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Aging Trestle Upgrade Projects at Wenjiapo and Dafosi Coal Mines

Project Background

The existing in-service trestle suffered from severe corrosion underneath and deterioration of its components. To prevent sudden safety incidents, the mine had installed temporary steel-frame shoring. This remedial measure incurred substantial annual steel-frame rental costs and occupied space needed for mine production. It could not fully eliminate the safety risks, which continued to affect stable and efficient mine operations.

Retrofit Plan

A new prefabricated enclosed steel-truss trestle was constructed with a clear width of 7.3m, a clear height of 2.7m and a length of 29.8m, seamlessly connecting the clean coal and washed mixed coal transfer points.

Versatility, Speed, Quality and Savings

Versatility. The prefabricated trestle meets the different conveying needs of materials including raw coal, clean coal and coal gangue.

Speed. Using prefabricated construction, the new trestle was lifted into place and replaced within 7 days while meeting the project's strict requirement for continuous, uninterrupted production.

Quality. The prefabricated trestle resolves corrosion risks, frees up construction space at the mines and eliminates long-standing production safety hazards at their source.

Savings. Replacing the temporary steel-frame supports substantially reduces operations and maintenance costs, with annual equipment maintenance and steel corrosion reduced by 30% compared with conventional solutions.

Prefabrication and Digital Intelligence Transform Conventional Trestles

Zhengyuan's intelligent prefabricated trestles overcome the operations and maintenance limitations of conventional industrial trestles by equipping each installation with a dedicated 'digital brain' and a comprehensive sensing network. This enables a transition from manual inspections and reactive fixes to intelligent sensing, proactive prediction, precise control and efficient maintenance. The system strengthens production safety across thermal power, chemical and coal preparation facilities, improves equipment performance and controls plant operations and maintenance costs, supporting stable and safe industrial production.

Modular Customization for Multiple Applications

Zhengyuan's intelligent prefabricated trestles use a modular design. Components are manufactured in batches at the factory and transported to the site for assembly. They can be customized to suit terrain, process connections and load parameters under different operating conditions, meeting the specific requirements of four major industrial applications and supporting different process stages.

Integrated Prefabricated Construction

The construction approach combines standardized factory prefabrication with modular on-site assembly, enabling standardized components and batch fabrication and installation. It follows the core requirements of industrial trestle construction and safety specifications and coal-conveying process design standards. It is suitable for the four major industrial settings of coal mines, coal preparation plants, thermal power plants and chemical facilities, covering the great majority of trestle project applications in these industries.

Flexible Column Spans

Precise modeling and calculations account for site elevation differences, obstacle locations, overhead clearance requirements and structural load standards. Span arrangements and structural load-bearing systems are optimized to avoid unsuitable span layouts or inadequate stability. For constrained sites that require crossings over structures, railways or roads, or clearance around pipelines and equipment, customized long-span designs are used. Completed projects have achieved spans of up to 60 m, while approved designs allow spans of up to 80 m.

Modular Cross-Section Adaptation

An adjustable modular cross-section design accommodates differences in equipment parameters and layouts across industries. It can match the full range of belt widths and belt speeds required for heavy-duty belt conveyor operation.

Prefabricated Construction for Faster Delivery

Compared with conventional truss construction, Zhengyuan's intelligent prefabricated trestles offer a substantial construction efficiency advantage. Component prefabrication and on-site foundation work can proceed in parallel, with only assembly required on site. This reduces construction time by more than 40% compared with conventional trestles and considerably shortens the overall project schedule. It is currently the industry's most effective approach to reducing trestle construction time.

The mature, highly standardized prefabricated construction process also reduces the likelihood of on-site rework. It avoids the complex procedures, long operating cycles and construction uncertainties associated with conventional truss methods, providing better overall construction efficiency and consistency.

Factory Prefabrication for Construction Quality

Zhengyuan's intelligent trestle components are prefabricated in standardized factories using processes including automated welding, mechanical polishing and painting. Production is unaffected by outdoor weather or environmental changes, providing much greater process consistency than on-site work. The factory's standardized quality control system strictly checks dimensional accuracy, weld quality, anti-corrosion coating thickness and structural performance. Components pass multiple inspections before dispatch to ensure compliance with national standards and avoid the quality variations associated with conventional cast-in-place construction.

Lower Maintenance Costs and Overall Resource Use

Factory prefabrication of Zhengyuan's intelligent trestles extends maintenance intervals and equipment service life. Intelligent operations and maintenance provide a clear fault identification system, substantially reducing manual troubleshooting costs. The highly integrated design reduces exposed, vulnerable connection points, lowering the likelihood of faults and the frequency of maintenance. Faulty components can be dismantled and replaced individually, without extensive shutdowns or demolition. Through material optimization, leaner staffing, reduced maintenance work and improved resource efficiency, this approach upgrades trestle operation and systematically lowers whole-life costs.

The Future of Zhengyuan Trestles

As industrial construction and digital intelligence technologies continue to advance and industry applications deepen, Shaanxi Zhengyuan Intelligent Equipment Co., Ltd. will further integrate new materials, equipment and technologies. The company will continue to develop toward greater intelligence, efficiency, environmental performance and safety, working to lead the smart and eco-friendly conveying systems industry.

Source · Shaanxi Zhengyuan Intelligent Equipment Co., Ltd. · Read the Original Article