Maccaferri offers a range of surface strengthening and support systems with high strength mesh systems designed to work in conjunction with anchorages, to increase the stability of unstable rock slope surfaces.
Maccaferri provides innovative engineered solutions for the mining industry, reducing safety risks from rockfalls, reducing erosion due to run-off, stabilising ground and reducing costs of construction for tip and crusher walls.
Wherever problems exist in the lifecycle of a mine, Maccaferri products and solutions can help. From access and materials handling infrastructure, rockfall hazard mitigation, product concentration and leachate storage, to dewatering and site remediation, these solutions are proven to reduce safety risks, reduce construction costs and maintain operations.
Rockfall hazard mitigation in open cast mines
Slopes within open cast mines can be steep to maximise extraction volume and minimise the space for infrastructure. Loose material detaching from these slopes affects mine safety and operations. Maccaferri offers high-tensile steel cable meshes and drapery mesh to contain rocks and provide surface stabilisation. Steelgrid HR is available in tensile strengths greater than 160kN/m, and HEA cable panels for demanding loads up to 200kN/m.
Maccaferri’s range of flexible rockfall protection barriers are available certified by ETAG up to 5,000kJ (MEL) energy absorption. Attached to the rock slope, above critical infrastructure (haul roads, conveyors, tips and crushers), these barriers progressively deform under impact, absorbing loads. Attenuator and hybrid barriers are also available.
Rockfall protection embankments featuring soil reinforced with geogrids, offer up to 20,000kJ energy absorption capacity and can accommodate multiple impacts without maintenance – a significant advantage for cost-conscious mine operators.
Mine access and materials handling infrastructure
Tip and crusher walls constructed from soil which is reinforced with Maccaferri geogrids, produce cost-effective structures. Wherever possible, Maccaferri tries to reuse site-won structural backfill in combination with Paralink and MacGrid geogrids to create reinforced soil structures, reducing costs and material waste.
With geogrid strengths up to 1,600kN/m, even the heaviest vehicles can be accommodated, and many crusher walls of over 20m have been constructed. Maccaferri’s soil reinforcement structures are available with a variety of face-finishes, including:
- Green Terramesh, Paragrid or MacGrid geogrid reinforcement for sloped vegetating faces
- Terramesh soil reinforcement system for gabion faced structures
- MacRES for vertical faced concrete panel walls
Lagoon lining systems, heap leach pads and product concentration
MacLine impermeable membranes waterproof lagoons and heap leach pads, containing concentrates and avoiding infiltration into the natural ground. Combined with MacDrain drainage geocomposites, leachates can be collected efficiently and reliably.
Containment dykes often feature Maccaferri MacGrid reinforced soil, or gabion retaining structures and major dump zones can be supported on basal reinforced platforms. These platforms are reinforced with Paralink or MacTex W2, at the heart of which is polyester reinforcement providing long-term high strength and low strain to minimise differential settlements.
MacTube geotextile tubes are used for dewatering mine tailings, sludge ponds or slurries. Slurry is pumped into the MacTube, which is designed to retain the solid particles while the filtrate fluids are released through the filter fabric of the tube walls. Once drained, the solid residue is left to dry before being disposed of in a controlled manner.
Erosion control and mine remediation
Reinstatement of the mine is vital. Maccaferri offers MacLine impermeable cappings and drainage systems to prevent surface water entering the deposits. MacDrain drainage geocomposites are available with a wide range of filters and core types to provide flow capacity under a variety of load conditions.
The rapid re-establishment of vegetation and soil erosion protection systems completes the closure operations. Maccaferri’s wide range of man-made MacMat and biodegradable BioMac soil stabilisation solutions facilitate this. These mats provide immediate erosion protection from rainfall impact or run-off and long-term root reinforcement.
Shotcrete and roof support in underground mines
Maccaferri’s Pararib tunnel reinforcement mesh contains loose and falling debris from shafts and excavations. Pararib is lightweight, white and flame retardant, making it ideal for use underground.
