What sets this design apart from the pack

---

 Big Roller™ has optimised its design through integration with the ground module transom member between the module legs.  A fully welded and integrated carry idler frame removes the materials required of an independently adjustable idler. Big Roller™ estimate this to be 50% reduction of steel on a per lineal meter basis.

 Big Roller™  has undertaken refinement of the process of fabrication to reduces costs, typically cutting, bending, welding and machining time, use of consumables, labour, surface treatments and Quality Control (Non-destructive testing and tolerances surveys).   

Having larger rollers spaced further apart enables  carry roller quantities to be reduce by over 55% (or equivalent to 10,000 rolls in 13.5kms of conveyor) 

Big Roller™  has sourced 100% recyclable roller materials and structures, enabling Clients the ability to participate in the circular economy. 

Various transport approaches are used by industry for OLC ground module sub-assemblies. A design can be stackable, packed in a transportation frame, nestable, or flat packed as components or crate packed to optimise weight and transport/shipping dimensional constraints. 

Big Roller™ has optimised around a goalpost design that incorporates both carry and return idlers for the ground module leg structure. This allows for combined module leg and sleeper transportation efficiencies, as the unit can be assembled and fully dressed with return and guide rolls and pull wire pigtails offsite. 

With fewer carry rollers per lineal meter required and lighter overall weights, a 10% improvement in shipping is achieved. 

With a 13.5m module length, Big Roller™ stringers and other transport bundles are ideally suited to packing within 40" and 45" intermodal containers for local and international freight. 

Big Roller™ estimate that the above transportation efficiencies result in 300 to 400 fewer trailer movements to the Pilbara that you don't need to account for in  Scope 1 and / or 2 emissions. 

With ample storage available at our Meenaar Facility in Northam, we can ship directly to the work site, thereby having no need for large multi hectare laydown yards, meaning less land clearing at site. 

Big Roller™ has integrated high precision roller mounting brackets within the ground module, as opposed to within an independent idler frame that is then fitted to a ground module (on stringer or legs), enabling a more streamlined construction process. 

A module including sleeper, can be taken off a truck, installed directly onto the prepared base, positioned to within 2cm using GPS machine control and stabilised. Once the sleeper is stable a survey of centreline, Easting and Northing coordinates and RL can be performed once through a survey prism jig and totalising station. With 6 degrees of freedom adjustment available locally via the foundation anchor bolt connection, fine tolerance adjustments are made in-situ until the final high accuracy position is achieved. 

The anchor bolts are locked onto the ground module feet with oversized washers and nuts and the GPS tolerance adjustment void is packed with grout to prevent movement. For horizontally curved conveyors the addition of appropriately angled wedge washer (top and bottom) allows for the frames angle tilt to be accommodated. 

Carry rollers are then fitted.  Stringers and cladding are pre-assembled alongside the conveyor and lifted into position. The module is then dressed at midspan locations with Pull Wire and Belt Drift Switch, Pull Wire Brackets, Panels and Cable Loop arrangements.

With larger modules and fewer components resulting from the larger idler span, Big Roller™  estimates that fabrication and construction schedule durations reduce by 1/3.