Field Operator (Gyratory Crusher)

Gyratory Crusher Field Operator

Department

Processing – Crushing & Milling

Job Purpose

To safely carry out field operations, inspections, and basic maintenance on the primary gyratory crusher, feeders, conveyors, and associated equipment. The Field Operator supports the Control Room Operator by ensuring safe ore flow, removing blockages, performing equipment checks, and executing plant start-up/shutdown procedures according to site standards.

Key Responsibilities

• Field Operations – Gyratory Crusher Area
• Perform manual and visual inspections of the gyratory crusher, dump pocket, apron feeders, scalping screens, and conveyors.
• Operate equipment locally when required (start/stop/reset).

Physically check:

• Ore levels in the dump pocket and surge bin
• Condition of feed chutes and liners
• Belt tracking and spillage
• Dust suppression systems
• Respond to radio instructions from the control room regarding plant adjustments or abnormalities.

Safety & Compliance

• Strictly follow site safety procedures, including:
• Lock-out/Tag-out (LOTO)
• Permit-to-work systems
• Working-at-heights and confined space protocols
• Maintain safe access ways, remove spillage, and ensure good housekeeping in the crusher area.
• Correctly use PPE and comply with Mine Health & Safety Act (MHSA) and company HSE standards.
• Report unsafe conditions, near-misses, and equipment hazards immediately.

Blockage & Upset Condition Management

• Assist in clearing blockages using approved methods (NO unauthorized entry into crusher chamber).
• Identify tramp metal risks and communicate with control room.
• Support safe crusher re-start procedures after trips, overloads, or mechanical stoppages.

Equipment Monitoring & Basic Maintenance

Check:

• Lubrication systems (oil levels, leaks)
• Hydraulic systems
• Motor/vibration sounds
• Temperature and pressure gauges

Identify wear on:

• Mantle and concaves
• Feeder pans
• Skirting and impact beds
• Perform basic preventative maintenance tasks under supervision (greasing, tightening, cleaning).

Communication & Coordination

• Maintain constant radio communication with the Control Room Operator.
• Coordinate with maintenance teams during breakdowns and planned shutdowns.
• Report hourly feedback on field conditions and equipment status.

Documentation & Reporting

• Complete checklists, log sheets, and shift handover reports.
• Report incidents, abnormalities, and maintenance needs promptly.

Required Skills & Competencies

Technical Competencies

Understanding of:

• Gyratory crusher operation and components
• Ore handling systems (feeders, conveyors, chutes)
• Basic mechanical tools
• Ability to identify faults or abnormal conditions.
• Ability to operate plant equipment locally.

Behavioural Competencies

• Strong safety mindset.
• Good communication skills (radio discipline).
• Reliability and teamwork.
• Ability to work under pressure during plant breakdowns.
• High level of situational awareness.

Qualifications & Experience

Minimum Requirements

• Grade 12 (Matric) or equivalent.
• At least 1–3 years experience in a crushing plant or mining environment.
• Physically fit to work in a heavy industrial area.
• Willingness to work shifts, overtime, and standby.

Preferred

• Mineral Processing or Plant Operations qualification (NQF Level 2–4).
• Experience specifically with primary gyratory crushers (Metso, Sandvik, FLSmidth).
• Basic mechanical or fitter skills.

Physical & Environmental Working Conditions

• Work conducted outdoors in dusty, noisy, and vibration-prone areas.
• Frequent climbing of stairs/ladders around crusher structures.
• Exposure to hot, cold, and wet conditions.
• Must handle emergency plant stoppages and rapid interventions.

Key Performance Indicators

• Safe execution of field tasks with zero harm.
• Timely response to control room instructions.
• Quality of inspections and reporting.
• Housekeeping standards in the crusher area.
• Uptime and efficiency of the primary crushing circuit.