Industries
Mining
Every hour of unplanned downtime on a critical asset costs hundreds of thousands. Villari's certified crack detection sensors keep your most valuable steel structures running - and extend their operational life.
THE COST OF DOING NOTHING
$130k/hr
Lost production per hour when a high-production bottleneck asset fails - before emergency repairs, idle labour, and penalties are added
$2m+/day
What a single cascading failure costs when the impact reaches crushers, conveyors, and the processing plant within minutes of the primary asset stopping.
3-5x
What emergency repairs cost compared to planned maintenance - up to 15× more when cascading delays and overtime are included.
Continuous & accurate inspection
Early detection of problems ensures safety for the structure and its operators.
Pays for itself in avoided inspections
Permanent wireless sensors replace recurring manual and rope-access inspections campaigns
Unplanned downtime is the most expensive problem in mining
Carefree installation
Only 5 minutes installation time per sensor probe, no surface preparation required.
Fail on your schedule, not the asset's
Repairs move from emergency callouts to planned maintenance windows
One structural failure. The whole value chain feels it.
Mining runs as a single connected chain. When a primary asset stops, every process downstream starves within minutes - from crusher to ball mill to ship-loader. The further upstream the failure, the bigger the financial cascade.
Haul Trucks & Shovels
Ball Mills
Crushers
Reclaimers & Excavators
Ship- (un)Loaders
BENEFITS OF CONTINUOUS MONITORING
From reactive to predictive - protecting your most valuable assets
Mining equipment is irreplaceable in the short term. A dragline, rope shovel, or conveyor that fails without warning doesn't just stop production - it triggers emergency repairs, logistics delays, and safety investigations that compound the loss. Villari's permanently installed wireless sensors continuously monitor fatigue crack development at the most critical structural locations. You get early warning, planned intervention, and the data to confidently extend asset life
Early warning before failure
Detect fatigue cracks early - plan a scheduled repair, not an emergency shutdown
Plan maintenance on your terms
Replace surprise failures with scheduled interventions during planned downtime windows.
Extend asset lifetime
Monitored structures can be operated safely beyond original design life — deferring CAPEX by years
Carefree installation
10 minutes per sensor, no surface preparation, no production stoppage required
Ferro One sensors can be installed along the hinge of the shells and the discharge and feed end.
The balance beam and boom are both difficult locations to reach, placing sensors here you can ensure you don't take your machine out of operation unnecessarily.
From haul trucks to ship-loaders
ASSETS WE MONITOR
Every asset class fails differently. Select yours to see where fatigue cracks start - and how continuous monitoring changes the outcome.
Haul Trucks
Ball Mills
Crushers
Reclaimers
Ship - (un)loaders
Haul truck body & chassis
Chassis frames accumulate fatigue at rear body mounts, frame rails, and suspension welds. Overloading above 105% rated capacity accelerates crack initiation 2.4×. Structural repair costs $150k–$500k; full frame replacement exceeds $2M.
THE CHALLENGE
$150k-$500k
cost of structural repair - a full replacement exceeds $2M.
Sensors at high-stress structural locations detect cracks early - enabling a planned weld repair instead of emergency fleet removal. Across a fleet of 20–30 trucks at $5M–$8M each, avoiding early chassis replacement is significant.
HOW VILLARI HELPS
Weeks, planned
instead of months offline - trunnion repairs become scheduled interventions.
Ball/SAG Mills Structure
Ball mills run under enormous continuous rotational load. The feed and discharge ends are most critical; cracking here means the mill cannot operate at all. Lead times on trunnion repair can take a plant offline for weeks to months.
THE CHALLENGE
Sensors at feed end, discharge end, and trunnion steelwork monitor continuously — turning a potential months-long repair into a planned intervention scheduled around a mill reline or maintenance shutdown.
HOW VILLARI HELPS
unplanned downtime per structural failure event, before counting lost throughput
12-48hrs
Crusher Structure
Crushers operate under severe high-frequency dynamic loading. Support structures crack at connection points and mounting frames, hard to access and rarely inspected. A structural failure triggers the full downstream cascade
THE CHALLENGE
Permanently installed sensors on support structure and connection welds monitor continuously, no production stoppage required. 48-hour reaction time flags cracks well before critical size.
HOW VILLARI HELPS
Zero
repeated rope-access inspection campaigns once sensors are installed
Reclaimers & Conveyors
Ship-loaders develop fatigue cracks at boom connection welds, portal frame joints, and counterweight attachments. A structural failure triggers vessel demurrage, tens of thousands per day in charter costs on top of lost production.
THE CHALLENGE
Permanently installed sensors eliminate repeated rope-access inspection campaigns. Hard-to-reach locations monitored continuously and remotely, closing the gap between periodic visits where cracks grow undetected.
HOW VILLARI HELPS
Ship - (un)loaders
Chassis frames accumulate fatigue at rear body mounts, frame rails, and suspension welds. Overloading above 105% rated capacity accelerates crack initiation 2.4×. Structural repair costs $150k–$500k; full frame replacement exceeds $2M.
THE CHALLENGE
$10k+ / day
in vessel demurrage charter costs after a failure - on top of lost production
Technology transfers directly from port crane monitoring - deployed on STS and bulk handling cranes across major global terminals. The structural loading profile is closely analogous.
HOW VILLARI HELPS
DNV certification confirms our commitment to improvement and sustainability. The DNV-RP-A203 qualification verifies our technology’s capabilities and limits, independently reviewed by DNV experts.
Other industries
Industries with heavily loaded steel structures
We work with asset owners, maintenance providers, NDT inspection companies, and engineering firms. We monitor bridges, cranes, girders and other critical steel assets across various industries. Reach out to explore new applications and lead the transformation in your industry.
