Railcar connector for fast, safe unloading of bottom-discharge hopper cars 

The Boot-Lift® Railcar Connector from Martin Engineering improves the speed and safety of connecting a hopper car to under-track conveying systems, preventing the loss of material to wind or contamination without workers crawling under the car. Installed on the track flanges and powered by an air-over- hydraulic design, the boot rises to the unloading gates for clean, efficient unloading of bottom-discharge hopper cars. Sponge seals fit securely to the gates for a clean transfer of material to the conveying system.

“Unloading bulk materials from railcars can be a difficult, dirty job,” observed Martin Engineering VP of Operations Robert Nogaj. “It can be a slow, labor-intensive and sometimes unsafe process. In many facilities, unloading requires workers to crawl beneath the cars to connect the outlet to the under-track system. The Boot-Lift eliminates that potential risk, and it can be easily operated from a remote control console.”

Models are available to suit virtually any bottom-discharge railcar design, including single- or double-opening, round-opening and GATX. Adaptor sheets and transition funnels are available for interchangeability, allowing operators to use the same connector for any number of different cars. Users can convert various car models from double- to single-pocket unloading or single to double by simply removing the standard sponge seals and replacing with the appropriate funnel and adaptor sheet.

The boot automatically connects with the railcar and rises as the load empties out, maintaining an effective seal throughout the process. The units require just 1 CFM of air supply at 90 PSI (28 LPM at 6.2 bar).

Martin Engineering offers two different types of aligners to simplify car positioning. The Boot-Lift Manual Aligner delivers up to six inches (152mm) of total adjustment, three inches (76mm) in each direction along the track. The pneumatic model provides up to eight inches (203mm) of total adjustment, four inches (101.5mm) in either direction. Remote control requires just 10PSI (0.7 bar) of compressed air.

The standard boot material is black vinyl-covered cloth. Other options are available, including polyethylene-lined; white synthetic rubber-coated cloth; food-grade polyethylene-lined polypropylene; and flame retardant coated polyester.

Martin Engineering supplies a number of related accessories, including funnel covers and rugged vinyl-covered cloth cylinder covers to help prevent damage and contamination of air cylinders from material build-up or difficult service environments. Replacement boots, sponge seals and other components are also available.

Founded in 1944, Martin Engineering is the global leader in technologies to make bulk materials handling cleaner, safer and more productive. The company supplies conveyor products and flow aids around the world for a wide variety of bulk material applications, including coal, cement, aggregate, biomass, grain, pharmaceuticals, food and other materials. The firm is headquartered in Neponset, IL, offering manufacturing, sales and service from factory-owned business units in Brazil, China, France, Germany, India, Indonesia, Mexico, Russia, South Africa, Spain,Turkey and the UK, and under exclusive licence with ESS Australia. 

Kiruna Wagon — new-generation wagons for the modern mining industry  

Kiruna Wagon specializes in the custom design and manufacture of wagons for rail freight of heavy bulk materials above and below ground. Based in Kiruna, the mining capital of Sweden, the company is able to draw on more than 100 years of experience in rail-bound ore transport and steel refinement and develop this knowledge further in order to meet the mining industry’s transport requirements of today.

Since the start in 2004, Kiruna Wagon has emerged as a leading European manufacturer of wagons for heavy rail transports and has established itself as a reliable supplier to modern mining companies. Among its clients are LKAB, New Boliden, Northland Resources and Rana Gruber.


Kiruna Wagon believes that higher axle loads, longer trains and lighter wagons is the way forward towards higher productivity and a lower environmental impact. Through the use of advanced high-strength steels, it is possible to lower the tare weight of the wagons which means that they can carry more payload. The increased load efficiency in combination with a reduced fuel consumption and an optimized life cycle results in a more environmentally friendly transport.

As supplier to some of the world’s most modern mines, Kiruna Wagon works with development, manufacture and maintenance from a lifecycle-cost (LCC) perspective. Through 

the lifecycle-cost (LCC) analysis, the company’s clients are able to make informed decisions and achieve the most economical process from inception to decommissioning. The goal is to deliver the world’s lowest lifecycle cost per metric tonne on rail- bound transports.


