Safely and Efficiently Assembling One of the World's Largest Machines

By Caterpillar | Posted August 4, 2022

With the assembly and commissioning of multiple giant Cat® 7495 Electric Rope Shovels under its belt, Cat dealer Ferreyros has developed significant expertise in the process. But that doesn’t make each one less of an undertaking.

Ferreyros recently completed three 7495s for the new Anglo American Quellaveco mine ― a greenfield copper operation set to begin first production later this year. Ferreyros captured the project in a video titled “A Giant is Born in The Peruvian Mining Industry.”

The 6-minute video is a step-by-step documentation of the effort it takes to assemble a machine that measures more than 20 meters (66 feet) high and weighs 1300 tonnes (1,433 tons). A team of Ferreyros experts has dedicated an average of more than 32,000 work-hours to each assembly in this project.

But perhaps the most impressive number is zero ― the number of recordable accidents during the execution of the enormous task.

Ferreyros applies world-class engineering techniques and relies on meticulous planning while following demanding safety standards in all stages of the assembly. The result is an efficient and agile process that ensures quality and safety.

"We are excited to share the birth of this mining production equipment, each capable of loading 140,000 tons of material in a single day,” said Fernando Armas Tamayo, vice president of Ferreyros’ large mining division. “Today, more than 20 giant Cat 7495 shovels are operating in Peruvian mining with maximum productivity and availability, with the permanent support of Ferreyros."

The support the dealer provides once the shovels are up and running is essential to the mines it serves. At Quellaveco, Ferreyros will be responsible for the mine’s 7495s along with a Cat 6060B Hydraulic Mining Shovel, the first of its kind in Peru. The shovels will load a fleet of 28 autonomous Cat 794 AC Trucks ― the first in the Andean country ― making Quellaveco the largest 100% autonomous haulage mine in South America.

This fleet will be responsible for helping Quellaveco achieve its goal to deliver an average of 300,000 tonnes (330,693 tons) per year in its first 10 years of operation. First production of copper is expected this year, with full production achieved in 2023.

Located in the Moquegua region of Peru ― the country’s most established copper-producing region ― Quellaveco sits at an altitude of 3000 meters (9,800 feet). Ferreyros will locate specially trained personnel on site at Quellaveco, along with a supply of spare parts and components to keep machines available. Ferreyros will also support owner Anglo American’s efforts to train local people to work on the project.

Ferreyros and owner Ferreycorp have a long history of supporting mining in Peru and contributing to the development of the country, celebrating 100 years in 2022.