savings compared. These mobile units enable ports to quickly adapt to different vessel sizes and cargo types, thereby reducing vessel turnaround times and increasing throughput. By eliminating the need for extensive infrastructure modifications, mobile shiploaders can minimise capital expenditures while still providing high-capacity loading rates.
Rapid deployment helps revenue stream begin to flow almost immediately. Unlike systems that experience downtime due to empty return cycles, mobile solutions enable continuous loading, maximising throughput while reducing operating costs. Designed for simplicity, these machines require minimal training, are easy to maintain, and eliminate complex electrical systems, allowing smooth, uninterrupted operations.
By embracing mobile solutions, companies like DEME and others within the offshore industry can unlock efficiency, safety, and environmental benefits in handling their offshore rock.
The CVOW project highlights the crucial role of partnerships and innovative solutions in advancing renewable energy.
Telestack said it is honoured to have collaborated with DEME to devise this shiploading system for a groundbreaking endeavour, which will not only bolster renewable energy capacity but potentially inspire confidence in offshore wind as a reliable and sustainable energy source.
Strategic collaboration
Telestack has successfully installed a TS52 radial stockpiling conveyor for MIBAU Stema UK. This strategic collaboration, facilitated by Telestack’s valued UK ports partner Cooper Specialised Handling, provides a key player in the European aggregates and shipping sector with an efficient and flexible material handling solution.
MIBAU Stema plays a crucial role in supplying aggregates from Norwegian quarries for various applications, including the asphalt, construction, and concrete industries. With an annual production exceeding 20 million tonnes of aggregate, MIBAU Stema efficiently delivers materials across terminals located around the North Sea and Baltic regions, utilising a fleet of self-discharging vessels for swift and seamless supply from quarry to customer.
“We are very happy to have worked with Telestack and Cooper Specialised handling on this high-capacity system from our self-discharge vessels,” MIBAU Stema UK managing director Martin Johansen said.
“The reliable operation of this system is critical to our business, so we had to ensure we had a proven and robust design, which we have received from Telestack and Cooper.
“This is the second high-capacity system we have received from Telestack, and we are happy to work with professional and customer-focused companies such as Telestack and Cooper Specialised Handling.”
The high-specification Telestack TS52 radial telescopic conveyor is deployed at MIBAU Stema’s Sheerness Port terminal in the UK where it is designed to enhance the efficient stockpiling and transfer of the high-volume aggregate directly from the self-discharge vessel, integrating with discharge process and operation.
The machine offers a versatile and cost-effective alternative to handling material from self-discharge vessels, which is typically done via wheel loaders, excavators and material handlers. The fact it takes many of these types of units working simultaneously to handle this tonnage via traditional methods can add significant costs to the process and also increase safety concerns due to traffic and multiple movements in the discharge area.
“We are incredibly proud to see the Telestack TS52 radial telescopic conveyor successfully commissioned at MIBAU Stema Sheerness terminal. This project truly exemplifies the power of collaboration, working closely with our esteemed UK Ports partner, Cooper Specialised Handling, to deliver a highly effective solution for a key player in the UK and European aggregates sector,” Telestack international sales manager Carl Donnelly said.
“The TS52 is a perfect fit for MIBAU Stema’s high-volume operations, offering the flexibility and efficiency they need to seamlessly integrate with their self-discharging vessels. The ability of our units to handle 2500-plus [tonnes per hour] on a consistent basis is a testament to our design, manufacturing, quality and installation and commissioning teams at Telestack.
“It’s fantastic to witness our conveyor technology providing such a significant impact on their productivity and operational flow. We look forward to seeing MIBAU Stema reap the benefits of this investment for years to come.”
The TS52 Stacker boasts a 52m unit, achieving output in excess of 2500 tonnes per hour with its 1400mm (55 inches) wide belt. The unit can discharge material up to 18m (60 feet) and ensures over 100,000 tonnes of aggregates can be stacked from a single position. The unit’s radial and telescopic features also allow for the separation of materials into individual storage bays, depending on the differing grades of materials.
The system also includes variable speed control (VSD) for flexibility in operation, along with dual access walkways for maintenance, lights for night time operation, radio remote control for all functions, and a specialised 250-micron marine-grade paint finish for operation in the corrosive port environment.
“This is a landmark supply for our business, both in scale and in customer significance. MIBAU Stema is a highly respected name in the industry, known for operational excellence and high-volume throughput,” Cooper Specialised Handling sales director Chris Barnes said.
“Being selected to support their UK operations with a Telestack solution is a strong endorsement of our technical capability and our ongoing commitment to delivering engineered solutions for the bulk handling sector.”
Stacks to offer
ProStack, a leading provider of bulk material handling solutions, has unveiled a new range of tracked conveyors specifically designed for small-to-medium-sized operations.
These new models offer a shorter conveyor length than the existing ProStack range, delivering greater choice without compromising on performance.
The latest additions include the TC 50, TC 60 and TR 60, tracked conveyors measuring 15m (50 feet) and 18m(60 feet), including a radial option. These models are engineered for efficient stockpiling and are ideal for operations where space, mobility or budget constraints are key considerations.
“This new range allows us to fill a gap in our portfolio with conveyors that are better suited to smaller-scale operations,” ProStack business line director Neil Robinson said.
“They’re compact, competitively priced, and tailored to meet the needs of a wider customer base.”
The new conveyors complement the broader ProStack line-up, which includes tracked feeders, bulk reception feeders, port hoppers, and telescopic conveyors. With this launch, ProStack continues to expand its offering to meet evolving customer demands.