Kiruna Wagon manufactures its products based on existing drawings or design new logistics systems to suit the client’s requirements. All its wagon types can be customized to fit line loads and loading gauge preconditions. The modular design of the wagons ensures high maintainability.

Since the company is located north of the Arctic Circle, its wagons are tested in a challenging subarctic climate and are constructed for a temperature interval of –40°C to +60°C.

The rail freight industry has a tradition of being innovative and in order to maintain its strong position in the market, Kiruna Wagon is committed to continual research and development. One of its strategies to secure its innovative edge is to collaborate with Lulea° University of Technology on its Sirius Projects which provide final-year engineering students with the opportunity to apply their skills and knowledge to real engineering problems. Through the collaboration, Kiruna Wagon gains access to innovative solutions developed by well-educated students who solve problems from completely new angles. The development of the second-generation Side Dumper has greatly benefited from this collaboration.


In order to market its products and come face-to-face with key customers, Kiruna Wagon participates in trade shows and conferences organized by the mining industry. Most recently it participated in the conference Innovative Mining: Safe, Smart & Sustainable in Perth, Australia, in November 2014. As the company broadens its target market and product range, it is interested in also attending conferences organized by the coal mining industry.


Bottom Dumper for high-capacity discharge

Kiruna Wagon’s Bottom Dumper is a strong feature of its product portfolio for modular standard products. Suitable for heavy transport of easily unloaded commodities, the robust Bottom Dumper has a mechanically controlled unloading system and a large bottom door for high-capacity continuous discharge of up to 20,000tph (tonnes per hour). The low-cost unloading station can unload up to 200 wagons per hour and is proven in a subarctic climate.

Thanks to its modular design, the Bottom Dumper is optimized for easy replacement of individual components – a damaged body or bottom door can be replaced by two persons within two hours.

Two Nordic mining companies, LKAB in Sweden and Rana Gruber in Norway, have chosen Kiruna Wagon’s Bottom Dumper for the transport of iron ore. The NO-RG Fanoo exported to Norway is a refined version of the wagon manufactured for LKAB, in more than 1000 units.

Side dumper for sealed transports

Kiruna Wagon’s Side Dumper is a four-axle bogie wagon with a carrying capacity of 73 tonnes. The wagon is equipped with a roof and optimized for sealed transports of hazardous and/or highly refined ore products in smaller volumes.

During discharge, the wagon is locked in the correct position before external lifters connect to the body and tip it to an angle of 55°. The opening of hatches is mechanically integrated in the tipping function. The roof is kept closed during the entire discharge process.

The robust Side Dumper handles sticky materials and can be loaded and unloaded from both sides. The unloading station is a simple and low-cost solution with a capacity to discharge up to 1,500tph.

The Side Dumper is used by New Boliden for the transport of copper ore from the mine in Aitik in Swedish Lapland to the smelter in Ro¨nnska¨r, beside the Bay of Bothnia.

A second-generation Side Dumper is currently under development. 

Rock Dumper for big boulders and small drifts
Kiruna Wagon’s Rock Dumper with effective bottom discharge is a heavy-duty concept that can handle drop-loaded boulders in sizes up to 1,000mm. 
The wagon, which is based on a technology that has been in use since the 1970s, is designed for rolling discharge and has a discharge capacity of approximately 10,000tph.

The Rock Dumper is dimensioned for a small drift with a width of 2,056mm and a height of 1,825mm. The rail gauge is only 891mm. These dimensions can be adjusted according to customer needs.

Kiruna Wagon’s Rock Dumpers are used by Swedish mining company LKAB in its underground mine in Kiruna.

Helix Dumper for tough-flowing commodities

Kiruna Wagon’s ground-breaking Helix Dumper combines optimal productivity with simplicity. The Helix Dumper is the wagon of choice for small fractions and tough-flowing commodities that are unsuitable for bottom discharge.

