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bucyrus car body 495 repair rebuild refurbish

Bucyrus 495 Car Body – Refurbishment Project Complete!

Together with our heavy haul partners, this 130 Ton Car Body and Swing Gear Rack is now heading back to the Wood Buffalo mine for re-installation on a Bucyrus 495 Electric Rope Shovel. This extensive refurbishment project was well suited for Gemini utilizing our core resource offering of welding, millwrighting and precision machining services.

Bucyrus 495 BI dipper transport to mine

Bucyrus 495 BI Dipper – Returning to Mine by Heavy Haul

Project Complete!

Gemini’s Welding, Fabrication & Heavy Equipment Repair Facility saw another Dipper leave for a Ft. McMurray mine where it will be mounted on a Bucyrus 495 BI Electric Rope Shovel. Refurbishment on this type of Heavy Mine Equipment is literally no small feat. Undoubtedly, this must have turned some heads on the Anthony Henday Drive (a major freeway that encircles Edmonton) as well as HWY 63.

Undoubtedly, this must have turned some heads on the Anthony Henday Drive…

Two mobile cranes with a combined 230 Ton heavy lift capacity were used

The Heavy Equipment Repair Team utilized a great deal of technical and trades resources to complete this Dipper project including: certified inspectors, NDE, crack repair, expendable wear component replacement, machining, millwrighting, welding & fabrication, overlay, build-up, critical alignment & assembly, and more.

Transporting this behemoth more than 450 km safely definitely takes some specialized equipment and a team of oversize load professionals. Two heavy lift mobile cranes with a combined 230 Ton lift capacity were used to maneuver the almost 168000 lb Dipper onto a hammock style conventional trailer.

As shown below, the coordinated effort of Gemini Machine Works and our Heavy Haul partners to get this massive component on the road and to its destination – professionally and safely.










Gemini had the privilege to build this portion of the top drive grabber, in this particular case we felt it deserved a place on our news is it offers a chance to showcase raw machining.

Not just a rough cast being cleaned up, but from a solid piece of steel to a complex finished product without leaving the shop. That in its self is impressive, however it doesn’t come easy, this project did take several of Gemini’s specialized machines as well many highly skilled people to meet our standard and the clients expectations.