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Caterpillar eases tight schedules

New wheel loaders from Caterpillar are helping RMC Topmix to meet tight schedules for the Dubai Airport expansion project.

01 April 2004

New G-Series II Caterpillar wheel loaders deployed at RMC Topmix’s new plant have helped it deliver ready-mix concrete on schedule for the prestigious Dubai International Airport (DIA) expansion project, says Mohammed Abdulrahman Al Bahar, the UAE-based Caterpillar dealer.

DIA has embarked on a $4.1 billion expansion which includes the construction of a new terminal in place of the existing Terminal 2, Concourse 2 and 3, Terminal 3 (underground), Dubai Flower Centre and Cargo Mega Terminal.
The fully computerised plant in the Al Qusais Industrial Area of Dubai commenced operations last November and caters exclusively to the requirements of the airport expansion project. The facility – which produces 900 cu m of concrete per hour has an underground water storage tank of a capacity of 1.3 million litres and has seven 23-m-high silos (four more to be added soon) to store 4,500 tonnes of cement. Aggregate from the company’s quarry in Fujairah (Gulf Quarry) and limestone from Stevinrock are transported by 270 trailers every day.
Several Cat loaders handle the aggregates at the quarry in Fujairah. The Cat 966G-II and a Cat 972G-II loaders feed the hoppers with aggregate, sand and other materials while a 938G-II and a 966G-II are engaged in loading and stockpiling operations at the plant. These machines are running continuously during the two 12-hour shifts at the site.
“For an operation such as ours, where the machines have to run 24 hours a day and 365 days a year – reliability is what matters,” says Gerard Boulomier, project manager, RMC Topmix. “Every 30 seconds, 18 tonnes of aggregate is transferred to the plant. Since this is a non-stop operation, we need the work to be done by reliable machines, which is why we have chosen Cat loaders.”
UK-headquartered RMC Topmix has plants in Abu Dhabi, Al Quoz (Jebel Ali), Sharjah and Ras Al Khaimah. “Our relationship with Al Bahar has stood for over 15 years. Cat machines are easy to operate and maintain; are economical in terms of fuel consumption, and we get good after-sales service,” he adds.

Cat G Series II wheel loaders
This new generation of wheel loaders from Caterpillar offer increased customer value and a lower cost per tonne by being more productive, more efficient, and more comfortable to operate, according to a spokesman of Al Bahar. These models are also easier to maintain and meet EU Stage II emissions regulations.
The key features of Cat wheel loaders include: Electronically-controlled Cat diesel engine which meets EU emissions regulations, while delivering more power, faster response and improved fuel economy. The new cooling system has a hydraulically-driven, electronically-controlled, variable-speed fan that improves engine efficiency and reduces noise levels.
“The electronically-controlled automatic transmission of the engine offers smooth, consistent shifting, for better productivity and operator comfort. Optional free wheel stator torque converter boosts power train efficiency, particularly in load-and-carry applications. The integrated braking system increases productivity and lowers operating costs by integrating transmission downshift and neutraliser controls, thereby optimising braking efficiency and brake life.
The G Series features electronic sensors on lift arm and bucket tilt cylinder, allowing the operator to adjust the bucket kick-out from the cab. A fine modulation mode ensures precise linkage control.
He continues: “Engine power is directed to the axles via an electronically-controlled, power shift transmission with an automatic shift facility and a kick-down feature that speeds up/down shifting and increases bucket fill speeds in applications such as face loading, where the loader will often approach the pile in second gear.
“Machine efficiency is further enhanced by the optional free wheel stator torque converter and an integrated oil-disc braking system that features all-hydraulic operation for better performance and greater reliability.

Enhanced versatility
“The G-Series II wheel loaders are built around an articulated main frame that offers excellent manoeuvrability and a four-plate loader tower that provides a rigid base for the solid plate lift arms and Z-bar loader linkage.
“A wide application range is ensured by an extensive line of buckets with rated capacities from 2.7 cu m on the 950G Series II up to 5.7 cu m on the 980G Series II. These buckets are ideal for the light to medium-duty applications associated with general excavation, truck loading and stockpiling. Heavy-duty rock buckets are available on the larger wheel loaders, enabling them to operate productively in tough face-loading applications. Special application arrangements including high-lift and logging are also available on selected models.”

Increased comfort
Operator comfort and efficiency is further enhanced by changes to the optional electro-hydraulic implement controls that allow in-cab adjustment of the bucket kick-out and finer modulation of the hydraulic control for the bucket and lift arms.
Routine maintenance is simplified and operating costs lowered by the introduction of better diagnostics and prognostics on the EMS III; and oil change intervals that have been doubled to 500 hours on the engine and 4,000 hours on the hydraulic system.
“The G-Series II wheel loaders offer many important benefits to mid-size wheel loader customers. Their new engines have made them more productive and use less fuel than the earlier models, while making them kinder to the environment in terms of their noise and exhaust emissions. They are also easier to control, more comfortable to operate and require less maintenance,” he concludes.