The wagon is based on a chassis that is well-proven on the iron ore line in northern Sweden but its body and discharge system introduce a new concept to ore logistics. Built for continuous, rolling discharge the Helix Dumper empties its load by rotating the body 148° while the chassis remains on the rail. The rotation, along with the rounded shape of the body, creates optimal conditions for effective discharge.

The Helix Dumper’s unloading station is a robust and low- cost solution which requires minimal maintenance. The system has a discharge rate of up to 18,500tph. No manual intervention or electrical power is required during unloading.

To minimize tare weight and maximize payload, the Helix Dumper is built mainly in high-strength steels, with a yield strength of 700MPa.  
Renowned Texas scrap handler goes for green SENNEBOGEN material handlers  

The Wilkinson name is so renowned for honourable service in South Texas, USA, that each of the three separate legacy businesses uniquely and proudly lists the family name first, regardless of which grandson of scrap handling pioneer S.H.Wilkinson it belongs to. To meet the ever-demanding production needs of today’s scrap metal business, the Wilkinson families have come to rely on another renowned family name — SENNEBOGEN.

“We have the capacity to load 15 rail bunkers at a time here, and we need those three SENNEBOGENs to do it,” says Scott Wilkinson, himself a 30-year industry veteran. “We've got a 24-hour timeframe to receive railcars and turn them around, and we need to have the ability to load 15 cars in those 24 hours.

As did its ‘cousin’ company in Brownsville,Wilkinson Gary Iron & Metal first introduced a grapple-equipped, SENNEBOGEN 835 M and later an 825 M to its Laredo fleet a few years ago. The larger machine keeps the Laredo yard's shredder full when not assisting the smaller machines in loading railcars with processed material during those intense, 15-car turnaround days. A normal weekly throughput rate is about 40 railcars, serviced full-time by the 825 M material handler.

But with the SENNEBOGEN material handlers, designed and built with a greater emphasis on durability and strength, and less on electronics, “You don't have the repair bills and breakdown issues that you normally have with other kinds of converted excavators,” Scott Wilkinson says. A SENNEBOGEN machine will operate throughout the day without overheating the engine or burning out any of the hydraulic system's components; an automatic reversible fan keeps the rads clear. “We always have the SENNEBOGENs running,” says Scott.

When a service or maintenance issue does arise,Waukesha- Pearce Industries (WPI), Inc., the local SENNEBOGEN dealer and their representative Darryl Woods are able to provide parts promptly, supported by SENNEBOGEN LLC’s 100,000ft2 fully- serviced parts facility in North Carolina. This, says Scott, is a substantial upgrade from a previous make of material handler used at the Laredo yard.

With their Cummins engines mounted front to back, the intelligently designed SENNEBOGEN machines are easy to work on, yet do not compromise creature comforts, says Scott. Each of his three SENNEBOGEN operators “absolutely loves” the easy-to-access, easy-to-operate, air-conditioned machines. The elevating cabs provide the operators with good visibility into trailers when unloading them, or railcars when loading them.  
Grabbing the market with KINSHOFER GmbH  

KINSHOFER GmbH is a medium sized company specializing in the development, production and sales of hydraulically operated crane and excavator attachments. Founded in 1971 and based at the southern edge of Munich’s dynamic financial region, today KINSHOFER GmbH is the centre of an international group of fifteen companies with about 470 employees worldwide.

KINSHOFER’s attachments are used widely throughout the bulk industry, including loading trains and barges.

An efficient team of highly qualified employees, extremely modern manufacturing facilities and sophisticated production logistics ensure fast reaction times for meeting customer demands. Whether on a crane, excavator or fork truck, KINSHOFER attachments noticeably improve the versatility and speed of any carrier machine. The company’s products are built to a very high quality — KINSHOFER is a great believer in the principle that you get what you pay for. Therefore its grabs are not cheap, but lower initial outlay on cheaper grabs can often be more expensive in the long run. Unreliable grabs, and those that require extensive maintenance, can have very high operating costs.