The new range is available globally through ProStack’s distribution network.
Preventing fugitive material
Most conveyors experience some degree of material loss due to spillage, leakage, dust and carryback, collectively known as fugitive materials. This loss can range from three per cent in poorly operated and maintained systems to less than 0.1 per cent in world-class operations, according to Martin Engineering president emeritus R. Todd Swinderman.
“Although fugitive materials cannot be completely eliminated from bulk material handling conveyors, the issue can be effectively managed, leading to cleaner, safer and more productive operations,” Swinderman said.
“The symptoms of a failure to control fugitive materials include unplanned downtime, excessive cleaning costs, premature equipment failure, regulatory violations and safety incidents. Addressing these symptoms with workable, long-term solutions will enhance performance, housekeeping and safety, and boost profitability.”
Swinderman said the location and particle sizes of the accumulations indicate the nature of fugitive material problems from any conveyor. Fugitive materials are generally categorised into spillage, leakage, dust and carryback.
“Spillage escapes the belt and collects under the conveyor in both the loading and discharge zones. Piles of spillage accumulate rapidly and occur due to overloaded belts, mis-tracking, and insufficiently sealed loading and discharge zones. This is best remedied with a skirtboard liner. A wear liner and a canoe liner protect the enclosure from abrasion wear,” Swinderman said.
“Leakage seeps, slowly accumulating in piles. The source of the leakage may not be immediately apparent. Apron-seal dual skirting along the skirt board rides the belt, creating a seal material from dust emissions.
“Dust commonly uses turbulent air to escape at the transfer point. In some studies, working in a dusty environment has been found to reduce worker productivity by as much as 20 per cent. Combustible dust poses fire and explosion hazards, as well as health and safety risks. A modular transfer point kit creates a loading zone, a settling zone and a stilling zone, separated by curtains, that control airflow and allow dust to settle back into the material stream.
“Carryback refers to fine material that adheres to the belt surface or gets trapped in imperfections after passing the belt cleaners. At the discharge and along the belt’s return path, this material falls beneath the system, generating dust and accumulating, sometimes encasing the belt and rolling components.”
Swinderman said a common production “upgrade” is to increase the speed of the belt.
Fugitive material problems are roughly proportional to the speed of the conveyor (or tonnage). If the belt speed is doubled, the fugitive material problem and operational costs (clean-up, maintenance, equipment replacement, etc) may also double.
“There’s an old adage: you can’t fit five pounds in a one-pound bag,” Swinderman said. “Careful consideration must be given to capacity calculations, the angle of belt incline, transfer point design, and access for cleaning and maintenance.
“To enhance control of fugitive materials, it is advisable to derate the capacity to 80 to 90 per cent of the theoretical capacity and employ slower belt speeds. Loading at an angle of less than five degrees and reducing the incline will help minimise flooding and material rollback at the tail.”
Swinderman said designing a longer and taller skirtboard enclosure with dust curtains will help control airflow and dust emissions. Access for cleaning and maintenance can reduce downtime by a third and significantly decrease exposure to hazards. If future capacity increases are likely, they should be factored into the initial design.
“A bulk handling operation located near a resort area was facing public outrage due to dust and spillage that were staining the beautiful sandy beaches a deep red. The mill faced daily fines and the risk of closure if the issues were not resolved,” Swinderman said.
“The main focus was on repairing transfer points, replacing idlers and alleviating some of the most significant material flow bottlenecks. The benefits were numerous.
“Spillage decreased from 2.8 per cent to 0.8 per cent of tonnes conveyed, idler life increased by 30 per cent, belt life improved by 25 per cent, and safety incidents and near misses were dramatically reduced,” Swinderman said. “Operators noticed most complaints shifted to the need to mow grass that grew back underneath the structure.
“However, the most significant benefit was the improvement in conveyor availability, enabling a 33 per cent increase in production without expanding the raw material yard’s receiving and storage capacity.”
Swinderman said managing fugitive material is a more economically and operationally sound than merely chalking it up as ‘the cost of doing business’.
“The effect that spillage, dust and carryback have on an operation is a tangible reminder of unnecessary inefficiency,” he said. “By working with experts and installing modern solutions to age-old conveyor problems and practising state-of-the-art maintenance, operators can significantly improve safety in the workplace and dramatically reduce the cost of operation.”
Cutting it
With over 45 years’ experience in the belt conveying world, Smiley Monroe’s expertise is trusted by the world’s largest manufacturers of mobile and static materials processing equipment. The company, which has its headquarters in Lisburn, Northern Ireland, provides precision-cut rubber and plastic parts that are vital role in maximising conveyor uptime, helping achieve consistent performance and reduced downtime.
Smiley Monroe lists five ways cut rubber and plastic parts work behind the scenes to help keep operations moving seamlessly:
1. Material spillage: Custom-cut rubber skirting seals load zones, preventing material overflow and protecting belt edges from premature wear.
2. Dust seals: Tailored dust seals contain airborne particles, enhancing air quality and safeguarding conveyor components from abrasive dust.
3. Gaskets: Precision-cut rubber gaskets ensure reliable sealing of covers and hatches, dampen vibrations, and resist wear and chemical exposure.
4. Wear liners: Durable wear liners shield high-impact areas like hoppers and chutes from abrasion, reduce material build-up, and minimise operational noise.
5. Ready-to-fit kits: Smiley Monroe offers part-numbered, CNC-cut kits that simplify ordering and installation, ensuring consistent quality and fit.
