Published in the May 2010 Coal USA Magazine

The OEM began working with management from Cline Resources subsidiary Sugar Camp Energy in 2008, when the two were looking for a solution to make slope construction at the Sugar Camp mine in Illinois safer for crews and progress more quickly.

Traditionally, workers would hold large beam components in place and then remain stationary until the beams were bolted and secured – a tedious and dangerous process.

“After several beams had been set, they were fastened together using connector bars and corrugated metal panels [and], finally, grout or concrete would be pumped around the metal to make a sealed structure,” according to Fletcher coal products sales manager Ben Hardman.

“To manage these operations, miners had to climb around the structures with tools and materials, maneuvering them into position.”

The resulting product from the two companies’ research was the Fletcher Beam Setter, an electric-over-hydraulic unit built on a small face drill chassis that uses a small boom to swing, lift and extend.

Accurate beam positioning is achieved by two 360-degree rotary actuators, and workers remain stable as the unit’s platform moves. Operators can also easily travel from platform to tram deck using Fletcher’s walk-over deck design.

According to JH Fletcher, the first Beam Setter at Sugar Camp was delivered in August 2008 and was designed for use under a 12-foot seam height without a platform – a feature which can now be found on the unit. In September 2009, the second unit was shipped to Patton Mining’s new Deer Run longwall operation now in development, and is in use within the mine’s 18ft operating height.

Patton Mining president Dwayne Francisco told Coal USA that the Beam Setter has played a significant role in the rapid progress that the 9Mtpa central Illinois mine is making toward going online in September 2010. Crews have their work cut out for them as they advance on the 2500ft slope, and the Fletcher unit is helping to get beams up in one motion without ladders or climbing.

In fact, Francisco noted, a manlift is being used to put workers in place ahead of the beams to keep them safe, secure and ready to set the structures within the 22ft wide by 16ft tall slope.

He estimates that each of the 650-plus beams to be placed at Deer Run can be set in about a half hour – a significant time savings over the estimated 2-3 hours needed for each beam using traditional methods.

“The beam setter allows us to cut installation time in half,” Francisco said, pointing out that Deer Run workers would be using chain hoists on scoops or other machines if not for the Beam Setter.

Hardman also noted the time and production savings the product brings, all while keeping the operator under a canopy and allowing workers to pre-assemble beams and tram them into the area of installation.

“The Fletcher Beam Setter has been a tremendous tool for Patton,” Francisco said.

“[It] has not only allowed our operation to be more efficient, but first and foremost allows my people to be in the safest environment possible.”