The strict quality of KINSHOFER’s P-grabs (orange peel grapples) has placed them among the best in the world, and users have responded with delight to this quality. A similar story applies also to KINSHOFER’s C-Series, which boasts the highest quality possible.

With over 43 years of experience and a continuing focus on the advancement of the attachment industry, KINSHOFER GmbH has become a ‘one-stop-shop’ and is now a market leader with a complete range of crane and excavator attachments, including a full line of strong reliable rotators, rotary actuators, tiltrotators, quick hitches and buckets.  
Top crane and excavator manufacturers continue to choose KINSHOFER as their OEM partner for their attachment demands. 


The C40HD is a popular grab in the KINSHOFER line. In October last year, the model was chosen by UK company Land Recovery Ltd, for use in its aggregate handling and recycling operations.

Land Recovery Ltd, one of UK’s specialist aggregate handling and recycling companies has continued expanding its modern fleet of plant with the purchase of a new Komatsu PC 360 LC fitted with a new KINSHOFER C40HD 175 re-handling clamshell. The clamshell was delivered and installed by KINSHOFER’s independent dealer for the North West, MTK (Breaker Hire and Sales) Ltd. 

The heavy duty clamshell bucket, which has a 2.1m3 capacity, was specified with additional bolt-on horizontal and vertical wear blades to help reduce wear caused by material abrasion, a heavy duty 360° continuous rotation system and then fitted to the dipper end of the Komatsu PC 360 before being deployed at a Network Rail Recycling site in Cambridgeshire.

Dan Beecroft, (Managing Director) was very careful in his choice of manufacturer and the support service on offer. “Both need to be reliable” said Dan,“I cannot afford for the clamshell grab to stop the excavator working or vice-versa.” Beecroft had dealt with MTK in the past, so he knew the company could be relied upon to provide him with the service required.  

“As a KINSHOFER – Demarec dealer, they arranged for a full assessment of the site and the application, calculating the optimum size of clamshell for the excavator I had in mind ... they then went one better by loaning me an attachment whilst mine was built to my specification.”

Among the key features of the C40HD clamshell is the wide pitch PCD ‘slew ring’ type rotation device for increased strength and stability, the use of high strength impact resistant materials which contribute to a low overall weight of the grab and the ‘flat bottom’ closing curve which prevents damage to railway wagons, boats and lorries. Bolt-on reversible horizontal and vertical wear blades protect surfaces vulnerable to abrasion, but also ensure rapid down time when being turned or replaced.  

The CVHD is a durable re-handling clamshell bucket, especially for loading bulk materials for excavators from 25t/55,000 lbs to 40t/88,000 lbs operating weight. It offers the following advantages:

  • maximum volume due to widely spaced pivots with a flat closing curve. Protection of the ground surface is guaranteed, e.g. discharge from boat and train carriages etc.; v precise positioning with an integrated rotator;
  • long life is ensured due to the use of 500HB steel in the manufacture of cutting edges. Shell back walls (standard version: 8mm/0.31in, HB 400) also resist highly abrasive materials. Bearing points with specially coated bushings and hardened pins;
  • with integrated rotation: swivel and bevel sealed. Rotary feedthrough and motor accessible directly;
  • integrated non-return valve guarantees security of the load; 
  • excellent digging characteristics are the result of high closing forces (57kN/12,540 lbf at an operating pressure of 35MPa/5,040psi);
  • here optional heavy duty (HD) version with reinforced shells.



The C40VHD and C60VHD grabs are also extremely popular. These are durable re-handling clamshell buckets, especially for loading bulk materials for excavators from 18t/39,600 lbs to 40t/88,000 lbs (C40VHD), as well as re-handling excavators from 20t/44,000 lbs to 40t/88,000 lbs or 40t/88,000 lbs to 60t/132,000 lbs (C60VHD) operating weight.