Wirand fibres are added to shotcrete to reinforce it and provide stabilisation of shafts, excavations and access tunnels and it can even replace traditional steel reinforcement mesh.
Quality mining products and services
Maccaferri aims to build mutually beneficial relationships with clients through the quality of its service and solutions. With nearly 30 manufacturing facilities around the world and more than 60 operating companies in 100 countries worldwide, Maccaferri’s engineers offer technical support, including analysis, design, solution selection and installation supervision.
Please use the form below to contact us, or inquire directly via the Maccaferri websites listed below and the regional offices tab of this company profile.
We offer dynamic rockfall barriers with energy absorption capacities from 250kj up to 8500kj, all tested in accordance with the ETAG 027 Guidelines and supplied in kits to be used in infrastructure and mining.
A coalfield needed to be developed from an existing one-dragline operation to a two-seam operation which will also eventually be upgraded to a four-dragline operation.
It was the client's plan to put up one more central ore handling plant consists of Screening, Crushing, Beneficiation and Grinding at iron ore in India. Part of the construction of the plant infrastructures at the Serajuddin Mines, Joda, Orissa, was entailed. providing access to 22m-high loading bin at the primary crusher.
Founded in 1879, Maccaferri is a leader in innovative and sustainable solutions to overcome environmental, geotechnical and hydraulic erosion problems.
Maccaferri UK and Ireland technical manager Nicola Brusa is to be a guest speaker at an IGNS UK & Western Institute of Mining & Minerals.
Tasiast open-pit gold mine, Mauritanian desert: the mining company KINROSS needed a retaining tip wall requiring two wing walls of 32.5m. To meet such a design requirement, the mine operator, AUSENCO, turned to Maccaferri for a cost-effective and flexible reinforced MSE wall system.
Grootegeluk Medupi Expansion Project: Maccaferri’s MSE ‘Paramesh’ Wall System Prevailed Over Concrete Retaining Systems
Maccaferri ‘Paramesh’ MSE wall System is a cross product consisting of Terramesh® units with ParaLink® geosynthetic soil reinforcement grids.
Flexible MacRes® system enables wall to be built using local Kalahari sand as backfill.
Easy-to-Install Tailing Discharge Canal for the Bozymchak Gold Mine in Kyrgyzstan with Maccaferri’s Reno Mattresses
The Bozymchak gold mine in Zhalalabadskya is operated by Kazakhmys Gold Kyrgyzstan.
Ease of installation and cost-effectiveness among the advantages offered by this solution. The availability of structural backfill material within mines makes geogrid reinforced soil structure very competitive compared to traditional reinforced concrete or sheet pile retaining structures.
Rockfall events can affect mine safety and operations. With more than 60 years’ experience in rockfall protection systems, we offer a wide range of Mac.RO™ systems to stabilize rock faces, reducing risks and costs.
Maccaferri’s Reinforced Soil Retaining Structure Supports Access Road in Vale Malaysian Distribution Centre
Due to the company's expansion, the Brazilian mining giant Vale has opened an iron ore distribution centre and pellet plant in Malaysia, in the town of Lumut, Perak.
A residual storage impoundment was at risk of overflow.
The S11D Eliezer Batista Complex is the largest mining complex in Vale's history and Maccaferri provided rockfall hazard mitigation measures to protect the mine railway infrastructure.
To maximise extraction volume and minimise the space for infrastructure, slopes within mines can be steep.
Indonesia's second-largest cement producer, PT Indocement, wanted to extend its factory in the South of Jakarta. The new retaining structure would be connected to the existing concrete vertical crusher wall.
An elevated increase in the global demand for geosynthetics can be partly attributed to an increase in the scale of mines in the past decade.
Located in the state of Goiás in Brazil, around 170km north-west of Brasilia, is the nickel-producing mine and processing plant, Barro Alto.
Bekaert and Maccaferri will establish a global sales and distribution joint venture to provide total construction reinforcement solutions for underground infrastructure projects, such as road, railway, metro, hydro power stations and utility and mining tunnels.