Due to the closed shells, these grabs are ideal for very fine- grained loads (e.g. fertilizer). Their excellent digging characteristics, the result of high closing forces due to two vertical cylinders,offer the following results:(C40VHD:A/B = 71kN/15,620 lbf/C = 65kN/14,300 lbf; C60VHD = 102kN/22, 440 lbf). 

American River Transportation Company (ARTCO), a subsidiary of Archer Daniels Midland Company recently selected Terex Port Solutions (TPS) to supply two diesel-electric Terex® Gottwald Model 8 floating cranes in the G HPK 8400 B four-rope-grab variant for professional bulk handling. When the two cranes are delivered in August and September of this year, they will augment ARTCO’s existing fleet of four Terex Gottwald floating cranes operating at five different buoy sets in the greater New Orleans area. With a maximum lifting capacity of 100 tonnes each and impressive 63-tonne grab curves, the new cranes are to specifically transship bulk products, including but not limited to fertilizers, salt, steel products and coal, between ocean-going vessels and river barges on the Mississippi. Both cranes will be delivered with pedestals that will be welded on site to the crane barges.

“ARTCO is part of ADM’s global logistics network that includes 2,500 barges, more than 27,000 railcars, 600 trucks, 1,300 trailers and more than 50 oceangoing vessels. Our customers on the Mississippi can depend on that network — and our expertise — to move their goods around the world efficiently,” says Jason Porter, director of Gulf operations at ARTCO. “These two new floating cranes, with their high handling rates and excellent reliability, will help us enhance our ability to serve our customers. We are pleased to be working again with Terex, a world leader that understands and delivers on our exacting requirements.”

Joe Krider,Vice President Supra Region Americas,TPS said: “This repeated ARTCO’s decision to purchase additional TPS cranes is a vote of confidence in our mobile harbour crane technology on barges. The order from ARTCO also illustrates once again the success story of Terex Gottwald floating cranes on the Mississippi, whose number will soon increase to a total of 21 machines.”


Terex Gottwald Model 8 floating cranes have a weighing system installed direct on the crane. The system is far more precise than conventional load measuring solutions on cranes. The measuring system accurately records the bulk quantity in the grab during a handling cycle; thus rendering external weighing systems and the associated additional work unnecessary. “Thanks to this innovation, we will be able to offer our customers an even higher level of specificity with regard to the freight quantities handled”, says Porter.


ADM’s operations in Louisiana involve agricultural processing and transportation and logistics, as the company sources crops and secures energy and transportation needs throughout the state. The company’s river operations in the Gulf — managed by ADM subsidiaryAmerican RiverTransportation Company (ARTCO) — include 20 harbour and fleet vessels, a full-service shipyard, a barge washing and repair facility, and stevedoring, crewboat and line handling services. ADM employs more than 650 employees in the south Louisiana port system.


For more than a century, the people of Archer Daniels Midland Company (NYSE:ADM) have transformed crops into products that serve the vital needs of a growing world. Today, it is one of the world’s largest agricultural processors and food ingredient providers, with more than 33,000 employees serving customers in more than 140 countries.With a global value chain that includes more than 460 crop procurement locations, 300 ingredient manufacturing facilities, 40 innovation centres and the world’s premier crop transportation network, ADM connects the harvest to the home, making products for food, animal feed, chemical and energy uses.


Terex Port Solutions is part of the Material Handling & Port Solutions business segment of Terex Corporation that supplies customers in ports with a unique combination of machines, software and services under the Terex and Terex Gottwald brands. Whether it is ship-to-shore cranes, reach stackers or fully automated, integrated handling systems for containers and bulk,Terex Port Solutions provides reliable solutions for rapid, safe, efficient handling of all forms of cargo with low downtimes and excellent return on investment.


Terex Corporation is a lifting and material handling solutions company reporting in five business segments:AerialWork Platforms, Construction, Cranes, Material Handling & Port Solutions and Materials Processing. Terex manufactures a broad range of equipment serving customers in various industries, including the construction, infrastructure, manufacturing, shipping, transportation, refining, energy, utility, quarrying and mining industries. Terex offers financial products and services to assist in the acquisition of Terex equipment through Terex Financial Services. 

Cutting edge rope technologies for heavy lifting applications on barges  

TEUFELBERGER’s high-performance steel wire ropes are developed specifically to lift extremely heavy loads and have been used successfully for this purpose for decades. High-quality raw materials, innovative technologies, and new manufacturing methods constitute the key to success. However, TEUFELBERGER also delivers fibre rope solutions that are ideally suited to moor big barges.

Salt water, wind, and climatic influences place extremely high demands on steel wire ropes that are used in and on water. The key factor in this regard is corrosion resistance. Therefore, TEUFELBERGER has focused its development efforts on this specific parameter. In fact, 2015 will see the market debut of its new ‘Protect’ line, a particularly corrosion-resistant series of steel wire ropes. Evolution TK16 and Evolution TK18 are the known and established non-rotating high-quality steel wire ropes from TEUFELBERGER. For the Offshore segment, these special rope models will now be the first to be launched as featuring the additional, exceptional characteristics of the new Protect technology: characteristics that will also significantly improve rope-based transport capabilities on barges.

‘Protect’ includes the interaction between a unique zinc/aluminium alloy coating of the individual steel wires and Pro Active Core Lubrication. The latter is special temperature- resistant grease providing significantly enhanced lubricating characteristics. Another indispensable ingredient is the plasticized Plastfill® core.

Protect Ropes offer compelling added value due to their markedly higher resistance to corrosion than conventional galvanized wires. Also, low friction considerably reduces wear within the rope. All these factors plus an excellent lubrication of the core, even in the case of active heave compensation (AHC), increase the lifetime of TEUFELBERGER’s high performance steel wire ropes.

Two technologies in particular make the non-rotating EVOLUTION TK16 and TK18 steel wire ropes so high performing. Firstly, the SUPERFILL® compaction technology, developed in cooperation with universities and independent research institutes, where every strand of the rope is compacted in a special procedure. This considerably improves the characteristics of the rope. Secondly, the plasticized PLASTFILL® core, where the lubricated steel core is overmoulded with a compact plastic cover.

Building on the developments of our rope specialists, suitable process technology used in manufacturing plays a decisive role in ensuring the quality of high-performance steel wire ropes. In this regard, process reliability is essential and also reveals itself in the form of consistent diameters along great manufactured lengths.

In the dry bulk cargo market,TEUFELBERGER ropes are used as a lighter-weight facewire to attach a towboat to a barge or tow of barges. TEUFELBERGER’s comprehensive Commercial Marine product line consists of the strongest, most reliable, and durable lines in the industry. The company’s ropes are easy to handle, easy to splice, and extremely strong while remaining light in weight. Specifically TEUFELBERGER’s Endura 12, its 12-strand HMPE line, is internationally recognized as a safe and efficient towing, mooring, and general purpose line. Endura 12 can be used in place of wire due to its high strength, low weight, and durability.

Like the Offshore segment, Heavy Lift applications require high- performance steel wire ropes of increasing thickness and thus weight. Consequently, a demand for additional manufacturing capacities has arisen in the rapidly growing segment of high- performance steel wire ropes, where TEUFELBERGER is one of the globally leading manufacturers. These additional capacities are scheduled to be available by the end of 2016 at a new manufacturing site in Germany.


TEUFELBERGER is a globally successful enterprise specializing in the development and production of ropes. Its wide-ranging product portfolio includes steel wire ropes (e.g. for ropeways and cranes), synthetic fibre ropes (e.g. for occupational safety and marine applications), plastic strapping, and baler twines. In addition to its headquarters at Wels, Austria,TEUFELBERGER operates other manufacturing sites in Austria, the Czech Republic,Thailand, and the US. A close-knit network of distribution partners ensures TEUFELBERGER’s worldwide presence. In 2014, its 950 employees generated about 182 million in total revenue, 57% in the EU, 13% in Asia, and 22% in America.